JP2009177864A - Stator with resin molded coil end - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achieve weight reduction of a stator with a resin molded coil end. <P>SOLUTION: A pair of steel plates 28 for sealing are provided on the opposite sides of a stator core 12a in the axial direction. A coil 14 is wound around the stator core 12a and the steel plates 28 for sealing, and a resin molded coil end 24 is provided by molding a coil end 20, i. e. a portion of the coil 14 projecting in the axial direction from the opposite sides of the stator core 12a in the axial direction, with resin 22. A hole 34 for removing the metal in order to reduce the weight is provided in the stator core 12a. Opposite ends of the hole 34 for removing the metal are closed by a pair of steel plates 28 for sealing. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention includes a stator core and a coil wound around the stator core, and the resin-molded coil end is formed by molding a coil end, which is a portion protruding in the axial direction from the axial end surface of the stator core, into a resin. The present invention relates to a provided stator with a resin mold coil end.

  Conventionally, in a rotating electrical machine including a stator and a rotor, it has been considered that a coil end which is a stator body constituting the stator and is a coil portion protruding in the axial direction from both axial end surfaces of the stator core is impregnated by varnish impregnation. Yes. In recent years, a resin-molded coil-end stator having a resin-molded coil end that is formed by resin-molding the coil end has been considered for cost reduction by automation at the time of manufacturing a rotating electrical machine.

  FIG. 7 is a schematic cross-sectional view showing a conventional stator with a resin mold coil end. FIG. 8 is an enlarged cross-sectional view corresponding to a portion A in FIG. 7 when a resin mold coil end is provided at the end of the stator core by injecting resin into the mold. As shown in FIGS. 7 and 8, the stator 10, which is a stator with a resin mold coil end, includes a stator core 12 configured by laminating a plurality of steel plates, and a coil 14. The stator core 12 includes a cylindrical yoke 16 and a plurality of teeth 18 protruding in the radial direction from the inner peripheral surface of the yoke 16, and a multi-phase coil 14 is wound around the teeth 18 in a concentrated winding manner. In addition, resin-molded coil ends 24 are provided at both axial ends of the stator 10 by molding the coil ends 20, which are coil portions protruding from both axial end surfaces of the stator core 12, with resin.

  In Patent Document 1, the lower surface of the peripheral edge of the stator is placed on the first mold jig, the second mold jig is placed on the upper surface of the peripheral edge of the stator, and the inner hole of the stator is attached to the third mold jig. It is described that the liquid mold resin is injected from the opening formed in the upper part of the second mold jig in a state of being penetrated and placed on the second step portion formed in the first mold jig. Yes. It is said that a molded stator can be obtained by removing the mold jig when the injected mold resin is solidified.

JP 2004-48957 A

  When the resin mold coil end 24 is provided as in the stator 10 shown in FIGS. 7 and 8 described above, the weight of the stator 10 is increased due to the provision of the resin 22. In particular, as a method of winding the coil 14 around the stator 10, the concentrated winding type and the distributed winding type as shown in FIGS. 7 and 8 are known. In the case of the concentrated winding type, The overall length of the yoke 16 in the axial direction is increased, and the weight is easily increased. That is, in the case of the concentrated winding type, the connection processing portion 26 for connecting the lead wire of the coil 14 is often provided on the outer diameter side of the resin mold coil end 24 on the axial end surface of the yoke 16, and the space is provided. In order to ensure, that is, it is necessary to provide the connection processing portion 26 and the resin-molded portion of the connection processing portion 26 on the outer side in the axial direction of the yoke 16, and the abutment portion of the resin injection mold or the resin mold seal portion. As the width in the radial direction of 16, it is necessary to secure a width larger than the radial width necessary for forming the magnetic circuit. Therefore, coupled with the necessity of resin molding of the coil end 20 and the connection processing unit 26, the overall weight is easily increased. In FIG. 8, the oblique lattice portion represents a resin mold seal portion for preventing the resin 22 from entering the injection unnecessary portion when the resin 22 is injected into the mold when the resin mold coil end 24 is formed. Yes.

  An object of the present invention is to reduce the weight of a stator with a resin mold coil end.

  A stator with a resin-molded coil end according to the present invention includes a stator core and a coil wound around the stator core. Of the coil, a coil end that is a portion protruding in the axial direction from the axial end surface of the stator core is molded into resin. A resin-molded coil end having a resin-molded coil end provided with a hollow portion for lightening provided inside the stator core for weight reduction It is an attached stator. Further, preferably, the solid body is not inserted into the hollow portion for removing the meat over the entire axial length.

  In the stator with a resin mold coil end according to the present invention, preferably, in the stator core, the axial end portion of the hollow portion for hollowing out is closed.

  In the stator with a resin mold coil end according to the present invention, preferably, the axial end portion of the hollowing cavity portion is closed by a member made of the same material as that constituting the stator core.

  Moreover, in the stator with a resin mold coil end according to the present invention, preferably, the axial end portion of the cavity for hollowing out is made of the same material as that constituting the stator core, and is made of a steel plate for sealing or a closing member made of steel. It is blocked.

  Moreover, in the stator with a resin mold coil end according to the present invention, preferably, a coolant is circulated inside the hollowing cavity.

  A stator with a resin-molded coil end that is provided with a resin-molded coil end by molding the coil end into a resin according to at least one of the above-described structures, and is a meat for weight reduction provided inside the stator core. A punching cavity is provided. For this reason, the weight of the stator core can be reduced, and the weight reduction can be achieved by providing the resin mold coil end, although the weight tends to increase.

  In addition, at least one of the above-described configurations closes the axial end portion of the cavity for hollowing out in the stator core. For this reason, since the resin mold coil end is provided on the side of the stator core in the axial direction, even when a liquid resin is injected into the mold, the resin can be prevented from entering the inside of the hollowing cavity. Therefore, weight reduction can be achieved more effectively.

  In addition, at least one of the above-described configurations, the end portion in the axial direction of the hollowing cavity portion is closed by a member made of the same material as that constituting the stator core. For this reason, even when a liquid resin is injected into the mold to provide a resin mold coil end, the resin is prevented from entering the inside of the hollowing cavity by the member forming the magnetic circuit, thereby reducing the weight. More effective. Further, there is no need to use a special member that does not form a magnetic circuit, only to prevent the resin from entering the inside of the hollowing cavity.

  In addition, the refrigerant is circulated inside the hollow portion for hollowing out by at least one of the above-described configurations. For this reason, the weight of the stator can be reduced, and an excessive temperature rise of the stator can be prevented to improve performance.

[First Embodiment]
Hereinafter, embodiments according to the present invention will be described in detail with reference to the drawings. 1 to 3 show a first embodiment of the present invention. FIG. 1 shows a stator with a resin mold coil end according to the present embodiment. In the stator, a resin mold coil end is provided at the end of the stator core by injecting resin into the mold. FIG. FIG. 2 is a schematic perspective view showing a state immediately before the stator core constituting the stator of FIG. 1 and a pair of sealing steel plates are combined. FIG. 3 is a partially enlarged view of the stator core of FIG.

  As shown in FIG. 1, a stator 10a for constituting a motor includes a stator core 12a provided at an intermediate portion in the axial direction and a pair of sealing steel plates 28 provided on both axial sides of the stator core 12a. Each sealing steel plate 28 is made of a steel plate such as an electromagnetic steel plate. The stator core 12 a includes a cylindrical yoke 16 having a substantially circular cross section, and teeth 18 projecting radially inward at a plurality of circumferentially spaced positions on the inner peripheral surface of the yoke 16. Such a stator core 12a is constituted by laminating a plurality of core steel plates made of steel plates such as electromagnetic steel plates having the same shape in the axial direction (vertical direction in FIG. 1).

  Further, as shown in FIG. 2, protrusions 30 projecting radially outward are provided at a plurality of circumferential locations (three locations in the figure) on the outer circumferential surface of the stator core 12 a, and the projections 30 penetrate in the axial direction. A bolt insertion intermediate hole 32 is provided. Such a protrusion 30 and the bolt insertion intermediate hole 32 are constituted by a part of a portion formed by laminating a plurality of core steel plates.

  Further, at the plurality of circumferential positions (12 in the drawing) of the yoke 16 constituting the stator core 12a, the lightening holes 34, which are lightening cavities having a substantially rectangular cross section, are provided for weight reduction. The yoke 16 is provided so as to penetrate in the axial direction. That is, the stator 10 a (FIG. 1) includes a lightening hole 34 provided inside the yoke 16. These thinning hole portions 34 are not limited to a shape having a substantially rectangular cross section as shown in detail in FIG. 3, and may be various shapes such as a circle.

  Further, in order to provide the lightening hole 34, a short hole portion 36 (FIG. 3) constituting the lightening hole 34 is formed at a position where the core steel plates are aligned with each other. In a state where a plurality of core steel plates are laminated, the short hole portions 36 formed in the plurality of core steel plates are connected in the axial direction to form the lightening hole 34.

  Returning to FIG. 2, each of the sealing steel plates 28 provided on both sides of the stator core 12 a has the same outer peripheral shape as the outer peripheral shape when the stator core 12 a is viewed in the axial direction. For example, a plurality of outer teeth elements 38 that are aligned with the plurality of teeth 18 provided on the inner peripheral surface of the stator core 12 a are formed on the inner peripheral surface of each sealing steel plate 28.

  Also, bolt insertion outer hole portions 40 are provided at a plurality of locations (three locations in the figure) aligned with the plurality of bolt insertion intermediate hole portions 32 provided in the stator core 12a in the portion near the outer periphery of each sealing steel plate 28. Forming. On the other hand, no hole is formed at a position where each of the steel plates for sealing 28 is aligned with the plurality of lightening holes 34 provided in the stator core 12a. Therefore, as shown in FIG. 2, with the pair of sealing steel plates 28 superimposed on both axial sides of the stator core 12a, as shown in FIG. A pair of sealing steel plates 28 is closed.

  When the stator 10a is configured, a pair of sealing steel plates 28 are overlapped on both axial sides of the stator core 12a, and the plurality of bolt insertion intermediate holes 32 and the plurality of bolt insertion outer holes 40 are aligned. Combine by state. Further, both end portions in the axial direction of the lightening hole 34 provided in the yoke 16 are closed by a pair of sealing steel plates 28 made of the same material as that constituting the stator core 12a. Further, the solid body is not inserted into the lightening hole 34 over the entire axial length.

  Further, the coil 14 is wound around the tooth 18 formed on the inner peripheral surface of the stator core 12a and the outer tooth element 38 formed on the pair of sealing steel plates 28 by a concentrated winding type. That is, the coil 14 is wound around the teeth 18 and the outer teeth elements 38 so that coils of different phases are wound around the teeth 18 and the outer teeth elements 38 in the circumferential direction.

  Further, as shown in FIG. 1, similarly to the conventional structure shown in FIGS. 7 to 8, the coil end 20, which is a coil portion protruding from both axial end surfaces of the stator core 12 a, The resin processing coil 26 is provided at both ends in the axial direction of the stator core 12a by molding the connection processing portion 26 formed by the lead wire of the coil 14 provided on the radially outer side of the coil end 20 with the resin 22. Yes.

  In FIG. 1, the resin mold seal portion is represented by a diagonal lattice portion. That is, even when the resin mold coil end 24 is molded, no resin is formed in the portion corresponding to the resin mold seal portion represented by the oblique lattice. The resin mold seal part may be a part of the mold. Further, when the resin mold coil end 24 is molded, a resin mold seal portion is provided on the outer side in the axial direction of the bolt insertion outer hole portion 40 (FIG. 2), and the bolt insertion outer hole portion 40 and the bolt insertion intermediate hole portion. The resin is prevented from entering inside 32 (FIG. 2). Before forming the resin mold coil end 24, the bolt insertion outer hole 40 is not formed in each sealing steel plate 28. After forming the resin mold coil end 24, the bolt insertion outer side is formed in each sealing steel plate 28. The hole 40 may be formed.

  The stator 10a configured in this manner is not illustrated by arranging a rotation shaft (not shown) on the inside so as to be rotatable with respect to the stator 10a, and providing a rotor (not shown) on a portion of the outer peripheral surface of the rotation shaft facing the stator 10a. Configure the motor. The motor may be a permanent magnet type motor in which permanent magnets are provided at a plurality of locations in the circumferential direction of the outer peripheral surface of the rotor, but may be other types of motors such as a synchronous motor. Further, the stator 12a after resin molding is fixed to a motor case (not shown) by bolts inserted through the bolt insertion intermediate hole 32 and the bolt insertion outer hole 40.

  According to the stator 10a of the present embodiment configured as described above, the stator core 12a and the coil 14 wound around the stator core 12a are provided, and the coil 14 projects in the axial direction from the axial end surface of the stator core 12a. The resin-molded coil end 24 is provided by molding the coil end 20 which is a part into the resin 22. Further, a lightening hole 34 is provided in the stator core 12a for weight reduction. For this reason, the weight of the stator core 12a can be reduced, and by providing the resin mold coil ends 24 on both sides in the axial direction, the weight can be reduced although the weight tends to increase.

  Further, in the stator core 12 a, both end portions in the axial direction of the lightening hole 34 are closed by a pair of sealing steel plates 28. Therefore, in order to mold the resin mold coil end 24 at the axial end of the stator core 12a, as shown in FIG. The resin can be prevented from entering the inside of the portion 34. Therefore, the weight reduction of the stator core 12a can be achieved more effectively.

  Further, the axial end of the lightening hole 34 is closed by a sealing steel plate 28 which is a member made of the same material as that constituting the stator core 12a. For this reason, even when liquid resin is injected into the mold in order to mold the resin mold coil end 24, the resin is prevented from entering the inside of the hole for hole 34 by the member forming the magnetic circuit, Weight reduction can be achieved more effectively. Further, there is no need to use a special member that does not form a magnetic circuit, only for preventing the resin from entering the inside of the lightening hole 34.

[Second Embodiment]
FIG. 4 is a schematic perspective view showing a stator core constituting the stator, which is a stator with a resin mold coil end in the second embodiment of the present invention. The stator core 12b that constitutes the stator of the present embodiment is the same as that of the first embodiment described above. 34 is formed. In addition, each protrusion 30 is formed with a bolt insertion intermediate hole 32 (see FIG. 2, not shown in FIG. 4) similar to the case of the first embodiment. Since other configurations and operations are the same as those in the first embodiment, the same parts are denoted by the same reference numerals, and overlapping illustrations and descriptions are omitted. In addition, the position and number of the lightening holes 34 provided in the stator are not limited to the case of each of the above embodiments, and can be various positions and numbers.

[Third Embodiment]
FIG. 5 is a half schematic cross-sectional view showing a stator core constituting the stator, which is a stator with a resin mold coil end, in the third embodiment of the present invention. In the stator of the present embodiment, the steel plate for sealing 28 (see FIGS. 1 and 2) is not laminated on either side of the stator core 12c in the axial direction. Instead, in the present embodiment, the closing members 42 are inserted and fixed at both end portions in the axial direction of the lightening holes 34 formed at a plurality of locations of the stator. The closing member 42 has a columnar shape with a substantially rectangular cross-sectional shape, and has a shape that can be inserted into and fixed to the end of the lightening hole 34 without a gap. Therefore, the end portion in the axial direction of the lightening hole 34 is closed by the closing member 42 that is a member made of the same material as that of the stator core 12c. The closing member 42 is made of a material other than steel, for example.

  When the stator is configured, the steel plates 28 for sealing (see FIGS. 1 and 2) are provided on both axial sides of the stator core 12c in a state where the coil 14 (see FIG. 1) is wound around the teeth 18 configuring the stator core 12c. The resin-molded coil end 24 (see FIG. 1) is directly provided without any intervening. For this reason, unlike the case of each said embodiment, the steel plate 28 for sealing can be abbreviate | omitted from a stator. Since other configurations and operations are the same as those of the first embodiment shown in FIGS. 1 to 3 described above, the same parts are denoted by the same reference numerals, and overlapping illustrations and descriptions are omitted.

[Fourth Embodiment]
FIG. 6 is a stator with a resin mold coil end in the fourth embodiment of the present invention, in which the stator pipe and the steel plate for sealing are partly omitted from the state where the cooling pipe is inserted. FIG. In the present embodiment, in the first embodiment shown in FIG. 1 to FIG. 3 described above, a plurality of lightening holes 34 formed in the yoke 16 constituting the stator core 12d of the pair of sealing steel plates 28. Of these, substantially rectangular through holes 44 are formed at positions aligned with some of the lightening holes 34. The cross-sectional shape of the through hole 44 may be a substantially rectangular shape similar to the cross-sectional shape of the opening of the lightening hole 34.

  Further, after providing a resin mold coil end 24 (see FIG. 1) (not shown) on both sides in the axial direction of the stator core 12d via a sealing steel plate 28, through holes 44 formed in each sealing steel plate 28, and A cooling pipe 46 is inserted through the lightening hole 34 aligned with the through hole 44. The cooling pipe 46 is not solid. That is, the cooling pipe 46 is formed with a flow path for circulating cooling water as a refrigerant. In the present embodiment, in the sealing steel plate 28, a through hole is not formed in a portion facing a portion other than the lightening hole 34 through which the cooling pipe 46 is inserted among the plurality of lightening holes 34. It is blocking.

  Further, the through holes 44 formed in each sealing steel plate 28 are formed by punching or the like after the resin mold coil ends 24 (see FIG. 1) are provided on both axial sides of the stator core 12d. With this configuration, the through hole 44 is not formed before the resin mold coil end 24 is formed. For this reason, at the time of molding the resin mold coil end 24, the liquid resin is prevented from entering the inside of the lightening hole 34. Further, when the resin mold coil end 24 is molded, a resin mold seal portion (see the oblique lattice portion in FIG. 1) is provided outside the bolt insertion outer hole portion 40 so that the bolt insertion outer hole portion 40 and the bolt insertion portion are inserted. The resin is prevented from entering the intermediate hole 32 (see FIG. 2). Even when the resin mold coil end 24 is provided, the resin is not provided at a position facing at least a portion where the through hole 44 for inserting the cooling pipe 46 is formed.

  When the stator is used, as shown by an arrow α in FIG. 6 from one side of the cooling pipe 46, cooling water as a refrigerant is supplied and cooling water is taken out from the other side. Both ends of the cooling pipe 46 are connected to a cooling circuit (not shown). The cooling circuit includes a heat exchanging unit and a cooling water pump, and the cooling water circulating through the cooling circuit by driving the cooling water pump decreases in temperature by passing through the heat exchanging unit. The refrigerant is supplied to the cooling pipe 46. As described above, in the present embodiment, a predetermined arbitrary hole for hole 34 is used for refrigerant circulation.

  According to this embodiment, the cooling water is circulated inside the meat removal hole 34. For this reason, the weight of the stator can be reduced, and an excessive temperature rise of the stator can be prevented to improve the performance.

  In the example shown in the figure, the cooling pipe 46 is inserted into the single hole 34 provided in the stator core 12d, and the single hole 34 is used for refrigerant circulation. I am doing. However, the present embodiment is not limited to the case where the number and position of the lightening holes 34 used for refrigerant circulation are provided only at the position shown in FIG. For example, among the plurality of lightening holes 34, a part of the lightening holes 34 at a plurality of positions at equal intervals in the circumferential direction or all of the lightening holes 34 are used for refrigerant distribution. You can also Also in this case, after the resin mold coil ends 24 (see FIG. 1) are provided on both sides in the axial direction of the stator core 12d, each of the sealing steel plates 28 is formed at a portion facing the lightening hole 34 used for refrigerant circulation. The through hole 44 is formed. Since other configurations and operations are the same as those of the first embodiment shown in FIGS. 1 to 3 described above, the same parts are denoted by the same reference numerals, and overlapping illustrations and descriptions are omitted.

  In each of the above embodiments, the case where the stator cores 12a, 12b, 12c, and 12d are made of steel plates has been described. However, the present invention is not limited to such a structure. For example, the stator cores 12a, 12b, 12c, and 12d may be made of a dust core. Further, in each of the above-described embodiments, the case where the coil 14 (see FIG. 1) is wound around the stator cores 12a, 12b, 12c, and 12d by the concentrated winding type has been described. However, the distributed winding type is used for the stator cores 12b, 12c, and 12d. The coil 14 can also be wound. However, from the aspect of making the effect of reducing the weight obtained by providing the configuration of the present invention more conspicuous, the stator cores 12a, 12b, 12c, and 12d are concentrated winding type as in the above embodiments. More preferably, the coil 14 is wound.

FIG. 7A shows a case where the resin-molded coil end is provided at the end of the stator core by injecting resin into the mold, which is the stator with the resin-molded coil end according to the first embodiment of the present invention. FIG. It is a schematic perspective view which shows the state just before combining the stator core which comprises the stator of FIG. 1, and a pair of steel plate for sealing. FIG. 3 is a partially enlarged view of the stator core of FIG. 2. It is a schematic perspective view which shows the stator core which comprises the stator which is a stator with a resin mold coil end of the 2nd Embodiment of this invention. It is a half part schematic sectional drawing which shows the stator core which comprises the stator which is a stator with a resin mold coil end of the 3rd Embodiment of this invention. FIG. 9 is a partial schematic perspective view showing a state in which a cooling pipe is inserted through a stator core and a steel plate for sealing in a stator which is a stator with a resin mold coil end according to a fourth embodiment of the present invention. FIG. It is a schematic sectional drawing which shows the stator with a resin mold coil end considered conventionally. FIG. 8 is an enlarged cross-sectional view corresponding to a portion A in FIG. 7 when a resin mold coil end is provided at the end of the stator core by injecting resin into the mold.

Explanation of symbols

  10, 10a Stator, 12, 12a, 12b, 12c, 12d Stator core, 14 coils, 16 yokes, 18 teeth, 20 coil ends, 22 resin, 24 resin molded coil ends, 26 connection processing section, 28 steel plate for sealing, 30 bumps Part, 32 bolt insertion intermediate hole part, 34 thinning hole part, 36 short hole part, 38 outer teeth element, 40 bolt insertion outer hole part, 42 closing member, 44 through hole, 46 cooling pipe.

Claims (5)

A stator core;
A coil wound around a stator core,
Among the coils, a stator with a resin mold coil end provided with a resin mold coil end by molding a coil end that is a portion protruding in the axial direction from the axial end surface of the stator core,
A stator with a resin mold coil end, comprising a hollow portion for lightening provided inside a stator core for weight reduction. In the stator with a resin mold coil end according to claim 1,
A stator with a resin-molded coil end, characterized in that the axial end portion of the hollowing cavity portion is closed in the stator core. In the stator with a resin mold coil end according to claim 2,
A stator with a resin mold coil end, characterized in that an axial end portion of a hollow portion for lightening is closed by a member made of the same material as that constituting the stator core. In the stator with a resin mold coil end according to claim 3,
A stator with a resin mold coil end, characterized in that an axial end portion of the hollow portion for hollowing out is closed by a steel sealing steel plate or a closing member, which is the same material as that constituting the stator core. In the stator with a resin mold coil end according to claim 1,
A stator with a resin-molded coil end, wherein a coolant is circulated inside a hollow portion for meat removal.

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