JP2011024342A - Wire and electrical apparatus using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a wire capable of reducing eddy current loss, and to provide an electrical apparatus that uses the wire. <P>SOLUTION: In the wire extending in a longitudinal direction, a spiral shape where a plate conductor 22 is wound appears in a cross section orthogonal to the longitudinal direction of the wire 20, insulating coatings 23 and 24 are formed on the surface of the plate conductor 22, and the insulating coatings 23 and 24 are interposed between the adjacent plate conductors 22. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a wire rod and an electric device using the same, and more specifically to a wire rod used for a rotating electric machine and an electric device using the same.

  Conventionally, the structure of the coil which comprises a rotary electric machine is disclosed by Unexamined-Japanese-Patent No. 2003-199275 (patent document 1) and Unexamined-Japanese-Patent No. 2008-148375 (patent document 2), for example.

JP 2003-199275 A JP 2008-148375 A

  Patent Document 1 discloses a coil configured by bending a rectangular wire subjected to an insulation coating process. It is disclosed that this improves the space factor.

  Patent Document 2 discloses a coil that reduces eddy currents by twisting a plurality of thin wire conductors.

  However, the conventional technique has a problem that the eddy current flowing through the coil cannot be sufficiently reduced.

  Accordingly, the present invention has been made to solve the above-described problems, and provides a wire rod capable of reducing eddy current and an electric device using the wire rod.

  The wire according to the present invention is a wire extending in the longitudinal direction, and a spiral shape in which a plate-like conductor is wound appears in a cross section orthogonal to the longitudinal direction of the wire, and an insulating film is formed on the surface of the plate-like conductor. And an insulating film is interposed between adjacent plate conductors.

  In the wire configured as described above, since an insulating film is interposed between adjacent plate conductors, generation of eddy currents in the wire can be suppressed. As a result, eddy current loss can be reduced.

Preferably, an insulating film is formed on each of the opposing surfaces of the plate-like conductor.
An electric device according to the present invention includes a tooth and a coil formed of the above-described wire material.

It is a figure for demonstrating the structure of the drive part of the vehicle provided with the rotary electric machine according to embodiment of this invention. It is a figure for demonstrating the structure of a part of rotary electric machine in which the wire according to this invention is used. It is a perspective view including the partial cross section for demonstrating in detail the plate-shaped conductor which comprises one wire shown in FIG. It is sectional drawing which expands and shows the part enclosed by IV which is a cross-sectional part of the wire shown in FIG. It is a figure for demonstrating the manufacturing method of the insulating film according to Embodiment 1 shown in FIG. It is sectional drawing which expands and shows the part enclosed by VI in FIG. It is a perspective view including the partial cross section for demonstrating the manufacturing method of the wire according to Embodiment 2 of this invention. It is a perspective view containing the partial cross section of the wire according to Embodiment 2 of this invention. It is a perspective view including the partial cross section for demonstrating the 1st process of the manufacturing method of the wire according to Embodiment 3 of this invention. It is a perspective view including the partial cross section for demonstrating the 2nd process of the manufacturing method of a wire according to Embodiment 3 of this invention. It is a perspective view of a wire according to completed Embodiment 3. It is sectional drawing along the XII-XII line | wire in FIG.

  Embodiments of the present invention will be described below with reference to the drawings. In the following embodiments, the same or corresponding parts are denoted by the same reference numerals, and description thereof will not be repeated. In addition, the embodiments can be combined.

(Embodiment 1)
FIG. 1 is a diagram for illustrating a configuration of a drive unit of a vehicle including a rotating electrical machine according to an embodiment of the present invention. In FIG. 1, the electric circuit for driving the rotary electric machine mounted in the vehicle according to this invention is shown. Referring to FIG. 1, a PCU (power control unit) 2700 includes a converter 2710, an inverter 2720, a control device 2730, capacitors C1 and C2, power supply lines PL1 to PL3, output lines 2740U, 2740V, and 2740W. including. Converter 2710 is connected between battery 3000 and inverter 2720, and inverter 2720 is connected to rotating electrical machine 2200 via output lines 2740U, 2740V, and 2740W.

  Battery 3000 connected to converter 2710 is a secondary battery such as nickel metal hydride or lithium ion. Battery 3000 supplies the generated DC voltage to converter 2710 and is charged by the DC voltage received from converter 2710.

Converter 2710 includes power transistors Q1 and Q2, diodes D1 and D2, and a reactor L. Power transistors Q1 and Q2 are connected in series between power supply lines PL2 and PL3, and receive a control signal from control device 2730 as a base. Diodes D1 and D2 are connected between the collector and emitter of power transistors Q1 and Q2, respectively, so that current flows from the emitter side to the collector side of power transistors Q1 and Q2. Reactor L has one end connected to power supply line PL1 connected to the positive electrode of battery 3000, and the other end connected to a connection point of power transistors Q1 and Q2.

  Converter 2710 boosts the DC voltage received from battery 3000 using reactor L, and supplies the boosted boosted voltage to power supply line PL2. In addition, converter 2710 steps down the DC voltage received from inverter 2720 and charges battery 3000.

  Inverter 2720 includes a U-phase arm 2750U, a V-phase arm 2750V, and a W-phase arm 2750W. Each phase arm is connected in parallel between power supply lines PL2 and PL3. U-phase arm 2750U includes power transistors Q3 and Q4 connected in series, V-phase arm 2750V includes power transistors Q5 and Q6 connected in series, and W-phase arm 2750W includes power transistors connected in series. Transistors Q7 and Q8 are included. Diodes D3 to D8 are respectively connected between the collector and emitter of power transistors Q3 to Q8 so that current flows from the emitter side to the collector side of power transistors Q3 to Q8. And the connection point of each power transistor in each phase arm is connected to the anti-neutral point side of each phase coil of rotating electrical machine 2200 as a motor generator via output lines 2740U, 2740V, 2740W.

  Inverter 2720 converts a DC voltage received from power supply line PL2 into an AC voltage based on a control signal from control device 2730, and outputs the AC voltage to rotating electric machine 2200. Inverter 2720 rectifies the AC voltage generated by rotating electric machine 2200 into a DC voltage and supplies the rectified voltage to power supply line PL2.

  Capacitor C1 is connected between power supply lines PL1 and PL3, and smoothes the voltage level of power supply line PL1. Capacitor C2 is connected between power supply lines PL2 and PL3, and smoothes the voltage level of power supply line PL2.

  Control device 2730 calculates each phase coil voltage of rotating electric machine 2200 based on the motor torque command value, each phase current value of rotating electric machine 2200, and the input voltage of inverter 2720, and based on the calculation result, power transistors Q3-3. A PWM (Pulse Width Modulation) signal for turning on / off Q8 is generated and output to inverter 2720.

  Control device 2730 calculates the duty ratio of power transistors Q1 and Q2 for optimizing the input voltage of inverter 2720 based on the motor torque command value and motor rotation speed described above, and the power is calculated based on the calculation result. A PWM signal for turning on / off transistors Q1 and Q2 is generated and output to converter 2710.

  Further, control device 2730 controls the switching operation of power transistors Q1 to Q8 in converter 2710 and inverter 2720 in order to charge battery 3000 by converting AC power generated by rotating electrical machine 2200 into DC power.

  In PCU 2700, converter 2710 boosts a DC voltage received from battery 3000 based on a control signal from control device 2730 and supplies the boosted voltage to power supply line PL2. Inverter 2720 receives the DC voltage smoothed by capacitor C2 from power supply line PL2, converts the received DC voltage into an AC voltage, and outputs the AC voltage to rotating electrical machine 2200.

  Inverter 2720 converts the AC voltage generated by the regenerative operation of rotating electrical machine 2200 into a DC voltage and outputs the DC voltage to power supply line PL2. Converter 2710 receives the DC voltage smoothed by capacitor C2 from power supply line PL2, and steps down the received DC voltage to charge battery 3000.

  FIG. 2 is a diagram for explaining a configuration of a part of a rotating electrical machine in which the wire according to the present invention is used. Referring to FIG. 2, rotating electric machine 2200 according to the present invention includes a tooth 10 and a coil 30 wound around the tooth 10. The coil 30 is configured by winding the wire 20 around the tooth 10. The teeth 10 are stator cores, and the teeth 10 and the coils 30 constitute a stator.

  In this embodiment, only the stator of rotating electric machine 2200 is shown, but rotating electric machine 2200 has a rotor. Moreover, although concentrated winding is shown in this embodiment as a winding method of the rotating electrical machine 2200, distributed winding may be used. A plurality of wire rods 20 are stacked and arranged.

  FIG. 3 is a perspective view including a partial cross-section for explaining in detail a plate-like conductor constituting one wire shown in FIG. 4 is an enlarged cross-sectional view of a portion surrounded by IV, which is a cross-sectional portion of the wire shown in FIG. 3 and 4, in the wire 20 extending in the longitudinal direction, the plate-like conductor 22 appears in a spiral shape as shown in FIGS. 3 and 4 in a cross section orthogonal to the longitudinal direction. An insulating film 23 is provided on the outer peripheral side of the plate-like conductor 22, and an insulating film 24 is provided on the inner peripheral side. Note that it is not necessary to provide both the insulating film 24 and the insulating film 23, and it is sufficient that at least one of the insulating film 24 and the insulating film 23 is provided.

  An insulating film 24 and an insulating film 23 are interposed between the adjacent plate conductors 22. An enamel insulating film 21 is formed on the outermost peripheral surface of the wire 20. As a method for forming the insulating film 24 and the insulating film 23, it is conceivable to apply a specific chemical to oxidize the surface of the plate-like conductor 22 to form an oxide insulating film. Further, as a method of forming the insulating film 24 and the insulating film 23, the insulating film 24 and the insulating film 23 may be configured by attaching an insulating film.

  FIG. 5 is a diagram for explaining a method of manufacturing the insulating film according to the first embodiment shown in FIGS. 3 and 4. 6 is an enlarged cross-sectional view of a portion surrounded by VI in FIG. Referring to FIGS. 5 and 6, first, plate-like conductor 22 is prepared, and the plate-like conductor is wound in a spiral shape (roll shape) as shown in FIG. An insulating film 24 is formed on the inner peripheral surface side of the plate-like conductor 22, and an insulating film 23 is formed on the outer peripheral side. And the wire 20 of the shape shown in FIG. 3 can be comprised by compressing the plate-shaped conductor 22 wound by roll shape.

  In the wire 20 configured as described above, eddy current can be reduced with respect to leakage magnetic flux from both the vertical and horizontal directions. Further, it can be manufactured at low cost.

Furthermore, since each wire is not separated, the generation of circulating current can be suppressed.
(Embodiment 2)
FIG. 7 is a perspective view including a partial cross section for illustrating a method of manufacturing a wire according to the second embodiment of the present invention. With reference to FIG. 7, in the manufacturing method of the wire according to the second embodiment, a plate-like conductor 22 similar to that of the first embodiment is prepared. Insulating films 23 and 24 are formed on both surfaces of the plate-like conductor 22, respectively. This plate-like conductor is formed into a wave shape as shown in FIG.

  FIG. 8 is a perspective view including a partial cross section of the wire according to the second embodiment of the present invention. Referring to FIG. 8, plate-like conductor 22 formed into a wave shape as shown in FIG. 7 is compressed into a rectangular wire shape. Then, the outer periphery is enameled to form an enamel insulating film 21. Thereby, the wire 20 as shown in FIG. 8 is completed. In the wire according to the second embodiment configured as described above, any copper can be used while maintaining a high space factor by using the plate-like conductor 22 which is a copper wire having an insulating film treatment applied to the surface of the coil before forming. Use a line shape. At this time, since the inside of the wire 20 is insulated, copper vortex loss can be reduced. Further, since the insulating films 23 and 24 are very thin, the space factor is not deteriorated. Moreover, since the coils are not completely separated, the efficiency is not deteriorated due to the circulating current.

(Embodiment 3)
FIG. 9 is a perspective view including a partial cross section for illustrating a first step of the method of manufacturing the wire according to the third embodiment of the present invention. Referring to FIG. 9, as in the second embodiment, plate-like conductor 22 is formed into a corrugated plate shape. Insulating films 23 and 24 are formed on the surface of the plate-like conductor 22.

  FIG. 10 is a perspective view including a partial cross section for illustrating a second step of the method of manufacturing a wire according to the third embodiment of the present invention. Referring to FIG. 10, the front portion of plate-like conductor 22 is twisted in the direction indicated by arrow R1, and the rear portion is twisted in the direction indicated by arrow R2. Then, after the plate-like conductor 22 is compressed, the enamel insulating film 21 is formed on the surface.

  FIG. 11 is a perspective view of a wire according to the completed third embodiment. FIG. 12 is a cross-sectional view taken along line XII-XII in FIG. Referring to FIGS. 11 and 12, in the front cross section, as shown in FIG. 11, insulating films 23 and 24 are formed so as to extend in the vertical direction. On the other hand, in the rear cross section (FIG. 12), the insulating films 23 and 24 are formed to extend in the lateral direction. That is, by twisting the plate-like conductor 22 in the step shown in FIG. 10, wires having various cross-sectional shapes as shown in FIGS. 11 and 12 can be manufactured.

  Thereby, since the coil internal insulation processing direction is different for each cross section, eddy current loss can be reduced without depending on the direction of leakage magnetic flux.

  Although the embodiment of the present invention has been described above, the embodiment shown here can be variously modified.

  First, although the cross section of the wire 20 was comprised in the rectangle, it does not necessarily need to be a rectangle and a cross section may be circular or an ellipse.

  Moreover, the wire 20 according to the present invention can be used not only for rotating electrical machines but also for electrical devices other than rotating electrical machines such as resolvers.

  Further, when the wire 20 according to the present invention is used as a rotating electrical machine, the present invention can be applied not only to the three-phase AC motor shown in FIG. 1 but also to a rotating electrical machine in which eddy current loss is a concern. It is.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  10 teeth, 20 wires, 21 enamel insulation film, 22 plate conductor, 23, 24 insulation film, 30 coils, 2200 rotating electrical machine, 2710 converter, 2720 inverter, 2730 controller, 2740U, 2740V, 2740W output line.

Claims (3)

A wire extending in the longitudinal direction,
In the cross section perpendicular to the longitudinal direction of the wire, a spiral shape in which a plate-like conductor is wound appears,
An insulating film is formed on the surface of the plate-shaped conductor,
A wire rod in which an insulating film is interposed between adjacent plate-like conductors.   The wire according to claim 1, wherein the insulating film is formed on each of the opposing surfaces of the plate-like conductor.   An electrical device comprising a tooth and a coil made of the wire according to claim 1, wherein the coil is wound around the tooth.

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