JP2002233095A - Electric equipment - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide electric equipment such as an electric motor and a generator having the stator coil of wiring constitution small in a connection part in the axial direction and superior in assembling. SOLUTION: In the electric equipment provided with a stator core 3 having a plurality of teeths 32 and a stator 2 comprising the two or more phase stator coil 4 wound around the stator core 3, at least one stator coil 4 comprises a plurality of unit coils 41, and at least one unit coil 41 is connected to the other unit coil 41 by a conductor 5 passing the inside of the stator coil 4 from the inner peripheral part to the outer peripheral part.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to an electric device,
In particular, various industrial motors and generators, such as electric vehicles,
The present invention relates to a motor and a generator used for a hybrid vehicle and the like, and an alternator, a starter, and a stator of a servomotor, a brushless motor, and an induction motor.

[0002]

2. Description of the Related Art Generally, a winding type of a motor is classified into a distributed winding in which a coil extends over a plurality of slots and a concentrated winding in which one coil is wound on one tooth. In recent years, in order to respond to demands for product miniaturization, high performance, and low cost, shortening the connection of each coil constituting the stator and reducing the volume occupied by the connection, especially the axial direction of the stator, have become important issues. Has become.

The coils of each phase of the stator winding need to be connected to each phase in a Y-connection or a △ -connection. Means to streamline terminal processing for each coil include:
The following method has been performed. One is that for each phase of insulators 71a and 71b in which a predetermined number of continuous winding coils for each phase are provided on the outer periphery of the core, as in JP-A-11-18331 shown in FIG. By arranging the crossovers 70 along the grooves 72a and 72b, the connection of each coil becomes unnecessary. In another method, Japanese Patent Laid-Open No.
As disclosed in Japanese Patent No. 233483, each coil is connected by a method in which terminal wires 74 of individually wound coils are connected to a separately provided wiring board 75.

However, in the former case, since it is necessary to arrange the crossover wires in the grooves of the insulator on the outer peripheral portion of the core and to secure the insulation between the phases, the crossover wire is large only for wiring in the outer peripheral portion of the core and in the axial direction of the core. Space is needed. In particular, in high-output motors represented by electric vehicles and hybrid vehicles, high efficiency and small size and light weight are issues, and the conductor area of the coil is increased with respect to motor specifications requiring high output. For example, the conductor cross-sectional area per turn of the coil is 4.0
Approximately 5.0 mm ² is required. Therefore, in the conventional method in which the crossovers are concentrated only on the outer peripheral portion, it is difficult to arrange the crossovers so as not to interfere with the thick crossovers of each phase, and a motor having a large core outer diameter or a motor in the axial direction becomes large. . On the other hand, in order to improve fuel efficiency, it is necessary to reduce the size and weight of the entire vehicle as well as to reduce the size and weight of the motor to be mounted.

In the latter case, since the terminals of each coil are connected to the conductor on the insulated wiring board and laminated in the axial direction, there is a problem that it is difficult to radiate Joule heat of the conductor. Therefore, in order to avoid heat generation on the wiring board, the required conductor
It is necessary to lower the resistance by increasing it by about 3 times,
As the motor output increases, the conductor cross-section increases,
The entire wiring board becomes larger. Also, when the motor outer diameter becomes large, there is a disadvantage in terms of cost in the case of a wiring board having a hollow structure.

[0006]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned conventional problems, and the connection portion is small in the axial direction.
An object of the present invention is to provide an electric device such as a motor or a generator having a stator coil having a wiring configuration excellent in assemblability.

[0007]

SUMMARY OF THE INVENTION The present invention is directed to an electric apparatus including a stator having a stator core having a plurality of teeth and two or more phases of stator coils wound on the stator core. One is composed of a plurality of unit coils, and at least one of the unit coils is an electric device connected to another unit coil by a conductor passing through the inside of the stator coil from the inner periphery to the outer periphery of the stator. is there.

[0008] The present invention is also an electric apparatus wherein the conductor is held by a positioning member attached to a stator core.

Further, the present invention is an electric device in which the unit coil is constituted by a concentrated winding wound intensively on one tooth.

Further, the present invention is an electric device in which the stator core is a core that is divided and assembled into at least one tooth portion and a core back portion.

Further, the present invention is an electric device in which the stator core is a core divided and assembled in a circumferential direction.

[0012]

Embodiments of the present invention will be described. Hereinafter, embodiments of the electric apparatus according to the present invention will be described with reference to FIGS. FIG. 1 is an explanatory plan view of a stator of a motor according to an embodiment. FIG. 2 is an explanatory diagram of the wiring conductor in the example. FIG. 3 is a schematic explanatory diagram of the motor of the embodiment. FIG. 4 is an explanatory diagram of the coil connection of the embodiment. FIG.
FIG. 4 is an explanatory view of a modification of the wiring conductor in the embodiment. FIG. 6 is an explanatory diagram of a stator in which the teeth portion and the core back portion in the embodiment are divided. FIG. 7 is an explanatory diagram of the circumferential division core in the embodiment.

An embodiment will be described. As shown in FIG. 3, the motor 1, which is an electric device of the embodiment, includes a stator 2, a rotor 11, a frame 12, a shaft 13, a bearing 14, a permanent magnet 15, and the like. As shown in FIG. 1, the stator 2 has a stator core 3 and a stator coil 4. The stator coil 4 is arranged in a plurality of slots 31 provided in the stator core 3 according to a predetermined rule. The rotor 11 is disposed rotatably. The stator core 3 has, for example, a thickness of 0.35 mm and a thickness of 0.3 mm.
It is made by punching and laminating a 5 mm thin electromagnetic steel sheet.
It is fixed by swaging or welding. The stator coil 4 is configured by connecting a plurality of unit coils 41 for each phase. The frame 12 fixes the stator 2 on the inner diameter side, and supports a shaft 13 fixed to the rotor 11 with a bearing 14. In this embodiment, as shown in FIG. 3, a magnet motor in which a permanent magnet 15 having a predetermined number of poles is arranged on a rotor 11 is used. The number of poles and the number of slots are designed according to the required performance of the motor from various combinations such as 8 poles 9 slots, 8 poles 12 slots, 10 poles 12 slots and 16 poles 24 slots.

As shown in FIG.
A concentrated winding stator with 24 phase slots is used. In FIG. 1, the left side shows a stator plan view, and the right side shows a stator sectional view at a position where a wiring conductor is arranged. In the case of FIG. 1, the stator coil 4 is composed of eight unit coils 41 per phase.
4A, the unit coils 41 of each phase are connected in series to form the stator coil 4, and the three-phase stator coil 4 at the neutral point N is connected.
Are connected. At this time, for example, if the number of turns per phase is designed to be 64 turns, the number of turns per unit coil is 8 turns. On the other hand, as shown in FIG. 4 (b), when the number of turns of one phase is the same, when the circuit is a parallel circuit, the connection is one series and eight parallel connections, and the number of turns per stator coil is 64 turns. The example shown in FIG. 1 has eight serial Y connections.

The connection between the unit coils in the motor of the embodiment will be described. When winding is performed so that the winding start point is on the inner diameter side and the winding end point is on the outer diameter side for one unit coil, it is necessary to connect the winding end point of one unit coil to the winding start point of the next unit coil. . Therefore, the connection between the unit coils is performed as shown in FIG.
The winding end point 43a of a and the winding start point 42b of the unit coil 41b separated by 45 degrees are connected by the wiring conductor 5. As shown in FIG. 2, the wiring conductor 5 is disposed at an end of the stator core 3 and passes through the inside of the stator coil 4 from the inner periphery to the outer periphery of the stator. This wiring conductor 5
Is formed, for example, by bending a copper wire rod having a surface insulated and coated into a predetermined shape. As an insulating material to be coated, an epoxy-based or fluorine-based insulating material having excellent heat resistance is preferably used. Further, a general enamel-coated electric wire or an enamel-coated rectangular wire may be used. Alternatively, after punching out of a thin copper plate into a predetermined shape, it may be formed at a predetermined angle and the surface may be insulated. At this time, if the terminal of the wiring conductor 5 is peeled off the insulating film in advance, or after performing the masking process only on the terminal portion, the insulating process is performed, and only the connection end portion is exposed copper. Connection becomes easy.
As a connection method, fusing, TIG welding, laser welding, soldering, or the like is selected according to the motor specification, and a highly mechanically and electrically reliable connection can be performed.

In the case of the 24-slot 8-series Y connection shown in FIG. 1, the wiring conductor 5 for connection between the unit coils 41 is
, One neutral point connection conductor, and three output line conductors are manufactured and assembled. Since all the unit coil connection conductors 5 have the same shape, they can be manufactured in the same mold in the case of bending. Also, when punching from a copper plate, it can be manufactured with a high material yield.

Next, a method for assembling the windings and the wiring conductors in the motor of the embodiment will be described with reference to FIGS. In order to secure insulation between the stator core 3 and the stator coil 4 in which electromagnetic steel sheets punched together are laminated,
As shown in FIG. 2, an end member 6 made of a synthetic resin or the like is attached to an end of the stator core 3 for each tooth 32.
Then, after the wiring conductors 5 are arranged on the end member 6 along the grooves 61 of the end member 6, winding of each unit coil 41 is performed. In this winding, as shown in FIG. 1, after the winding start point 42a of the unit coil 41a is temporarily fixed or fused to the inner diameter side end 51a of the wiring conductor 5a,
The winding is started, and after the winding of the unit coil 41a is completed, the winding end point 43a is connected to the outer diameter side end 52b of the adjacent wiring conductor 5b. Thereby, the terminal processing operation is completed simultaneously with the winding. Therefore, the wiring conductors 5 arranged in advance
In addition, since the terminal wire of the unit coil 41 can be connected simultaneously with the winding, the terminal processing work that had to be performed in a separate step in the conventional method can be greatly rationalized.

As shown in FIG. 5, the stator core 3
The end member 6b provided with a hole 62b, which is made of a synthetic resin or the like for each tooth 32, is attached to the end of each of the teeth 32, and the wiring conductor 5 is inserted into the hole 62b of the end member 6b. It is also possible to wind each unit coil after bending and arranging the distal end of No. 5.

The configuration in which the end members 6 are arranged for each of the teeth 32 has been described above. However, in the case of a small-diameter stator, the end members 6 are integrally formed in an annular shape and assembled to the stator core 3. Alternatively, the end member 6 may be integrally formed at the end of the stator core 3 with a mold or the like. Furthermore, when integrally molded, the end member 6 is molded in a state where the wiring conductor 5 is assembled, so that the wiring conductor 5 is formed.
Can also reduce the number of assembly steps.

FIG. 6 shows an example of a winding method in the case of using a core that is divided and assembled into a tooth portion and a core back portion as a stator core in the motor of the embodiment.
This will be described with reference to FIG. Teeth part 732 and core back part 3
FIG. 6 shows a 12-slot stator as a stator core divided into three. FIG. 6A shows a punching layout of the tooth portion and the core back portion, FIG. 6B shows the stacked tooth portion 32 and the core back block 34, and FIG. The assembling method will be described. The teeth portion 32 is divided for each tooth, and is punched and laminated by a predetermined thickness in a mold. The core back block 33 has a structure in which a core back block 34 divided into six in the circumferential direction is assembled. The core back block 34 is assembled in a brick shape after punching and laminating a predetermined number of sheets in a mold. Thus, the core back portion 33 is assembled in an annular shape. By this dividing method, the material utilization rate of the core can be improved, and the material cost is reduced by 4 compared with the method of integrally punching.
It can be reduced by 0 to 60%. In addition, with the configuration in which the teeth are divided, the unit coil 41 can be assembled after being wound substantially aligned outside the core. As shown in FIG. 6C, the unit coil 41 is wound in advance with a winding frame having a predetermined shape. After the winding, the winding frame can be used as a mold to form a cross section of the coil housed in the slot to increase the winding density. Further, in order to maintain the winding shape, the unit coil 41 can be integrated and handled as a component by conducting and fixing the current using a self-fused electric wire. After winding, teeth part 3
Before inserting the unit coil 41 into 2, the end member made of synthetic resin or the like is arranged between the inside of the unit coil 41 and the end of the tooth 32. It is preferable to assemble a wiring conductor in advance on this end member. Unit coil 4 for teeth 32
After inserting the end member 1 with the wiring conductor and the end member with the wiring conductor, each tooth portion 32 is inserted into the core back portion 33 as shown in FIG. After assembly, the winding start point 42 and the winding end point 43 of the unit coil are connected to the ends of the wiring conductors arranged in advance.
By dividing the teeth portion 32 and the core back portion 33 in this manner, the unit coil 41 can be wound at a high density outside the core, so that the winding space factor can be improved, and the motor has a high efficiency. In addition, the size and weight can be reduced.

Next, a winding method in an example in which the stator core of the motor of the embodiment is divided in the circumferential direction of the state will be described with reference to FIG. FIG. 7 schematically shows an end portion of one circumferentially divided core 35 when the stator core is divided in units of one tooth in the circumferential direction. The circumferential division core 35 is formed by punching and laminating a thin electromagnetic steel sheet as described above, and is fixed by caulking or welding. An end member 6 made of a synthetic resin or the like is assembled at an end of the circumferentially divided core 35, and a wiring conductor 5 is placed thereon.
Assemble. Thereafter, the core is set on a winding machine and wound on a tooth including the wiring conductor 5. The winding end is
Temporarily fixed to the end member 6. After a predetermined number of windings, the circumferentially-divided cores 35 are assembled into a tubular shape, and each winding end is connected to a predetermined wiring conductor 5 as in FIG. in this way,
A wiring conductor that forms a predetermined connection circuit by connection with the unit coil can be assembled in advance in the core and wound thereon, thereby streamlining terminal processing.

In the case of a motor requiring a large output,
The conductor cross-sectional area of the coil increases, and a winding having a large wire diameter is required. In the case of an enamel-coated wire generally used for winding, the minimum bending radius that can guarantee insulation is 1/1 of the wire diameter.
2, preferably more than the wire diameter. For this reason, the wire diameter increases with an increase in the output of the motor, and a space necessary for winding is created between the coil and the teeth. At this time, in the conventional method, the end of the winding bobbin is thickened, or a gap is provided between the teeth and the coil. In the embodiment, by utilizing this space, the wiring conductor can be arranged inside the coil, and the space necessary only for ensuring the insulation of the winding can be effectively utilized. As a result, the overall length of the stator can be reduced and the size of the motor can be reduced.

Further, the wire used for the winding in the above embodiment is not limited to a round wire, and may be a substantially flat wire formed before winding or a commercially available flat wire. The winding space factor can be improved.

The present invention relates to a connection structure of a stator in an electric machine, and has been described as a magnet motor in which a magnet is arranged on a rotor. There is a similar effect. In the embodiment, the concentrated winding has been described.
Also in the distributed winding, the minimum bending R due to thickening is the same as described above, and therefore, by using the wiring conductor of the embodiment,
Similar effects can be obtained.

Also, in an electric machine comprising a stator having at least two or more phases of coils on a stator core, terminal wires of each coil are distributed to the inner diameter side and the outer diameter side of the stator according to the connection specification of each coil. By arranging the terminals and connecting the terminal to another coil via a conductor component passing through the inside of the coil, it is possible to avoid the concentrated arrangement of the wiring portion and suppress the height of the connection portion. In addition, since the wiring process can be performed simultaneously with the winding in a state where the wiring conductors are arranged in advance, the connection work can be rationalized. In particular, in the case of a coil having a concentrated winding, one coil is wound around one tooth, so that the wiring conductor parts can be easily arranged. Furthermore, the stator core is
By adopting a split configuration, the coil can be wound at high density outside the core, so that the winding space factor can be improved,
High efficiency, small size and light weight of the motor can be achieved. In addition, since the ends of the coil to be connected to the rigid wiring parts are connected and welded, the coil terminals and the wiring parts are overlapped and welded, or connected by a connection method such as heat caulking or brazing, The conductor parts can be easily assembled.

Although the rotary electric motor has been mainly described as the electric apparatus of the present invention, the present invention is not limited to this, and the same effects can be obtained by applying the present invention to a linear motor (linear motor).
The same applies to the generator. Further, 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.

[0027]

According to the present invention, it is possible to obtain an electric device such as a motor or a generator having a stator coil having a wiring structure with a small connection portion in the axial direction and excellent in assemblability.

[Brief description of the drawings]

FIG. 1 is an explanatory plan view of a stator of a motor according to an embodiment.

FIG. 2 is an explanatory diagram of a wiring conductor in an embodiment.

FIG. 3 is a schematic explanatory view of a motor according to the embodiment.

FIG. 4 is an explanatory diagram of a coil connection of the embodiment.

FIG. 5 is an explanatory view of a modification of the wiring conductor in the embodiment.

FIG. 6 is an explanatory diagram of a stator in which a teeth portion and a core back portion in the embodiment are divided.

FIG. 7 is an explanatory diagram of a circumferential division core in the embodiment.

FIG. 8 is an explanatory view of a stator structure of a motor of Conventional Example 1.

FIG. 9 is an explanatory diagram of a stator structure of a motor of Conventional Example 2.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Motor 2 Stator 3 Stator core 31 Slot 32 Teeth part 33 Core back part 34 Core back block 35 Circumferentially divided core 4 Coil 41 Unit coil 42 Winding start point 43 Winding end point 5 Wiring conductor 51 Wiring conductor inner diameter side end part 52 Wiring Conductor outer diameter side end 6, 6b End member 61 Groove 62b Hole 11 Rotor 12 Frame 13 Shaft 14 Bearing 15 Permanent magnet

Continued on the front page (72) Inventor Takashi Yasuhara 2520 Takahiro, Hitachinaka-shi, Ibaraki Pref.Hitachi, Ltd.Automotive equipment group (72) Inventor Toshiaki Ueda 2520 Odaitakaba, Hitachinaka-shi, Ibaraki Hitachi Ltd. F-term in the automotive equipment group (reference)

Claims (5)

[Claims] 1. An electric apparatus including a stator including a stator core having a plurality of teeth and two or more phases of stator coils wound on the stator core, wherein at least one of the stator coils is formed from a plurality of unit coils. An electric device, wherein at least one of the unit coils is connected to another unit coil by a conductor passing through the inside of the stator coil from the inner periphery to the outer periphery of the stator. 2. The electric device according to claim 1, wherein the conductor is held by a positioning member attached to the stator core. 3. The electric device according to claim 1, wherein the unit coil is formed of a concentrated winding wound around one tooth. 4. The electric device according to claim 1, wherein the stator core is a core divided and assembled into at least one teeth portion and a core back portion. 5. The electric device according to claim 1, wherein the stator core is a core divided and assembled in a circumferential direction.