JP2011217484A - Rotary electric machine and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve output characteristics while miniaturizing a rotary electric machine.SOLUTION: The rotary electric machine 10 includes an outer core 12 where a plurality of slots 14 including an opening 16 are extended in a diametric direction and are formed on an inner periphery surface, and an inner core 11 disposed inside the outer core 12. Inside the slot 14 to which a coil 21 is attached, a high-density part having a locally high electric wire density of the coil 21 is formed in a radial inner part of the outer core 12, and a low-density part having a locally low electric wire density of the coil 21 is formed in a radial outer part of the outer core 12.

Description

  The present invention relates to a rotating electrical machine having an inner core and an outer core in which the inner core is disposed, and a method for manufacturing the same.

  A rotating electrical machine used as an electric motor or a generator has a cylindrical inner core and a cylindrical outer core in which the inner core is disposed. There are two types of rotating electrical machines: an inner rotor type in which an inner core is a rotor or rotor and an outer core is a stator or stator, and an outer rotor type in which an outer core is a rotor and an inner core is a stator. The form in which the coil is attached to the stator is a winding type stator, and the form in which the coil is attached to the rotor is a winding type rotor.

  For example, a permanent magnet type electric motor includes a rotating electrical machine in which a cylindrical outer core around which a coil is wound is a stator, and an inner core provided with a permanent magnet and disposed inside the outer core is a rotor. In the rotating electrical machine of this form, the outer core has a plurality of slots that have openings on the inner peripheral surface thereof and extend radially outward from the openings, and windings or coils are incorporated in the slots. It will be. As winding forms of the coil, there are distributed winding and concentrated winding.

  In recent years, the demand for using a servo motor as an electric motor for driving an injection shaft of an injection molding machine and a pressurizing ram of a press machine that require high output and large torque for the purpose of improving control performance and high acceleration operation has been increased. ing. As a requirement for this type of electric motor, in addition to reducing the inertia or inertia of the rotor of the rotating electrical machine in order to enhance the characteristics of high acceleration / deceleration operation, it is necessary to increase the instantaneous maximum torque and the instantaneous maximum output as much as possible. It has been demanded. If the radius of the rotor is reduced, the rotor can have a structure with small inertia, but the total area of the permanent magnets attached to the rotor is reduced accordingly, so that the total amount of magnetic flux cannot be increased. Become. For this reason, a method is adopted in which the instantaneous maximum torque is increased by increasing the amount of winding of the stator and increasing the amount of current in a short time.

  In order to increase the winding amount, the stator has a slot shape that is long in the radial direction in order to increase the winding space.

  When a winding is installed in a slot with a high space factor, starting with a deep slot formed long in the radial direction, the position of each wire inside each slot according to the coil pattern depends on the coil insertion order. It depends on the fixed constraints. In particular, when a coil is inserted into a slot by distributed winding using an inserter, U, V. In order to insert a coil of each phase such as the W phase, the coil already inserted is pushed by the coil inserted later in the slot corresponding to the coil with the early insertion order. An electric wire is pushed to the bottom side of the slot, and a dead space is generated on the inlet side of the slot. On the other hand, in the slot corresponding to the coil whose insertion order is later, the interference space formed by the coil end portion of the coil whose insertion order is early is obstructed, and the electric wire is not pushed to the bottom side of the slot, and the slot Electric wires are unevenly distributed at the entrance portion, and a dead space is generated on the bottom side.

  In order to average the space factor of the windings in each slot, Patent Document 1 proposes an electric motor in which the wire cross section of the windings in the early insertion order is enlarged.

  As in the electric motor described in Patent Document 1, in a coil to which a larger wire cross-sectional area is assigned, the wire diameter can be increased, so that a difference in resistance value for each winding can be suppressed. . In other words, by assigning a large cross-sectional area to the coil that has a longer circumference due to the arrangement of the wires, and instead adjusting the resistance value by increasing the wire diameter, a balanced three-phase winding is realized. Yes.

JP 2002-315248 A

  However, when examining the difference in winding characteristics depending on the position of the wire in the slot, when there is an electric wire on the bottom side of the slot compared to the case where there is an electric wire on the slot entrance side, the normal design details are as follows in most cases. It turned out to be like this. First, the induced voltage coefficient is the same. This indicates that there is no difference in the induced voltage coefficient if the permanent magnet magnetic flux is designed to flow efficiently through the teeth. The torque constant is then the same. This indicates that the same output torque can be expected as long as a predetermined torque component current can be supplied. Furthermore, when the electric wire is on the bottom side of the slot, the coil inductance tends to be larger than when the electric wire is on the slot inlet side. That is, when there is an electric wire on the slot entrance side, the magnetic flux generated by the coil easily leaks between adjacent teeth. No matter how good the design is, there is a nature that can make a difference. As a result, the terminal voltage of the winding becomes higher, so that the output limit is inferior under the limited maximum voltage value.

  For this reason, it does not surface in the operation in the range where the drive circuit has a margin, but if you try to operate to the limit of the drive circuit, it will be disadvantageous in the stator where the electric wire is unevenly distributed on the bottom side of the slot, The output characteristics cannot be improved. In the electric motor described in Patent Document 1, the difference in resistance value is eliminated, but the magnitude of the inductance is not considered, and if it is attempted to operate to the limit of the drive circuit, it becomes a disadvantageous state. .

  An object of the present invention is to improve output characteristics while reducing the size of a rotating electrical machine.

  A rotating electrical machine of the present invention is a rotating electrical machine having an outer core in which a plurality of slots having openings on the inner peripheral surface extend in the radial direction, and an inner core disposed inside the outer core. A high density portion having a high local wire density of the coil is formed in the radially inner portion of the outer core inside the slot to be mounted, and a local wire density of the coil is formed in the radially outer portion of the outer core. A low density portion having a low thickness is formed.

  The rotating electrical machine of the present invention is characterized in that the high-density portion and the low-density portion are formed in all the slots in which coils are mounted. The rotating electrical machine according to the present invention is characterized in that a coil wound in the slot is unevenly distributed in a radially inner portion of the outer core, and a coil non-existing region is formed in a radially outer portion of the slot. The rotating electrical machine of the present invention is characterized by having a filler injected into the coil absence region.

  A method of manufacturing a rotating electrical machine according to the present invention is provided for a rotating electrical machine having an outer core in which a plurality of slots having openings on the inner peripheral surface extend in the radial direction and an inner core disposed inside the outer core. In the manufacturing method, a coil winding step of winding a coil around the slot of the outer core, and a coil end portion of the coil extending along the end surface of the outer core are moved radially inward of the outer core by a coil end moving jig. A coil end portion moving step of moving the coil in the slot radially inward by the coil end portion, and inside the slot in which the coil is mounted, the coil in the radially inner portion of the outer core. A high density portion having a high local wire density is formed, and the local wire density of the coil is formed on the radially outer portion of the outer core. And forming a have low density portion.

  The method for manufacturing a rotating electrical machine according to the present invention is characterized in that the high-density portion and the low-density portion are formed in all the slots in which coils are mounted. In the method of manufacturing a rotating electrical machine according to the present invention, after the coil end portion is moved to the radially inner portion of the outer core by the coil end moving jig, a slot insertion bar is inserted into the slot and wound around the slot. And a coil non-existing region is formed in a radially outer portion of the slot. The method for manufacturing a rotating electrical machine according to the present invention includes a filler injection step of injecting a filler into the coil absence region.

  A method of manufacturing a rotating electrical machine according to the present invention is provided for a rotating electrical machine having an outer core in which a plurality of slots having openings on the inner peripheral surface extend in the radial direction and an inner core disposed inside the outer core. In the manufacturing method, a coil winding step of winding a coil around the slot of the outer core, and a coil moving step of moving the coil in the slot radially inward, inside the slot in which the coil is mounted, Forming a high density portion having a high local wire density of the coil in the radially inner portion of the outer core and forming a low density portion having a low local wire density of the coil in the radially outer portion of the outer core; It is characterized by. The method for manufacturing a rotating electrical machine according to the present invention is characterized in that the high-density portion and the low-density portion are formed in all the slots in which coils are mounted. The method of manufacturing a rotating electrical machine according to the present invention is characterized in that a slot insertion bar is inserted into the slot, and a coil wound in the slot is moved to a radially inner portion of the outer core. The method of manufacturing a rotating electrical machine according to the present invention includes a filler injection step of injecting a filler into a coil absence region formed in a radially outer portion of the slot by moving a coil.

  According to the present invention, the outer core in which the inner core is disposed is formed with a plurality of slots in which coils are mounted extending in the radial direction of the outer core. Since a high density portion with a high local wire density of the coil is formed and a low density portion with a low local wire density of the coil is formed in the radially outer portion, the magnetic flux generated in the outer core by the coil is The center is located on the side closer to the inner core, and the leakage flux is reduced, so that the inner core and the magnetic flux are efficiently coupled. Accordingly, the inductance of the coil can be reduced without changing the shape of the outer core, and the voltage can be further reduced when a current is passed through the coil. In addition, it is possible to drive with a larger current at the maximum voltage that the drive circuit can output. As a result, even if the diameter of the core on the rotation side is reduced, the instantaneous maximum torque can be increased, and the output characteristics and the rotation speed can be improved while reducing the size of the rotating electrical machine.

  If the high density part and the low density part are formed in all the slots where the coils are installed, the center of the magnetic flux generated by all the coils can be located closer to the inner core, and the leakage magnetic flux is reduced. The inner core and the magnetic flux can be combined more efficiently.

It is the schematic which shows the arrangement | positioning state of the coil in the outer core of the rotary electric machine which is one embodiment of this invention. It is an enlarged view which shows a part of FIG. (A) is the schematic which shows typically the generation | occurrence | production state of the magnetic flux in the outer core of the rotary electric machine of this invention, (B) is typical about the generation | occurrence | production state of the magnetic flux in the outer core of the conventional rotary electric machine as a comparative example. It is the schematic shown in FIG. It is a front view which shows the manufacturing apparatus of the outer core shown in FIG. It is an expanded sectional view of the reel jig seen from the 5-5 line direction in FIG. It is a top view of the coil insertion jig seen from the 6-6 line direction in FIG. It is a top view which shows the coil insertion jig of the state in which the coil for 1 phase was transferred from the reel jig. It is a front view of the coil insertion jig seen from the 8-8 line direction in FIG. It is a front view which shows the coil insertion jig in the state in which the coil for 1 phase was inserted in the slot of an outer core. It is the schematic which shows the arrangement | positioning state of a coil when the coil of the 1st phase is inserted in the slot of an outer core. It is the schematic which shows the arrangement | positioning state of a coil when the coil of a 2nd phase is inserted in the slot of an outer core. It is the schematic which shows the arrangement | positioning state of a coil when the coil of a 3rd phase is inserted in the slot of an outer core. (A) is a partially omitted enlarged sectional view in the direction of line 13A-13A in FIG. 10, (B) is a partially omitted enlarged sectional view in the direction of line 13B-13B in FIG. 11, and (C) is FIG. It is a partially-omission expanded sectional view of the 13C-13C line direction in FIG. It is a partially omitted sectional view showing an outer core in a state where all coils are inserted and set in a coil end moving jig. (A) is a partially omitted cross-sectional view showing an outer core in a state where a coil end moving jig is assembled, and (B) shows an outer core in a state where a slot insertion bar is inserted into the coil end moving jig. FIG. FIG. 4 is a partially omitted cross-sectional view showing the outer core in a state where a filler is injected into a coil absence region on the bottom side of the slot. It is the schematic which shows the arrangement | positioning state of the coil in the outer core of the rotary electric machine which is other embodiment of this invention. It is the schematic which expands and shows a part of FIG.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. 1 and 2 includes a cylindrical inner core 11 and a cylindrical outer core 12 into which the inner core 11 is incorporated. The rotating electrical machine 10 is of an inner rotor type in which an inner core 11 is a rotor or rotor and an outer core 12 is a stator or stator. The outer core 12 as a stator core is provided with a plurality of teeth 13 extending in the radial direction from the outer peripheral portion toward the inner peripheral surface, and slots 14 extending in the radial direction are formed between the teeth 13. Yes. Each slot 14 is closed on the outer side in the radial direction by a bottom surface 15 formed on the outer peripheral side of the outer core 12, and opens on the inner peripheral surface of the outer core 12 through an opening 16. The opening 16 faces the outer peripheral surface of the inner core 11 with a gap 17 between the inner core 11 and the outer core 12.

  As shown in FIG. 2, projections 18 extending on both sides in the circumferential direction are provided at the radially inner ends of the teeth 13, and the openings 16 are formed between the projections 18 adjacent in the circumferential direction. It has become. The opening 16 is set to a width smaller than the entire width of the slot 14, and the opening 16 has a constricted shape. Inside the constricted portion, as shown in FIG. 2, a wedge 19 is incorporated after a coil is mounted in each slot 14. The wedge 19 has a length corresponding to the length of the outer core 12 in the axial direction, and is disposed inside the opening 16 so as to be parallel to the rotation center axis O of the inner core 11. In FIG. 1, the wedge 19 is not shown. Moreover, in each figure, illustration is abbreviate | omitted about the insulator in a slot for insulating a coil from a core.

  A permanent magnet for four poles (not shown) is incorporated in an inner core 11 as a rotor in the rotating electrical machine 10 shown in FIG. 1, and a total of 48 teeth 13 are arranged at a constant interval in the circumferential direction in the outer core 12. The rotating electrical machine 10 is a 4-pole 48-slot three-phase rotating electrical machine. A plurality of three-phase four-pole coils 21 are mounted on the outer core 12 in a distributed winding manner by coils 21 made of covered electric wires incorporated into the respective slots 14.

  The one-phase, one-pole coil is provided with a large coil 21 (a) mounted in two slots 14 which are paired with 10 slots 14 in the circumferential direction, and the large coil 21 (a). A small coil 21 (b) mounted on the slot 14 on the inner side in the circumferential direction of the slot 14 with eight slots 14 therebetween. FIG. 1 shows a large coil 21 (a) and a small coil 21 (b) for one pole of U, V, and W phases, and the large coil is marked with a in parentheses. Is shown in parenthesis with the symbol b. Each coil 21 has a straddling portion, that is, a coil end portion 22, and the coil end portion 22 is disposed on both front and rear end surfaces of the outer core 12. As for the coil end portion 22, in FIG. 1, reference numeral 22 is given only to a coil for one phase.

  As is widely known, since it is impossible in practice to arrange the wires without any gaps, the cross-sectional area of the entire wire portion arranged in each slot 14 is different from that of the slot 14. It is set to be smaller than the area. Therefore, the shape of the outer core 12 is set so that the ratio of the entire cross-sectional area of the electric wire portion to the cross-sectional area of the slot 14, that is, the space factor does not exceed the upper limit value according to the reference value. Normally, the space factor is set such that a relatively large space remains in the slot 14 when the entire electric wires in the slot 14 are bundled, that is, when they can be densely arranged. This is to prevent the wires from being damaged when the coil is attached to the outer core 12.

  As shown in FIGS. 1 and 2, the coil 21 is arranged in each slot 14 so as to be unevenly distributed on the radially inner side of the outer core 12, and the radially inner side of the slot 14 is the most dense. The electric wires are arranged, and the electric wires are arranged in the most sparse manner on the radially outer side of the slot 14, that is, on the bottom surface 15 side. As shown in FIG. 1 and FIG. 2, by arranging the coils 21 in the slots 14 so as to be unevenly distributed radially inward, a coil absent region 23 is formed on the bottom surface 15 side of each slot 14. . The wire density in the coil absence region 23 is the sparse.

  FIG. 3A is a schematic view schematically showing a state of generation of magnetic flux in the outer core 12 when a part of the outer core 12 in FIGS. 1 and 2 is enlarged and a current flows through the coil. ) Is a schematic diagram schematically showing the state of magnetic flux generation in a conventional outer core 12 as a comparative example. The actual magnetic flux diagram is more complicated than the case shown in FIG. 3 and takes various forms depending on the operating state of the rotating electrical machine. In these drawings, the state of magnetic flux generation is shown in a simplified manner.

  As shown in FIG. 3A, when the coil 21 is arranged in a radially inward direction on the outer core 12, the magnetic flux 24 generated in the outer core 12 by the coil 21 is closer to the inner core 11. The center will be located and it can couple | bond with the inner core 11 efficiently. On the other hand, as shown in FIG. 3B as a comparative example, the slot 14a in which the coil 21 is unevenly distributed on the bottom surface 15 side of the slot 14 and the slot in which the coil 21 is unevenly distributed in the radial center of the slot 14 are provided. In 14b, the center of the magnetic flux is located on the side far from the inner core 11. For this reason, magnetic fluxes 25 and 26 that flow across the slots 14a and 14b and flow to the adjacent teeth 13 inside the outer core 12 are generated, and the inner core 11 cannot be efficiently coupled. As a result, an extra voltage for changing the magnetic flux that does not work effectively is generated in the outer core 12, and a state in which the inductance is large occurs.

  In the rotating electrical machine 10 of the present invention, as shown in FIG. 3A, the coil 21 is unevenly distributed on the radially inner side of the outer core 12, so that the density of the electric wire constituting the coil 21 is reduced to the diameter of the slot 14. The coil 21 is arranged such that the inner side in the direction is the most dense and the outer side in the radial direction of the slot 14 is the sparsest. In this way, the high density portion 27 having a high local wire density of the coil 21 is formed in the slot 14 in the radially inner portion of the outer core 12, that is, the portion close to the opening 16, and the local wire density is low. Since the low density portion 28 is formed in the radially outer portion of the outer core, that is, the portion close to the bottom surface 15 side, unlike FIG. 3B shown as a comparative example, the leakage magnetic flux is reduced and the coil inductance is reduced. be able to. As a result, when a current is passed through the coil, the voltage can be lowered, and driving with a larger current is possible at the maximum voltage that the drive circuit can output. As a result, even if the diameter of the inner core 11 as the rotor is reduced, the instantaneous maximum torque can be increased, and the output characteristics can be improved while downsizing the rotating electrical machine.

  FIG. 4 is a front view showing an outer core manufacturing apparatus for manufacturing the outer core of the rotating electrical machine 10 shown in FIGS. 1 and 2.

  As shown in FIG. 4, the outer core manufacturing apparatus includes a reel jig 41 for forming a coil, and an inserter for mounting the coil formed by the reel jig 41 on the outer core 12 of a rotating electrical machine. And a coil insertion jig 42.

  As shown in FIG. 4, the reel jig 41 has a rotating body 43 that rotates about a central axis O <b> 1, and the rotating body 43 has a first coil for forming the large coil 21 (a). A coil winding portion 44 and a second coil winding portion 45 for forming the small coil 21 (b) are provided. The covered electric wire as the coil material, that is, the element wire 40 is supplied from the nozzle 46, and while the reel jig 41 is rotated about the central axis O1, the element wire 40 is fed out from the nozzle 46 and the nozzle 46 is supplied. Is moved in the direction along the central axis O1, so that the large coil 21 (a) is wound around the coil winding portion 44, and the small coil 21 (b) is wound around the coil winding portion 45 to the large coil 21 (a). It is wound continuously. Thus, the coil 21 is formed by winding the wire 40 around the coil winding portions 44 and 45 by the winding process using the winding frame jig 41. Each coil 21 is in a state in which the strands 40 are in contact with each other or substantially in contact with each other and are wound around the reel jig 41 in a spiral shape.

  FIG. 5 is an enlarged cross-sectional view of the reel jig 41 viewed from the direction of line 5-5 in FIG. Each coil 21 in the state of being wound around the winding jig 41 has a loop shape, and the winding diameter of the large coil 21 (a) is larger than the winding diameter of the small coil 21 (b). Note that the wire 40 is shown as a single line in FIG. 4, whereas in FIG. 5, the wire diameter is exaggerated and shown as a double line.

  FIG. 6 is a plan view of the coil insertion jig 42 as seen from the 6-6 line direction in FIG. The coil insertion jig 42 has a support base 51 as shown in FIG. 4, and a rotating body 52 is incorporated in the support base 51 so as to be rotatable about the central axis O2. A pair of five rod-like blades 53 extending in the vertical direction in FIG. 4 are attached to the rotating body 52. As shown in FIG. 6, a gap 57 into which the coil formed by the winding frame jig 41 enters is provided between the blades 53. As shown in FIG. 6, four pairs of blade pairs 54 paired by five blades 53 are provided by being shifted by 90 degrees in the circumferential direction of the rotating body 52. A pair of wedge guides 55 are provided outside each blade 53. As shown in FIGS. 4 and 6, the wedge guide 55 is disposed in the lower part of each blade 53 in FIG. 4, and between the pair of wedge guides 55 is the same coil as between the blades 53. There is a gap 57 into which is inserted.

  The coil formed by the reel jig 41 shown in FIG. 4 is transferred from the reel jig 41 to the coil insertion jig 42. This delivery operation is performed by moving the reel jig 41 downward toward the coil insertion jig 42 in FIG. However, the transfer operation may be performed by moving the coil insertion jig 42 upward toward the reel jig 41, or the transfer operation may be performed using a transfer jig.

  As shown in FIG. 5, a blade insertion hole 47 is formed in the reel jig 41. When the reel jig 41 is moved downward toward the coil insertion jig 42, the blades 53 of the two blade pairs 54 that are shifted from each other by 90 degrees enter the blade insertion hole 47. Thereby, the large coil 21 (a) and the small coil 21 (b) for one phase and one pole formed by the winding jig 41 have the coil end portions 22 on one side of the blade 53 and the wedge guide 55, respectively. The sandwiched state is transferred from the winding frame jig 41 to the coil insertion jig 42. In FIG. 6, the coil for one phase and one pole composed of the large coil 21 (a) and the small coil 21 (b) formed by the winding frame jig 41 is transferred to the coil insertion jig 42. The transferred state is indicated by a two-dot chain line. When the coils for one pole and one pole are transferred to the coil insertion jig 42, the coil insertion jig 42 is indexed and rotated 90 degrees.

  Therefore, by passing the coil insertion jig 42 by indexing and rotating the coil insertion jig 42, the operation for transferring the coil for one phase and one pole formed by the reel jig 41 to the coil insertion jig 42 is performed four times. The coils for one phase and four poles are transferred to the coil insertion jig 42. FIG. 7 shows a state where coils for one phase and four poles are set in the coil insertion jig 42 by repeating the coil winding operation and the coil transfer operation four times.

  Since a coil for one phase and four poles is set from one reel jig 41 to the coil insertion jig 42, the blade pair 54 is arranged in the circumferential direction as shown in FIGS. There are four pairs that are 90 degrees apart. Since each of the blade pairs 54 is set with coils for two poles adjacent to each other in the circumferential direction, the blade pair 54 has five blades 53.

  A stripper 56 is attached to the coil insertion jig 42 so as to be movable in the vertical direction in FIG. As shown in FIG. 7, the coil is inserted into the outer core 12 of the rotating electrical machine 10 by the stripper 56 of the coil insertion jig 42 with the coils for one phase and four poles set in the coil insertion jig 42. The operation is performed.

  FIG. 8 is a front view of the coil insertion jig 42 as seen from the direction 8-8 in FIG. After the outer core 12 is conveyed above the coil insertion jig 42, the outer core 12 is moved downward and the respective blades 53 are inserted into the inner peripheral surface of the outer core 12. The lowering movement limit of the outer core 12 is regulated by the front end of the wedge guide 55 abutting against the lower end surface of the outer core 12. In FIG. 8, the outer core 12 in a state of being abutted against the wedge guide 55 is indicated by a two-dot chain line.

  Under this state, the stripper 56 is moved upward in FIG. 8 to insert the stripper 56 into the inner peripheral surface of the outer core 12. By this coil insertion step, each coil 21 is inserted into the slot 14 as shown in FIG. In FIG. 9, the large coil 21 (a) mounted on the outer core 12 is shown, and the small coil 21 (b) is mounted in the slot 14 on the inner side in the circumferential direction than the large coil 21 (a). It will be. Thus, as shown in FIG. 10, for example, the U-phase coil 21 (U) is inserted into the 16 slots 14 of the outer core 12, and the coil 21 for one phase and four poles is wound around the slot 14. Is completed. In FIG. 10, the coil end portion 22 is shown radially outward of the outer core 12 for the convenience of drawing, but the coil end portion 22 is disposed along the end surface of the outer core 12.

  13A is a partially omitted enlarged cross-sectional view in the direction of the line 13A-13A in FIG. 10, and the coil 21 first mounted in the slot 14 is disposed at the radial center of the slot 14. . As for the arrangement state of the coil 21, both the large coil 21 (a) and the small coil 21 (b) for the U phase are similarly arranged in the central portion in the radial direction.

  Next, the coil insertion jig 42 is indexed for the operation of transferring another one-phase one-pole coil 21, for example, the V-phase coil 21 to the coil insertion jig 42 with respect to the above-described reel jig 41. By rotating and performing four times, the four-phase coil 21 for V-phase is transferred to the coil insertion jig 42 and then inserted into the other 16 slots 14 as shown in FIGS. To do. Thereby, the winding process of the coil of the second phase is completed. FIG. 11 shows a state where the second-phase coil 21 is inserted into the slot 14 in this way. When the second-phase coil 21 (V) is inserted into the slot 14, the coil end portion 22 of the one-phase coil 21 (U) in which the coil end portion 22 of the coil has already been inserted is moved radially outward. Therefore, as shown in FIG. 11, the first-phase coil 21 (U) is displaced radially outward in the slot 14.

  FIG. 13B is a partially omitted enlarged sectional view in the direction of line 13B-13B in FIG. 11, and the first phase coil 21 (U) already mounted in the slot 14 is pressed radially outward, The newly mounted second-phase coil 21 (V) is positioned on the radially inner side of the slot 14.

  Further, using the coil insertion jig 42 described above, the first phase coil 21 (U) and the second phase coil 21 (V) are used in the same manner as the first phase coil 21 (U) and the third phase coil 21 corresponding to four poles. The W-phase coil 21 (W) is inserted into the remaining 16 slots 14 as shown in FIGS. FIG. 12 shows a state in which the coil winding process of the third phase coil 21 (W) into the slot 14 is completed. When the third phase coil 21 (W) is inserted into the slot 14, the coil end portion 22 of the second phase coil 21 (V) in which the coil end portion 22 has already been inserted is moved radially outward. Therefore, as shown in FIG. 12, the coil end portion 22 of the second-phase coil 21 (V) is shifted outward in the radial direction.

  FIG. 13C is a partially omitted enlarged cross-sectional view in the direction of line 13C-13C in FIG. 12, and the second-phase coil 21 (V) already mounted in the slot 14 is pressed radially outward, The newly mounted third-phase coil 21 (W) is arranged on the radially inner side of the slot 14.

  As described above, when the coil winding process is completed around the outer core 12 of one rotating electrical machine 10 by three coil insertion operations, the coil end portion 22 of the coil 21 (U) that has previously entered the slot 14. Will interfere with the coil end portion 22 of the coil 21 (V) to be wound next, and the coil end portion 22 of the coil 21 (U) previously wound in the slot 14 is pressed outward in the radial direction. You will receive power. However, in order to avoid mutual interference between the coil end portions 22, the coil 21 that has previously entered the slot 14 may be shifted in advance radially outward prior to the insertion of the next coil 21. As shown in FIG. 12, the coil 21 is unevenly distributed on the bottom surface 15 side of the slot 14 in a state where all the coils 21 are wound around the outer core 12, or the coil 21 is located at the radial center of the slot 14. 3 is unevenly distributed, the center of the magnetic flux is located on the side farther from the inner core 11 in the slots 14a and 14b, as shown in FIG. For this reason, magnetic fluxes 25 and 26 that flow across the slots 14a and 14b and flow to the adjacent teeth 13 inside the outer core 12 are generated, and the inner core 11 cannot be efficiently coupled.

  In the outer core 12 of the present invention, as shown in FIG. 3A, the coils 21 are arranged in an unevenly distributed position on the radially inner side of the outer core 12, and the coils 21 are locally located inside the slots 14. The high density portion 27 having a high electric wire density is formed in the radially inner portion of the outer core 12 and the low density portion 28 having a low local wire density is formed in the radially outer portion of the outer core. The center of the magnetic flux 24 generated in 12 is located on the side closer to the inner core 11 and can be efficiently coupled to the inner core 11.

  FIG. 14 is a cross-sectional view showing a coil end moving jig 61 for arranging the coils 21 so as to be unevenly distributed on the radially inner side of the outer core 12. The coil end moving jig 61 is divided into a plurality of three or four in the circumferential direction, and the outer core 12 enters each coil end moving jig 61 as shown in FIG. A recess 62 is formed. Each coil end moving jig 61 has a facing surface 63 that faces the end surface of the outer core 12, extends from the inner end of each facing surface 63 outward in the axial direction, and curves radially outward. Thus, a pressing portion 64 is formed.

  Therefore, when the coil end moving jig 61 is engaged with the outer core 12, the coil end portions 22 of the coils 21 move radially inward as shown in FIG. 21 is also pulled by the coil end part 22 and moves radially inward. As a result, the coils 21 in each slot 14 are unevenly distributed radially inward and disposed in the slot 14, and a coil absent region 23 is formed on the bottom surface 15 side of the slot 14. . As shown in FIG. 15A, the coil end moving jig 61 is provided with each slot so that the coil 21 in the slot 14 does not remain partially curved radially outward of the slot 14 as shown in FIG. 14 is formed so that a slot insertion rod 66 is inserted into each of the rod insertion grooves 65.

  FIG. 15B is a diagram showing a state in which the slot insertion bar 66 is inserted into the bar insertion groove 65. By inserting the slot insertion bar 66 into the bar insertion groove 65 in this manner, The coils can be reliably distributed radially inward. Thereby, the electric wire of the coil 21 can be prevented from remaining in the radially outer portion of the slot 14. As described above, when the coil 21 is arranged so as to be unevenly distributed on the radially inner side of the outer core 12, the magnetic flux 24 generated in the outer core 12 by the coil 21 is generated as shown in FIG. As a result, the center is located on the side closer to, so that it can be efficiently coupled to the inner core 11 and the inductance can be reduced. Thereby, even if the diameter of the inner core 11 as a rotor is reduced, the instantaneous maximum torque can be increased.

  Although the description is omitted, the wedge 19 is loaded in advance in the wedge guide, and when each coil is inserted, the wedge pusher (not shown) rises in the wedge guide in conjunction with the rise of the stripper, and the wedge 19 is pushed out. Then, it is inserted into the slot just behind the opening so as to follow the inserted coil. Thus, before the coil end moving jig 61 moves the coil end portion 22, the wedge 19 is inserted into the slot 14 while being positioned inside the opening portion 16 in advance.

  As shown in FIG. 16, a filler 67 is injected into the coil absence region 23 so that the coil 21 does not move into the coil absence region 23 in the process of using the rotating electrical machine 10. As the filler 67, varnish or resin is used. As a method of injecting the varnish into the coil absent region 23, there are a method of immersing the outer core 12 in a liquid varnish and a method of injecting the varnish from the nozzle into the coil absent region 23. In any method, the varnish is dried and solidified to prevent the coil from moving to the coil absence region 23. FIG. 16 shows a state where the varnish is cured. In addition, as a method of injecting the resin as the filler 67 into the coil absent region 23, there is a method of injecting a molten resin into each coil absent region 23 using a resin mold, and by curing this, The coil is prevented from moving to the coil absence area 23. When the resin is injected into the coil absence region 23 using the resin mold, the slot insertion bar 66 is removed from the slot 14 and the slot insertion bar 66 is synchronized with the resin injection timing. There is a method of extracting.

  The outer core 12 shown in FIG. 1 is provided with a coil 21 for one pole and one phase formed by a large coil and a small coil, and is provided with 48 slots 14. When a coil for one pole and one phase is formed by a single coil, an outer core having 24 slots 14 is formed. The reel jig 41 for manufacturing the outer core 12 has a coil winding portion for forming one coil.

  FIG. 17 is a schematic view showing a coil arrangement state in an outer core of a rotating electrical machine 10 according to another embodiment of the present invention, and FIG. 18 is a schematic view showing a part of FIG. 17 in an enlarged manner.

  The rotary electric machine shown in FIGS. 17 and 18 is a 54-slot 12-pole synchronous motor. The inner core 11 is provided with twelve permanent magnets 20 as indicated by broken lines, and the outer core 12 is provided with 54 pieces. A slot 14 is provided. As shown in FIG. 18, this type of outer core 12 has a slot 14 in which two sets of coils having the same phase are mounted, and a slot 14 in which two coils having different phases are mounted. Each coil 21 is hatched and shaded. For the outer core 12, as in the case described above, a plurality of outer core manufacturing apparatuses having a reel jig and a coil insertion jig similar to the outer core manufacturing apparatus shown in FIG. All the coils 21 are mounted by repeating the coil insertion process. After all the coils 21 are mounted, the coil end portion moving step shown in FIG. 15A, the uneven distribution step shown in FIG. 15B, and the filler injection step shown in FIG. 16 are executed.

  In the illustrated outer core 12, the coils 21 are mounted in distributed winding. However, in the case of the outer core of the type in which the coils are mounted in concentrated winding, each coil 21 is similarly mounted after the coils 21 are mounted. Is unevenly distributed radially inward of the slot 14, thereby forming a high density portion having a high electric wire density in the radially inner portion of the slot 14 and forming a low density portion having a low electric wire density in the radially outer portion. .

  When winding a coil by feeding an electric wire from the nozzle to each tooth 13 by concentrated winding, the coil end portion is moved radially inward of the outer core 12 by a coil end moving jig as in distributed winding, The coil is moved radially inward of the outer core 12 by inserting a slot insertion rod into the slot. As described above, even when the coil is wound around the outer core 12 by concentrated winding, a high-density portion in which the local wire density of the coil is high on the radially inner portion of the outer core 12 by the coil winding step and the coil moving step. And a low density portion having a low local wire density of the coil is formed on the radially outer portion of the outer core 12. Also in the case of concentrated winding, if the coil wound in the slot 14 is unevenly distributed in the radially inner portion of the outer core 12 to form a coil absent region in the radially outer portion of the slot 14, the radially outer side of the slot 14 It is possible to prevent the coil from remaining in the part. Furthermore, when varnish or resin is injected into this coil absence region, it is possible to reliably prevent the coil from moving to the coil absence region.

  The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the scope of the invention. The present invention can be applied to an outer rotor type rotating electric machine as long as the outer core is a rotor as long as a coil is mounted in a slot of the outer core. Further, the present invention is not limited to a synchronous rotating electric machine, and the present invention can be applied to, for example, manufacturing an induction rotating electric machine. Furthermore, the present invention is not limited to a three-phase rotating electrical machine, but may be a single-phase rotating electrical machine, and the present invention can be applied to the manufacture of a DC rotating electrical machine.

DESCRIPTION OF SYMBOLS 10 ... Rotary electric machine, 11 ... Inner core, 12 ... Outer core, 13 ... Teeth, 14 ... Slot, 15 ... Bottom, 16 ... Opening, 17 ... Gap, 18 ... Protrusion, 19 ... Wedge, 20 ... Permanent magnet, 21 DESCRIPTION OF SYMBOLS ... Coil, 22 ... Coil end part, 23 ... Coil absent area | region, 24 ... Magnetic flux, 27 ... High density part, 28 ... Low density part, 41 ... Winding jig, 42 ... Coil insertion jig, 51 ... Support stand, 52 ... Rotating body, 53 ... Blade, 56 ... Stripper, 61 ... Coil end moving jig, 66 ... Slot insertion rod.

Claims (12)

In a rotating electrical machine having an outer core formed with a plurality of radially extending slots having an opening on the inner peripheral surface, and an inner core disposed inside the outer core,
A high density portion having a high local wire density of the coil is formed in the radially inner portion of the outer core inside the slot in which the coil is mounted, and a local portion of the coil is formed in the radially outer portion of the outer core. A rotating electrical machine characterized by forming a low-density portion having a low electric wire density.   The rotating electrical machine according to claim 1, wherein the high density portion and the low density portion are formed in all the slots in which coils are mounted.   3. The rotating electrical machine according to claim 1, wherein a coil wound in the slot is unevenly distributed in a radially inner portion of the outer core, and a coil absence region is formed in a radially outer portion of the slot. Rotating electric machine.   4. The rotating electrical machine according to claim 3, further comprising a filler injected into the coil absence region. In a manufacturing method of a rotating electrical machine having an outer core formed with a plurality of slots having an opening on the inner peripheral surface extending in the radial direction, and an inner core disposed inside the outer core,
A coil winding step of winding a coil around the slot of the outer core;
A coil that moves the coil end portion of the coil extending along the end face of the outer core radially inward of the outer core by a coil end moving jig, and moves the coil in the slot radially inward by the coil end portion. An end part moving step,
A high density portion having a high local wire density of the coil is formed in the radially inner portion of the outer core inside the slot in which the coil is mounted, and a local portion of the coil is formed in the radially outer portion of the outer core. A method of manufacturing a rotating electrical machine, wherein a low-density portion having a low electric wire density is formed.   6. The method of manufacturing a rotating electrical machine according to claim 5, wherein the high density portion and the low density portion are formed in all the slots in which the coils are mounted.   The method of manufacturing a rotating electrical machine according to claim 5 or 6, wherein after the coil end portion is moved to the radially inner side of the outer core by the coil end moving jig, a slot insertion rod is inserted into the slot, and A method of manufacturing a rotating electrical machine, comprising the step of unevenly distributing a coil wound in a slot in a radially inner portion of the outer core, and forming a coil non-existing region in a radially outer portion of the slot.   8. The method of manufacturing a rotating electrical machine according to claim 7, further comprising a filler injection step of injecting a filler into the coil absence region. In a manufacturing method of a rotating electrical machine having an outer core formed with a plurality of slots having an opening on the inner peripheral surface extending in the radial direction, and an inner core disposed inside the outer core,
A coil winding step of winding a coil around the slot of the outer core;
A coil moving step of moving the coil in the slot radially inward,
A high density portion having a high local wire density of the coil is formed in the radially inner portion of the outer core inside the slot in which the coil is mounted, and a local portion of the coil is formed in the radially outer portion of the outer core. A method of manufacturing a rotating electrical machine, wherein a low-density portion having a low electric wire density is formed.   10. The method of manufacturing a rotating electrical machine according to claim 9, wherein the high density portion and the low density portion are formed in all the slots in which the coils are mounted.   11. The method of manufacturing a rotating electrical machine according to claim 9 or 10, wherein a slot insertion rod is inserted into the slot, and a coil wound in the slot is moved to a radially inner portion of the outer core to thereby adjust the diameter of the slot. A method of manufacturing a rotating electrical machine, wherein a coil absence region is formed on an outer side portion in the direction.   12. The method of manufacturing a rotating electrical machine according to claim 11, further comprising a filling material injecting step of injecting a filling material into a coil absent region formed in a radially outer portion of the slot by moving a coil. Electric manufacturing method.

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