JP2009148133A - Molded coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded coil in which the number of components is further reduced and the weight is reduced, by viewing overall of a motor, including other components. <P>SOLUTION: This molded coil 10 is a molded coil of split stators circularly arranged to form a stator 50, wherein one or more recess grooves 11 are formed from one side surface Ss to the other side surface Ss on a coil end surface Se of the molded coil 10. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a molded coil, and more specifically to a molded coil in a split stator of a stator of a motor used in an automobile or the like.

Generally, motors are required to have high output and small size. For this reason, parts are reduced, production processes are simplified, etc., without increasing the output, but rather with higher output. For example, the stator production efficiency has been hindered because the winding process of each stator coil is complicated, and a proposal has been made to simplify the stator assembly process by using a molded coil in which the coil is resin-molded ( Patent Document 1). In this method, the stator is easily completed by preparing annularly arranged stator teeth that project the molded coil radially outward from the annular inner ring, and inserting the molded coil into the annularly arranged stator teeth. Can do.
JP 2007-195333 A

  However, the purpose of the split stator using the resin mold is limited in that the manufacturing process is only partially simplified and the entire motor, including other parts, is viewed to reduce the parts and reduce the weight. It is enough. SUMMARY OF THE INVENTION An object of the present invention is to provide a molded coil capable of promoting reduction of parts and weight reduction by using a resin mold and looking around the entire motor including other parts.

  The molded coil of the present invention is a molded coil of a split stator that is arranged in an annular shape to form a stator, and one or the other side surface side from one side surface side to the coil end surface of the molded coil or A plurality of concave grooves are provided.

  With the above configuration, the bus bar can be stored in the recessed groove, so that it is not necessary to provide a separate bus bar housing case, and the motor can be reduced in weight and the number of parts can be reduced.

  Both ends of the winding of the mold coil are projected to one coil end side of the mold coil, and the concave groove is positioned on the coil end surface on the side where both ends of the winding are projected, The end of the coil protrudes from one end of the coil, the other end protrudes from the other end of the coil, and the one end and the other end of the winding occupy diagonal positions on the coil end surface. Can be. As a result, the bus bar and both ends of the coil winding are relatively close to each other, so that the possibility of reducing parts for electrical connection can be increased. Furthermore, since the winding occupies the diagonal position of the coil end surface, both ends of the winding overlap in the stator radial direction in the movement of the welding head at the time of welding operation between both ends of the coil winding and the bus bar or the like. Interference due to proximity can be mitigated.

  The plurality of concave grooves may be provided with intersecting grooves at two locations so that the wall of the concave groove is cut out and one end and the other end of the winding can be seen. Thus, when welding the bus bar and the end of the coil winding, the work can be smoothly performed using the grip jig of the welding head.

  According to the molded coil of the present invention, the entire motor can be looked over, and the reduction and weight reduction of parts can be promoted.

(Embodiment 1)
1 to 4 are perspective views showing a molded coil 10 according to Embodiment 1 of the present invention, and FIG. 5 is a plan view showing a stator 50 assembled in an annular shape by using these molded coils 10. . The mold coil 10 shown in FIGS. 1 to 4 is different in the number and arrangement of the concave grooves 11 provided on the coil end surface Se, and the reason why the molded coils 10 having different concave grooves 11 are necessary. Can be understood from the form of the concave groove 11 of each mold coil 10 in the stator 50 shown in FIG.

  First, the molded coil 10 shown in FIGS. 1-4 is demonstrated. In the molded coil 10, the coil winding is covered with the mold resin 7, and both ends 3 a and 3 b of the winding protrude outward from the coil end surface Se. One end 3a of the winding is located on the inner peripheral surface Si side (one end of the coil) when assembled to the stator, and the other end 3b is located on the outer peripheral surface So side (the other end of the coil) The other end 3a and the other end 3b occupy diagonal positions on the coil end surface Se. The molded coil 10 according to the present embodiment (FIGS. 1 to 4) has a coil end surface Se projecting from both ends 3a and 3b of the winding from one coil side surface Ss to the other coil side surface Ss. It is characterized in that one or a plurality of concave grooves 11 are formed.

  The groove 11 is defined by the groove wall 11w and the groove bottom 11b, and the depth of the groove 11 is determined by the top surface 11t and the groove bottom 11b of the groove wall 11w. In the molded coil 10 shown in FIG. 1, one concave groove 11 is provided along the inner peripheral surface Si side of the coil end surface Se. The planar shape of the concave groove 11 is preferably an arc shape along the inner circumferential surface Si. The mold coil 10 in FIG. 1 corresponds to the mold coil 10 between the 12 hour line (radial line) and the 1 hour line (radial line) of the annular stator 50 in FIG. As will be described in detail later, a neutral point bus bar is accommodated in the concave groove 11 of the mold coil 10. One end 3a of the winding protrudes into a portion where the groove wall 11w on the inner peripheral surface Si side is notched. The other end 3b protrudes diagonally to the one end 3a on the outer peripheral surface So side of the flat coil end surface Se having no surrounding groove wall or the like. The mold resin 7 of the mold coil 10 is formed with a core occupation space 8 in order to insert a magnetic core (not shown) from the outer peripheral surface So side.

  The molded coil 10 shown in FIG. 2 has one inner circumferential surface Si side that is the same as the groove 11 of the molded coil shown in FIG. 1 and the other coil side surface Ss from the outer circumferential surface So side of one coil side surface Ss. A total of two concave grooves 11 with one at the middle position are arranged. The mold coil 10 in FIG. 2 corresponds to the mold coil 10 between the 1 o'clock line and the 2 o'clock line of the annular stator 50 in FIG. 5. One concave groove 11 on the inner peripheral surface Si side is preferably circular as described above, but the other concave groove is arcuately curved from the outer peripheral surface So side to the center position. It is good to do.

  The molded coil 10 shown in FIG. 3 includes one coil side surface Ss from the outer peripheral surface So side to the middle position of the other coil side surface Ss and the middle of one coil side surface Ss substantially parallel to the one. A total of two concave grooves 11 with one from the position to the inner peripheral surface Si side of the other coil side surface Ss are arranged. It is preferable that both the concave grooves 11 bend at a sharp curve rather than the curvature of the circumference of the annular stator. The mold coil 10 in FIG. 3 corresponds to each of the eight mold coils 10 in total between the 1 o'clock lines from the 2 o'clock line to the 10 o'clock line in the annular stator 50 in FIG. 5. Therefore, the molded coil 10 having the shape of the concave groove 11 shown in FIG. 3 is most often used for the annular stator 50 of the present embodiment.

  The mold coil 10 shown in FIG. 4 corresponds to the mold coil 10 between the 10 o'clock line and the 11 o'clock line of the annular stator 50 of FIG. The molded coil 10 shown in FIG. 4 may be replaced with the molded coil 10 shown in FIG. That is, if only one concave groove 11 on the inner peripheral side is used without using one concave groove 11 on the outer peripheral side of the molded coil 10 shown in FIG. 3, it is necessary to prepare the mold coil 10 in FIG. There is no. However, it is safe to prepare. In any mold coil 10, the resin thickness of the coil end surface Se provided with the groove 11 (the distance between the envelope surface of the coil winding and the groove groove bottom surface 11b of the mold resin) is the resin on the other coil end surface. It may be the same as the thickness (distance between the envelope surface of the coil winding and the surface of the mold resin). In addition, since various stresses are applied to the mold resin on the coil end surface on which the concave groove is formed from the concave groove wall 11w or the like when the bus bar and the winding are connected, the resin thickness thereof is the coil on the opposite side. You may make it thicker than the resin thickness of an end surface.

  FIG. 5 shows a state in which a stator 50 is formed by inserting a core with a back yoke 41b formed in a single piece into the space occupied by the core, that is, after forming a molded coil into a divided stator, and arranging the divided stator in an annular shape. FIG. Both ends 3a and 3b of the coil winding protrude to the coil end surface Se. Here, the core is configured integrally with a tooth (not shown) and a back yoke 41b. The teeth are exposed on the inner peripheral surface Si. In FIG. 5, the concave groove 11 provided on the coil end surface Se of each mold coil 10 has a start point and an end point necessary for wiring continuously with the concave groove 11 of the adjacent mold coil 10, and these start point and end point. In order to realize the above, it has a circular shape or an arc shape having a larger curvature. A bus bar (not shown) is accommodated in the concave groove 11 in order to supply AC power converted by the inverter module or the like to the stator 50 (see FIG. 7).

  When the molded coil 10 of the present invention is used, the bus bar is arranged in the stator rather than as a separate member. Conventional bus bars are located outside the motor, and development has been focused on simplifying the connection structure with the stator of the motor after being housed in the bus bar housing. However, in the present invention, one or a plurality of concave grooves 11 are provided on the coil end surface Se of the molded coil 10, and the bus bar is accommodated in the concave grooves 11, so that it is much easier than the conventional bus bar configuration. The bus bar housing can be omitted. As a result, weight reduction, parts reduction, simplification of the manufacturing process, and improvement in economy can be obtained.

  Next, the case where the above-described molded coil 10 is used for a three-phase AC motor will be described. FIG. 6 is a diagram showing an equivalent circuit of the stator 50 of the three-phase AC motor. Molded coil 10 is arranged separately into one that is supplied with U-phase power, one that is supplied with V-phase power, and one that is supplied with W-phase power. In each phase, four mold coils 10 are arranged in series, and bus bars 21a to 21c, 22a to 22c, 23a to 23c, and 24 are electrically connected between the mold coils 10. One end 3a of the coil winding of the molded coil 10 located at the extreme end (center side in FIG. 6) of each phase is connected to a neutral point (reference point) bus bar 24 in common to each phase. Further, the other end 3b of the coil winding of the outermost mold coil 10 connected in series is connected to a power supply terminal (not shown) and is supplied with AC power converted from an inverter module or the like.

FIG. 7 is a plan view showing wiring such as bus bars in the actual stator 50 corresponding to the equivalent circuit of FIG. There are four mold coils 10 for each phase, and four of them are connected in series. The neutral-point bus bar 24 shown in FIG. 6 is located on the inner peripheral surface side in a range slightly exceeding the 2 o'clock line from the 12 o'clock line in FIG. 7. Here, the positions of four U-phase molded coils 10 connected in series are collectively shown.
(Molded coil receiving U-phase power supply): U1 (12 o'clock to 1 o'clock), U2 (3 o'clock to 4 o'clock), U3 (6 o'clock to 7 o'clock), U4 (9 o'clock to 10 o'clock)
Each V-phase molded coil 10 is in contact with the U phase with a delay of 1 hour, and the W-phase mold coil 10 is in contact with the V phase with a delay of 1 hour. In the U phase, the winding end 3a of the molded coil 10 (U1) and the bus bar 24 at the neutral point are connected at a welding point F. This mold coil 10 (U1) is the mold coil 10 shown in FIG. The adjacent V-phase molded coil 10 and the W-phase molded coil 10 adjacent thereto are also commonly connected to the neutral point bus bar 24 at its end 3a. The V-phase molded coil 10 connected to the neutral point is the molded coil shown in FIG. 2, and the adjacent W-phase molded coil 10 is the molded coil 10 shown in FIG. These three types (FIGS. 1 to 3) of the molded coil 10 realize a common connection to the neutral point G shown in FIG. In FIG. 7, one mold coil without a groove is shown between the 11 o'clock and 12 o'clock lines, but this mold coil can be used for any other grooved mold without using a groove. Can be replaced with a coil.

  One end 3a passes through the mold coil 10 (U1), and the end 3b is connected to the coil end 3a of the mold coil U2 by a welding point F by a bus bar 21a. The bus bar 21a is housed in a concave groove 11 that curves sharply from the outer peripheral side to the inner peripheral side. It passes through the mold coil 10 (U2) and is connected from its end 3b to the mold coil 10 (U3) by the bus bar 21b. As can be seen from FIG. 7, these mold coils 10 (U2, U3, etc.) are of the type shown in FIG. As described above, the connection of one bus bar to the other end (end on the outer peripheral side) 3b of the winding of the U-phase molded coil 10 and the two U-shaped two molded coils 10 are overcome, and the next U-phase The one bus bar is connected to one end (end on the inner peripheral side) 3a of the winding of the mold coil 10 of the above, and the mold of the U phase is between the 9 o'clock line and the 10 o'clock line. The coil 10 (U4) is reached and connected to the power supply terminal from the outer peripheral side end 3b of the molded coil 10 (U4).

  Formation of the connecting portion F between the both ends 3a and 3b of each mold coil 10 and the bus bar can be performed by spot welding. When the ease of spot welding is important, it is better not to dispose the groove wall 11w in the vicinity of both ends 3a and 3b of the windings of each mold coil 10. By removing the groove wall 11w in the vicinity of both ends 3a and 3b, the end of the winding projecting from the coil end surface Se is made, for example, by projecting the pressure application gripping part associated with the spot welding electrode into a small shape. 3a, 3b and the bus bar stored in the concave groove 11 can be overlapped and sandwiched. As a result, the connection between the bus bars 21a to 21c, 22a to 22c, 23a to 23c, and 24 and the coil ends 3a and 3b becomes very easy.

  The mold coil 10 can be manufactured using, for example, the coil 3 shown in FIG. This coil 3 is a coil formed by winding a rectangular wire having a rectangular cross section in an edgewise manner. The mold coil 10 shown in FIGS. 1 to 4 can be produced by inserting this coil into a mold and injecting a molten resin into the mold. In general, when the coil 3 is wound around the coil, the coil is elongated with a space in the axial direction due to its elastic force, but in order to correct this, when injecting the resin into the mold, It is better to apply pressure in the axial direction to eliminate space and make a tight winding state. The method of applying pressure in the axial direction can be realized by inserting a pin into the mold and applying it with the pin.

By using the mold coil 10 described above, the following effects can be obtained.
(1) A separate bus bar including a bus bar casing in a state separated from the stator is not required.
(2) For this reason, the fixing part for arrange | positioning and fixing the bus bar with a housing | casing of another member around the stator of a motor is not required.
(3) The manufacturing process is simplified, and various manufacturing processes, transportation processes, and the like can be omitted.
The economic improvements, weight reductions, and miniaturizations due to the above (1) to (3) are obvious and large.

(Embodiment 2)
FIG. 9 is a diagram showing a molded coil 10 according to the second embodiment of the present invention. The difference from the molded coil in the first embodiment shown in FIGS. 1 to 4 is that a crossing groove 31 is provided so as to cross the extending direction of the concave groove 11. It is the characteristic of the mold coil 10 of a form. The intersecting groove 31 is defined by the intersecting groove bottom 31b and the intersecting groove wall 31w. Then, the coil winding ends 3a and 3b are notched through the groove wall 11w so that they can be seen from the peripheral surface side opposite to the peripheral surface side where the winding ends 3a and 3b are located. Is formed. That is, the intersecting groove bottom 31 b and the intersecting groove wall 31 w are both formed as notches in the recessed groove wall 11 w of the recessed groove 11.

  By forming the crossing groove 31 as shown in FIG. 10, for example, when spot welding the end 3b of the coil winding and the bus bar 23a, it is necessary to use a relatively large grip jig / earth 61b. The operation can be performed smoothly while applying pressure easily. That is, when the end 3b of the winding and the connecting portion 23t of the bus bar 23a are overlapped, it is necessary to grasp the pressure from both sides and apply it by the jig and ground 61b. Becomes an obstacle to the movement of the jig / earth 61b, which impairs workability. In the operation shown in FIG. 10, current can be passed from the electrode 61 a while the bus bar 23 a is housed in the concave groove 11, and resistance heat can be generated and welded at the boundary between the winding end 3 b and the bus bar 23 a. If there is no crossing groove 31, the bus bar 23 a may be completely moved out of the concave 5 groove to work, and not only the number of processes is increased but also the bus bar is fixed above the concave groove. This will increase the manufacturing cost, for example, by requiring a temporary fixing device for the bus bar. By adding a relatively simple process of forming the crossing groove 31, a very complicated process of connecting the bus bar and the coil winding can be simplified, and the bus bar temporary fixing device and the like accompanying the process can be omitted. .

  FIG. 11 is a partial plan view after connecting a stator formed using molded coil 10 in the present embodiment and a three-phase AC bus bar. Although it is basically the same as the wiring state shown in FIG. 7, provision of the intersecting grooves 31 makes it possible to use a temporary fixing tool or the like using a versatile spot welding apparatus as described in FIG. 10. It is great that a highly reliable weld F can be easily formed without any problems.

(Other embodiments)
1. In the above-described embodiment, the use of the molded coil of the present invention is not particularly limited, but in fact, the molded coil of the present invention has a possibility of being used for any application in which a motor is used.
2. In the embodiment of the present invention, the specific number of poles and slots has been described, but the molded coil of the present invention can be used for a motor having any number of poles and slots. it can.
3. In the above embodiment, only the edgewise type coil using the flat wire has been described, but it is not limited to the flat wire but may be a round wire, and the flat wire is not limited to the edgewise type.
4. The plurality of mold coils of each phase of the three-phase AC motor are connected in series, but may be connected in parallel. In this case, the concave grooves are provided concentrically.
5). In the above embodiment, the concave groove 11 has a curved shape connecting the start point and the end point. However, the bus bar is flexible, and the circular concave groove is stepped between the start point and the end point. It may be in the form of connecting.

  Although the embodiments and examples of the present invention have been described above, the embodiments and examples of the present invention disclosed above are merely examples, and the scope of the present invention is the implementation of these inventions. It is not limited to the form. The scope of the present invention is indicated by the description of the scope of claims, and further includes meanings equivalent to the description of the scope of claims and all modifications within the scope.

  According to the molded coil of the present invention, it is possible to promote the reduction of parts, weight reduction, downsizing, and improvement of economy by looking over the entire motor including other parts.

It is a perspective view which illustrates the mold coil in Embodiment 1 of this invention. It is a perspective view which shows another mold coil in Embodiment 1 of this invention. It is a perspective view which shows another mold coil in Embodiment 1 of this invention. It is a perspective view of a mold coil different from the above in Embodiment 1 of the present invention. It is a top view in the state where the division stator obtained from the above-mentioned mold coil was assembled to the stator. It is an equivalent circuit diagram of the stator of a three-phase AC motor. It is a top view of the state which connected the mold coil and bus bar of the stator. It is a perspective view which shows the coil (winding as it is) before making it a mold coil. It is a perspective view which shows the mold coil in Embodiment 2 of this invention. It is a figure which shows the state which assembled a stator using the mold coil shown in FIG. 9, and spot-welded a bus-bar and the other end of a coil. FIG. 10 is a partial plan view of a state in which the stator is assembled using the molded coil or the like shown in FIG. 9 and the bus bar and the coil are connected.

Explanation of symbols

3 windings, 3a, 3b winding ends, 7 mold resin, 8 core space, 10 mold coil, 11 groove, 11b groove bottom, 11t top surface of groove wall, 11w groove wall, 21a-21c, 22a to 22c, 23a to 23c, 24 Bus bar, 31 Cross groove, 31b Cross groove bottom, 31w Cross groove wall, 41b Back yoke, 50 Stator, 61a Electrode, 61b Grab jig and ground, Se coil end surface, Si inner peripheral surface , So outer peripheral surface, Ss coil side surface, U, V, W, G Three-phase AC phase.

Claims (3)

A mold coil of a split stator that is arranged in a ring to form a stator,
A molded coil, wherein one or a plurality of concave grooves are provided on a coil end surface of the molded coil from one side surface side to the other side surface side.   Both ends of the winding of the mold coil protrude to one coil end side of the mold coil, and the concave groove is located on a coil end surface on the side where both ends of the winding protrude, and the winding One end of the wire protrudes from one end of the coil, the other end protrudes from the other end of the coil, and one end and the other end of the winding are the coil end. The molded coil according to claim 1, which occupies a diagonal position of a surface. The plurality of concave grooves extend so as to intersect the direction in which the concave grooves extend, cut out the wall of the concave groove, and intersecting grooves at two locations so that one end and the other end of the winding can be seen through. The molded coil according to claim 1, wherein the molded coil is attached.

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