JP2012110077A - Stator and stator structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator and a stator structure in which an insulation securing part is reduced and a height of a coil end is suppressed.SOLUTION: In a stator structure, a stator 10 is formed by arranging flat conductors D in a stator core 20. A plurality of segment coils SC each formed to have an approximately U shape by bending the flat conductor D in the edgewise direction are superposed on each other, and lead side LS end parts are twisted at 90 degrees in the same direction so as to form a first twisted segment conductor SC12. A segment coil formed by superposing and twisting two segment coils SC at 180 degrees is superposed on the other segment coils SC, and lead side LS end parts are twisted at 90 degrees in the same direction so as to form a second twisted segment conductor SC22. The first twisted segment conductor SC12 is inserted in a slot 12 arranged in the stator core 20. Only one set of the second twisted segment conductor SC22 per one phase is inserted in a slot 12, and the lead side LS end parts of the segment coils SC are jointed.

Description

  The present invention relates to a stator and a stator structure using segment coils, and more particularly to a technique for reducing the height of the coil end of the stator by devising the shape of the segment coils.

  In recent years, in view of environmental problems, there are an increasing number of cases in which a driving motor is mounted on an automobile. It is desirable that the drive motor mounted on the vehicle has a large output for moving the vehicle and is space-saving for being mounted on the vehicle. In order to improve the output, a method for increasing the cross-sectional area of the coil used for the motor and increasing the space factor of the stator is being sought. On the other hand, with respect to miniaturization of motors, miniaturization has been studied by various approaches.

  Patent Document 1 discloses a technique related to a segment sequential joining stator coil of a rotating electrical machine and a manufacturing method thereof. By changing the axial length of the top portion of the segment coil for each adjacent segment coil, the radial length of the stator due to the swelling of the top portion is reduced. If the cross-sectional area of the coil is increased in order to increase the output of the stator, the minimum bending radius at the coil end inevitably increases, resulting in swelling in the radial direction. However, by changing the axial length of the top of the segment coil for each adjacent segment coil, it is possible to avoid bending portions at the coil end from overlapping, resulting in a reduction in the radial length of the stator. It becomes possible to do.

  Patent Document 2 discloses a technique relating to a method for manufacturing a stator winding. Patent Document 3 discloses a technique related to a winding joining method for a rotating electrical machine. In any case, a set segment in which two U-shaped segments are overlapped is inserted in a radial direction in a slot of a stator core, and the lead side is welded to form a stator.

  Patent Document 4 discloses a technique related to a stator of a segment coil rotating electrical machine and a method for manufacturing the same. In Patent Document 4, as in Patent Document 2 and Patent Document 3, a substantially U-shaped conductor segment is used. The same is true in that the stator is formed by welding at the joining end of each conductor segment. However, a powder coating film for preventing corona discharge is fixed to the outer peripheral surface of each joining end. Patent Document 5 discloses a technique related to a segment type stator structure. Similarly to Patent Documents 2 to 4, Patent Document 5 uses substantially U-shaped segments.

JP 2004-032882 A JP 2008-148431 A JP 2008-154433 A JP 2004-064989 A Japanese Patent Laid-Open No. 2006-166592

  However, when the segment type stator is formed by applying the techniques described in Patent Documents 1 to 5, it is considered that there are problems described below.

  In the techniques described in Patent Documents 1 to 3, the coil is formed using a small segment and a large segment arranged on the outer periphery of the small segment on the non-lead side. And in patent document 1 and patent document 2, although it devised so that the interference part with an adjacent segment may not generate | occur | produce by dodging the turn part of a segment to the axial direction of a stator, when the number of turns of a coil increases, Since the method requires the height of the coil end, it is not suitable for downsizing the stator. Even in Patent Document 3, in the coil end portion bent in a U-shape, the large segment needs to pass the outer periphery of the small segment, so that the coil end becomes high.

  Even in the techniques described in Patent Document 4 and Patent Document 5, when the number of turns of the coil is increased, a part for securing interphase insulation by increasing the number of windings at the coil end becomes complicated, and the height of the coil end increases. It can be considered.

  Accordingly, an object of the present invention is to provide a stator and a stator structure that reduce the insulation securing portion and reduce the height of the coil end in order to solve such problems.

  In order to achieve the above object, a stator structure according to an aspect of the present invention has the following characteristics.

(1) In a stator structure in which a flat conductor is used and a stator is formed by arranging the flat conductor in a stator core, the flat conductor is bent in an edgewise direction and formed into a substantially U-shape. Is formed into a first set segment, and the two lead side end portions of the first set segment are twisted 90 degrees in the same direction to form a first twist set segment, and the two segments are overlapped. The second twisted segment is formed by overlapping the one twisted 180 degrees and the other segment, and the two lead side end portions of the second pair segment are twisted 90 degrees in the same direction respectively to form the second twisted segment. Then, the first twist assembly segment is inserted into a slot provided in the stator core, the second twist assembly segment is inserted into the slot by one set per one phase, and the segment of the segment is inserted into the slot. Wherein the stator by bonding the de-side end portion is formed.

(2) In the stator structure according to (1), each of the first twisted assembly segment and the second twisted assembly segment has a high-insulation segment in which the insulation property of the segment is higher than that of the other segment at the end. It is preferable to be characterized by this.

(3) In the stator structure according to (1) or (2), the first twist assembly segment and the second twist assembly segment include one of the lead side end portions and the other of the lead side end portions. Is bent in one direction along the circumferential direction of the stator core, and is bent in one direction along the circumferential direction of the stator core, inserted in the different slots, and located in the innermost peripheral portion of the stator core. The lead side end of the segment located on the outermost periphery is bent in the other direction along the circumferential direction of the stator core, and the segment on the lead side end is located on the outermost periphery and the innermost periphery. It is preferable that two segments other than the segment to be bent are bent in pairs, and the adjacent pairs are bent in opposite directions along the circumferential direction of the stator core.

  In order to achieve the above object, a stator according to another aspect of the present invention has the following characteristics.

(4) In a stator having a segment formed by bending a plurality of rectangular conductors into a U shape and a stator core having a slot for inserting the segment, a plurality of the segments are stacked, and the stator core A first twisted assembly segment having a twisted portion to which a twist of 90 degrees is applied between the in-slot conductor portion inserted in the slot and the coil end portion located at one end of the stator core; Two segments stacked and twisted 180 degrees and the other segments are overlapped, and the in-slot conductor portion inserted into the slot, and a coil end portion positioned at one end of the stator core A second twisted assembly segment having a twisted portion to which a twist of 90 degrees is added, and only one set of the second twisted assembly segment is used per one phase. To.

(5) In the stator according to (4), each of the first twisted assembly segment and the second twisted assembly segment has a high-insulation segment in which the insulating property of the segment is higher than that of the other segment at the end. Is preferably characterized.

(6) In the stator according to (4) or (5), the first twist assembly segment and the second twist assembly segment include one of a lead side end portion and the other of the lead side end portion. The segments inserted in the different slots and positioned at the innermost periphery of the stator core and the segments positioned at the outermost periphery of the stator core are opposite in the circumferential direction of the stator core. Of the rectangular conductors at the end on the lead side, two bent portions other than the outermost segment and the segment located at the innermost periphery are bent in pairs, and the adjacent pair is the circumference of the stator core It is preferable to bend in the opposite direction along the direction.

  With the stator structure according to one aspect of the present invention having such characteristics, the following operations and effects can be obtained.

  The aspect of the invention described in the above (1) is a stator structure in which a flat conductor is used and the stator is formed by arranging the flat conductor in the stator core. A plurality of U-shaped segments are overlapped to form a first set segment, and two lead side end portions of the first set segment are respectively twisted 90 degrees in the same direction to form a first twisted set segment, Two segments are overlapped and twisted 180 degrees and other segments are overlapped to form the second set segment, and the two lead side ends of the second set segment are twisted 90 degrees in the same direction, respectively, and the second twisted A set segment is formed, the first twist assembly segment is inserted into a slot provided in the stator core, the second twist assembly segment is inserted into the slot per one phase, and the lead side ends of the segments are joined. In which the stator is formed by.

  Since the lead side end portions of the first twist assembly segment and the second twist assembly segment are respectively twisted by 90 degrees in the same direction, the conductor directions in the in-slot conductor portion and the coil end are different by 90 degrees. As a result, at the coil end on the opposite lead side, the flat rectangular conductor is placed on the radiation on the end face of the stator. In the prior art as shown in Patent Document 1 to Patent Document 3, the U-shaped segment has two rectangular conductors overlapping in the axial direction of the coil end, and the minimum height of the coil end is a large segment. This is considered to be influenced by the minimum bend radius of edgewise bend.

  On the other hand, in the present invention, as a result of forming the paired segments at the coil end on the opposite lead side, the segments are arranged so as to be long in the radial direction of the stator and arranged on the radiation of the stator. For this reason, as compared with Patent Documents 1 to 3, the coil end can be shortened by at least the width of the segment arranged on the outer peripheral side called the large segment. Therefore, it is possible to contribute to lowering the height in the axial direction at the coil end of the stator, and it is possible to reduce the size of the stator.

  Further, the aspect of the invention described in (2) is that, in the stator structure described in (1), the first twisted assembly segment and the second twisted assembly segment are higher in the insulation of the segment than the other segments at the end. It has a high insulation segment.

  In the prior art, if the interphase insulation in the stator is a three-phase stator, interphase insulating paper is required for both the coil end on the opposite lead side and the coil end on the lead side. This is because the phase is different between adjacent paired segments, and the potential difference between the phases is higher than the potential difference between the inphases, so that higher insulation is required than between the paired segments in the same phase. Therefore, it is necessary to secure insulation by using interphase insulating paper, or without using interphase insulating paper, and to increase the insulation of the rectangular conductor to such an extent that interphase insulation is possible. However, if the insulating coating is made thick in order to improve the insulation, there is a problem that the space factor of the stator is lowered and the performance of the stator is lowered.

  In the present invention, the use of a highly insulating segment at the end of the first torsion segment or the second torsion assembly segment formed by overlapping a plurality of segments eliminates the need for thickening the entire insulation coating, and specifications for interphase insulating paper The number of sheets can be reduced. Therefore, it can contribute to cost reduction.

  The aspect of the invention described in (3) above is the stator structure described in (1) or (2), wherein the first twist assembly segment and the second twist assembly segment are one of the lead side end portions, The stator core is inserted into a slot different from the other end of the lead side, and the lead side end of the segment located at the innermost peripheral portion of the stator core is bent in one direction along the circumferential direction of the stator core. Bend the lead-side end of the segment located on the outermost periphery of the core in the other direction along the circumferential direction of the stator core, and out of the segments on the lead-side end other than the segments located on the outermost and innermost circumferences Each pair is bent in pairs, and adjacent pairs are bent in opposite directions along the circumferential direction of the stator core.

  The number of interphase insulating papers used on the lead side of the stator can be reduced by bending the segments other than the segments located on the outermost and innermost segments of the stator in pairs. It becomes. This is because a rectangular conductor of the same phase is arranged in the stator slot and a segment of another phase is arranged in the adjacent slot. I need paper. However, since two pairs are bent in pairs, no interphase insulating paper is required between adjacent pairs of pairs, and as a result, the amount of interphase insulating paper used can be reduced. This can contribute to cost reduction of the stator.

  Moreover, the following operation | movement and an effect are acquired by the stator by one aspect | mode of this invention which has such a characteristic.

  The aspect of the invention described in the above (4) is a stator having a segment formed by bending a plurality of rectangular conductors into a U shape and a stator core having a slot into which the segment is inserted. A first torsion having a twisted portion in which a twist of 90 degrees is applied between the in-slot conductor portion that is overlapped and inserted into the slot of the stator core and the coil end portion located at one end of the stator core A pair of segments, two segments that are twisted 180 degrees and another segment are overlapped, between the in-slot conductor inserted in the slot and the coil end located at one end of the stator core And a second twisted assembly segment having a twisted portion to which a twist of 90 degrees is applied, and only one set of the second twisted assembly segment is used per one phase.

  As in the invention related to the stator structure described in (1) above, the lead side end of the first twist assembly segment or the large biennial assembly segment is twisted 90 degrees in the same direction, so that the in-slot conductor The direction of the conductor at the part and the coil end is 90 degrees different. As a result, in the coil end on the opposite lead side, the flat rectangular conductor is placed on the radiation on the end face of the stator, so that it is arranged on the outer peripheral side called a large segment as compared with Patent Documents 1 to 3. The equivalent of the segment width can shorten the coil end. Therefore, it is possible to contribute to lowering the height in the axial direction at the coil end of the stator, and it is possible to reduce the size of the stator.

  The aspect of the invention described in the above (5) is the stator described in (4), wherein the first twisted assembly segment and the second twisted assembly segment have higher segment insulation at the end than other segments. It has a high insulation segment.

  As in the invention related to the stator structure described in (2) above, the entire insulation is achieved by using a highly insulating segment at the end of the first twisted segment or the second twisted segment formed by overlapping a plurality of segments. It is not necessary to increase the thickness of the coating, and the number of sheets of interphase insulating paper can be reduced. Therefore, it can contribute to cost reduction.

  The aspect of the invention described in (6) is the stator described in (4) or (5), wherein the first twisted assembly segment and the second twisted assembly segment include one of the lead side end portions and the lead The other end of the side end portion is inserted into a different slot, and the segment located at the innermost peripheral portion of the stator core and the segment located at the outermost outer periphery of the stator core are reversed along the circumferential direction of the stator core. Of the rectangular conductor at the end on the lead side, except for the segment located on the outermost and innermost circumferences, bent in pairs, and adjacent pairs are reversed along the circumferential direction of the stator core. It is bent in the direction.

  As in the invention related to the stator structure described in (3) above, by interleaving two segments in pairs, no interphase insulating paper is required between adjacent segments, and as a result The amount of insulating paper used can be reduced. This can contribute to cost reduction of the stator.

It is a schematic diagram of the top view of a stator of this embodiment. It is the elements on larger scale of the plane of a stator of this embodiment. It is the perspective view seen from the center side of the stator of this embodiment. It is a model perspective view showing the 1st step of the formation process of the segment conductor before the 1st twist of this embodiment. It is a schematic plan view which shows the 2nd step of the formation process of the 1st twist segment conductor of this embodiment. It is a model side view which shows the 2nd step of the formation process of the 1st twist segment conductor of this embodiment. It is a schematic diagram showing the 1st step of the formation process of the 2nd twisted segment conductor of this embodiment. It is a side surface schematic diagram of the stator of this embodiment. It is the schematic plan view seen from the non-lead side in the state where the W-phase segment coil was inserted of this embodiment. It is the perspective view which represented typically the process of the segment coil by the side of this embodiment. It is a partial enlarged view of the lead side of the stator of the present embodiment.

  First, an embodiment of the present invention will be described.

  In FIG. 1, the schematic diagram of the top view of the stator 10 of this embodiment is shown. FIG. 2 shows a partially enlarged view of the plane of the stator 10. FIG. 3 is a perspective view seen from the center side of the stator 10. The stator 10 is formed by arranging a rectangular conductor D formed in a U-shape called a segment coil SC on a stator core 20. The stator 10 is an 8-pole stator 10 that forms a three-phase motor having a U phase, a V phase, and a W phase. The flat conductor D is made of a metal having a rectangular cross section with high conductivity, such as copper or aluminum, and an insulating coating is provided on the periphery thereof. The insulating coating will be described later.

  The stator core 20 is formed in a substantially cylindrical shape by laminating a large number of electromagnetic steel plates, teeth 11 are formed toward the inner peripheral side, and slots 12 are formed between adjacent teeth 11. In the present embodiment, the stator core 20 has 48 teeth 11 and the slots 12 have 48 slots. A plurality of segment coils SC are inserted into the slot 12 with an insulator 25 disposed therein, and the insulator 25 is made of resin and ensures insulation between the stator core 20 and the segment coil SC. The stator core 20 is provided with three ribs 21 that are convex toward the outer periphery, and the ribs 21 are provided with bolt holes 22. A bolt (not shown) is passed through the bolt hole 22 and used for attaching a cover (not shown) or attaching the stator core 20 to an engine or the like.

  The segment coil SC inserted into the stator core 20 is formed by bending a flat conductor D into a U shape and overlapping it. Next, the manufacturing procedure of the segment coil SC will be described using schematic diagrams. The first is a manufacturing procedure of the first torsion segment conductor SC12.

  FIG. 4 is a schematic perspective view showing the first stage of the molding process of the first pre-twisted segment conductor SC11. FIG. 5 is a schematic plan view showing a second stage of the process of forming the first torsion segment conductor SC12. FIG. 6 shows a side view of FIG. As a procedure for forming the first twisted segment conductor SC12, first, it is necessary to arrange a plurality of flat conductors D bent in a U shape as shown in FIG. This state is referred to as a first pre-twisted segment conductor SC11 corresponding to the first set segment. The first flat conductor D1 is formed by bending a straight flat conductor D in an edgewise direction. The second rectangular conductor D2 to the fifth rectangular conductor D5 are also formed in the same shape as the first rectangular conductor D1. However, the second rectangular conductor D2 to the fifth rectangular conductor D5 are provided with an insulation coating to such an extent that insulation between the in-phase rectangular conductors D is possible. The first rectangular conductor D1 is provided with a thicker insulating coating than the other rectangular conductors D, and the insulating coating film is set to a thickness that allows insulation with other phases.

  The first to fifth rectangular conductors D1 to D5 are simply laminated as shown in FIG. 4 to form the first pre-twisted segment conductor SC11. After that, the non-lead side RLS of the first pre-twisted segment conductor SC11 is held by a jig (not shown), and the lead side LS is twisted 90 degrees as shown in FIG. 4, respectively, as shown in FIGS. By forming the twisted portion S1, the first twisted segment conductor SC12 corresponding to the first twisted assembly segment is formed. Thus, the first torsion segment conductor SC12 in which the in-slot conductor portion SS and the coil end portion SE are formed is formed. In the case of the 8-pole stator 10, 15 first twisted segment conductors SC12 are required per phase.

  FIG. 7 is a schematic diagram showing the first stage of the molding process of the second pre-twisted segment conductor SC21. The formation process is slightly different between the second pre-twisted segment conductor SC21 corresponding to the second set segment and the first pre-twisted segment conductor SC11 corresponding to the first set segment. Specifically, as shown in FIG. 7, first the first rectangular conductor D1 and the second rectangular conductor D2 are first stacked and then twisted 180 degrees, and in this state, the third rectangular conductor D3, the fourth rectangular conductor D4, and the fifth rectangular conductor. Overlapping D5, the second pre-twisted segment conductor SC21 is formed. That is, of the five rectangular conductors D that are edgewise bent into a U-shape, the one that is twisted ahead by two is defined as the second pre-twisted segment conductor SC21.

  As shown in FIG. 6, the second pre-twisted segment conductor SC21 is further twisted by 90 degrees in the same manner as the first pre-twisted segment conductor SC11, thereby forming the twisted portion S1 to form the second twisted group segment. A segment conductor SC22 is formed. The second twisted segment conductor SC22 is formed in this way, but the appearance of the second twisted segment conductor SC22 is the first twisted segment conductor SC12 except that the first flat conductor D1 and the second flat conductor D2 are twisted 180 degrees. The figure is omitted because it is almost the same. One second twisted segment conductor SC22 is required per one phase.

  FIG. 8 shows a schematic side view of the stator 10. FIG. 9 is a schematic plan view seen from the side opposite the lead with the W-phase segment coil SC inserted. As described above, the plurality of segment coils SC are twisted one by one to form the first torsion segment conductor SC12 and the second torsion segment conductor SC22. Then, a first torsion segment conductor SC12 and a second torsion segment conductor SC22 for three phases are prepared, and the first torsion segment conductor SC12 and the second torsion segment conductor are provided in the slot 12 of the stator core 20 as shown in FIG. Insert SC22.

  Although the insertion process is not shown, the insulator 25 is also inserted into the slot 12 of the stator core 20 before the first torsion segment conductor SC12 and the second torsion segment conductor SC22 are inserted. Further, in FIG. 8, it seems that the segment coil SC is inserted in the same slot 12, but this is a result schematically shown in the drawing problem, and actually, as shown in FIG. In-slot conductor portion SS of segment coil SC (first torsion segment conductor SC12 and second torsion segment conductor SC22) is inserted into different slot 12.

  Specifically, as shown in FIG. 9, one of the in-slot conductor portions SS of the W-phase first segment conductor SCW1 is inserted into the inner periphery of the slot 12 in the W-phase first slot W1 of the first pole P1. The other of the in-slot conductor portions SS of the W-phase first segment conductor SCW1 is inserted on the outer peripheral side of the slot 12 in the W-phase first slot W1 of the second pole P2 that is separated by five slots. That is, the first torsional segment conductor SC12 or the second torsional segment conductor SC22 is inserted into the slot 12 of the stator core 20 after being deformed so as to be inserted into the slot 12 separated by 5 slots.

  Similarly, for the W-phase second segment conductor SCW2, one of the in-slot conductors SS of the W-phase second segment conductor SCW2 is on the inner peripheral side of the slot 12 in the W-phase second slot W2 of the first pole P1. The other of the in-slot conductor portions SS of the W-phase second segment conductor SCW2 is inserted on the outer peripheral side of the slot 12 in the W-phase second slot W2 of the second pole P2 that is inserted and separated by 5 slots. Thereafter, the W-phase first twisted segment conductor SC12 or the second twisted segment conductor SC22 for the remaining six poles is inserted and arranged as shown in FIG. Similarly, the first torsion segment conductor SC12 and the second torsion segment conductor SC22 are inserted for the U phase and the V phase. In FIG. 9, the thick line indicates the position where the first flat conductor D1 is disposed.

FIG. 10 is a perspective view schematically showing the processing of the segment coil SC on the lead side LS. The stator core 20 is indicated by an imaginary line. After the in-slot conductor portion SS of the segment coil SC is inserted into the slot 12, it is necessary to deform the lead side LS as shown in FIG. If the slot 12 on the left side of the drawing is the first slot 121, the slot 12 on the right side of the drawing becomes the seventh slot 127 separated by 5 slots. In each slot 12, the in-slot conductor portion SS of the W-phase first segment conductor SCW1 of the first pole P1 is inserted. Then, a rectangular conductor D is irradiated on the radiation from the center of the stator 10 around the fourth slot 124.
The first rectangular conductor D1 to the fifth rectangular conductor D5 are bent so that the end faces thereof are aligned.

For convenience, the in-slot conductor portion SS of the W-phase first segment conductor SCW1 will be referred to as an inner circumferential slot inner conductor portion SSI and an outer circumferential slot inner conductor portion SSO. As a result of bending the inner-slot in-slot conductor SSI and the outer-slot in-slot conductor SSO of the segment coil SC of the W-phase first segment conductor SCW1, the inner circumference in the W-phase first segment conductor SCW1 of the first pole P1. The first rectangular conductor D1, the fourth rectangular conductor D4, and the fifth rectangular conductor D5 of the side slot conductor portion SSI, and the first rectangular conductor D1, the second rectangular conductor D2, and the fifth rectangular conductor of the outer slot side conductor portion SSO. D5 is arranged on the fourth slot 124. In other words,
The second rectangular conductor D2, the third rectangular conductor D3, the fourth rectangular conductor D4, and the fifth rectangular conductor D5 of the inner circumferential slot in-conductor portion SSI of the W-phase first segment conductor SCW1 are bent in the same direction as a pair, The first rectangular conductor D1, the second rectangular conductor D2, the third rectangular conductor D3, and the fourth rectangular conductor D4 of the side slot in-conductor portion SSO are bent in the same direction as a pair.

  Although not shown, the second pole disposed on the inner peripheral side of the seventh slot 127 that is separated by five slots is disposed next to the first rectangular conductor D1 of the inner-slot-side in-slot conductor SSI. The second flat conductor D2 and the third flat conductor D3 in the W-phase first segment conductor SCW1 of P2 are arranged in order. Further, the third rectangular conductor D3 of the W-phase first segment conductor SCW1 of the eighth pole P8 (not shown) arranged on the outer peripheral side of the first slot 121 adjacent to the second rectangular conductor D2 of the outer-slot in-slot conductor SSO. And the 4th rectangular conductor D4 is arrange | positioned in order.

  FIG. 11 shows a partially enlarged view of the lead side LS of the stator 10. FIG. 11 is a partially enlarged view of the stator 10 corresponding to FIG. 10 on the lead side LS side, in which a plurality of interphase insulating papers IP are inserted. For convenience, the first row LE1 to the tenth row LE10 will be referred to in order from the inner peripheral side of FIG. Then, the rectangular conductor D arranged in the first row LE1 by welding is joined to the rectangular conductor D arranged in the second row LE2, and the third row LE3 is joined to the fourth row LE4 and the fifth row. LE5 is joined to the sixth row LE6, the seventh row LE7 is joined to the eighth row LE8, and the ninth row LE9 is joined to the tenth row LE10.

  When FIG. 10 and FIG. 11 are made to correspond to each other, the first row LE1, the fourth row LE4, and the fifth row from the inner-slot in-slot portion SSI of the W-phase first segment conductor SCW1 of the first pole P1 A flat rectangular conductor D is wired to the column LE5, and the sixth column LE6, the seventh column LE7, and the tenth column from the outer-slot in-slot conductor SSO of the W-phase first segment conductor SCW1 of the first pole P1. It can be seen that the rectangular conductor D is wired to LE10. In the second row LE2 and the third row LE3, the rectangular conductor D is wired from the inner-slot in-slot portion SSI of the W-phase first segment conductor SCW1 of the second pole P2. In the eighth row LE8 and the ninth row LE9, the rectangular conductor D is wired from the outer-slot in-slot portion SSO of the W-phase first segment conductor SCW1 of the eighth pole P8.

  Of the interphase insulating paper IP, the first interphase insulating paper IP1 is inserted between the third row LE3 and the fourth row LE4, and the second interphase insulating paper IP2 is inserted between the seventh row LE7 and the eighth row LE8. The third interphase insulating paper IP3 is inserted between the column LE8 and the ninth column LE9 and the tenth column LE10.

  Note that the left first space SP11, the left second space SP12, the left third space SP13, the right first space SP21, the right second space SP22, and the right third space SP23 shown in FIG. 11 are actually adjacent to each other. The flat rectangular conductor D of the segment coil SC is arranged. Specifically, the rectangular conductor D corresponding to the second row LE2 and the third row LE3 of the eighth pole P8 of the V-phase second segment conductor SCV2 is inserted into the left first space SP11. A rectangular conductor D corresponding to the sixth row LE6 and the seventh row LE7 of the eighth pole P8 of the V-phase second segment conductor SCV2 is inserted into the left second space SP12. In the left third space SP13, a rectangular conductor D corresponding to the tenth column LE10 of the eighth pole P8 of the V-phase second segment conductor SCV2 is inserted. On the other hand, a rectangular conductor D corresponding to the first row LE1 of the W-phase second segment conductor SCW2 of the first pole P1 is inserted into the right first space SP21. The rectangular conductor D corresponding to the fourth row LE4 and the fifth row LE5 of the W-phase second segment conductor SCW2 of the first pole P1 is inserted into the right second space SP22. In the right third space SP23, the eighth column LE8 and the ninth column LE9 of the W-phase second segment conductor SCW2 of the first pole P1 are inserted.

  In this way, the first torsion segment conductor SC12 and the second torsion segment conductor SC22 are inserted into the stator core 20, deformed and joined as shown in FIG. 10, and as a result, the stator as shown in FIGS. 10 will be formed. As a result of continuously arranging FIGS. 11A and 11B, the state shown in FIG. 2 is obtained. However, in FIG. 2, it is difficult to produce a three-dimensional effect due to a drawing problem. Is expressed with dot hatching.

  Since the stator 10 of the present embodiment has the above-described configuration, the following operations and effects are shown.

  First, the effect is that the height of the coil end of the stator 10 can be suppressed. The stator 10 of the present embodiment uses a flat conductor D, and in the stator structure in which the flat conductor D is arranged on the stator core 20 to form the stator 10, the flat conductor D is bent in the edgewise direction. A plurality of segment coils SC formed in a substantially U shape are stacked to form a first pre-twisted segment conductor SC11, and two lead-side LS end portions of the first pre-twisted segment conductor SC11 are respectively 90 in the same direction. The first twisted segment conductor SC12 is twisted to form a second twisted segment conductor SC21 by overlapping two segment coils SC with 180 degrees twisted and another segment coil SC. Two lead-side LS ends of the front segment conductor SC21 are twisted by 90 degrees in the same direction, respectively, and the second twisted segment conductor S 22, the first torsion segment conductor SC12 is inserted into the slot 12 provided in the stator core 20, the second torsion segment conductor SC22 is inserted into the slot 12 by one set per one phase, and the lead side LS of the segment coil SC. The stator 10 is formed by joining the end portions.

  Therefore, the end portions on the lead side LS of the first torsion segment conductor SC12 and the second torsion segment conductor SC22 are respectively twisted 90 degrees in the same direction, so that the conductor direction in the in-slot conductor portion SS and the coil end is 90 degrees. It will be in a different state. As a result, the rectangular conductors D are arranged side by side at the coil end of the opposite lead side RLS. Therefore, the rectangular conductor D does not need to be laminated in the axial direction of the stator 10 at the coil end on the opposite lead side RLS of the stator 10, and even if the number of turns of the coil using the rectangular conductor D is increased, the coil The axial height of the end does not change. That is, it is possible to contribute to the downsizing of the stator 10.

  Another effect is that it is possible to reduce interphase insulating paper. In the stator 10 of the present embodiment, the first torsion segment conductor SC12 and the second torsion segment conductor SC22 have high insulation segments (first rectangular conductors) in which the insulation of the segment coil SC is higher than the other segment coils SC at the ends. D1), and the first torsion segment conductor SC12 and the second torsion segment conductor SC22 are inserted and fixed in different slots 12 at one end of the lead side LS end and the other end of the lead side LS end. The lead-side LS end portion of the segment coil SC located at the innermost peripheral portion of the child core 20 is bent in one direction along the circumferential direction of the stator core 20, and the segment coil SC located at the outermost periphery of the stator core 20 is bent. Among the segment coils SC of the lead side LS end portion, the lead side LS end portion is bent in the other direction along the circumferential direction of the stator core 20. Except segment coil SC which is located outermost and innermost is bent in pairs two by two, and adjacent pairs are those which are bent in opposite directions along the circumferential direction of the stator core 20.

  In this manner, inter-phase insulating paper can be reduced by bending the segment coils SC adjacent to each other on the lead side LS of the stator 10 in pairs and thickening the insulation coating of the first flat conductor D1. .

  First, the anti-lead side RLS of the stator 10 will be described. In general, interphase insulating paper IP is also required for the anti-lead side RLS of the stator 10. However, in the case of the present embodiment, the insulation coating of the first flat conductor D1 is thickened in the segment coil SC that is overlaid. As a result, the first flat conductor D1 is formed at the end of the first twisted segment conductor SC12. Will be placed. As shown in FIG. 9, the W-phase second segment conductor SCW2 of the first pole P1 adjacent to the W-phase first segment conductor SCW1 of the first pole P1 is the first rectangular conductor provided in the W-phase first segment conductor SCW1. Separated by D1. Similarly, the V-phase second segment conductor SCW2 of the eighth pole P8 adjacent to the left side of the W-phase first segment conductor SCW1 (not shown) is separated by the first flat conductor D1 included in the V-phase second segment conductor SCW2. become. In FIG. 9, the first flat conductor D1 is indicated by a thick line. The first rectangular conductor D1 has a thick insulation coating and can be insulated between phases. For this reason, the interphase insulating paper IP on the non-lead side RLS is unnecessary by preparing the first flat rectangular conductor D1.

  Next, the lead side LS of the stator 10 will be described. As shown in FIG. 11, in the lead side LS, the first rectangular conductors D1 are arranged in the first row LE1 and the sixth row LE6. For this reason, compared with the case where nine sheets of interphase insulating paper IP are usually required between each row, in the case of this embodiment, the interphase insulating paper IP required for the lead side LS as shown in FIG. Will need only three.

  Specifically, since the rectangular conductor D having a thick insulation coating called the first rectangular conductor D1 is used in the first row LE1 and the sixth row LE6, the rectangular conductor D adjacent thereto is used. In contrast, interphase insulation is possible, and because the segment coil SC is bent in pairs, interphase insulation is not required between the rectangular conductors D bent in pairs. Due to the effect, the interphase insulating paper IP is reduced.

  Further, the insulating property is enhanced by thickening the insulating coating only for the first flat conductor D1. It is possible to provide the first rectangular conductor D1 to the fifth rectangular conductor D5 with insulation capable of interphase insulation. However, in order to reduce the space factor of the stator 10, as a result, the stator 10 can be downsized. Contrary to high output. In the present embodiment, since the insulation coating of the second rectangular conductor D2 to the fifth rectangular conductor D5 is not thickened, the above effect can be obtained while minimizing the decrease in the space factor inside the slot 12. it can. In order to improve the insulation of the first rectangular conductor D1, an insulating coating film having a higher insulating property than that used for the second rectangular conductor D2 to the fifth rectangular conductor D5 is used, and the first rectangular conductor D1 to the fifth rectangular conductor are used. It does not prevent the thickness of the insulating coating film of the conductor D5 from being about the same.

  Although the invention has been described according to the present embodiment, the invention is not limited to the embodiment, and by appropriately changing a part of the configuration without departing from the spirit of the invention. It can also be implemented.

  For example, changing the number of flat conductors D inserted into the slots 12 of the stator core 20 is not prevented. Structurally, the number of the rectangular conductors D inserted into the slots 12 of the stator core 20 is an even number, but it is necessary to increase or decrease depending on the design concept of the stator 10. The method of the present invention can obtain the effect corresponding to the increase / decrease in the number of flat conductors D inserted into the slots 12 of the stator core 20.

  Further, the number of slots 12 of the stator core 20, the configuration of the stator core 20, and other configurations are not disturbed within a range that does not disturb the spirit of the invention. For example, the number of slots 12 of the stator core 20 should be changed as appropriate according to the design concept. Further, the stator core 20 can be applied to a split core type or an integral core type, and the present invention is not limited thereto.

10 Stator 11 Teeth 12 Slot 20 Stator Core 21 Rib 22 Bolt Hole 25 Insulator D Flat Rectangular IP Interphase Insulation Paper LS Lead Side RLS Anti-Lead Side S1 Twist Section SC Segment Coil SC11 First Pre-Twisted Segment Conductor SC12 First Twisted segment conductor SC21 Second twisted segment conductor SC22 Second twisted segment conductor SCV2 V-phase second segment conductor SCW1 W-phase first segment conductor SE Coil end portion SS In-slot conductor portion SSI Inner peripheral side slot in-conductor portion SSO Outer circumference Side slot conductor

Claims (6)

In a stator structure in which a flat conductor is used and a stator is formed by arranging the flat conductor in a stator core,
The rectangular conductor is bent in an edgewise direction to form a first set of segments by overlapping a plurality of segments formed in a substantially U shape,
Two lead side end portions of the first set segment are respectively twisted 90 degrees in the same direction to form a first twist set segment,
Two segments are stacked and twisted 180 degrees and the other segments are stacked to form a second set of segments,
Two lead side end portions of the second set segment are respectively twisted 90 degrees in the same direction to form a second twist set segment,
Inserting the first twisted assembly segment into a slot provided in the stator core, inserting the second twisted assembly segment into the slot by one set per one phase;
A stator structure, wherein a stator is formed by joining the lead side end portions of the segments. The stator structure according to claim 1,
The first torsion group segment and the second torsion group segment have a high-insulation segment in which the insulating property of the segment is higher than that of the other segment at the end. In the stator structure according to claim 1 or 2,
The first torsion group segment and the second torsion group segment are inserted into the slots different in one of the lead side end portions and the other of the lead side end portions,
Bending the lead side end of the segment located in the innermost peripheral portion of the stator core in one direction along the circumferential direction of the stator core;
Bending the lead side end of the segment located on the outermost periphery of the stator core in the other direction along the circumferential direction of the stator core;
Of the segments on the lead side end, two segments other than the outermost and innermost segments are bent in pairs, and the adjacent pairs are along the circumferential direction of the stator core. A stator structure that is bent in the opposite direction. In a stator having a segment formed by bending a plurality of flat conductors into a U shape, and a stator core having a slot for inserting the segment,
A plurality of the segments are stacked, and a twist of 90 degrees is applied between the in-slot conductor portion inserted in the slot of the stator core and the coil end portion located at one end of the stator core. A first twisted assembly segment having a twisted portion;
Two segments stacked and twisted 180 degrees and the other segments are overlapped, and the in-slot conductor portion inserted into the slot, and a coil end portion positioned at one end of the stator core A second twisted assembly segment having a twisted portion to which a twist of 90 degrees is added,
The second torsion group segment is used only for one group per phase. The stator according to claim 4,
The first torsional assembly segment and the second torsional assembly segment have a high-insulation segment in which the insulating property of the segment is higher than that of the other segment at the end. In the stator according to claim 4 or 5,
The first twisted assembly segment and the second twisted assembly segment are inserted into the different slots on one side of the lead side end and the other of the lead side end,
The segment located at the innermost periphery of the stator core and the segment located at the outermost periphery of the stator core are bent in the opposite direction along the circumferential direction of the stator core,
Of the rectangular conductors at the lead-side end portions, except the segment located on the outermost periphery and the innermost periphery, two pairs are bent in pairs, and the adjacent pairs are along the circumferential direction of the stator core. The stator is bent in the opposite direction.

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