JP2013051750A - Rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotary electric machine with an insulation paper capable of improving bending processing accuracy of a coil constituted by bending a segment coil conductor.SOLUTION: A rotary electric machine comprises: a coil wound around a stator core 28 by inserting plural coil conductors 100 in slots 38 formed on the stator core 28, and bending and coupling them; and an insulation paper 50 interposed between an inner wall of the slot 38 and the coil conductor 100 and insulating them. The insulation paper 50 has both ends 58, 60 projecting outward in an axial direction of the slot 38. A folding part 62 that can be engaged with an axial end face of the stator core 28 is formed only on one end 58 on an insertion side of the coil conductor 100, and the other end 60 is made of an insulation paper portion with thickness of one sheet.

Description

  The present invention relates to a rotating electrical machine, and more particularly to a rotating electrical machine in which insulating paper is interposed between a coil conductor inserted in a slot of a magnetic core and an inner wall of the slot.

  2. Description of the Related Art Conventionally, a stator for a rotating electrical machine is known that includes an insulating paper for insulating a coil inserted into a slot of a stator core from the stator core.

  For example, JP 2008-289284 A (Patent Document 1) is used for an electric motor including a starter core formed by stacking flat plates and a coil inserted into a slot portion provided in a stator core. Insulating paper that insulates the stator core from the coil and that is filled with a fixing material that fixes the coil is disclosed between the insulating paper and the coil. This insulating paper is formed along the inner wall of the slot portion of the stator core, and is connected to the cylindrical main body portion provided with a coil on the inner peripheral side, protrudes from the slot portion, and the slot portion becomes farther away from the slot portion. And an inclined surface that is inclined so as to spread from the inner wall to the outer peripheral side of the main body. Accordingly, when the fixing material is filled between the coil and the insulating paper, the fixing material can be prevented from flowing between the insulating paper and the stator core.

  JP 2009-38918 A (Patent Document 2) includes a stator core having a tooth portion, a stator coil wound around the tooth portion, an insulating paper provided between the tooth portion and the stator coil, and There is disclosed a stator that is provided at an end portion in the axial direction of a tooth portion and that is deformable by winding a stator coil around the tooth portion and includes a soft portion that is softer than insulating paper. Thereby, it is described that the damage caused by the insulating paper being sandwiched between the tooth portion and the segment coil conductor when bending the segment coil conductor constituting the stator coil can be suppressed.

JP 2008-289284 A JP 2009-38918 A

  As described in Patent Document 2, a stator coil is formed by connecting a plurality of segment coil conductors into a slot and then bending them and then connecting the ends of each segment coil conductor by welding or the like. In a rotating electrical machine equipped with a stator, when bending a leg portion of a segment coil conductor protruding from an end of a stator core using a bending jig, for example, as described in Patent Document 1, insulating paper protruding from a slot is used. If the end portions of the sheet are overlapped by a plurality of paper thicknesses, it becomes difficult to dispose the bending jig close to the leg portion, and there is a problem that the accuracy of bending processing is deteriorated. In particular, when the coil end portion protruding from the end face of the stator core at the axial end portion is constituted by the legs of a large number of segment coil conductors bent in this way, the coil end portion of the coil end portion is piled up due to the stacking of the bending accuracy. The axial dimension increases, leading to an increase in the size of the stator.

  The objective of this invention is providing the rotary electric machine provided with the insulating paper which can improve the bending process precision of the coil comprised by bending a segment coil conducting wire.

  The rotating electrical machine according to the present invention includes a coil wound around the magnetic core by a plurality of coil conductor wires being inserted into a slot formed in the magnetic core and then connected by bending, and an inner wall of the slot And an insulating paper that is interposed between and insulates between the coil conductors, the insulating paper having both ends protruding outward in the axial direction of the slot. A folded portion that is engageable with the axial end surface of the magnetic core is formed only at one end portion of the coil conductor wire insertion side into the slot, and the other end portion of the insulating paper is one sheet. It is made of an insulating paper portion having a thickness of.

  In the rotating electrical machine according to the present invention, a folded portion is formed at one end of both ends of the insulating paper protruding outward in the axial direction of the slot, and the other end is formed of an insulating paper portion having a thickness of one sheet. Therefore, when the leg portion of the coil conductor is bent using a bending jig, the bending jig can be bent in a state where the bending jig is closest to the leg portion of the coil conductor. Thereby, a bending process of a coil conducting wire can be performed with a sufficient precision, and the enlargement of a coil end part and by extension, a stator can be suppressed.

  Further, in the rotating electrical machine according to the present invention, the end of the folded portion formed at one end of the insulating paper is engaged with the end surface of the magnetic core, so that the axial positioning of the insulating paper can be easily performed. It is possible to effectively prevent the insulating paper from shifting in the axial direction when the coil conductor is inserted into the insulating paper from the side where the folded portion is formed.

1 is an axial sectional view of a rotating electrical machine according to an embodiment of the present invention. It is sectional drawing of the stator core in the AA line shown in FIG. It is sectional drawing which expands and shows one slot in a stator. It is a perspective view of the insulating paper in this embodiment. It is a perspective view of one segment coil conducting wire which is a unit which constitutes a coil. It is a figure which shows a mode that insulating paper is inserted in a slot in the state seen from the inner peripheral side of the stator core. It is a figure which shows a mode that a segment coil conducting wire is inserted into the inner side of the insulating paper arrange | positioned in a slot in the state seen from the inner peripheral side of the stator core. It is a figure which shows a mode when the leg part of the segment coil conducting wire inserted in the slot performs a bending process using a bending jig in the state seen from the inner peripheral side of the stator core. It is an enlarged view of the B section in FIG.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments according to the present invention (hereinafter referred to as embodiments) will be described in detail with reference to the accompanying drawings. In this description, specific shapes, materials, numerical values, directions, and the like are examples for facilitating the understanding of the present invention, and can be appropriately changed according to the application, purpose, specification, and the like. In addition, when a plurality of embodiments and modifications are included in the following, it is assumed from the beginning that these characteristic portions are used in appropriate combinations.

  FIG. 1 is a side sectional view of a rotating electrical machine 10 according to an embodiment of the present invention. As shown in FIG. 1, the rotating electrical machine 10 includes a rotor 14 fixed to a rotary shaft 12 that is rotatably provided about a rotation axis X, and a cylindrical stator 16 provided around the rotor 14. And.

  The rotor 14 is formed in a cylindrical rotor core 18 formed by laminating a plurality of electromagnetic steel plates, and is inserted into an outer peripheral edge side of the rotor core 18 and inserted into a permanent magnet insertion hole 20 extending in the rotation axis X direction. A plurality of permanent magnets 22 and an end plate 24 that clamps the rotor core 18 from both sides in the axial direction are provided. The permanent magnet 22 is fixed in the permanent magnet insertion hole 20 with a resin 26. The rotor may be, for example, a salient pole type rotor that does not include a permanent magnet.

  The stator 16 includes a stator core 28 formed in a substantially cylindrical shape so as to surround the rotor 14, and a coil 30 attached to the stator core 28. The stator core 28 is fixed on the inner peripheral surface of the cylindrical case 32. The stator core 28 is configured by laminating a number of electromagnetic steel plates punched into an annular shape in the axial direction and integrally connected by caulking or the like, for example. However, the stator core 28 is not limited to this, and the stator core 28 is formed by arranging a plurality of divided cores made of a steel plate laminated body or a powder magnetic core in an annular shape and fixing them integrally by the case 32. Also good.

  2 is a cross-sectional view of stator core 28 taken along line AA shown in FIG. As shown in FIG. 2, the stator core 28 includes an annular yoke portion 34 extending in the circumferential direction of the stator core 28, and projects radially inward from the inner circumferential surface of the yoke portion 34 toward the rotor 14. And a teeth portion 36 provided with a gap. A slot 38 extending in the radial direction of the stator core 28 is formed between the teeth portions 36. Similarly to the teeth portion 36, the slots 38 are formed at intervals in the circumferential direction and extend over the axial direction of the stator core 28.

  FIG. 3 is an enlarged sectional view showing one slot 38 in the stator 16. FIG. 4 is a perspective view of the insulating paper 50 disposed in the slot 38. The slot 38 opens toward the inner peripheral surface of the stator core 28. The opening 40 on the radially inner side of the slot 38 is defined by the end surface on the radially inner side of the tooth portion 36 adjacent in the circumferential direction.

  Here, the teeth portion 36 is formed at a main body portion 42 that protrudes in the radial direction of the stator core 28 from the inner peripheral surface of the yoke portion 34, and a radially inner side end portion of the main body portion 42. Overhang portions 44 and 45 projecting in the circumferential direction are provided. Thereby, the opening 40 on the radially inner side is defined between the protruding portions 44 and 45 on both sides, and is formed narrower than the width w of the slot 38 on the radially outer side than the opening 40. In the present embodiment, the slot 38 is formed so that the circumferential width w is constant over the radial direction except for the opening 40.

  The inner surface of the slot 38 includes an inner peripheral surface 381 located on the outermost radial direction side, and a side wall surface 382 defined by the side surface of the main body 42 of the tooth portion 36, which is connected to the inner peripheral surface 381. The side wall surface 383 that faces the side wall surface 382 in the circumferential direction, the front wall surface 384 that is connected to the side wall surface 382 on the radially inner side, and the front wall surface that is connected to the side wall surface 383 on the radially inner side 385. Here, the front wall surface 384 is defined by the back surface of the overhang portion 44, and the front wall surface 385 is defined by the back surface of the overhang portion 45.

  Insulating paper 50 disposed along the inner surface of the slot 38 is inserted into the slot 38 formed in this way. As shown in FIGS. 3 and 4, the insulating paper 50 is formed by bending one insulating sheet into a substantially U-shape. As the insulating sheet, for example, a resin sheet or film is preferably used. For example, a nonwoven fabric or the like may be used as long as it has sufficient flexibility to ensure electrical insulation between the stator core 28 and the coil 30 and bend easily. Other thin materials may be used. Further, the insulating paper 50 is not limited to a single-layer structure, and may have a multi-layer structure in which an adhesive layer or the like is laminated on a base material layer.

  The insulating paper 50 includes a side surface insulating portion 52 extending along the side wall surface 382, a side surface insulating portion 54 extending along the side wall surface 383, and the end portions of the side surface insulating portion 52 and the side surface insulating portion 54 radially outward. And an outer peripheral insulating portion 56 to be connected. Here, in the insulating paper 50, the lengths in the longitudinal direction (that is, the radial direction) of the side surface insulating portions 52 and 54 are formed to be substantially the same radial length as the side wall surfaces 382 and 383 of the slot 38. Thereby, each inner peripheral side edge part of the side surface insulation parts 52 and 54 faces the opening part 40 in an open state.

  The coil 30 is inserted into the slot 38 in which the insulating paper 50 is inserted. The coil 30 is disposed in a state insulated from the stator core 28 by the insulating paper 50. The coil 30 is constituted by a coil wire 68 having a square wire having a substantially square cross section, and a plurality of (10 in this embodiment) coil wire 68 are arranged in a line in one slot 38. Yes. By arranging the square wires in the slots 38 in this way, the space factor, which is the volume ratio of the coil wires occupying the slots 38, is increased, and the output efficiency of the rotating electrical machine 10 is improved.

  A rectangular wire having a rectangular cross section is used as the coil wire 68 of the present embodiment, but a square wire having a substantially square cross section may be used, or a conducting wire having a circular cross section may be used. . The circumferential width of the coil wire 68 is set to be slightly smaller than the value obtained by subtracting the thickness of the side insulating portions 52 and 54 from the slot width w. That is, when the coil wire 68 is inserted into the insulating paper 50 arranged in the slot 38 from the axial direction, the coil wire 68 is inserted so as not to contact the inner surface of the insulating paper 50 as much as possible. is there. Further, a predetermined distance d is ensured between the radially inner side surface of the coil wire 68 positioned at the innermost peripheral portion and the radially inner end surface of the tooth portion 36. Is preferred. Thereby, the amount of interlinkage magnetic flux from the rotor 14 to the coil 30 can be reduced, the occurrence of coil copper vortex loss can be suppressed, and the output efficiency of the rotating electrical machine 10 can be improved.

  As shown in FIG. 5, the insulating paper 50 has an axial length longer than that of the stator core 28. When inserted and disposed in the slot 38 from the axial direction, the insulating paper 50 extends outward from the axial end surface of the stator core 28. It has two ends 58, 60 that will protrude. A folded portion 62 is formed at one end 58 of the insulating paper 50. In contrast, the other end portion of the insulating paper 50 is not formed with a folded portion, and is composed of an insulating paper portion having a thickness of one sheet. The folded portion 62 of the insulating paper 50 is formed by bending the end portion of the insulating sheet with a constant width, and the tip 63 engages with the axial end surface of the stator core 28 when inserted into the slot 38 for insulation. It has a function of accurately determining the axial position of the paper 50.

  In FIG. 4, the axial length Lu of the one end portion 58 of the insulating paper 50 substantially corresponds to the length of the folded portion 62. Further, the axial length Ls of the in-slot portion disposed in the slot 38 in the insulating paper 50 corresponds to the axial length of the stator core 28. Furthermore, the length Lu of the other end 60 of the insulating paper 50 may be the same as the length Lt of the one end 58, or may be formed shorter than the length Lt. In this way, by making the length of the other end portion 60 relatively short, the usage amount of the insulating paper 50 can be reduced and the cost can be reduced.

  The rotating electrical machine 10 according to the present embodiment is supplied with three-phase AC power, and the coil 30 includes a U-phase coil, a V-phase coil, and a W-phase coil. Each of these three-phase coils is accommodated in, for example, 16 slots 38 in slots 38 formed in a line of 48 in the circumferential direction. In this case, a U-phase coil, a V-phase coil, and a W-phase coil may be sequentially arranged in each slot 38 along the circumferential direction, or an in-phase coil is inserted in each of two adjacent slots 38. And you may arrange | position each phase coil sequentially in the circumferential direction.

  FIG. 5 is a perspective view showing the segment coil conducting wire 100 that is a unit of the coil wire 68 constituting the coil 30. The segment coil conducting wire 100 is formed by bending a rectangular wire having a rectangular cross section into a substantially U shape, and has two leg portions 102 and 104 extending in parallel to each other, and proximal ends of the leg portions 102 and 104. The continuous part 106 is provided. For example, a copper core member 108 is exposed at the distal ends of the legs 102 and 104 by removing the insulating coating. The intermediate portions 102 a and 104 a of the leg portions 102 and 104 constitute a coil wire 68 disposed in the slot 38.

  The leg portions 102 and 104 of the segment coil conductor 100 having such a shape are inserted from one end side in the axial direction of the stator core 28 into the insulating paper 50 inserted into the two slots 38 that are spaced apart in the circumferential direction. The plurality of segment coil conductors 100 are sequentially inserted into the two slots 38 in the same manner and arranged in the radial direction, so that the coil wire 68 is inserted in the slot 38 in an aligned manner. The At this time, the tip portions of the leg portions 102 and 104 protrude from the other axial end surface of the stator core 28.

  And the front-end | tip part of the leg parts 102 and 104 of the segment coil conducting wire 100 is bent to the outer side as shown by the broken line 110 in FIG. The leg portions 102 or 104 of another segment coil conductor 100 and the core member 108 are welded and connected to each other, or bent inward as shown by a one-dot chain line 112 in FIG. The leg portions 102 or 104 and the core members 108 of the other segment coil conductors 100 adjacent to each other are connected to each other by welding, or one leg portion 102 is bent outward while the other leg portion. 104 is bent inward, and another segment coil conducting wire 100 adjacent to the circumferential direction or the radial direction and the core member 108 are welded and connected.

  In this way, the segment coil conductors 100 arranged in the slot 38 are sequentially electrically connected to form a U-phase coil, a V-phase coil, and a W-phase coil. One end of each phase coil is connected to the input terminal of the three-phase AC power of the rotating electrical machine 10, and the other end of each phase coil is commonly connected at the neutral point.

  Next, with reference to FIGS. 6 to 9, the insertion arrangement of the insulating paper 50 with respect to the stator core 28 and the insertion and bending of the segment coil conductor 100 will be described.

  FIG. 6 is a view showing a state in which the insulating paper 50 is inserted into the slot 38 as seen from the inner peripheral side of the stator core 28. FIG. 7 is a diagram showing a state in which the segment coil conductor 100 is inserted inside the insulating paper 50 arranged in the slot 38 as viewed from the inner peripheral side of the stator core 28. FIG. 8 is a view showing a state where the leg portion 102 of the segment coil conductor 100 inserted into the slot 38 is bent using the bending jig 70 as seen from the inner peripheral side of the stator core 28. . FIG. 9 is an enlarged view of a portion B in FIG. 6-9, illustration of the overhang | projection parts 44 and 45 of the teeth part 36 is abbreviate | omitted in order to make the inside of the slot 38 easy to see.

  In FIG. 6 (the same applies to FIGS. 7 to 9), the stator core 28 is arranged such that the axial direction is in the vertical direction. In this state, the insulating paper 50 is inserted into the slot 38 from the lower side of the stator core 28. At this time, the insulating paper 50 is inserted from the other end portion 60 on the side where the folded portion 62 is not provided from the axial opening of the slot 38.

  As shown in FIG. 7, when the insulating paper 50 is inserted into the slot 38, the leading end 63 of the folded portion 62 provided at one end 58 of the insulating paper 50 is the lower end surface of the tooth portion 36, that is, the stator core 28. Abuts on the lower end surface. Accordingly, the axial position of the insulating paper 50 with respect to the stator core 28 is accurately positioned. At this time, the other end portion 60 of the insulating paper 50 is in a state protruding from the upper end surface of the stator core 28 by a predetermined length. In this way, the insertion and arrangement of the insulating paper 50 into the slot 38 are completed.

  Subsequently, the leg portions 102 and 104 (only one leg portion 102 is shown here) of the segment coil conductor 100 are inserted into the insulating paper 50 arranged in the slot 38 upward from below along the axial direction. The At this time, the axial position of the segment coil conductor 100 with respect to the stator core 28 is accurately determined by a positioning jig or device (not shown). Alternatively, the axial position of the segment coil conductor 100 with respect to the stator core 28 may be determined by the continuous portion 106 of the segment coil conductor 100 contacting the one end 58 of the insulating paper 50.

  Even when the leg portion 102 may come into contact with the inner surface of the insulating paper 50 when the segment coil conductor 100 is inserted, the folded portion 62 of the insulating paper 50 is engaged with the lower end surface of the stator core 28. It is possible to effectively suppress the shift of the axial direction position.

  When the insertion and disposition of the leg portion 102 of the segment coil conductor 100 inside the insulating paper 50 is completed, next, as shown in FIG. 8, the leg portion 102 is bent to the tip portion of the leg portion 102, 104 protruding from the upper end surface of the stator core 28. Apply processing. At this time, the bending jig 70 is placed on the upper end surface of the stator core 28. The bending jig 70 has a substantially arc-shaped curved surface on the upper surface, and has a predetermined length equal to or longer than the slot 38 along the radial direction.

  When bending the leg portion 102 of the segment coil conductor 100 using the bending jig 70 as described above, the bending jig 70 is disposed as close as possible to the tip end portion of the leg portion 102 of the segment coil conductor 100, It is preferable to bend the tip of the leg 102 in the direction of arrow C.

  However, if the bent portion is formed at the upper end portion of the insulating paper 50 protruding from the slot 38, the thickness of the insulating paper for a plurality of sheets overlaps and becomes thicker, so the bending jig 70 is close to the leg portion 102. Therefore, it becomes difficult to arrange and bending accuracy is deteriorated. In particular, when the coil end portion protruding from the upper end surface of the stator core 28 at the axial end portion is constituted by the leg portions 102 and 104 of the multiple segment coil conductors 100 thus bent, the bending accuracy is deteriorated. Stacking increases the axial dimension of the coil end, leading to an increase in the size of the stator 16.

  On the other hand, in the present embodiment, the other end portion 60 of the insulating paper 50 protruding from the upper end surface of the stator core 28 is composed of an insulating paper portion having a thickness of one sheet. Therefore, as shown in FIG. 9, the bending jig 70 can be disposed in the state of being closest to the leg portion 102 with the other end portion 60 formed of one sheet of insulating paper interposed therebetween. As a result, the bending positions and the bending shapes of the leg portions 102 and 104 of the segment coil conductor 100 can be accurately defined, and the bending can be performed with high accuracy. The coil end portion of the coil 30 and thus the large size of the stator 16 can be obtained. Can be suppressed. In the bending process of the segment coil conducting wire 100, the bending process may be performed while twisting the leg portions 102 and 104.

  Further, in the case where cylindrical insulating paper having a radially inner side closed is used, the tensile force accompanying the bending of the leg portions 102 and 104 of the segment coil conductor 100 acts, whereby the radially inner side of the insulating paper is applied. Although the portion may be damaged, the insulating paper 50 in this embodiment is open on the radially inner side, so that the side insulating portions 52 and 54 are not damaged when the segment coil conductor 100 is bent, and the coil The insulation performance with respect to 30 can be maintained and secured.

  After bending the leg portions 102 and 104 of all the segment coil conductors 100 arranged in the slot 38 as described above, the core members 108 exposed at the tips of the leg portions 102 and 104 are welded together. A coil 30 is formed. Thereby, winding of the coil 30 around the stator core 28 is completed.

The rotating electricity according to the present invention is not limited to the configuration described in the above embodiment, and various modifications and improvements may be made within the scope of matters described in the claims and their equivalents. Of course.
For example, in the above description, the example in which the magnetic core around which the coil is wound is the stator core has been described. However, the present invention can also be applied to the case where the coil is wound around the rotor core that is the magnetic core.

  DESCRIPTION OF SYMBOLS 10 Rotating electrical machine, 12 Rotating shaft, 14 Rotor, 16 Stator, 18 Rotor core, 20 Permanent magnet insertion hole, 22 Permanent magnet, 24 End plate, 26 Resin, 28 Stator core, 30 Coil, 32 Case, 34 York part, 36 Teeth part , 38 slots, 40 openings, 42 main body, 44, 45 overhang, 50 insulation paper, 52, 54 side insulation, 56 outer peripheral insulation, 58 one end, 60 other end, 62 folded portion, 63 Tip, 68 Coil wire, 70 Bending jig, 100 segment coil conductor, 102, 104 Leg, 102a, 104a Intermediate part, 106 Continuous part, 108 Core material, 381 Inner peripheral surface, 382, 383 Side wall surface, 384, 385 Front wall, d distance, w slot width, X axis of rotation.

Claims (1)

A plurality of coil conductors are inserted into a slot formed in the magnetic core and then bent and connected to each other, and the coil is wound around the magnetic core, and between the inner wall of the slot and the coil conductor. A rotating electric machine comprising insulating paper interposed to insulate both,
The insulating paper has both end portions protruding outward in the axial direction of the slot, and only one end portion on the insertion side of the coil conducting wire into the slot among these end portions is the axial end surface of the magnetic core. The rotating electric machine is formed with a folded portion that can be engaged with the insulating paper, and the other end portion of the insulating paper is formed of an insulating paper portion having a thickness of one sheet.

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