JP2009106045A - Rotating electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a rotating electric machine suppressing an increase in inductance of a stator winding. <P>SOLUTION: A stator core at each phase is independently arranged in a rotational-axis direction and a magnetic pole of the each stator core is arranged in a peripheral direction as a rotational direction. Grooves extending in a rotational-axis direction are formed between magnetic poles, and the stator winding is disposed in a rotational-axis direction. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a rotating electrical machine including a stator and a rotor, for example, an induction motor including a stator and a rotor, a magnet-type rotating electrical machine including a rotor having a magnet, or a rotor having a reluctance barrier structure. The present invention relates to a reluctance type rotating electric machine.

  In conventional rotating electric machines such as motors and generators, the stator windings are complicated, which has a great problem in terms of productivity. As a rotating electrical machine that improves productivity, a claw pole type rotating electrical machine described in, for example, “JP 2006-296188 A” (Patent Document 1) is known.

JP 2006-296188 A

  The claw pole motor type rotating electrical machine described in Patent Document 1 has a problem that the inductance of the stator winding is large. For example, when the inductance of the stator winding increases in a motor or generator, there is a problem that the phase difference between current and voltage increases and the power factor, which is a main characteristic of the motor and generator, is reduced.

  An object of the present invention is to provide rotating electricity that is excellent in productivity of a stator and that can reduce an increase in inductance of a stator winding.

  One of the features of the present invention is that it has a stator and a rotor, and the stator has at least two rotor cores arranged side by side in the rotational axis direction, and each rotor core is in the circumferential direction. It has a plurality of magnetic poles arranged in the rotation direction, and a stator winding is arranged between the magnetic poles.

  Another feature of the present invention includes a stator and a rotor, and the stator has at least two rotor cores arranged side by side in the rotation axis direction, and each rotor core is arranged in the circumferential direction. A plurality of magnetic poles, grooves are formed between the magnetic poles in the direction of the rotation axis, and stator windings are arranged in the grooves.

  According to the present invention, there is an effect that an increase in inductance of the stator winding can be suppressed or reduced.

  According to the embodiment described below, since there is no axially extending claw provided between the circumferential stator winding and the rotor surface, which is found in a general claw pole type stator, There is an advantage that it is easy to produce a stator core.

  In the following embodiments, since there is no claw having a shape extending in the rotation axis direction between the circumferential stator winding and the rotor surface and interlinking with the stator winding, the inductance of the stator winding Is lower than that of a general claw pole type stator.

  Compared to a general claw-pole type stator, the area of the magnetic body that encloses the stator winding 122 is small, so that the inductance of the stator winding can be greatly reduced.

  In the following embodiments, the stator windings are arranged in the rotation axis direction and the rotor cores are arranged in phase units and arranged in the rotation axis direction as in a general slot tooth type rotating electrical machine. The stator winding has a shape that is easy to produce, and has an effect of excellent productivity.

  In the following embodiments, since the stator winding is arranged in the rotation axis direction between the magnetic poles arranged in the circumferential direction, the rotor-side facing surface of the stator magnetic pole is opposed to a general claw pole type magnetic pole. Can be increased and efficiency is improved.

  In the following embodiments, the stator magnetic poles are formed by stacking the stator cores in the axial direction, so that iron loss due to eddy current can be greatly reduced.

  In the following embodiments, since laminated steel sheets are used, there is an effect that the mechanical strength is very strong as compared with the case where a dust core is used.

[Description of the basic structure of the stator]
A basic configuration of a stator according to an embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a perspective view showing a basic configuration of a stator according to an embodiment of the present invention. FIG. 2 is another example of the basic configuration of the stator shown in FIG. 1, and is an example in which a hook is provided on each tooth of the basic configuration according to the embodiment of FIG. 2A is an overall view of the basic configuration of a stator according to another embodiment, and FIG. 2B is a partial cross-sectional view of the basic configuration of the stator shown in FIG. 2A. FIG. 2C is a partial cross-sectional view in which the viewpoint of the basic configuration of the stator shown in FIG. 2A is further changed, and FIG. 2D is a rotation axis of the basic configuration of the stator shown in FIG. It is a vertical partial sectional view. 3 is a perspective view showing a stator core having a basic configuration of the stator shown in FIG. 1, and FIG. 4 is a perspective view showing a stator core having a basic configuration of a stator according to another embodiment shown in FIG. is there. FIG. 5 shows still another embodiment of the stator core 104 shown in FIG. FIG. 6 shows a stator winding used in the basic configuration of the stator shown in FIGS.

  The basic structure 102 of the stator shown in FIG. 1 or 2 has a stator core 104 and a stator winding 122. Teeth 106 acting as the magnetic poles of the stator are provided at equal intervals over the entire circumference on the rotor side of the basic structure 102 of the stator, and 106A are alternately arranged on the teeth for convenience of explaining the operation later. And 106B, but the teeth 106A and 106B perform the same function. The above-described rotor is rotatably provided inside the teeth 106A and 106B. However, the rotor is not illustrated in FIGS. 1 to 4 in order to avoid complicated explanation. As the rotor, a Rundel type is used when the present invention is used as an AC generator. It is also possible to use a permanent magnet rotor having a permanent magnet on the surface or inside, a flux barrier rotor that generates reluctance torque by limiting the magnetic flux of the D axis or Q axis, or a cage rotor. A rotary electric machine can be configured by combining the rotor and the stator, and the rotary electric machine acts as a motor or a generator.

  The basic configuration 102 of the stator shown in FIG. 1 and the basic configuration 102 of the stator shown in FIG. 2 are almost the same, but the basic configuration 102 of the stator shown in FIG. Each has a flange 108, and the area of the rotor side surface of the basic structure 102 of the stator is increased to improve the output characteristics. Further, the stator core 104 shown in FIG. 5 is still another embodiment of the stator core 104 shown in FIGS. 3 and 4, and the core back 112 that connects adjacent teeth 106 has a curved shape and is excellent in productivity. .

  As shown in FIGS. 2A to 2C, teeth 106 are arranged at equal intervals on a circumferential surface that is a surface perpendicular to the rotation axis, and the teeth 106 are alternately displaced in the rotation axis direction. Therefore, every other recess is formed at the end of the basic structure 102 of the stator in the direction of the rotation axis in accordance with the teeth 106. A stator winding 122 is disposed in the recess, and the protrusion from the stator core 104 at the end of the rotating shaft of the stator winding 122 can be reduced or eliminated.

  FIG. 2D shows a cross-sectional view in which the teeth 106A-1, the teeth 106B-1 and the teeth 106B-2 shown in FIG. 2B are partially sectioned on a plane perpendicular to the rotation axis. As shown in FIG. 2D, a groove 114 extending in the direction of the rotation axis such as a slot is formed between each of the teeth 106A and the teeth 106B, and the stator winding 122 is accommodated in the groove 114. The difference from the conventional stator is that a single-phase winding is inserted into the groove 114 and the stator winding 122 has a simple configuration. For this reason, productivity is excellent and reliability is improved. As shown in FIG. 2D, the teeth 106 are connected by a core back 112. Further, a flange 108 is formed on the rotor side of each tooth 106, and the rotor side of each groove 114 is narrowed by the flange 108. With this structure, the area of the surface facing the rotor is increased and the characteristics of the rotating electrical machine are improved.

  The stator core 104 shown in FIGS. 3 to 5 is the stator core 104 of the basic configuration 102 of the stator shown in FIGS. 1 and 2, and a plurality of teeth 106 are arranged along the circumferential direction on the rotor side. It has equal intervals across. In this embodiment, 20 teeth 106 are provided. These teeth 106 are respectively connected to adjacent teeth 106 by a core back 112, and a space 114 or a slot 114 extending in the rotation axis direction for inserting a stator winding is formed between the adjacent teeth 106. . The stator core 104 shown in FIGS. 1 to 5 has a shape in which the teeth 106 are alternately shifted in the direction of the rotation axis, and the teeth 106A are shifted to the other side with respect to the teeth 106B. For this reason, a space is formed on one side of the teeth 106, and the protrusion on one side of the stator winding 122 can be eliminated by arranging the stator winding 122 in this space. It can be made small. Also, copper loss is reduced. Similarly, since the tooth 106B is shifted to one side with respect to the tooth 106A, a space is formed on the other side of the tooth 106. By disposing the stator winding 122 in this space, the protrusion on the other side of the stator winding 122 can be eliminated, and the basic structure 102 of the stator can be reduced in size as described above. Also, copper loss is reduced.

  However, the above-described alternately displaced arrangement structure of the teeth 106 is not essential, and even if there is no displaced structure, it functions as the basic structure 102 of the stator of the rotating electric machine, and the winding operation of the stator winding 122 is very much. Because of its simplicity, it is extremely superior in terms of productivity over the conventional stators of rotating electrical machines. Further, the inductance of the stator can be greatly reduced compared to a general claw pole type stator having a large number of claws provided on the rotor side as described in JP-A-2006-296188 and JP-A-2005-151785. effective.

  The stator core 104 shown in FIGS. 3 to 5 has a welded portion 116 in which the outer peripheral surface of the core back 112, which is the opposite side of the teeth 106, is fixed by welding. As will be described later, in order to improve productivity and to reduce waste of materials, the stator core 104 is produced by winding a continuous thin steel plate in the circumferential direction as described later. Since the welded portion 116 is formed on the outer peripheral surface of the core back 112 corresponding to each tooth 106, the continuous thin plate-shaped magnetic steel plate is wound in the circumferential direction, and the stator and the core back 112 are then wound at the welded portion 116. By forming with a press or the like, the teeth 106 can be easily shifted in the direction of the rotation axis.

  FIG. 6 shows a stator winding 122 used in the basic structure 102 of the stator. In this embodiment, the stator winding 122 is a wave winding. Concentrated windings other than wave windings can also be used, but a wave winding stator winding 122 will be described as an example. The wave winding stator winding 122 shown in FIG. 6 connects the inter-magnetic pole portion 124 of the stator winding with one magnetic pole end portion 126 of the stator winding and the other magnetic pole end portion 128 of the stator winding. It has a continuous shape made by The inter-magnetic pole portions 124 of the stator winding are alternately connected by one magnetic pole end 126 of the stator winding or the other magnetic pole end 128 of the stator winding, and one magnetic pole end of the stator winding is connected. The portions 126 are respectively inserted into the grooves 114 having a shape extending in the rotation axis direction of the stator core 104 shown in FIGS. The axial ends of the stator core 104 are alternately formed with depressions corresponding to the teeth 106, and one magnetic pole end 126 of the stator winding is formed in the depression formed at one end of the stator core 104. Is inserted, and the other magnetic pole end portion 128 of the stator winding is inserted into a recess formed in the other end of the stator core 104. As described above, it is not always necessary to form depressions at both ends of the rotating shaft of the stator core 104. In this case, one magnetic pole end portion 126 of the stator winding or the other magnetic pole end portion of the stator winding. Reference numeral 128 denotes a shape protruding from both ends of the stator core 104 in the rotation axis direction.

  When the winding shown in FIG. 6 is mounted on the stator core 104 shown in FIG. 3 to FIG. 5, the structure crosses alternately in the grooves 114 provided in the axial direction of the stator core. The winding form is the same as the winding structure, and the winding covers all slots. For this reason, electrical characteristics are improved with respect to a claw pole type stator having a claw between the stator and the rotor.

[Description of stator for three-phase AC rotating electrical machine]
The basic structure 102 of the stator described above functions as a one-phase stator for the entire stator. Next, the stator 100 related to three-phase alternating current will be described with reference to FIGS. FIG. 7 is a perspective view of a stator 100 of a three-phase rotating electrical machine made by combining the basic configurations of the stator shown in FIG. 1 or FIG. FIG. 8 is a development view of the three-phase AC stator 100 shown in FIG.

  The stator 100 shown in FIG. 7 uses a basic configuration 102 of three stators as a U-phase stator 102U, a V-phase stator 102V, and a W-phase stator 102W, respectively. The U-phase stator 102U, the V-phase stator 102V, and the W-phase stator 102W are arranged separately in the rotation axis direction, but the rotor is common, and the basic configuration 102 of the stator of each phase is as follows. They are arranged in phase with each other.

[Description of the phase between each phase]
When configuring the stator 100 of the multiphase rotating electrical machine using the basic structure 102 of the stator described above, the stators of the respective phases are arranged separately in the axial direction. If the relative positional relationship between the stators of the respective phases is a two-phase rotating electric machine, the basic structure 102 of the stator is arranged with a phase of 90 degrees in terms of electrical angle. That is, they are arranged with a shift of ¼ of the mechanical angle per pole pair on the rotor side.

  Further, in the case of the stator 100 of the three-phase rotating electric machine, the electric angles are arranged with a phase of 120 degrees. That is, they are arranged with a shift of 1/3 of the mechanical angle per pole pair on the rotor side. FIG. 7 shows an example of the stator 100 of the three-phase rotating electric machine. FIG. 7 shows a stator of a 20-pole three-phase rotating electric machine. Since there are 20 poles, the number of pole pairs is 10. For this reason, the mechanical angle of the phase-to-phase pole shift is 1/3 of 36 degrees, which is 10 mechanical angles, that is, 12 degrees.

  The above description is a case where the rotor has a common structure with respect to the basic structure 102 of each stator constituting the stator 100 and the rotor does not have a phase. Making the rotor a common structure simplifies the configuration of the entire rotating electrical machine, and is highly effective in terms of downsizing and productivity. In particular, when the rotating electric machine is used as an AC generator, the disclosed basic windings 102 of the stator 100 can share the disclosed windings, and high output can be obtained.

  However, no phase is provided at the attachment position between each phase on the stator side, and the rotor side is divided corresponding to each phase, and the poles of the portions corresponding to each stator on the rotor side are respectively as described above. It is also possible to arrange them with the phases constituting the multi-phase rotating electrical machine. This phase relationship is the same as that described on the stator side.

  In the above description, two-phase alternating current and three-phase alternating current have been described as representatives of the stator 100 of the multi-phase rotating electrical machine, but the same idea can be applied to multi-layer alternating current. For example, when configuring the stator 100 of a six-phase AC generator, six basic configurations 102 of the stator may be arranged in the axial direction, and the phase may be 60 degrees in electrical angle. By dividing the six-phase AC generator into three phases and connecting them in parallel after rectification, the maximum current per phase can be reduced, and the current capacity of the rectifier circuit and the like can be reduced.

[Description of three-phase stator structure]
FIG. 7 shows a stator 100 for a three-phase AC rotating electric machine as a representative example of the stator 100 for the multilayer rotating electric machine. A specific structure of the stator 100 will be described with reference to FIG. The basic configuration 102 of the stator described in FIG. 1 and FIG. 2 is arranged by arranging three stator blocks of a U-phase stator 102U, a V-phase stator 102V, and a W-phase stator 102W in the axial direction. In this configuration, a magnetic insulating member having a magnetic shielding function is provided between the phases in order to reduce the leakage magnetic flux between the phases. This magnetic insulation member is arranged as necessary and is not essential, but reducing the leakage magnetic flux leads to an improvement in efficiency and an improvement in characteristics.

  The insulating material is preferably composed of a non-magnetic polymer material or a non-conductive substance such as ceramic. Furthermore, improvement in heat dissipation can be expected by using a material having good thermal conductivity. Although not shown here, the magnetic insulation member 3 has a fitting shape function such as a groove, a hole, or a protrusion, a shaft, and an inlay for positioning the stator core so that the stator block has high accuracy. Positioning can be realized. This positioning is because the circumferential position of the stator and the coaxiality affect the torque ripple of the rotating electrical machine.

  It is also possible to form this magnetic shield with a metal-based material. Specifically, for metals, aluminum alloys, nonmagnetic stainless alloys, copper alloys, and the like are suitable. Although there is a problem of cost, lightweight titanium is also a candidate. In addition, LCP (liquid crystal polymer), PPS (polyphenylene sulfide resin), PBT (polybutylene terephthalate resin), PET (polyethylene resin), nylon reinforced with glass fiber, PC (polycarbonate resin), etc. are candidates. As mentioned. Carbon fiber reinforced resins and thermosetting resins such as epoxy and unsaturated polyester are also candidates. It is desirable to determine these materials according to the thermal and mechanical strength constraints required by the motors and generators used. These production methods include die-casting for aluminum and copper alloys, and machining for stainless steel alloys by cold forging and warm forging. The resin material can be manufactured by a method such as injection molding. When using a metal-based material, it is necessary to determine the shape while paying attention to the eddy current generation path.

[Description of AC generator for vehicles]
Next, an embodiment in which the stator 100 shown in FIG. 7 is used in a vehicle alternator will be described with reference to FIGS. 9 to 11. FIG. 9 is a side sectional view of the vehicle alternator, FIG. 10 is a perspective view showing a rotor of the vehicle alternator, and FIG. 11 is a perspective view of a partial sectional view of the vehicle alternator. . A stator 100 is provided between a front housing 212 arranged on the left side in FIG. 9 and a rear housing 222 arranged on the right side in the figure. The stator 100 has a U-phase stator 102U, a V-phase stator 102V, and a W-phase stator 102W arranged in the rotation axis direction.

  A Rundel type rotor 252 is rotatably provided inside the stator 100 through a gap. The front housing 212 and the rear housing 222 are each provided with a bearing, and a shaft 236 is rotatably held by the bearing. A Rundel-type rotor 252 shown in FIG. 10 is fixed to the shaft 236 and rotates with the rotation of the shaft 236.

  As shown in FIG. 10, the Rundel type rotor 252 has one rotor claw magnetic pole 262A extending from the front side toward the rear side and the other rotor claw magnetic pole 262B extending from the rear side toward the front side. A field winding 264 that generates a magnetic flux based on a supplied field current is provided inside the one rotor claw magnetic pole 262A and the other rotor claw magnetic pole 262B.

  A pulley provided on the shaft 236 rotates from an internal combustion engine provided on the vehicle via a power transmission belt, the Rundel type rotor 252 rotates, and AC power is induced in the stator 100. This AC power is full-wave rectified by a rectifier circuit, a DC current is output from the terminal 242 and charged to a storage battery mounted on the vehicle.

  In order to cool the interior of the vehicle alternator, two fans 232 are fixed to the shaft 236 on both sides of the Rundel-type rotor 252, and the front housing 212 and the rear side are arranged based on the rotation of the shaft 236. Air is introduced and discharged from the ventilation holes 238 provided in the housing 222.

  The Rundel-type rotor 252 shown in FIG. 10 has 16 magnetic poles, but this is schematically illustrated, and the Rundel-type rotor 252 includes the magnetic poles of the basic configuration 102 of the stator that constitutes the stator 100. It is desirable to have the same number of magnetic poles. When the number of magnetic poles of the basic configuration 102 of each stator constituting the stator 100 is 20, the number of magnetic poles of the Rundel rotor 252 is desirably 20. One rotor claw magnetic pole 262A and the other rotor claw magnetic pole 262B have the same shape, the circumferential width A at the base of the claw magnetic pole is wide, and the circumferential width B of the claw at the opposite portion of the stator 100. It is slightly narrower, and the circumferential width C beyond that is further narrowed. The tip of the claw has a small magnetic flux density, and no magnetic saturation occurs even if the circumferential width C is narrowed. The Rundel type rotor 252 may rotate at a high speed of 10,000 or more revolutions per minute, and it is desirable to reduce the centrifugal force. Therefore, the circumferential width C of the tip of the claw is made as narrow as possible. As a result, lifting due to the centrifugal force at the tip of the rotor claw magnetic pole can be reduced, and the gap between the stator 100 and the Rundel-type rotor 252 can be reduced. Efficiency can be improved by reducing the gap.

  FIG. 12 is an explanatory diagram for explaining the operation of the AC generator shown in FIGS. 10 to 12. The operating principle described here is also the basic operation of the stator shown in FIG. 1, FIG. 2, or FIG. 12A shows a state in which one rotor claw magnetic pole 262A is approaching the teeth 106A of the AC generator, and FIG. 12B shows that the other rotor claw magnetic pole 262B is approaching the teeth 106A of the AC generator. Indicates the state that is on the way. In the figure, the teeth 106A and the teeth 106B show the side surfaces of the rotor, that is, the stator surface is seen from the outer peripheral surface of the rotor. Originally, the rotor corresponds to all phase teeth 106 which are the inner surfaces of all the stators arranged in parallel in the axial direction. In FIG. 12, only the stator for one phase is shown, and the relationship with the rotor cannot be accurately described, but the broken line 262-1 conceptually shows the rotor, and the magnetic poles of the Rundel-type rotor 252 that is the rotor are shown. A broken line 262-2 is provided to indicate the state.

  FIG. 12A shows a state where one rotating rotor claw magnetic pole 262A is approaching the tooth 106A, and the magnetic flux Φ1 from one rotor claw magnetic pole 262A to the tooth 106A increases, and the teeth The magnetic flux Φ2 toward the core back 112 through 106A increases, the magnetic flux Φ4 through the core back 112 increases, and the magnetic fluxes Φ6 and Φ9 returning from the core back 112 through the teeth 106B to the other rotor claw magnetic pole 262B increase. This magnetic flux is linked to the stator winding 122 disposed inside the groove 114, and induces a current in the direction of the arrow in the stator winding 122.

  On the other hand, when one rotor claw magnetic pole 262A moves away from the teeth 106A and the other rotor claw magnetic pole 262B approaches, the direction of the magnetic flux of the stator is reversed, and the magnetic flux Φ9 is transferred from one rotor claw magnetic pole 262A to the teeth 106B. The magnetic flux increases in the direction in which the magnetic flux Φ6 core back 112 passes from the teeth 106B as the magnetic flux Φ4, passes through the teeth 106A as the magnetic flux Φ2, and the magnetic flux Φ1 returns to the other rotor claw magnetic pole 262B. As a result, a current in the direction opposite to that shown in FIG.

  The above description is the operation of the stator for one phase in the stator 100 of FIG. 9, but a common rotor is used in each of the U-phase stator 102U, the V-phase stator 102V, and the W-phase stator 102W. The above operation occurs, and a three-phase alternating current is generated. If the number of the basic structure 102 of the stator which comprises the stator 100 is increased in FIG. 9, the number of the alternating current power which generate | occur | produces will increase according to it, and will be multiphased.

[Description of Rundel type rotor 252]
Next, another embodiment of the Rundel type rotor 252 of the vehicle alternator will be described with reference to FIG. FIG. 13A is a perspective view of the Rundel type rotor 252, and FIG. 13B is a partial cross-sectional view in which a groove 272 for reducing eddy current is formed in the rotor claw magnetic pole 262 of the Rundel type rotor 252. 13C is a partial cross-sectional view illustrating another embodiment in which a groove 272 for reducing eddy current is formed in the rotor claw magnetic pole 262. FIG.

  The Rundel-type rotor 252 is wound with a field winding on its inner side, and rotor claw magnetic poles 262 are alternately extended along the rotation axis on the outer peripheral side thereof, so that one rotor claw magnetic pole 262A and the other rotation are rotated. Acts as a claw magnetic pole 262B. Fans 232 are fixed to both ends of the rotor claw magnetic pole 262 in the rotation axis direction. The overall structure of the AC generator is as described in FIG. 9 and FIG. 11, and a DC current is supplied to the field winding via a slip ring provided on the shaft 236, thereby Thus, one rotor claw magnetic pole 262A acts as an N magnetic pole, and the other rotor claw magnetic pole 262B acts as an S magnetic pole.

  Since the claw-shaped magnetic pole is an electromagnet that is magnetized by a magnetic flux generated by a direct current, it is considered that the influence of eddy current is small. However, in reality, a harmonic magnetic flux is generated on the surface of the magnetic pole due to the harmonics of the slot, and an eddy current is generated due to the influence. Therefore, the grooves described in FIGS. 13B and 13C are formed on the surface of the rotor claw magnetic pole to suppress the generation of eddy currents. In FIG. 13B, a square groove is formed on the surface of the rotor claw magnetic pole 262. In FIG. 13C, a V-shaped groove is formed. These grooves shown in FIGS. 13B and 13C are examples, and are not limited to square shapes or V shapes.

  Next, still another embodiment of the Rundel type rotor 252 for an AC generator will be described with reference to FIG. In the above-described Rundel type rotor 252, as shown in FIG. 13A, one rotor claw magnetic pole 262 A and the other rotor claw magnetic pole 262 B have a target shape in the circumferential direction perpendicular to the rotation axis. The opposing surface with the stator is tapered toward the tip of the nail. Since the rotor claw magnetic pole 262 has a large amount of magnetic flux at the base portion and is likely to be magnetically saturated, the root portion has a cross-sectional area as large as possible.

  As shown in FIGS. 9 and 11, when the stators of the respective phases constituting the stator are arranged along the rotation axis, there is a possibility that the output characteristics between the phases become unbalanced. In particular, the output of the phase sandwiched inside tends to be small with respect to the phase arranged on both sides. In order to make the output characteristics between the phases uniform, it is desirable to increase the output of the phase sandwiched between them. In the embodiment of FIG. 14, the permanent magnet is placed near the center of the run-axis type rotor 252 in the rotational axis direction. The structure is arranged to increase the magnetomotive force that generates the magnetic flux interlinking with the stator winding 122 of the phase sandwiched between them. 14 (a) is a perspective view of a Rundel type rotor 252 which is another embodiment, FIG. 14 (b) is a partially enlarged view showing the shape of a claw and a permanent magnet, and FIG. 14 (c) is FIG. FIG. 14 (d) is a partial sectional view showing the shape of the claw and the permanent magnet shown in FIG. 14 (b) or FIG. 14 (c). It is.

  A permanent magnet 274 is provided between one rotor claw magnetic pole 262A and the other rotor claw magnetic pole 262B located on the outer peripheral side of the Rundel-type rotor 252, and the AC generator shown in FIGS. The permanent magnet 274 is provided at the center of the rotation shaft of the Rundel type rotor 252 in order to increase the amount of interlinkage magnetic flux of the stator winding 122 located inside the stator 100. As shown in FIG. 14D, a field winding 264 is provided inside the rotor claw magnetic pole 262 and the permanent magnet 274.

  In the Rundel type rotor 252 described above, it is necessary to mount a permanent magnet 274 between the claws of one rotor claw magnetic pole 262A and the other rotor claw magnetic pole 262B. However, if the permanent magnet 274 is to be mounted between the one and the other rotor claw magnetic poles 262A and 262B, the shape of the base portion of the adjacent rotor claw magnetic poles is widened and the permanent magnet 274 is difficult to insert. It becomes. In the embodiment of FIG. 14, in order to increase the cross-sectional area of the magnetic circuit through which the magnetic flux passes at the root portion of each rotor claw magnetic pole 262, only the side opposite to the rotational direction of the Rundel-type rotor 252 is surrounded. The claw shape extends in the direction, and the cross-sectional area through which the magnetic flux passes is increased. In this way, if only one direction side in the rotational direction, which is the circumferential direction, is wide, the permanent magnet 274 shown in FIG. 14 (a) has a wide width as shown in FIG. 14 (b) and FIG. 14 (c). The permanent magnet 274 can be mounted from the axial direction side where the root portion is not formed.

  It should be noted that the technical idea of using a claw having a shape that is widened in the direction opposite to the rotation direction of the Rundel type rotor 252 can also be applied to the embodiment described in FIGS. 9 to 11. Thus, it becomes possible to attach the permanent magnet 274 as necessary while securing the cross-sectional area through which the magnetic flux passes.

[Method for Manufacturing Stator Core 104]
Next, a method for manufacturing the stator core 104 will be described with reference to FIG. The stator magnetic poles of the rotating electrical machine are processed by press punching an iron plate such as an electromagnetic steel plate, cold rolled steel plate, and electromagnetic stainless steel to form a stator sheet iron core 1042 shown in FIG. The stator sheet iron core 1042 is provided with a notch 1142 for forming a groove 114. A laminated core 1044 is manufactured by laminating the stator thin plate cores 1042 in the direction of the rotation axis. The laminated iron core 1044 is fixed by welding, and the welded portions 116 are provided at equal intervals over the entire circumference of the laminated iron core 1044. However, FIG. ing. The welded portion is desirably the outer peripheral portion of the core back 112 that is less affected by the magnetic properties. As described above, the welded portion is desirably provided at equal intervals throughout the entire outer peripheral portion of the core back 112. For example, it is desirable to provide the core back 112 on the outer peripheral side corresponding to the teeth 106.

  As a processing method of the stator sheet iron core 1042, laser processing, electric discharge processing, and the like are possible in addition to punching processing such as press processing. After the laminated core 1044 shown in FIG. 15A is manufactured, the stator magnetic poles may be processed and formed by a press or the like so that the stator magnetic poles are alternately shifted in the direction of the rotation axis as shown in FIG. 15C. In this way, the stator core 104 of the stator shown in FIGS. 3 to 5 is manufactured. The stator winding 122 shown in FIG. 6 is inserted into the stator core 104 and fixed. In FIG. 15A, the stator sheet iron core 1042 having the notches 1142 is manufactured by punching, and the stacked cores 1044 are manufactured by stacking them in a laminated structure.

  Another method of manufacturing the laminated core 1044 will be described with reference to FIG. Similar to the notch 1142, a thin steel plate 1046 having notches 1146 formed in the groove 114 for inserting the stator winding 122 at equal intervals is produced by punching using a press or the like. Next, it winds as shown in FIG.15 (b), and the laminated iron core 1044 is manufactured. The difference from the laminated core 1044 shown in FIG. 15A is that the stator core 104 is continuous. The method shown in FIG. 15B has an advantage that the waste of material is reduced as compared with the method of FIG. The method of making the stator core 104 from the laminated core 1044 shown in FIG. 15B is the same as that shown in FIG. 15A, and the laminated thin steel plates 1046 are fixed by welding.

  As shown in FIG. 15 (c), the stator core 104 is formed by being alternately shifted for each tooth in the rotation axis direction, and is recessed at each end of the stator core 104 in the rotation axis direction alternately for each tooth. Is formed. By disposing the stator winding 122 in this recess, the basic structure 102 of the stator shown in FIGS. 1 and 2 is made. However, in view of the operation of the rotating machine, it is not necessary to provide the depressions at both ends of the rotating shaft due to the alternating displacement for each tooth as shown in FIG. In this case, the stator winding 122 protrudes alternately at both ends of the stator core 104 in the rotation axis direction. In the structure shown in FIG. 15C, the core back 112 is formed at a steep angle. However, it is easier to manufacture with a smooth curve, and mechanical distortion is reduced. The structure is shown in FIG. 5 described above.

  FIG. 16 shows an example of a method for producing a one-phase stator integrated with a magnetic insulating plate from the basic structure 102 of the stator shown in FIGS. 1 and 2. In addition, the stator 100 shown in FIG. 7 can be easily manufactured by combining the stator blocks for one phase manufactured integrally with the magnetic insulating plate.

  FIG. 16B shows the stator block 304 after integral molding. The stator block 304 is made by covering the stator core 104 and the stator winding 122 for one phase with a resin 302 or the like. By combining a plurality of stator blocks 304 for one phase in the direction of the rotation axis, the stator 100 can be easily manufactured.

  FIG. 16A shows the structure of a mold for manufacturing the stator block 304. The mold 312 as a base has means for holding the basic structure 102 of the stator including the stator core 104 around which the stator winding 122 is wound, and the holding means has a positional relationship in the circumferential direction. It has a holding part which can position with high precision. The basic configuration 102 of the stator is fixed to the holding portion, and the mold is clamped with a mold 314 having an injection portion (gate) in a state where the basic configuration 102 of the stator is fixed. A space into which resin is injected is formed by fitting the upper and lower molds, and a space and a magnetic shield existing between the laminated stator core 104 and the stator winding 122 serving as magnetic poles The resin is filled in the space created at both ends in the direction of the rotation axis that is desired. A resin layer having a magnetic shielding action is formed at both ends in the rotation axis direction of the stator core 104 and the stator winding 122, and the amount of magnetic flux leaking to each other when overlapped with another stator block 304 is caused by the resin layer. Can be reduced.

  A positioning shape can be formed on the resin layer. For example, in the stator block 304 shown in FIG. 16B, protrusions 316 and grooves 318 are formed on the surface of the resin layer. When forming a multiphase stator, the stator blocks 304 are stacked in the direction of the rotation axis corresponding to each of the multiphase phases, and the stator blocks 304 are held in a positional relationship with a predetermined phase in the circumferential direction. It is necessary to. By forming the protrusions 316 and the grooves 318 on the surface of the resin layer in the predetermined phase relationship, the protrusions 316 of the stator blocks 304 are inserted into the grooves 318, thereby enabling accurate circumferential positioning.

  In this method, resin-based materials can be used, and LCP (liquid crystal polymer), PPS (polyphenylene sulfide resin), PBT (polybutylene terephthalate resin), PET (polyethylene resin), or nylon reinforced with glass fiber , PC (polycarbonate resin) and the like. In addition, a carbon fiber reinforced resin, a thermosetting resin such as an epoxy type or an unsaturated polyester type can also be used. It is desirable to determine these materials according to the thermal and mechanical strength constraints required by the motors and generators used.

[Description of Other Manufacturing Method of Stator Core 104]
Next, still another manufacturing method or another shape of the stator core 104 shown in FIG. 15 is shown in FIG. In the embodiment described above with reference to FIG. 15, the stator core 104 is composed of an electromagnetic steel plate that is integrally formed in the circumferential direction. However, an integrated shape is not essential from the electrical characteristics. FIG. 17 shows a stator magnetic circuit having a core shape of one pole pair (for two poles). FIG. 17A shows one pole pair of the stator core 104 shown in FIGS. In the structure of a rotating electrical machine that is a motor or generator, the flow of magnetic flux from the rotor covers the magnetic flux of one pole pair on the rotor side, so the flow of magnetic flux between adjacent pole pairs Do not need. Therefore, by dividing the iron core in the circumferential direction, it is possible to satisfy the same characteristics as when integrated. Therefore, the stator core 104 is assembled by combining iron core pieces having teeth 106A and teeth 106B as shown in FIG. 17 (a), and fixing the above-described structure using a motor or a generator. It becomes possible to configure a child. In addition, the same code | symbol shows the function and effect of the same code | symbol demonstrated previously.

  FIG. 17B shows a shape having a hook at the tip of the teeth 106A or 106B shown in FIG. This kite has the purpose of effectively collecting the flux flowing in from the rotor and the function of preventing the winding out of the wound stator winding 122. FIG. 17 (c) shows a structure in which the iron core is formed in a staggered shape in the axial direction, but the positional relationship of the magnetic poles does not overlap in the rotation axis direction. In order to secure a large space for arranging the stator winding 122 and to simplify the shape of the stator winding 122 and improve productivity and workability, the shape on the iron core side has been devised. It is an example. The stator core 104 in FIGS. 3 to 5 or 17 has a laminated structure of magnetic thin plates, but is not limited to a laminated structure, and may be manufactured by compression molding a dust core or the like. However, laminated steel sheets are superior in terms of strength, reliability, and magnetic properties. In addition, although description is abbreviate | omitted in description of FIG.17 (b) and FIG.17 (c), the same code | symbol as previous description does not have the same effect | action, and has the same effect.

  FIG. 18 shows a manufacturing concept of the stator core 104, which is a stator core for one phase, using the iron core shown in FIG. The inter-magnetic pole portions 124 of the stator winding 122 of the stator winding 122 shown in FIG. 6 are inserted into the grooves 114 extending in the rotation axis direction between the teeth 106A and the teeth 106B. Thereafter, the magnetic pole pairs in FIG. 18A are fixed by welding or the like, whereby the stator core 104 integrated in the circumferential direction is completed.

  In the structure shown in FIG. 18A or the structure shown in FIGS. 1 to 5, the groove 114 along the rotation axis exists, and the inter-magnetic pole portion 124 of the stator winding of the stator winding 122 is inserted into the groove 114. Shape. On the other hand, in the embodiment shown in FIG. 18B, the teeth 106A and the teeth 106B are completely displaced in the rotation axis direction. In this shape, the stator winding 122 can be inserted into the groove 114 with almost no bending in the rotation axis direction. For this reason, the productivity of the stator winding 122 is excellent, the insertion of the stator winding 122 into the groove 114 is easy, and the workability is excellent. However, there is a disadvantage that the cross-sectional area of the magnetic circuit facing the rotor becomes small, and the output tends to decrease. However, when the output may be small, the production cost is low and effective.

  The basic structure 102 of the finally completed stator is the same as that shown in FIGS. 1 and 2, and the stator winding 122 is used for posting that goes back and forth between one end and the other end along the rotation axis. And has the structure shown in FIGS. 2B to 2D. The stator core 104 in the above drawing has a shape partially overlapping at the central portion in the rotational axis direction of the stator core 104 formed of the teeth 106A and the teeth 106B shifted in the rotational axis direction, as shown in FIG. 2 (d). As in the cross section, the arrangement is almost the same as the winding arrangement of the slot tooth type rotating electrical machine. Therefore, the magnetic circuit is efficiently constructed on the surface facing the rotor, and excellent electrical characteristics can be obtained. On the other hand, the stator winding 122 is greatly simplified compared to the slot tooth type rotating electric machine, and excellent productivity can be obtained, and the shape of the stator winding 122 is simple, so that it is excellent in safety and reliability. effective.

  FIG. 19 shows another embodiment of the stator winding 122. In the structure shown in FIGS. 1 and 2, the stator winding 122 is bent at an angle close to a substantially right angle at a portion connecting the rotation axis direction and the circumferential direction. That is, the stator winding 122 has a portion substantially parallel to the rotation axis. In an actual coated magnet wire, if it is bent at a right angle, the resin film for insulation may be damaged, and it is necessary to pay various attentions at the time of work. It is desirable to form with a certain degree of bending R (radius). In this regard, it is desirable to pay attention to the operation of forming the stator winding 122 in the shapes shown in FIGS. In the shape shown in FIG. 19, the groove 114 between the teeth 106A and the teeth 106B is widened in the circumferential direction. The gap between the magnetic poles of the iron core is loosened so that the portion of the stator winding 122 in the rotation axis direction can be arranged obliquely. This structure has an advantage that the bending R (radius) can be made gentle, and the workability is improved. However, the structure of FIGS. 1 and 2 can increase the space factor of the stator winding 122 (the ratio of the conductor cross-sectional area to the slot), and has the effect of easily obtaining a high output. In view of improving efficiency, it is desirable to take into consideration that the space factor of the stator winding 122 does not become small in the structure of FIG.

  FIG. 20 shows a cross-sectional shape of the stator winding 122 for improving the space factor. Normally, as shown in FIG. 20 (a), it is conceivable to use a magnet wire having a round cross section as a winding. However, in order to improve the space factor, a flat magnet wire is used to improve the space factor. The space factor can be increased by arranging and arranging as shown in FIG. Further, when the stator winding 122 is manufactured in advance as shown in FIG. 6 and then integrated with the stator core 104, a step of forming the cross-sectional shape of the stator winding 122 into a desired shape is provided. Is desirable. When the cross-sectional shape of the stator winding 122 is formed, the space factor can be increased by forming a line having a substantially circular cross section into a shape as shown in FIG.

[Application to rotating electrical machines such as motors]
FIG. 21B is a perspective view of the rotating electrical machine when the stator 100 shown in FIG. 7 is applied to the rotating electrical machine, and FIG. 21A is a development view of the rotating electrical machine shown in FIG. . A bearing 414 and a bearing 412 are fixed to the front housing 418 and the rear housing 416, respectively, and a shaft 436 is rotatably held by the bearings 414 and 412. A rotor 404 is fixed to the shaft 436. A stator 100 shown in FIG. 7 is provided outside the rotor 404 through a gap. By fixing the front housing 418 and the rear housing 416 with the through bolts 452, the stator 100 is fixed and held between the front housing 418 and the rear housing 416. An outer ring 401 made of an aluminum material or the like is further provided on the outer periphery of the stator 100, and the rotating electrical machine is hermetically sealed.

  As the rotor 404, a cage rotor shown in FIG. 22A, a rotor having a permanent magnet shown in FIG. 22B, or a rotor incorporating a magnetic flux barrier shown in FIG. 22C can be used. 22A to 22C are cross-sectional views of the rotor 404 taken along a plane perpendicular to the rotation axis of FIG. A cage rotor 404 shown in FIG. 22A has a plurality of conductor bars 462 arranged in the direction of the rotation axis on the inner periphery of the rotor core 472 and arranged at equal intervals over the entire circumference. 462 is electrically short-circuited by short-circuit rings (not shown) at both ends of the rotating shaft of the rotor. When an alternating current is supplied to the stator 100 of FIG. 21 and a rotating magnetic field is generated, a current is induced in the conductor bar 462, and a rotating torque is generated. By controlling the slip between the alternating current supplied to the stator 100 and the rotor 404, it is possible to control the rotational torque generated in the rotor 404 and the induced power induced in the stator winding. .

  FIG. 22B shows an example in which a permanent magnet rotor is used as the rotor 404 in FIG. The permanent magnet 464 may be provided on the surface of the rotor core 472 of the rotor 404 or may be provided inside. FIG. 22B shows an example provided inside the rotor core 472. When an alternating current is supplied to the stator 100 of FIG. 21, a rotating magnetic field is generated, and a rotating torque is generated in the rotor 404 having the permanent magnet. By controlling the alternating current supplied to the stator 100 and the phase of the magnetic poles of the rotor 404, the rotational torque and generated power can be controlled.

  FIG. 22C shows an example in which a rotor having a magnetic flux barrier 468 is used as the rotor 404 in FIG. By forming, for example, a gap in the q-axis magnetic path as a magnetic flux barrier in the rotor core 472, the magnetoresistance of the d-axis and the q-axis based on the rotating magnetic field generated by supplying an alternating current to the stator 100 is reduced. A difference occurs, and a rotational torque is generated based on the difference in magnetic resistance.

  As described above, the stator 100 described above functions as a generator or a motor by being combined with various rotors, and can be used for various applications. In any case, since the shape of the stator 100 is simple, and particularly the shape of the stator winding 122 is simple, the productivity is excellent. In the above embodiment, the coil ends of the stator winding 122 in the axial direction can be reduced or eliminated, the size can be reduced, and the copper loss can be reduced.

It is a perspective view which shows the basic composition of the stator which is one embodiment of this invention. FIG. 2A is a perspective view showing another embodiment of the basic configuration of the stator shown in FIG. 1, FIG. 2A is a perspective view showing the entire basic configuration of the stator according to the embodiment, and FIG. 2 (a) is a partial sectional view of the basic configuration of the stator, FIG. 2 (c) is a partial sectional view of the basic configuration of the stator shown in FIG. It is a fragmentary sectional view perpendicular | vertical to the rotating shaft of the basic composition of the stator shown to Fig.2 (a). It is a perspective view which shows the stator core of the basic composition of the stator shown in FIG. FIG. 4 is a perspective view showing a stator core having a basic configuration of a stator according to another embodiment shown in FIG. FIG. 5 shows still another embodiment of the stator core shown in FIG. 3 is a stator winding used in the basic configuration of the stator shown in FIGS. 1 and 2. It is a perspective view of the stator which is one embodiment of the present invention. FIG. 8 is a development view of the stator shown in FIG. 7. It is side surface sectional drawing of the alternating current generator for vehicles which is one embodiment of this invention. It is a perspective view which shows the rotor of the alternating current generator for vehicles shown in FIG. FIG. 10 is a partial cross-sectional view of the vehicle AC generator shown in FIG. 9. It is operation | movement explanatory drawing explaining operation | movement of the alternating current generator of FIGS. 10-12. FIG. 13A is a perspective view of a Rundel-type rotor, and FIG. 13B is a Rundel-type rotor according to another embodiment of the present invention. FIG. 13C is a partial cross-sectional view for explaining another embodiment. FIG. 14A is another embodiment of FIG. 13, FIG. 14A is a perspective view of a Rundel type rotor that is another example, and FIG. 14B is a partially enlarged view showing the shapes of a claw and a permanent magnet. 14 (c) shows another embodiment of the shape of the claw and permanent magnet shown in FIG. 14 (b), and FIG. 14 (d) shows the claw portion shown in FIG. 14 (b) or FIG. 14 (c). It is a fragmentary sectional view. Explanatory drawing explaining the manufacturing method of a stator core, FIG.15 (a) is the manufacturing method by cutting, FIG.15 (b) is other embodiment of a manufacturing method, FIG.15 (c) is the manufactured stator. It is a perspective view which shows an iron core. FIG. 16A shows a structure of a mold for manufacturing a stator block, and FIG. 16B is a perspective view of the manufactured stator block. FIG. 17A shows one pole pair of the stator core shown in FIGS. 3 to 5, and FIG. 17B shows one pole of the stator core with a hook. FIG. 17 (c) shows another unipolar pair of stator cores. The other embodiment of the manufacturing method of the stator for 1 phase is shown. It is a perspective view which shows other embodiment of the stator for 1 phase. It is a fragmentary sectional view of a stator winding. It is a perspective view which shows application to the rotary electric machine which is other embodiment. It is sectional drawing of the rotary electric machine rotor shown in FIG.

Explanation of symbols

102 Stator 102U U-phase stator 102V V-phase stator 102W W-phase stator 104 Stator core 106A, 106B Teeth 108 鍔 112 Core back 114 Groove 116 Welded portion 122 Stator winding 122U U-phase stator winding 122V V Phase stator winding 122W W phase stator winding 130 Magnetic insulation plate

Claims (10)

  A stator and a rotor rotatably held; the stator has at least two rotor cores arranged side by side in the rotation axis direction of the rotor; each rotor core is arranged in a circumferential direction A rotating electrical machine comprising a plurality of magnetic poles, grooves each extending in the direction of the rotation axis are provided between the magnetic poles, and a stator winding is disposed in the grooves.   A stator and a rotor held rotatably; the stator has at least three rotor cores arranged side by side in the rotation axis direction of the rotor, and each rotor core is arranged in a circumferential direction; A rotating electrical machine comprising a plurality of magnetic poles, grooves each extending in the direction of the rotation axis are provided between the magnetic poles, and a stator winding is disposed in the grooves.   A stator and a rotor held rotatably; the stator has at least three rotor cores arranged side by side in the rotation axis direction of the rotor, and each rotor core is arranged in a circumferential direction; And a plurality of magnetic poles extending in the rotational axis direction are provided between the magnetic poles, and the magnetic poles arranged in the circumferential direction are alternately shifted in the rotational axis direction and rotated. The axial end portions of the magnetic poles are formed at every other end in the axial direction, and a stator winding is disposed in the groove and in the recesses at the axial end portions of the magnetic poles. Rotating electric machine.   4. The rotating electrical machine according to claim 1, wherein the stator cores arranged side by side in the rotational axis direction are formed by winding continuous thin steel plates in the circumferential direction and laminating in the rotational axis direction. A rotating electric machine characterized by having a shape.   4. The rotating electrical machine according to claim 1, wherein the stator cores arranged side by side in the rotational axis direction are divided in the circumferential direction in units of pole pairs composed of two magnetic poles. Rotating electric machine.   4. The rotating electrical machine according to claim 1, wherein the stator cores arranged side by side in the rotation axis direction are formed by laminating thin plate cores in the rotation axis direction, and the thin plates are formed by caulking or welding. A rotating electrical machine characterized in that a shaped iron core is fixed in the stacking direction.   7. The rotating electrical machine according to claim 1, wherein the rotor is a Rundel-type claw pole rotor, and an alternating current is induced in the stator winding based on the rotation of the rotor. Electric.   The rotating electrical machine according to claim 7, wherein the stator claw magnetic pole is provided with a skew of 0 to 20 degrees with respect to an axial line.   9. The rotating electrical machine according to claim 7, wherein the number of poles of the rotor and the number of magnetic poles of the stator are the same.   9. The rotating electrical machine according to claim 7, wherein the number of poles of the rotor and the number of poles of the stator are 20 poles.

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