JP2006340581A - Rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a small-sized rotary electric machine exhibiting superior productivity, while securing magnetic performance. <P>SOLUTION: The rotary electric machine is equipped with a rotor that is rotatable about a rotary shaft and an annular stator accommodating the rotor on its inner peripheral side. The stator includes an annular yoke part and a plurality of teeth, which are arranged in a ring shape, on the inner peripheral side of the yoke part and are wound with a coil. An insulator 10 is fitted to the teeth of a division core, respectively. The insulator 10 has the side faces of the teeth 10B, which are directed in a direction parallel to the rotary shaft and are tilted, with respect to the rotary shaft at a specified angle and supports 10A, 10C which are provided on the side faces and restrict the position of the coil, in the radial direction that is orthogonal to the rotary shaft. The faces abutting against the coil of the supports 10A, 10C are tilted with respect to the rotary shaft at the angle, corresponding to the specified angle. Preferably, the support 10A is provided with a groove 16 as a pull-out part for pulling out the winding of the coil in the radial direction. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a rotating electrical machine, and more particularly to a rotating electrical machine including a stator core and a coil wound around the stator core.

  In recent years, vehicle propulsion motors are used in electric vehicles, hybrid vehicles, fuel cell vehicles, and the like. Such a vehicle propulsion motor is required to have a high output and a small size, and in order to realize this, various devices for increasing the space factor of the stator coil of the motor have been made.

  Japanese Laid-Open Patent Publication No. 2002-247789 (Patent Document 1) discloses a conventional technique of a stator coil structure in which the winding space is increased in a concentrated winding type coil to increase the space factor in the slot.

FIG. 13 is an explanatory view of the shape of a coil end portion of a conventional stator coil structure.
Referring to FIG. 13, the coil 518 is formed by winding the winding 517 with the insulator 512 mounted on the surface of the stator teeth, the taper member 516 being further disposed on the stator teeth 527 of the stator core. .

  The insulator 512 includes a bobbin portion 521 that protrudes inside the outer ring-shaped outer edge portion, a coil flange portion 522 at the tip of the bobbin portion 521, a slot flange portion 523 below the coil flange portion 522, an outer edge portion, and a bobbin. The slot insertion part 524 formed in the lower side of the part 521 and the wall-shaped protrusion 525 provided in the outer edge part of the base side of the bobbin part 521 are included.

  A portion of the coil 518 that protrudes from the slot 513, that is, a portion of the coil 518 that passes over the taper member 516 is a coil end, that is, a portion of the coil that protrudes from both end faces of the cylindrical stator.

When the area of the coil end forming portion between the coil flange portion 522 and the projection 525 is Sc and the area of the slot 513 is Ss above the inclined surface of the taper member 516, as shown by the KK cross section in FIG. In this prior art, the heights of the coil flange portion 522 and the protrusion 525 are set so that Sc ≧ Ss / 2. As a result, the coil flange portion 522 prevents the winding from dropping from the stator teeth end to the inner peripheral side, and the winding area of the coil end portion becomes larger than the winding area of the slot passage portion. By winding the winding with a margin without applying an excessive force at the end, the coil ends arranged in layers can be formed with high density.
JP 2002-247789 A (FIG. 8) JP 2004-350449 A JP 2005-57931 A

  In the case of adopting a split core in which a core is created by dividing each tooth, when winding the coil around the stator tooth, winding is started with the yoke side being clamped. Therefore, workability is better when the start end is arranged on the inner peripheral side of the stator teeth so as not to interfere with the clamp.

  In the conventional stator structure shown in FIG. 13, the starting end is disposed on the inner peripheral side of the stator teeth, and the winding is tensioned when the winding is wound around the taper member 516 disposed in the tooth portion to form the coil. When the winding is applied, there is a possibility that the winding slips along the tapered portion during winding of the first-stage winding of the coil, and the winding collapses.

  However, if the coil is wound with the tension reduced, the space factor cannot be increased.

  An object of the present invention is to provide a rotary electric machine that is small and has high productivity while ensuring magnetic performance.

  In summary, the present invention is a rotating electrical machine, and includes a rotor that can rotate around a rotating shaft and an annular stator that accommodates the rotor on the inner peripheral side. The stator includes an annular yoke portion and a plurality of teeth portions that are annularly arranged on the inner peripheral side of the yoke portion and on which a coil is wound. Each of the plurality of teeth portions has a side surface that is parallel to the rotation axis and is inclined at a predetermined angle with respect to the rotation axis, and a radial coil position that is provided on the side surface and orthogonal to the rotation axis. The surface of the support portion that comes into contact with the coil is inclined at an angle corresponding to a predetermined angle with respect to the rotation axis.

Preferably, the support portion is provided with a lead-out portion that pulls out the coil winding in the radial direction.
More preferably, the lead-out part is a groove provided in the support part.

  Preferably, the stator includes a core that is divided and formed by a magnetic compact for each of the plurality of teeth.

  More preferably, the support portion is a part of an insulator disposed between the stator core and the coil.

  Preferably, the stator includes a magnetic core provided for each of the plurality of teeth, and an insulator that is disposed between the core and the coil and insulates the core from the coil. The surface that is in contact with the coil of the insulator has a curvature that allows the windings to be in close contact with each other at the corners.

  ADVANTAGE OF THE INVENTION According to this invention, the improvement of the space factor of the coil of a rotary electric machine and suppression of coil collapse are compatible, and winding productivity and quality improve.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the drawings, the same reference numerals indicate the same or corresponding parts.

  FIG. 1 is a cross-sectional view of a cross section perpendicular to the rotation axis of a rotating electrical machine 1 according to an embodiment of the present invention.

  Referring to FIG. 1, a rotating electrical machine 1 includes a rotor 2 that rotates around a rotation axis, and an annular stator 4 that has a hollow portion that accommodates the rotor 2 at the center and is fixed to a case (not shown). . The stator 4 includes a plurality of divided stators 6. Each divided stator 6 includes a divided stator core, a coil 8 wound around a tooth portion, and an insulator that performs insulation between the core and the coil 8.

FIG. 2 is a perspective view showing the shape of the divided stator in FIG.
Referring to FIG. 2, split stator 6 includes split stator core 20, insulator 10 attached to the tooth portion of split stator core 20, and coil 8 wound around the tooth portion of split stator core 20 via the insulator. Including.

  The insulator 10 includes a support portion 10A on the inner diameter side and a support portion 10C on the outer diameter side that constrain the position of the radial coil 8 orthogonal to the rotation axis. The coil 8 has a winding end 12 at the start of winding and a winding end 14 at the end of winding. 10 A of support parts are provided with the groove | channel which is an extraction | drawer part for extracting the edge part 12. As shown in FIG.

FIG. 3 is a diagram for explaining the shape of the insulator 10 in more detail.
With reference to FIG. 3, in order to explain the shape of the insulator 10, the coil 8 is shown in a state where the coil end portion is removed.

  The coil 8 is wound around a tooth portion 10B between the support portion 10A and the support portion 10C. The support portion 10A is provided with a groove 16 as a lead-out portion for pulling out a winding start portion of the winding. Note that the lead-out portion may be a through hole instead of the groove 16 as long as the end of the winding can be drawn out.

4 is a partial cross-sectional view taken along the line IV-IV in FIG.
Referring to FIG. 4, insulator 10 is attached to divided stator core 20, and then coil 8 is wound. The coil 8 is restrained in the radial position by the support portion 10A and the support portion 10C, and is prevented from being collapsed.

FIG. 5 is a perspective view showing the shape of the split stator core 20.
Referring to FIG. 5, the divided stator core 20 is for one pole, and the yoke portion 20 </ b> C and the teeth portion 20 </ b> B form a substantially T-shape. The divided stator core 20 is made of a powder magnetic material obtained by compressing magnetic powder with a molding die, and the yoke portion 20C, the teeth portion 20B, and the magnetic pole piece portion 20A are integrally formed. On both sides of the tooth portion 20B in the circumferential direction (corresponding to the θ direction in FIG. 5), slots are formed between adjacent teeth portions 20B (not shown).

  The divided stator core 20 has a first feature that the length in the axial direction (corresponding to the z direction in FIG. 5) differs between the yoke portion 20C and the teeth portion 20B. More specifically, as shown in FIG. 5, the yoke portion 20 </ b> C has protruding portions that protrude outward in the axial direction from both axial end surfaces of the teeth portion 20 </ b> B. For this reason, the yoke part 20C is longer than the teeth part 20B by this protruding part in the axial direction.

  Further, the split stator core 20 has a second feature that the shape of the cross section perpendicular to the radial direction in the tooth portion 20B gradually changes along the radial direction. For example, in the tooth section 20B of FIG. 5, the A cross section in the plane A located on the innermost peripheral side, the C cross section in the plane C located on the outermost peripheral side, and the B cross section in the plane B located intermediate between these The shapes are different from each other.

  In addition, a relationship that the areas are equal to each other and the aspect ratios are different from each other is established between the radial cross sections including the A to C cross sections. These features can be easily realized by making use of the moldability of the stator core 100 as a powder magnetic material.

  FIG. 6 is a perspective view showing the shape of an insulator attached to the stator core shown in FIG.

FIG. 7 is a view showing the left half of the insulator 10.
FIG. 8 is a view showing the right half of the insulator 10.

  An insulator 10 is attached to each of the divided cores of the stator. The insulator 10 faces a direction parallel to the rotation axis and is inclined at a predetermined angle with respect to the rotation axis, and a side surface of the tooth portion 10B and a radial coil position perpendicular to the rotation axis is provided on the side surface. And supporting portions 10A and 10C for restraining. The surfaces (coil end taper portions described later) that contact the coils of the support portions 10A and 10C are inclined at an angle corresponding to a predetermined angle with respect to the rotation axis. Preferably, the support portion 10A is provided with a groove 16 which is a lead-out portion for drawing a coil winding in the radial direction.

  The insulator 10 is divided into a left half 30 and a right half 32 as shown in FIGS. 7 and 8, respectively, and these are attached to the divided stator core 20 shown in FIG. As a material of the insulator, an insulating resin such as PPS (polyphenylene sulfide) or PBT (polybutylene terephthalate) can be used.

  The insulator 10 includes a tooth portion 10B around which the coil is wound and support portions 10A and 10C that restrain the position of the coil in the radial direction. The support portion 10A is provided with a groove 16 serving as a lead-out portion for pulling out a winding start portion of the coil winding. A non-slip striped pattern is engraved on the side surface of the tooth portion 10B in accordance with the pitch of the coil to be wound.

FIG. 9 is a view of the left half of the insulator of FIG. 7 as viewed from the direction D1.
A region 46 surrounded by the coil end taper portions 42 and 44 and the surface 48 is a portion in which a coil winding portion is accommodated. The surface 48 is a surface parallel to the teeth portion of the stator core, and the angle θ1 is determined so that the coil end taper portions 42 and 44 are perpendicular to the teeth portion of the stator. By doing so, as shown in FIG. 4, even if the windings of the coils are arranged in an orderly manner and tension is applied, the collapse is less likely to occur.

FIG. 10 is a view of the left half of the insulator as viewed from the direction D2 in FIG.
Referring to FIG. 10, coil end taper portions 42 and 44 are protrusions provided so as to be substantially perpendicular to surface 48 as shown in FIG. 9. Due to the protrusions, the coils are arranged in an orderly manner.

  In FIG. 10, a region 56 surrounded by the surfaces 52, 58 and 54 forms a slot portion for accommodating the coil. The surface 58 is a surface parallel to the teeth portion of the stator core, and the angle θ2 is determined so that the surfaces 52 and 54 are substantially perpendicular to the surface 58.

11 is a cross-sectional view taken along the line XI-XI in FIG.
11, portions 36 and 38 correspond to the upper portion 36 and the lower portion 38 that cover the teeth portion of the stator core in FIG. The insulator 10 has a shape whose corner is a curvature R1 in the drawing so that the coil can be easily wound.

  In other words, the insulator has a shape with a curvature R1 in which the thickness of the corner is thicker than the thickness of the other portion and the winding easily adheres to the corner. The curvature R1 is determined in consideration of the thickness and hardness of the winding. And in order to avoid stress concentrating on the magnetic powder core and damaging the core, the corner portions are thick. The corner 34 has a thick shape.

  Although not shown in the schematic shape of the core shown in FIG. 5, in order to make it closely contact with the corner portion 34, the corner portion of the teeth portion 20 </ b> B of the split stator core 20 has a depression (groove, corresponding to the corner portion 34 of the insulator). Notch) is provided.

FIG. 12 is a diagram for explaining a coil winding process.
As shown in FIG. 12, the magnetic pole piece side of the core on which the insulator is mounted is held by the jig 62, and the yoke side is clamped by the clamp jigs 64 and 66 as indicated by the arrows to start winding. At this time, if the winding start is on the outer diameter side as indicated by T2, the windings may interfere with the clamp jigs 64 and 66, and the winding may collapse or the windings may be damaged.

  In the present embodiment, as shown in FIG. 6, since the groove 16 for drawing out the winding at the winding start portion is provided in the insulator, winding can be started from the inner diameter side as shown at T1, position determination and reliability of the winding are possible. Improves.

  According to the present embodiment, an insulator structure with a constant cross-sectional area can be realized without using a spacer such as a tapered member as in the prior art, and rotation can be performed while suppressing the coil end height while ensuring magnetic performance. The shaft length of the electric machine can be shortened.

  Further, by tilting the coil end portion and the support portion of the insulator together, it is possible to improve both the space factor and suppress the coil collapse.

  Furthermore, winding productivity and quality are improved by providing a groove in the support portion of the insulator and arranging the coil winding start end on the inner peripheral side.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

It is sectional drawing by a cross section perpendicular | vertical to the rotating shaft of the rotary electric machine 1 which concerns on embodiment of this invention. It is a perspective view which shows the shape of the division | segmentation stator in FIG. It is a figure for demonstrating the shape of the insulator 10 in detail. It is a fragmentary sectional view in the IV-IV cross section of FIG. 3 is a perspective view showing a shape of a split stator core 20. FIG. It is the perspective view which showed the shape of the insulator with which the stator core shown in FIG. 5 is mounted | worn. It is the figure which showed the left half of the insulator. It is the figure which showed the right half of the insulator. It is the figure which looked at the left half of the insulator of FIG. 7 from D1 direction. It is the figure which looked at the left half of the insulator from D2 direction of FIG. It is sectional drawing in the XI-XI cross section in FIG. It is a figure for demonstrating the winding process of a coil. It is shape explanatory drawing of the coil end part of the conventional stator coil structure.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Rotating electric machine, 2 rotors, 4 stators, 6 division | segmentation stators, 8 coils, 10 insulators, 10B teeth part, 10A, 10C support part, 12, 14 Winding edge part, 16 groove | channel, 20 division | segmentation stator core, 20B teeth part, 20C Yoke part, 20A magnetic pole piece part, 30 insulator left half, 32 insulator right half, 34 corner part, 36, 38 part, 42, 44 coil end taper part, 48, 52, 54, 58 plane, 46, 56 region, 62 Jig, 64, 66 Clamp jig, 100 Stator core.

Claims (6)

A rotor rotatable around a rotation axis;
An annular stator for accommodating the rotor on the inner peripheral side,
The stator is
An annular yoke portion;
Including a plurality of teeth arranged in a ring on the inner peripheral side of the yoke and wound with a coil;
Each of the plurality of teeth portions is
A side surface facing in a direction parallel to the rotation axis and inclined at a predetermined angle with respect to the rotation axis;
A support portion that is provided on the side surface and restrains the position of the coil in the radial direction orthogonal to the rotation axis;
A rotating electrical machine in which a surface of the support portion that contacts the coil is inclined at an angle corresponding to the predetermined angle with respect to the rotation axis.   The rotating electrical machine according to claim 1, wherein the support portion is provided with a drawing portion that draws the winding of the coil in the radial direction.   The rotating electrical machine according to claim 2, wherein the drawing portion is a groove provided in the support portion. The stator is
The rotating electrical machine according to claim 1, comprising a core that is divided and formed by magnetic powder compacts for each of the plurality of teeth.   The rotating electrical machine according to claim 4, wherein the support portion is a part of an insulator disposed between the stator core and the coil. The stator is
A magnetic core provided for each of the plurality of teeth;
An insulator disposed between the core and the coil to insulate the core from the coil;
The core side surface of the insulator has a shape along the core,
The rotating electrical machine according to claim 1, wherein a surface of the insulator that abuts on the coil has a curvature shape in which a winding easily adheres at a corner.

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