JP2009254001A - Coil and split stator equipped with this coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil which can reduce loss due to an eddy current, is easily processed by winding a wire and can be easily stacked and assembled to a stator and the like. <P>SOLUTION: The coil 1 is provided with a plurality of cylindrical coil members 6, 7, 8, 9 which are stacked in nest and assembled. The cylindrical coil members are each formed so as to have inner spaces 12, 13, 14, 15 each having at least one cross sectional width tapered in a direction perpendicular to a coil shaft, respectively. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a coil and a split stator including the coil. Specifically, the present invention relates to a coil suitable for a stator of an electric motor and the like and a split stator.

  In general, electric motors are required not only to have high output and high efficiency, but also to be small and light. For this reason, various improvements and developments have been made.

  In an electric motor, a coil is formed by winding a winding made of a conductor around a core of a stator made of a magnetic material. However, in order to realize a smaller size at a high output, the space factor of the winding is used. Is required to be improved to the limit. In order to increase the magnetic force and obtain a large output, it is necessary to pass a large current through the winding. In order to increase the space factor and allow a large current to flow, a rectangular winding having a rectangular cross section is often employed. In particular, the edgewise coil formed by winding the above-described rectangular winding with its short side directed toward the coil axis not only increases the space factor and secures the number of turns, but also a molded coil. Since the so-called cassette method can be employed in which the core is inserted into the teeth portion of the core and assembled, the assembly process can be reduced.

On the other hand, the edgewise coil has a wide conductor width because the cross section of the winding is rectangular, and a large eddy current tends to be generated because the short side is wound toward the axis of the coil. For this reason, there is a problem that the loss is large. In addition, when forming a coil, there is a problem that bending is difficult because the conductor width in the bending direction is wide. In order to avoid the inconvenience of the edgewise coil, a plurality of copper wires having a small conductor width are wound in parallel, and these are electrically connected in parallel to reduce eddy current and facilitate processing. A coil is provided that can.
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  The coil described in Patent Document 1 is configured by winding a plurality of parallel lines in which thin conductors covered with an insulating layer are joined in parallel in one plane in the width direction.

  The coil described in Patent Document 1 employs a winding having a circular cross section, so that a gap is generated between adjacent windings, and the space factor cannot be increased. In addition, since the coils are formed by winding the windings in an annular shape, when used in a split stator arranged in an annular shape, a large gap is generated between adjacent stators, which increases the efficiency of the motor. Have difficulty.

  Furthermore, it is difficult to position a plurality of windings to be combined, and each winding is easily deformed because a plurality of thin wires having a circular cross section are wound. For this reason, in order to position each winding and to ensure shape retention, an adhesion process for bonding and fixing each winding is required.

  The present invention solves the above-mentioned conventional problems, reduces loss due to eddy currents, is easy to wind, has high shape retention, and can be easily assembled to a stator or the like. It is an issue to provide.

  The coil according to the present invention includes a plurality of cylindrical coil members stacked and assembled in a nested manner, and each cylindrical coil member has a taper shape with at least one cross-sectional width in a direction perpendicular to the coil axis. It is formed with a changing internal space.

  In the present invention, a plurality of cylindrical coil members are assembled in a nested manner. Therefore, by forming at least one cross-sectional width in a direction perpendicular to the coil axis of each cylindrical coil member into a tapered shape, each cylindrical coil member can be positioned and assembled via these tapered surfaces. Therefore, each cylindrical coil member can be assembled with high accuracy and easily.

  The shape in which the cross-sectional width changes into a taper shape is not particularly limited. For example, as in the invention described in claim 2, each of the cylindrical coil members can be configured to have a truncated pyramid-shaped or truncated cone-shaped internal space. Each cylindrical coil member disposed on the inner side is positioned and laminated on the inner peripheral surface of the outer cylindrical coil member. In particular, when a cylindrical coil member having a truncated pyramid internal space is configured and assembled to a core of a split stator of an electric motor, a dead space between the split stators can be minimized.

  Furthermore, since each cylindrical coil member can be positioned and laminated via the tapered surface, the winding of each cylindrical coil member is not easily displaced or deformed, and the shape retaining property of the coil is improved. Therefore, it is possible to assemble each cylindrical coil member without bonding or the like.

  Although the cross-sectional form of the winding constituting the cylindrical coil member is not particularly limited, it is preferable to employ a winding having a rectangular cross section as in the invention described in claim 3. A winding having a rectangular cross section has high shape retention after winding, and can prevent deformation and the like during assembly.

  Moreover, when the said rectangular cross section is employ | adopted, like the invention described in Claim 4, a cylindrical coil member can be formed by winding the short width surface of each coil | winding toward a coil axis | shaft. In this case, each coil member is formed by edgewise winding a rectangular wire.

  On the other hand, like the invention described in claim 5, each cylindrical coil member can be formed by winding the long width surface of each winding toward the coil axis. In this case, each cylindrical coil member is configured in a form in which a flat wire is wound flatwise.

  The connection form of the plurality of cylindrical coil members is not particularly limited. As in the invention described in claim 6, the plurality of cylindrical coil members can be connected in parallel.

  For example, each of the cylindrical coil members is configured such that the above-described cross-section of a winding having a conventional rectangular cross-section wound edgewise is divided in the radial direction of the coil, and the terminals of each cylindrical coil member are integrated. By connecting them together, it is possible to form a coil having characteristics equivalent to those of a coil in which a rectangular winding is wound edgewise and generating little eddy current.

  Further, as in the invention described in claim 7, the plurality of cylindrical coil members can be connected in series to constitute a coil.

  As in the invention described in claim 5, when the long-width surface of the winding having a rectangular cross section is wound around the coil axis, the cross-sectional width in the coil diameter direction of each winding is reduced, thereby suppressing the generation of eddy currents. Can do. On the other hand, there is a problem that the number of turns of each cylindrical coil is reduced. However, it is possible to secure the number of turns by connecting the plurality of stacked cylindrical coil members in series, and the above-described disadvantage can be solved.

  In addition, in a coil configured by winding a winding having a rectangular cross section in a plurality of stages flatwise, it is difficult to process the rewind portion, and a space is often generated to reduce the space factor. In this invention, since each cylindrical coil member laminated | stacked on the radial direction of a coil can be formed separately, it becomes possible to raise the space factor in a winding part. Moreover, when the cylindrical coil members having different winding directions are assembled alternately, it is possible to extend the connection terminals of the respective cylindrical coil members from the same part, and the series connection of the respective cylindrical coil members can be easily performed. It is also possible to do this.

  The invention described in claim 8 is such that the cross-sectional area of the winding of the cylindrical coil member assembled outside is set larger than the cross-sectional area of the winding of the cylindrical coil member assembled inside.

  In order to improve the efficiency of generating magnetic lines of force in the coil, it is preferable to make the magnitude of the current flowing in each winding the same. On the other hand, in the present invention, since the winding diameter of the cylindrical coil member disposed on the outside increases, the length of the winding also increases, and the resistance increases accordingly. By adopting the above configuration, the magnitude of the current flowing through each coil member can be made constant, the generation of eddy current and leakage magnetic flux can be prevented, and the efficiency of the coil can be increased.

  The invention described in claim 9 is such that the plurality of cylindrical coil members are molded of resin.

  By resin-molding an assembly of a plurality of cylindrical coil members, the cylindrical coil members are not separated and can be easily assembled to the core of the stator. Moreover, heat dissipation can be improved by employ | adopting a thing with high heat conductivity for the said mold resin.

  According to a tenth aspect of the present invention, a coating layer having a predetermined thickness is provided on the inner peripheral portion of the coil.

  In a split stator or the like such as an electric motor, an insulating insulator is interposed between a coil and a tooth portion around which the coil is wound. By employ | adopting the said structure, the function of the said insulator can be given to the said coating layer. Accordingly, an insulator is not required, and the number of parts and the number of assembling steps can be reduced.

  The invention described in claim 11 relates to a split stator including the coil described in claims 1 to 10 and a core in which a tooth portion is inserted in the internal space of the coil.

  The type of the electric motor and the form of the core and the like are not particularly limited. The said core can employ | adopt what was formed with the laminated steel plate, what was compacted, etc. In order to increase the efficiency of the electric motor by reducing the gap between adjacent cores, it is preferable to employ a split stator having a core with a rectangular cross section.

  According to a twelfth aspect of the present invention, the split stator is configured by including an insulator interposed between the tooth portion and the inner peripheral surface of the coil.

  The form of the insulator is not particularly limited. In the present invention, it is desirable to adopt a form that can hold the plurality of cylindrical coil members and that can be attached to the teeth integrally.

  According to the present invention, it is possible to provide a coil that can reduce loss due to eddy current, can be easily wound, and can be easily assembled to a stator core and the like.

  Embodiments of the present invention will be specifically described below with reference to the drawings.

  FIG. 1 is an overall perspective view showing an example of a coil according to the present invention. FIG. 2 is an exploded perspective view of the coil 1.

  The coil 1 is formed by assembling four substantially rectangular cylindrical coil members 6, 7, 8, and 9 formed by winding windings 2, 3, 4, and 5 each having a rectangular cross section. The

  As shown in FIG. 3, each of the cylindrical coil members 6, 7, 8, 9 has a tapered shape in which a pair of opposed coil inner peripheral surfaces 10 a, 10 a is inclined at an angle A with respect to the coil axis X. As shown in the figure, the internal space 12, 13, 14, 15 having a truncated pyramid shape is opened, and the windings 2, 3, 4, and 5 are wound. Moreover, each cylindrical coil member 6,7,8,9 is a coil | winding which comprises the cylindrical coil member arrange | positioned inside on the internal peripheral surface of the coil | winding which comprises the cylindrical coil member arrange | positioned outside. The windings 2, 3, 4, and 5 are wound so that the outer peripheral surfaces of the windings are in contact with each other without gaps.

  As the windings 2, 3, 4 and 5, copper wires having a substantially rectangular cross section are employed as shown in FIG. 3, and each winding is provided with an insulation coating (not shown).

  As shown in FIG. 3, in this embodiment, the tapered coil inner peripheral surfaces 10 a of the stacked cylindrical coil members 6, 7, 8, 9 and the outer periphery of the cylindrical coil member inserted therein The surface 11a is brought into contact with and assembled. Moreover, in the present embodiment, each of the cylindrical coil members 6, 7, 8, and 9 is formed in a rectangular cylindrical shape as a whole. For this reason, each cylindrical coil member 6,7,8,9 can be positioned with high precision, and can be assembled | attached easily.

  Moreover, since each cylindrical coil member 6,7,8,9 can be positioned and laminated | stacked via the said taper-shaped coil inner peripheral surface 10a and the coil outer peripheral surface 11a which are made to contact, each cylindrical coil member 6, after an assembly | attachment. The windings 2, 3, 4, and 5 of 7, 8, and 9 are not easily displaced or deformed. Moreover, in the present embodiment, since the winding having a rectangular cross section is employed, the shape retaining property of the coil itself is high. Therefore, the coil 1 can be formed by assembling the cylindrical coil members 6, 7, 8, 9 without bonding or the like.

  4 and 5 show an example in which a split stator of an electric motor is configured using the coil 1 according to the present embodiment.

  The divided stator 20 is wound around the outer periphery of the tooth portion 22, the yoke portion 21 disposed on the outer peripheral side of the stator, the core 23 provided with the tooth portion 22 having a rectangular cross section disposed on the inner peripheral side, and the teeth portion 22. And a resin insulator 24 interposed between the outer peripheral portion of the tooth portion 22 and the inner peripheral portion of the coil 1.

  As is clear from FIG. 5, in this embodiment, the split stator 20 can be formed simply by fitting the insulator 24 and the coil 1 into the tooth portion 22. For this reason, not only can the assembly work of the stator be performed easily, but also the number of assembly steps can be reduced.

  Further, the taper angle A of the inner peripheral surface 10 a of the coil 1 shown in FIG. 3 is set to an angle corresponding to the number of divisions of the divided stator 20. For this reason, when the divided stator 20 is assembled in an annular shape, the gap between the adjacent divided stators can be minimized, and the performance of the stator can be improved. The taper angle A may be set in accordance with the number of divisions of the divided stator, and in this embodiment, is set to about 10 ° (a total of 20 ° on both side tapers).

  In the split stator 20 according to the present embodiment, the terminal portions 2a, 3a, 4a, 5a extending from the yoke side of the four cylindrical coil members 6, 7, 8, 9 arranged in the radial direction, and the teeth The four cylindrical coil members 6, 7, 8, 9 arranged in the radial direction are connected in parallel by short-circuiting the terminal portions 2b, 3b, 4b, 5b extending to the portion side. . Accordingly, the thick wire rectangular coil having a rectangular cross section is configured to exhibit the same function as edgewise winding.

  By adopting the above configuration, it is possible to suppress the generation of eddy currents, which has been a problem when edge-wise winding a thick rectangular coil having a conventional rectangular cross section, and improve the performance of the coil. Moreover, since the windings 2, 3, 4 and 5 are made of copper wires having a rectangular cross section, and the windings 2, 3, 4 and 5 are configured to contact each other without any gaps, the coil space is increased. The rate does not decrease.

  Furthermore, in the said embodiment, the coil winding diameter becomes large with respect to the length of the coil | winding of the cylindrical coil member arrange | positioned inside the winding length of the cylindrical coil member arrange | positioned outside. It gets longer by minutes. For this reason, there exists a possibility that the resistance of the cylindrical coil member arrange | positioned outside may become large, and may reduce the efficiency of a coil. In order to avoid the above inconvenience, the cross-sectional area of the winding of the cylindrical coil member assembled outside can be set larger than the cross-sectional area of each winding of the cylindrical coil member assembled inside.

  FIG. 6 shows a second embodiment of the coil and the split stator according to the present invention.

  In the second embodiment, the coil formed body 31 is formed by resin-molding the entire coil 1 shown in FIG. Although not shown, the resin is filled without any gap between the cylindrical coil members and between adjacent windings.

  The mold resin is not particularly limited, and various resins can be employed. For example, what knead | mixed the alumina powder etc. for improving heat conductivity to an epoxy resin etc. is employable. Moreover, the manufacturing method of the said coil molded object 31 is not specifically limited, either, The injection molding method which inserted the said coil 1 can be employ | adopted.

  In the second embodiment, the insulating coating layer 32 corresponding to the insulator shown in FIG. 4 is integrally formed on the inner peripheral side of the coil 31, and the internal space 33 corresponds to the form of the tooth portion 22 of the core 23. Is formed.

  As is apparent from FIG. 6, by adopting the coil molded body 31 formed by resin molding of the coil 1, the coil molded body 31 is fitted to the tooth portion 22 without inserting an insulator. As a result, the split stator 30 can be assembled. Therefore, the assembly process can be further facilitated. In addition, the number of parts when assembling can be reduced.

  Furthermore, the gap between the outer surface of the tooth portion 22 and the inner peripheral surface of the coil 1 can be reduced, and the divided stator 30 with high heat dissipation can be formed.

  7 and 8 show a third embodiment of the present invention.

  In the third embodiment, the coil 51 is formed by assembling cylindrical coil members 56, 57, 58, and 59 having different winding directions of the windings 52, 53, 54, and 55 in a nested manner. .

  As the windings 52, 53, 54, and 55, as shown in FIG. 8, conventionally used rectangular wires having a rectangular cross section are employed, and the long surfaces of these windings are directed toward the coil axis X, The coil 51 is formed by winding in the same manner as in the first embodiment.

  Since the windings 52, 53, 54, and 55 are wound with the long-width surface directed toward the coil axis X, the number of windings of the cylindrical coil members 56, 57, 58, and 59 is extremely reduced. On the other hand, in this embodiment, as shown in FIG. 8, each terminal is connected so that each cylindrical coil member may be connected in series. That is, as shown in FIG. 8, the terminals 55b and 54b and 52b and 53b on the side extending from the tip end side of the teeth portion are respectively connected, and the terminals 53a and 54a extending on the yoke side are connected. The With this connection, the cylindrical coil members 56, 57, 58, 59 are connected in series, and a current is passed from the terminals 52a, 55a extending from the yoke side, as in the case of a coil wound with a single winding. Can function.

  In the present embodiment, the number of windings can be ensured by combining a plurality of cylindrical coil members 56, 57, 58, and 59, although the rectangular wire of the conventional form is flatwise wound. It becomes.

  Moreover, since each said cylindrical coil member 56,57,58,59 can be formed separately, respectively, winding each winding 52,53,54,55 in the form which suppressed the dead space to the minimum. Is also possible.

  Furthermore, in this embodiment, since the coil 51 is formed by alternately assembling the cylindrical coil members 56, 57, 58, 59 in which the winding directions of the windings 51, 52, 53, 54 are different, each winding is formed. These can be connected at the portion where the terminal extends, and the respective cylindrical coil members 56, 57, 58, 59 can be connected in series. For this reason, it is also possible to easily handle the wiring in the stator.

  In addition, the extension form and connection form of the terminal of the cylindrical coil members 56, 57, 58, and 59 shown in FIG. 8 are only embodiments, and various extension forms and connection forms can be employed. For example, each coil can be connected by welding or the like without bending and extending the terminal.

  The present invention is not limited to the embodiment described above. It should be thought that embodiment disclosed this time is an illustration and restrictive at no points. The scope of the present invention is defined not by the above-described meaning but by the scope of the claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of the claims.

  With the coil according to the present invention, loss due to eddy current can be reduced, winding can be easily performed, and assembly to a stator or the like can be facilitated.

It is the whole coil perspective view concerning the invention in this application. It is a disassembled perspective view of the coil shown in FIG. It is sectional drawing which follows the III-III line in FIG. FIG. 2 is an overall perspective view of a split stator employing the coil shown in FIG. 1. It is sectional drawing which shows the assembly process of the division | segmentation stator which employ | adopted the coil shown in FIG. It is sectional drawing which shows the assembly process of the coil which concerns on 2nd Embodiment of this invention, and a division | segmentation stator. It is a side view which shows the assembly process of the coil which concerns on the 3rd Embodiment of this invention. It is a side view after the assembly of the coil shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coil 6 Cylindrical coil member 7 Cylindrical coil member 8 Cylindrical coil member 9 Cylindrical coil member 12 Internal space 13 Internal space 14 Internal space 15 Internal space

Claims (12)

While including a plurality of cylindrical coil members stacked and assembled in a nested manner,
Each of the cylindrical coil members is a coil formed with an internal space in which at least one cross-sectional width in a direction orthogonal to the coil axis changes in a tapered shape.   The coil according to claim 1, wherein the internal space is a truncated pyramid or truncated cone space.   Each coil which comprises each cylindrical coil member is a coil in any one of Claim 1 or Claim 2 provided with a rectangular cross section.   The coil according to claim 3, wherein each of the windings is wound with a short-width surface directed toward a coil axis.   The coil according to claim 3, wherein each of the windings is wound with a long surface facing the coil axis.   The coil according to any one of claims 1 to 5, wherein the plurality of cylindrical coil members are connected in parallel.   The coil according to any one of claims 1 to 6, wherein the plurality of cylindrical coil members are connected in series.   The cross-sectional area of the coil | winding of the cylindrical coil member assembled | attached outside is set larger than the cross-sectional area of the coil | winding of the cylindrical coil member assembled | attached inside, It is any one of Claim 1-7 The described coil.   The coil according to any one of claims 1 to 8, wherein the plurality of cylindrical coil members are molded of resin.   The coil of Claim 9 provided with the coating layer of predetermined thickness in the said coil inner peripheral part. A coil according to claims 1 to 10;
A split stator comprising: a core having a tooth portion inserted in an internal space of the coil.   The split stator according to claim 11, further comprising an insulator interposed between the tooth portion and the inner peripheral surface of the coil.

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