JP2005137126A - Coil structure of stator and manufacturing method for the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil structure of and a manufacturing method for stators wherein high cooling capability is obtained and uneven cooling of a stator is reduced. <P>SOLUTION: The stator is constructed by disposing core assemblies 122, formed by winding coils 42 around cores 41 formed of laminated steel plates, in the circumferential direction. Cooling members 43 for cooling the coils 42 are disposed between the coils 42 of the adjacent core assemblies 122. The stator is so constructed that the distance between the coils 42 and the cooling members 43 is smaller than that between the cores 41 and the coils 42. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention is a stator configured by arranging a core assembly component formed by winding a coil around a core made of laminated steel sheets in the circumferential direction, and cools the coil between coils of adjacent core assembly components. The present invention relates to a coil structure and a manufacturing method of a stator in which a cooling member is arranged.

Conventionally, as a stator cooling structure in a multi-axis multilayer motor applied to, for example, a hybrid drive unit, a method of filling a stator assembly with a resin having a high heat transfer efficiency is known as a stator fixing method as a heat source. It has been. And the passage which lets a refrigerant pass to resin near the stator, and circulates cooling water in the passage, cools the resin and cools a stator indirectly, and aims at stabilization of performance ( For example, Patent Document 1). However, in this example, there is a problem that cooling of the stator is biased and the stator cannot be uniformly cooled in the circumferential direction.
JP 2000-14086 A

  In order to alleviate the bias of stator cooling in the multi-axis multilayer motor described above, as shown in FIG. 19, a core assembly component formed by winding a coil 502 around a core 501 made of laminated steel plates is arranged in the circumferential direction. A stator 503 is also considered which is a configured stator 503 in which a cooling member 504 for cooling the coil 501 is disposed between the coils 501 of adjacent core assembly parts.

  In the conventional example described above, a large amount of current is passed through the coil 502 in order to use the core 501 as an electromagnet. At that time, heat is generated. The cooling member 504 constitutes a passage through which the refrigerant that absorbs and generates heat is absorbed. However, since the coil 502 is usually wound around the core 501, as shown in FIG. 19, the coil 502 and the core 501 are in close contact with each other, and conversely, a gap is generated between the cooling member 504 and the coil 502. It was. In the conventional example described above, since the stator 503 has such a structure, a slight gap is generated between the coil 502 and the cooling member 504 in manufacturing, or the gap distribution is uneven. As a result, there was a problem that cooling capacity was lowered and cooling unevenness still occurred.

  An object of the present invention is to solve the above-described problems and to provide a stator coil structure and a manufacturing method capable of obtaining a high cooling capacity with little uneven cooling of the stator.

  The stator coil structure of the present invention is a stator configured by arranging a core assembly part formed by winding a coil around a core made of laminated steel sheets in the circumferential direction, and is a coil of adjacent core assembly parts In the stator in which the cooling member for cooling the coil is arranged, the distance between the coil and the cooling member is made smaller than the distance between the core and the coil.

  In addition, the stator manufacturing method of the present invention is prepared by separately preparing a core made of laminated steel sheets and a coil wound in an annular shape with dimensions larger than those wound in advance on the laminated steel sheets. The core assembly parts and the cooling members are alternately arranged in the circumferential direction so that the coil is pressed against the cooling member by its own elastic force, and the coil is made a cooling member rather than the core. It is characterized by being placed close to each other.

  In the stator coil structure of the present invention, since the distance between the coil and the cooling member is narrower than the distance between the core and the coil, the gap between the coil and the cooling member can be minimized, and the cooling capacity Can be maximized.

  In a preferred example of the stator coil structure of the present invention, an insulating material having a high elastic modulus is provided between the core and the coil to form a core assembly component, and the core assembly component and the cooling member are alternately arranged in the circumferential direction. The coil can be pressed against the cooling member by the cushioning effect of the insulating material, and the coil can be disposed closer to the cooling member than the core. In this example, the coil swells to the cooling member side by winding the coil with an elastic member interposed between the core and the coil. In addition, since the cooling member is not crushed by the elastic member, further cooling capacity can be improved.

  Furthermore, in a preferred example of the coil structure of the stator of the present invention, the cross-sectional shape of the core made of laminated steel sheets is a tapered shape whose width in the circumferential direction decreases as it goes in the central direction when arranged as a stator. Can do. In this example, the wedge force generated when the core is pushed into the coil is expanded outward, so that the coil can be pressed against the cooling member with a larger force, and the cooling capacity can be improved. In this example, more preferably, the coil and the core made of the laminated steel sheet are not directly slid, but an insulating material is interposed between 1 and 2 parts, so that unnecessary rubbing or the like does not occur in the coil.

  In the method of manufacturing a stator according to the present invention, a core made of laminated steel sheets and a coil wound in an annular shape with dimensions larger than those wound in advance on the laminated steel sheets are separately prepared. A core assembly part is formed by mounting on the core, and the core assembly part and the cooling member are alternately arranged in the circumferential direction, so that the coil is pressed against the cooling member by its own elastic force, and the coil is more cooled than the core. Therefore, the coil wound larger can generate a pressing force against the cooling member by its own elastic force, thereby improving the cooling capacity.

  In a preferred embodiment of the method for manufacturing a stator according to the present invention, when a core assembly is formed by mounting an annular coil on a core, an insulating material having a high elastic modulus is provided between the core and the coil. Can do. In this example, the coil swells to the cooling member side by winding the coil with an elastic member interposed between the core and the coil. In addition, since the cooling member is not crushed by the elastic member, further cooling capacity can be improved.

  Furthermore, in a preferred embodiment of the method for manufacturing a stator according to the present invention, when a core assembly is formed by mounting an annularly wound coil on a core, the cross-sectional shape goes in the center direction when arranged as a stator. Accordingly, a core made of a laminated steel sheet having a tapered shape whose width in the circumferential direction is reduced can be pushed into a coil wound in an annular shape. In this example, the wedge force generated when the core is pushed into the coil is expanded outward, so that the coil can be pressed against the cooling member with a larger force, and the cooling capacity can be improved.

  Furthermore, in the preferred embodiment of the stator manufacturing method of the present invention, the coil is wound separately from the core, and then molded in a ring shape with resin, the outer periphery side of the mold (cooling when assembled on the stator) The flow and injection position of the resin can be adjusted so that the coil approaches the member side. In this example, the thickness of the resin molded with the coil can be controlled to a thickness that maximizes cooling performance while ensuring the thickness necessary for insulation on the cooling member side, so that both insulation and cooling properties can be achieved. it can.

The best mode for carrying out the present invention will be described below with reference to the drawings.
First, an example of a multi-axis multilayer motor to which the stator coil structure and the manufacturing method of the present invention are applied will be described.

[Overall configuration of hybrid drive unit]
FIG. 1 is an overall view of a hybrid drive unit to which a multi-axis multi-layer motor is applied. In FIG. 1, E is an engine, M is a multi-axis multi-layer motor, G is a Ravigneaux type compound planetary gear train, D is a drive output mechanism, Reference numeral 1 denotes a motor cover, 2 denotes a motor case, 3 denotes a gear housing, and 4 denotes a front cover.

  The engine E is a main power source of the hybrid drive unit, and the engine output shaft 5 and the second ring gear R2 of the Ravigneaux type planetary gear train G are connected through a rotation fluctuation absorbing damper 6 and a multi-plate clutch 7. ing.

  The multi-axis multilayer motor M is a sub-power source having two motor generator functions although it is one motor in appearance. The multi-axis multilayer motor M is fixed to the motor case 2 and includes a stator S as a fixed armature wound with a coil, an inner rotor IR disposed inside the stator S and having a permanent magnet embedded therein, and the stator The outer rotor OR, which is arranged outside the S and has a permanent magnet embedded therein, is arranged in three layers on the same axis. The first motor hollow shaft 8 fixed to the inner rotor IR is connected to the first sun gear S1 of the Ravigneaux-type compound planetary gear train G, and the second motor shaft 9 fixed to the outer rotor OR is the Ravigneaux-type compound planetary gear. It is connected to the second sun gear S2 of row G.

  The Ravigneaux-type compound planetary gear train G is a planetary gear mechanism having a continuously variable transmission function that changes a transmission gear ratio steplessly by controlling two motor rotation speeds. The Ravigneaux type planetary gear train G includes a common carrier C that supports the first pinion P1 and the second pinion P2 that mesh with each other, a first sun gear S1 that meshes with the first pinion P1, and a second sun gear that meshes with the second pinion P2. It has five rotating elements, S2, a first ring gear R1 that meshes with the first pinion P1, and a second ring gear R2 that meshes with the second pinion P2. A multi-plate brake 10 is interposed between the first ring gear R1 and the gear housing 3. An output gear 11 is connected to the common carrier C.

  The drive output mechanism D includes an output gear 11, a first counter gear 12, a second counter gear 13, a drive gear 14, a differential 15, and drive shafts 16L and 16R. The output rotation and output torque from the output gear 11 pass through the first counter gear 12 → second counter gear 13 → drive gear 14 → differential 15 and are transmitted from the drive shafts 16L and 16R to the drive wheels (not shown). The

  That is, the hybrid drive unit connects the second ring gear R2 and the engine output shaft 5, connects the first sun gear S1 and the first motor hollow shaft 8, and connects the second sun gear S2 and the second motor shaft 9. And the output gear 11 is connected to the common carrier C.

[Configuration of multi-axis multilayer motor]
2 is a longitudinal sectional view showing a multi-axis multilayer motor M to which the present invention is applied, FIG. 3 is a partially longitudinal front view showing the multi-axis multilayer motor M to which the present invention is applied, and FIG. It is the figure which looked at the child from the back side.

  In FIG. 2, reference numeral 1 denotes a motor cover, and 2 a motor case. A multi-axis multilayer motor M constituted by an inner rotor IR, a stator S, and an outer rotor OR is disposed in a motor chamber 17 surrounded by them. Yes.

  The inner rotor surface of the inner rotor IR is fixed by press-fitting (or shrink fitting) to the stepped shaft end portion of the first motor hollow shaft 8. As shown in FIG. 3, twelve inner rotor magnets 21 (permanent magnets) are embedded in the inner rotor IR in the axial direction with respect to the rotor base 20 in consideration of magnetic flux formation. However, the two are arranged in a V-shape to show the same polarity and are in a three-pole pair.

  The stator S includes a stator piece laminate 41 in which the stator pieces 40 are laminated, a coil 42, a cooling medium passage 43 for cooling the stator, an inner side bolt / nut 44, and an outer side bolt / nut 45. . The front side end of the stator S is fixed to the motor case 2 via the front side end plate 47 and the stator shaft 48.

  The coil 42 has 18 coils, and as shown in FIG. 4, the coil 42 is arranged on the circumference while repeating the 6-phase coil three times.

  A composite current is applied to the six-phase coil 42 from an inverter (not shown) through the power supply connection terminal 50, the bus bar radial stack 51, the power connector 52, and the bus bar axial stack 53. This composite current is a combination of a three-phase alternating current for driving the outer rotor OR and a six-phase alternating current for driving the inner rotor IR.

  The outer rotor OR has an outer cylindrical surface fixed to the outer rotor case 62 by brazing or bonding. And the front side connection case 63 is being fixed to the front side of the outer rotor case 62, and the back side connection case 64 is being fixed to the back side. The second motor shaft 9 is splined to the back side connection case 64. In the outer rotor OR, as shown in FIG. 3, twelve outer rotor magnets 61 (permanent magnets) arranged in consideration of magnetic flux formation with respect to the rotor base 60 are embedded in the axial direction at both end positions. ing. Unlike the inner rotor magnet 21, the outer rotor magnet 61 is different in polarity one by one and forms a six-pole pair.

  In FIG. 2, reference numerals 80 and 81 denote a pair of outer rotor support bearings that support the outer rotor 6 on the motor case 2 and the motor cover 1. 82 is an inner rotor support bearing that supports the inner rotor IR to the motor case 2, 83 is a stator support bearing that supports the stator S with respect to the outer rotor OR, and 84 is between the first motor hollow shaft 8 and the second motor shaft 9. This is an intermediate bearing.

  In FIG. 2, 85 is an inner rotor resolver that detects the rotational position of the inner rotor IR, and 86 is an outer rotor resolver that detects the rotational position of the outer rotor OR.

[Configuration of planetary gear mechanism]
FIG. 5 is a longitudinal sectional view showing a Ravigneaux type compound planetary gear train G of the hybrid drive unit. In FIG. 5, 2 is a motor case, 3 is a gear housing, and 4 is a front cover. A Ravigneaux type planetary gear train G and a drive output mechanism D are arranged in a gear chamber 30 surrounded by them.

  The second ring gear R2 of the Ravigneaux type planetary gear train G is driven to rotate from the engine E when the multi-plate clutch 7 is engaged via the rotation fluctuation absorbing flywheel damper 6, the transmission input shaft 31, and the clutch drum 32. Torque is input.

  A first motor hollow shaft 8 is splined to the first sun gear S1 of the Ravigneaux type planetary gear train G, and the first torque and the first torque are transmitted from the inner rotor IR of the multi-axis multilayer motor M according to the determined motor operating point. The first rotation speed is input.

  A second motor shaft 9 is splined to the second sun gear S2 of the Ravigneaux type planetary gear train G, and the second torque and the second torque are output from the outer rotor OR of the multi-axis multilayer motor M according to the determined motor operating point. Two revolutions are input.

  A multi-plate brake 10 is provided between the first ring gear R1 of the Ravigneaux type planetary gear train G and the gear housing 3, and when the multi-plate brake 10 is engaged at the time of starting or the like, the first ring gear R1 is Stop.

  An output gear 11 that is rotatably supported by a stator shaft 48 via a bearing is splined to the common carrier C of the Ravigneaux type planetary gear train G.

  The drive output mechanism D includes a first counter gear 12 that meshes with the output gear 11, a second counter gear 13 provided on the shaft portion of the first counter gear 12, and a drive gear 14 that meshes with the second counter gear 13. And have. The final reduction ratio is determined by the ratio of the number of teeth of the second counter gear 13 and the drive gear 14.

  A fastening pressure is supplied to the clutch piston 33 of the multi-plate clutch 7 by a clutch pressure oil passage 34 formed in the front cover 4. A fastening pressure is supplied to the brake piston 35 of the multi-plate brake 10 by a brake pressure oil passage 36 formed in the front cover 4. The clutch piston 33 and the brake piston 35 are disposed inside the front cover 4, the clutch piston 33 is disposed at an inner circumferential position, and the brake piston 35 is disposed at an outer circumferential position thereof.

  A shaft center oil passage 37 is formed in the transmission input shaft 31, and lubricating oil is supplied to the shaft center oil passage 37 through a lubricant oil passage 38 formed in the front cover 4. The

[Stator structure]
FIG. 6 is an enlarged longitudinal sectional view showing a stator S and a motor case member of a multi-axis multilayer motor to which the present invention is applied.

  The stator piece laminate 41 is configured by laminating a plurality of stator pieces 40 in the axial direction and winding a coil 42 of a flat copper wire around the outer periphery thereof so as to reciprocate in the axial direction.

  In the front side blanket 70 and the back side blanket 71, a plurality of stator piece laminated bodies 41 around which the coil 42 is wound are arranged at equal intervals on the circumference centering on the motor rotation axis, and at both axial end positions. The stator piece 40 is positioned while being positioned.

  The front side end plate 47 and the back side end plate 49 are arranged outside the brackets 70 and 71. A stator shaft 48 is fixed to the front end plate 47.

  The inner side bolt and nut 44 and the outer side bolt and nut 45 are inserted through both end plates 47 and 49, tightened by rotating the nut, and fixed as a whole by the frictional force generated by this tightening. Constructs a skeletal structure.

  The stator cooling pipe 72 is disposed at a position between the coiled stator piece laminated bodies 41 adjacent in the circumferential direction, and both ends thereof are supported by the front bracket 70 and the rear bracket 71.

  The resin mold portion 46 is formed by placing a skeletal structure supporting the stator cooling pipe 32 in a mold having a concave shape that matches the stator shape, pouring the molten resin, and filling the space with the molten resin. The Note that 74 is a refrigerant introduction path formed in the motor case 2, 74 ′ is a refrigerant discharge path formed in the motor case 2, and 77 is a bolt for fixing the stator S to the motor case 2.

[Stator cooling structure]
7 is a cross-sectional view showing the stator cooling structure and the flow of the refrigerant in the present invention, FIG. 8 is a cross-sectional view showing the refrigerant distribution lid member of the stator cooling structure along the line 7A-A, and FIG. 9 is the stator along the line 7B-B. FIG. 10 is a sectional view showing a refrigerant forward path and a refrigerant return path of the stator cooling structure taken along line 7C-C, and FIG. 11 is a refrigerant U of the stator cooling structure taken along line 7D-D. It is a figure which shows a turn lid member.

  In the multi-axis multilayer motor M, an inner rotor IR and an outer rotor OR are disposed concentrically with a stator S interposed therebetween, and an inner rotor and an outer rotor are disposed concentrically with the stator interposed therebetween.

  The stator S includes a stator piece laminate 41 in which coils 42 (multiphase coils) arranged at an equal pitch around a circumference around a motor rotation axis are wound, and a stator that cools the coil heat generation of the stator piece laminate 41 And a cooling refrigerant path 43.

  The refrigerant path 43 includes a refrigerant introduction path 90, a refrigerant distribution lid member 91, a refrigerant distribution plate member 92, a refrigerant forward path 93, a refrigerant return path 94, a refrigerant U-turn lid member 95, a refrigerant discharge path 96, It is set as the structure provided with.

  The refrigerant introduction path 90 is formed in the resin mold portion 46 as shown in FIG. 7 (a), and guides the refrigerant from the outside to the refrigerant introduction port at the stator end.

  As shown in FIG. 8, the refrigerant distribution lid member 91 has a donut shape, is provided with a partition wall 91c of an outward path 91a and a return path 91b in the circumferential direction, and extends from the refrigerant introduction path 90 to a start portion 91d of the outward path 91a. Guide the refrigerant.

  As shown in FIG. 9, the refrigerant distribution plate member 92 includes a forward distribution hole 92a communicating with the forward path 91a and a return distribution hole 92b communicating with the backward path 91b in the circumferential direction. Open to the position to be.

  As shown in FIG. 10, the refrigerant forward path 93 is formed through the resin mold portion 46 of the stator S in the axial direction, and one end communicates with the forward path distribution hole 92a.

  As shown in FIG. 10, the refrigerant return path 94 is formed through the resin mold portion 46 of the stator S in the axial direction, and one end thereof communicates with the return path distribution hole 92b.

  As shown in FIG. 11, the refrigerant U-turn lid member 95 is formed with a communication recess 95a corresponding to a pair of refrigerant outward paths 93 and a refrigerant return path 94, and is set adjacent to the circumferential direction in the refrigerant forward path 93 and the refrigerant return path. The other end of 94 is communicated.

  As shown in FIG. 7 (b), the refrigerant discharge path 96 passes through the refrigerant return path 94 and the return distribution hole 92 b of the refrigerant distribution plate member 92, and from the end portion 91 e of the return path 91 b of the refrigerant distribution lid member 91. Discharge the refrigerant.

  As shown in FIG. 10, the refrigerant forward path 93 and the refrigerant return path 94 are disposed between the coils 42 adjacent in the circumferential direction. Note that the numbers of circles in the reciprocating refrigerant paths are the same, the numbers without "'" correspond to the refrigerant forward path 93, and the numbers with "'" are the refrigerant return path 94. It corresponds to.

  The partition wall 91c of the refrigerant distribution lid member 91 maintains a circumferential cross-sectional area in a constant direction from a portion close to the refrigerant introduction passage 90 to a portion far from the refrigerant introduction passage 90, and a circumferential return cross-sectional area as a refrigerant discharge passage 96. It is an annular partition wall that maintains a constant cross-sectional area from near to far.

  Next, the operation will be described.

[Basic functions of multi-axis multi-phase motor]
By adopting a multi-axis multilayer motor M in which two magnetic lines of outer rotor magnetic field lines and inner rotor magnetic field lines are formed with two rotors and one stator, the coil 42 and a coil inverter (not shown) are replaced with two inner rotors IR and outer rotors. Can be shared for OR. Then, by applying a composite current obtained by superimposing the current for the inner rotor IR and the current for the outer rotor OR to one coil 42, the two rotors IR and OR can be controlled independently. That is, in appearance, it is a single multi-axis multilayer motor M, but it can be used as a combination of different or similar functions of the motor function and the generator function.

  Therefore, for example, compared to the case where a motor having a rotor and a stator and a generator having a rotor and a stator are provided, the size is greatly reduced, which is advantageous in terms of space, cost, and weight, and can be used as a common coil. Thus, loss due to current (iron loss, switching loss) can be prevented.

  Moreover, it has a high degree of freedom in selection, such as using not only (motor + generator) but also (motor + motor) or (generator + generator) by combined current control. When used as a drive source, the most effective or efficient combination can be selected from among these many options according to the vehicle state.

[Stator cooling]
When a large current is passed through the coil 42 when the multi-axis multilayer motor M is driven, the coil 42 generates heat. This heat causes the electrical efficiency and mechanical efficiency to deteriorate. Further, in the multi-axis multilayer motor M, the coils 42 that are heating elements are arranged in the stator S at equal pitches on the circumference around the motor rotation axis. Therefore, in order to remove the heat, it is necessary to cool without deviation in the circumferential direction of the stator S.

  Hereinafter, the stator cooling action by the stator cooling structure of this example will be described with reference to FIGS. 7 and 12.

  As shown in FIG. 7A, the refrigerant that has passed through the refrigerant introduction path 74 formed in the motor case 2 from the outside is the refrigerant introduction path 90 → the forward path 91a of the refrigerant distribution lid member 91 → the refrigerant distribution plate member in the forward path. The forward flow distribution hole 92a → the refrigerant forward passage 93 → the refrigerant U-turn cover member 95 flows into the communication recess 95a.

  In the return path, as shown in FIG. 7B, the return path 94 → the return distribution hole 92 b of the refrigerant distribution plate member 92 → the return path of the refrigerant distribution cover member 91 from the communication recess 95 a of the refrigerant U-turn cover member 95. The refrigerant flows from 91 b to the refrigerant discharge path 96, passes through the refrigerant discharge path 74 ′ formed in the motor case 2 from the refrigerant discharge path 96, and is discharged to the outside.

  In this refrigerant flow, a set of the refrigerant forward path 93 and the refrigerant backward path 94 is adjacent in the circumferential direction, and the refrigerant distribution lid member 91 is provided with a circumferential partition wall 91c that partitions the forward path 91a and the backward path 91b.

  For this reason, for example, in FIG. 12, if the flow path length of the forward distribution hole 92a of the refrigerant distribution plate member 92 and the refrigerant introduction path 90 is short as in the combination of the forward path (1) and the return path (1) ′, the refrigerant The flow path length between the return distribution hole 92b of the distribution plate member 92 and the refrigerant discharge path 96 is increased, and conversely, the forward path of the refrigerant distribution plate member 92 as in the return path (9) ′ in the forward path (9). If the flow path length between the distribution hole 92a and the refrigerant introduction path 90 is long, the flow path length between the return distribution hole 92b of the refrigerant distribution plate member 92 and the refrigerant discharge path 96 is short.

  Thus, since the total flow path length of the refrigerant for passing through the forward path 91a and the return path 91b of the refrigerant distribution lid member 91 is substantially the same length (less than one round of the refrigerant distribution lid member 91), Refrigerant paths 43 (from the refrigerant introduction path 90 to the refrigerant discharge path) represented by the combinations of (1), (1) ′ to (9), (9) ′ distributed including the round trip path and the U-turn path 96) is substantially the same length, the cooling effect of each refrigerant passage 43 becomes substantially uniform, and the cooling bias of the stator S can be alleviated.

  The flow path resistance can be adjusted and the flow rate of each refrigerant path 43 can be made uniform by changing the size of the forward distribution hole 92a and the return distribution hole 92b of the refrigerant distribution plate member 92.

  Further, as shown in FIG. 6, since the refrigerant U-turn lid member 95 is pushed outward in the axial direction by the refrigerant flowing inside the refrigerant U-turn lid member 95, this force acts on the stator support bearing 83. That is, the preload can be applied to the stator support bearing 83 by the refrigerant.

  A feature of the present invention is to provide a stator coil structure and a manufacturing method that can be suitably used in addition to the cooling structure of the stator S (stator) of the multi-axis multilayer motor M having the above-described configuration. Hereinafter, the coil structure and manufacturing method of the stator according to the present invention will be described in detail.

  FIG. 13 is a view showing an example of the stator coil structure of the present invention. In the example shown in FIG. 13, a part of the stator S (stator) of the multi-axis multilayer motor M is shown, and the gap between the coil 42 and the core 41 made of the stator piece laminate is increased, The gap with the cooling member 43 through which the refrigerant passes is minimized. This maximizes the cooling capacity. In the example shown below, the coil 42 is configured by being concentratedly wound around each core 41.

  14A to 14C are views showing other examples of the stator coil structure of the present invention. 14A is a front view of the core 41 made of a stator piece laminate, and FIG. 14B is an example of the core assembly component 122 in which the coil 42 is wound around the core 41 as viewed from the inner peripheral side of FIG. FIG. 14C is a view of the state in which the cooling member 43 is disposed between two adjacent core assembly parts 122 as viewed from the inner peripheral side of FIG.

  In the example shown in FIGS. 14A to 14C, a core assembly component in which an insulating elastic body 120 made of an insulating material having a high elastic modulus, for example, fluorine rubber, is disposed on both sides of the core 41 and a coil 42 is wound on the outside thereof. 122 is shown. In the example shown in FIGS. 14A to 14C, when the core assembly part 122 is disposed at a predetermined position, the insulating elastic body 120 is crushed due to the dimensional relationship, and the coil 42 is in close contact with the cooling member 43 due to the cushion effect. . Thereby, the cooling capacity can be further improved.

  FIGS. 15A to 15C are diagrams for explaining an example of each process for manufacturing the stator shown in FIG. 13. The manufacturing method of the stator of the present invention will be described with reference to FIGS. 15A to 15C. First, the core 41 composed of the stator piece laminate having the structure shown in FIG. 15A and the structure shown in FIG. A coil 42 that is annularly wound with a dimension W2 larger than the dimension W1 wound around the core 41 made of the stator piece laminate of the structure shown is separately prepared in advance. Then, the coil 42 wound in an annular shape is attached to the core 41 to form the core assembly part 122. As shown in FIG. 15C, the core assembly parts 122 and the cooling members 43 are alternately arranged in the circumferential direction. Thus, the stator having the structure shown in FIG. 13 is manufactured.

  Accordingly, the coil 42 is pressed against the cooling member 43 by the elastic force of the coil 42 itself, and the coil 42 is disposed closer to the cooling member 43 than the core 41. At this time, the coil 42 is brought into close contact with the cooling member 43, and as a result, the coil 42 slightly extends (expands) slightly in the vertical direction. Further, since the cores 42 are individually supported, they are not affected by the deformation of the coils 42.

  FIGS. 16A to 16C are views for explaining another example of each process for manufacturing the stator shown in FIG. The stator manufacturing method of the present invention will be described with reference to FIGS. 16 (a) to 16 (c). First, a core 41 composed of a stator piece laminate having the structure shown in FIG. 16 (a), and FIG. A coil 42 having an annular configuration and having the structure shown is separately prepared in advance. Then, the coil 42 wound in an annular shape is attached to the core 41 to form the core assembly part 122. As shown in FIG. 16C, the core assembly parts 122 and the cooling members 43 are alternately arranged in the circumferential direction. Thus, the stator having the structure shown in FIG. 13 is manufactured.

  16 (a) to 16 (c) is different from the example shown in FIGS. 15 (a) to 15 (c) in that an insulating elastic body is mounted between the shape of the core 41 and the core 41 and the coil 42. Is a point. That is, as shown in FIG. 16A, the core 41 has a taper shape having a taper angle 130 in which the width in the circumferential direction decreases as it goes in the central direction when the core 41 is disposed as a stator. At the same time, when the core assembly part 122 is formed, the elastic modulus is high between the core 41 and the coil 42 as shown in FIGS. 16 (c) and 17 when the core assembly 122 is viewed from above. An insulating elastic body 131 made of an insulating material such as fluorine rubber is disposed.

  Thereby, when the core 41 is inserted into the hole of the coil 42 from the outside, the coil 42 is expanded by the taper angle 130 provided in the core 41, and the coil 42 can be further pressed against the cooling member 43. Further, when the core 41 is inserted into the hole of the coil 42 from the outside, it is the insulating elastic body 131 as a spacer that is pushed and widened by the taper angle 130 provided in the core 41, and the coil 42 is not damaged. Although the insulating elastic body 131 is provided in the above-described example, the core 41 having the taper angle 130 without using the insulating elastic body 131 can be used. However, in that case, the effect of not damaging the coil 42 cannot be obtained.

  FIG. 18 is a view for explaining still another example of the stator manufacturing method of the present invention. FIG. 18 shows a mold 141 for molding a coil 42 separately wound. When this coil 141 is used to mold a coil 42 wound separately from the core 41 into an annular shape with resin, the coil 42 is placed on the outer peripheral side 142 of the mold 141 (the cooling member 43 side when assembled to the stator). Adjust the resin flow and injection position so that the Specifically, as shown in FIG. 18, two gates 140 into which resin is poured are arranged on the inner peripheral side of the mold 141. By doing so, a force acts on the coil (not shown) set in the mold 141 in the direction of the white arrow in the figure. As a result, the coil spreads to the cooling member 43 side after the resin is cured.

  The stator coil structure and manufacturing method of the present invention can be used in addition to the conventional stator cooling structure to further increase the cooling capacity, and particularly as a stator cooling structure for a multi-axis multilayer motor. It can be preferably used.

1 is a schematic overall view showing a hybrid drive unit to which a multi-axis multilayer motor having a stator cooling structure is applied. It is a vertical side view which shows the multi-axis multilayer motor M to which the stator cooling structure was applied. It is a partially longitudinal front view showing a multi-axis multilayer motor M to which a stator cooling structure is applied. It is the figure which looked at the multi-axis multilayer motor M to which the stator cooling structure was applied from the back side of the stator. It is a vertical side view which shows the Ravigneaux type compound planetary gear train G and the drive output mechanism D of the hybrid drive unit to which the multi-axis multilayer motor is applied. It is a vertical side view which shows the stator and motor case member of the multi-axis multilayer motor M to which the stator cooling structure is applied. (A), (b) is sectional drawing which shows the stator cooling structure and the flow of a refrigerant | coolant, respectively. It is sectional drawing which shows the refrigerant | coolant distribution lid member of the stator cooling structure by the FIG. 7A line. It is a figure which shows the refrigerant | coolant distribution plate member of the stator cooling structure by the FIG. 7B-B line. It is sectional drawing which shows the refrigerant | coolant forward path and refrigerant | coolant backward path | route of a stator cooling structure by FIG. 7C-C line. It is a figure which shows the U-turn lid member of the stator cooling structure by the FIG. 7D line. It is an operation explanatory view showing the flow of the refrigerant in the refrigerant distribution lid member of the stator cooling structure. It is a figure which shows an example of the coil structure of the stator of this invention. (A)-(c) is a figure which shows the other example of the coil structure of the stator of this invention, respectively. (A)-(c) is a figure for demonstrating an example of each process of manufacturing the stator shown in FIG. 13, respectively. (A)-(c) is a figure for demonstrating the other example of each process of manufacturing the stator shown in FIG. 13, respectively. It is the figure which looked at the core assembly 122 from the top. It is a figure for demonstrating the further another example of the manufacturing method of the stator of this invention. It is a figure which shows an example of the structure of the conventional stator.

Explanation of symbols

41 Core 42 Coil 43 Cooling member 120, 131 Insulating elastic body 122 Core assembly part 130 Taper angle 140 Gate 141 Type 142 Outer peripheral side

Claims (7)

  A stator configured by arranging a core assembly part formed by winding a coil around a core made of laminated steel sheets in the circumferential direction, and a cooling member for cooling the coil is disposed between the coils of adjacent core assembly parts A stator coil structure, wherein the distance between the coil and the cooling member is smaller than the distance between the core and the coil.   An insulating material having a high elastic modulus is provided between the core and the coil to form a core assembly part, and the core assembly part and the cooling member are alternately arranged in the circumferential direction, thereby cooling the coil by the cushion effect of the insulating material. The stator coil structure according to claim 1, wherein the coil is pressed against the member and the coil is disposed closer to the cooling member than the core.   The stator coil structure according to claim 2, wherein the cross-sectional shape of the core made of the laminated steel plate is a tapered shape in which the width in the circumferential direction decreases as it goes in the central direction when the core is arranged as a stator.   Separately prepare a core made of laminated steel and a coil wound in an annular shape with dimensions larger than those previously wound around the laminated steel sheet, and attach the annularly wound coil to the core to form a core assembly part. The stator is manufactured by alternately arranging the assembly parts and the cooling members in the circumferential direction so that the coil is pressed against the cooling member by its own elastic force, and the coil is arranged closer to the cooling member than the core. Method.   5. The method of manufacturing a stator according to claim 4, wherein an insulating material having a high elastic modulus is provided between the core and the coil when the annularly wound coil is attached to the core to form the core assembly part.   From a laminated steel sheet with a taper shape in which the width in the circumferential direction decreases as it goes in the central direction when it is arranged as a stator when forming a core assembly by attaching an annular coil to the core The method for manufacturing a stator according to claim 4 or 5, wherein the core is pushed into a coil wound in an annular shape.   When the coil is wound separately from the core and then molded in an annular shape with resin, the resin flow and injection position are set so that the coil approaches the outer peripheral side of the mold (the cooling member side when assembled to the stator). The method for manufacturing a stator according to any one of claims 4 to 6, wherein the adjustment is performed.

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