JP2009254172A - Stator and assembling method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator in which a distance between a coil and a core can be properly ensured, and to provide an assembling method thereof. <P>SOLUTION: A cassette coil 30 is provided with a coil member 20, and a molding member 31 for molding the coil member. The cassette coil 30 has an opening 33 larger than the outer dimension of a teeth portion 51b of a split core 51. The relative position between the teeth portion 51b and the cassette coil 30 is determined by positioning portions C1-C4 of the molding member 31. A space Sp exists between the molding member 31 of the cassette coil 30 and the teeth portion 51b. A resin is injected into the space Sp to form an embedded resin portion 40. A distance between the coil member 20 and the teeth portion 51b (core) is held within a predetermined range and partial discharge can be prevented. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a stator disposed in a motor, a generator, and the like and an assembling method thereof.

  A stator (stator) of a motor or a generator is configured by winding a coil around a core. In the case of a stator having a yoke part and a tooth part protruding from the yoke part, the coil is wound around the tooth part. Recently, a structure of a cassette coil formed by resin molding of a coil member has been proposed. In that case, a stator coil is assembled by setting a cassette coil formed in advance in the tooth portion. Patent Document 1 discloses a stator structure using a cassette coil.

The core of Patent Document 1 has an annular stator teeth body and an annular stator yoke. The ring-shaped stator teeth body is formed by connecting a plurality of teeth in a ring shape. The ring-shaped stator yoke is formed by connecting a plurality of yokes in a ring shape. The cassette coil is attached to each tooth in the annular stator teeth body.
JP 2007-195333 A

  The stator of Patent Document 1 makes it easy to assemble the stator and eliminates the need for an insulating insulator or the like. Therefore, it is expected that productivity is improved and manufacturing costs are reduced.

  However, the structure of Patent Document 1 has the following problems. When the cassette coil is attached to the core (the teeth of the ring-shaped stator teeth body in the same document), a gap is generated between the core and the opening of the cassette coil. For this reason, the position of the cassette coil may fluctuate during use, and the distance between the coil and the core may be partially reduced. At this time, if the distance between the coil and the core is too small, partial discharge may occur and the insulating film may deteriorate.

  An object of the present invention is to provide a stator and a method for assembling the stator that can appropriately secure a distance between a coil and a core.

  The stator of the present invention includes a cassette coil in which a coil member is sealed with a mold member. The mold member of the cassette coil has a positioning portion that determines the relative position of the cassette coil with respect to the core. The distance between the coil member and the core is set within a predetermined range.

  With this structure, the distance between the coil and the core in the cassette coil is maintained within a predetermined range. Therefore, an insulation distance for preventing discharge can be secured between the core and the coil member.

  When the cassette coil is mounted, a gap is generated between the cassette coil and the core. Therefore, it is preferable to provide a resin embedding part that fills this gap between the cassette coil and the core. With this structure, since the resin has a larger dielectric constant than air, the discharge suppression function is also improved by the resin embedding part. Furthermore, since the resin-embedded portion has a higher thermal conductivity than the gap, heat generated by the core and the coil member is easily released to the outside.

  It is preferable that the resin embedding part is provided at least between the coil side part of the core and the mold member. Thereby, the heat dissipation function from the coil side part with large heat generation in the core and the coil member can be enhanced. However, it is more preferable that the resin embedding part is also provided between the coil end part of the core and the mold member.

  If the distance between the core and the coil member is smaller than 0.1 mm, partial discharge as described above tends to occur. On the other hand, if the distance between the core and the coil member exceeds 1.0 mm, the dimension becomes excessive. Further, since the proportion of the conductor area entering the slot is reduced, the output of a motor or the like in which the stator is arranged is reduced. Therefore, the predetermined range is preferably 0.1 mm to 1.0 mm.

  When the resin embedding part contains the inorganic filler, the thermal conductivity is increased and the heat dissipation function is improved.

  When the core has a yoke part and a tooth part, the coil member is attached so as to surround the tooth part.

The stator assembling method of the present invention undergoes the following procedure. After the coil member is formed, the coil member is sealed with a mold resin to form a cassette coil having an opening larger than the outer shape of the core. Next, the stator core is inserted into the opening of the cassette coil, and the resulting gap is filled with a resin material.
By this method, a stator that can exhibit the above-described effects is assembled.

When forming the cassette coil, it is preferable to adopt the following method. First, a mold having a convex portion corresponding to the core is used. And mold resin is inject | poured in the state which put the board member which has the thickness corresponded to a clearance gap along the convex part.
By this method, a gap between the coil member and the core can be easily secured.

  According to the stator of the present invention or the assembling method thereof, the distance between the coil and the core can be ensured appropriately. Therefore, occurrence of partial discharge can be suppressed.

-Coil assembly process-
FIG. 1 is a perspective view showing a method for assembling a coil member according to an embodiment of the present invention.
The assembling apparatus according to the present embodiment includes a coil winding roller 14 provided with four individual winding portions 14a to 14d, a collect roller 15, a pinch roller 16, a plate thickness correcting roller 17, and a bending roller 18. I have. The individual winding portions 14a to 14d of the coil winding roller 14 are configured to rotate independently of each other.

  The four coil wires 11 unwound from the individual unwinding portions 14a to 14d are gradually collected in the collecting region Ra. The four coil wires 11 are bundled into a single rectangular wire by the collecting roller 15. As shown in an enlarged detail in the lower left diagram of FIG. 1, the divided rectangular wire 10 is configured by collecting four coil wires 11 in a flat plate shape. Since the coil wires 11 are electrically connected to each other at both ends, the divided rectangular wire 10 substantially functions as one rectangular wire. Each coil wire 11 includes a copper wire 12 having a substantially rectangular cross section and a coating film 13 that covers the copper wire 12. The skin covering film 13 is made of an imide resin typified by polyimide, polyamideimide, polyesterimide or the like. The cross-sectional dimensions of the copper wire 12 are about 0.95 mm for the short side and about 1.20 mm for the long side, and the thickness of the coating film 13 is about 0.03 mm.

  The axial direction of the pinch roller 16 and the axial direction of the plate thickness correcting roller 17 are substantially orthogonal to each other. The divided rectangular wire 10 is bent substantially at a right angle by the bending roller 18 in the bending region Rb. Although not shown, a guide member is provided between the pinch roller 16, the bending roller 18, and the plate thickness correcting roller 17. The guide member sandwiches the divided rectangular wire 10 along the flat plate surface and both end surfaces. The divided rectangular wire 10 is bent into an edgewise shape in a direction in which the flat plate surface is substantially orthogonal to the roller surface of the bending roller 18.

The bent divided rectangular wires 10 are overlapped with each other in the winding region Rd. Thereby, the coil member 20 wound so that the circumference | surroundings of the core (tooth part) mentioned later may be enclosed is formed. When the divided rectangular wire 10 is viewed as a single rectangular wire, a so-called edgewise coil shape is formed. Although not shown, the assembling apparatus is equipped with a mechanism for rotating the coil member 20.
However, the coil shape of the present invention is not limited to the flat dividing line of the present embodiment. The present invention can also be applied to a coil member in which one coil wire is wound. Further, the present invention can be applied to a coil having an arbitrary cross-sectional shape such as a circular, rectangular, or polygonal cross-sectional shape.

-Assembly process of cassette coil and stator-
FIG. 2 is a perspective view showing the structure of the cassette coil 30 and the split core 51 in the present embodiment. In the figure, the x direction is the rotor side direction, the y direction is the coil side direction, and the z direction is the coil end direction. That is, the coil member 20 and the coil side portion of the tooth portion 51b are portions parallel to the xz plane shown in FIG. The coil end portions of the coil member 20 and the teeth portion 51b are portions parallel to the xy plane shown in FIG.

  Thereafter, the coil member 20 is molded by the mold member 31 to form the cassette coil 30. In FIG. 2, the mold member 31 is displayed as a transparent body. Of the coil member 20, two terminals 21 and 22 projecting toward the coil end side are exposed from the mold member 31.

  The mold member 31 includes an opening 33 and two flanges 35 extending in the direction opposite to the x direction. When the cassette coil 30 is mounted, the tooth portion 51 b is fitted into the opening 33 of the mold member 31. At that time, the upper and lower surfaces of the yoke portion 51 a are sandwiched between the two flange portions 35 of the cassette coil 30.

  As the mold member 31, PPS resin (polyphenylene sulfide), LCP resin (liquid crystal polymer), epoxy resin, unsaturated polyester resin (BMC), or the like is used.

  The split core 51 has a yoke part 51 a and a teeth part 51 b that protrudes from the yoke part 51 to the rotor side. In the present embodiment, the split core 51 has a laminated steel plate structure in which a large number of magnetic steel plates are laminated with an insulating layer interposed therebetween. However, you may employ | adopt what is called a powder core structure formed by compression-molding the magnetic powder which has an insulating film.

  FIGS. 3A to 3C are cross-sectional views showing a process of attaching the cassette coil 30 to the tooth portion 51b. 3A to 3C show changes in the structure in a cross section parallel to the xy plane shown in FIG.

  FIG. 3A is a cross-sectional view of the cassette coil 30. As will be described later, the opening 33 of the cassette coil 30 is larger than the outer shape of the tooth portion 51 b of the split core 51.

  FIG. 3B is a cross-sectional view showing a state in which the tooth portion 51 b is inserted into the opening 33 of the cassette coil 30. As shown in the figure, a gap Sp exists between the mold member 31 of the cassette coil 30 and the tooth portion 51b.

  FIG. 3C is a cross-sectional view when the divided stator 50A is assembled. In the present embodiment, resin is injected into the gap Sp between the cassette coil 30 and the tooth portion 51b to form the embedded resin portion 40. As the resin of the embedded resin portion 40, epoxy resin, BMC resin (unsaturated polyester resin), or the like is used. It is preferable that an insulating filler is added to the resin embedding part 40. By adding the inorganic filler, the thermal conductivity of the resin embedding part 40 is improved.

  4 (a) and 4 (b) are longitudinal sectional views showing a process of mounting the cassette coil 30 on the tooth portion 51b. 4A and 4B show changes in the structure in a cross section parallel to the yz plane shown in FIG.

FIG. 4A is a longitudinal sectional view showing a state in which the tooth portion 51 b is inserted into the opening 33 of the cassette coil 30. Positioning portions C1 to C4 that engage with the tooth portion 51b are provided at four corners of the mold member 31. The relative positions of the tooth portion 51b and the cassette coil 30 are determined by the positioning portions C1 to C4. Further, a gap Sp is provided between the mold member 31 of the cassette coil 30 and the tooth portion 51b.
However, the positioning part should just be provided in two corners which mutually oppose. Or you may provide a positioning part in four sides.

  At this time, the distance between the tooth portion 51b and the coil member 20 is determined to be within a predetermined range. In the present embodiment, the predetermined range is 0.1 mm to 1.0 mm.

  FIG. 4B is a longitudinal sectional view when the divided stator 50A is assembled. Resin is injected into the gap Sp shown in FIG. 4A to form the embedded resin portion 40. However, it is not necessary to form the embedded resin portion 40 in all the gaps Sp. If the embedded resin portion Sp is formed on the coil side portion, the heat radiation function of the coil side portion that generates a large amount of heat can be ensured.

  In the present embodiment, as shown in FIG. 3C and FIG. 4B, a resin embedding portion 40 is provided. However, the assembly of the split stator 50A may be completed in the state shown in FIG. 3B or 4A without forming the resin embedding portion 40. Even in this case, if the relative position between the cassette coil 30 and the tooth portion 51b is fixed by the positioning portions C1 to C4, the distance between the two is held within a predetermined range.

-Details of the molding process-
FIG. 5 is a perspective view showing a state where the coil member 20 is set in the mold. As shown in FIG. 5, the mold mold includes a lower mold 60A and a lower mold 60B. FIG. 6 is a cross-sectional view showing a state where the coil member 20 is installed in the lower mold 60A and the upper mold 60B is lowered.

As shown in FIG. 5, the lower mold 60A is provided with a convex portion 63 corresponding to the shape of the tooth portion 51b. And the coil member 20 is installed in the area | region (die cavity Dc) between the convex part 63 and frame part of 60 A of lower molds.
On the other hand, four plate members 61 are attached to the upper mold 60B. A release agent is applied to the plate member 61. In FIG. 5, only two plate members 61 are displayed for easy viewing, but the plate members 61 are also provided at the positions indicated by broken lines.

  As shown in FIG. 6, the upper mold 60 </ b> B and the lower mold 60 </ b> A are set along the plate member 61 along the convex portion 63 of the lower mold 60 </ b> B. Mold resin is injected into a portion of the die cavity Dc excluding the coil member 20.

  When mold resin is injected into the die cavity Dc, the cassette coil 30 shown in FIGS. 3C and 4A is formed. That is, the gap Sp shown in FIG. 3C or FIG. 4A has a shape corresponding to the plate member 61 shown in FIG.

In the present embodiment, the plate member 61 is in contact with the convex portion 63. Thereby, the relative positions of the lower mold 60A and the upper mold 60B are also determined.
However, the plate member 61 and the convex portion 63 may not be in contact with each other. This is because the relative positions of both molds 60A and 60B are determined if they are structured to fit together. Then, the shape of the gap Sp is set by the plate member 61.

FIG. 7 is a cross-sectional view showing a schematic structure of the stator 50 in which the divided stator 50A is annularly combined. A rotor (not shown) provided with permanent magnets is disposed inside the stator 50.
Instead of the split core 50, an annular integrated stator that is continuously connected by a yoke portion may be used. In that case, a plurality of teeth portions protrude from the stator to the rotor side.

As a procedure for assembling the stator 50, the following procedure is suitable. First, the divided stator 50A is assembled. At that time, the embedded resin portion 40 is formed by embedding a resin in the gap Sp between the tooth portion 51 b and the cassette coil 30. Each divided stator 50A formed in this way is assembled in an annular shape. Thereafter, the stator 50 is assembled by being enclosed from the outside by using a ring member or the like (not shown).
First, after assembling each cassette coil 30 in an annular shape, the teeth 51b may be set in each cassette coil 30.

  According to the present embodiment, the distance between the coil member 20 and the tooth portion 51b is set within a predetermined range in the state shown in FIG. 3 (b) and FIG. 4 (a). Therefore, while using the split stator 50A, it is possible to prevent partial discharge due to the partial approach of both. The resin embedding part 40 may not be formed in this state.

In the present embodiment, the predetermined range is 0.1 mm to 1.0 mm, but is not limited to this. Generally, when the distance between the core and the coil member is smaller than 0.1 mm, partial discharge tends to occur.
However, the insulation distance for preventing partial discharge differs depending on the voltage between the coil and the core and the dielectric constant of the member disposed between them. Therefore, the lower limit of the predetermined range in the present invention may be an insulation distance determined by the structure of the stator. In addition, the upper limit of the predetermined range in the present invention does not necessarily have a critical significance, and therefore there is no need to have an upper limit.
However, generally, when the distance between the core and the coil exceeds 1.0 mm, the dimension becomes excessive. Further, since the proportion of the conductor area entering the slot is reduced, the output of a motor or the like in which the stator is arranged is reduced. Therefore, the upper limit of the predetermined range is preferably 1.0 mm.

  In the present embodiment, a resin embedding portion 40 that fills the gap Sp in the state shown in FIGS. 3C and 4B is further provided. Since the resin in the resin embedding part 40 has a dielectric constant larger than that of air, this structure also improves the discharge suppressing function. Since the resin embedding portion 40 has a larger thermal conductivity than the gap, the heat generated by the tooth portion 51b and the coil member 20 is easily released to the outside.

  The resin embedding part 40 may be provided only in the coil side part of the teeth part 51b. The coil side portion is a portion of the tooth portion 51b or the coil member 20 that is parallel to the xz plane shown in FIG. If the resin embedding 40 is provided in the coil side portion where the heat generation amount is large, the heat generation of the tooth portion 51b and the coil member 20 can be effectively released.

  In the resin molding process of the cassette coil 30, the gap Sp can be easily and reliably set by the plate member 61. As a result, the distance between the coil member 20 and the tooth portion 51b (the core 9 can be set within a predetermined range. Further, since the release agent is applied to the surface of the plate member 40, the mold is removed after molding. Becomes easy.

(Other embodiments)
In the said embodiment, the salient pole structure in which the teeth part 51b protruded from the yoke part 51a was employ | adopted as a structure of a core. However, the core structure of the present invention is not limited to such an embodiment, and other structures can be adopted.

  In each of the above-described embodiments, the example in which the cassette coil is used as a part of the rotary motor has been described. However, the cassette coil of the present invention can also be used for linear motors, generators, reactors, transformers, and the like.

  The structure of the embodiment of the present invention disclosed above is merely an example, and the scope of the present invention is not limited to the scope of these descriptions. 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.

  The cassette coil and the stator of the present invention can be used for a linear motor, a generator, a reactor, a transformer, and the like. These devices are arranged in hybrid vehicles, electric vehicles, fuel cell vehicles, robots, and various industrial equipment.

It is a perspective view which shows the assembly method of the coil member which concerns on embodiment of invention. It is a perspective view which shows the structure of the cassette coil which concerns on embodiment, and a split core. (A)-(c) is a cross-sectional view which shows the process of mounting | wearing a teeth part with a cassette coil. (A), (b) is a longitudinal cross-sectional view which shows the process of mounting | wearing the teeth part with the cassette coil 30. FIG. It is a perspective view which shows the state which set the coil member to the mold die. It is a cross-sectional view showing a state where a coil member is installed in a lower mold and the upper mold is lowered. It is sectional drawing which shows the schematic structure of the stator 50 which combined the division | segmentation stator in cyclic | annular form.

Explanation of symbols

Sp gap Dc Die cavity 10 Divided rectangular wire 20 Coil member 21 and 22 Terminal 30 Cassette coil 31 Mold member 33 Opening part 35 Clamping part 40 Resin embedding part 50 Stator 50A Split stator 51 Split core 51a York part 51b Teeth part 60A Lower metal Mold 60B Upper mold 61 Plate member 63 Projection

Claims (9)

A core mainly composed of a magnetic material;
A coil member wound in a shape surrounding the periphery of the core, and a cassette coil having a mold member for sealing the coil member;
A stator with
The mold member of the cassette coil has a positioning portion that determines a relative position between the core and the cassette coil,
A stator in which a distance between the coil member and the core is set within a predetermined range. The stator according to claim 1, wherein
A stator in which a resin embedding portion is provided between the core and the cassette coil. The stator according to claim 1 or 2,
The resin embedding part is a stator provided at least between a coil side part of the core and the mold member. The stator according to claim 3,
The resin embedding part is a stator provided between a coil end part of the core and the mold member. In the stator according to any one of claims 1 to 4,
The stator has a predetermined range of 0.1 mm to 1.0 mm. In the stator according to any one of claims 1 to 5,
The said resin embedding part is a stator containing the inorganic filler. In the stator according to any one of claims 1 to 6,
The core has a yoke part and a teeth part protruding from the yoke part,
The said coil member is a stator attached so that the said teeth part may be enclosed. A method for assembling a stator by assembling a core and a coil member surrounding the core,
Forming a coil member wound in a shape surrounding the periphery of the core;
Sealing the coil member with a mold resin to form a cassette coil having an opening larger than the outer shape of the core;
Inserting the core into the opening of the cassette coil (c);
A step (d) of filling a gap between the opening of the cassette coil and the core with a resin material;
Assembling method of stator including The stator assembly method according to claim 8, wherein
In the step (b), a mold having a convex portion corresponding to the core is used,
A method for assembling a stator, in which a mold resin is injected in a state in which a plate member having a thickness corresponding to the gap is placed along the convex portion.

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