JP2005051981A - Armature for rotary electric machines, and production of armature coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To secure a space for electrical connections, dispense with electric connection work, and freely set the number of turns of the armature coils, in this electric rotating machine which includes a core having a plurality of slots, and the plurality of armature coils formed by forming a square-shaped conductor so as to be accommodated in a pair of slots selected among the plurality of slots. <P>SOLUTION: A pair of coil ends 17 provided with the armature coils 14 is formed by a pair of inclination portions 17a in which a layering direction of the square-shaped conductor 18 is the same as the one of a coil edge 16, and of which the one edge is respectively continued to both the coil edges 16, and a torsion connecting portion 17b of which the layering directions at both the inclination portions 17a are mutually reverse, which connects between the other ends of both the inclination portions 17a by twisting so that both the inclination portions 17a positions may be mutually drafted in a radius direction of the armature core 11, and which roughly aligns the layering direction of the square-shaped conductor 18 with an axial direction of the armature core 11. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a rotating electrical machine having a core having a plurality of slots and a plurality of armature coils formed by forming a rectangular conductor so as to be received in a pair of slots selected from the plurality of slots. The present invention relates to an improvement in a method for manufacturing a child and an armature coil.

In order to increase the space factor, a device in which a rectangular conductor formed in a substantially U shape or a V shape is accommodated in a slot is already known, for example, in Patent Document 1.
JP-A-11-155270

  By the way, when the armature coil is used as a power generation coil of a rotating electric machine, for example, an alternator, the number of turns of the armature coil and the power generation frequency are in a proportional relationship. It becomes an important factor in the design of However, in the above-described conventional device, when the number of turns is set to a plurality, the electrical connection on one coil end side is unavoidable, and it is not only necessary to secure a space for the connection, but also welding, etc. Connection process is required.

  The present invention has been made in view of such circumstances, and a rotating electrical machine that can freely set the number of turns of an armature coil while eliminating the need for securing a space for electrical connection and electrical connection work. A first object is to provide an armature, and a second object is to provide a method of manufacturing an armature coil that can appropriately manufacture an armature coil.

  In order to achieve the first object, according to a first aspect of the present invention, there is provided an armature core having a plurality of slots, and a rectangular conductor so as to be received in a pair of slots selected from the plurality of slots. A plurality of armature coils formed by molding a plurality of armature coils, wherein the armature coils are configured such that a part of a rectangular conductor integrally connected is laminated in the depth direction of the slot. The square conductor is wound so as to integrally have a pair of coil sides respectively accommodated in the slots and a pair of coil ends connecting both ends of the coil sides, and both the coil ends are formed by the square shape. A pair of slopes in which the conductors are laminated in the same direction as the coil sides, and one end is connected to each of the coil sides, and the conductors are inclined away from the armature core as they approach each other. And the laminating direction of the two inclined portions are reversed to each other, and the positions of the two inclined portions are twisted so as to be displaced from each other in the radial direction of the armature core, and the other ends of both inclined portions are connected. It is characterized by comprising a torsional coupling portion in which the lamination direction of the rectangular conductors is substantially along the axial direction of the armature core.

  According to a second aspect of the invention, in addition to the configuration of the first aspect of the invention, the rectangular conductor has at least a winding start portion and a winding end portion, and the number of laminated portions of the rectangular conductor is even and odd. A first coil side which is one of the above, a second coil side where the number of laminated portions of the rectangular conductor is the other of the even and odd numbers, and a portion of the rectangular conductor which is the same number of laminated layers as the second coil side. A plurality of armatures that are integrally provided with a pair of coil ends that connect both ends of the coil sides while being laminated, and in which the winding direction of the rectangular conductors is alternately reversed along the circumferential direction of the armature core The coil stacks and accommodates the first and second coil sides of the pair of armature coils whose winding directions are opposite to each other in the same slot of the armature core, and between the first coil sides of each armature coil. Armature connecting the connecting wire As distributed alternately in the axial direction end side of the armature core along the circumferential direction of A, characterized in that it is attached to the armature core.

  According to a third aspect of the invention, in addition to the configuration of the first or second aspect of the invention, a plurality of the armature coils and a connecting wire connecting the armature coils are integrally formed. It is characterized by that.

  In addition to the configuration of the invention described in any one of claims 1 to 3, the invention described in claim 4 is a Landel rotor, and a front and rear bracket on which a shaft of the rotor is rotatably supported, The armature core is sandwiched as a stator core between the front and rear brackets of a rotating electrical machine including a cooling fan fixed to the rotor, and selected from the plurality of slots provided on the inner periphery of the armature core The armature coil is wound around the armature core so that the coil sides are accommodated in the pair of slots.

  In order to achieve the second object, according to a fifth aspect of the invention, in manufacturing the armature coil according to the first or second aspect, a pair of linear portions extending in parallel to each other and the linear portions are connected. Forming a preform formed by winding a rectangular conductor in one plane so as to form a pair of bent portions, and holding the portion corresponding to the coil side of the straight portions. And sequentially applying the forces in the directions perpendicular to the one plane in a direction perpendicular to each other.

  According to the sixth aspect of the present invention, in manufacturing the armature coil according to the third aspect, a pair of straight portions extending in parallel with each other and a pair of curved portions connecting the two straight portions are formed in one plane. A first step of preparing a pre-formed product comprising a plurality of pre-formed parts formed by winding a rectangular conductor in the same direction and a plurality of connecting parts integrally connecting the pre-formed parts; and each pre-formed part The armatures in the plurality of preformed portions are configured to simultaneously apply forces in directions perpendicular to the one plane to the holding portion while holding a portion corresponding to the coil side of both linear portions included in A second step of plastically processing the preform is configured by sequentially forming coils and forming crossovers by the plurality of connecting portions.

  Furthermore, when manufacturing the armature coil according to claim 3, the invention according to claim 7 is parallel to the first straight line portion and the first straight line portion having the winding start portion on the inner peripheral side and the winding end portion on the outer peripheral side. A plurality of pre-formed portions formed by winding a rectangular conductor in one plane so as to have a second linear portion extending and a pair of curved portions connecting the two linear portions, and the winding directions of the rectangular conductor are opposite to each other A first step of preparing a preform including a plurality of connecting portions that connect the plurality of preforming portions so as to integrally connect the winding start portion and the winding end portion of the preforming portion, A force in a direction in which the portions corresponding to the first and second coil sides of the first and second linear portions included in the preforming portions are separated from each other in a direction perpendicular to the one plane on the holding portion. Add both at the same time. And the second step of plastically processing the preform so that each of the preforming portions constitutes an armature coil and each of the plurality of connecting portions constitutes a crossover wire. .

  According to the first aspect of the present invention, since the armature coil is configured by winding the rectangular conductor, it is not necessary to secure a space for electrical connection and electrical connection work is unnecessary. It is possible to freely set the number of turns, and at the coil ends of the armature coils in which one coil side is accommodated in the mutually adjacent slots, the slots avoid the interference of the inclined portions with each other. And the torsional coupling portions are arranged at intervals in the slot arrangement direction, and the lamination direction of the rectangular conductors at the torsional coupling portion is the lamination direction at the coil side. Since the difference is 90 degrees, the width of the twisted connection portion along the slot arrangement direction is constant, and mutual interference between coil ends can be prevented regardless of the number of turns. .

  According to the second aspect of the present invention, the winding directions of the rectangular conductors between the armature coils in which the first and second coil sides are stacked and accommodated in the same slot are opposite to each other. The direction of current flow in the first and second coil sides is the same, and the armature core can be made compact while avoiding mutual interference between the coil ends, and the number of turns can be increased. Since the number of stacked first and second coil sides accommodated in the same slot is (even number + odd number), the number of turns can be set to an odd number. In addition, since the length between the winding start portion and the winding end portion connected by the jumper wire corresponds to the length between the first and second coil sides in each armature coil, the length of the jumper wire is short. In addition, since the connecting wires are alternately arranged on both end sides in the axial direction of the armature core, it is easy to secure a space for arranging the connecting wires.

  According to the third aspect of the present invention, it is possible to save labor for electrically connecting a plurality of armature coils, and to reduce the number of assembling work steps.

  According to the fourth aspect of the present invention, in the alternator configured to form the power generation coil using the rectangular conductive wire, the number of turns of the power generation coil can be freely set while preventing mutual interference between the coil ends. By arranging the torsional coupling portions at the ends of the coils at intervals in the slot arrangement direction, the cooling air generated by the cooling fan can be circulated between the coil ends of the armature coils to improve the cooling efficiency. Can be high. Moreover, when the plurality of armature coils and the connecting wires connecting the armature coils are integrally formed, the number of assembling steps for the alternator can be reduced.

  According to the fifth aspect of the present invention, it is possible to easily manufacture an armature coil having a coil end composed of a pair of inclined portions and a twisted connecting portion connecting the two inclined portions.

  According to the sixth aspect of the present invention, it is possible to simultaneously and easily form a plurality of armature coils having the same winding direction of the rectangular conductors and a plurality of jumper wires integrally connecting the armature coils. Can do.

  Further, according to the seventh aspect of the present invention, a plurality of armature coils arranged with the winding directions of the rectangular conductors alternately reversed, and a plurality of jumper wires integrally connecting the armature coils can be easily and simultaneously performed. Can be formed.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below based on examples of the present invention shown in the accompanying drawings.

  1 to 8 show a first embodiment of the present invention. FIG. 1 is a longitudinal side view of an alternator, FIG. 2 is a partially cutaway front view of a stator, and FIG. 3 is a direction of arrow 3 in FIG. 4 is a partially cutaway side view as seen from FIG. 4, FIG. 4 is a developed circumferential view showing the configuration of the coil unit, and FIG. 5 is a view in the direction of arrow 5 in FIG. 3 with the single-phase coil unit mounted on the armature core. FIG. 6 is a diagram seen from the direction of arrow 6 in FIG. 3 in a state where a single-phase coil unit is mounted on the armature core, and FIG. 7 is a diagram for explaining a method for manufacturing the armature coil FIG. 8 is a perspective view of a preform for manufacturing a coil unit.

  First, in FIG. 1, an alternator 25A, which is a rotating electrical machine, is mounted on an automobile such as a truck. A Landel rotor 26A, a front bracket 28A on which a shaft 27A of the rotor 26A is rotatably supported, and a rear A bracket 29A, an excitation core 30A fixedly supported by the rear bracket 29A, an excitation coil 31A wound around the excitation core 30A so as to magnetize the rotor 26A, and a cooling unit fixed to the rotor 26A And a stator 10 as an armature that is sandwiched between the front and rear brackets 28A and 29A.

  The rotor 26A has a plurality of claw-shaped magnetic poles 34a disposed between a first rotor core 33 having a plurality of claw-shaped magnetic poles 33a at regular intervals in the circumferential direction and a plurality of claw-shaped magnetic poles 33a provided in the first rotor core 33. And the second rotor core 34 having equal intervals in the circumferential direction are coupled in a ring shape and fixed to the shaft 27A. Cylindrical boss portions 35 and 36 are coaxially provided at the center of the front and rear brackets 28A and 29A, and one end of a shaft 27A is rotatable through a bearing 37 on the boss portion 36 of the rear bracket 29A. Supported. The other end of the shaft 27A penetrates the boss portion 35 of the front bracket 28A and protrudes outward, and a bearing 38 is provided between the boss portion 35 and the shaft 27A.

  A cooling fan 32A is fixed to the shaft 27A of the rotor 26A outside the front bracket 28A. The front bracket 28A has a plurality of air circulation holes 39 for circulating cooling air generated by the cooling fan 32A. The rear bracket 29A is also provided with a plurality of air circulation holes (not shown) for circulating the cooling air.

  A pulley 40 is fixed to the other end of the shaft 27A outside the cooling fan 32A, and an endless belt (not shown) for transmitting power from an engine (not shown) is wound around the pulley 40.

  A cover 42A is attached to the rear bracket 29A so as to form a storage chamber 41 between the rear bracket 29A and the outer surface of the rear bracket 29A. In the storage chamber 41, a rectifier 47 comprising a pair of heat sinks 43, 44 fixed to the rear bracket 29A with a space between each other, a plurality of diodes 45, 46, attached to the heat sinks 43, 44, and A regulator 48 and the like fixed to the rear bracket 29A are accommodated. The cover 42A is provided with a plurality of air circulation holes 49.

  On the inner surface side of the rear bracket 29A, a cylindrical excitation core 30A inserted into the rotor cores 33 and 34 is fixed by a plurality of screw members 50, and the excitation coil 31A is wound around the excitation core 30A. .

  Referring to FIGS. 2 and 3 together, the stator 10 has a U-phase, V-phase, and W-phase so that a stator core 11 as an armature core forms a three-phase two-circuit with an electrical angle shifted by 30 degrees. .., 12V..., 12W... And the stator core 11 is sandwiched between front and rear brackets 28A and 29A that are fastened together by a plurality of through bolts 51. A cylindrical yoke portion 11a and a plurality of salient pole portions 11b, 11b,... Which are formed in a substantially T shape and project from the inner periphery of the yoke portion 11a are integrated. It is comprised by laminating | stacking a steel plate, and slot 13,13 ... is formed between each salient pole part 11b, 11b .... Thus, the number of the salient pole portions 11b, 11b... Is, for example, 96, 72, 60, 48, 36 or 30, and the same number of slots 13 as the salient pole portions 11b, 11b. , 13... Are formed on the inner periphery of the yoke portion 11a.

  In such an alternator 25A, an AC electromotive force is generated in each of the coil units 12U, 12V, and 12W according to the rotation of the shaft 27A, the AC electromotive force is rectified to a direct current by the rectifier 47, and the voltage is adjusted by the regulator 48. DC power is output from the alternator 25A as, for example, battery charging power.

  Referring also to FIG. 4, the U-phase coil unit 12U includes a plurality of slots 13, 13... That are selected from a plurality of slots 13, 13. When the armature coils 14, 14... Are connected to each other by connecting wires 15... And the slots 13, 13. S13, S19; S25, S31; S37, S43; S49, S55; Slots 13, 13,.

  Referring to FIGS. 5 and 6 together, the armature coil 14 includes a pair of coil sides 16 and 16 accommodated in the slots 13 and 13 respectively, and a pair of ends connecting the coil sides 16 and 16. The rectangular conductors 18 that are integrally formed with the coil ends 17 and 17 and have a rectangular cross section and are insulated on the entire outer surface are integrally connected with a turn number of, for example, “3”. The wrapping module is formed by winding.

  Thus, at both coil sides 16, a part of the rectangular conductor 18 is laminated in the depth direction of the slot 13. The coil ends 17 are connected to the coil sides 16 and 16 at one end, and a pair of inclined portions 17a and 17a inclined so as to be separated from the stator core 11 as they come close to each other, and their inclined portions. 17a and 17a, and the torsional connection part 17b which connects between the other ends. Moreover, the stacking direction of the rectangular conductors 18 at the two inclined portions 17a and 17a is the same as the stacking direction of the coil sides 16 and 16 connected to the inclined portions 17a and 17a. The inclined layers 17a and 17a are twisted approximately 180 degrees so that the stacking directions of the inclined portions 17a and 17a are opposite to each other and the positions of the inclined portions 17a and 17a are shifted from each other in the radial direction of the stator core 11, and the torsion coupling portion 17b. The stacking direction of the rectangular conductor 18 is substantially 90 degrees different from the stacking direction of the inclined portions 17a and 17a on both sides, that is, the stacking direction of the coil sides 16 and 16, and substantially along the axial direction of the stator core 11.

  Such armature coils 14 are attached to the stator core 11 so that one coil side 16 of the pair of armature coils 14 is accommodated in the same slot 13 as shown in FIG. Thereby, a U-phase coil unit 12U is configured.

  By the way, by accommodating one coil side 16, 16 of the pair of armature coils 14, 14 in the same slot 13, a coil unit 12 </ b> U is constructed in which the number of turns is twice the number of turns of each armature coil 14. This is to keep the thickness of the gathered portion of the coil ends 17 along the radial direction of the stator core 11 relatively small even if a relatively large number of turns are obtained. That is, as shown in FIGS. 5 and 6, the torsional coupling portion 17 b at the coil end 17 of the single armature coil 14 can be arranged so as to be substantially along the radial direction of the stator core 11. Even if the number of turns of the U-phase coil unit 12 </ b> U is increased by accommodating one coil side 16, 16 of the coil 14, in the same slot 13, the torsional connection portion 17 b. It is possible to arrange them adjacent to each other, and the stator core 11 can be made compact while avoiding interference between the coil ends 17.

  Similarly, the V-phase and W-phase coil units 12V and 12W are configured by mounting a plurality of armature coils 14 on the stator core 11 in the same manner as the U-phase coil unit 12U. The units 12U..., 12V..., 12W... Are attached to the starter core 11 so that the positions of the slots 13 and 13 that accommodate the coil sides 16 and 16 are sequentially shifted in the circumferential direction of the stator core 11. Two circuits are configured.

  In manufacturing the armature coil 14, the first step of preparing the preform 19 shown in FIG. 7A and the second step of plastically deforming a part of the preform 19 are executed. The preform 19 in the first step constitutes a pair of straight portions 20, 20 extending in parallel to each other and a pair of curved portions 21, 21 connecting the straight portions 20, 20. The rectangular conductor 18 is wound in one plane.

  In the second step, the part corresponding to the coil sides 16 and 16 (the range indicated by the chain line in FIG. 7) of both the straight parts 20 and 20 included in the preform 19 is held in the holding part. Forces in directions perpendicular to the plane are separated from each other as shown by arrows, and both straight portions 20, 20 excluding portions corresponding to the coil sides 16, 16 and the both bent portions As shown in FIG. 7B, the armature coil 14 is manufactured by plastically deforming 21 and 21 so as to form the coil ends 17 and 17.

  By the way, the connecting wires 15 connecting the plurality of armature coils 14 constituting each of the coil units 12U, 12V, and 12W are formed integrally with the armature coils 14 ... In manufacturing such a plurality of crossover wires 15 and a plurality of armature coils 14 as shown in FIG. 8, as shown in FIG. 8, preformed portions 19 ′ corresponding to the plurality of preformed products 19 shown in FIG. And a preformed product 23 comprising a plurality of preformed parts 19 'having the same winding direction of the rectangular conductor 18 and connecting parts 22 integrally connecting the preformed parts 19', the manufacturing process described with reference to FIG. According to the method, the plurality of preformed portions 19 '... are simultaneously plastically deformed.

  That is, a preform 23 having a plurality of preformed portions 19 'formed by winding the rectangular conductor 18 in the same direction in one plane and a plurality of connecting portions 22 integrally connecting the preformed portions 19'. The first step to be prepared and the portions corresponding to the coil sides 16 and 16 of both the straight portions 20 and 20 provided in the respective preformed portions 19 'are held in the holding portion in a direction perpendicular to the one plane. The armature coils 14 are each composed of a plurality of preformed portions 19 'so as to simultaneously apply force in the direction away from each other, and the connecting wires 15 that are inverted approximately 180 degrees in the middle at the plurality of connecting portions 22 ... The second step of plastic working the preform 23 as configured is sequentially executed.

  By the way, the armature coils 14 are accommodated in a plurality of sets of slots 13, 13... Of the armature coils 14... Of the coil sides 16, 16. Thus, before mounting on the stator core 11, the tip of each salient pole portion 11b, 11b ... of the stator core 11 has a shape in which the slots 13, 13 ... are opened as shown by the chain lines in FIG. After insertion of the coil sides 16, 16 ... into the slots 13, 13 ..., the tip portions of the salient pole portions 11b, 11b ... are plastically deformed so as to be substantially T-shaped so as to close the slots 13, 13 .... .

  Next, the operation of the first embodiment will be described. The armature coil 14 is formed in a pair of slots 13 and 13 such that a part of the rectangular conductor 18 that is integrally connected is laminated in the depth direction of the slot 13. A rectangular conductor 18 is wound so as to integrally have a pair of coil sides 16 and 16 to be accommodated and a pair of coil ends 17 and 17 connecting both ends of the coil sides 16 and 16. Therefore, it is not necessary to secure a space for electrical connection on one side of both coil ends 17 and 17, and it is possible to freely set the number of turns without requiring electrical connection work.

  The coil ends 17 are arranged so that the rectangular conductors 18 are stacked in the same direction as the coil sides 16 and 16, and one ends of the coil sides 16 and 16 are connected to each other, and the coil ends 17 are separated from the stator core 11 as they approach each other. The pair of inclined portions 17 a, 17 a and the laminating direction of both inclined portions 17 a, 17 a are reversed to each other, and the positions of both inclined portions 17 a, 17 a are substantially 180 so that they are displaced from each other in the radial direction of the stator core 11. The other end of both inclined portions 17a and 17a are connected to each other so as to be twisted, and the lamination direction of the rectangular conductor 18 is substantially aligned with the axial direction of the stator core 11 so as to be different from the inclined portions 17a and 17a by 90 degrees. And a twisted connecting portion 17b.

  Therefore, at the coil ends 17 and 17 of the armature coils 14 and 14 in which the coil sides 16 and 16 are accommodated in the slots 13 and 13 adjacent to each other, the inclined portions 17a, 17a. As a result, the slots 13 and 13 are arranged at intervals in the longitudinal direction of the slots 13 and the torsion coupling portions 17b are arranged at intervals in the slot arrangement direction (the circumferential direction of the stator core 11). Since the stacking direction of the rectangular conductors 18 at 17b differs from the stacking direction at the coil side 16 by 90 degrees, the width of the torsional connecting portion 17b along the slot arrangement direction is constant, and the coil end is constant regardless of the number of turns. The mutual interference between 17 and 17 can be prevented.

  Further, since the plurality of armature coils 14 and the connecting wires 15 that connect the armature coils 14 are integrally formed, the plurality of armature coils 14 are electrically connected to each other. It is possible to save labor and reduce the assembly work man-hours.

  Moreover, the armature coil 14 includes a Landel type rotor 26A, front and rear brackets 28A and 29A on which a shaft 27A of the rotor 26A is rotatably supported, and a cooling fan 32A fixed to the rotor 26A. In the alternator 25A provided, the stator core 11 sandwiched between the front and rear brackets 28A, 29A is coiled into a pair of slots 13, 13 selected from among a plurality of slots 13, 13 ... provided on the inner periphery of the stator core 11. Since it is wound so as to accommodate the sides 16, 16, in the alternator 25 </ b> A configured to form a power generation coil using a rectangular conducting wire, the armature is prevented while preventing mutual interference between the coil ends 17. Coil 14 ... that is, the number of turns of the power generation coil can be set freely When the torsional coupling portions 17b of the coil ends 17 are arranged at intervals in the slot arrangement direction, the cooling air generated by the cooling fan 32A is generated between the coil ends 16 of the armature coils 14. Thus, the cooling efficiency can be increased.

  Further, since the plurality of armature coils 14 and the connecting wires 15 connecting the armature coils are integrally formed, it is possible to reduce the man-hours for assembling the alternator 25A.

  Further, when the armature coil 14 is manufactured, a pair of straight portions 20, 20 extending in parallel to each other and a pair of curved portions 21, 21 connecting the straight portions 20, 20 are formed in a single plane. A first step of forming a preform 19 formed by winding the conductor 18, and holding the portion corresponding to the coil sides 16 and 16 of the two straight portions 20 and 20, while holding the portion on the one plane And a second step of applying forces in directions perpendicular to each other in a direction perpendicular to each other, a portion excluding a portion corresponding to the coil sides 16 and 16 of both the straight portions 20 and 20, and a bent portion 21 , 21 are plastically deformed so as to form coil ends 17, 17, and the armature coil 14 is manufactured, and a twist connecting the pair of inclined portions 17 a, 17 a and the inclined portions 17 a, 17 a Communicating The armature coil 14 having a coil end 17, 17 consisting of portions 17b can be easily manufactured.

  In addition, when manufacturing the coil units 12U, 12V, and 12W integrally including a plurality of armature coils 14 and a plurality of crossover wires 15 that connect the armature coils 14 to each other, a plurality of spares shown in FIG. A preformed product 23 comprising a preformed portion 19 'corresponding to the molded product 19 and a connecting portion 22 integrally connecting the plurality of preformed portions 19' having the same winding direction of the rectangular conductor 18. And a portion corresponding to the coil sides 16 and 16 of both linear portions 20 and 20 included in each of the preforming portions 19 '... while holding the portion corresponding to the coil sides 16 and 16 in the direction perpendicular to the one plane. The armature coils 14 are each composed of a plurality of preformed portions 19 'so as to simultaneously apply forces in directions away from each other, and the crossover wires 15 are composed of a plurality of connecting portions 22 ... respectively. The second step of plastically processing the prepared article 23 is sequentially executed, whereby a plurality of armature coils 14 and the connecting wires 15 that integrally connect the armature coils 14. It is possible to manufacture simultaneously and easily.

  FIG. 9 shows a second embodiment of the present invention, and parts corresponding to the first embodiment are given the same reference numerals.

  The alternator 25B includes a Landel rotor 26B, a front bracket 28B and a rear bracket 29B on which a shaft 27B of the rotor 26B is rotatably supported, an excitation core 30B fixedly supported by the front bracket 28B, and the rotor. An exciting coil 31B wound around the exciting core 30B so as to magnetize 26B, cooling fans 32B and 52 fixed to the rotor 26B, and an electric machine held between the front and rear brackets 28B and 29B. And a stator 10 as a child.

  The shaft 27B of the rotor 26B is rotatably supported at the center of the front and rear brackets 28B and 29B. A cooling fan 32B is fixed to the shaft 27B outside the front bracket 28B, and a pulley 40 is fixed. The front bracket 28B is provided with a plurality of air circulation holes (not shown) for circulating cooling air generated by the cooling fans 32B and 52, and for circulating the cooling air also to the rear bracket 29B. A plurality of air circulation holes 53 are provided.

  A cover 42B is attached to the rear bracket 29B, a rectifier 47, a regulator 48, and the like are accommodated between the covers 42B in the rear bracket 29B, and a plurality of air circulation holes 54 are provided in the cover 42B.

  The stator core 11 constituting a part of the stator 10 is sandwiched between front and rear brackets 28B and 29B that are fastened to each other by a plurality of through bolts 55, and the stator core 11 has U-phase, V-phase, and W-phase. The stator 10 is configured by mounting the coil units 12U, 12V, and 12W.

  In addition, a cooling fan 52 is fixed to the surface of the rotor 26B facing the rear bracket 29B side, and the fan 52 rotates the shaft 27B from the outside of the cover 42B through the air circulation holes 53, 54,. The air sucked inward of the bracket 29B flows to the stator 10 side. Further, since the other fan 32B also rotates in accordance with the rotation of the shaft 27B, the air flowing through the stator 10 is led out of the front bracket 28B through the air circulation hole of the front bracket 28B.

  According to the second embodiment, the same effect as that of the first embodiment can be obtained, and the cooling air generated by the cooling fans 32B and 52 is more circulated between the coil ends 16 of the armature coils 14. It is possible to increase the cooling efficiency by effectively distributing it.

  10 to 17 show a third embodiment of the present invention. FIG. 10 is a partial front view of the stator, FIG. 11 is a view taken in the direction of arrow 11 in FIG. 10, and FIG. 11 is a view as viewed from the direction of the arrow 12 in FIG. 11 when mounted on the stator core, FIG. 13 is a view as viewed from the direction of the arrow 14 in FIG. FIG. 15 is a perspective view of a single-phase coil unit, FIG. 16 is a circumferential development showing the configuration of each phase coil unit, and FIG. 17 is a preforming for forming the coil unit. It is a perspective view of goods.

  First, in FIG. 10 and FIG. 11, a stator 60 includes a stator core 61 serving as an armature core, three-phase U1, V1, and W1 phase coil units 62U1, 62V1, and 62W1 as a first set, The three-phase U2-phase, V2-phase, and W2-phase coil units 62U2, 62V2, and 62W2 that are a set of the above are mounted so as to form a three-phase two-circuit with an electrical angle shifted by 30 degrees, The stator core 61 integrally includes a cylindrical yoke portion 61a and a plurality of salient pole portions 61b, 61b... That are formed in a substantially T shape and project from the inner periphery of the yoke portion 61a. A plurality of magnetic steel plates are laminated, and slots 63, 63... Are formed between the salient pole portions 61b, 61b. Thus, the number of the salient pole portions 62b, 62b... Is 96, for example, and the same number of slots 63, 63... As the salient pole portions 61b, 61b. .

  12 to 15 together, the U1-phase coil unit 62U1 is accommodated in a plurality of sets of slots 63, 63, each of which is selected from a plurality of slots 63, 63,. A plurality of armature coils 64, 64... Are connected to each other by crossover wires 65.

  The armature coil 64 integrally includes first and second coil sides 66 and 67 accommodated in the slots 63 and 63, and a pair of coil ends 68 and 68 connecting both ends of the coil sides 66 and 67, respectively. The rectangular conductor 18 is formed by winding a rectangular conductor 18 having a rectangular cross section and having an insulation treatment applied to the entire outer surface. The rectangular conductor 18 is formed on the first and second coil sides 66 and 67. Are stacked in the depth direction of the slots 63 and 63.

  In addition, the first coil side 66 has at least a winding start portion 66a and a winding end portion 66b of the rectangular conductor 18, and the number of laminated portions of the rectangular conductor 18 is one of an even number and an odd number. In the example, the number of stacked layers is an even number “4”. Further, the second coil side 67 is a part in which the number of laminated portions of the rectangular conductor 18 is the other of the even number and the odd number, and is an odd number “3” in the third embodiment. Further, the number of the laminated coil ends 68 is the same as that of the second coil side 67, which is “3” in the third embodiment.

  The coil ends 68 are connected to the coil sides 66 and 67 at one end and a pair of inclined portions 68a and 68a inclined so as to be separated from the stator core 61 as they come close to each other. It consists of the twist connection part 68b which connects between the other ends of the parts 68a and 68a. In addition, the lamination direction of the rectangular conductors 18 at both the inclined portions 68a and 68a is the same as the lamination direction of the coil sides 66 and 67 connected to the inclined portions 68a and 68a, but the torsion coupling portion 68b. Is twisted approximately 180 degrees so that the laminating directions of the inclined portions 68a and 68a are opposite to each other and the positions of the inclined portions 68a and 68a are displaced from each other in the radial direction of the stator core 61. The stacking direction of the rectangular conductors 18 at the portion 68b is approximately 90 degrees different from the stacking direction of the inclined portions 68a and 68a on both sides, that is, the stacking direction of the coil sides 66 and 67, and in the axial direction of the stator core 61. Are stacked.

  Such armature coils 64 are integrally connected with the connecting wires 65 so that the winding directions of the rectangular conductors 18 are alternately reversed along the circumferential direction of the stator core 61. The first and second coil sides 66 and 67 of a pair of armature coils 64 and 64 that are opposite to each other are stacked and accommodated in the same slot 63, and between the first coil sides 66 of each armature coil 64. Are connected to the stator core 61 so as to be alternately distributed to both axial ends of the stator core 61 along the circumferential direction of the stator core 61, thereby forming a U1-phase coil unit 62U1. The Thus, the intermediate portion of the crossover wire 65 is formed so that the crossover wire 65 ties the armature coils 64, whose winding directions are opposite to each other, and is thus twisted approximately 180 degrees, It becomes the reversal system of the lap winding module.

  The first set of V1 and W1 phase coil units 62V1 and 62W1 and the second set of U2, V2 and W2 phase coil units 62U2, 62V2 and 62W2 are also included in the first set of the U1 phase. In the same manner as the coil unit 62 U 1, a plurality of armature coils 64... Are mounted on the stator core 61.

  Moreover, both sets of coil units 62U1, 62V1, 62W1; 62U2, 62V2, 62W2 are shown in FIG. 16 when the slots 63, 63,... Are numbered in the order of S1 to S96 in the circumferential direction of the stator core 61. In this manner, the positions of the slots 63, 63... That accommodate the coil sides 66, 67... Are shifted one by one in the circumferential direction of the stator core 61. Thus, the coil units 62U1, 62V1, 62W1; 62U2, 62V2, 62W2 are mounted on the starter core 11, and both sets of coil units 62U1, 62V1, 62W1; It connects so that the sex points N1 and N2 may be comprised.

  In manufacturing the armature coil 64, the first step of preparing the preform 69 shown in FIG. 17 and the second step of plastically deforming the preform 69 are executed. The preform 69 in this step is integrally provided with a plurality of coil forming portions 70 and curved connecting portions 71 connecting the coil forming portions 70.

  The coil forming portion 70 includes a first straight portion 72 having a winding start portion 72a on the inner peripheral side and a winding end portion 72b on the outer peripheral side, a second straight portion 73 extending in parallel with the first straight portion 72, and both straight portions. The rectangular conductor 18 is wound in one plane so as to have a pair of curved portions 74, 74 connecting the portions 72, 73, and is formed in a shape corresponding to the armature coil 64. In addition, the preform 69 is configured such that a plurality of coil forming portions 70 in which the winding directions of the rectangular conductors 18 are alternately reversed are connected to each other by the plurality of connecting portions 71. The connecting portions 71... Integrally connecting the winding start portion 72 a in one coil forming portion 70 and the winding end portion 72 b in another coil forming portion 70 connected to the coil forming portion 70 are alternately arranged on the opposite side. become.

  In the second step, the portions corresponding to the first and second coil sides 66 and 67 of the armature coil 64 among the first and second linear portions 72 and 73 included in the coil forming portion 70. A force in a direction away from each other in a direction perpendicular to the one plane is applied to the holding portion, and portions corresponding to the first and second coil sides 66 and 67 of the first and second linear portions 72 and 73 are provided. A plurality of armatures that are integrally connected so that the portion to be removed and the bent portions 74 and 74 are plastically deformed so as to form coil ends 68 and 68 and a connecting wire 65 is formed at the connecting portion 71. The coils 64 and the plurality of connecting wires 65 can be formed simultaneously and easily.

  According to the third embodiment, the following operations and effects can be obtained in addition to the operations and effects obtained in the first embodiment. That is, the winding directions of the rectangular conductors 18 between the armature coils 64 and 64 in which the first and second coil sides 66 and 67 are stacked and accommodated in the same slot 63 are opposite to each other. The current flow directions in the first and second coil sides 66 and 67 are the same, and the stator core 61 can be made compact while avoiding mutual interference between the coil ends 68... And the number of turns can be increased. In addition, since the number of stacked first and second coil sides 66 and 67 accommodated in the same slot 63 is (even number + odd number), the number of turns can be set to an odd number. Moreover, since the connecting wires 65 are alternately distributed and arranged on both axial ends of the stator core 61, it is easy to secure a space for arranging the connecting wires 65.

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

It is a vertical side view of the alternator of 1st Example. It is a partially cutaway front view of a stator. FIG. 3 is a partially cutaway side view seen from the direction of arrow 3 in FIG. 2. It is the circumferential direction expanded view which shows the structure of a coil unit. It is the figure seen from the 5 arrow direction of FIG. 3 in the state which mounted | wore the stator core with the single phase coil unit. It is the figure seen from the 6 arrow direction of FIG. 3 in the state which mounted | wore the stator core with the single phase coil unit. It is a perspective view for demonstrating the manufacturing method of an armature coil. It is a perspective view of the preforming product for manufacturing a coil unit. It is a vertical side view of the alternator of 2nd Example. It is a partial front view of the stator of 3rd Example. It is 11 arrow line view of FIG. FIG. 12 is a view taken along arrow 12 of FIG. 11 in a state where a single-phase coil unit is mounted on the stator core. FIG. 13 is a view taken along arrow 13 in FIG. 11 in a state where a single-phase coil unit is mounted on the stator core. It is the figure which saw through the stator core seeing from the 14 arrow direction of FIG. It is a perspective view of a single phase coil unit. It is a development view in the circumferential direction showing the configuration of each phase coil unit. It is a perspective view of the preforming object for shape | molding a coil unit.

Explanation of symbols

10 ... Stator 11 as armature, 61 ... Stator core 13 as armature core, 63 ... Slot 14, 64 ... Armature coil 15, 65 ... Crossover 16, 66, 67 ... Coil sides 17 and 68 ... Coil ends 17a and 68a ... Inclined parts 17b and 68b ... Twist connection parts 18 ... Rectangular conductors 19, 69 ... Preliminary molded parts 19 ', 70 .. Preliminary forming parts 20, 72, 73 ... straight parts 21, 74 ... curved parts 22, 71 ... connecting parts 25A, 25B ... alternators 26A, 26B as rotating electric machines 27A 27B ... Shafts 28A, 28B ... Front brackets 29A, 29B ... Rear brackets 32A, 32B, 52 ... Cooling fans 66a, 72a ... Winding start portions 66b, 7 b ··· winding end section

Claims (7)

  An armature core (11, 61) having a plurality of slots (13, 63) and a square shape so as to be received in a pair of slots (13, 63) selected from the plurality of slots (13, 63). In the armature for a rotating electrical machine having a plurality of armature coils (14, 64) formed by forming a conductor (18), the armature coils (14, 64) are one of the rectangular conductors (18) that are integrally connected. A pair of coil sides (16; 66, 67) respectively housed in the slots (13, 63) so that the portions are stacked in the depth direction of the slots (13, 63), and the coil sides thereof The square conductor (18) is wound so as to integrally have a pair of coil ends (17, 68) connecting both ends of (16; 66, 67), and the both coil ends (17, 68). Is the rectangular conductor (18) The armature cores (11, 61) are arranged in the same direction as the coil sides (16; 66, 67) with one end connected to the coil sides (16; 66, 67) and closer to each other. The pair of inclined portions (17a, 68a) inclined so as to be separated from each other) and the stacking directions of both inclined portions (17a, 68a) are reversed to each other, and the positions of both inclined portions (17a, 68a) are The armature cores (11, 61) are twisted so as to be displaced from each other in the radial direction to connect the other ends of both inclined portions (17a, 68a) and the stacking direction of the rectangular conductors (18) is set to the armature core (18). 11, 61) and a torsional connection portion (17 b, 68 b) substantially along the axial direction.   A first coil side (66) which has at least a winding start portion (66a) and a winding end portion (66b) of the rectangular conductor (18), and the number of laminated portions of the rectangular conductor (18) is one of an even number and an odd number. ), A second coil side (67) in which the number of laminated portions of the rectangular conductor (18) is the other of the even and odd numbers, and the rectangular conductor (18) with the same number of laminated layers as the second coil side (67). ) And a pair of coil ends (68) that connect both ends of the coil sides (66, 67), and a winding direction of the rectangular conductor (18) is the armature core (61). A plurality of armature coils (64) that are alternately reversed along the circumferential direction of the first and second coils of the pair of armature coils (64) in which the winding directions are opposite to each other. Side (66, 67) with armature core (61) The armature is stacked and accommodated in the same slot (63) and the connecting wire (65) connecting the first coil sides (66) of the armature coils (64) is provided along the circumferential direction of the armature core (61). The armature for a rotating electrical machine according to claim 1, wherein the armature core (61) is attached to the armature core (61) so as to be alternately distributed to both axial ends of the core (61).   The plurality of armature coils (14, 64) and the connecting wires (15, 65) connecting the armature coils (14, 64) are integrally formed continuously. The armature for rotary electric machines according to 1 or 2.   Landel-type rotor (26A, 26B), front and rear brackets (28A, 29A; 28B, 29B) on which the shafts (27A, 27B) of the rotor (26A, 26B) are rotatably supported, and the rotor ( The armature core (11) is a stator core between the front and rear brackets (28A, 29A; 28B, 29B) of a rotating electric machine including a cooling fan (32A; 32B, 52) fixed to the 26A, 26B). And the coil side (16) is accommodated in a pair of slots (13) selected from the plurality of slots (13) provided on the inner periphery of the armature core (11). The electric machine for a rotating electric machine according to any one of claims 1 to 3, wherein a child coil (14) is wound around the armature core (11). .   In manufacturing the armature coil according to claim 1 or 2, a pair of straight portions (20; 72, 73) extending in parallel to each other and a pair of curved portions (20; 72, 73) connecting the straight portions (20; 72, 73). 21, 74) to form a preform (19, 70) formed by winding the rectangular conductor (18) in one plane, and the straight portions (20; 72, 73) Of these, the step of applying the forces in the direction perpendicular to the one plane to the holding portion while holding the portion corresponding to the coil side (16; 66, 67) is sequentially executed. A method for manufacturing an armature coil.   In manufacturing the armature coil according to claim 3, a pair of straight portions (20) extending in parallel with each other and a pair of curved portions (21) connecting the straight portions (20) are formed on a plane. And a plurality of preforming portions (19 ') formed by winding the rectangular conductor (18) in the same direction and a plurality of connecting portions (22) integrally connecting the preforming portions (19'). A first step of preparing an article (23), and holding the portion corresponding to the coil side (16) of both linear portions (20) included in each of the preforming portions (19 ′) The armature coils (14) are respectively configured by a plurality of preformed portions (19 ′) so as to simultaneously apply forces in directions perpendicular to the one plane and away from each other, and the plurality of connecting portions (22). Configure the crossover (15) respectively Method of manufacturing an armature coil, characterized by sequentially executing the second step of plastic working said preform (23) so as to.   In manufacturing the armature coil according to claim 3, a first straight portion (72) and a first straight portion (72) having an inner circumferential winding start portion (72 a) and an outer circumferential winding end portion (72 b). A plurality of rectangular conductors (18) wound in one plane so as to have a second straight line portion (73) extending in parallel with each other and a pair of curved portions (74) connecting the straight line portions (72, 73). And the winding start portion (72a) and the winding end portion (72b) of the preforming portion (70) in which the winding directions of the rectangular conductors (18) are opposite to each other. A first step of preparing a preform (69) including a plurality of connecting portions (71) for connecting the plurality of preformed portions (70) so as to be connected to each other, and each of the preformed portions (70) Of the first and second straight portions (72, 73) provided A plurality of pre-formed parts are formed by simultaneously holding the portions corresponding to the first and second coil sides (66, 67) while simultaneously applying forces in the directions perpendicular to the one plane to the holding portions. The armature coil (64) is configured by (70), and the preform (69) is plastically processed so that the connecting wire (65) is configured by the plurality of connecting portions (71). And a step of sequentially executing the steps.

Images