JP2003333781A - Electric rotating machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To make the dimension small axially of an electric rotating machine while making connection of a coil without using a separate part for the connection. <P>SOLUTION: In the counterclockwise of a split core 12a, a split core 12b of the same shape to it is connected. One end of a coil 14 is extended as an extension part 16 from the split core 12b, a first extension part 16a in the root part of this coil 14 is electrically connected to a first fixed part 18b of a terminal 18. A third extension part 16c in the tip end of the extension part 16 is engaged with a second fixed part 18c of the terminal 18 in the adjacent split core 12a. The 16 other split cores 12 are similarly made in annular connection, to electrically connect each of the third extension part 16c and the second fixed part 18c. Each extension part 16 is formed with the common line of a stator 10. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotary electric machine, for example, a rotary electric machine such as a motor or a generator, and more particularly to a rotary electric machine having a plurality of split cores connected in an annular shape.

[0002]

2. Description of the Related Art Some stators of rotary electric machines are composed of a plurality of split cores. The split core includes an arc-shaped yoke portion and a pole portion that extends in the inner diameter direction,
A coil is wound around the pole portion.

In this type of stator, an annular common wire bus bar is used as a method of connecting the common wires of the coils wound around the split cores to each other (for example,
JP-A-6-233483)). With this configuration, a plurality of bus bars can be formed into a laminated structure, which is small and easy to manufacture.

Further, a printed circuit board provided on an axial end surface is used (for example, refer to Japanese Patent Laid-Open No. 7-308040), a bent coil and an end plate provided with a groove for guiding the coil are provided. Thing (for example, JP-A-10-2
No. 48187), etc. have been proposed.

[0005]

By the way, in the above-mentioned prior art, it is necessary to prepare other components for connection such as a common wire bus bar, a printed circuit board or an end plate in addition to the stator body and the coil. Therefore, there are disadvantages that the number of parts is large, the cost is high, and the number of assembling steps is large. Further, since the coil connection structure is disposed on the axial end surface of the stator core, the entire rotary electric machine has a shape elongated in the axial direction.

Further, since the printed circuit board has a small allowable current, it cannot be used for a large current type stator.

The present invention has been made in view of the above problems, and the wiring of the coil is performed without using separate connecting parts such as the common wire bus bar, the printed circuit board, or the end plate, and the rotating electric machine. An object of the present invention is to provide a rotating electric machine that can reduce the axial dimension of the rotating electric machine.

[0008]

A rotary electric machine according to the present invention has a plurality of metal terminals and a plurality of split cores, the split cores being a coil and an insulator around which the coil is wound. And a laminated steel plate, the insulator has a portion for fixing the terminal, and a guide portion for extending the coil to the adjacent insulator side, the split cores are continuously provided in an annular shape, It is characterized in that one end of a coil forming the split core is electrically connected to one end of a coil of another split core adjacent thereto via the terminal.

By thus connecting the coils using the terminals, the coils of the adjacent split cores are directly connected to each other, and separate parts for connection such as a common wire bus bar, a printed circuit board or an end plate are unnecessary. Become.

Further, one end of the coil extends from the insulator to the inner diameter side of the rotating electric machine, a first extending portion, a second extending portion extending in the circumferential direction, and an outer diameter side. And a third extension part connected to the terminal, and the first extension part, the second extension part and the third extension part are located on the same plane, one end of the coil The parts can be curved and connected, and the axial dimension of the stator can be made small.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of a rotary electric machine according to the present invention will be described below with reference to the accompanying FIGS.

As shown in FIG. 1, a stator 10 that employs the connection structure according to the present embodiment is a so-called three-phase Y-type connection stator, and has three-phase input terminals U, V, W, and 18.
And the divided cores 12.

As shown in FIGS. 2 to 5, the split core 12 in a state before the stator 10 is assembled is a laminated steel plate 24 in which a plurality of substantially T-shaped steel plates punched by a press are caulked and integrated. Insulators 21 and 22 that insulate the laminated steel plate 24, and a coil 1 wound around the laminated steel plate 24 via the insulators 21 and 22.
4 and terminals 18 and 28 made of metal.

The laminated steel plate 24 has a substantially T shape, and is "T".
The portion 24a corresponding to the upper side of the letter becomes a yoke in the stator 10. Further, the portion 24b corresponding to the lower side extending portion of the "T" is the pole portion (or salient pole portion) of the stator 10.

The coil 14 is a wire 13 having an insulating coating.
Consists of. The extending portion 16 which is one end of each coil 14 on the inner diameter side (arrow A side) of the stator 10 is provided with the split core 12
They are electrically connected to each other at the terminals 18 provided at and form a neutral point of the Y-connection. Each coil 1
The other end on the outer diameter side (the side opposite to the arrow A) of 4 is connected to one of the input terminals U, V, W by a ring-shaped input line bus bar (not shown). Specifically, every third 6
6 split cores 12 are connected to the input terminal U, other than that, every other 6 split cores 12 are connected to the input terminal V, and the remaining 6 split cores 12 are connected to the input terminal W. Has been done. Each split core 12, input terminals U, V, W
The input line bus bar and the input line bus bar are assembled on a hollow housing (or case) 19.

The terminal 18 has a connecting annular groove 8 which will be described later.
8 and is insulated by the sealant 20 injected into the connecting annular groove 88.

As described above, the split core 12 includes the coil 1
A metal terminal 18 for fixing and electrically connecting the extending portion 16 which is one end on the inner diameter side of the coil 4, and the coil 1.
4 includes a metal terminal 28 for fixing one end portion 26 on the outer diameter side of 4 and electrically connecting it. Terminal 1
8 and the terminal 28 are made of the same member.

The extending portion 16 has a first extending portion 16a extending to the inner diameter side, a second extending portion 16b extending in the circumferential direction, and a third extending portion 16c extending to the outer diameter side. And a curved or bent structure. The root portion of the first extending portion 16a is the terminal 1
8 is electrically connected to a first fixing portion 18b, which is one end of the first fixing portion 18b, and its position is fixed, while the first extending portion 16a has two cutout portions 30 provided before and after the first fixing portion 18b. And 32 are guided in the direction of arrow A.

The second extending portion 16b is the first extending portion 16
The third extending portion 16c is curved or bent so as to be orthogonal to a.
Extends so as to be more orthogonal to the second extending portion 16b. In fact, the first extending portion 16a and the second extending portion 1
6b and the third extending portion 16c are located in the same virtual plane.

As shown in FIGS. 3 to 5, the terminal 18
(And 28) are substantially T-shaped metal terminals and are inserted into the groove 70 (84) of the insulator 21.
a (28a) and a first fixing portion for fixing the first extending portion 16a
The fixed portion 18b (28b) and another adjacent split core 12
Second fixing portion 18c (28) for fixing the third extending portion 16c of
c) and. A small projection (engagement portion) 18 pressed by a punch or the like is provided at a slightly upper portion of the insertion portion 18a (28a).
d (28d) is provided.

As shown in FIG. 4, the insulators 21 and 22 have a coil winding portion 3 around which the coil 14 is wound.
4, 36, and peripheral walls 40 and 42 provided on the inner diameter side and perpendicular to the surfaces of these coil winding portions 34 and 36.
And peripheral walls 44 and 46 provided on the outer diameter side and perpendicular to the surfaces of the coil winding portions 34 and 36. The coil winding portion 34 and the coil winding portion 36, the peripheral wall 40 and the peripheral wall 42, and the peripheral wall 44 and the peripheral wall 46 are partially overlapped and coupled with each other. That is, the insulator 22 is inserted from below the insulator 21 so that both insulators 21 and 22 are inserted.
And are integrated. A large number of laminated steel plates 24 are inserted into the hole 48 at the center obtained as a result of such integration, and the laminated steel plates 24 and the coil 14 are electrically insulated.

Above the inner diameter side of the insulator 21 (opposite direction when the direction of the insulator 22 is downward), a part of the peripheral wall 40 is formed, and a first upper wall 50 standing upright in the axial direction of the stator 10 is formed. A second upper wall 52 which is spaced from the first upper wall 50 on the inner diameter side and is substantially parallel to the first upper wall 50.
And a connecting surface 54 connecting the lower ends of the first upper wall 50 and the second upper wall 52.

The insulator 21 has two pedestals 56 and 58 extending from the right and left roots of the second upper wall 52 toward the inner diameter side. Among these, in the table part 58 on the right side in FIG. The guide portion 60 has a thick wall shape for guiding. The guide portion 60 forms one side surface of the cutout portion 30.

A notch 64 is provided at a position symmetrical to the notch 30 on the second upper wall 52. The notch 32 is provided in the first upper wall 50 in the outer diameter direction (the direction opposite to the arrow A) with respect to the notch 30.

A small piece 68 having a notch (engaged portion) 66 in the circumferential direction is erected on the slightly inner diameter side of the first upper wall 50, and between the small piece 68 and the first upper wall 50. In the groove 7
0 is provided.

The guide portion 60, the connecting surface 54, and the right side edge portion of the first upper wall 50 slightly project to form a projecting portion 72.

FIG. 5 shows a state in which the insulator 21 is seen from diagonally above the back side of FIG. As shown in this FIG.
A cutout 74 through which the end of the coil 14 passes is provided slightly left of the center of the peripheral wall 44 (right in FIG. 5). Further, the left end portion (the right end portion in FIG. 5) of the peripheral wall 44 forms a recessed portion 76 on the inner surface side of the protruding portion 75 that slightly protrudes toward the outer diameter side. The right end portion of the peripheral wall 44 has a protruding portion 78 that slightly protrudes in a shape that fits into the recessed portion 76.
Are formed.

A small piece 80 having the same shape as the small piece 68 is provided upright on the outer peripheral side of the peripheral wall 44 at the center in the circumferential direction. The small piece 80 has a notch 82 extending in the circumferential direction.
Is provided. A groove 84 having the same shape as the groove 70 is provided between the small piece 80 and the peripheral wall 44.

At the left end portions of the connecting surface 54, the first upper wall 50 and the second upper wall 52, inner surfaces of these are slightly recessed to form a recess portion 86. The recess 86 has a shape that meshes with the protrusion 72.

The material of the insulators 21 and 22 is, for example, PPS (polyphenylene sulfide).
Is preferable because it is excellent in heat resistance, mechanical strength, rigidity, electrical insulation, dimensional stability, and creep resistance.

Next, a method of assembling the split core 12 with the insulators 21 and 22, the terminals 18 and 28, the laminated steel plate 24, and the coil 14 will be described.

First, the groove 70 of the insulator 21 (see FIG. 3).
Insert the insertion portion 18a of the terminal 18 into the reference portion 18). The small protrusion 18d of the terminal 18 is formed by the cutout portion 66 of the small piece 68.
And acts as a retainer for the terminal 18.
Similarly, the insertion portion 28a of the terminal 28 is inserted into the groove 84 (see FIG. 3) of the insulator 21. Small protrusion 28d
Engages with the notch 82 and acts as a retainer for the terminal 28.

Next, a large number of laminated steel plates 24 are inserted into the holes 48 (see FIG. 4) formed by the insulators 21 and 22.

Then, the wire 1 is wound around the coil winding portions 34 and 36.
3 is wound and the coil 14 is formed. Specifically, FIG.
As shown in FIG. 1, first, the insulators 21 and 22 having the laminated steel plates 24 interposed therein are fixed by the first jig 100 and the second jig 102. The first jig 100 holds the outer diameter side of the insulator 21, that is, the peripheral wall 44 side. The first jig 100 is driven by a winding motor (not shown) to have an axial center C.
It can rotate around. The second jig 102 holds the inner diameter side of the insulator 21, that is, the peripheral wall 40 side.

Further, as shown in FIG. 7, the second jig 10
2, pins 102a, 102b, 102 provided on the upper surface of
Wire guide mechanism (not shown) for c and 102d
The strands 13 are sequentially entangled by. The end of the wire 13 before the pin 102a is chucked (not shown) by the second jig 1
It is fixed integrally with 02. The strand guide mechanism,
Further, the strand 13 is guided so as to be entwined with the side surface of the guide portion 60, and the strand 13 is guided to the coil winding portions 34 and 36 via the notch 30, the first fixing portion 18b, and the notch 32.
Guide At this time, the first extending portion 16a, the second extending portion 16b, and the third extending portion 16c are formed by the relative positions and shapes of the pins 102c and 102d and the guide portion 60.

The wire 1 guided to the coil winding portions 34 and 36
The end of 3 is led out from the wire supply part 104. The wire supply unit 104 can advance and retreat in the direction of arrow B parallel to the axis C, and the amount of advance and retreat can be controlled in synchronization with the amount of rotation of the winding motor.

Then, the winding motor rotates the first and second jigs 100 and 102 and the insulators 21 and 22 about the axis C. At this time, the wire 13 is wound around the coil winding portions 34 and 36 while advancing and retracting the wire supply unit 104 in the arrow B direction according to the rotation amount of the winding motor.

Next, as shown in FIG. 8, after the wire 13 is wound and the coil 14 is formed, the wire 13 is guided by the wire guide mechanism through the notch 74 and the first fixing portion 28b. The pins 100a and 100b so as to be entwined with each other. The strand 13 is guided to the pin 100b so as to pass through the groove formed in the center.

Next, the wire 13 extending from the coil 14
Both ends of the are temporarily fixed by the first fixing portion 18b of the terminal 18 and the first fixing portion 28b of the terminal 28.

Furthermore, the wire 13 extending from the coil 14
Both ends of the are cut at cutting points 106 and 108.
The cutting point 106 is between the pins 102c and 102d, and when the split core 12 is assembled to the stator 10 as described later, the third extending portion 16c is attached to the second fixing portion 18c of the split core 12 adjacent thereto. The position where it is located is suitable as this cutting position. In addition, the cutting point 108 is
It is on the slightly outer diameter side of the first fixing portion 28b.

Thereafter, the split core 12 is removed from the first jig 100 and the second jig 102, and the winding process of the coil 14 is completed.

Next, the split core 1 around which the coil 14 is wound.
2 to the stator 10 with respect to the procedure of FIG.
This will be described with reference to 1.

First, as shown in FIG.
The first split core 12 (discriminated as the split core 12a) is positioned and set.

Next, as shown in FIG. 10, the second split core 12 (discriminated as split core 12b) is set on the right side of the split core 12a, that is, in the counterclockwise direction in FIG. At this time, when the split core 12b is set in the housing 19 from above, the third extending portion 16c of the coil 14 of the split core 12b is located on the second fixing portion 18c of the terminal 18 constituting the split core 12a. It will be. In this way, the coil 1 can be manufactured by a simple insertion method.
The fourth extending portion 16c of No. 4 is engaged with the second fixing portion 18c.

At this time, the recessed portion 86 (see also FIG. 5) of the insulator 21 constituting the split core 12a and the projection 72 of the insulator 21 on the split core 12b side mesh with each other, so that the connecting surfaces 54, A part of each of the first upper walls 50 and the second upper walls 52 overlaps and abuts each other, and the joint portion forms a surface without a step. In this way, at the connecting portion between the split cores 12a and 12b, the first upper wall 50 and the second upper wall 52 of the insulator 21 are joined together without a gap to form the connecting annular groove 88.

In addition, the third extending portion 16c is connected to the second fixing portion 18
The step of engaging the c and the step of connecting the adjacent split cores 12b need not be performed simultaneously as described above. For example, after engaging the third extending portion 16c with the second fixing portion 18c, The split cores 12b may be connected.

After that, the split core 12 is subjected to the same procedure.
Another split core 12 is sequentially connected to the left side of b up to the seventeenth split core 12 (discriminated as a split core 12q. See FIG. 11).

Next, as shown in FIG. 11, the last split core 12 (discriminated as a split core 12r) is set between the split cores 12q and 12a. At this time,
The extension 16 of the coil 14 on the split core 12a side is retracted to a position where it does not interfere with the split core 12r.

After setting the split core 12r, the extending portion 16 of the coil 14 on the split core 12a side is returned to its original position,
The split core 12r is engaged with the second fixing portion 18c.

The split core 12 does not have to be directly arranged in the housing 19, but may be arranged in a predetermined holder or ring and then press-fitted into the housing 19.

In this way, when the eighteen split cores 12 are connected, the connecting annular groove 88 is formed.

Next, the first extending portion 16a of each coil 14
And the first fixing portion 18b of the terminal 18 are connected. In addition, the third extending portion 16c of each coil 14 and the terminal 18
The second fixing portion 18c is connected. Specifically, the first fixing portion 18b is thermocompression-bonded to the first extending portion 16a, and the insulating coating film coated on the first extending portion 16a is melted and removed. The copper wire 16a and the first fixing portion 18b are electrically connected. Similarly, the third extending portion 16c and the second fixing portion 18c are also connected by thermocompression bonding. In addition, by the same procedure, each split core 1
The second fixing portion 28c of the terminal 28 on the outer diameter side of 2
Is connected to the input line bus bar.

In this way, the common wires of the coils 14 are connected to each other via the terminals 18. At this time,
Since the terminal 18 is a part of the split core 12, it is not necessary to use a separate component for connection during connection work. That is, since a dedicated separate component such as a common wire bus bar or a printed circuit board is not required, the connection work can be performed easily and the number of assembly steps can be reduced.

After that, the sealant 20 for insulation is injected into the connecting annular groove 88 to insulate the terminal 18.

In this way, the 18 split cores 12 are connected, and the assembly of the stator 10 is completed.

In the above embodiment, the terminals 18 and 28 have been described as being incorporated in the insulators 21 and 22 in advance. However, the terminals 18 and 28 and the insulators 21 and 22 are prepared as separate parts. May be. In this case, after connecting the split cores 12 in an annular shape, connecting parts corresponding to the terminals 18 and 28 may be arranged in alignment with the first and second fixing portions 18b and 18c of the terminal 18. After that, the insulating coating is melted and removed by thermocompression bonding so that electrical connection can be made.

Next, a modification of this embodiment will be described with reference to FIG. In this modified example, the extension portion 2 corresponding to the extension portion 16 which is one end on the inner diameter side of each coil 14
00, the second extending portion 16b extending in the circumferential direction.
The portion corresponding to is the longer second extending portion 200b. Specifically, the extension part 200 includes a first extension part 200a extending to the inner diameter side, a second extension part 200b extending to the vicinity of the notch 30 of the adjacent insulator 21, and
It has a curved or bent structure with the third extending portion 200c extending to the outer diameter side.

The third extending portion 200c passes through the notch 30 in the adjacent insulator 21 and is connected by the first fixing portion 18b of the terminal 18. That is, the first
The fixed portion 18b collectively connects the two first extension portions 200a extending from the coil 14 and the third extension portion 200c extending from the adjacent insulator 21.

With this structure, the connection process between the terminal 18 and the wire can be completed only once.

As described above, according to the stator 10 incorporated in the rotary electric machine according to the present embodiment and its modification, the common wire of the stator 10, that is, each of the extending portions 16 and 2 is formed.
00 and the terminal 18 do not use the bus bar for the common line, the number of parts can be reduced. Further, since the common wire bus bar according to the prior art is manufactured by a punching structure or the like, the terminal 18 used in the stator 10 has a high material utilization rate (yield) and can be manufactured at low cost.

The extension portions 16 are all formed in the same plane. That is, since the stator 10 does not extend in the axial direction, the axial dimension of the stator 10 can be narrowed.

Furthermore, in connection with the extension parts 16 and 200,
The first extending portions 16a and 200a extending in the inner diameter direction also have an extremely short length, and the shaft diameter of the rotor (not shown) set on the inner diameter side of the stator 10 can be increased.

The terminal 18 has a simple structure and is easy to manufacture, store and handle. Terminal 18
Is attached by an extremely simple procedure of inserting it into the groove 70 of the insulator 21, and the small protrusion 18d and the notch 66 are engaged to prevent the detachment.

The first extending portions 16a and 200a are cut away from each other before and after being fixed by the first fixing portion 18b of the terminal 18.
Since it is held and guided by 0 and 32,
Positioning is surely done. In addition, the first extending portion 16a,
The corners that move from 200a to the second extending portions 16b and 200b have a uniform bent shape along the side surface of the guide portion 60.

Further, since the printed circuit board or the like is not used to connect the common line, the allowable current is large.

The rotary electric machine according to the present invention is not limited to the above-described embodiment, and it goes without saying that various configurations can be adopted without departing from the gist of the present invention.

[0067]

As described above, according to the rotating electric machine of the present invention, it is possible to connect the coils without using separate connecting parts, and therefore the number of parts and the manufacturing process can be shortened. It is possible, and the rotary electric machine can be manufactured at low cost.

Further, since the connecting parts for restricting the axial size and the allowable current of the rotating electric machine are not required, the axial size can be reduced and the allowable current can be increased.

[Brief description of drawings]

FIG. 1 is a plan view in which a sealant is partially omitted in a stator of a rotating electric machine according to this embodiment.

FIG. 2 is a perspective view of a split core assembled to a stator.

FIG. 3 is a partially omitted perspective view of a terminal and an insulator to which the terminal is assembled.

FIG. 4 is a perspective view showing an insulator, a terminal, and a laminated steel plate.

FIG. 5 is a perspective view of an insulator and a terminal as viewed from the outer diameter direction.

FIG. 6 is an explanatory plan view showing a state in which the split core before the coil is wound is fixed to the jig.

FIG. 7 is an explanatory plan view showing a state immediately before a coil is wound around a split core.

FIG. 8 is an explanatory plan view showing a step of cutting a wire by winding a coil around a split core.

FIG. 9 is a partially enlarged plan view of the stator with one split core set in the housing.

FIG. 10 is a partially enlarged plan view of a stator with two split cores set in a housing.

FIG. 11 is a partially enlarged plan view of the stator with 18 split cores set in the housing.

FIG. 12 is a partially omitted perspective view of a split core assembled in a stator in a modification of the present embodiment.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 ... Stator 12 ... Split core 13 ... Element wire 14 ... Coil 16, 16a-16c, 200, 200a-200c ...
Extensions 18, 28 ... Terminals 18b, 18c
... fixing parts 18d, 28d ... small protrusions (engaging parts) 20 ... sealing agents 21, 22 ... insulators 30, 32 ... notches 50, 52 ... upper wall 54 ... connecting surface 60 ... guide part 88 ... connecting annular groove

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Masaaki Kaku             1-10-1 Shinsayama, Sayama City, Saitama Prefecture             Engineering Co., Ltd. F term (reference) 5H002 AA06 AA07 AB01 AC08 AE08                 5H603 AA03 AA09 BB01 BB12 CA01                       CA05 CB12 CC11 CC17 CD21                 5H604 AA08 BB01 BB14 CC01 CC05                       CC16 DB01 PB03 PC03 QB03                       QB17

Claims (2)

[Claims] 1. A plurality of metal terminals and a plurality of split cores, wherein the split cores each include a coil, an insulator around which the coil is wound, and a laminated steel plate, and the insulator comprises: A part for fixing the terminal, and a guide part for extending the coil to the adjacent insulator side, the split cores are continuously connected in an annular shape, and one end of the coil configuring the split core is provided. A rotating electric machine, which is electrically connected to one end of a coil of another adjacent split core via a terminal. 2. The rotating electrical machine according to claim 1, wherein one end of the coil has a first extending portion extending from the insulator to an inner diameter side of the rotating electrical machine and a second extending portion extending in a circumferential direction. And a third extending part extending to the outer diameter side and connected to the terminal, wherein the first extending part, the second extending part and the third extending part are on the same plane. A rotating electrical machine characterized by being located at.