JP2009011063A - Stator of rotating electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator of a rotating electric machine having a high winding occupation rate and low coil end, and to provide a manufacturing method having high assemblability. <P>SOLUTION: A stator winding 20 employs a conductor 32 having a rectangular cross section for its wire material 30, and is a shaped winding provided with crank portions 44, 46, 48 on its turn portion 42. The stator includes split cores 12 segmented in a circumferential direction, and the split cores 12 are fixed in interlayer in such a way that soft magnetic thin plate materials each having inclined split surfaces 13a, 13b having a circumferential adjacent surface inclined in a diameter direction are laminated in an opposite inclination direction per predetermined number of sheets and an outer circumferential surface portion 9 of a yoke portion 12a is welded on the outside of a slit 14. With this configuration, the split cores 12 alternately form externally expanding sector-like lap portions 18 respectively with a predetermine laminate thickness on mutual adjacent portions in a circumferential direction in an axial direction. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a split core type stator of a rotating electrical machine and a method for manufacturing the same. The present invention is applied to a stator of a rotary electric machine for driving a hybrid vehicle or an electric vehicle and a manufacturing method thereof.

2. Description of the Related Art In recent years, a rotating electric machine for a hybrid vehicle is desired to have a stator that can reduce the size of a motor and its manufacturing technology because of improved fuel efficiency and restrictions on vehicle mounting. In order to reduce the size, a winding method that can increase the slot space factor of the stator winding (conductor) and reduce the coil end is desirable. FIG. 9 shows a conventional stator (see Patent Document 1). However, the reference numerals in FIG. 9 are irrelevant to the reference numerals in the other drawings describing the embodiment of the present invention. The stator is manufactured by aligning rectangular wires in the slot direction (radial direction) and winding them in an annular shape to pre-configure a shaping coil having the same shape as the stator winding, aligning the coil ends, and weaving them together. They are overlapped at the lap portion and arranged annularly on the outer periphery of the shaping coil, these divided cores are moved radially inward, the shaping coil is inserted into the slot, and the stator is assembled. In addition, the wrap part said above means the site | part where the cores which adjoin the circumferential direction overlap in an axial direction.
Japanese Patent No. 3604326

  According to the above-described conventional stator manufacturing method, the stator winding can be manufactured with a high space factor and a low coil end. However, the stator shown in FIG. 9 has no problem with a vehicular generator having a relatively small core back radial thickness, but is not suitable for a high torque motor such as a motor for driving a vehicle. Since the radial thickness of the (iron portion) is large, the wrap portion of the split core is increased in the radial direction, and the radial length of the slot is also increased. As a result, the moving distance to the inner side in the radial direction of the wrap portion of the split core is increased. As a result, in the above-described conventional method of assembling the stator by moving each divided core radially inward with respect to the shaped coil, there is a problem that the coil insertion work into the slot and the work of assembling the divided core become complicated. It was.

  In addition, in the conventional stator shown in FIG. 9, since the core back of the divided core is divided at a 1-slot pitch, the magnetic resistance of the divided portion is superimposed for each slot, resulting in a decrease in the amount of magnetic flux and a decrease in torque. It was a negative factor for downsizing of rotating electrical machines.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a compact stator capable of improving the coil insertability into the slot and the core assembly property, and a method for manufacturing the same.

  A stator of a rotating electrical machine according to the present invention includes a soft magnetic stator core having a plurality of teeth and slots alternately formed at a predetermined pitch in the circumferential direction, and a yoke portion connecting the radially outer ends of the teeth in the circumferential direction. In a stator of a rotating electrical machine including a plurality of divided cores divided at the yoke portion and a stator winding wound around the slot, the divided core is disposed at one end in the circumferential direction of the yoke portion. An inclined split surface (13a) that monotonously inclines toward the circumferential protruding side as it is positioned and displaced radially outward, and a circumferential direction as it is located at the other circumferential end of the yoke portion and displaced radially outward A soft magnetic thin plate having an inclined divided surface (13b) that monotonously inclines toward the receding side is turned upside down and laminated every predetermined number, and the yoke portions of two divided cores adjacent in the circumferential direction are arranged in the axial direction. The outer expansion that overlaps and meshes with each other It is set to its features in that it has a fan-shaped wrap portion in the axial direction alternately.

  That is, the present invention relates to a stator core (hereinafter referred to as a split core) made of a soft magnetic material divided in the circumferential direction and a stator wound around a slot formed between a plurality of teeth protruding from a yoke portion of the split core. In a stator of a rotating electrical machine composed of windings, a split core is formed by laminating magnetic steel sheet pieces separated by inclined divided surfaces whose adjacent surfaces are inclined in the radial direction in the opposite inclined direction every predetermined number of sheets. A stator yoke portion that is continuous in an annular shape is formed by sandwiching adjacent split cores at the fan-shaped wrap portion. According to the present invention, since the adjacent surfaces of the split cores are inclined in the radial direction, the contact location between the split cores is continuously moved from the outer periphery of the lap portion to the inner periphery, and the stator is set on the inner diameter side. Smooth movement to the winding. Therefore, in a vehicle drive motor with a thick core back and a large slot depth, the core assembly property can be improved and the coil insertion property into the slot is improved. Further, since the core back is divided at least at intervals of two slots, the number of divisions can be halved and the magnetic resistance can be reduced. As a result, it is possible to provide a stator that can reduce the size of the rotating electrical machine without impairing the effect of reducing the size of the shaped winding suitable for high space factor and low coil end.

  In a preferred embodiment, the two inclined division surfaces (13a) and (13b) are inclined in the same direction in contact with or close to each other at the fan-shaped wrap portion. That is, in this aspect, the inclined dividing surface of the divided core has the same direction inclination angle in the fan-shaped wrap portion. For this reason, the overlapping area between the split cores decreases as the wrap portion is positioned on the outer periphery (radially outer side), and gradually increases as it is positioned on the inner periphery (radially inner side). As a result, it is possible to smoothly start the coil insertion that requires fine adjustment for the initial alignment of the core and the coil.

  In a preferred embodiment, the split core includes a parallel slot (14) formed between two teeth (12b, 12b) extending radially inward at a certain distance in the circumferential direction, and the two teeth ( 12b, 12b)) and a half slot with a half width in the circumferential direction formed on the outer side in the circumferential direction. That is, in this aspect, the split core is provided with two teeth, the side wall from the opening at the center of the stator core inner diameter to the inner diameter is parallel, and the parallel slot in which the center line of the side wall intersects the center of the stator core inner diameter; One slot side wall is provided on the opposite side of the two teeth. For this reason, the split core can be moved to the stator inner diameter side using both side walls of the parallel slot as a guide, the insertion of the slot accommodating portion of the stator winding becomes smooth, and the assembling property of the stator core is improved.

  In a preferred aspect, the portion of the maximum radius of curvature of the outer peripheral surface portion of the split core is formed on a radial extension line of the circumferential intermediate point of the parallel slot (14), and the outer peripheral surface portion of the split core is in the peripheral direction. The stator core is formed smaller than the maximum radius of the outer peripheral surface of the stator core. For this reason, even if the slot accommodating portions of the stator windings to be aligned in a line in the radial direction are slightly deviated from the radial direction and the split core is deflected with respect to the stator center, the stator core is restored to the center with respect to the split core. By applying a force in the direction, the split core can be moved to the inner diameter side of the stator while suppressing the deflection, the insertion of the slot accommodating portion of the stator winding becomes smooth, and the assembling property of the stator core is improved.

  In a preferred aspect, the split core includes a claw-like protrusion (16) projecting at an acute angle at the radially outer end of the inclined split surface (13a), and a radial direction of the inclined split surface (13b). It has a chamfered portion (17) which is formed by chamfering at the outer end portion and is in contact with or close to the claw-like projection (16). That is, according to this aspect, the claw-like protrusion is provided at the acute angle portion that is the portion on the one side in the circumferential direction of the divided core, and the chamfered portion is provided at the obtuse angle portion that is the portion on the other side in the circumferential direction of the divided core. For this reason, the divided cores can be fixed in an annular shape by pressing the claw-like projections from the outer diameter side and plastically deforming them until they come into contact with the chamfered part of the obtuse angle part.

  In a preferred aspect, the claw-shaped protrusion (16) and the tip end portion in the circumferential direction of the inclined divided surface (13a) are chamfered so as to be thin in the axial direction. As a result, the split core can be smoothly assembled without being caught at the beginning of assembly, and the core can be easily assembled.

  In a preferred embodiment, the inclined divided surfaces (13a, 13b) of the divided core are inclined by 1/2 to 1 slot substantially in the circumferential direction. When the inclined dividing surface is inclined by approximately 1/2 slot, the claw-like projections press down the outer periphery of the center of the teeth, so that firm fixation can be performed. In addition, when the inclined dividing surface is inclined by approximately 1 slot, the claw-like projections are aligned in a line in the axial direction (stacking direction) with one slot jumping, so that the pushing-down process from the outer diameter side can be simplified.

  In a preferred aspect, the split core is a chamfered radial portion (13c) formed by chamfering at a corner portion defined by the inclined split surface (13a) and an outer peripheral surface portion of the split core (12). The radial chamfered portion (13c) and the chamfered portion (17) are formed with a V-shaped groove portion (8) for joining in the stator core lamination direction. That is, in this aspect, the split core has a radial chamfered portion at a corner portion where the inclined divided surface and the outer peripheral surface are close to each other at an acute angle, and the radial chamfered portion and the other of the inclined divided surface face each other. Since the V-shaped groove for bonding in the stacking direction is formed, it is not necessary to provide an extra V-shaped groove for bonding.

  In a preferred embodiment, the inclined dividing surfaces (13a, 13b) are inclined by one slot in the circumferential direction. For this reason, since the V-shaped groove portions for joining in the core lamination direction are aligned in a line in the axial direction (stacking direction) with one slot jump, the joining (welding) process can be shortened.

  In a preferred aspect, the distal end portion of the radial chamfered portion (13c) is chamfered and thinned in the stacking direction. Thereby, the division | segmentation core assembly | attachment can be performed smoothly without being caught, and a core assembly | attachment becomes easy.

  In a preferred aspect, the inner wall surface of the slot of the stator core is covered with an insulating resin layer. Thus, the conventional slot insulating paper can be omitted, and the stator winding can be easily assembled with the slot accommodating portion.

  In a preferred embodiment, the insulating resin layer is formed by electrodeposition coating. For this reason, the insulating resin layer does not become too thick, and the space factor of the coil can be improved.

  In a preferred aspect, the stator winding is formed by winding a wire having an insulating film that is formed by extrusion molding and covers the outer peripheral surface of a conductor having a rectangular cross section. For this reason, the interphase insulating paper conventionally required for countermeasures against partial discharge (corona discharge) can be eliminated, and winding is facilitated. Further, since the coil conductor has a rectangular cross-sectional shape, the slot space factor of the coil can be improved.

  In a preferred aspect, the stator winding has an inner layer insulating film (34) covering an outer peripheral surface of a conductor having a rectangular cross section, and has a glass transition temperature lower than that of the inner layer insulating film (34) and has the inner layer insulating film. Each slot accommodating portion 40 of the stator winding (20) accommodated in one slot has an outer layer insulating film (36) that covers the film (34), and is arranged at least in the radial direction. Thereby, it has an outer-layer insulating film with a low glass transition temperature. When the temperature is high, the outer layer insulating film is softened before the inner layer, and the wires in the same slot are thermally bonded to each other so as to be aligned and integrated in the radial direction, whereby the mechanical strength can be improved.

  A method of manufacturing a stator for a rotating electrical machine according to the present invention includes a plurality of teeth and slots alternately formed at a predetermined pitch in the circumferential direction, and a soft magnetic having a yoke portion that connects the radially outer end portions of the teeth in the circumferential direction. A multi-phase stator in which a plurality of split cores obtained by splitting the stator core at the yoke portion is prepared, and four or more slot accommodating portions having a substantially rectangular cross section to be accommodated in the slots are arranged in the radial direction. The winding is manufactured by distributed winding, and each of the divided cores is annularly arranged on the radially outer side of the stator winding, and then moved radially inward to form the stator core and the slot accommodating portion of the stator winding. In the stator of the rotating electrical machine, wherein the divided core has two teeth (12b, 1) extending across an odd-numbered slot (14). b) and a gap portion corresponding to a half slot which is provided on both circumferential sides of the two teeth (12b, 12b) and finally becomes an even-numbered slot (15). . According to the present invention, a high slot space factor can be realized while simplifying the manufacturing process by the split core type stator.

  This will be further described below.

  As the stator coil, a concentrated winding coil and a distributed winding coil are known. The former can shorten the coil end, but is inferior to the latter in terms of torque ripple and average output when the diameter of the stator core is equal. For this reason, distributed winding is the mainstream in many motors. However, the distributed winding stator coil has a problem that the coil winding operation becomes complicated and the slot space factor cannot be increased. For this reason, it is conceivable that the stator coil is manufactured in a completed form in advance before being inserted into each slot of the stator core, and the stator core is completed by fitting the stator coil into the split core. In this case, since the stator coil can be molded in advance, it can be accommodated in the slot with a high slot space factor using a flat wire conductor. In order to increase the output of the motor, the radial length is greatly increased with respect to the circumferential width of the slot to form a deep slot, and rectangular wire conductors, that is, wires are stacked in multiple stages of four or more layers in the radial direction. It is important to increase electrical loading.

  However, in the step of manufacturing the stator core by each divided core, the divided core is essentially moved radially inward (that is, in the diameter reduction direction) of the motor. For this reason, there is no problem when the diameter of the split core is reduced in parallel with the line connecting the circumferential center positions of the slot portions. However, for example, three slots are provided in one split core, and When the diameter of the split core is reduced in parallel with the line connecting the circumferential center positions, the lines connecting the circumferential center positions of the respective portions of the slots on both sides in the circumferential direction do not coincide with the moving direction of the split core. Then, it turned out that it becomes difficult to fit the slot accommodating part of the molded stator coil in a slot. This problem can be solved by dividing the yoke portion of the stator core at an intermediate position in the circumferential direction of each slot. However, in this case, the magnetic resistance increases and it is difficult to ensure the rigidity of the stator core.

  The present invention is a drastic solution to this problem, and each of the divided cores is provided with two teeth on both sides in the circumferential direction with one parallel slot interposed therebetween, and further, a half slot is provided on the outer side in the circumferential direction of these two teeth. A minute gap is provided. In this way, by reducing the diameter of each divided core in the direction in which the line connecting the circumferential midpoints of the parallel slots and the direction of movement of the divided cores coincide with each other, the slot accommodating portion of the stator coil is placed in this one parallel slot. We can pay without problem. Further, since the slots on both sides of this one parallel slot are divided in half in the circumferential direction, the stator coil can be satisfactorily inserted into the gap between the two slot accommodating portions adjacent to each other in the circumferential direction, When the diameter of the split core is reduced, it is possible to satisfactorily suppress the problem that the tip end portion of the tooth is caught by the slot accommodating portion, and it is possible to manufacture a stator of a rotating machine with high productivity and reliability.

  Hereinafter, preferred embodiments of a stator of the present invention will be described with reference to the drawings.

(First embodiment)
(Basic structure of stator)
A stator according to the first embodiment is shown in FIG.

  A stator 10 shown in FIG. 5 is used for a vehicle-driven generator motor. 10 is a stator, 11 is a stator core, 12 is a split core, and 20 is a stator winding. A rotor (not shown) is rotatably accommodated inside the stator 10 in the radial direction. A large number of magnetic poles having different polarities alternately in the circumferential direction are formed by permanent magnets on the outer periphery of the rotor. The outer peripheral surface of the rotor faces the inner peripheral surface of the stator 10 via a minute air gap. The stator core 11 is configured by annularly combining a number of divided cores 12 formed by laminating electromagnetic steel plates having a predetermined thickness in the axial direction. The stator core 11 has odd-numbered slots 14 and even-numbered slots 15. As shown in FIG. 1, one split core 12 is composed of split cores 12 that are adjacent to each other at the core back (joint portion) adjacent to the bottom of the slot 15. In this embodiment, the stator core 11 is not divided at the core back portion adjacent to the bottom of the slot 14, and the number of divisions is halved compared to the conventional one. The split core 12 will be described in detail later. The stator winding 20 is wound by three-phase wave winding, and the stator winding 20 having the same phase is wound around the two adjacent slots 14 and 15. That is, in this embodiment, a configuration of 2 slots per phase per pole is adopted. In order to ensure insulation between the stator winding 20 and the stator core 11, slot insulation paper 80 (not shown) is provided on the inner walls of the slots 14 and 15.

(Wire 30)
The structure of the coil conductor of the stator winding 20, that is, the wire 30, will be described with reference to FIG.

  The wire 30 of the stator winding 20 is composed of a conductor 32 having a rectangular cross-section made of copper. The outer peripheral surface of the conductor 32 is covered with a resin inner layer insulating film 34, and a resin outer layer insulating film 36 is formed on the outer side thereof. The inner insulating film 34 is made of an enamel layer such as polyamideimide, and the outer insulating film 36 is formed of an extrusion-coated resin layer such as PPS. The total thickness of the insulating film including the inner layer insulating film 34 and the outer layer insulating film 36 is set to 100 μm to 170 μm. Thereby, the partial discharge (corona discharge) by a surge voltage can be prevented only with these insulating films. Conventionally, insulating paper is required between the winding phases having a high potential difference. However, the insulating paper can be omitted by the insulating film having the two-layer structure, and the winding work is facilitated.

(Shape of stator winding 20)
The shape of the stator winding 20 will be described with reference to FIG.

  The stator winding 20 includes a slot accommodating portion 40 accommodated in each of the slots 14 and 15 of the stator core 11 and two slot accommodating portions 40 extending in the axial direction and the circumferential direction and separated from each other by approximately one magnetic pole pitch in the circumferential direction. It has the turn part 42 which connects edge parts in the axial direction both ends of the stator core 12. As shown in FIG.

  A crank portion (head top portion) 44 that extends in the circumferential direction without protruding outward in the axial direction is formed in the central portion of the turn portion 42. The wire 30 extends in the circumferential direction at the crank portion 44 and is skewed by the radial width so as to be displaced in the radial direction, and both ends of the crank portion 44 are shifted in the radial direction by the radial width. Yes. In other words, one end and the other end of the crank portion 44 are displaced in the radial direction by the radial width of the wire 30. This shift is formed continuously from one end of the crank portion 44 to the other end, and the crank portion 44 is skewed in the radial direction as it is displaced in the circumferential direction. The circumferential width of the skewed crank portion 44 is approximately one slot pitch, and the crank portions 44 of each turn portion connected to the slot accommodating portion at the same radial position of the slot are arranged at equal positions in the axial direction. Thereby, since the turn part 42 of the mutually adjacent wire 30 can be arrange | positioned with high density, the swelling of a coil end can be reduced. Further, as shown in FIG. 1B, the turn part 42 connected to the slot accommodating part 40 in the slot adjacent to this one slot is different from the turn part 42 connected to the slot accommodating part 40 in one slot. It arrange | positions so that it may adjoin to an axial direction. Thereby, the swelling of a coil end can be reduced. A crank portion 46 that extends along the end surface 13 of the stator core 11 in the circumferential direction (precisely tangential direction) is formed at the end of the turn portion 42 that is continuous with the end of the slot accommodating portion 40. Thereby, the height of a coil end can be reduced. That is, the coil end height can be lowered even with full-pitch winding by the same geometric effect as short-pitch winding with a coil side pitch shorter than the pole pitch. Further, the turn portion 42 has a crank portion 48 that is located in the middle between the end portion and the top portion of the turn portion 42 and extends in the circumferential direction in the same manner as the crank portion 46 at an interval of one slot. Thereby, coil end height can be made still lower.

  After all, in this embodiment, the slot space factor can be increased by using the conductor 32 having a rectangular cross section. Further, since the crank portion 46 and the crank portion (the top portion) 44 are provided in the turn portion 42 of the stator winding 20 and the intermediate crank portion 48 is provided in two stages, a low and compact coil end can be realized. . Furthermore, since each side of the rectangular cross section of the conductor 32 extends in the radial direction and the circumferential direction, the bending of the crank portions 44, 46, 48 is simplified. Furthermore, since the rigidity of the turn part 42 after the crank parts 44, 46 and 48 are formed by bending is increased, it is possible to satisfactorily suppress the vibration of the coil end accompanying the operation of the rotating electrical machine.

(Split core 12)
An example of a method for winding the divided core 12 and the above-described stator winding 20 around the stator core 11 will be described with reference to FIGS. 1 and 2. FIG. 1A is a partial plan view of the stator core 11 after the stator winding 20 is assembled, and FIG. 1B is a partial front view of the stator 10 after the stator winding 20 is assembled. FIG. 1B shows two divided cores 12 adjacent to each other. 2A is a partial plan view of the stator core 11 before the stator winding 20 is assembled, and FIG. 2B is a partial front view of the stator 10 before the stator winding 20 is assembled. FIG. 2B shows two divided cores 12 adjacent to each other. However, the turn part 42 of the stator winding 20 is omitted, and the cross section of the wire 30 of the slot accommodating part 40 is shown in a simplified manner.

  The split core 12 is configured by laminating soft magnetic thin plate materials such as electromagnetic steel plates in the axial direction. Each split core 12 has a yoke part (back yoke) 12a and two teeth 12b projecting radially inward from the yoke part 12a. The teeth 12b protrude toward the axis, and a slot 14 is formed between the two teeth 12b. The circumferential width of the slot 14 is constant at each radial position. That is, the two side surfaces of the slot 14 are parallel slots from the opening portion 19a at the radially inner end of the slot 14 to the inner diameter portion 19b, and the line connecting the circumferential intermediate points of the two side surfaces is , Extending radially through the motor shaft.

  The radially inner end of the yoke portion 12a protrudes in the circumferential direction by approximately half the circumferential width of the slot 15 from the side surface on the outer side in the circumferential direction of the tooth 12b. The two teeth 12b are individually formed with side walls 15a and 15b for the slots on both sides in the circumferential direction with the slot 14 in between. For this reason, when the yoke portions 12a of the two split cores 12 are combined, the circumferential width of the slot 15 is defined by the radially inner end portions of the yoke portions 12a that are in contact with each other. Therefore, one divided core 12 has slots 15 by half slots adjacent to the outer surfaces on both sides in the circumferential direction of the teeth 12b.

  The shape of the yoke portion 12a of the split core 12, particularly the shape of the contact surface thereof, will be further described with reference to FIG. One soft magnetic thin plate material of the yoke portion 12a is inclined and divided so as to incline toward the circumferentially protruding side from the radially inner end facing the slot 15 toward the radially outer end forming the outer circumferential surface of the stator core 11. It has surfaces 13a and 13b. The inclined division surface 13a of the yoke portion 12a is inclined so as to protrude in the circumferential direction as it goes outward in the radial direction, and the inclined division surface 13b of the yoke portion 12a is retracted in the circumferential direction as it goes outward in the radial direction. It is inclined to. The inclined divided surface 13a of one soft magnetic thin plate member belonging to one divided core 12 is in contact with the inclined divided surface 13b of one soft magnetic thin plate member belonging to another divided core 12 adjacent in the circumferential direction. Yes.

  As shown in FIGS. 1 and 2 (A), a large number of soft magnetic thin plate materials that are laminated in the axial direction to constitute each divided core 12 are a predetermined number of sheets adjacent to each other (3 in FIGS. 1 and 2 (A)). Are turned inside out. For this reason, the two divided cores 12 adjacent to each other have a meshing structure, and the magnetic resistance is reduced. The split core 12 is interlayer-fixed in the stacking direction by a joining means such as laser welding at a circumferential intermediate position of the slot 14 (arrow position in FIG. 2B). Thereby, as shown to FIG. 1, FIG. 2 (B), as for the split core 12, the circumferential direction both ends of the yoke part 12a are the next yoke part centering on the radial direction inner side edge part of the yoke part 12a. The fan-shaped wrap portion 18 is overlapped with 12a in the axial direction. The inclined divided surfaces 13a and 13b of the divided core 12 have a shape with an inclination angle in the same direction so as to facilitate the engagement at the portions of the fan-shaped wrap portions 18 that overlap each other in the axial direction.

  That is, the three sheets of soft magnetic thin plate material of the split core 12 on the front side of the drawing have an inclination that goes to the upper right as going outward in the radial direction, and the next three soft magnetic thin plate materials move leftward in the radial direction. It has an upward slope and is alternately combined every three sheets.

  Reference numeral 16 denotes a claw-shaped protrusion that is provided at the end on the acute angle side of both end portions in the circumferential direction of the yoke portion 12 a and protrudes in the circumferential direction. Therefore, the claw-shaped protrusion 16 is the radial direction of the fan-shaped wrap portion 18. It is provided at the outer end. Reference numeral 17 denotes a chamfered portion provided at an end portion on the obtuse angle side of both end portions in the circumferential direction of the yoke portion 12a. The claw-like protrusion 16 of one split core 12 has a shape that comes into contact with the chamfered portion 17 of the adjacent split core 12. The claw-shaped protrusion 16 is pushed down until it comes into contact with the chamfered portion 17 by pressing the claw-shaped protrusion 16 from the radially outer side to the radially inner side in order to fix the divided cores 12 to each other. Thereby, the split cores 12 are fixedly fixed in an annular shape. Furthermore, in this embodiment, the claw-shaped protrusion 16 and the inclined divided surface 13a fitted into the fan-shaped wrap portion 18 are chamfered for easy assembly.

  The claw-like projections 16 provided at the radially outer end of the inclined dividing surface 13a are formed so as to be located on the radially outer side of the teeth 12b, particularly on the circumferential center of the teeth 12b. As a result, when the claw-shaped protrusion 16 is pressed inward in the radial direction, the teeth 12b can receive it, so that it is possible to realize strong adhesion between the claw-shaped protrusion 16 and the chamfered portion 17 in contact therewith. Note that the inclination angle of the inclined divided surfaces 13a and 13b may be further increased. For example, when the inclined dividing surfaces 13a and 13b are inclined by one slot, the claw-like projections 16 can be aligned in a line in the axial direction (stacking direction) by skipping one slot, and the pushing-down process from the outer diameter side can be shortened.

  The split core 12 has a radius of curvature of the arcuate outer peripheral surface portion of the yoke portion 12a smaller than the radius of curvature of the stator outermost diameter in order to obtain good assemblability even if the stator winding 20 has a large variation in shape. The intersection of the center line of the side wall of the parallel slot and the outer peripheral surface portion is formed smaller than the outermost diameter portion of the stator. With the split core 12 having such a shape, even if the split core 12 is deflected with respect to the center of the stator due to a radial shift of the slot accommodating portion 40 of the stator winding that should be aligned in a row in the radial direction. A restoring force in the center direction can be applied. Thereby, the core can be moved to the stator inner diameter side while suppressing the deflection of the split core 12, the insertion of the slot accommodating portion 40 becomes smooth, and the assembling property of the stator core 11 is improved.

(Assembly process)
A process of winding the stator winding 20 around the stator core 11 and combining the split cores 12 in an annular shape to form the stator core will be described with reference to FIGS.

  First, as shown in FIG. 2, the stator winding 20 is formed so that the wires 30 of the slot accommodating portion 40 of the stator winding 20 are arranged at positions where they are accommodated in the slots 14 and 15. In this embodiment, the wire rod 30 of the slot accommodating portion 40 of the stator winding 20 is a wave winding coil arranged in slots 14 and 15 in the radial direction.

  Next, half the number of the split cores 12 is arranged in an annular shape outside the stator winding 20 in the radial direction. Next, after the adjacent divided cores 12 are combined at the end of the fan-shaped wrap portion 18, each divided core 12 is moved inward in the radial direction, and the slot accommodating portion 40 of the stator winding 20 and the slot insulating paper surrounding it. 80 are loaded into the slots 14 and 15. As a result, the two adjacent divided cores 12 and 12 are in the state shown in FIG. 1, and the adjacent divided cores 12 are sandwiched in the axial direction by the fan-shaped wrap portion 18, and as a result, a strong structure connected in an annular shape. The stator coupling portion 11a is formed on the yoke portion 12a. A wedge 82 made of an insulating resin or the like is inserted in the openings 19 a of the slots 14 and 15 in the axial direction, and the slot accommodating portion 40 is sealed in the slots 14 and 15.

(Second Embodiment)
A second embodiment of the present invention will be described with reference to FIGS. FIG. 6 is a schematic perspective view showing a state where two divided cores 12 are being assembled, FIG. 7 is a partial perspective view showing a state after the assembly, and FIG. 8 is a plan view of the stator. However, FIGS. 6 and 7 show only the stator core, and illustration of the stator winding 20 is omitted.

  In FIG. 6, the split core 12 is made of a soft magnetic thin plate material such as an electromagnetic steel plate, and has a yoke portion 12 a and two teeth 12 b that protrude radially inward from the yoke portion 12 a. The slot 14 provided between the two teeth 12b is a parallel slot defined by two parallel side walls from the opening 19a to the inner diameter portion 19b. A line connecting the circumferential intermediate points between these two side walls extends in the radial direction and reaches the motor shaft center. In the two teeth 12b, side walls 15a and 15b are individually formed on the opposite sides of the slot 14, and the slots 15 are formed in half.

  The split core 12 is formed by turning over and stacking a predetermined number of soft magnetic thin plate materials having inclined split surfaces 13a and 13b individually at both ends in the circumferential direction of the yoke portion 12a. The respective soft magnetic thin plate members are bonded to each other by laser welding the outer peripheral surface portion 9 of the yoke portion 12a located on the outer side in the circumferential direction of the slot 14 in the axial direction. Positioned in the circumferential contact portion of each divided core 12, the yoke portion 12 a has a fan-shaped wrap portion 18 that spreads outward, and the sector-shaped wrap portions 18 are alternately stacked in the axial direction by the predetermined number. .

  In this embodiment, the inclined division surfaces 13a and 13b formed at both circumferential ends of the yoke portion 12a are obliquely provided in a substantially straight line. A corner portion formed by the radially outer end portion of the inclined dividing surface 13a and the outer peripheral portion of the yoke portion 12a is chamfered to form a radially chamfered portion 13c. As a result, in the assembled state (see FIG. 7), the V-shaped groove portion 8 is formed between the radial chamfered portion 13c and the inclined divided surface 13b facing the circumferential direction. The V-shaped groove portion 8 is formed linearly in the axial direction by the number of laminated soft magnetic thin plate materials. When laser welding is performed in the V-shaped groove portion 8, there is no flow of molten liquid and high quality bonding is possible, and there is no need to add a step of providing a V-shaped groove portion for bonding.

  Further, in this embodiment, as shown in FIG. 7, the inclined division surfaces 13a and 13b are inclined by one slot pitch in the circumferential direction. As a result, as shown in FIG. 8, the V-shaped groove portions 8 for core lamination direction joining can be aligned in a line in the axial direction (lamination direction) with one slot jumping, so that the joining process by laser welding or the like is shortened. be able to.

  Also in this embodiment, the core assembly is facilitated by chamfering the stacking direction end face 13d (see FIG. 6) of the radial chamfer 13c of the split core 12. As a result, it is possible to reduce the catch between the tips of the fan-shaped wrap portion 18 at the beginning of the divided core assembly and to perform smooth assembly.

  In this embodiment, the inner walls of the slots 14 and 15 of the stator core 11 are coated with an insulating resin layer (not shown), thereby making it easy to assemble the stator winding 20 by omitting the slot insulating paper 80. it can.

  In addition, the insulating resin layer provided on the inner wall of the slot is formed by electrodeposition coating. Thereby, the space factor of the slot accommodating part 40 of the stator winding | coil 20 can be improved, without impairing productivity.

(Third embodiment)
Differences of the third embodiment of the present invention will be described with reference to FIG. FIG. 4 is a cross-sectional view of the wire 30 of the stator winding 20. The wire 30 of the stator winding 20 covers the outer peripheral surface of the conductor 32 having a rectangular cross section with an inner insulating film 34 made of a thermoplastic resin having a relatively high glass transition temperature or a polyamideimide having no glass transition temperature. Furthermore, the outer peripheral surface of the inner insulating film 34 is covered with an outer insulating film 36 such as nylon having a relatively low glass transition temperature. As a result, at a high temperature, the outer layer insulating film 36 is softened before the inner layer insulating film 34 and the wires 30 in the same slot are thermally bonded to each other, and they are integrated in a state in which they are aligned in the radial direction. The mechanical strength of the winding 20 can be improved. In addition, even if excessive vibration or the like is applied, the adhesion portion between the inner insulating film 34 and the outer insulating film 36 is first peeled off, so that the adhesion between the inner insulating film 34 and the conductor 32 can be maintained, and the conductor 32 is maintained. The electrical insulation can be ensured.

(Other embodiments)
In the above embodiment, a conductor having a rectangular cross-sectional shape is used as the wire 30 of the stator winding 20, but a round wire having a circular cross-sectional shape that is easily available may be used, and only the slot accommodating portion 40 may be pressed to obtain a flat cross-sectional shape. . As described above, the present invention is not limited to the above-described embodiment, and can be applied to various embodiments without departing from the gist thereof.

It is a figure which shows the state which assembled | attached the stator core and stator winding of 1st Embodiment, FIG. 1 (A) is a partial top view of the stator core after a stator winding is assembled | attached, FIG. 1 (B) is a stator winding. It is a partial front view of the stator after assembling. It is a figure which shows the state in the middle of assembling the stator core and stator winding of 1st Embodiment, FIG. 2 (A) is a partial top view of the stator core in the middle of assembling a stator core, FIG.2 (B) is a stator winding. It is a partial front view of the stator in the middle of an assembly. (A) is a perspective view which shows the shape of the wire used for 1st Embodiment, (B) is a fragmentary perspective view which shows the state which wound this wire around the stay core. It is sectional drawing of a wire. It is a whole perspective view of a stator. It is a fragmentary perspective view which shows the assembly middle state of the stator core of 2nd Embodiment. It is a fragmentary perspective view of the assembled stator core of 2nd Embodiment. It is a top view of the stator of a 2nd embodiment. (A) is a front view of a conventional stator, and (B) is a plan view thereof.

Explanation of symbols

8 V-shaped groove portion 9 Outer peripheral surface portion 10 Stator 11 Stator core 11a Stator coupling portion 12 Divided core 12a Joint portion 12b Teeth 13 End surface 13a Inclined divided surface 13b Inclined divided surface 13c Radial chamfered portion 13d Laminated direction end surface 14 Slot 15 Slot 15a Side wall 16a Claw-shaped projection portion 17 Chamfered portion 18 Fan-shaped lap portion 19a Opening portion 19b Inner diameter portion 20 Stator winding 30 Wire material 32 Conductor 34 Inner layer insulating coating 36 Outer layer insulating coating 40 Slot accommodating portion 42 Turn portion 44 Crank portion 46 Crank portion 48 Crank portion 80 slot insulation paper 82 wedge

Claims (14)

A soft magnetic stator core having a plurality of teeth and slots alternately formed at a predetermined pitch in the circumferential direction and a yoke portion connecting the radially outer ends of the teeth in the circumferential direction is divided by the yoke portion. In a stator of a rotating electrical machine comprising a plurality of divided cores and a stator winding wound around the slot,
The split core is
It is located at one end in the circumferential direction of the yoke part and is located at the other end in the circumferential direction of the yoke part, and an inclined division surface (13a) that monotonously inclines toward the circumferentially protruding side as it is displaced radially outward. A soft magnetic thin plate material having an inclined divided surface (13b) that monotonously inclines toward the circumferentially receding side as it is displaced radially outward, and is turned upside down and laminated every predetermined number of sheets,
A stator of a rotating electrical machine, wherein yoke portions of two split cores adjacent to each other in the circumferential direction have fan-shaped wrapping portions extending outwardly and overlapping each other in the axial direction. The stator of the rotating electrical machine according to claim 1,
The stator of a rotating electrical machine according to claim 2, wherein the two inclined divided surfaces (13a) and (13b) are in contact with or close to each other at the fan-shaped wrap portion and are inclined in the same direction. In the stator of the rotating electrical machine according to claim 1 or 2,
The split core includes a parallel slot (14) formed between two teeth (12b, 12b) extending radially inward at a certain distance in the circumferential direction, and the two teeth (12b, 12b)). A stator for a rotating electrical machine comprising a bifurcated split core having a half slot with a half width in the circumferential direction formed on the outer side in the circumferential direction. In the stator of the rotating electrical machine according to any one of claims 1 to 3,
A portion of the maximum radius of curvature of the outer peripheral surface portion of the split core is formed on a radial extension line of the circumferential intermediate point of the parallel slot (14), and the outer peripheral surface portion of the split core is connected in the peripheral direction. A stator for a rotating electrical machine that is smaller than the maximum radius of the outer peripheral surface of the rotating electric machine. The stator of the rotating electrical machine according to any one of claims 2 to 4,
The split core is chamfered at a claw-like protrusion (16) projecting at an acute angle at the radially outer end of the inclined split surface (13a) and at a radially outer end of the inclined split surface (13b). A stator for a rotating electrical machine, which is formed and has a chamfered portion (17) in contact with or close to the claw-shaped protrusion (16). The stator of the rotating electrical machine according to claim 5,
A stator for a rotating electrical machine in which the claw-shaped protrusions (16) and the circumferential tip portions of the inclined dividing surfaces (13a) are chamfered so as to be thin in the axial direction. In the stator of the rotating electrical machine according to claim 5 or 6,
The stator of a rotating electrical machine in which the inclined divided surfaces (13a, 13b) of the divided core are inclined by approximately 1/2 to 1 slot in the circumferential direction. The stator of the rotating electrical machine according to claim 5,
The divided core has a radial chamfered portion (13c) formed by chamfering at a corner portion defined by the inclined divided surface (13a) and an outer peripheral surface portion of the divided core (12), The said radial direction chamfer part (13c) is a stator of the rotary electric machine by which the V-shaped groove part (8) for stator core lamination direction joining is formed with the said chamfer part (17). The stator of the rotating electrical machine according to claim 8,
The stator of a rotating electrical machine in which the inclined division surfaces (13a, 13b) are inclined by one slot in the circumferential direction. The stator of the rotating electrical machine according to claim 9,
The tip of the radial chamfered portion (13c) is a stator of a rotating electrical machine that is chamfered and thinned in the stacking direction. The stator of the rotating electrical machine according to any one of claims 1 to 10,
A stator of a rotating electrical machine, wherein an inner wall surface of a slot of the stator core is covered with an insulating resin layer. The stator of the rotating electrical machine according to claim 11,
The insulating resin layer is a stator of a rotating electric machine formed by electrodeposition coating. The stator of the rotating electrical machine according to any one of claims 1 to 12,
The stator winding is a stator of a rotating electrical machine formed by winding a wire having an insulating coating that is formed by extrusion and covers an outer peripheral surface of a conductor having a rectangular cross section. The stator of the rotating electrical machine according to any one of claims 1 to 13,
The stator winding has an inner insulating film (34) covering an outer peripheral surface of a conductor having a rectangular cross-sectional shape, and an inner insulating film (34) having a glass transition temperature lower than that of the inner insulating film (34). An outer layer insulating coating (36) to be coated;
Each slot accommodating portion 40 of the stator winding (20) accommodated in one slot is a stator of a rotating electrical machine that is arranged at least in the radial direction.

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