JP2008253063A - Stator for motor and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator for a motor and a manufacturing method for the stator, capable of reducing the connection works among wave-winding coils with one another, and improving the space factor of a conductor in slot and reducing the size of coil end part. <P>SOLUTION: The stator for the motor is constituted by laying out a three-phase coil in the plurality of slots 21 of a stator core 2. A coil of each phase is constituted, by using the wave-winding coil 4 formed by alternately connecting slot conductor parts 41 with a coil end conductor part 42 at both sides in an axial direction L of the stator core 2. When the wave-winding coil 4 is constituted as one turn configuration part of the slot conductor part 41, of which the number corresponds to the number of the slots 21 of each phase and the coil end conductor part 42 which mutually connects the slot conductor parts 41, two turn configurational parts 4A, 4B which are laminated in the radial direction of the stator core 2 are formed by one continuous conductor, having a flat shape in a cross section so that the conductor overlaps the flat surface directions. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a motor stator in which a plurality of coils are arranged in a distributed winding state in a plurality of slots in a stator core, and a method for manufacturing the same.

  For example, a stator for a three-phase motor in which three-phase coils of U-phase, V-phase and W-phase are arranged on the stator core is obtained by winding a copper wire having a circular cross section, many of which are insulated and coated, multiple times. A three-phase coil is used. On the other hand, there are various methods for assembling the coil to the stator core for the purpose of reducing the size of the coil end portion (portion in which a part of the coil protrudes from the axial end surface of the stator core) and simplifying the process of assembling the coil to the stator core. It is considered.

  For example, in the multiphase wave winding of a rotating electrical machine disclosed in Patent Document 1, a transition conductor that constitutes a coil end by connecting a slot conductor portion inserted into each slot of the stator core and the same side end portion of the slot conductor portion. It is disclosed that a coil conductor of each phase having a wave shape is formed by a portion. Further, in Patent Document 1, the leading end portion of the transition conductor portion is displaced in the radial direction by a step or more than the substantially radial thickness of the transition conductor portion, and the respective transition conductor portions deformed into the same shape are sequentially shifted in the circumferential direction. Thus, the coil end is reduced in size, and resistance power loss due to useless wiring extension of the transition conductor portion is prevented.

  By the way, the conventional wave winding is formed by using a single conductor to have a length having slot conductor portions corresponding to the number of slots of each phase. And the wave winding is arrange | positioned in a slot in the state which goes around the circumferential direction of a stator core. In addition, in each slot, in order to arrange the slot conductor portions in the radial direction, the wave windings of each phase that goes around the circumferential direction of the stator core are arranged in the slot a plurality of times (multiple turns). Yes.

However, in the conventional wave winding, it is necessary to perform welding or the like for each wave winding forming each turn and to join the wave windings to each other. For this reason, there are many joining portions of wave windings, and this joining operation is not easy.
Moreover, in patent document 1, the crossing conductor part is extended diagonally from the slot conductor part, and this crossing conductor part is formed in the mountain shape. Therefore, the axial dimension of the coil end portion may be increased.

JP 2000-69700 A

  The present invention has been made in view of the above-described conventional problems, and can reduce the joining work between the wave winding coils, improve the space factor of the conductor in the slot, and reduce the size of the coil end portion. An object of the present invention is to provide a stator for a motor and a method for manufacturing the same.

A first invention is a motor stator having a stator core having a plurality of slots, and a plurality of coils arranged in a distributed winding state with a predetermined number of slots in the plurality of slots,
The coil is formed by alternately connecting the slot conductor portions arranged in the slot by coil end conductor portions arranged to protrude outside the slot at one axial end side and the other axial end side of the stator core. It is configured using wave winding coils,
In the slot, the slot conductor portion is arranged in multiple stages in the radial direction of the stator core,
When the number of the slot conductor portions corresponding to the number of the slots of each phase in the stator core and the coil end conductor portion connecting the slot conductor portions are one turn constituting portion, the wave coil is The two continuous turn components are formed by a single flat conductor that is aligned in the radial direction of the stator core with the flat surface direction of the conductor flattened.
The two turn components are formed by sequentially arranging one slot in the circumferential direction of the stator core from the slot conductor at the first winding end to the slot conductor at the first winding end in the slot. A turn component,
Folded from the slot conductor at the end of the one-side winding, and arranged in the slot sequentially from the slot conductor at the start of the other side to the slot conductor at the end of the other-side winding around the other circumferential direction of the stator core. And the other turn constituent part formed by arranging the slot conductor part at the end of the other side winding in the same slot as the slot conductor part at the end of the one side winding,
The coil end conductor part in the one turn constituent part and the coil end conductor part in the other turn constituent part are alternately arranged in the circumferential direction of the stator core on both sides in the axial direction of the stator core. Yes,
A stator for a motor, characterized in that a plurality of the wave winding coils composed of the two turn components are joined to form the coil of each phase (Claim 1).

In the motor stator of the present invention, two turn components overlapping in the radial direction of the stator core are formed by the wave winding coil in which one continuous conductor having a flat cross section is formed into a wave shape. As a result, in each phase coil, one wave winding coil can form a slot conductor portion and a coil end conductor portion for two turns in the circumferential direction of the stator core, which are arranged in the slots of each phase. Stepped slot conductor portions can be formed.
And the coil of each phase is formed by joining this wave winding coil two or more. Therefore, when each phase coil is formed by joining a plurality of the above-mentioned wave winding coils, the wave winding is compared with the case where each phase coil is formed using a conventional wave winding coil composed of one turn component. The number of joints between the coils can be reduced, and this joining work can be reduced.

  Further, in each phase slot, slot conductor portions made of a conductor having a flat cross section (a conductor having a smaller thickness in the radial direction than the width in the circumferential direction) are stacked in a plurality of stages in the radial direction of the stator core. It is arranged. Also, the number of slot conductors in one turn component (number from one winding start end to one winding end) and the number of slot conductors in the other turn component (other winding starting end to the other) The number up to the end of the side winding) is the same. The slot conductor portion at the other end of the winding is disposed in the same slot as the slot conductor portion adjacent to the slot conductor at the end of one side winding, and the slot conductor portion at the end of the other side winding is It is arranged in the same slot as the slot conductor at the end of the side winding.

Thus, by arranging one wave coil in the slot of each phase, the slot conductor part in one turn constituent part and the slot conductor part in the other turn constituent part can be equally distributed in all slots. Further, the slot conductor portions for two stages can be arranged so as to overlap in the radial direction of the stator core.
Therefore, when a coil of each phase is formed by joining a plurality of wave winding coils, the space factor of the slot conductor portions of a plurality of stages in the slot of each phase can be improved.

  Further, by folding back from the slot conductor portion at the end of the one side winding in the opposite direction in the circumferential direction of the stator core, the other turn constituent portion is formed, so that the coil end conductor portion in one turn constituent portion and the other The coil end conductor portions in the turn constituent portions are alternately arranged in the circumferential direction of the stator core on both sides in the axial direction of the stator core. That is, the coil end conductor part in each turn constituent part can be arranged to face the space on the side where the coil end conductor part is not formed on both axial sides of the adjacent slot conductor parts.

  As a result, the coil end conductor portion of one wave-wound coil projects from the one end side in the axial direction and the other end side in the axial direction of the stator core, so that no space is wasted and the stator core is Coil end conductors can be arranged equally in the direction. Therefore, when a coil of each phase is formed by joining a plurality of wave winding coils, the coil end portions on both sides in the axial direction of the stator core can be reduced in size.

  Therefore, according to the stator for a motor of the present invention, it is possible to reduce the work of joining the wave winding coils, and it is possible to improve the space factor of the conductor in the slot and reduce the size of the coil end portion.

According to a second aspect of the present invention, there is provided a method of manufacturing a stator for a motor having a stator core having a plurality of slots and a plurality of coils arranged in a distributed winding state with a predetermined number of slots in the plurality of slots.
A wave winding intermediate having a plurality of slot conductor portions parallel to each other and a plurality of coil end conductor portions that alternately connect the slot conductor portions at one end side and the other end side is formed from a conductor having a substantially round cross section. In addition, when the number of the slot conductor portions corresponding to the number of slots of each phase in the stator core and the coil end conductor portion connecting the slot conductor portions are one turn constituting portion, the turn constituting portion is A wave winding step of forming the wave winding intermediate in a length constituted by two consecutively;
Except for the slot conductor portion at the end of one side winding in one of the turn components, all the remaining slot conductor portions in the wave winding intermediate body and all the coil end conductor portions are connected to the wave winding intermediate body. A flattening step of flattening in a direction parallel to the plane forming the wave shape;
By twisting the slot conductor portion at the one end of the one side winding by 180 ° around the central axis, the slot conductor portion at the one end of the one side winding and the slot conductor portion at the other end of the other side in the turn component The remaining slot conductor portions excluding are overlapped with the flat surface direction aligned, and the coil end conductor portion in one of the turn constituent portions and the coil end conductor portion in the other turn constituent portion are overlapped. A twisting step of alternately arranging the slot conductor portions in the direction in which the slot conductor portions are arranged at either one end side or the other end side of the slot conductor portion;
An additional flattening step of flattening the slot conductor portion at the end of the one-side winding in accordance with the surface direction in which the corrugated intermediate body is flattened;
A film forming step of forming an insulating film on the surface of the wave winding intermediate to form a wave winding coil having the two turn components;
The wave conductor in a state where the slot conductor portion at the end of one side winding in one of the turn components and the slot conductor portion at the end of other winding in the other turn component are disposed in the same slot. And a stator forming step of forming a stator by disposing the wound coils in the plurality of slots and joining the wave coils of each phase to each other. Item 5).

The method for manufacturing a motor stator according to the present invention is a method suitable for manufacturing a motor stator that exhibits the above-described excellent effects.
Specifically, in the wave winding step, a wave intermediate body having a length constituting two of the turn components is formed using a conductor having a substantially round cross section, and in the flat step, All parts except the slot conductor at the end of the side winding are flattened.

  Then, in the twisting step, the two turn constituent parts of the wave winding intermediate body are overlapped by twisting the slot conductor part at the end of the one side winding by 180 ° around the central axis. At this time, the slot conductor portion at the end of the one side winding remains a conductor having a substantially round cross section, and can be easily twisted around its central axis, and maintains a substantially round cross section even after twisting. be able to.

  In the two turn components, the remaining slot conductor in one turn component excluding the slot conductor at the end of one side winding in one turn component and the end of the other side winding in the other turn component The remaining slot conductor portions in the other turn constituent portion excluding the end slot conductor portion overlap with each other in the flat surface direction. Further, the coil end conductor portion in one turn constituent portion and the coil end conductor portion in the other turn constituent portion are arranged in the direction in which the slot conductor portions are arranged on both one end side and the other end side of the slot conductor portion. Alternatingly arranged.

  Next, in the additional flattening step, the slot conductor portion at the end of one side winding having a substantially round cross section is flattened in the same direction as the other slot conductor portions, and in the film forming step, the surface of the wave winding intermediate is insulated. A film is formed to form a wave winding coil having the two turn components. In this way, after each processing of the wave winding process in the wave winding process, the twisting process in the twisting process, the flattening process and the flattening process in the additional flattening process is finished, by forming the insulating film, It is possible to prevent the insulation coating from peeling off on the surface of the wave winding coil. Moreover, by performing each of the above steps, a wave winding coil in which two turn components overlap each other can be easily formed.

  Thereafter, in the stator forming step, the wave coils are arranged in a plurality of slots, and the wave coils of the respective phases are joined together to form a stator. At this time, the slot conductor portion at the end of the one side winding in the one turn component and the slot conductor portion at the end of the other side winding in the other turn component are disposed in the same slot, The two-stage slot conductor portions overlapping in the radial direction of the stator core can be arranged equally.

  Thereby, the space factor of the slot conductor portions of the plurality of stages in the slot of each phase can be improved. Moreover, since the coil part for 2 turns is formed with the wave winding coil, the joining location of wave winding coils can be decreased, and this joining operation can be reduced. In addition, the coil end conductor portions in the two turn constituent portions can be arranged equally in the circumferential direction of the stator core on either one axial end side or the other axial end side of the stator core, The coil end portion in can be reduced in size.

  Therefore, according to the method of manufacturing a stator for a motor of the present invention, it is possible to reduce the joining work between the wave winding coils, to improve the space factor of the conductor in the slot and to reduce the size of the coil end portion. A stator for a motor that can be manufactured can be easily manufactured.

A preferred embodiment in the first and second inventions described above will be described.
In the first invention, the other turn constituent portion is folded back with respect to the one turn constituent portion because the slot conductor portion at the end of the one-side winding is twisted by 180 ° around the central axis. It is preferable that it is present (claim 2).
In this case, the wave winding coil having the two turn components can be easily formed.

Further, in the plurality of slots, three-phase coils of U phase, V phase and W phase formed by joining a plurality of the wave winding coils are respectively arranged, and the three-phase wave winding coils are Preferably, the stator cores are alternately stacked one by one or a predetermined number in the radial direction of the stator core.
In this case, the arrangement state on the stator core can be made as uniform as possible between the three-phase wave winding coils. Thereby, the length of the three-phase coil can be made as uniform as possible, and the performance of the motor configured using the stator can be improved.

The wave winding coils have the same cross-sectional area over the entire length, and the wave winding coils also have the same cross-sectional area. The stator core has teeth between the slots in the circumferential direction. A core forming block divided into a number corresponding to the number of the slots in the shape is joined, and the plurality of slots are formed in a shape in which the circumferential width increases toward the outer side in the radial direction of the stator core. In addition, it is preferable that the slot conductor portions of the plurality of stages arranged in the slot have a larger circumferential width as the slot conductor portions are located radially outward.
In this case, the radial thickness of the slot conductor portion can be reduced compared to the case where the circumferential widths of the plurality of stages of slot conductor portions arranged in the slot are uniform in the radial direction. The number of slot conductor portions arranged inside can be increased. In addition, since the radial thickness of the slot conductor portion can be reduced, the rotor diameter (outer diameter) of the rotor disposed on the inner peripheral side of the stator can be easily ensured to be large. Therefore, it is effective for improving the performance of the motor.

In the second invention, in the wave winding step, the interval between the slot conductor portions in the one turn constituent portion is greater than the interval between the slot conductor portions in the other turn constituent portion. In the stator forming step, it is preferable that the wave winding coil is disposed in the plurality of slots in a state where the one turn constituent part is located on the outer peripheral side of the other turn constituent part ( Claim 6).
In this case, when the wave winding coil is assembled to the stator core, the one turn component and the other turn component are connected in accordance with the difference between the inner and outer circumferences generated in one turn component and the other turn component. It can be placed in multiple slots.

Further, in the stator forming step, as the stator core, a plurality of core forming blocks divided into a number corresponding to the number of the slots in the circumferential direction of the stator core are used, and the core forming block is between the slots. It is formed into a shape having teeth, and the above-described wave winding coils of each phase are joined to form an annular coil of each phase, and the coils of each phase are overlapped in the radial direction to form an annular coil An assembly is formed, and the core is formed by inserting the teeth from outside in the radial direction into the through holes formed between the slot conductor portions and the coil end conductor portions of the coil assembly. It is preferable to form the stator by joining the blocks together.
In this case, it is easy to arrange the wave-wound coils in a plurality of slots, and in particular, for each slot whose circumferential width increases toward the outer side in the radial direction, the space factor is high. Each slot conductor part in a wave winding coil can be arranged.

Further, in the stator forming step, the wave coils can be sequentially arranged in the plurality of slots, and the wave coils of each phase can be joined to each other (claim 8).
In this case, the wave winding coil can be assembled to the stator core that is not divided by devising when the slot conductor portions of the wave winding coil are arranged in each slot.

In addition, a U-phase, a V-phase, and a W-phase wave coil are formed through the wave winding step, the flattening step, the twisting step, the additional flattening step, and the film forming step, and the stator forming step In the above, it is preferable that the three-phase wave winding coils are alternately arranged one by one or every predetermined number in the radial direction of the stator core.
In this case, the arrangement state on the stator core can be made as uniform as possible between the three-phase wave winding coils. Thereby, the length of the three-phase coil can be made as uniform as possible, and the performance of the motor configured using the stator can be improved.

Hereinafter, embodiments of the motor stator according to the present invention will be described with reference to the drawings.
As shown in FIGS. 1 to 3, the motor stator 1 of this example includes a stator core 2 having a plurality of slots 21 and a plurality of phases arranged in a distributed winding state with a predetermined number of slots in the plurality of slots 21. Coils 3U, V, and W.
As shown in FIG. 4, the coils 3U, V, and W of each phase are configured so that the slot conductor portions 41 arranged in the slot 21 are connected to each other at one end side in the axial direction L and the other end side in the axial direction L of the stator core 2. The wave winding coils 4 are alternately connected by the coil end conductor portions 42 that protrude from the slot 21. Further, as shown in FIG. 9, the slot conductor portions 41 are arranged in a plurality of stages in the radial direction R of the stator core 2 in the slot 21.

As shown in FIGS. 4 to 6, the wave winding coil 4 is a coil end conductor that connects the slot conductor portions 41 and the slot conductor portions 41 with the number corresponding to the number of slots 21 U, V, and W of each phase in the stator core 2. When the portion 42 is a single turn component, the two turn components 4A are overlapped in the radial direction R of the stator core 2 by aligning the surface direction in which the conductor is flattened by one continuous conductor having a flat cross section. , B are formed.
The two turn constituent parts 4A and B are composed of one turn constituent part 4A and the other turn constituent part 4B arranged on the inner peripheral side of the one turn constituent part 4A.

  As shown in FIGS. 4 and 6, one turn constituting portion 4 </ b> A is formed in one turn C <b> 1 in the circumferential direction C of the stator core 2 from one side winding start end slot conductor portion 41 </ b> A to one side winding end end slot conductor portion 41 </ b> B. Are sequentially arranged in the slot 21. The other turn constituting portion 4B is folded back from the slot conductor portion 41B at the end of the one-side winding, and is wound around the other side C2 in the circumferential direction C of the stator core 2 from the slot conductor portion 41C at the other end of the winding. The slot conductor part 41D up to the end end is sequentially arranged in the slot 21, and the slot conductor part 41D at the other end of the winding is arranged in the same slot 21 as the slot conductor part 41B at the end of the one side winding. .

  The coil end conductor portion 42 in one turn constituent portion 4A and the coil end conductor portion 42 in the other turn constituent portion 4B are alternately arranged in the circumferential direction C of the stator core 2 on both sides in the axial direction L of the stator core 2. It is arranged. As shown in FIGS. 1 to 3, the motor stator 1 of this example includes coils 3 </ b> U, V, and W of respective phases formed by joining a plurality of wave-wound coils 4 composed of two turn components 4 </ b> A and 4 </ b> B. have.

  1 to 3 are views showing the coil end conductor portions 42 of the U-phase, V-phase, and W-phase coils 3U, V, and W in the motor stator 1, and FIG. It is a figure which shows the wave winding coil 4 before performing. FIG. 5 is a diagram showing one wave coil 4 in the motor stator 1, and FIG. 6 is a diagram schematically showing this one wave coil 4.

The motor stator 1 of this example will be described in detail below with reference to FIGS.
The motor stator 1 of this example is used for a three-phase AC motor used in a hybrid car or an electric vehicle. The three-phase coils 3U, V, and W of U phase, V phase, and W phase are assembled to the stator core 2. Configured.
As shown in FIGS. 11 and 12, the wave winding coil 4 of this example is formed by flattening a conducting wire having a substantially round cross section (in this example, a round wire), and has the same cross-sectional area over its entire length. . Further, the cross-sectional areas of the plurality of wave winding coils 4 forming the coils 3U, V, W of each phase are also the same.

As shown in FIGS. 8 and 9, the stator core 2 of the present example has a core forming block 20 divided into a number corresponding to the number of slots 21 in a shape having teeth 22 between the slots 21 in the circumferential direction C. Joined. The plurality of slots 21 are formed in a shape in which the width in the circumferential direction C increases toward the outside in the radial direction R of the stator core 2.
As shown in FIG. 8, in the stator core 2, a U-phase slot 21 </ b> U, a V-phase slot 21 </ b> V, and a W-phase slot 21 </ b> W are repeatedly formed one by one in the circumferential direction C. As shown in FIG. 1, the number of slots 21 in this example is 24, and eight U-phase slots 21U, V-phase slots 21V, and eight W-phase slots 21W are formed.

As shown in FIGS. 7 and 9, in each wave-wound coil 4, the slot conductor portion 41 and the coil end conductor portion 42 are flat so that the thickness dimension in the radial direction R of the stator core 2 becomes small. That is, the slot conductor portion 41 has a smaller thickness dimension in the radial direction R than the width dimension in the circumferential direction C, and the coil end conductor portion 42 has a thickness in the radial direction R with respect to the width dimension in the axial direction L. The dimensions are small. The coil end conductor portion 42 is further flatter than the slot conductor portion 41 (the thickness dimension in the radial direction R is further reduced).
Further, an insulator 211 is provided on the inner wall surface and the opening of each slot 21, and an interphase insulator 212 is provided between the coil end conductor portions 42 of each wave winding coil 4.

Here, FIG. 7 is a diagram showing the slot conductor portion 41 disposed in the slot 21 and the coil end conductor portion 42 connected to the slot conductor portion 41, and particularly shows a cross section of the slot conductor portion 41 in the U-phase slot 21U. The V-phase slot 21V and the W-phase slot 21W also have the same structure although the rising position in the radial direction R of the coil end conductor portion 42 is slightly different.
Further, as shown in the figure, the coil end conductor portion 42 is deformed outward in the radial direction R from the slot conductor portion 41, thereby efficiently arranging a plurality of coil end conductor portions 42 and The end portion 31 is downsized in the radial direction R.
Further, as shown in FIG. 9, the plurality of slot conductor portions 41 arranged in each slot 21 have a shape of the slot 21 whose width in the circumferential direction C increases toward the outside in the radial direction R of the stator core 2. Following the above, the width in the circumferential direction C increases as the slot conductor portion 41 is located outward in the radial direction R.

As shown in FIGS. 8 to 10, in the plurality of slots 21, three-phase coils 3U, V, and W of U-phase, V-phase, and W-phase formed by joining a plurality of wave winding coils 4 are arranged. It is. In this example, the U-phase, V-phase, and W-phase coils 3U, V, W are each composed of a 10-turn corrugated conductor that makes 10 turns in the circumferential direction C of the stator core 2, and In each slot 21U, V, W, 10 stages of slot conductor portions 41 are arranged.
As shown in FIGS. 1 to 3, the three-phase wave winding coils 4U, V, and W in the motor stator 1 are arranged as evenly as possible in the three-phase wave winding coils 4U, V, and W. In order to do so, the stator cores 2 are arranged alternately in the radial direction R of the stator core 2 one by one or every predetermined number.

  In this example, as shown in FIG. 7, the three-phase wave winding coils 4U, V, W are divided into two wave winding coils 4U, V, W for each phase from the inner peripheral side in the radial direction R of the stator core 2. After alternately arranging twice each, the wave winding coils 4U, V, W of each phase are alternately arranged once each. That is, the three-phase coils 3U, V, W of this example are V-turn conductors (two V-phase wave coils 4V), four turns from the inner peripheral side of the stator core 2 in the radial direction R. Minute W-phase conductors (two W-phase wave winding coils 4W), and four turns of U-phase conductors (two U-phase wave winding coils 4U) are repeated twice in sequence, then two turns V-phase conductor (one V-phase wave coil 4V), two turns of W-phase conductor (one W-phase wave coil 4W), two turns of U-phase conductor (one U-phase The wave winding coil 4U) is formed by sequentially performing once. In addition, the wave coils 4U, V, and W of each phase can be arranged in various arrangement patterns other than this.

  Further, as shown in FIGS. 4 and 6, in the wave winding coils 4U, V, and W of each phase in the motor stator 1, the other turn constituent portion 4B disposed on the inner peripheral side of the one turn constituent portion 4A. Is folded with respect to the one turn component 4A by twisting the slot conductor part 41B at the end of one side winding by 180 ° around the central axis.

Next, the manufacturing method of the stator 1 for motors of this example is demonstrated.
In this example, the motor stator 1 is manufactured by performing the following wave winding process, flattening process, twisting process, additional flattening process, film forming process, and stator forming process.
First, in the wave winding process, as shown in FIG. 11, a plurality of slot conductor portions 41 parallel to each other and a plurality of slot conductor portions 41 alternately connected at one end side and the other end side from a conductor having a substantially circular cross section. The wave winding intermediate body 40 having the coil end conductor portion 42 is formed. And this wave winding intermediate body 40 connects the slot conductor portions 41 with the number of slot conductor portions 41 corresponding to the number of slots 21U, V, W of each phase in the stator core 2 (eight in this example). When the coil end conductor portion 42 is used as one turn constituent portion, the two turn constituent portions are formed to have a length that is formed continuously.

In addition, in the wave winding process, the slot conductor portion in one turn constituent portion 4A disposed on the outer peripheral side of the stator core 2 with respect to the other turn constituent portion 4B in consideration of the inner / outer peripheral difference generated when assembled to the stator core 2 The interval between the 41 is formed larger than the interval between the slot conductor portions 41 in the other turn constituting portion 4B.
Next, in the flattening step, as shown in FIG. 12, all of the remaining slot conductor portions 41 in the wave winding intermediate 40 are all except for the slot conductor portion 41B at the end of one side winding in one turn constituting portion 4A. The coil end conductor portion 42 is flattened in a direction parallel to a plane forming the wave shape of the wave winding intermediate body 40.

  Next, in the twisting process, as shown in FIG. 13, the slot conductor 41B at the end on one side of the one turn component 4A is twisted by 180 ° around its central axis, thereby providing the slot conductor at the end on one side. The remaining slot conductor portions 41 except for the portion 41B and the slot conductor portion 41D at the other end of the other turn constituting portion 4B are overlapped with each other in the plane direction in which they are flattened. At this time, the coil end conductor portion 42 in one turn constituent portion 4A and the coil end conductor portion 42 in the other turn constituent portion 4B are both on one end side and the other end side of the slot conductor portion 41. The slot conductor portions 41 are alternately arranged in the direction in which they are arranged.

In the twisting process, when the two turn components 4A and 4B of the wave winding intermediate body 40 are overlapped, the slot conductor portion 41B at the end of the one-side winding remains a conductor having a substantially round cross section, and its central axis It can be easily twisted around and can maintain a substantially round cross section even after twisting.
Next, in the additional flattening step, as shown in FIG. 4, the slot conductor portion 41 </ b> B at the end of one side winding having a substantially round cross section is flattened in accordance with the surface direction in which the wave winding intermediate body 40 is flattened (other slots). Flattened in the same direction as the conductor 41).
Next, in the coating forming step, an insulating coating made of varnish or the like is formed on the entire surface of the wave winding intermediate 40 to form the wave winding coil 4 having two turn components 4A and 4B. At this time, it is possible to prevent an insulating film from being formed on a part of the joining portion 43 for joining the wave winding coils 4 to each other.

  In this way, after each processing of the wave winding process in the wave winding process, the twisting process in the twisting process, the flattening process, and the flattening process in the additional flattening process is finished, the insulating film is formed and the wave winding coil 4 is formed. Further, it is possible to prevent the insulation film from peeling off on the surface of the wave winding coil 4. Moreover, by performing each of the above steps, the wave winding coil 4 in which the two turn components 4A and 4B overlap can be easily formed.

  Thereafter, in the stator forming step, as shown in FIGS. 4 to 6, the slot conductor portion 41B at the one end winding end in the one turn constituent portion 4A and the slot at the other end winding end in the other turn constituent portion 4B. The wave winding coil 4 is disposed in the plurality of slots 21 in a state where the conductor portion 41 </ b> D is disposed in the same slot 21. Further, the wave winding coil 4 is disposed in the plurality of slots 21 in a state where one turn component 4A is positioned on the outer peripheral side of the other turn component 4B. Then, according to the difference between the inner and outer circumferences generated in one turn component 4A and the other turn component 4B, one turn component 4A and the other turn component 4B can be arranged in the plurality of slots 21. it can.

Further, in the stator forming process of this example, as shown in FIG. 14, as the stator core 2, a plurality of cores divided into a number (24 in this example) corresponding to the number of slots 21 in the circumferential direction C of the stator core 2. Block 20 is used. The core forming block 20 is formed in a shape having teeth 22 between the slots 21, and the slots 21 are formed between the core forming blocks 20 joined to each other.
Further, as shown in the figure, in this example, the wave coils 4U, V, W of the respective phases are joined outside the stator core 2 to form the coils 3U, V, W of the respective annular shapes. At the same time, the coils 3U, V, and W of each phase are overlapped in the radial direction R to form the annular coil assembly 30.

  More specifically, when forming the coil assembly 30, as shown in FIGS. 5 and 10, in each phase, any one of the wound coils 4 is formed in a circular shape along the circumferential direction C of the stator core 2. A joint 43 formed at the tip of the slot conductor 41 at the other end of the winding in one of the wave coils 4, and a slot conductor at the first winding start in the other coil 4 The joining portion 43 formed at the tip end portion of 41 is joined by welding or the like via the bridge conductor 5. In this example, as shown in FIG. 10, the five wave coils 4 are joined together to form coils 3U, V, and W of each phase constituting a conductor for 10 turns. Here, FIG. 10 is a diagram schematically showing a plurality of wave winding coils 4 constituting the coils 3U, V, W of each phase.

  Further, a joint 43 located in the middle part of each phase coil 3U, V, W composed of a 10-turn coil conductor (10 turn constituent parts) is joined by a crossover conductor 5, and the three-phase coil 3U, In order to perform star connection of V and W, one of the joints 43 positioned at both ends of the coils 3U, V, and W of each phase is joined by bundling the three-phase joints 43 as a neutral point, and the other is pulled out. Used as a line.

  As shown in FIGS. 14 and 15, the three-phase coils 3U, V, and W are formed between the slot conductor portions 41 and the coil end conductor portions 42 in the coil assembly 30 in which the coils 3U, V, and W are formed in a circular shape. A motor provided with three-phase coils 3U, V, and W by inserting the teeth 22 of the core forming block 20 from the outside in the radial direction R into the through hole 49 and joining the core forming blocks 20 to each other. The stator 1 can be formed. In addition, after joining the several core formation block 20, the whole core formation block 20 which performed this joining can be fitted and integrated in the ring member 23 (refer FIG. 1).

  In the motor stator 1 of this example, two turn components 4A and B that overlap in the radial direction R of the stator core 2 are formed by a wave coil 4 in which a continuous conductor having a flat cross section is formed into a wave shape. is doing. Thereby, in each phase coil 3U, V, and W, the slot conductor part 41 and the coil end conductor part 42 for two rounds in the circumferential direction C of the stator core 2 can be formed by one wave coil 4. The two-stage slot conductor portions 41 arranged in the slots 21U, V, W of each phase can be formed.

A plurality of wave winding coils 4 are joined to form coils 3U, V, and W for each phase. Therefore, when each phase coil 3U, V, W is formed by joining a plurality of wave winding coils 4, each phase coil 3U, V, W is formed using a conventional wave winding coil composed of one turn component. As compared with the case of forming the wire coil, it is possible to reduce the number of places where the wave winding coils 4 are joined, and to reduce this joining work.
For example, in the case of forming a 10-turn coil conductor in the stator, when using a conventional wave-wound coil composed of one turn component, it is necessary to join with 9 crossover conductors in FIG. As shown in FIG. 5, when the wave winding coil 4 composed of the two turn components 4A and B of this example is used, it is only necessary to join with the transition conductors 5 at four locations.

  Further, in the slots 21U, V, W of each phase, the slot conductor portion 41 made of a conductor having a flat cross section (a conductor having a thickness dimension in the radial direction R smaller than the width dimension in the circumferential direction C) is provided on the stator core 2. In the radial direction R, they are arranged in multiple stages. Further, the number of slot conductor portions 41 in one turn constituent portion 4A (the number from the one side winding start end to the one side winding end end, eight in this example) and the slot conductor portion 41 in the other turn constituent portion 4B. (The number from the other side winding start end to the other side winding end end, eight in this example). The slot conductor portion 41C at the other end of the winding is disposed in the same slot 21 as the slot conductor portion 41 adjacent to the slot conductor portion 41B at the end of the one side winding, and the slot conductor at the end of the other side winding. The part 41D is arranged in the same slot 21 as the slot conductor part 41B at the end of one side winding.

Thus, by disposing one wave coil 4 in each phase slot 21U, V, W, slot conductor part 41 in one turn constituent part 4A and slot conductor part 41 in the other turn constituent part 4B. Thus, the slot conductor portions 41 corresponding to two stages can be equally arranged in all the slots 21 so as to overlap in the radial direction R of the stator core 2.
Therefore, when the coils 3U, V, W of each phase are formed by joining a plurality of wave winding coils 4, the space factor of the slot conductor portions 41 of the plurality of stages in the slots 21U, V, W of each phase is improved. Can be made.

  In addition, by turning back from the slot conductor portion 41B at the end of the one side winding in the reverse direction in the circumferential direction C of the stator core 2 to form the other turn constituent portion 4B, the coil end in one turn constituent portion 4A The conductor portions 42 and the coil end conductor portions 42 in the other turn constituting portion 4B are alternately arranged in the circumferential direction C of the stator core 2 on both sides in the axial direction L of the stator core 2. That is, the coil end conductor portions 42 in the respective turn constituent portions 4A and 4B are arranged to face the spaces on the sides where the coil end conductor portions 42 are not formed on both sides in the axial direction L of the adjacent slot conductor portions 41. be able to.

  As a result, in the coil end portion 31 formed to protrude from the one end side in the axial direction L and the other end side in the axial direction L of the stator core 2 by the coil end conductor portion 42 in one wave-wound coil 4, useless space. The coil end conductor portion 42 can be arranged evenly in the circumferential direction C of the stator core 2 (see FIG. 7). Therefore, when the coils 3U, V, and W of each phase are formed by joining a plurality of wave winding coils 4, the coil end portions 31 on both sides in the axial direction L of the stator core 2 can be reduced in size.

  Therefore, according to the motor stator 1 and the manufacturing method thereof of the present example, the work of joining the wave winding coils 4 can be reduced, the space factor of the conductor in the slot 21 can be improved, and the coil end portion 31 can be reduced. Miniaturization can be achieved.

  In addition, although illustration is abbreviate | omitted, in the said stator formation process, the wave winding coil 4 can be sequentially arrange | positioned in the some slot 21, and the wave winding coils 4U, V, and W of each phase can also be joined. In this case, the wave winding coil 4 can be assembled to the stator core 2 that is not divided by devising when the slot conductor portions 41 of the wave winding coil 4 are arranged in the slots 21. In this case, the slot 21 can be easily inserted into the slot 21 by making the width in the circumferential direction C of the stator core 2 substantially uniform. .

Explanatory drawing which shows the coil of the U phase in a stator in an Example. Explanatory drawing which shows the V-phase coil in a stator in an Example. Explanatory drawing which shows the coil of the W phase in a stator in an Example. Explanatory drawing which shows the wave winding coil which has two turn structure parts in an Example. Explanatory drawing which shows the one wave winding coil in a stator in an Example. Explanatory drawing which shows typically the one wave winding coil arrange | positioned in a stator core in an Example. Cross-sectional explanatory drawing which shows the slot conductor part and coil end conductor part of a wave winding coil in an Example. Explanatory drawing which expands and shows a part of U-phase coil in a stator in an Example. Explanatory drawing which shows the slot conductor part of the multistage arrange | positioned in the slot in an Example. Explanatory drawing which shows typically the several wave winding coil which comprises the coil of each phase in an Example. Explanatory drawing which shows the corrugated intermediate body shape | molded from the conductor of a cross-sectional substantially round shape in an Example. Explanatory drawing which shows the corrugated intermediate body which flattened each conductor part except the slot conductor part of the one end winding end in an Example. Explanatory drawing which shows the wave winding intermediate body twisted 180 degrees centering | focusing on the slot conductor part of the one side winding end in an Example. Explanatory drawing which shows the state which assembles | assembles a several core formation block to the coil assembly in an Example. Explanatory drawing which shows the state which assembled | attached the several core formation block to the coil assembly in the Example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Stator for motors 2 Stator core 20 Core formation block 21 Slot 22 Teeth 3 Coil 31 Coil end part 30 Coil assembly 4 Wave winding coil 40 Wave winding intermediate body 4A One turn composition part 4B The other turn composition part 41 Slot conductor part 41A Slot conductor portion at the first winding end 41B Slot conductor portion at the one winding end 41C Slot conductor portion at the other winding start 41D Slot conductor portion at the other winding end 42 Coil end conductor portion C Circumferential R diameter direction

Claims (9)

In a stator for a motor having a stator core having a plurality of slots, and a plurality of coils arranged in a distributed winding state with a predetermined number of slots in the plurality of slots,
The coil is formed by alternately connecting the slot conductor portions arranged in the slot by coil end conductor portions arranged to protrude outside the slot at one axial end side and the other axial end side of the stator core. It is configured using wave winding coils,
In the slot, the slot conductor portion is arranged in multiple stages in the radial direction of the stator core,
When the number of the slot conductor portions corresponding to the number of the slots of each phase in the stator core and the coil end conductor portion connecting the slot conductor portions are one turn constituting portion, the wave coil is The two continuous turn components are formed by a single flat conductor that is aligned in the radial direction of the stator core with the flat surface direction of the conductor flattened.
The two turn components are formed by sequentially arranging one slot in the circumferential direction of the stator core from the slot conductor at the first winding end to the slot conductor at the first winding end in the slot. A turn component,
Folded from the slot conductor at the end of the one-side winding, and arranged in the slot sequentially from the slot conductor at the start of the other side to the slot conductor at the end of the other-side winding around the other circumferential direction of the stator core. And the other turn constituent part formed by arranging the slot conductor part at the end of the other side winding in the same slot as the slot conductor part at the end of the one side winding,
The coil end conductor part in the one turn constituent part and the coil end conductor part in the other turn constituent part are alternately arranged in the circumferential direction of the stator core on both sides in the axial direction of the stator core. Yes,
A stator for a motor, wherein a plurality of the wave winding coils composed of the two turn components are joined to form the coil of each phase.   2. The other turn component according to claim 1, wherein the slot conductor at the end of the one-side winding is turned by 180 ° about its central axis, thereby turning back to the one turn component. A stator for a motor. In claim 1 or 2, in the plurality of slots, three-phase coils of U phase, V phase, and W phase formed by joining a plurality of the wave winding coils are arranged, respectively.
The stator for motors, wherein the three-phase wave winding coils are alternately stacked one by one or every predetermined number in the radial direction of the stator core. In any one of Claims 1-3, while the said wave winding coil has the same cross-sectional area in the full length, the cross-sectional area of the said wave winding coils is also the same,
The stator core is formed by joining core forming blocks divided into a number corresponding to the number of the slots in a shape having teeth between the slots in the circumferential direction,
The plurality of slots are formed in a shape in which the width in the circumferential direction increases toward the outside in the radial direction of the stator core,
The stator for a motor, wherein the plurality of stages of slot conductor portions arranged in the slot have a circumferential width that is larger toward a slot conductor portion located radially outward. In a method of manufacturing a stator for a motor having a stator core having a plurality of slots and a plurality of coils arranged in a distributed winding state with a predetermined number of slots in the plurality of slots,
A wave winding intermediate having a plurality of slot conductor portions parallel to each other and a plurality of coil end conductor portions that alternately connect the slot conductor portions at one end side and the other end side is formed from a conductor having a substantially round cross section. In addition, when the number of the slot conductor portions corresponding to the number of slots of each phase in the stator core and the coil end conductor portion connecting the slot conductor portions are one turn constituting portion, the turn constituting portion is A wave winding step of forming the wave winding intermediate in a length constituted by two consecutively;
Except for the slot conductor portion at the end of one side winding in one of the turn components, all the remaining slot conductor portions in the wave winding intermediate body and all the coil end conductor portions are connected to the wave winding intermediate body. A flattening step of flattening in a direction parallel to the plane forming the wave shape;
By twisting the slot conductor portion at the one end of the one side winding by 180 ° around the central axis, the slot conductor portion at the one end of the one side winding and the slot conductor portion at the other end of the other side in the turn component The remaining slot conductor portions excluding are overlapped with the flat surface direction aligned, and the coil end conductor portion in one of the turn constituent portions and the coil end conductor portion in the other turn constituent portion are overlapped. A twisting step of alternately arranging the slot conductor portions in the direction in which the slot conductor portions are arranged at either one end side or the other end side of the slot conductor portion;
An additional flattening step of flattening the slot conductor portion at the end of the one-side winding in accordance with the surface direction in which the corrugated intermediate body is flattened;
A film forming step of forming an insulating film on the surface of the wave winding intermediate to form a wave winding coil having the two turn components;
The wave conductor in a state where the slot conductor portion at the end of one side winding in one of the turn components and the slot conductor portion at the end of other winding in the other turn component are disposed in the same slot. And a stator forming step of forming a stator by arranging a wound coil in the plurality of slots and joining the wave winding coils of each phase to each other. 6. The wave winding step according to claim 5, wherein the interval between the slot conductor portions in the one turn constituent portion is formed larger than the interval between the slot conductor portions in the other turn constituent portion. And
In the stator forming step, the wave winding coil is disposed in the plurality of slots in a state where the one turn component is located on the outer peripheral side of the other turn component. Production method. 7. The stator forming step according to claim 5, wherein a plurality of core forming blocks divided into a number corresponding to the number of the slots in the circumferential direction of the stator core are used as the stator core. Formed into a shape with teeth between slots,
The above-described wave winding coils of each phase are joined to form an annular coil of each phase, and the coils of each phase are overlapped in the radial direction to form an annular coil assembly. By inserting the teeth from outside in the radial direction into the through holes formed between the slot conductor portions and the coil end conductor portions in the appendage, and joining the core forming blocks together, the stator Forming a stator for a motor.   7. The stator for a motor according to claim 5, wherein in the stator forming step, the wave winding coils are sequentially arranged in the plurality of slots, and the wave winding coils of each phase are joined to each other. Method. In any one of Claims 5-8, after the said wave winding process, the said flat process, the said twist process, the said additional flat process, and the said film formation process, the wave of three phases of U phase, V phase, and W phase Forming a wound coil,
In the stator forming step, the three-phase wave winding coils are alternately arranged one by one or every predetermined number in the radial direction of the stator core.

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