JP2005269730A - Method of manufacturing rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a rotary electric machine which can raise the cooling efficiency of a stator. <P>SOLUTION: At a resin molding time, a plurality of divided stator cores 201 on which a coil 202 is wound, are fixed by a resin mold 206. A resin 203 is injected in the resin mold and molded in the state that a wedge-like water passage pipe 204 having the same shape as a space in which each coil winding surface 202a becomes a tapered surface is held movably in the space formed between adjacent divided stator cores. Thus, a water passage pipe is slid into a space between the adjacent coils due to the difference of the pressure receiving surfaces of the wedge-like water passage pipe so that the water passage pipe is brought into close contact with the coil. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention is a rotating electrical machine having a multi-axis multilayer structure in which an outer rotor and an inner rotor that can be independently controlled are arranged inside and outside of a cylindrical stator, respectively, in which coils are concentratedly wound, A method of manufacturing a rotating electrical machine having a stator structure comprising a plurality of divided stator divided stator cores arranged and a water pipe arranged between the divided stator divided stator cores, wherein the divided stator divided stator core and the water pipe are molded and fixed with resin. It is about.

  Conventionally, an outer rotor and an inner rotor are arranged on the inner and outer circumferences with a cylindrical stator in between, and the outer rotor and inner rotor can be independently controlled by flowing a composite current through a multiphase coil wound around the stator. There is known a rotating electric machine having a multi-axis multilayer structure. As an example of a stator cooling structure in this rotating electric machine, a structure in which the stator is cooled by a water pipe arranged between divided stator cores is known.

  On the other hand, although it is not a rotating electrical machine having a multi-axis multilayer structure, a rotating electrical machine composed of a stator and a rotor is known in which a stator is cooled using a water pipe provided between split stator cores (for example, patents). Reference 1). In this example, a water pipe is provided in the stator axial direction between the teeth of the divided stator core, and the water pipe extending in the stator axial direction is connected by a communication passage at one end to determine the position of the water pipe. Thereafter, resin molding fills the space between the water pipe and the coil wound around the teeth.

In addition, although not a rotating electrical machine having a multi-axis multilayer structure, a structure in which a stator is cooled by means other than a water pipe is also known in a rotating electrical machine including a stator and a rotor (see, for example, Patent Document 2). In this example, the coil and the teeth of the split stator core are in close contact via an insulating member that is deformed by at least one of stress and heat during resin molding, and the heat of the coil is radiated to the housing case through the split stator core. .
Japanese Patent Laid-Open No. 10-327558 JP 2002-51491 A

  In the conventional cooling structure described in Patent Document 1 described above, there are water pipes extending in the stator axial direction between the circumferentially arranged coils, and they are connected by a communication path at one end, Since the position of the water channel pipe is regulated, it is difficult to bring a plurality of water channel pipes into close contact with the coil. That is, since the resin is filled or an air layer is generated between the pipe and the water pipe, the thermal resistance from the coil to the water pipe increases, and the cooling efficiency deteriorates. There was a problem. Further, in the conventional cooling structure described in Patent Document 1 described above, the degree of adhesion between the coil and the divided stator core is increased, and the heat of the coil is radiated to the housing case through the divided stator core. However, there is a problem that the cooling capacity is not sufficient to cool the motor with high output and high power density because the heat is only released from the case.

  Further, in a rotating electric machine having a multi-axis multilayer structure, an attempt is made to use a rotating electric machine cooling structure (described in Patent Documents 1 and 2) of another structure in a structure for cooling the stator by a water pipe arranged between divided stator cores. However, since the rotor exists inside and outside, it is necessary to use a split stator core, and as a result, a rotary electric machine having a multi-axis multilayer structure in which resin is filled from both the outer peripheral side and the inner peripheral side of the split stator core during resin molding. Then, there also existed a problem which cannot use those cooling methods as it is. For this reason, there is an increasing demand for the development of an optimal stator cooling structure in a rotating electrical machine having a multi-axis multilayer structure.

  An object of the present invention is to provide a method of manufacturing a rotating electrical machine that can solve the above-described problems and increase the cooling efficiency of a stator.

  A method of manufacturing a rotating electrical machine according to the present invention is a rotating electrical machine having a multi-axis multilayer structure in which an outer rotor and an inner rotor that can be independently controlled are arranged inside and outside of a cylindrical stator, and a coil is concentratedly wound on each of them. In a method of manufacturing a rotating electrical machine having a stator structure comprising a plurality of divided stator cores arranged circumferentially and water channel pipes arranged between the divided stator cores, wherein the divided stator cores and water channel pipes are molded and fixed with resin. A plurality of divided stator cores around which coils are wound are fixed by a resin mold during resin molding, and are the spaces formed between adjacent divided stator cores, each coil winding surface being the same as a taper surface. Injecting resin into a resin mold and molding it while holding a wedge-shaped water channel pipe having a shape More, it is characterized in that the difference in pressure receiving area of the wedge-shaped waterway pipe slid into the space between adjacent coils waterways pipe, brought into close contact with the water channel pipe and the coil.

  In the method for manufacturing a rotating electrical machine of the present invention, the split stator core is fixed by the resin mold, and the water pipe moves to the inside of the stator due to the difference between the pressure at the time of resin molding and the pressure receiving area on the inner and outer periphery of the water pipe. When the water pipe and the water pipe are in close contact, the thermal resistance can be reduced and the cooling efficiency can be increased. In addition, since the coil winding surface is tapered so that the gap between the coils becomes narrower toward the inside of the stator, the wedge effect is achieved when the water pipe enters between the coils due to the pressure during resin molding. And the stator circularity can be maintained by the stress in the stator circumferential direction, and the electromagnetic performance of the motor can be improved.

  In addition, in the suitable example of the manufacturing method of the rotary electric machine of this invention, it is comprised so that an insulating member may be provided between a water pipe and a coil, and a water pipe and a coil may be closely_contact | adhered via an insulating member at the time of resin molding. it can. If comprised in this way, in addition to the effect mentioned above, since an insulating member is interposed between a channel pipe and a coil, even if it slips on the coil surface when a channel pipe moves, it will damage a coil. Can be prevented.

  Moreover, in the suitable example of the manufacturing method of the rotary electric machine of this invention, it can comprise so that the insulating member which deform | transforms with at least one of the pressure at the time of resin molding and a heat | fever can be used as an insulating member. If comprised in this way, in addition to the effect mentioned above, the insulating member arrange | positioned between a water pipe and a coil will deform | transform at least one of the stress at the time of resin molding, and a heat | fever, and the clearance gap between a water pipe and a coil is made. Since the formation of the buried air layer can be suppressed, the cooling efficiency of the motor can be improved.

  Further, in a preferred example of the method for manufacturing a rotating electrical machine of the present invention, a rib having a width wider than the gap between the coils and narrower than the width of the outer periphery of the water pipe is provided at the inner peripheral end of the water pipe. It can arrange so that a channel pipe may be located in the space between, and it may be arranged so that a rib may be located in the inner circumference side of a division stator core. If comprised in this way, in addition to the effect mentioned above, even if resin is filled from the stator inner peripheral side at the time of resin molding, it is possible to prevent the water channel pipe from being pushed out to the stator outer peripheral side.

Embodiments of the present invention will be described below in detail with reference to the drawings.
FIG. 1 is an overall view of a hybrid drive unit to which a multi-axis multilayer motor as an example of a rotating electrical machine that is an object of the present invention is applied. The multi-axis multi-layer motor described below is for explaining the basic configuration, and features of the present invention will be described in detail later. In FIG. 1, E is an engine, M is a multi-shaft multilayer motor, G is a Ravigneaux type planetary gear train, D is a drive output mechanism, 1 is a motor cover, 2 is a motor case, 3 is a gear housing, 4 is a front cover is there.

  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 the 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 16 and 16. The output rotation and output torque from the output gear 11 pass through the first counter gear 12, the second counter gear 13, the drive gear 14, and the differential 15, and are transmitted from the drive shafts 16 and 16 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.

  FIG. 2 is a diagram showing in more detail an example of a multi-shaft multilayer motor that is combined with a Ravigneaux type planetary gear train and constitutes a vehicle hybrid transmission that is an object of the present invention. The structure of the rotating electrical machine of the present invention can be applied to this multi-axis multilayer motor. The multi-axis multilayer motor having the configuration shown in FIG. 2 includes a single annular stator 101, an inner rotor 102 disposed rotatably on a predetermined rotation axis O coaxial with each other in the radial direction inside and outside, and A triple structure including the outer rotor 103 is formed and housed in the housing 104.

  Each of the inner rotor 102 and the outer rotor 103 includes laminated cores 124 and 125 that are laminated in the rotor axis direction of a plate material made by press-molding electromagnetic steel sheets or the like. Permanent magnets penetrating in the direction are arranged at equal intervals in the circumferential direction. In the inner rotor 102 and the outer rotor 103, the number of pole pairs between them is made different by changing the number of magnetic poles to be arranged. As an example, the number of magnets itself is the same for the inner rotor 102 and the outer rotor 103, which is twelve. However, since the inner rotor 102 forms one pole with two magnets, Since the outer rotor 103 forms one pole with one magnet, the number of pole pairs is six.

  When the inner rotor 102 and the outer rotor 103 are accommodated in the housing 104, the outer rotor 103 is provided with a torque transmission shell 105 drivingly coupled to the outer periphery of the laminated core 125, and both ends of the torque transmission shell 105 are respectively provided as bearings. The torque transmission shell 105 is coupled to the outer rotor shaft 109 on the bearing 107 side.

  The inner rotor 102 is provided at the center of the laminated core 124 with a hollow inner rotor shaft 110 penetrating the outer rotor shaft 109 rotatably therein, and between the laminated core 124 of the inner rotor 102 and the inner rotor shaft 110. Drive coupled. An intermediate portion of the inner rotor shaft 110 is rotatably supported in a fixed stator bracket 113 by a bearing 112, and one end portion (left end portion in FIG. 1) is rotatable to a corresponding end wall of the torque transmission shell 105 by a bearing 114. To support.

  The stator 101 includes a large number of stator teeth formed by laminating I-shaped stator steel plates made by press-forming electromagnetic steel plates in the stator axial direction. As shown in FIG. 2, electromagnetic coils 117 are wound around the individual stator teeth at the teeth between the outer rotor side yoke and the inner rotor side yoke, and these coiled stator teeth are equally spaced in the same circumferential direction. In other words, a stator core is formed by arranging in a circular shape, and the stator core is integrated by being sandwiched between the brackets 113 and 118 on both sides in the stator axial direction by some means and molded entirely with the resin 120. .

  In driving the motor, the rotation positions of the inner rotor 102 and the outer rotor 103 detected by the rotation sensor 148 and the rotation sensor 147, that is, the positions of the two rotors 102 and 103 corresponding to the positions of the permanent magnets provided as described above. A composite current obtained by combining drive currents having different phases is supplied to the electromagnetic coil 117 of the stator 101, thereby generating a rotating magnetic field for both the rotors 102 and 103 individually in the stator. In synchronism, the rotors 102 and 103 can be individually rotated.

  Next, a method for manufacturing a rotating electrical machine of the present invention that can be suitably used as a cooling structure for the stator 101 in the rotating electrical machine having a multi-axis multilayer structure having the above-described configuration will be described.

  FIG. 3 is a diagram for explaining a method of manufacturing a rotating electrical machine according to the present invention. In the example shown in FIG. 3, a part of the cross section of the stator 101 in the example shown in FIG. 2 is shown. In the following description, for the sake of simplicity, the same reference numerals as those shown in FIG. In the example shown in FIG. 3, a plurality of divided stator cores 201 formed by laminating electromagnetic steel sheets in the stator axial direction are arranged at equal intervals in the same circumferential direction. An electromagnetic coil 202 is wound around each divided stator core 201 between the outer rotor side yoke and the inner rotor side yoke. Then, the divided stator core 201 around which these electromagnetic coils 202 are wound is sandwiched by some means between brackets (not shown here) on both sides of the stator axial direction, and is integrated by being molded entirely with the resin 203, The stator 101 is configured.

  4 (a) and 4 (b) are enlarged views showing the periphery of the water channel in order to explain an example of the manufacturing method of the rotating electrical machine of the present invention. In the example shown in FIGS. 4A and 4B, the stator 101 has an independent arrangement in which the stator 202 is arranged between the adjacent divided stator cores 201 and the divided stator cores 201 arranged in a circumferential shape with the coils 202 concentrated. It consists of a water pipe 204. The shape of the water channel pipe 204 is a wedge-shaped shape that is a space formed between the adjacent divided stator cores 201 and has the same shape as a space in which the winding surface 202a of each coil 202 is a tapered surface. . A water channel 205 for passing water is provided in the water channel pipe 204.

  As shown in FIG. 4A, at the time of resin molding, the split stator core 201 is fixed to the resin mold 206 and the water channel pipe 204 is movably held in the space between the adjacent split stator cores 201. In this state, the resin 203 is poured evenly from the inside and outside of the divided stator core 201. At this time, since the cross section of the water channel pipe 204 has a wedge shape, the pressure receiving area of the resin 203 is different between the outer peripheral side and the inner peripheral side of the water channel pipe 204. Due to the difference in pressure receiving area, the water pipe 204 moves to the inside of the stator 101 with the filling of the resin 203, and comes into close contact with the coil 202. At this time, the water channel pipe 204 moves so as to slide on the winding surface 202a which is the surface of the coil 202, but an insulating paper 207 as an insulating member is provided between the water channel pipe 204 and the coil 202 as a preferable example. Therefore, it is possible to prevent the insulating coating on the winding surface 202a of the coil 202 from being damaged.

  As described above, since the stator 101 is manufactured according to the method for manufacturing a rotating electrical machine of the present invention, the coil 202 and the water channel pipe 204 can be more closely adhered to each other, thereby reducing the thermal resistance and improving the cooling efficiency. be able to. Further, since the gap between the coils 202 becomes narrower toward the inside of the stator 101, the water channel pipe 204 enters between the coils 202 due to pressure during resin molding. Therefore, the wedge effect is generated, the roundness of the stator 101 can be maintained by the stress in the circumferential direction of the stator 101, and the electromagnetic performance of the motor can be improved.

  FIG. 5 is a view for explaining another example of the method for manufacturing a rotating electrical machine of the present invention. In the example shown in FIG. 5, a good heat conductive insulating member 208 that deforms at least one of stress and heat during resin molding is interposed between the coil 202 and the water pipe 204 instead of the insulating paper 207. . By doing so, when the water channel pipe 204 slides on the winding surface 202a of the coil 202, the unevenness of the coil 202 and the winding surface 202a of the water channel pipe 204 is lost without losing the function of preventing the coating of the coil 202 from being damaged. The air layer formed by the above can be filled with the heat conductive insulating member 208, and the cooling efficiency can be further improved.

  Here, as the heat conductive insulating member 208, rubber or elastomer using silicone as a base material can be used. Moreover, a metal filler can also be added to such an extent that insulation performance is not impaired, preferably for improving thermal conductivity.

  FIG. 6 is a view for explaining still another example of the method for manufacturing a rotating electrical machine of the present invention. In the example shown in FIG. 6, a rib 209 that is wider on the inner peripheral side of the water channel pipe 204 than the gap 202 i at the innermost peripheral portion of the coil 202 and narrower than the width 204 o on the outer peripheral side of the water channel pipe 204. And the movement of the water channel pipe 204 to the outer peripheral side of the stator 101 is restricted. By doing so, it is possible to prevent the water channel pipe 204 from moving to the outer peripheral side of the stator 101 even if the resin filling is uneven. Thereafter, if the resin is filled, the water channel pipe 204 moves to the inner peripheral side of the stator 101 due to the difference in pressure receiving area, and is in close contact with the coil 202. In addition, in accordance with the presence of the rib 209, the insulating paper 207 or the good thermal conductive insulating member 208 is provided on the side surface of the coil 202 on the inner peripheral side of the stator 101, and the insulating film of the coil 202 is protected at this portion. Is preferred.

  In the above-described example, the example in which the resin 203 is poured evenly from the inside and the outside of the divided stator core 201 into the resin mold 206 has been described, but the present invention is not limited to this. For example, even when the resin 203 is poured into the resin molding side 206 from one place, the resin 203 wraps around the inner side and the outer side of the divided stator core 201, and therefore the method of manufacturing a rotating electrical machine according to the present invention that uses the difference in pressure receiving area of the water pipe 204. Can be suitably applied.

  The method for manufacturing a rotating electrical machine according to the present invention can be suitably used for a purpose of increasing the cooling efficiency of a stator in a rotating electrical machine having a three-layer structure having a rotor inside and outside and a stator between the rotors.

1 is a schematic overall view showing a hybrid drive unit to which a multi-axis multilayer motor is applied. It is a vertical side view which shows the multi-axis multilayer motor used as the object of this invention which comprises a hybrid transmission for vehicles combining with a Ravigneaux type planetary gear train. It is a figure for demonstrating the manufacturing method of the rotary electric machine of this invention. (A), (b) is a figure which expands and shows a water channel periphery, in order to demonstrate an example of the manufacturing method of the rotary electric machine of this invention. It is a figure for demonstrating the other example of the manufacturing method of the rotary electric machine of this invention. It is a figure for demonstrating the further another example of the manufacturing method of the rotary electric machine of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 101 Stator 102 Inner rotor 103 Outer rotor 201 Divided stator core 202 Electromagnetic coil 202a Winding surface 202i Inner peripheral side gap 203 Resin 204 Water pipe 204o Outer peripheral side width 205 Water path 206 Resin molding die 207 Insulating paper 208 Good heat conductive insulating member 209 ribs

Claims (4)

A rotating electric machine having a multi-axis multilayer structure in which an outer rotor and an inner rotor that can be controlled independently are arranged inside and outside of a cylindrical stator, and a plurality of coils each having a coil wound in a concentrated manner and arranged circumferentially In the manufacturing method of a rotating electrical machine having a stator structure composed of a split stator core and a water pipe arranged between the split stator cores, and the stator ring and the water pipe are molded and fixed with resin.
At the time of resin molding, a plurality of divided stator cores around which coils are wound are fixed by a resin mold, and the space is formed between adjacent divided stator cores, and each coil winding surface has the same shape as a tapered surface. With a wedge-shaped water channel pipe having a movable shape, the space between adjacent coils is determined by injecting resin into a resin mold and molding the resin due to the difference in pressure-receiving area of the wedge-shaped water channel pipe. A method of manufacturing a rotating electrical machine, wherein the water pipe and the coil are brought into close contact with each other.   The method for manufacturing a rotating electrical machine according to claim 1, wherein an insulating member is provided between the water pipe and the coil, and the water pipe and the coil are brought into close contact with each other through the insulating member at the time of resin molding.   The method for manufacturing a rotating electrical machine according to claim 2, wherein an insulating member that is deformed by at least one of pressure and heat during resin molding is used as the insulating member.   At the end on the inner peripheral side of the water pipe, a rib that is wider than the gap between the coils and narrower than the width of the outer periphery of the water pipe is disposed, and the water pipe is positioned in the space between the coils. The method for manufacturing a rotating electrical machine according to any one of claims 1 to 3, wherein the ribs are arranged on the inner peripheral side of the divided stator core.

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