JP2007135340A - Stator of rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce the size and cost of a stator by forming a bus bar of a rod material. <P>SOLUTION: In the stator of rotary electric machine, a coil is wound around each of tooth 1 arranged annularly and each phase of the each coil is connected by the bus bar 3 (3a, 3b, 3c) made of a cable and extending along annular arrangement of the tooth 1. The buses 3a, 3b, 3c and 3d of each phase are arranged in parallel on the side face of the tooth arranged annularly. Each tooth is elongated radially as the rotary electric machine is enlarged and the side face of each tooth is also widened. Consequently, the bus bars can be juxtaposed easily on the side face and only the thickness of the juxtaposed bus bars contributes to enlargement of the stator in the axial direction. It is a structure advantageous for miniaturization of the stator. Material is wasted in case of punching from a metal plate material, but since a cable is formed by drawing, cost is significantly lower than that of a punched product. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a stator of a rotating electric machine for a hybrid vehicle, a fuel cell vehicle, and the like, and a bus bar coupling unit used for the stator.

  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 teeth (each coil slot) 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 each tooth. (See Patent Documents 1 to 3).
Japanese Patent Laid-Open No. 06-234383 JP 2003-134724 A JP 2004-56873 A

The bus bar is generally formed by punching out from a metal plate in an annular shape (see Patent Document 2), and there is also one using a cable (see Patent Document 3).
Moreover, the connection structure of each coil and the bus bar is a unit for connection in which annular bus bars of the same size of each phase are stacked and integrated via an insulating layer (Patent Document 1: Reference 16, Reference 2: 2: Reference 17, Patent Document 3: No. 20) is provided to face the side surface of each coil in an annular arrangement (Patent Document 1), or is provided to face the outer peripheral surface of each coil (Patent Document 3). The terminal of each coil is connected to the bus bar of the unit 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.
In addition, the technique described in Patent Document 3 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 a reduction in the diameter is required, there is an obstacle. It becomes.

  In view of the above situation, it is a first object of the present invention to reduce manufacturing costs, and a second problem is to make it easier to reduce the size of a stator.

First, in order to achieve the first problem, the present invention forms the bus bar with a bar.
Forming by punching from a metal plate is wasteful in material, but a rod is formed by drawing or the like, and is much cheaper than its punched product. In addition, since the rod has shape retention, it can be easily formed into a ring shape.

Next, in order to achieve the second problem described above, the present invention pays attention to the fact that this kind of rotating electrical machine normally requires reduction in the radial direction, and the bus bars of the respective phases are annularly formed. They were arranged in parallel on the side of the teeth.
The radial direction of the annular teeth becomes longer with the increase in size of the rotating electrical machine, and the side surfaces of the teeth become wider along with this, but conventionally, the wide side surfaces have 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.

  According to the present invention, as described above, the bus bar is formed of the bar material, so that the cost can be reduced. Further, since the bus bars of each phase are arranged in parallel on the side surfaces of the respective coils, a structure that is very effective for reducing the size of the stator can be obtained.

As one embodiment of the present invention, in a stator of a rotating electrical machine in which a coil is wound around an annular tooth for each phase, and each coil is connected to each phase by an annular bus bar along the annular shape of the tooth. The bus bar is formed of a bar, and the bus bars of the respective phases are arranged in parallel on the side surfaces of the teeth and stored in the holder, and the bus bars of the respective phases are electrically insulated.
The bar-shaped bus bar may have various cross-sectional shapes such as a perfect circular shape, the same elliptical shape, or a polygonal shape, and a rectangular rectangular wire is preferable from the viewpoint of space efficiency.

  The electrical insulation can be performed by a partition between the bus bars provided in the holder, or by an insulation coating on a bar material forming the bus bar to form an insulation coated electric wire (cable). In the latter case, in the connection portion between each coil and the bus bar, the insulation of the bus bar is peeled off for the connection. Therefore, it is preferable to provide a partition to electrically insulate the connection portion. However, it is not necessary to provide a partition wall at the connection portion as long as the insulation between the bus bars is maintained by the insulation coating of the other bus bars.

If each bus bar is electrically insulated and integrated in advance and the coupling unit is attached to the teeth, the bus bar can be attached to the teeth and connected to the coil.
As the bus bar coupling unit, it is possible to adopt a configuration in which the bus bars are arranged in parallel along the side surfaces of the annular teeth and are electrically insulated and stored in the holder.
At this time, the above-mentioned partition, insulation coating, etc. can be considered for the electrical insulation. Further, if each bus bar is gathered except for the connection portion with the coil, the occupied area can be reduced, which is advantageous for downsizing. Furthermore, if the insulating coating is made of an organic system, the bus bars can be bonded and integrated with the organic insulating coating, which is advantageous for downsizing the bus bar assembly. At this time, other adhesives can be used.
The bus bar to which the ground side of the coil for each phase is connected can also be stored in the holder. This is advantageous for further downsizing. At this time, similarly to the other bus bars, the bus bar can be a bar, an insulating coating, an organic insulating coating, or the like, and the bus bars of the respective phases can be combined.

  1 to 3, 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, and each tooth 1 arranged in an annular shape as in the prior art. Coils are wound around each of the coils, and the outer ends of the coils are connected for each phase by annular bus bars 3 (3a, 3b, 3c) along the annular arrangement of the teeth 1, and the inner ends (ground side) End) is connected by an annular bus bar 3d. The teeth 1 are arranged in an annular shape and fixed by a metal cylinder 4 by shrinkage or the like.

  Each of the bus bars 3a, 3b, 3c, and 3d is formed of a cable (for example, trade name: magnet wire) in which a single wire (bar material) is coated with an enamel such as polyamideimide and electrically insulated and coated, as shown in FIG. As shown in FIG. 3, the bus bars 3 a, 3 b, 3 c, and 3 d are housed in a holder 11 to form a coupling unit 10. Usually, the bar material can be continuously formed with an organic insulating film such as enamel at the time of drawing, and the organic insulating film can provide high heat resistance, so that the inexpensive bus bar 3 and the coupling unit 10 can be obtained. Can be obtained. A commercially available cable can be used as the cable forming the bus bar 3.

  The holder 11 is formed with partition walls 12 separating the bus bars 3, and the bus bars 3 a, 3 b, 3 c and 3 d are electrically insulated by the partition walls 12. For this reason, for each bus bar 3a, 3b, 3c, 3d, a non-insulating coating, for example, a single wire that is not covered with an insulation coating, can be used.

Connection of the coil terminal (connection end) to each bus bar 3 is performed via a conventionally known connection terminal fitting 5. The connection terminal metal fitting 5 of this embodiment comprises a terminal metal fitting 5a connected to the bus bar 3 and a terminal metal fitting 5b to which a coil end raised from the tooth 1 is connected, and both the terminal metal fittings 5a and 5b are fitted and connected. Has been.
In addition, external connection terminals 6 (6a, 6b, 6c) are connected to the bus bars 3a, 3b, 3c of each phase, and the coils are connected to an external controller or the like by the connection terminals 6. The power is appropriately supplied to each coil.
The connection terminal fitting 5 (5b) and the coil terminal are connected by, for example, TIG welding, laser welding or the like, and the connection terminal fitting 5 (5a) and the bus bar 3 are connected by, for example, fusing, pressure welding, pressure bonding, or the like. To do.
The coupling unit 10 fills the holder 11 with an insulating resin as necessary.

In order to connect the coils with the coupling unit 10, the coupling unit 10 is overlaid (set) on the resin-molded teeth 1, and the terminal of each coil is connected to the connection terminal fitting 5 (5 b). By doing. At this time, one terminal fitting 5a of the connection terminal fitting 5 is provided in advance on the coupling unit 10 side, and the other terminal fitting 5b is provided with the coil end connected to the tooth 1 side. Both terminal fittings 5a and 5b are connected.
Thereafter, if necessary, the teeth 1 and the coupling unit 10 are integrated by the resin mold C or the like, and the bus bars 3 of the respective phases are opposed to the coil surfaces on the side surfaces of the teeth 1 shown in FIG. A stator S of a 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 teeth 1 in the annular arrangement.

  As illustrated in FIG. 4, the coupling unit 10 may be configured such that only the bus bars 3 a, 3 b, and 3 c for each phase are stored in the holder 11. If the cable (bus bar 3) is insulated, the holder 11 does not have the partition wall 12 as shown in FIGS. 5 and 6, and the connection portion with the coil and the connection with the external terminal 6 are used. In the part, the partition wall 12 is fitted and provided by adhesion or the like for electrical insulation. At this time, if the insulating coating is organic, the bus bars 3 can be bonded and integrated with the organic insulating coating, and the bus bar coupling unit 10 can be downsized. At this time, other adhesives can be used.

Schematic perspective view of one embodiment (A), (b) is a perspective view of the main part of the part removal of the same embodiment Sectional view of the bus bar coupling unit of the same embodiment Cross-sectional view of a bus bar coupling unit of another embodiment Sectional drawing of the bus bar coupling | bonding unit of another Example is shown, (a) is a non-connecting part with a coil, (b) is the same connecting part. Sectional drawing of the bus bar coupling | bonding unit of another Example is shown, (a) is a non-connecting part with a coil, (b) is the same connecting part.

Explanation of symbols

1 Teeth 3, 3a, 3b, 3c, 3d Bus bar 4 Casing (cylindrical)
5, 5a, 5b Connection terminal fittings 6, 6a, 6b, 6c External terminal 10 Busbar coupling unit 11 Holder 12 Bulkhead

Claims (12)

In a stator S of a rotating electrical machine in which a coil is wound around an annular tooth 1 for each phase, and each coil is connected to each phase by an annular bus bar 3a, 3b, 3c along the annular shape of the tooth 1.
The bus bars 3a, 3b, 3c are formed of bar material, and the bus bars 3a, 3b, 3c of the respective phases are arranged in parallel on the side surface of the tooth 1 and accommodated in the holder 11, and the bus bars 3a, 3b of the respective phases. A stator of a rotating electrical machine, wherein the electrical insulation is provided between 3c.   The stator for a rotating electric machine according to claim 1, wherein the holder 11 is provided with a partition wall 12 between the bus bars 3a, 3b, 3c to achieve the electrical insulation.   The bus bars 3a, 3b, and 3c are covered with a bar material, and the insulation is provided by the insulating coating. A partition wall 12 is provided at a connection portion of the bus bars 3a, 3b, and 3c with the coils. 2. The stator for a rotating electrical machine according to claim 1, wherein the connecting portion is electrically insulated.   The stator of the rotating electrical machine according to claim 3, wherein the bus bar 3a, 3b, 3c is reduced in an occupied area by gathering parts other than the connection portion.   The stator of a rotating electrical machine according to claim 4, wherein the insulating coating is organic, and the bus bars 3a, 3b, 3c are integrally bonded and integrated with the organic insulating coating. .   The stator of a rotating electrical machine according to any one of claims 1 to 5, wherein a bus bar (3d) to which a ground side of the coil for each phase is connected is also accommodated in the holder (11). A bus bar coupling unit 10 used for a stator of a rotating electrical machine according to claim 1,
Each of the bus bars 3a, 3b, 3c is made of a bar material, and is electrically insulated from each other in the holder 11, and is arranged and accommodated in parallel along the side surface of the annular tooth 1. Bus bar coupling unit for stators of rotating electrical machines.   8. The stator bus bar coupling unit for a rotating electric machine according to claim 7, wherein the holder 11 is provided with a partition wall 12 between the bus bars 3a, 3b, 3c to perform the electrical insulation.   The bus bars 3a, 3b, and 3c are covered with insulating material on the bar material, and the insulation is provided by the insulating coating. A partition wall 12 is provided at a connection portion of the bus bars 3a, 3b, and 3c with the coils. 8. The bus bar coupling unit for a stator of a rotating electric machine according to claim 7, wherein the connection portion is electrically insulated.   The bus bar coupling unit for a stator of a rotating electric machine according to claim 9, wherein each bus bar 3a, 3b, 3c is collectively reduced in area other than the connection portion.   11. The stator for a rotating electrical machine according to claim 10, wherein the insulating coating is organic, and the bus bars 3a, 3b, 3c are integrally bonded and integrated with the organic insulating coating. Bus bar coupling unit.   The bus bar coupling unit for a stator of a rotating electric machine according to any one of claims 7 to 11, wherein the bus bar 3d to which the ground side of the coil for each phase is connected is also accommodated in the holder 11.

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