JP2002034190A - Rotating machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotating machine, such as a motor and generator, having small connection or crossover sections and formed out of stator windings of wiring constitution excellently easy to assemble with reliability, and a manufacturing method therefor. SOLUTION: In this rotating machine, the winding order of two or more coils continuously wound is changed for each phase to make the rise positions of terminals different from each other for each coil group of the respective phases. It is thus possible to prevent the interference of crossovers of the respective phases in assembling a stator, enhance ease of assembly, and enhance phase-to-phase insulation reliability by separately disposing the respective crossovers.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a motor (rotary motor, linear motor) and a rotating machine such as a generator used for various industrial equipment, and in particular, to a high-output electric power which needs to flow a large current. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotating machine such as a motor and a generator that realizes downsizing by using a concentrated winding capable of shortening a coil end located at an end of a stator winding used in an automobile, a hybrid car, and the like.

[0002]

2. Description of the Related Art For example, in a rotating machine such as a motor or a generator employing a concentrated winding, coils of each phase of a stator winding are coiled for each phase in a Y-connection or a △ -connection. Need to be connected. In the concentrated winding, the following method is used as a means for streamlining the terminal processing of each coil. One is Japanese Unexamined Patent Publication No.
As disclosed in Japanese Patent No. 18331, an insulator 31a in which a crossover of a coil in which a predetermined number of coils are continuously wound in each phase is provided on the outer periphery of the core,
By arranging the crossover wires 9 along the grooves 32a and 32b for each phase of 31b, connection of each coil is not required. In another method, Japanese Patent Laid-Open No. 6-2334 shown in FIG.
As disclosed in Japanese Patent Publication No. 83, the connection of each coil is performed by connecting the terminal wires 34 of the coils individually wound to a separately provided wiring board 35.

[0003]

However, in the former case,
Since it is necessary to arrange the crossover wires in the grooves of the insulator at the outer peripheral portion of the core and to secure insulation between the phases, a large area is required only for wiring in the outer peripheral portion of the core and in the axial direction of the core. In particular, for high-output motors represented by electric vehicles and hybrid vehicles, high efficiency, small size and light weight are issues.
The conductor area of the coil is increased in accordance with the specifications for higher output. For example, the conductor cross-sectional area per coil turn is 4.
It is in need of 0mm ² ~4.5mm ² degree. Therefore, in the conventional method in which the crossover wires are concentrated only on the outer peripheral portion, it is difficult to arrange the crossover wires of each phase so as not to interfere with each other, and a motor having a large core outer diameter or a motor having a large core diameter. Becomes On the other hand, in order to improve the fuel efficiency, it is necessary to reduce the size and weight of the entire vehicle and the size and weight of the motor to be mounted. Further, since the crossovers are arranged on substantially the same circumference, an insulating material for securing insulation between phases is required.

[0004] In the case of the latter connection by a wiring board,
Since each coil is wound as a single unit, operations such as peeling of the film of each coil terminal, connection to the substrate, and insulation of the connection portion are required for each coil, and the number of connection steps is increased. Furthermore, in the case of a high-output motor, since the conductor area is large, it is difficult to lay out the conductors of each phase in the wiring board at high density, and the wiring board becomes thicker in the axial direction or larger in the radial direction. Further, in a configuration in which thin plates for each phase are laminated in the axial direction as in a conventional type wiring board, there is a problem that heat dissipation of conductors in the wiring board is poor.

[0005] An object of the present invention is to solve the above problems.
A rotating machine that achieves high output, high efficiency, and small size and light weight by reducing or simplifying the crossover wire or connection portion (end coil portion) at both end surfaces of the stator core, etc., and improving the winding space factor. Is to provide. Further, another object of the present invention is to reduce or simplify the crossover portion or the connection portion (end coil portion) at both end portions of the stator core and the like, improve the winding space factor, increase the output, and increase the efficiency. It is an object of the present invention to provide a method for manufacturing a rotating machine capable of manufacturing a rotating machine that is compact and lightweight.

[0006]

In order to achieve the above object, the present invention relates to a rotating machine having a stator having a plurality of coil groups in a stator core. The rising position is different at both end portions of the stator core, and the positions at which the coil portions are connected between the coil groups of each phase are dispersed in the radial direction so that the terminals of the coil portions do not cross each other. I do. The present invention also provides a rotating machine having a stator having a plurality of coil groups in a stator core, wherein each of the coil groups of each phase is configured by connecting a plurality of coil sections with a crossover, and It is characterized in that the rising positions from the coil portions in the crossovers for the respective groups are made different at both end portions of the stator core so that the crossovers do not cross each other between the coil groups of the respective phases.

The present invention also provides a rotating machine having a stator having a plurality of coil groups of a plurality of phases on a stator core, wherein each of the plurality of coil groups is connected in series with a plurality of coil sections via a crossover. The crossover wire for each coil group of each phase may be arranged so as to be separated from each other at both end surfaces of the stator core. Further, the present invention is characterized in that in the rotating machine, the stator core is constituted by a split core including a teeth portion and a core back portion. Further, the present invention is characterized in that in the rotating machine, a coil group of each phase is incorporated in a tooth portion of a divided core. Further, the present invention is characterized in that in the rotating machine, the coil group of each phase is formed by a plurality of concentrated winding coils.

Further, the present invention is characterized in that in the rotating machine, the coil group of each phase is formed by a plurality of continuous winding coils. Further, the present invention is characterized in that, in the rotating machine, a coil group of each phase is formed by a plurality of coil portions fixed by pressing. Further, the present invention, in a rotating machine having a stator provided with a plurality of phase coil groups in the stator core, the rising position of the terminal of the coil unit for each of the coil groups of each phase is configured to be different at both end faces of the stator core, A connection plate is formed on both end surfaces of the stator core, the connection plate having a conductor pattern connected to a terminal of a coil unit for each of the coil groups of each phase.

Further, the present invention is directed to a rotating machine having a rotor having a plurality of coil groups in a rotor core, wherein a rising position of a terminal of a coil portion is made different at both end faces of the stator core for each of the coil groups of each phase. It is characterized in that the terminals of the coil section do not cross each other between the coil groups of the respective phases. The present invention also provides a manufacturing process in which a continuous winding coil group in which a plurality of coil portions are continuously connected by a crossover is sequentially formed and removed for a plurality of phases by using a series-arranged type winding frame. The continuous winding coil groups for a plurality of phases that are sequentially formed and removed are sequentially changed, and the rising position from the coil portion of the crossover wire at each end face of the stator core is different for each phase of the continuous winding coil groups for each phase. A step of assembling the crossover wires into the stator core so that the crossover wires do not cross each other between the coil groups.

The present invention also provides a manufacturing step of sequentially forming and removing a continuous winding coil group in which a plurality of coil portions are continuously connected at a terminal using a series-arranged winding frame for a plurality of phases. Continuous winding coil groups for a plurality of phases sequentially formed and removed in the process are sequentially incorporated into the stator core by changing the rising position from the coil portion at the terminal at each end surface of the stator core for each phase of the continuous winding coil groups. A step of connecting the terminals of the coil units for each of the coil groups of the respective phases incorporated at both end surfaces of the stator core with a connection plate having a conductor pattern formed thereon. .

As described above, according to the above configuration,
Interference of the crossover between the coil groups of each phase can be prevented, the crossover and the connection portion can be reduced in size, and the entire rotating machine such as the stator and the motor can be reduced in size. Further, according to the above configuration, the coil group of each phase is formed by connecting a plurality of coil portions by a crossover and being continuously wound, so that an operation of connecting the coil portions is unnecessary. ,
In addition, since the crossovers are arranged so as to be spatially separated from the crossovers of the other phases, the interphase insulation can be simplified, the cost of the insulating member can be reduced, and the number of steps can be reduced. Further, since the crossovers are spatially separated from each other, the heat dissipation of the crossover portion can be improved.

Further, according to the above-described structure, the coil group of each phase having the coil portion fixed by pressing is fixed to the stator core in which the teeth portion is divided. Thus, high output, high efficiency, small size and light weight can be achieved. In addition, since the rising position of the crossover is different for each phase coil group, when assembling the high space factor coil, the crossover does not interfere and the assemblability can be improved. Further, according to the configuration,
When the connection of the crossover (terminal) is performed by the connection board over the coil groups of a plurality of phases, since the rising position of the crossover differs for each coil group of each phase, the connection may be performed using a single-layer conductor pattern. Thus, the connection plate can be reduced in size and simplified.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION A concentrated winding according to the present invention capable of shortening a coil end located at an end of a stator winding used in a high-output electric vehicle, a hybrid vehicle or the like which requires a large current to flow. An embodiment of a rotating machine such as a motor and a generator, which realizes miniaturization by utilizing the present invention, will be described with reference to the drawings. First, an embodiment according to the present invention will be described with reference to FIGS. FIG. 1 is a plan view of a stator showing one embodiment of a rotary motor according to the present invention, FIG. 2 is a perspective view of a stator showing one embodiment of a linear motor (linear motor) according to the present invention, and FIG. 1, a schematic configuration diagram showing a rotary motor, particularly a magnet motor, and FIG. 4 is an explanatory diagram showing an embodiment of a connection diagram of the coil shown in FIG. As shown in FIG. 3, the motor 1 has a stator 2 in which a coil group 8 is arranged according to a predetermined rule in a plurality of slots 7 a provided in a stator core 7, and is rotatably arranged in the stator 2. It is composed of a rotor 3. Frame 4
The stator 2 is fixed to the inner diameter side, and the shaft 5 fixed to the rotor 3 is supported by the bearing 6.

The stator core 7 has a thickness of, for example, 0.35 m.
It is formed by laminating thin electromagnetic steel sheets having a thickness of about 0.5 mm and 0.5 mm, and is fixed by caulking or welding.
Further, in the embodiment shown in FIG.
Are assembled by dividing the teeth portion 7b and the core back portion 7c (for example, the teeth portion 7
The protrusions b are fitted together and caulked or assembled by welding. In the configuration, the teeth portion 7b and the core back portion 7c are separately punched and laminated, and the teeth portion 7b is divided to improve the assemblability of the coil group 8. In the embodiment shown in FIG. 3, the magnet motor in which the permanent magnet 10 having a predetermined number of poles is arranged on the rotor 3 is shown. The number of poles and the number of slots are designed according to the required performance of the motor from various combinations such as, for example, 8 poles, 9 slots, 8 poles, 12 slots, 10 poles, 12 slots, and 16 poles, 24 slots. FIG. 1 shows an embodiment of a concentrated winding stator having three phases and 12 slots. In this case, it is composed of four coil groups per phase. For example, in the case of four series Y connection, FIG.
As shown in (4), four coil units of each phase are connected in series, and a connection configuration is made to connect a three-phase coil group at the neutral point N. At this time, for example, when the number of turns per phase is designed to be 40 turns, the number of turns per coil part is 10 turns. Here, as shown in FIG. 4B, the number of parallel circuits may be four and the number of turns per coil part may be 40 turns by connecting one series and four parallel connections, but the number of parallel circuits is increased. Then, it is susceptible to the influence of the imbalance of the coil resistances, and the circulating current flows in the connection circuit, which may reduce the efficiency. In addition, the number of coil terminals to be processed increases, which also causes an increase in the number of work steps. Therefore, in the present invention, at least two or more (plural) coil portions are connected in a coil connection. In addition, the present invention relates to a crossover connecting the coils of the stator, other rotor structure,
The same effect is obtained with other types of motors and generators.

The stator 2 shown in FIG. 1 has a three-phase, twelve-slot configuration, and is an embodiment in which one-phase coil groups are arranged at 90-degree pitches. Therefore, if the three-phase coil group is a U coil group 8a, a V coil group 8b, and a W coil group 8c, the U, V, and W coil groups are arranged every 30 degrees. As shown in FIG. 4A, in the case of four series Y connection, the coil unit is continuously wound for each phase.

Here, as shown in FIGS. 1 and 2, in the present invention, at both end portions (end coil portions) of the stator core 7, the crossover wire 9a of the U coil group 8a is set to the outer diameter side, and the W coil The connecting wire 9c of the group 8c is disposed on the inner diameter side, and the connecting wire 9b of the V coil group 8b is disposed substantially at the center of the coil.
As described above, the connecting wire 9 of each coil group 8a, 8b, 8c
The rising positions of a, 9b, and 9c are changed for each phase at the end face of the stator core, and the shapes are dispersed in the radial direction, so that the crossovers 9a to 9c interfere (intersect).
Can be prevented, and assemblability is improved. Also,
Since the crossover wires 9a to 9c for each phase are arranged apart from each other in the radial direction on the end face of the stator core, it is possible to eliminate or simplify the interphase insulation. Further, in the present embodiment, the configuration in which the coil portions of each phase are sequentially arranged in the circumferential direction in the 12-slot core has been described. However, the present invention is not limited to this coil arrangement. For example, the same configuration as shown in FIGS. A similar effect can be obtained even in a winding specification in which two coil portions of a phase are adjacent to each other and another phase is arranged next to the two coil portions.

Next, as described above, an embodiment of the means for changing the rising of the crossover for each phase according to the present invention will be described with reference to FIGS. 5 and 6. FIG. FIG. 5 shows the winding order of each phase. The lower side of the drawing shows the inner diameter side of the stator core, and the upper side shows the outer diameter side of the stator core. In this embodiment, the winding in which the arrangement of the wires in the coil unit is two layers in one turn of the coil unit is shown. 5 (a), (b),
(C) shows the U coil group 8a, the V coil group 8b, and the W coil group 8c formed in the same winding direction (for example, left-handed winding). Also, circled numbers in the figure are numbers indicating the winding order. The U coil group 8a has a winding start point Ps and a winding end point Pe on the outer diameter side, and the W coil group 8c has a winding start point Ps and a winding end point Pe on the inner diameter side, as opposed to the U coil group 8a. In the V coil group 8b, the winding start point Ps is on the outer diameter side, and the winding end point Pe is on the inner diameter side. in this way,
In order to control the arrangement of the wires located in the slots and perform the alignment winding, it is necessary to change the trajectory of the wires, for example, after winding the first layer and before starting the winding of the second layer. Therefore, FIG.
As shown in FIGS. 6A and 6B, the guide block 20 for holding the end of the first layer and guiding the line trajectory to the next winding position is moved upward by a not-shown actuator. , It is possible to selectively change the trajectory of the wire and skip the wire to a predetermined position for winding. 25 is a core metal block in the bobbin, 26
Indicates a brim block in the bobbin. In particular, 1.2m
In the case of a thick line of m or more, the winding tension is large and it is difficult to control only the traverse of the winding machine. Therefore, the winding track is controlled by a mechanism driven separately from the main winding by the guide block 20 or the like. Control is required.

Next, an embodiment of a stator core according to the present invention in which teeth are divided and a winding method for achieving a high space factor will be described with reference to FIGS. 7 and 8. FIG. FIGS. 7A, 7B, and 7C show an embodiment of a stator core (split core) divided into a tooth portion 7b and a core back portion 7c. FIG. 7A is a punching layout of a tooth portion and a core back portion, FIG. 7B is a stacked tooth portion 7b, a core back block 7d, and FIG.
The method for assembling the split core will be described. The teeth portion 7b is divided for each tooth, and is punched and laminated in a mold by a predetermined thickness. The core back portion 7c has a structure in which a core back block 7d divided into six in the circumferential direction is assembled. That is, every predetermined number of sheets, after punching and laminating in a mold,
By assembling the core back block 7d into a brick shape, the core back portion 7c is assembled in an annular shape. By this dividing method, the material utilization rate of the core can be improved, and the material cost can be reduced by 40 to 60% as compared with the method of integrally punching. Further, by forming the teeth 7b in a divided configuration, as shown in FIG. 7 (c), the coils arranged and wound outside the core can be assembled into the teeth 7b, so that the winding space factor is reduced. As a result, the efficiency and size and weight of the motor can be reduced.

FIG. 8 shows this winding method. The winding frame for continuous winding 24 is of a serial arrangement type, and has a cored metal block 25 having a flat cross section and a brim block 26 for guiding a coil.
And guide pins 27 for guiding the trajectory of the crossover 9 on the brim block 26. These are positioned and assembled. As shown in FIG. 10B, the root portion 30 and the distal end portion 31 of the cored bar block 25 are rotatably supported respectively. Further, a rotation shaft 32 provided at a root portion of the cored block 25 is configured to be rotationally connected to a rotation drive source (not shown). Further, as shown in FIGS. 8 and 10, the brim block 26 is formed in a U-shape so that it can be inserted into and removed from the metal core block 25.

First, before winding, the slot insulating member 12 is set on the metal core block 25 in advance. The insulating member 12 needs to be selected in consideration of cross-section pressure molding and coil fixing in a later process. It is good to use it as a bobbin shape manufactured to the shape corresponding to 25. Alternatively, a bobbin formed of a heat-resistant resin may be used. Further, in the subsequent step of forming a cross section, the tensile strength of the insulating material is set to 7 kg / mm in order to increase the design margin of the insulating properties of the insulating material.
It is better to select two or more. Further, in order to reduce copper loss (Joule heat loss caused by coil resistance and current) which is a cause of motor efficiency reduction, coil groups 8a to 8
c should be wound with a minimum circumference, and in order to realize this, the core axial dimension Lm of the cored bar block 25 is
Considering the minimum bending radius of the winding to the stator stacking thickness L, the minimum value is preferably obtained by adding the clearance of assembly.

Further, before winding, the open end of the U-shaped brim block 26 is inserted into the metal core block 25, and into the pin insertion holes formed in the metal brim block 26 and the metal core block 25, from the side. By inserting the member 26a with the pin planted therein, the brim block 26 is
Fix to 5.

Next, the outline of the winding operation will be described. First,
After the winding start point Ps is fixed to the guide pins 27 arranged on the brim block 26, as shown by the arrow in FIG. By running in the axial direction, winding of a predetermined number of turns is performed for each coil portion between the brim blocks 26. In the middle of the winding, as described with reference to FIGS. 5 and 6, after a predetermined number of windings, the guide block 20 is pressed against the wire to control the position of the wire to be wound next, and The winding end point Pe is arranged at a predetermined position. When the winding of one coil portion is completed, a wire is wound on the guide pin 27 on the adjacent brim block 26, and winding is continuously performed.

As shown in FIGS. 9 (a), 9 (b) and 9 (c), the position and direction of the crossover between the coil portions are changed, and the order of continuous winding is changed. By that
The positions of the winding start point Ps and the winding end point Pe of the coil groups 8a to 8c can be maintained at the positions described with reference to FIGS. 5A, 5B, and 5C. FIG. 9A shows a winding start point Ps and a winding end point Pe.
FIG. 9 (b) shows a winding method of the V coil group 8b with the winding start point Ps on the outer diameter side and the winding end point Pe on the inner diameter side. , FIG. 9 (c)
Shows the winding method of the W coil group 8c with the winding start point Ps and the winding end point Pe on the inner diameter side. 9 (a) and 9 (b)
In the winding order, as shown by the arrow, winding is performed from the upper side to the lower side. In FIG. 9C, as the winding order, as shown by the arrow, the winding is performed from the lower side to the upper side. Become.

Next, a molding and fixing step performed to improve the space factor of the winding will be described with reference to FIG. FIG.
FIG. 10A is a perspective view showing a method of forming a coil cross section, and FIG.
(B) shows a section forming method corresponding to continuous winding. Pressing blocks 28 are set on both sides of a coil continuously wound by the winding method shown in FIGS. 8 and 9, and pressure is applied from both sides, so that the coil cross section extends along the brim block 26 and the pressing block 28. Can be molded into a cross section. The pressurizing unit 29 is configured so that a pressurizing block 28 provided corresponding to the coil is attached to the pressurizing unit 29 so as to perform collective pressurizing. At this time, since the winding frame is also used as a molding die, the aligned winding state in the previous process is maintained. Further, as described with reference to FIG. 6, since the wires intersect at the coil end portion, the wires hardly intersect at the molded portion, and the insulation of the wire does not deteriorate. The inclination angle of the coil contact surface of the pressure block 27 is an angle corresponding to a predetermined number of slots. Further, the mold is configured to have a pressurized amount in consideration of the springback after molding. What is the processing pressure? For example, when the conductor constituting the coil is made of copper, the insulating film is made of polyamideimide, and a wire having a conductor diameter of 2.0 to 2.6 composed of one kind of insulation is used, in order to prevent the insulation characteristics from deteriorating, The processing pressure is preferably set to 35 kg / mm ² or less.

By this cross-section shaping, a series of coil sections are fixed for each phase coil group while the cross-section of the series of coil sections is being pressed. At this time, an insulating material may be fixed together. As a method, the wire is formed as a self-bonding wire having a fusion layer as an outermost layer, and the current in the coil end is heated or heated by a heater or the like, so that the fusion layer is melted and the wires in the coil portion are joined together. Is fixed. As described above, since the cross-section shaping and the fixing of the wires are performed while maintaining the aligned windings, a high space factor can be realized without deteriorating the alignment, and the rising position Ps of the crossover wire 9 can be realized. , Pe can be fixed at predetermined positions.

As described above, at the stage where the continuous winding coil 8 connected by the crossover wire 9 with the rising positions Ps and Pe fixed at predetermined positions for each phase is completed, the member 26a having the pin implanted is formed. Is extracted from the pin insertion holes formed in the collar block 26 and the core block 25, so that the collar block 26 can be removed from the core block 25. When the brim block 26 is removed from the core block 25, the continuous winding coil 8 having the crossover wire 9 removed from the guide pin 27 remains on the core block 25. Then, by removing the core block 25, the continuous winding coil 8 having the crossover 9 for each phase is completed. After inserting and assembling the completed continuous winding coil for each phase into the teeth portion 7b described in FIG. 7, the stator is assembled into the core back portion 7c, whereby a stator having a high winding space factor can be completed. . When assembling a coil group (continuous winding coil) for each phase formed by pressure molding on the teeth 7b, the crossover positions of the continuous coils are different for each phase coil group. No intersection).

In this embodiment, the method of forming the cross section in the slot after aligning and winding the round wire has been described. In order to shorten the axial direction, in the state shown in FIG.
The molding on the coil end side may be performed. Further, the space factor of the winding may be improved by using not only the round wire but also a substantially rectangular wire formed before the winding or a commercially available rectangular wire. Further, in the present embodiment, the assembling method has been described with respect to the split core in which the teeth portion is split. May be. As a result, it is possible to reduce the work of insulating the crossover wire portion that is continuously wound and to reduce the material cost of the insulating member. ,
This will be described with reference to FIGS. FIG. 11 shows a U continuous winding coil (U coil group) in which eight sets of the two adjacent coil parts shown in FIG. 13A and FIG. 13B are alternately arranged at 45 ° intervals. 8'a and the two adjacent coil portions shown in FIG. 13 (a) and FIG.
A V continuous winding coil (V coil group) 8'b arranged in a set;
13 (c) and FIG. 13 (d) with respect to two adjacent coil portions, a W continuous winding coil (W coil group) 8'c in which eight sets are alternately arranged at 45 degree intervals.
Are shown in an embodiment constructed by incorporating them into a stator.

FIG. 13 (a) shows a right-handed coil portion 80a having an outer diameter side as a winding start point Ps1 and an inner diameter side as a winding end point Pe1, and a winding section at the inner diameter side as a winding start point Ps2 and winding the outer diameter side. The left-handed coil portion 80b, which is the end point Pe2, is formed continuously with the crossover 81a on the inner diameter side. The coil unit 8
0a and the coil part 80b have different winding directions as indicated by arrows. FIG. 13B shows a left-handed coil portion 80c in which the outer diameter side has a winding start point Ps1 and the inner diameter side has a winding end point Pe1, and the inner diameter side has a winding start point Ps2 and the outer diameter side has a winding end point Pe2. The right-handed coil part 80d is formed continuously with the connecting wire 81b on the inner diameter side. Note that the winding directions of the coil portions 80c and 80d are different as indicated by arrows. The one shown in FIG.
A left-handed coil portion 80e whose inner diameter side is a winding start point Ps1 and whose outer diameter side is a winding end point Pe1, and a right-handed coil portion 80f whose outer diameter side is a winding start point Ps2 and whose inner diameter side is a winding end point Pe2 are outer diameter sides. Are formed continuously at the crossover line 81c. In addition,
The coil part 80e and the coil part 80f have different winding directions as indicated by arrows. FIG. 13 (d) shows a winding start point Ps1 on the inner diameter side and a winding end point Pe1 on the outer diameter side.
And a winding start point Ps2 on the outer diameter side.
And the left-handed coil part 80 whose inner diameter side is the winding end point Pe2
h is continuously formed by the crossover wire 81d on the outer diameter side. In addition, the coil part 80g and the coil part 80h have different winding directions as indicated by arrows.

The crossover wire 9'a arranged on the outer diameter side of the U continuous winding coil (U coil group) 8'a incorporated in the stator described above and the W continuous winding coil (W coil group) 8 ' The crossover wire 9'c arranged on the inner diameter side of the crossover wire 'c' can be arranged without interference by shortening the length of the crossover wire, and further, the V continuous winding coil (V coil group) 9'b
The crossover wire 9'c of the W continuous winding coil 8'c is slightly different from the crossover wire 9'b of the W continuous winding coil 8'c because the crossover wire 9'b is disposed at an intermediate portion between the outer diameter side and the inner diameter side. By pushing inward, the length of the crossover can be reduced to prevent interference. NU, NW,
The NVs are connected in common and can constitute a stator having the connection coils shown in FIG.

FIG. 12 shows a U-continuous winding coil (U) in which eight sets of two adjacent coil parts shown in FIG. 13 (a) and FIG. 13 (b) are alternately arranged at 45 ° intervals. A coil group) 8'a and a V-continuously wound coil (8 sets of two adjacent coil sections alternately arranged at intervals of 45 degrees with those shown in FIG. 13A and those shown in FIG. 13B) V coil group) 8 ″ b and W continuous winding coils in which eight sets of two adjacent coil parts shown in FIG. 13C and FIG. 13D are alternately arranged at 45 ° intervals. (W coil group) 8′c is shown in an embodiment constructed by incorporating it into a stator, which differs from FIG. In this way, the crossover in the V continuous winding coil 8 "b By connecting b on the outer diameter side, the crossover wire 9'a disposed on the outer diameter side of the U continuous winding coil 8'a is slightly pushed out to the outer diameter side, thereby shortening the crossover wire and causing interference. Can be prevented. In particular, in the case of the embodiment shown in FIG. 12, compared with the embodiment shown in FIG. 11, the crossover wire 9'a arranged on the outer diameter side of the U continuous winding coil 8'a is slightly pushed out to the outer diameter side. Therefore, the interference of the crossover can be easily realized. The NU, NW, and NV are commonly connected, and can constitute a stator having the connection coils shown in FIG.

FIG. 16 shows a U-continuous winding coil, a V-continuous winding coil, and a W-continuous winding in which two adjacent coil portions having the configuration shown in FIG. 13A are sequentially arranged at intervals of 45 degrees. 7 shows a comparative example in which a wire coil is inserted into a stator. FIG. 17 shows two adjacent coil portions in FIG.
A U-continuous winding coil, a V-continuous winding coil, and a W-continuous winding coil in which the configuration shown in FIG. 3A and the configuration shown in FIG. Shows a comparative example inserted. Thus, in the case of the comparative example shown in FIGS. 16 and 17, the crossover of the U continuous winding coil, the crossover of the V continuous winding coil, and the crossover of the W continuous winding coil intersect. It is clear that it will.

However, in the embodiment of the present invention shown in FIG. 11 and FIG.
Interference between the crossover of the continuous winding coil and the crossover of the W continuous winding coil can be prevented by shortening the length of the crossover.

Next, the U-winding coil 8'a and the V-winding coils 8'b, 8 "inserted (incorporated) into the stator.
An embodiment in which the connecting wires of the b and W winding coils 8'c are connected by using a single connection plate 90 will be described with reference to FIG. FIG. 14 shows a U-winding coil 8 ′ shown in FIG.
a, a simplified connection plate 90 provided on each of both end faces of the stator core 7 in a stator in which the V winding coil 8 "b and the W winding coil 8'c are incorporated. As shown in FIG. 12, by forming the U winding coil 8'a, the V winding coil 8'b, 8 "b, and the W winding coil 8'c, the crossover of each coil does not interfere. Therefore, it is possible to connect the coil portions of each phase coil group using one connection plate 60 on which a simplified one-layer wiring pattern (conductor pattern) as shown in FIG. 14 is formed. Become. As the connection plate 90, a one-layer conductor pattern 92 for connecting the coils is formed on an insulating resin substrate or a ceramic substrate 91.
1 through the through holes formed in each of the conductor patterns 9
2 and the electric wire of each coil are connected by soldering, fusion bonding, caulking, or the like. Then, if necessary, the conductor pattern including the connection portion formed on the substrate 91 is covered with an insulator.

In the case of the connection plate 90 corresponding to the embodiment shown in FIG. 11, the substrate 91 is arranged so as to correspond to the crossover 9'c.
It is necessary to protrude the conductor pattern formed on the inner side of the inner side of the coil to the extent that it does not contact the rotor. In addition, a U-continuously wound coil, a V-continuously wound coil which prevents interference in the crossover portion according to the present invention described above,
As shown in FIG. 15, the W and W continuous winding coils may be mounted on a rotor.

According to the embodiment of the present invention described above, at least two stator cores or rotor cores are provided.
In a motor composed of a stator or a rotor having a coil group of more than one phase, the rising position of the terminal of the coil unit is changed for each coil group of each phase, so that the position at which the coil units are connected to each other for each phase coil group. Are distributed in the radial direction,
Interference (crossing) of the crossover of each phase can be prevented,
The crossover and the connecting portion can be reduced in size, and the stator or the rotor and the entire motor can be reduced in size. In addition, since the crossover is arranged so as to be spatially separated from the crossover of the other phase, interphase insulation can be simplified,
Cost reduction and man-hour reduction of the insulating member can be achieved.
Further, since the crossovers are spatially separated from each other, the heat dissipation of the crossover portion can be improved.

According to the embodiment of the present invention,
For each coil group of each phase, in particular, a portion located in the slot of the coil portion wound on the stator core is formed, and the coil portion is incorporated in the stator core into which the teeth portion is divided, so that the winding is formed. The space factor can be improved, and high output, high efficiency, small size and light weight can be achieved. In addition, since the rising position of the crossover is different for each phase, when assembling the high space factor coil, the crossover does not interfere,
The assemblability is improved.

The rotary motor has mainly been described above. However, the present invention is not limited to this, and similar effects can be obtained by applying the present invention to a linear motor (linear motor) as shown in FIG. The same applies to the generator. In addition, since the motor and the generator are key parts of the set product, high efficiency, small size, light weight, and low price of the set product using the present invention can be realized. In particular, the effect is large in an electric vehicle, a hybrid vehicle, and the like that require a stator winding using a coil having a large conductor cross-sectional area with a small mounting space for a high-output motor.

[0038]

According to the present invention, the winding space factor can be improved and the output can be increased by miniaturizing or simplifying the crossover portions or connection portions (end coil portions) at both end portions of the stator core and the like. In addition, there is an effect that a rotating machine with high efficiency and small size and light weight can be realized. In particular, small mounting space for the high output motor, an electric vehicle in which the conductor cross-sectional area (4.0mm ² ~4.5mm ² about) stator windings are required with large coils, the hybrid vehicle or the like, increase the effect can do.

[Brief description of the drawings]

FIG. 1 is a plan view of a stator showing an embodiment of a rotary motor according to the present invention.

FIG. 2 is a perspective view of a stator showing one embodiment of a linear motor (linear motor) according to the present invention.

FIG. 3 is a schematic configuration diagram of the rotary motor shown in FIG. 1;

FIG. 4 is an explanatory diagram showing one embodiment of a connection diagram of the coil shown in FIG. 1;

FIG. 5 is an explanatory diagram showing a winding order for each phase according to the present invention.

FIG. 6 is an explanatory diagram showing a method of changing a winding order according to the present invention.

FIG. 7 is an explanatory diagram of a split core according to the present invention.

FIG. 8 is an explanatory diagram showing a continuous winding method for a coil group (continuously wound coil) of each phase according to the present invention.

FIG. 9 is an explanatory diagram showing a continuous winding in which the winding order is changed for each phase coil group according to the present invention.

FIG. 10 is an explanatory view showing a method of pressure forming and fixing a series of coil portions.

FIG. 11 shows a three-phase 16 in the rotary motor according to the present invention.
FIG. 3 is a plan view showing a first embodiment of a slot stator.

FIG. 12 shows a three-phase 16 in the rotary motor according to the present invention.
FIG. 6 is a plan view showing a second embodiment of the slot stator.

FIG. 13 is a view for explaining four types of winding methods for two adjacent coil portions used in the embodiment shown in FIGS. 11 and 12;

FIG. 14 is a view showing an embodiment of a connection plate corresponding to the embodiment shown in FIG. 12 according to the present invention.

FIG. 15 is a plan view of a rotor showing an embodiment of the rotary motor according to the present invention.

FIG. 16 shows a three-phase 16 in the rotary motor according to the present invention.
It is a top view showing the 1st comparative example of the stator of the slot.

FIG. 17 shows a three-phase 16 in the rotary motor according to the present invention.
It is a top view showing the 1st comparative example of the stator of the slot.

FIG. 18 is a view showing a conventional stator structure.

FIG. 19 is a view showing another conventional stator structure.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Motor, 2 ... Stator, 3 ... Rotor, 4 ... Frame, 5 ... Shaft, 6 ... Bearing, 7 ... Stator core, 7
a: slot, 7b: teeth portion, 7c: core back portion, 7d: core back block, 8: coil group, 8a,
8'a: U coil group (U continuous winding coil), 8b, 8 '
b, 8 "b... V coil group (V continuous winding coil), 8c,
8'c: W coil group (W continuous winding coil), 9a, 9
b, 9c, 9'a, 9'b, 9'c, 9 "b ... crossover,
DESCRIPTION OF SYMBOLS 10 ... Permanent magnet, 12 ... Insulating member, 20 ... Guide block, 24 ... Series-arranged winding frame (continuous winding frame), 25
... Core bar block, 26. Brim block, 27... Guide pin, 28... Pressure block, 29.
-80h ... coil part, 81a-81d ... crossover.

────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] August 4, 2000 (200.8.4)

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Full text

[Correction method] Change

[Correction contents]

[Document Name] Statement

[Title of the Invention] Rotating machine

[Claims]

And wherein 1 0] removed are sequentially formed by using a series arrangement type of the bobbin for a plurality of phases of continuously wound coils, which had been successively with a crossover wire plurality of coil portions manufacturing process, in the manufacturing process The continuous winding coil groups for a plurality of phases that are sequentially formed and removed are sequentially changed. Assembling into a stator core such that the crossovers between the coil groups do not cross each other.

And wherein 1 1] Removing a plurality of coil portions are sequentially formed by using a series arrangement type bobbin for multiple phases continuously wound coils which had been continuously in the terminal manufacturing process, sequentially in the manufacturing process The continuous winding coil groups for a plurality of phases to be formed and removed are sequentially incorporated into the stator core by changing the rising position from the coil portion at the terminal at each end face of the stator core for each phase of the continuous winding coil groups. A step of connecting the terminals of the coil portions for each of the coil groups of the respective phases incorporated by a connection plate on which a conductor pattern is formed at both end portions of the rotating machine.

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a motor (rotary motor, linear motor) and a rotating machine such as a generator used for various industrial equipment, and in particular, to a high-output electric power which needs to flow a large current. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotating machine such as a motor and a generator that realizes downsizing by using a concentrated winding capable of shortening a coil end located at an end of a stator winding used in an automobile, a hybrid car, and the like.

[0002]

2. Description of the Related Art For example, in a rotating machine such as a motor or a generator employing a concentrated winding, coils of each phase of a stator winding are coiled for each phase in a Y-connection or a △ -connection. Need to be connected. In the concentrated winding, the following method is used as a means for streamlining the terminal processing of each coil. One is Japanese Unexamined Patent Publication No.
As disclosed in Japanese Patent No. 18331, an insulator 31a in which a crossover of a coil in which a predetermined number of coils are continuously wound in each phase is provided on the outer periphery of the core,
By arranging the crossover wires 9 along the grooves 32a and 32b for each phase of 31b, connection of each coil is not required. In another method, Japanese Patent Laid-Open No. 6-2334 shown in FIG.
As disclosed in Japanese Patent Publication No. 83, the connection of each coil is performed by connecting the terminal wires 34 of the coils individually wound to a separately provided wiring board 35.

[0003]

However, in the former case,
Since it is necessary to arrange the crossover wires in the grooves of the insulator at the outer peripheral portion of the core and to secure insulation between the phases, a large area is required only for wiring in the outer peripheral portion of the core and in the axial direction of the core. In particular, for high-output motors represented by electric vehicles and hybrid vehicles, high efficiency, small size and light weight are issues.
The conductor area of the coil is increased in accordance with the specifications for higher output. For example, the conductor cross-sectional area per coil turn is 4.
It is in need of 0mm ² ~4.5mm ² degree. Therefore, in the conventional method in which the crossover wires are concentrated only on the outer peripheral portion, it is difficult to arrange the crossover wires of each phase so as not to interfere with each other, and a motor having a large core outer diameter or a motor having a large core diameter. Becomes On the other hand, in order to improve the fuel efficiency, it is necessary to reduce the size and weight of the entire vehicle and the size and weight of the motor to be mounted. Further, since the crossovers are arranged on substantially the same circumference, an insulating material for securing insulation between phases is required.

[0004] In the case of the latter connection by a wiring board,
Since each coil is wound as a single unit, operations such as peeling of the film of each coil terminal, connection to the substrate, and insulation of the connection portion are required for each coil, and the number of connection steps is increased. Furthermore, in the case of a high-output motor, since the conductor area is large, it is difficult to lay out the conductors of each phase in the wiring board at high density, and the wiring board becomes thicker in the axial direction or larger in the radial direction. Further, in a configuration in which thin plates for each phase are laminated in the axial direction as in a conventional type wiring board, there is a problem that heat dissipation of conductors in the wiring board is poor.

[0005] An object of the present invention is to solve the above problems.
A rotating machine that achieves high output, high efficiency, and small size and light weight by reducing or simplifying the crossover wire or connection portion (end coil portion) at both end surfaces of the stator core, etc., and improving the winding space factor. Is to provide. Further, another object of the present invention is to reduce or simplify the crossover portion or the connection portion (end coil portion) at both end portions of the stator core and the like, improve the winding space factor, increase the output, and increase the efficiency. It is an object of the present invention to provide a method for manufacturing a rotating machine capable of manufacturing a rotating machine that is compact and lightweight.

[0006]

In order to achieve the above object, the present invention relates to a rotating machine having a stator having a plurality of coil groups in a stator core. The rising position is different at both end portions of the stator core, and the positions at which the coil portions are connected between the coil groups of each phase are dispersed in the radial direction so that the terminals of the coil portions do not cross each other. I do. The present invention also provides a rotating machine having a stator having a plurality of coil groups in a stator core, wherein each of the coil groups of each phase is configured by connecting a plurality of coil sections with a crossover, and It is characterized in that the rising positions from the coil portions in the crossovers for the respective groups are made different at both end portions of the stator core so that the crossovers do not cross each other between the coil groups of the respective phases.

The present invention also provides a rotating machine having a stator having a plurality of coil groups of a plurality of phases on a stator core, wherein each of the plurality of coil groups is connected in series with a plurality of coil sections via a crossover. The crossover wire for each coil group of each phase may be arranged so as to be separated from each other at both end surfaces of the stator core. Further, the present invention is characterized in that in the rotating machine, the stator core is constituted by a split core including a teeth portion and a core back portion. Further, the present invention is characterized in that in the rotating machine, a coil group of each phase is incorporated in a tooth portion of a divided core. Further, the present invention is characterized in that in the rotating machine, the coil group of each phase is formed by a plurality of concentrated winding coils.

Further, the present invention is characterized in that in the rotating machine, the coil group of each phase is formed by a plurality of continuous winding coils. Further, the present invention is characterized in that, in the rotating machine, a coil group of each phase is formed by a plurality of coil portions fixed by pressing. Further, the present invention, in a rotating machine having a stator provided with a plurality of phase coil groups in the stator core, the rising position of the terminal of the coil unit for each of the coil groups of each phase is configured to be different at both end faces of the stator core, A connection plate is formed on both end surfaces of the stator core, the connection plate having a conductor pattern connected to a terminal of a coil unit for each of the coil groups of each phase.

[0009] Also, the present invention includes a manufacturing step of removing are sequentially formed by using a series arrangement type of the bobbin for a plurality of phases of continuously wound coils, which had been successively a plurality of coil portions in connecting wire, The continuous winding coil groups for a plurality of phases that are sequentially formed and removed in the manufacturing process are sequentially changed, and the rising position from the coil portion of the crossover wire at each end face of the stator core is changed for each continuous winding coil group of each phase. A step of assembling the crossover wires into the stator core so that the crossover wires do not cross each other between the coil groups of the respective phases.

The present invention also provides a manufacturing step of sequentially forming and removing a continuous winding coil group in which a plurality of coil portions are continuously connected at a terminal using a series-arranged winding frame for a plurality of phases. Continuous winding coil groups for a plurality of phases sequentially formed and removed in the process are sequentially incorporated into the stator core by changing the rising position from the coil portion at the terminal at each end surface of the stator core for each phase of the continuous winding coil groups. A step of connecting the terminals of the coil units for each of the coil groups of the respective phases incorporated at both end surfaces of the stator core with a connection plate having a conductor pattern formed thereon. .

As described above, according to the above configuration,
Interference of the crossover between the coil groups of each phase can be prevented, the crossover and the connection portion can be reduced in size, and the entire rotating machine such as the stator and the motor can be reduced in size. Further, according to the above configuration, the coil group of each phase is formed by connecting a plurality of coil portions by a crossover and being continuously wound, so that an operation of connecting the coil portions is unnecessary. In addition, since the crossovers are arranged so as to be spatially separated from the crossovers of the other phases, the interphase insulation can be simplified, the cost of the insulating member can be reduced, and the number of steps can be reduced. Further, since the crossovers are spatially separated from each other, the heat dissipation of the crossover portion can be improved.

Further, according to the above-described structure, the coil group of each phase having the coil portion fixed by pressing is fixed to the stator core in which the teeth portion is divided. Thus, high output, high efficiency, small size and light weight can be achieved. In addition, since the rising position of the crossover is different for each phase coil group, when assembling the high space factor coil, the crossover does not interfere and the assemblability can be improved. Further, according to the configuration,
When the connection of the crossover (terminal) is performed by the connection board over the coil groups of a plurality of phases, since the rising position of the crossover differs for each coil group of each phase, the connection may be performed using a single-layer conductor pattern. Thus, the connection plate can be reduced in size and simplified.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION A concentrated winding according to the present invention capable of shortening a coil end located at an end of a stator winding used in a high-output electric vehicle, a hybrid vehicle or the like which requires a large current to flow. An embodiment of a rotating machine such as a motor and a generator, which realizes miniaturization by utilizing the present invention, will be described with reference to the drawings. First, an embodiment according to the present invention will be described with reference to FIGS. FIG. 1 is a plan view of a stator showing one embodiment of a rotary motor according to the present invention, FIG. 2 is a perspective view of a stator showing one embodiment of a linear motor (linear motor) according to the present invention, and FIG. 1, a schematic configuration diagram showing a rotary motor, particularly a magnet motor, and FIG. 4 is an explanatory diagram showing an embodiment of a connection diagram of the coil shown in FIG. As shown in FIG. 3, the motor 1 has a stator 2 in which a coil group 8 is arranged according to a predetermined rule in a plurality of slots 7 a provided in a stator core 7, and is rotatably arranged in the stator 2. It is composed of a rotor 3. Frame 4
The stator 2 is fixed to the inner diameter side, and the shaft 5 fixed to the rotor 3 is supported by the bearing 6.

The stator core 7 has a thickness of, for example, 0.35 m.
m, laminated thin electromagnetic steel sheets of 0.5 mm,
It is fixed by swaging or welding. Further, in the embodiment shown in FIG.
Are assembled by dividing the teeth portion 7b and the core back portion 7c (for example, the teeth portion 7
The protrusions b are fitted together and caulked or assembled by welding. In the configuration, the teeth portion 7b and the core back portion 7c are separately punched and laminated, and the teeth portion 7b is divided to improve the assemblability of the coil group 8. In the embodiment shown in FIG. 3, the magnet motor in which the permanent magnet 10 having a predetermined number of poles is arranged on the rotor 3 is shown. The number of poles and the number of slots are designed according to the required performance of the motor from various combinations such as, for example, 8 poles, 9 slots, 8 poles, 12 slots, 10 poles, 12 slots, and 16 poles, 24 slots. FIG. 1 shows an embodiment of a concentrated winding stator having three phases and 12 slots. In this case, it is composed of four coil groups per phase. For example, in the case of four series Y connection, FIG.
As shown in (4), four coil units of each phase are connected in series, and a connection configuration is made to connect a three-phase coil group at the neutral point N. At this time, for example, when the number of turns per phase is designed to be 40 turns, the number of turns per coil part is 10 turns. Here, as shown in FIG. 4B, the number of parallel circuits may be four and the number of turns per coil part may be 40 turns by connecting one series and four parallel connections, but the number of parallel circuits is increased. Then, it is susceptible to the influence of the imbalance of the coil resistances, and the circulating current flows in the connection circuit, which may reduce the efficiency. In addition, the number of coil terminals to be processed increases, which also causes an increase in the number of work steps. Therefore, in the present invention, at least two or more (plural) coil portions are connected in a coil connection. In addition, the present invention relates to a crossover connecting the coils of the stator, other rotor structure,
The same effect is obtained with other types of motors and generators.

The stator 2 shown in FIG. 1 has a three-phase, twelve-slot configuration, and is an embodiment in which one-phase coil groups are arranged at 90-degree pitches. Therefore, if the three-phase coil group is a U coil group 8a, a V coil group 8b, and a W coil group 8c, the U, V, and W coil groups are arranged every 30 degrees. As shown in FIG. 4A, in the case of four series Y connection, the coil unit is continuously wound for each phase.

Here, as shown in FIGS. 1 and 2, in the present invention, at both end portions (end coil portions) of the stator core 7, the crossover wire 9a of the U coil group 8a is set to the outer diameter side, and the W coil The connecting wire 9c of the group 8c is disposed on the inner diameter side, and the connecting wire 9b of the V coil group 8b is disposed substantially at the center of the coil.
As described above, the connecting wire 9 of each coil group 8a, 8b, 8c
The rising positions of a, 9b, and 9c are changed for each phase at the end face of the stator core, and the shapes are dispersed in the radial direction, so that the crossovers 9a to 9c interfere (intersect).
Can be prevented, and assemblability is improved. Also,
Since the crossover wires 9a to 9c for each phase are arranged apart from each other in the radial direction on the end face of the stator core, it is possible to eliminate or simplify the interphase insulation. Further, in the present embodiment, the configuration in which the coil portions of each phase are sequentially arranged in the circumferential direction in the 12-slot core has been described. However, the present invention is not limited to this coil arrangement. For example, the same configuration as shown in FIGS. A similar effect can be obtained even in a winding specification in which two coil portions of a phase are adjacent to each other and another phase is arranged next to the two coil portions.

Next, as described above, an embodiment of the means for changing the rising of the crossover for each phase according to the present invention will be described with reference to FIGS. 5 and 6. FIG. FIG. 5 shows the winding order of each phase. The lower side of the drawing shows the inner diameter side of the stator core, and the upper side shows the outer diameter side of the stator core. In this embodiment, the winding in which the arrangement of the wires in the coil unit is two layers in one turn of the coil unit is shown. 5 (a), (b),
(C) shows the U coil group 8a, the V coil group 8b, and the W coil group 8c formed in the same winding direction (for example, left-handed winding). Also, circled numbers in the figure are numbers indicating the winding order. The U coil group 8a has a winding start point Ps and a winding end point Pe on the outer diameter side, and the W coil group 8c has a winding start point Ps and a winding end point Pe on the inner diameter side, as opposed to the U coil group 8a. In the V coil group 8b, the winding start point Ps is on the outer diameter side, and the winding end point Pe is on the inner diameter side. in this way,
In order to control the arrangement of the wires located in the slots and perform the alignment winding, it is necessary to change the trajectory of the wires, for example, after winding the first layer and before starting the winding of the second layer. Therefore, FIG.
As shown in FIGS. 6A and 6B, the guide block 20 for holding the end of the first layer and guiding the line trajectory to the next winding position is moved upward by a not-shown actuator. , It is possible to selectively change the trajectory of the wire and skip the wire to a predetermined position for winding. 25 is a core metal block in the bobbin, 26
Indicates a brim block in the bobbin. In particular, 1.2m
In the case of a thick line of m or more, the winding tension is large and it is difficult to control only the traverse of the winding machine. Therefore, the winding track is controlled by a mechanism driven separately from the main winding by the guide block 20 or the like. Control is required.

Next, an embodiment of a stator core according to the present invention in which teeth are divided and a winding method for achieving a high space factor will be described with reference to FIGS. 7 and 8. FIG. FIGS. 7A, 7B, and 7C show an embodiment of a stator core (split core) divided into a tooth portion 7b and a core back portion 7c. FIG. 7A is a punching layout of a tooth portion and a core back portion, FIG. 7B is a stacked tooth portion 7b, a core back block 7d, and FIG.
The method for assembling the split core will be described. The teeth portion 7b is divided for each tooth, and is punched and laminated in a mold by a predetermined thickness. The core back portion 7c has a structure in which a core back block 7d divided into six in the circumferential direction is assembled. That is, every predetermined number of sheets, after punching and laminating in a mold,
By assembling the core back block 7d into a brick shape, the core back portion 7c is assembled in an annular shape. By this dividing method, the material utilization rate of the core can be improved, and the material cost can be reduced by 40 to 60% as compared with the method of integrally punching. Further, by forming the teeth 7b in a divided configuration, as shown in FIG. 7 (c), the coils arranged and wound outside the core can be assembled into the teeth 7b, so that the winding space factor is reduced. As a result, the efficiency and size and weight of the motor can be reduced.

FIG. 8 shows this winding method. The winding frame for continuous winding 24 is of a serial arrangement type, and has a cored metal block 25 having a flat cross section and a brim block 26 for guiding a coil.
And guide pins 27 for guiding the trajectory of the crossover 9 on the brim block 26. These are positioned and assembled. As shown in FIG. 10B, the root portion 30 and the distal end portion 31 of the cored bar block 25 are rotatably supported respectively. Further, a rotation shaft 32 provided at a root portion of the cored block 25 is configured to be rotationally connected to a rotation drive source (not shown). Further, as shown in FIGS. 8 and 10, the brim block 26 is formed in a U-shape so that it can be inserted into and removed from the metal core block 25.

First, before winding, the slot insulating member 12 is set on the metal core block 25 in advance. It is necessary to select the insulating member 12 in consideration of cross-section pressure molding and coil fixation in a later process. For example, using an aramid paper, an engineering plastic material, a liquid crystal polymer, or the like, It is preferable to use it as a bobbin shape manufactured in a shape corresponding to the winding frame 25. Alternatively, a bobbin formed of a heat-resistant resin may be used. Further, it is more preferable to select an insulating material having a tensile strength of 7 kg / mm ² or more in order to increase the design margin of the insulating properties of the insulating material in the subsequent cross-section forming step. Further, in order to reduce copper loss (Joule heat loss caused by coil resistance and current) which causes a reduction in motor efficiency, the coil groups 8a to 8c should be wound with a minimum circumference. In order to realize this, the core axial dimension Lm of the cored metal block 25 may be set to the minimum value obtained by adding the clearance for assembly in consideration of the minimum bending radius of the winding to the stator stacking thickness L.

Further, before winding, the open end of the U-shaped brim block 26 is inserted into the metal core block 25, and into the pin insertion holes formed in the metal brim block 26 and the metal core block 25, from the side. By inserting the member 26a with the pin planted therein, the brim block 26 is
Fix to 5.

Next, the outline of the winding operation will be described. First,
After the winding start point Ps is fixed to the guide pins 27 arranged on the brim block 26, as shown by the arrow in FIG. By running in the axial direction, winding of a predetermined number of turns is performed for each coil portion between the brim blocks 26. In the middle of the winding, as described with reference to FIGS. 5 and 6, after a predetermined number of windings, the guide block 20 is pressed against the wire to control the position of the wire to be wound next, and The winding end point Pe is arranged at a predetermined position. When the winding of one coil portion is completed, a wire is wound on the guide pin 27 on the adjacent brim block 26, and winding is continuously performed.

As shown in FIGS. 9 (a), 9 (b) and 9 (c), the position and direction of the crossover between the coil portions are changed, and the order of continuous winding is changed. By that
The positions of the winding start point Ps and the winding end point Pe of the coil groups 8a to 8c can be maintained at the positions described with reference to FIGS. 5A, 5B, and 5C. FIG. 9A shows a winding start point Ps and a winding end point Pe.
FIG. 9 (b) shows a winding method of the V coil group 8b with the winding start point Ps on the outer diameter side and the winding end point Pe on the inner diameter side. , FIG. 9 (c)
Shows the winding method of the W coil group 8c with the winding start point Ps and the winding end point Pe on the inner diameter side. 9 (a) and 9 (b)
In the winding order, as shown by the arrow, winding is performed from the upper side to the lower side. In FIG. 9C, as the winding order, as shown by the arrow, the winding is performed from the lower side to the upper side. Become.

Next, a molding and fixing step performed to improve the space factor of the winding will be described with reference to FIG. FIG.
FIG. 10A is a perspective view showing a method of forming a coil cross section, and FIG.
(B) shows a section forming method corresponding to continuous winding. Pressing blocks 28 are set on both sides of a coil continuously wound by the winding method shown in FIGS. 8 and 9, and pressure is applied from both sides, so that the coil cross section extends along the brim block 26 and the pressing block 28. Can be molded into a cross section. The pressurizing unit 29 is configured so that a pressurizing block 28 provided corresponding to the coil is attached to the pressurizing unit 29 so as to perform collective pressurizing. At this time, since the winding frame is also used as a molding die, the aligned winding state in the previous process is maintained. Further, as described with reference to FIG. 6, since the wires intersect at the coil end portion, the wires hardly intersect at the molded portion, and the insulation of the wire does not deteriorate. The inclination angle of the coil contact surface of the pressure block 27 is an angle corresponding to a predetermined number of slots. Further, the mold is configured to have a pressurized amount in consideration of the springback after molding. Processing pressure, for example, the conductors constituting the coils as copper, the insulating film polyamideimide, when using a wire of conductor diameter 2.0 to 2.6 which is an insulating one thickness, deterioration of the insulation properties In order to prevent this, the processing pressure is preferably set to 35 kg / mm ² or less.

By this cross-section shaping, a series of coil sections are fixed for each phase coil group while the cross-section of the series of coil sections is being pressed. At this time, an insulating material may be fixed together. As a method, the wire is formed as a self-bonding wire having a fusion layer as an outermost layer, and the current in the coil end is heated or heated by a heater or the like, so that the fusion layer is melted and the wires in the coil portion are joined together. Is fixed. As described above, since the cross-section shaping and the fixing of the wires are performed while maintaining the aligned windings, a high space factor can be realized without deteriorating the alignment, and the rising position Ps of the crossover wire 9 can be realized. , Pe can be fixed at predetermined positions.

As described above, at the stage where the continuous winding coil 8 connected by the crossover wire 9 with the rising positions Ps and Pe fixed at predetermined positions for each phase is completed, the member 26a having the pin implanted is formed. Is extracted from the pin insertion holes formed in the collar block 26 and the core block 25, so that the collar block 26 can be removed from the core block 25. When the brim block 26 is removed from the core block 25, the continuous winding coil 8 having the crossover wire 9 removed from the guide pin 27 remains on the core block 25. Then, by removing the core block 25, the continuous winding coil 8 having the crossover 9 for each phase is completed. After inserting and assembling the completed continuous winding coil for each phase into the teeth portion 7b described in FIG. 7, the stator is assembled into the core back portion 7c, whereby a stator having a high winding space factor can be completed. . When assembling a coil group (continuous winding coil) for each phase formed by pressure molding on the teeth 7b, the crossover positions of the continuous coils are different for each phase coil group. No intersection).

In this embodiment, the method of forming the cross section in the slot after aligning and winding the round wire has been described. In order to shorten the axial direction, in the state shown in FIG.
The molding on the coil end side may be performed. Further, the space factor of the winding may be improved by using not only the round wire but also a substantially rectangular wire formed before the winding or a commercially available rectangular wire. Further, in the present embodiment, the assembling method has been described with respect to the split core in which the teeth portion is split. May be. As a result, it is possible to reduce the work of insulating the crossover wire portion that is continuously wound and to reduce the material cost of the insulating member. Next, an embodiment of a three-phase 48- slot stator in which interference of the crossover 9 for each phase is prevented will be described with reference to FIGS. FIG. 11 shows an example in which two adjacent coil portions are alternately shown in FIG. 13A and those shown in FIG.
A set of U continuous winding coils (U coil group) 8'a;
V-continuously wound coil (V coil group) 8'b in which eight sets of two adjacent coil parts shown in FIG. 13A and FIG. 13C are alternately arranged at intervals of 45 degrees.
And a continuous W coil (W coil group) in which eight sets of two adjacent coil parts shown in FIG. 13C and FIG. 13D are alternately arranged at 45 ° intervals.
8'c shows an embodiment constructed by incorporating it into a stator.

FIG. 13 (a) shows a right-handed coil portion 80a having an outer diameter side as a winding start point Ps1 and an inner diameter side as a winding end point Pe1, and a winding section at the inner diameter side as a winding start point Ps2 and winding the outer diameter side. The left-handed coil portion 80b, which is the end point Pe2, is formed continuously with the crossover 81a on the inner diameter side. The coil unit 8
0a and the coil part 80b have different winding directions as indicated by arrows. FIG. 13B shows a left-handed coil portion 80c in which the outer diameter side has a winding start point Ps1 and the inner diameter side has a winding end point Pe1, and the inner diameter side has a winding start point Ps2 and the outer diameter side has a winding end point Pe2. The right-handed coil part 80d is formed continuously with the connecting wire 81b on the inner diameter side. Note that the winding directions of the coil portions 80c and 80d are different as indicated by arrows. The one shown in FIG.
A left-handed coil portion 80e whose inner diameter side is a winding start point Ps1 and whose outer diameter side is a winding end point Pe1, and a right-handed coil portion 80f whose outer diameter side is a winding start point Ps2 and whose inner diameter side is a winding end point Pe2 are outer diameter sides. Are formed continuously at the crossover line 81c. In addition,
The coil part 80e and the coil part 80f have different winding directions as indicated by arrows. FIG. 13 (d) shows a winding start point Ps1 on the inner diameter side and a winding end point Pe1 on the outer diameter side.
And a winding start point Ps2 on the outer diameter side.
And the left-handed coil part 80 whose inner diameter side is the winding end point Pe2
h is continuously formed by the crossover wire 81d on the outer diameter side. In addition, the coil part 80g and the coil part 80h have different winding directions as indicated by arrows.

The crossover wire 9'a arranged on the outer diameter side of the U continuous winding coil (U coil group) 8'a incorporated in the stator described above and the W continuous winding coil (W coil group) 8 ' The crossover wire 9'c arranged on the inner diameter side of the crossover wire 'c' can be arranged without interference by shortening the length of the crossover wire, and further, the V continuous winding coil (V coil group) 9'b
The crossover wire 9'c of the W continuous winding coil 8'c is slightly different from the crossover wire 9'b of the W continuous winding coil 8'c because the crossover wire 9'b is disposed at an intermediate portion between the outer diameter side and the inner diameter side. By pushing inward, the length of the crossover can be reduced to prevent interference. NU, NW,
The NVs are connected in common and can constitute a stator having the connection coils shown in FIG.

FIG. 12 shows a U-continuous winding coil (U) in which eight sets of two adjacent coil parts shown in FIG. 13 (a) and FIG. 13 (b) are alternately arranged at 45 ° intervals. A coil group) 8'a and a V-continuously wound coil (8 sets of two adjacent coil sections alternately arranged at intervals of 45 degrees with those shown in FIG. 13A and those shown in FIG. 13B) V coil group) 8 ″ b and W continuous winding coils in which eight sets of two adjacent coil parts shown in FIG. 13C and FIG. 13D are alternately arranged at 45 ° intervals. (W coil group) 8'c shows an embodiment constructed by being incorporated in a stator.

The difference from FIG. 11 is that the crossover wire 9 "b is connected on the outer diameter side in the V continuous winding coil 8" b. By connecting the connecting wire 9b of the V continuous winding coil 8 "b on the outer diameter side in this way, the connecting wire 9'a arranged on the outer diameter side of the U continuous winding coil 8'a can be slightly reduced in outer diameter. By pushing out to the side, the crossover can be shortened to prevent interference, and in particular, in the case of the embodiment shown in FIG. Since it is easy to slightly push out the crossover wire 9'a arranged on the outer diameter side of the wire a, the interference of the crossover wire can be easily realized.
Are connected in common to form a stator having coils of the connection shown in FIG.

FIG. 16 shows a U-continuous winding coil, a V-continuous winding coil, and a W-continuous winding in which two adjacent coil portions having the configuration shown in FIG. 13A are sequentially arranged at intervals of 45 degrees. 7 shows a comparative example in which a wire coil is inserted into a stator. FIG. 17 shows two adjacent coil portions in FIG.
A U-continuous winding coil, a V-continuous winding coil, and a W-continuous winding coil in which the configuration shown in FIG. 3A and the configuration shown in FIG. Shows a comparative example inserted. Thus, in the case of the comparative example shown in FIGS. 16 and 17, the crossover of the U continuous winding coil, the crossover of the V continuous winding coil, and the crossover of the W continuous winding coil intersect. It is clear that it will.

However, in the embodiment of the present invention shown in FIG. 11 and FIG.
Interference between the crossover of the V continuous winding coil and the crossover of the W continuous winding coil can be prevented by shortening the length of the crossover.

Next, the U-winding coil 8'a and the V-winding coils 8'b, 8 "inserted (incorporated) into the stator.
An embodiment in which the connecting wires of the b and W winding coils 8'c are connected by using a single connection plate 90 will be described with reference to FIG. FIG. 14 shows a U-winding coil 8 ′ shown in FIG.
a, a simplified connection plate 90 provided on each of both end faces of the stator core 7 in a stator in which the V winding coil 8 "b and the W winding coil 8'c are incorporated. As shown in FIG. 12, by forming the U winding coil 8'a, the V winding coil 8'b, 8 "b, and the W winding coil 8'c, the crossover of each coil does not interfere. Therefore, it is possible to connect the coil portions of each phase coil group using one connection plate 60 on which a simplified one-layer wiring pattern (conductor pattern) as shown in FIG. 14 is formed. Become. As the connection plate 90, a one-layer conductor pattern 92 for connecting the coils is formed on an insulating resin substrate or a ceramic substrate 91.
1 through the through holes formed in each of the conductor patterns 9
2 and the electric wire of each coil are connected by soldering, fusion bonding, caulking, or the like. Then, if necessary, the conductor pattern including the connection portion formed on the substrate 91 is covered with an insulator.

In the case of the connection plate 90 corresponding to the embodiment shown in FIG. 11, the substrate 91 is arranged so as to correspond to the crossover 9'c.
It is necessary to protrude the conductor pattern formed on the inner side of the inner side of the coil to the extent that it does not contact the rotor. In addition, the stator winding of the adduction type motor is described above .
Continuously wound coils, V continuously wound coils, and W continuously wound coil as illustrated in FIG. 15, the outer rotor type motor stator
It is also possible to configure as a winding.

According to the embodiment of the present invention described above, in a motor constituted by a stator having a stator core having at least two or more phases of coil groups, the rising position of the terminal of the coil portion is determined for each phase of the coil groups. , The positions at which the coil portions are connected to each other are dispersed in the radial direction for each coil group of each phase, so that interference (intersection) of the crossovers of each phase can be prevented, and thus, the crossovers and the connection portions are small. It is possible to reduce the size of the stator and the motor as a whole. In addition, since the crossovers are arranged so as to be spatially separated from the crossovers of the other phases, the interphase insulation can be simplified, the cost of the insulating member can be reduced, and the number of steps can be reduced. Further, since the crossovers are spatially separated from each other, the heat dissipation of the crossover portion can be improved.

According to the embodiment of the present invention,
For each coil group of each phase, in particular, a portion located in the slot of the coil portion wound on the stator core is formed, and the coil portion is incorporated in the stator core into which the teeth portion is divided, so that the winding is formed. The space factor can be improved, and high output, high efficiency, small size and light weight can be achieved. In addition, since the rising position of the crossover is different for each phase, when assembling the high space factor coil, the crossover does not interfere,
The assemblability is improved.

The rotary motor has mainly been described above. However, the present invention is not limited to this, and similar effects can be obtained by applying the present invention to a linear motor (linear motor) as shown in FIG. The same applies to the generator. In addition, since the motor and the generator are key parts of the set product, high efficiency, small size, light weight, and low price of the set product using the present invention can be realized. In particular, the effect is large in an electric vehicle, a hybrid vehicle, and the like that require a stator winding using a coil having a large conductor cross-sectional area with a small mounting space for a high-output motor.

[0039]

According to the present invention, the winding space factor can be improved and the output can be increased by miniaturizing or simplifying the crossover portions or connection portions (end coil portions) at both end portions of the stator core and the like. In addition, there is an effect that a rotating machine with high efficiency and small size and light weight can be realized. In particular, small mounting space for the high output motor, an electric vehicle in which the conductor cross-sectional area (4.0mm ² ~4.5mm ² about) stator windings are required with large coils, the hybrid vehicle or the like, increase the effect can do.

[Brief description of the drawings]

FIG. 1 is a plan view of a stator showing an embodiment of a rotary motor according to the present invention.

FIG. 2 is a perspective view of a stator showing one embodiment of a linear motor (linear motor) according to the present invention.

FIG. 3 is a schematic configuration diagram of the rotary motor shown in FIG. 1;

FIG. 4 is an explanatory diagram showing one embodiment of a connection diagram of the coil shown in FIG. 1;

FIG. 5 is an explanatory diagram showing a winding order for each phase according to the present invention.

FIG. 6 is an explanatory diagram showing a method of changing a winding order according to the present invention.

FIG. 7 is an explanatory diagram of a split core according to the present invention.

FIG. 8 is an explanatory diagram showing a continuous winding method for a coil group (continuously wound coil) of each phase according to the present invention.

FIG. 9 is an explanatory diagram showing a continuous winding in which the winding order is changed for each phase coil group according to the present invention.

FIG. 10 is an explanatory view showing a method of pressure forming and fixing a series of coil portions.

FIG. 11 shows a three-phase 48 in the rotary motor according to the present invention.
FIG. 3 is a plan view showing a first embodiment of a slot stator.

FIG. 12 shows a three-phase 48 in the rotary motor according to the present invention.
FIG. 6 is a plan view showing a second embodiment of the slot stator.

FIG. 13 is a view for explaining four types of winding methods for two adjacent coil portions used in the embodiment shown in FIGS. 11 and 12;

FIG. 14 is a view showing an embodiment of a connection plate corresponding to the embodiment shown in FIG. 12 according to the present invention.

Shows an embodiment of an outer rotor type motor according to Figure 15 the present invention
It is a top view of a stator .

FIG. 16 shows a three-phase 48 in the rotary motor according to the present invention.
It is a top view showing the 1st comparative example of the stator of the slot.

FIG. 17 shows a three-phase 48 in the rotary motor according to the present invention.
It is a top view showing the 1st comparative example of the stator of the slot.

FIG. 18 is a view showing a conventional stator structure.

FIG. 19 is a view showing another conventional stator structure.

[Description of Signs] 1 ... motor, 2 ... stator, 3 ... rotor, 4 ... frame, 5 ... shaft, 6 ... bearing, 7 ... stator core, 7
a: slot, 7b: teeth portion, 7c: core back portion, 7d: core back block, 8: coil group, 8a,
8'a: U coil group (U continuous winding coil), 8b, 8 '
b, 8 "b... V coil group (V continuous winding coil), 8c,
8'c: W coil group (W continuous winding coil), 9a, 9
b, 9c, 9'a, 9'b, 9'c, 9 "b ... crossover,
DESCRIPTION OF SYMBOLS 10 ... Permanent magnet, 12 ... Insulating member, 20 ... Guide block, 24 ... Series-arranged winding frame (continuous winding frame), 25
... Core bar block, 26. Brim block, 27... Guide pin, 28... Pressure block, 29.
-80h ... coil part, 81a-81d ... crossover.

 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Takashi Ishigami 292 Yoshida-cho, Totsuka-ku, Yokohama-shi, Kanagawa Prefecture Inside of Hitachi, Ltd. (72) Inventor Koichiro Ohara 7-1-1, Higashi-Narashino, Narashino-shi, Chiba F-term (reference) 5H002 AA07 AB06 AB09 AC06 AE07 AE08 5H603 AA09 CA01 CA04 CA10 CB04 CB05 CB11 CB20 CB23 CB24 CC03 CC11 CC17 CD05 CE01 5H604 AA08 CC01 CC05 CC14 PC03 QB03 QB12 QC05 5H615 AA01 PP01 PP07 PP08 PP14 PP16 SS11 SS16 SS19

Claims (12)

[Claims] 1. A rotating machine having a stator having a plurality of coil groups in a stator core, wherein a rising position of a terminal of a coil portion is made different at both end faces of the stator core for each phase coil group. A rotating machine characterized in that terminals of the coil section do not cross each other between groups. 2. A rotating machine having a stator having a plurality of coil groups in a stator core, wherein each of the coil groups in each phase is configured by connecting a plurality of coil portions with a crossover, and the coil group in each phase is provided. A rotating machine characterized in that the rising position from the coil portion in the crossover is different at both end portions of the stator core, so that the crossovers do not cross each other between the coil groups of each phase. 3. A rotating machine having a stator having a plurality of coil groups on a stator core, wherein each of the plurality of coil groups is connected in series by a plurality of coil sections with a crossover, and the coils of each of the phases are formed. A rotating machine, wherein the crossover wires of each group are arranged so as to be separated from each other at both end surfaces of the stator core. 4. The rotating machine according to claim 1, wherein said stator core is constituted by a split core comprising a teeth portion and a core back portion. 5. The rotating machine according to claim 4, wherein a coil group of each phase is incorporated in the teeth portion. 6. The rotating machine according to claim 1, wherein the coil group of each phase is formed by a plurality of concentrated winding coils. 7. The rotating machine according to claim 1, wherein a coil group of each phase is formed by a plurality of continuous winding coils. 8. The rotating machine according to claim 1, wherein the coil group of each phase is formed by a plurality of coil portions fixed by pressing. 9. A rotating machine having a stator having a plurality of coil groups in a stator core, wherein the rising position of the terminal of the coil portion is made different at both end faces of the stator core for each of the coil groups of each phase. A rotating machine comprising: a connection plate on both end surfaces of a stator core, the connection pattern being formed with a conductor pattern connected to a terminal of a coil unit for each coil group of each phase. 10. A rotating machine having a rotor having a plurality of coil groups in a rotor core, wherein a rising position of a terminal of a coil section is different at both end faces of the stator core for each of the coil groups of each phase. A rotating machine characterized in that terminals of the coil section do not cross each other between coil groups. 11. A manufacturing step for sequentially forming and removing a continuous winding coil group in which a plurality of coil portions are continuously connected by a crossover with respect to a plurality of phases using a series-arranged type winding frame; The continuous winding coil groups for a plurality of phases to be formed and removed are sequentially changed, and the rising position from the coil portion of the crossover wire at each end face of the stator core is different for each phase of the continuous winding coil groups, for each phase. Assembling into a stator core such that the crossover wires do not cross each other between the groups. 12. A manufacturing step of sequentially forming and removing a continuous winding coil group in which a plurality of coil portions are continuously connected at a terminal using a series-arranged winding frame for a plurality of phases; The continuous winding coil groups for a plurality of phases to be removed are sequentially removed, and the rising positions from the coil portion in the terminal are different at both end faces of the stator core for each continuous winding coil group of each phase, and incorporated into the stator core. A step of connecting the terminals of the coil portions for each of the coil groups of the built-in phases at both end portions with a connection plate on which a conductor pattern is formed.