JP2006180615A - Stator of rotating electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a structure enabling reduction in the size of a stator S. <P>SOLUTION: The stator of a rotating electric machine is constituted such that coils 2 are wound around to annularly arranged divided cores 1, and the coils 2 are connected to one another at each phase by ring-shaped bus bars 3(3a, 3b and 3c) that are disposed along the annular arrangement of the divided cores 1. The bus bar 3 of each phase is arranged so as to oppose each coil face of the annularly arranged divided core 1 side faces, and the bus bars 3a, 3b, 3c and 3d of each phase are arranged in parallel with the annularly arranged divided core side faces. The radial direction of the divided core is elongated accompanied by the enlargement of the rotating electric machine, and accordingly the side face of the divided core is broadened, thus making easy to arrange the divided cores on the side faces in parallel therewith. Furthermore, the thickness of the bus bar suffices for an amount of the expansion of the axial direction of the stator caused by the parallel arrangement of the bus bars. This leads the structure to the one that is advantageous to the reduction in the size of the stator. By arranging the bus bars 3a, 3b and 3c of each phase in a zigzag state, connecting points of coil ends 2b and the bus bars can be arranged on one and the same circumference c<SB>2</SB>. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a stator of a rotating electrical machine for a hybrid vehicle, a fuel cell vehicle and the like.

  Today, hybrid vehicles and fuel cell vehicles have been developed from the viewpoint of environmental problems. These vehicles use a rotating electrical machine as an auxiliary drive source or a main drive source, and the rotating electrical machine is naturally required to be downsized. One means for reducing the size of the rotating electrical machine is to reduce the size of the stator.

A coil is wound around each of the divided cores arranged in an annular shape on the stator, and each coil is connected to each phase by an annular bus bar along the annular arrangement of the divided cores (patent) References 1 and 2).
Japanese Patent Laid-Open No. 06-234383 JP 2004-56873 A

  The connection structure of each coil and bus bar is a unit for connection (Patent Document 1: Reference 16, Reference 20: Reference 20) in which annular bus bars of the same size of each phase are overlapped and integrated via an insulating layer. Provided facing the side surface of each coil in an annular arrangement (Patent Document 1), or provided facing the outer peripheral surface of each coil (Patent Document 2), the terminal of each coil is connected to the bus bar of the connection unit. Connected for each phase.

Since each of the prior art connection units has a bus bar stacked in the axial direction of the unit, the bus bar is thick in the stacking direction, and the thickness may hinder the miniaturization of the stator. For example, in the technique described in Patent Document 1, since the connection unit is provided to face the side surface of each coil arranged in an annular shape, the axial direction of the stator becomes long, and the reduction of the length is required. Is an obstacle.
Further, the technique disclosed in Patent Document 2 is provided with the connection unit on the outer peripheral surface of each annularly arranged coil. Therefore, when the radial direction of the stator becomes long and the diameter needs to be reduced, it is an obstacle. It becomes.

  This invention makes it a subject to make it easy to achieve size reduction of a stator in view of the above condition.

  In order to achieve the above object, the present invention pays attention to the fact that this kind of rotating electric machine usually requires reduction in the radial direction. Each phase bus bar is provided opposite to each coil surface.

Next, in order to reduce the axial direction of the stator, the bus bars of the respective phases are arranged in parallel on the side surface of the annular core.
The radial direction of the annular core becomes longer with the increase in size of the rotating electrical machine, and the side surface of the core becomes wider along with this, but conventionally, the wide side surface has not been effectively used. It is easy to parallel the bus bars on the widened side surface, and the axial expansion of the stator by the parallel bus bars is only the thickness of the bus bar. For this reason, it can be said that it is an advantageous structure for size reduction of the stator.

Further, according to the present invention, the bus bars of the respective phases are formed in an inner and outer zigzag shape in a staggered pattern along the circumferential direction of the annular core, and all the connection points with the respective coils are on the same circumference.
If it does in this way, in the winding operation | work to the core of the coil of each phase, the position of the winding terminal will become on the same periphery, and the winding operation | work will become easy.

  On the other hand, if the terminals from the winding layer of each coil are raised in a staggered pattern along the circumferential direction of the annular core, the bus bar can be made into an annular shape, and the bus bar can be easily manufactured. Become.

In the present invention, as described above, the bus bars for each phase are provided facing the side surfaces of the coils of the core, and the bus bars for the phases are arranged in parallel on the side surfaces of the coils. A very effective structure can be obtained.
Further, if the bus bar has an inner and outer zigzag shape, it becomes easy to manufacture the divided coils. Conversely, if the terminals of each divided coil are raised to the zigzag shape, an inexpensive bus bar can be obtained.

As one embodiment of the present invention, in a stator of a rotating electrical machine, a coil is wound around an annular core for each phase, and each coil is connected to each phase by an annular bus bar along the annular shape of the core. A bus bar for each phase is provided opposite to the coil surface on the side surface of the core, the bus bar for each phase is arranged in parallel on the side surface of the core, and the bus bar for each phase is connected to the annular circumference of the core. It is possible to adopt a configuration in which all the connection points with the respective coils are on the same circumference as zigzag shapes in a staggered pattern along the direction.
If it does in this way, in the winding operation of each coil, the position of the winding terminal will be on the same circumference, and the winding operation will become easy.

As another embodiment, in a stator of a rotating electrical machine in which a coil is wound around an annular core for each phase, and each coil is connected to each phase by an annular bus bar along the annular shape of the core. Each phase bus bar is provided in an annular shape so as to face each coil surface of the core side surface, and is arranged in parallel on the core side surface, and the terminal from the winding layer of each coil is arranged in the annular circumferential direction of the core A configuration is adopted in which it is set up in a staggered pattern along with the bus bar of each phase.
In this way, it is not necessary to form each bus bar in a zigzag shape.

Various known means such as soldering, laser brazing, laser welding, electron beam welding, ultrasonic welding and the like can be employed for connecting the coils to the bus bars of the above phases. At that time, if the end of each coil is inserted and fixed in each bus bar, the connection strength is assisted by the mechanical fixing force, so that the connection reliability is increased. The connection can be made only by a mechanical fixing force.
For the insertion and fixation, it is preferable to increase the mechanical strength of the bus bar by using the bus bar as a rectangular copper material. This rectangular copper material can be manufactured at low cost by drawing, and its shape can be easily changed by forming.

The coil terminal is fixedly inserted into the bus bar by, for example, forming an insertion hole at a connection point with each coil of the bus bar, and inserting a fastening cylinder into the insertion hole. The fastening connector is inserted into the fastening cylinder by inserting the cylindrical connector into which the terminal is inserted, both fitting surfaces of the fastening cylinder and the connector are tapered. The body is expanded in diameter, pressed against the inner surface of the insertion hole and fixed to the material to be connected, and the connector is fastened to the fastening cylinder and the connector is reduced in diameter to fasten the coil terminal. it can.
With such a mechanical fixing structure, the fixing action is simple and easy to automate.

  Further, as another fixing means, an insertion hole is formed at a connection point with each coil of the bus bar, and a fastening cylinder is fitted into the insertion hole, and a terminal of the coil is fixed to the fastening cylinder. Insert the connector, both the fitting surface of the fastening cylinder and the connector are tapered, and by inserting the connector into the fastening cylinder, the connector is fastened to the fastening cylinder, It is also possible to adopt a configuration in which the fastening cylinder is expanded and pressed against the inner surface of the insertion hole.

In addition to the above-mentioned square steel material, well-known ones such as an insulated coated electric wire, an insulated coated copper wire, and a conductor punched piece can be used as the bus bar.
If the bus bars made of these various materials are electrically insulated and integrated, and the coupling unit is attached to the core, the work of attaching the bus bar to the core and connecting to the coil becomes easy.

  As the bus bar coupling unit, the bus bars of the respective phases are arranged in parallel along the side surface of the annular core and are electrically insulated and integrated, and the buses of the respective phases are connected to the cores. It is possible to adopt a configuration in which all the connection points with each coil are on the same circumference in a zigzag shape in a staggered pattern along the circumferential direction.

In addition, the bus bars of each phase are arranged in parallel so as to form an annular shape along the side surface of the annular core and are electrically insulated and integrated, and terminals from the winding layer of each coil are It can also be set as the structure which stood up and connected in the zigzag form along the annular | circular circumferential direction of the said core.
In these bus bar coupling units, the bus bar of each phase may be formed with a hole into which the terminal from the winding layer of each coil is inserted and fixed.
The integration of each bus bar in an electrically insulated state is performed by various appropriate means such as separating each bus bar from resin molding, or individually covering the bus bars with an organic resin and bonding them together with an adhesive or the like. Is adopted.

An embodiment is shown in FIGS. 1 to 6, and this embodiment relates to a stator S of a rotating electric machine for a fuel cell vehicle or a rotating electric machine for a hybrid vehicle. Each of the coils 2 is wound, and the outer end 2b of each coil 2 is connected to each phase by an annular bus bar 3 (3a, 3b, 3c) along the annular arrangement of each divided core 1, The end 2a is connected by an annular bus bar 3d. The divided cores 1 are arranged in an annular shape and fixed to a shrinkage or the like by a metal cylinder 4, and the inner and outer ends 2a, 2b of the winding layer of each coil 2 are on the same circumference c ₁ of the bus bar mounting surface, c ₂ Standing up.

Each bus bar 3a, 3b, 3c, 3d is made of a drawn flat rectangular copper rod (wire). connection hole 5 is formed (equal intervals of six to each bus bar), so that its respective connection holes 5 becomes the same circumference on c _2, the respective bus bars 3a, 3b, 3c are each split core with 1 is formed in a zigzag pattern in a zigzag pattern along the circumferential direction of the arrangement. Inside the bus bar 3d, equally spaced on the number of coils 2 (18) of the connection hole (through hole) 5 is formed, the connection hole 5 has a same circumference on c _1.

  As shown in FIGS. 5 and 6 (a) to 6 (c), the connection of the coil 2 terminals (connection ends) 2a and 2b to each bus bar 3 is as follows. This is done by a cylindrical connector 7 fitted into the fastening cylinder 6 (in the respective drawings in FIG. 6, the organic resin coating 11 described later is omitted). The fastening cylinder 6 and the connector 7 are formed with slits 6 a and 7 a in the axial direction, both fitting surfaces 6 b and 7 b are tapered, and the connector 7 is inserted into the fastening cylinder 6. Then, the diameter of the fastening cylinder 6 is increased and the diameter of the connector 7 is reduced.

  Accordingly, as shown in FIG. 6A, the fastening cylinder 6 and the connector 7 are fitted into the connection hole 5 of the bus bar 3, and the terminal 2a of the coil 2 is connected to the connector 7 as shown in FIG. 6B. 2b, and when the fastening cylinder 6 is further fitted into the bus bar 3 by driving or the like as shown in (c), the fastening cylinder 6 is expanded and connected by the tapered surfaces 6b and 7b. Although the child 7 is subjected to a diameter reducing action, the connecting hole 5 does not increase in diameter, so the connector 7 is mainly reduced in diameter to firmly fasten the terminals 2a and 2b of the coil 2, and the fastening cylinder 6 is The terminal 2a, 2b of the coil 2 is firmly fastened to the bus bar 3 by being firmly pressed against the inner surface of the connection hole 5.

  Each bus bar 3a, 3b, 3c, 3d is coated 11 with an organic resin such as polyamide imide and electrically insulated, and the three outer bus bars 3a, 3b, 3c are, as shown in FIG. The connecting unit 10 is assembled and bonded by an adhesive. In general, a rectangular copper bar can be continuously coated with an organic resin 11 at the time of drawing, and can have high heat resistance with the organic resin coating 11, so that an inexpensive bus bar 3 or coupling unit can be obtained. 10 can be obtained.

  The connection unit 12a, 12b, 12c of each bus bar 3a, 3b, 3c is pulled out from the coupling unit 10, and each coil 2 is connected to an external controller etc. by this connection terminal 12a, 12b, 12c, Power is appropriately supplied to the coil 2.

The fastening cylinder 6 and the connector 7 are fitted into the connection holes 5 of the bus bars 3, and the bus bars 3 are connected to the terminals 2a and 2b of the coil 2 protruding from the core 1 in the casing 4, as shown in FIG. The connecting units 10 are overlapped on the resin-molded core 1 (resin mold C) and the terminals 2a and 2b of the respective coils 2 are inserted into the connection holes 5 (connectors 7) so that the connection holes 5 of the coils 2 and 5 coincide. Then, the fastening cylinder 6 is driven (pushed), and the coil 2 is connected to each bus bar 3 (see FIGS. 6A to 6C).
Thereafter, if necessary, the core 1 and the coupling unit 10 are integrated by a resin mold or the like, and each phase bus bar 3 is opposed to each coil 2 surface on the side surface of each annular core 1 shown in FIG. Is obtained, and the stator S of the rotating electrical machine is obtained in which the bus bars 3 of the respective phases are arranged in parallel on the side surfaces of the annularly arranged divided cores 1.

In addition, the thickness of each bus bar 3a, 3b, 3c, 3d can be appropriately set according to the conduction current value, the degree of coupling with the coil terminals 2a, 2b, and the like. It can also be thick as shown. Further, as shown in FIGS. 7 and 8, the bus bars 3 a, 3 b, 3 c, and 3 d can be integrated into a flat ring shape by a resin mold 11 ′ to form a coupling unit 10.
At this time, similarly to the embodiment shown in FIGS. 3 and 4, the outer bus bars 3a, 3b, and 3c and the inner bus bar 3d can be made into the coupling unit 10 in which the resin mold 11 ′ is separately provided. If the inner bus bar 3d is resin-molded, there is an advantage that it becomes the same height as the coupling unit 10 of the outer bus bars 3a, 3b, 3c. 2a can be connected.

The bus bars 3a, 3b, and 3c of the respective phases are not wave-shaped as shown in FIG. 2, but are polygonal as shown in FIG. 9, and all the connection points 2b of the coils 2 are arranged in an annular arrangement. The arrangement may be c ₂ on the same circumference.
Further, as shown in FIG. 10, the bus bars 3a, 3b, and 3c of each phase are formed in an annular shape, and the terminals 2b from the winding layers of the coils 2 are arranged in the divided cores 1 in an annular arrangement. It is also possible to start up in a zigzag zigzag pattern along the circumferential direction and connect to the bus bars 3a, 3b, 3c of each phase.

As a means for connecting the coil 2 terminals 2a, 2b to the bus bar 3, as shown in FIGS. 11 and 12 (the coating 11 with organic resin is omitted, the same applies hereinafter), the terminal of the coil 2 is crimped to the connector 7, etc. Then, the coil terminals 2a and 2b can be connected to the bus bar 3 by fastening the connector 7 to the connection hole 5 via the fastening cylinder 6 in the same manner as described above. 12 (a)-(c)). At this time, as shown in FIG. 13, only the press-fitting of the connector 7 into the connection hole 5 may be performed. Also, as shown in FIG. 14, after the connector 7 is inserted (press-fitted), caulking or the like is performed. You can also
Further, as shown in FIG. 15 (a), after inserting the coil terminals 2a and 2b into the connection holes 5, laser brazing using a brazing material a, laser welding as shown in FIG. 15 (b), shown in FIG. Thus, various means such as electron beam b welding can be considered.

In the embodiment, the core 1 is divided, but the core 1 may be an undivided annular one, and in that case, the coil of each phase along the circumferential direction of the annular core 1. 2 are alternately wound in order.
Needless to say, the present invention is not limited to the stator S of the rotating electric machine for fuel cell vehicles or hybrid vehicles of the embodiment, and can be applied to the stators of various rotating electric machines regardless of the size.

Schematic perspective view of one embodiment The same plan view The assembly action diagram The coupling unit is shown, (a) is a sectional view, (b) is a perspective view. Assembly explanatory diagram of the same embodiment Coil terminal connection action explanation diagram to bus bar Action diagram Action diagram Assembly example of another embodiment Sectional view of the bus bar coupling unit of the same embodiment Partial removal plan view of another embodiment Partial removal plan view of another embodiment Perspective view for explaining the coil terminal connection jig to the bus bar Coil terminal connection action explanation to bus bar by the jig Other coil terminal connection explanatory diagram to the bus bar Other coil terminal connection explanatory diagram to the bus bar Other coil terminal connection explanatory diagram to the bus bar Other coil terminal connection explanatory diagram to the bus bar

Explanation of symbols

1 Split core 2 Coil 2a, 2b Coil terminal (coil connection end, connection point)
3, 3a, 3b, 3c, 3d Bus bar 4 Casing 5 Coil end connection hole (insertion hole) of bus bar
6 Fastening cylinder 7 Tubular connector 10 Busbar coupling unit 11 Organic resin coating

Claims (7)

A coil 2 is wound around an annular core 1 for each phase, and each coil 2 is connected to each phase by an annular bus bar 3a, 3b, 3c along the annular shape of the core 1. In
The bus bars 3a, 3b, 3c of the respective phases are provided facing the coil 2 surface of the side surface of the core 1, and the bus bars 3a, 3b, 3c of the respective phases are arranged in parallel on the side surface of the core 1, and The bus bars 3a, 3b, 3c of each phase are formed in a zigzag shape in a zigzag pattern along the annular circumferential direction of the core 1, and all the connection points 2b with the coils 2 are c ₂ on the same circumference. A stator of a rotating electrical machine characterized by the above. A coil 2 is wound around an annular core 1 for each phase, and each coil 2 is connected to each phase by an annular bus bar 3a, 3b, 3c along the annular shape of the core 1. In
The bus bars 3a, 3b, 3c of the respective phases are provided in an annular shape so as to face the surfaces of the coils 2 on the side surface of the core 1, and are arranged in parallel on the side surfaces of the core 1, and from the winding layers of the coils 2 The stator 2 of the rotating electrical machine is characterized in that the end 2b of the core 1 is raised in a staggered pattern along the annular circumferential direction of the core 1 and connected to the bus bars 3a, 3b, 3c of each phase.   The connection of each coil to the bus bars 3a, 3b, 3c of each phase is made by inserting and fixing a terminal 2b of each coil 2 to each bus bar 3a, 3b, 3c. The stator of the rotary electric machine as described in 2. A bus bar coupling unit used for the stator of the rotating electrical machine according to claim 1,
The bus bars 3a, 3b, 3c for each phase are arranged in parallel along the side surface of the annular core 1 and are electrically insulated and integrated, and the bus bars 3a, 3b, 3c for each phase. the rotary electric machine, characterized in that all of the staggered along the circumferential direction is the inner and outer zigzag shape the core 1 of the connection point 2b between the coils 2 is in the same circumference on c ₂ Busbar coupling unit for stator. A bus bar coupling unit used for a stator of a rotating electrical machine according to claim 2,
The bus bars 3 a, 3 b, 3 c of each phase are arranged in parallel along the side surface of the annular core 1 and are electrically insulated and integrated, and are wound around the coils 2. A stator bus bar coupling unit for a rotating electric machine, wherein terminals 2b from the rotating layer are connected in a staggered manner along the annular circumferential direction of the core 1.   The bus bar coupling unit for a stator of a rotating electric machine according to claim 4 or 5, wherein the bus bars 3a, 3b, 3c of each phase are respectively coated with an organic resin, and are bonded together and integrated.   7. A hole 5 into which a terminal 2b from a winding layer of each coil 2 is inserted and fixed is formed in each phase bus bar 3a, 3b, 3c. A bus bar coupling unit for a stator of a rotating electric machine according to 1.

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