JP2001157422A - Method of winding stator in dynamo-electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the productivity while preventing the damage of a coil and besides, to materialize the downsizing and the performance enhancement of a stator, in addition to enabling the end of the coil to be cooled effectively, when winding each foil of U phase, V phase, and W phase on a stator core. SOLUTION: Each coil unit 25U, 25V, and 25W of U phase, V phase, and W phase is constituted, by inserting one hand of both coil side parts that the coils 42U, 42V, 42W; 43U, 43V, and 43W of U phase, V phase, and W phase being constituted by winding lead wires by the numbers of turns half the numbers of turns set in every slot 37 posses, and then, bringing down each coil 42U, 42V, 42W; 43U, 43V, and 43W in the reverse direction to the direction 49 of circulation of a cooling air current, thereby inserting the other coil side parts into the slots 37 severally, and then, electrically connecting each coil 42U, 42V, 42W; 43U, 43V, and 43W severally.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a stator in which a U-phase, V-phase and W-phase coil unit is wound around a stator core having a plurality of slots on its inner periphery, and a rotor coaxially surrounded by the stator. And a cooling fan fixed to the rotor at a portion corresponding to one axial end of the stator so as to allow cooling air to flow between the inside and the outside of the stator.
The present invention relates to an improvement in a winding method for winding V-phase and W-phase coils.

[0002]

2. Description of the Related Art Conventionally, such a rotating electric machine is already known, for example, from Japanese Patent Publication No. 4-24939.

[0003]

In such a rotating electric machine, the coil ends of the U-phase, V-phase and W-phase coil units, which are arranged on both ends in the axial direction of the stator, are separated from the cooling fan. However, effective cooling is difficult only by applying cooling air to the coil ends from the inside or outside. Therefore, in the technology disclosed in the above publication, each coil end is shaped so that the coil end of each phase is shifted in the axial direction of the stator core and a gap is formed between the coil ends of each phase in the radial direction of the stator core. It is processed so that cooling air is effectively applied to the coil ends of each phase.

However, in the technique disclosed in the above publication,
The coil ends are complicatedly overlapped, and the shaping takes time. Further, the pressing or deformation at the time of shaping may damage the conductive wire and cause leakage. Also, in the above-mentioned conventional type, the coil units of each phase are wound at once by a complicated and large-sized winding machine, and then these coil units are inserted into the stator core by an insertion machine. In addition to the swelling, the length and weight of the stator in the axial direction are increased, and the length of the conductive wire constituting each coil is increased, resulting in low efficiency and high cost.

The present invention has been made in view of such circumstances, and has been made to be able to effectively cool the coil end portion.
An object of the present invention is to provide a method of winding a stator in a rotating electric machine that improves productivity while preventing damage to a coil, and that further reduces the size and performance of the stator.

[0006]

To achieve the above object, according to the first aspect of the present invention, a U-phase, V-phase and W-phase coil unit is wound around a stator core having a plurality of slots on an inner periphery. A rotor coaxially surrounded by the stator, and a cooling fan fixed to the rotor at a portion corresponding to one axial end of the stator so as to allow cooling air to flow between the inside and the outside of the stator. When winding the U-phase, V-phase, and W-phase coil units on the stator core, two circumferentially adjacent slots can be respectively housed in a pair of slots interposed therebetween. It has a pair of coil sides and a pair of coil ends connecting both ends of the coil sides, and the number of turns is half the number of turns set for each slot U that only formed by winding a conductor wire endlessly
Phase, V-phase and W-phase coils are 1/3 of the total number of slots
A first step of preparing each of the coils, and a step of making one of a pair of coil side portions of the U-phase, V-phase and W-phase coils different from a slot adjacent to each other in the circumferential direction so that each slot has a different phase. A second step of inserting the U-phase, V-phase and W-phase coils in a direction opposite to the direction of the cooling air flow by the cooling fan, thereby inserting the one coil side portion in the same phase. A third step of inserting the other coil side into the slot in which the U-phase, V-phase and W-phase coils are respectively electrically connected to form U-phase, V-phase and W-phase coil units. And a fourth step to configure are sequentially executed.

[0007] According to the method of the first aspect,
Since the number of turns set for each slot is secured by dividing it into two coils that are half the number of turns set and inserting it into each slot, the amount of protrusion of the coil end from the end face of the stator core Can be kept relatively small, the axial length of the stator can be reduced, and the length of the conductor constituting each coil can be shortened, and the weight of the stator can be reduced by reducing the amount of copper. At the same time, the performance can be improved and the cost can be reduced by reducing the resistance value. In a portion corresponding to each slot at both ends of the stator core, another two phases having different phases are provided between the coil ends of a pair of in-phase coils adjacent in the circumferential direction of the stator core.
The coil ends of the phase coils are arranged, and gaps between the coil ends are formed at positions spaced apart in a direction along the radial direction of the stator core, between the inside and outside of the stator core. At one end in the direction, the gaps extend along the direction of the cooling air flow by the cooling fan. Therefore, the cooling air from the cooling fan can be circulated through the gaps to effectively cool the coil ends at both ends of the stator core, and increase the contact area of the coil ends with the cooling air to increase the cooling efficiency. In particular, at one end of the stator, the cooling air from the cooling fan can flow more smoothly to improve the cooling efficiency. Further, the gap can be formed only by inserting the coil side portion into each slot instead of shaping the coil end portion, so that it is possible to improve the productivity and to make the conductive wire in each coil damaged. , And the possibility of occurrence of leakage is reduced.

[0008] The invention according to claim 2 provides the above-mentioned claim 1.
In addition to the configuration of the invention described, in the first step,
A first coil having a pair of coil terminals extending substantially in parallel from one end of both coil sides and a second coil having a pair of coil terminals extending in a substantially X-shape from one end of both coil sides. , V-phase, and W-phase, respectively, and in the second step, the first and second coils for each of the U-phase, V-phase, and W-phase having the coil terminals on the same side in the axial direction of the stator core. Are alternately arranged in the circumferential direction of the stator core, and in the fourth step, coil terminals of the same phase corresponding to the same slot are electrically connected to each other.

According to such a method of claim 2,
The work of electrically connecting the U-phase, V-phase, and W-phase coils to form the coil units of each phase is facilitated. In other words, coils of the same phase that are adjacent to each other along the circumferential direction of the stator core need to have the winding directions of their conducting wires reversed, whereas the two coil terminals of the first coil are substantially parallel, Since both coil terminals of the two coils intersect in a substantially X-shape, only by electrically connecting the coil terminals of the same phase corresponding to the same slot, the coil terminals of the same phase adjacent to each other along the circumferential direction of the stator core are connected. It is possible to electrically connect the U-phase, V-phase and W-phase coils such that the winding directions of the coils are reversed.

According to a third aspect of the present invention, in addition to the configuration of the first or second aspect, in the first step, an insulating sheet having heat resistance and impregnated with a varnish is provided. Wound around the length of the coil side portion of the coil over the axial thickness of the stator core,
The heating process is performed on the insulating sheets after the lapse of the fourth step. According to such a configuration, it is possible to prevent each coil from directly contacting the stator core and being damaged, By melting the varnish by heating and hardening by cooling after the heating treatment, it is possible to secure reliable insulation properties and to fix each coil unit to the stator core.

According to a fourth aspect of the present invention, in the first step, each of the U-phase, V-phase and W-phase coils includes The method according to claim 4, wherein the coil ends provided in pairs are formed in an arc shape bulging outward from the stator core when the coils are mounted on the stator core. In addition, the gap formed between the coil ends can be curved so that the cooling air by the cooling fan can flow more smoothly, and the productivity is reduced because the coil is not shaped after winding each coil. Never.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described based on embodiments of the present invention shown in the accompanying drawings.

1 to 11 show a first embodiment of the present invention. FIG. 1 is a vertical sectional side view of an alternator, FIG. 2 is a plan view of a stator core, and FIG. 3 is a sectional view taken along line 3-3 in FIG. Figure,
FIG. 4 is a view for explaining an electrical connection state of each coil unit in the stator, FIG. 5 is a side view of the first coil prepared in the first step, and FIG. 6 is a second view prepared in the first step. FIG. 7 is a perspective view for explaining the processing in the second step, FIG. 8 is a view showing the processing state in the second step as viewed from one side in the axial direction of the stator core, and FIG. FIG. 10 is a view of the processing situation in one step in the axial direction of the stator core, FIG. 10 is a view of the state of FIG. 9 as viewed from the inside in the radial direction of the stator core, and FIG. 1 to show relative positions of
FIG. 12 is a sectional view taken along line 11-11 of FIG.

Referring to FIG. 1, this rotating electric machine is, for example, an alternator mounted on a vehicle, and a stator core 24 is sandwiched between first and second brackets 22 and 23 which are mutually fastened by a plurality of fastening bolts 21. The U-phase, V-phase and W-phase coil units 25U, 25V, 25W are wound around the stator core 24 to form the stator 26.

A rotor 2 coaxially surrounded by a stator 26
The rotating shaft 28 in 7 penetrates freely through the second bracket 23, and a pair of ball bearings 29, 29 are interposed between the rotating shaft 28 and the second bracket 23.

A pulley 30 is fixed to the outer end of the rotary shaft 28. To this pulley 30, rotational power from an engine (not shown) is input via an endless belt (not shown). The rotation shaft 28, that is, the rotor 27
Is driven to rotate.

A cover 31 is mounted on the second bracket 23, and a circular opening 31a for disposing the pulley 30 is provided at the center of the cover 31.

A first cooling fan 32 is fixed to the rotor 27 at a portion corresponding to one end of the stator 26 on the side of the first bracket 22, and a second cooling fan 32 is attached to the rotating shaft 28 between the second bracket 23 and the cover 31. 2 The cooling fan 33 is fixed. The first bracket 22 is provided with air inlets 34 for introducing air from the outside by rotation of the first cooling fan 32.
Are formed at a plurality of locations on the inner surfaces of the first and second brackets 22 and 23 at a portion corresponding to the stator core 24 to allow the cooling air from flowing from inside to outside of the stator 26. Thus, the second cooling fan 33
The cooling air that has flowed inward through the other end of the stator 26 from the flow grooves 35.
It is sucked through 29 and discharged out of the cover 31.

Referring to FIG. 2 and FIG.
Reference numeral 4 denotes a substantially ring-shaped stator core 24 formed by laminating a large number of magnetic steel plates. A plurality of substantially T-shaped, for example, 36 teeth 36A, 3 are provided on the inner periphery of the stator core 24.
6A are integrally provided so as to protrude inward, and a plurality of, for example, 36 slots 37, 37 are formed between the teeth 36A, 36A.

In FIG. 4, U-phase, V-phase and W-phase coil units 25U, 25V, 25W are provided with slots 37, 37,. And one end of each of the U-phase, V-phase, and W-phase coil units 25U, 25V, and 25W is connected to the middle through connection lines 38U, 38V, and 38W. The other end of the U-phase, V-phase and W-phase coil units 25U, 25V, 25W is connected to the lead point 40U,
It is connected to U-phase, V-phase and W-phase output terminals 41U, 41V, 41W via 40V, 40W.

In winding such U-phase, V-phase and W-phase coil units 25U, 25V, 25W around the stator core 24, processing in first to fourth steps described in detail below will be described. Are sequentially executed.

First, in the first step, U
Phase, V phase and W phase first coils 42U, 42V, 42
W, U-phase, V-phase and W-phase second coils 4 shown in FIG.
3U, 43V and 43W are prepared.

U-phase first and second coils 42U, 43
U is a slot 37 provided on the inner periphery of the stator core 24,
37... Half of the total number of slots, ie, slot 3
When the total number of 7, 37... Is 36 as in this embodiment, six are prepared, and the V-phase first and second coils 42V and 43V and the W-phase first and second coils 42W, 43W are also prepared for each half of the total number of slots 37, 37...

Each of the first coils 42U, 42V, 42W and each of the second coils 43U, 43V, 43W have half the number of turns set for each slot 37, 37, for example, for each slot 37, 37,. When the number of turns set to is 18 turns, the conductor is wound endlessly by 9 turns.

The first coils 42U, 42V, 42
W is a pair of coil side portions 44 that can be stored in the slot 37.
a, 44b and a pair of coil ends 45a, 45b connecting between both ends of the coil side portions 44a, 44b. 46b is both coil side portions 44a, 4
4b is extended substantially in parallel from one end side.

Each of the second coils 43U, 43V, 43W
Is a pair of coil side portions 44 that can be stored in the slot 37.
a, 44b and a pair of coil ends 45a, 45b connecting between both ends of the coil side portions 44a, 44b. 46b is both coil side portions 44a, 4
4b is extended from one end side in a substantially X-shaped manner.

Moreover, each of the coils 42U, 42V, 42
W; the width W of the coils 43U, 43V, 43W, that is, the distance between the two coil side portions 44a, 44b is adjacent to the stator core 24 in the circumferential direction when one of the coil side portions 44a is stored in a specific slot 37. 2 slots 3
A value is set so that the other coil side portion 44b can be accommodated in the slot 37 at a position where the first and second coil sides 7 and 37 are interposed between the specific slot 37. Each coil 42U, 42
V, 42W; coil ends 45a, 45b... Of the coils 43U, 43V, 43W
V, 42W; formed in an arc shape bulging outward from the stator core 24 when the coils 43U, 43V, 43W are mounted on the stator core 24.

Further, each of the coils 42U, 42V, 42W;
Coil sides 44a, 4 of coils 43U, 43V, 43W
The insulating sheets 47, which have heat resistance and are impregnated with varnish, are wound around a length L of the stator core 24 in the axial length d (see FIG. 3) of 4b. As the insulating sheet 47, for example, a Nomex varnish tape (trade name) manufactured by DuPont can be suitably used. At this time, since the Nomex varnish tape is poor in flexibility, it is desirable to temporarily fix the insulating sheets 47, 47 with the adhesive tapes 48, 48.

In the next second step, FIGS. 7 and 8
, The U-phase, V-phase and W-phase first coils 42
U, 42V, 42W and the second coils 43U, 43
V, 43W, a pair of coil sides 44a,
44b are connected to the respective coil terminals 46a, 46
.. are arranged on the same side in the axial direction of the stator core 24, and the slots 37, 37,.
From one axial side of the stator core 24.

In the first step, the insulating sheet 4
7 is temporarily fixed with an adhesive tape 48, the adhesive tape 48 may be peeled off before executing the process of the second step, or the adhesive tape 4 may be heated by a heating process described later.
When 8 does not melt, it may not be peeled off.

In the process of the second step, for example, the U-phase first coil 42U, the W-phase first coil 42W, V
The first coils 42V, the second coils 43U of the U phase, the second coils 43W of the W phase, the second coils 43W of the W phase, and the second coils 43V of the V phase are arranged in the circumferential direction of the stator core 24 in this order. The coil side portions 44a of 42V, 43U, 43W, 43V are inserted into the slots 37. That is, the coil side portions 44a are made to be different in phase from the slots 37 adjacent to each other in the circumferential direction so that the U-, V-, and W-phase coils 42U, 4
2V, 42W; 43U, 43V, 43W coil side 4
4a are inserted into the slots 37, and the first and second coils 42U, 42V, 42W of each phase;
V, 43W are alternately arranged in the circumferential direction of the stator core 24.

In the third step, as shown in FIGS. 9 and 10, U-phase, V-phase and W-phase coils 42U, 4
2V, 42W; 43U, 43V, 43W are tilted to one side in the circumferential direction of the stator core 24, so that the slot 37 in which the one coil side portion 44a, which is in phase, is inserted.
Are inserted into the other coil side portions 44b, respectively. That is, the coil side portion 4 of the U-phase first coil 42U
The coil side portion 44b of the U-phase second coil 43U is inserted into the slot 37 in which the U-phase second coil 4a is inserted.
The coil side 44b of the U-phase first coil 42U is inserted into the slot 37 of the coil 43U where the coil side 44a is inserted, and the slot 37 of the W-phase first coil 42W where the coil side 44a is inserted. To W
The coil side 44b of the W-phase second coil 43W is inserted by inserting the coil side 44b of the second phase coil 43W.
Is inserted into the slot 37 into which the first coil 42 of the W phase is inserted.
The coil side 44b of the V-phase second coil 43V is inserted into the slot 37 in which the coil side 44a of the V-phase first coil 42V is inserted. The coil side 44b of the V-phase first coil 42V is inserted into the slot 37 in which the coil side 44a of the two coils 43V is inserted.

In addition, each coil 42 in the third step
The direction in which U, 42V, 42W; 43U, 43V, 43W is set to be opposite to the direction 49 in which the cooling air flows through the first cooling fan 32 fixed to the rotor 27 at one end of the stator 26. That is, the first cooling fan 3
2 rotates clockwise in FIG. 11 so that the cooling air flow direction 49 is also clockwise in FIG. 11, and in the third step, the coils 42U, 42V, 42W;
3U, 43V and 43W are to be tilted counterclockwise in FIG.

In the last fourth step, the U-phase, V-phase and W-phase first and second coils 42U, 42V, 42
W; 43U, 43V, 43W are electrically connected by welding, fusing, etc., respectively, as shown in FIG.
V-phase and W-phase coil units 25U, 25V, 2
5W.

At this time, the first coils 42U, 42V, 42
W coil terminals 46a and 46b are parallel to each other, and the coil terminals 46a and 46W of the second coils 43U, 43V and 43W.
Since 46b intersects substantially in an X shape, each slot 37
, The first coils 42U, 42V, 4
2W coil terminal 46a and second coils 43U, 43
V, 43W coil terminals 46a are electrically connected to each other, and the coil terminals 46b of the first coils 42U, 42V, 42W and the coil terminals 46b of the second coils 43U, 43V, 43W are electrically connected to each other. Become.

After the processing of the fourth step is further performed, the insulating sheets 47 are heated by heating the entire stator 26. As a result, the varnish impregnated in the insulating sheet 47 is melted, and the varnish is hardened by cooling after the heating process, so that reliable insulation can be ensured and the coil units 25 can be secured.
U, 25V, 25W can be fixed to the stator core 24.

Next, the operation of the first embodiment will be described. Each of the coil units 25U, 2
When winding 5V, 25W, as mentioned above,
By sequentially executing the process of the fourth step, the number of turns set for each slot 37, 37... Is reduced by two coils 42U, which are half the set number of turns.
42V, 42W; 43U, 43V, 43W, which are secured by inserting them into the slots 37, 37,... And the coil end 45 from the end face of the stator core 24.
a, 45b... can be kept relatively small. Therefore, the axial length of the stator 26 can be reduced, and the coils 42U, 42V, 42W;
3U, 43V, 43W, the length of the conductor wire is shortened, the weight of the stator 26 can be reduced by reducing the amount of copper, and the performance can be improved and the cost can be reduced by reducing the resistance value.

In a portion corresponding to each slot 37 at both ends of the stator core 24, a pair of in-phase coils 42U, 43U;
2V, 43V; 42W, 43W coil ends 45a, 4
The coil ends 45a, 45b of the other two-phase coils having different phases are arranged between the coil ends 5b..., And each coil end is placed at a position spaced apart in a direction along the radial direction of the stator core 24. The gap between 45a and 45b is
The inner and outer portions are formed as shown in FIG. Moreover, at one axial end of the stator 26, the gap is formed by the first cooling fan 32 in the cooling air flow direction 49.
Along. Therefore, the cooling air from the cooling fans 32 and 33 is circulated through the gaps so that the coil ends 45a, 45b.
Can be effectively cooled, and the contact area of the coil ends 45a, 45b... With the cooling air can be increased to increase the cooling efficiency. In particular, at the one end of the stator 26, the first cooling fan 32 Cooling air can be more smoothly circulated to improve the cooling efficiency.

Further, the gap can be formed only by inserting the coil side portions 44a, 44b in each of the slots 37, 37, instead of shaping the coil end portions 45a, 45b. And each coil 42U, 42V, 42W; 43U,
The conductive wires at 43 V and 43 W can be hardly damaged, and the possibility of leakage is reduced.

In the above-described second step, the pair of coil terminals 26a, 26b are connected to both coil side portions 44a, 44b.
Coils 42U, 42 extending substantially in parallel from one end of
V, 42W, and the second coils 43U, 43V, 43W in which the pair of coil terminals 26a, 26b extend in a substantially X-shape from one end of both coil sides 44a, 44b.
Phase, V-phase, and W-phase are alternately arranged in the circumferential direction of the stator core 24. In the fourth step, in-phase coil terminals 26a, 26a;
6b are electrically connected to each other.

Accordingly, the U-phase, V-phase and W-phase coils 42U, 42V, 42W; 43U, 43V, 43W are electrically connected so that the coil units 25U, 25
The work of configuring V and 25W is facilitated. That is, in-phase coils 42U, 43U; 42V, 43V; 42W, 43 which are adjacent to each other along the circumferential direction of the stator core 24.
W needs to be reversed in the winding direction of the conductor, but both coil terminals 26 of the first coils 42U, 42V, 42W
a and 26b are substantially parallel, while the second coil 43
Since both coil terminals 26a, 26b of U, 43V, 43W intersect substantially in an X shape, coil terminals 26a, 26a of the same phase corresponding to the same slot 37;
6b, the stator core 24
In-phase coil coils 4 adjacent to each other along the circumferential direction of
The winding directions of 2U, 43U; 42V, 43V; 42W, 43W are reversed so that the U-phase, V-phase, and W-phase coils 42U, 42V, 42W; 43U, 43V, 43
W can be electrically connected.

In the first step, the insulating sheets 47, 4 having heat resistance and impregnated with varnish are used.
7 are used as the coils 42U, 42V, 42W;
U, 43V, 43W of the coil sides 44a, 44b,... Are wound around the axial length d or more of the stator core 24, and are wrapped around the insulating sheets 47, 47,. Since the heating process is performed, each coil 42
U, 42V, 42W; 43U, 43V, 43W can be prevented from directly contacting the stator core 24 and being damaged, and can be reliably melted by heating the varnish and hardened by cooling after the heating treatment. Insulation can be ensured and each coil unit 25
U, 25V, 25W can be fixed to the stator core 24.

In the first step, U-phase, V-phase and W-phase coils 42U, 42V, 42W; 43U,
Coil end portions 4 each having 43V and 43W pairs.
5a, 45b... Are connected to the coils 42U, 42V, 4
Since 2W; 43U, 43V, 43W are formed in an arc shape bulging outwardly of the stator core 24 when the cooling fan 32 is mounted on the stator core 24, the gap formed between the coil ends 45a, 45b. , 33 to allow the cooling air to flow more smoothly. Moreover, each coil 42U, 42V, 42W; 43U,
Since it is not shaped after winding of 43V and 43W, productivity does not decrease.

As a second embodiment of the present invention, as shown in FIG. 12, first coils 42U, 42V and 42W and second coils 43U, 43V and 43W (not shown) are connected to a stator core 24 (first embodiment). It may be prepared in the first step by shifting in the axial direction (see example).
By doing so, the axial length of the stator 26 is longer than that of the first embodiment, but the mass of the coil ends 45a and 45b is dispersed, and the contact area with the cooling air is increased. Effective cooling becomes possible.

FIG. 13 shows a third embodiment of the present invention, in which the first coils 42U, 42V, 42W and the coil sides 44a of the second coils 42U, 42V, 42W (not shown) are slotted. After the lapse of the second step of insertion into each of the coils 42 as in the second embodiment.
U, 42V, 42W; 43U, 43V, 43W may be shifted in the axial direction of the stator core 24, and the third embodiment can provide the same effect as the second embodiment.

FIG. 14 shows a fourth embodiment of the present invention, in which a plurality of teeth 36B provided on the inner periphery of the stator core 24 are formed so as to form slots 37, 37,. It may be formed so as to be substantially L-shaped. In this manner, in the third step, the coils 42U, 42V, and 42W; 43U, 43V, and 43W can be easily tilted to insert the coil side parts 44b into the slots 37.

Further, as in the fifth embodiment shown in FIG.
Each of the teeth 36C, 36C... May be a linear shape inclined in a direction at an angle to the radial direction of the stator core 24. According to the fifth embodiment, in the third step, the coils 42U, 42V , 42W; 43
It becomes easy to insert the coil side parts 44b into the slots 37 by tilting the U, 43V, 43W.

Although the embodiments of the present invention have been described in detail, the present invention is not limited to the above embodiments, and various design changes can be made without departing from the present invention described in the appended claims. It is possible to do.

For example, in the above embodiment, the alternator has been described as the rotating electric machine. However, the present invention relates to a stator having a stator core wound with U-phase, V-phase and W-phase coil units, a rotor, and a stator. The present invention can be widely applied to a rotating electric machine including a cooling fan fixed to a rotor at a portion corresponding to one axial end of a stator so that cooling air is circulated between the outside and the outside.

In the above embodiment, the first cooling fan 32
Flow grooves 35 for letting the cooling air from
Although provided at a plurality of locations on the inner surfaces of the first and second brackets 22 and 23 at portions corresponding to the stator core 24, a plurality of outlets for discharging cooling air from the first cooling fan 32 to the outside are provided. A plurality of air suction ports provided on the first bracket 22 at a portion corresponding to one end of the stator 26 and for introducing air sucked by the second cooling fan 33 from the outside are portions corresponding to the other end of the stator 26. It may be provided on the second bracket 23.

Further, the air sucked by the second cooling fan 33 is supplied to the second bracket 23 by the first and second brackets 2.
A plurality of communication holes leading to the cover 31 from between 2 and 23 may be provided.

[0052]

As described above, according to the first aspect of the present invention, the axial length of the stator can be reduced and the weight of the stator can be reduced, so that the performance can be improved and the cost can be reduced. Further, gaps between the coil ends are formed between the inside and the outside of the stator core at positions spaced apart in a direction along the radial direction of the stator core. At one axial end of the stator, the gaps are formed by the cooling fan. In the cooling air flow direction. Therefore, the coil ends at both ends of the stator core can be effectively cooled, and the contact area of the coil ends with the cooling air can be increased to increase the cooling efficiency. The cooling air from the fan can be more smoothly circulated to improve the cooling efficiency. Further, the productivity can be improved, and the conductive wire in each coil can be hardly damaged, and the possibility of occurrence of a leak can be reduced.

According to the second aspect of the present invention, the U phase,
The work of electrically connecting the V-phase and W-phase coils to form the coil unit of each phase is facilitated.

According to the third aspect of the present invention, it is possible to prevent each coil from directly contacting the stator core and being damaged, to ensure a reliable insulation property, and to assure each coil unit. Can be fixed to the stator core.

Further, according to the present invention, the gap formed between the coil ends can be curved so that the cooling air from the cooling fan can flow more smoothly, and the productivity is reduced. Never.

[Brief description of the drawings]

FIG. 1 is a vertical sectional side view of an alternator according to a first embodiment.

FIG. 2 is a plan view of a stator core.

FIG. 3 is a sectional view taken along line 3-3 in FIG. 2;

FIG. 4 is a diagram for explaining an electrical connection state of each coil unit in a stator.

FIG. 5 is a side view of a first coil prepared in a first step.

FIG. 6 is a side view of a second coil prepared in a first step.

FIG. 7 is a perspective view for explaining a process in a second step.

FIG. 8 is a diagram showing the processing state in the second step as viewed from one side in the axial direction of the stator core.

FIG. 9 is a diagram showing the processing state in the third step as viewed from one side in the axial direction of the stator core.

10 is a view of the state of FIG. 9 as viewed from the inside in the radial direction of the stator core.

FIG. 11 is a cross-sectional view taken along the line 11-11 in FIG. 1 for showing the direction of the flow of cooling air from the cooling fan and the relative position of each coil.

FIG. 12 is a view showing a coil according to a second embodiment.

FIG. 13 is a perspective view showing a state in a second step of the third embodiment.

FIG. 14 is a plan view showing a part of a stator core according to a fourth embodiment.

FIG. 15 is a plan view showing a part of a stator core according to a fifth embodiment.

[Explanation of symbols]

 37 ... slot 24 24 ... stator core 25U, 25V, 25W ... coil unit 26 ... stator 27 ... rotor 32 ... cooling fan 42U, 42V, 42W ... first coil 43U, 43V, 43W ... second coil 44a, 44b ... coil side 45a, 45 ... coil end 46a, 46b ... coil end 47 ... insulating sheet 49 ... cooling air flow direction

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Claims (4)

[Claims] 1. A stator (26) formed by winding a U-phase, V-phase and W-phase coil unit (25U, 25V, 25W) around a stator core (24) having a plurality of slots (37) on an inner periphery thereof. The rotor (27) coaxially surrounded by the stator (26) and the stator (2) so as to allow cooling air to flow between the inside and outside of the stator (26).
6) the rotor (27) at a portion corresponding to one axial end;
And a cooling fan (32) fixed to the stator core (24), the U-phase, V-phase and W-phase coil units (25U, 25V, 25W) are wound around the stator core (24) in the circumferential direction. A pair of slots (37) having two adjacent slots (37) interposed therebetween
And a pair of coil side portions (44a, 44
b) and a pair of coil ends (45a, 45b) connecting both ends of the coil side portions (44a, 44b), and is endless by half the number of turns set for each slot (37). U consisting of a wire wound around
Phase, V phase and W phase coils (42U, 42V, 42
W; 43U, 43V, 43W), each step of preparing 1/3 of the total number of slots (37);
Phase, V phase and W phase coils (42U, 42V, 42
W; 43U, 43V, 43W), each slot (44a) of the pair of coil side portions (44a, 44b) is made different in phase from the slot (37) adjacent to each other in the circumferential direction. 37), and U-phase, V-phase and W-phase coils (42
U, 42V, 42W; 43U, 43V, 43W) in the opposite direction to the cooling air flow direction (49) by the cooling fan (32) to insert the one coil side portion (44a) in the same phase. A third step of inserting the other coil side portion (44b) into the slot (37), and the U-phase, V-phase and W-phase coils (42U,
42V, 42W; 43U, 43V, 43W) are electrically connected to form a U-phase, V-phase, and W-phase coil unit (25U, 25V, 25W). A winding method for a stator in a rotating electric machine, characterized in that: 2. In the first step, a pair of coil terminals (46a, 46b) are connected to both coil side portions (44a, 44b).
b) extending substantially in parallel from one end of the first coil (42U,
42V, 42W) and a pair of coil terminals (46a, 46W).
b) extend from one end side of both coil side portions (44a, 44b) so as to intersect substantially in an X shape (43U, 43V,
43W) are prepared for each of the U-phase, V-phase and W-phase, and in the second step, each of the coil terminals (46a, 46b) is set on the same axial side of the stator core (24) as the U-phase. , V-phase and W-phase first and second coils (42U, 42V, 42W; 43U, 43V, 43
W) are alternately arranged in the circumferential direction of the stator core (24), and in the fourth step, the coil terminals (46a, 46b) of the same phase corresponding to the same slot (37) are electrically connected to each other. The winding method for a stator in a rotating electric machine according to claim 1, wherein 3. An insulating sheet having heat resistance and impregnated with a varnish in the first step.
To each of the coils (42U, 42V, 42W; 43U,
43V, 43W) coil side portions (44a, 44b)
The method according to claim 1, wherein the insulating sheet (47) is subjected to a heating treatment after the fourth step has passed, wherein the insulating sheet (47) is wound around a region having a length equal to or longer than the axial thickness of the stator core (24). 3. A winding method of a stator in the rotating electric machine according to 1 or 2. 4. In the first step, each of U-phase, V-phase and W-phase coils (42U, 42V, 42W; 43
U, 43V, 43W) are provided with coil ends (45a, 45b) provided in pairs, respectively, of the coils (42U, 43W).
42V, 42W; 43U, 43V, 43W) are formed in an arc shape swelling outwardly of the stator core (24) when the stator core (24) is mounted on the stator core (24). The winding method of a stator in the rotary electric machine according to the above.