JP2013118750A - Axial gap type rotary electric machine and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an axial gap type rotary electric machine and a manufacturing method thereof in which a continuous winding coil around which a cable is wound with a high density can be assembled easily in an axial direction, the rotary electric machine can be low-priced, its cooling performance is improved and inter-phase insulation is ensured.SOLUTION: For a continuous winding coil, a centralized winding coil around which a cable is wound with a high density is wound continuously via a crossover track and such continuous winding coils are prepared for three phases. The crossover tracks of the continuous winding coils for two phases are tilted at different angles in the axial direction beforehand and the continuous winding coils for three phases are combined in the axial direction and annularly formed. In another embodiment, the crossover tracks of the continuous winding coils for three phases are molded beforehand into detoured shapes, respectively, in the radial direction in the bottoms, centers and tops of the coils, and the continuous winding coils for three phases are combined in the axial direction and annularly assembled. Furthermore, in another embodiment, wiring blocks for position fixture are inserted into the crossover tracks for three phases.

Description

  The present invention relates to an axial gap type rotating electrical machine such as a motor or a generator and a method for manufacturing the same.

  In recent years, with global warming becoming more serious, there is an increasing demand for energy saving in electrical equipment. At present, about 55% of the annual power consumption in Japan is consumed by the motor, so attention is paid to the high efficiency of the motor. Conventionally, a design using a rare earth magnet having a high energy product has been adopted to increase the efficiency of the motor. However, the prices of Nd (neodymium) and Dy (dysprosium), which are raw materials for rare earth magnets, have soared in recent years due to restrictions on export quotas in China, the largest producer. China's export quota regulation policy is to prevent environmental destruction caused by the mining of Nd and Dy, and it is highly likely that the price of rare earths will continue to rise and supply will be difficult. For this reason, an axial gap type motor is attracting attention as one of means for realizing a high school rate of a motor using only a ferrite magnet without using a rare earth magnet. Axial gap motors have a larger magnet area than conventional radial gap motors, so they can compensate for the decrease in holding power when switching to ferrite magnets, and the efficiency can be equal to or higher than the conventional ones. It is. As the configuration of the axial gap type motor, there are combinations of a 1 rotor-2 stator type, a 2 rotor-1 stator type, a 1 rotor-1 stator type, and the like.

  As a background art in this technical field, there is JP 2008-172859 A (Patent Document 1). In Patent Document 1, four in-phase coils are wound continuously, and an y-connection is used to constitute an axial gap type motor (1 rotor-1 stator type). Patent Document 1 describes a reduction in the price of a motor by reducing the number of connection points with continuous windings, and collecting the connecting wires connecting the coils on the inner diameter side of the coil to make the coil outer diameter side free space. It is assumed that there is an aim of improving the cooling performance of the motor by bringing the diameter side and the motor case into contact.

JP 2008-172859 A

  However, when three-phase continuous winding coils with a high space factor are created by winding the wires with high density in the configuration of Patent Document 1 and they are assembled in the axial direction of the rotating electrical machine, the connecting wires between the phases interfere with each other. As a result, a problem that the insulation space distance cannot be maintained occurred. Therefore, the present invention makes it possible to easily assemble a continuous winding coil in which electric wires are wound at high density in the axial direction of the rotating electrical machine, and to reduce the cost of the rotating electrical machine (the number of connection points) and to improve the cooling performance (coil the connecting wire to the coil). The present invention provides an axial gap type rotating electrical machine that achieves interphase insulation (regulates the position of the crossover wire) and a manufacturing method thereof.

  The axial gap type rotating electric machine according to the present invention extends a winding end line of a coil formed by winding an electric wire to form a winding start line of an adjacent coil as a jumper, and continuously winds a plurality of winding coils. The three-phase continuous winding unit of U, V, and W is configured, and the transition of each phase between one coil of the continuous winding unit of each U, V, and W phase and an adjacent coil. It is characterized in that the space distance at the crossing portion of the wires is arranged so as to maintain a predetermined insulating space distance in the radial direction and the axial direction of the rotating electrical machine.

  The axial gap type rotating electrical machine of the present invention extends the winding end line of the coil from the top or bottom of the coil in the radial direction of the rotating electrical machine, and the winding start line of the next coil that is continuously wound is the winding end line. The crossing portion of the crossover wire is introduced in the axial direction from the opposite bottom or top, and the crossover portion of the crossover wire is inclined with respect to the radial direction of the rotating electrical machine.

  The axial gap type rotating electrical machine according to the present invention includes a connecting wire of the U-phase continuous winding unit, a connecting wire of the V-phase continuous winding unit, and a connecting wire of the W-phase continuous winding unit. The introduction angle of the winding start line introduced into the coil from the transition part of each phase and the winding end line extending from the coil to the transition part so that the height in the axial direction of the rotating electrical machine at the transition part of the transition line is different. The extending angle is made to be different for each continuous winding of each phase and is inclined in the axial direction of the rotating electrical machine.

  The axial gap type rotating electrical machine according to the present invention includes a connecting wire of the U-phase continuous winding unit, a connecting wire of the V-phase continuous winding unit, and a connecting wire of the W-phase continuous winding unit. The connecting wire is composed of an extending part and an introducing part extending in the radial direction of the rotating electrical machine, a vertical part extending in the axial direction of the rotating electrical machine, and a connecting part extending from one coil to the adjacent coil, the connecting part The rotary electric machine in the axial direction is arranged at different heights.

  The axial gap type rotating electrical machine according to the present invention includes a crossover portion of the U-phase continuous winding unit, a crossover portion of the V-phase continuous winding unit, and a crossover portion of the W-phase continuous winding unit. It is characterized by comprising a spacer block for holding each of the crossover portions.

The manufacturing method of the axial gap type rotating electrical machine of the present invention extends a winding end line of a coil formed by winding an electric wire to form a winding start line of an adjacent coil as a jumper, and continuously winds a plurality of windings. A coil is continuously formed, and a continuous winding unit for U, V, and W 3 phases having the same configuration is formed in advance.
The spatial distance in the crossover part of each phase between one coil and the adjacent coil of each phase continuous winding unit is maintained at a predetermined interphase insulation distance in the radial and axial directions of the rotating electrical machine. It is characterized by arranging and assembling.

The manufacturing method of the axial gap type rotating electrical machine of the present invention extends a winding end line of a coil formed by winding an electric wire to form a winding start line of an adjacent coil as a jumper, and continuously winds a plurality of windings. After continuously forming the coil and forming in advance a continuous winding unit for U, V, W 3 phases of the same configuration,
By forming the winding end line and winding start line between the connecting wire and the coil so as to be inclined at different angles in each of the U, V, and W phases, interphase insulation between the connecting wires of each phase It is characterized by keeping a distance.

The manufacturing method of the axial gap type rotating electrical machine of the present invention extends a winding end line of a coil formed by winding an electric wire to form a winding start line of an adjacent coil as a jumper, and continuously winds a plurality of windings. After continuously forming the coil and forming in advance a continuous winding unit for U, V, W 3 phases of the same configuration,
By forming the winding end wire and the winding start wire so as to extend from the lower bottom portion, the center portion, and the upper bottom portion of the coil for each phase, the interphase insulation distance between the connecting wires of each phase is maintained. Features.

  According to the present invention, crossover wires of a continuous winding coil in which electric wires are wound at high density can be combined and formed into an annular shape without interfering with each other, and the cost is reduced (the number of connection points is small) and the cooling performance is improved. It is possible to provide an axial gap type rotating electrical machine that realizes the securing of the inter-phase insulation distance (regulating the position of the connecting wire) (collecting the connecting wires on the inner diameter side).

FIG. 1 is a schematic diagram showing the arrangement of connecting wires of respective phase coils of a 12-slot motor according to an embodiment of the present invention. FIG. 2 is a connection diagram of each phase coil of a 12-slot motor according to an embodiment of the present invention. FIG. 3 is a perspective view showing a state in which four continuous winding coils for three phases according to an embodiment of the present invention (a single coil is wound in two stages) are assembled in the axial direction. FIG. 4 is a perspective view showing a state where four continuous winding coils for three phases according to an embodiment of the present invention are assembled (a single coil is three-stage winding). FIG. 5 is a perspective view showing the structure of a four-phase wound coil (one coil is a two-stage winding) for one phase (U phase) according to an embodiment of the present invention. FIG. 6 is a cross-sectional view of the first coil starting winding of a four-phase winding coil (one coil is a two-stage winding) for one phase (U phase) according to an embodiment of the present invention. FIG. 7 is a perspective view showing the structure of one continuous phase (V phase) four-continuous winding coil (a single coil is a two-stage winding) according to an embodiment of the present invention. FIG. 8 is a cross-sectional view of a first coil starting winding of a four-phase wound coil (a single coil is a two-stage winding) for one phase (V phase) according to an embodiment of the present invention. FIG. 9 is a perspective view showing a structure of a four-phase wound coil (one coil is a two-stage winding) for one phase (W phase) according to an embodiment of the present invention. FIG. 10 is a cross-sectional view of a first coil starting winding of a single-phase (W-phase) four-continuous winding coil (a single coil is two-stage winding) according to an embodiment of the present invention. FIG. 11 is a perspective view showing a state in which four-phase continuous coils for three phases according to an embodiment of the present invention (a single coil is a two-stage coil) is assembled in the axial direction. FIG. 12 is a perspective view showing the structure of one phase (U phase) of four continuous winding coils (a single coil is two-stage winding) according to an embodiment of the present invention. FIG. 13 is a perspective view showing the structure of one phase (U phase) of four continuous winding coils (one coil is three-stage winding) according to an embodiment of the present invention. FIG. 14 is a perspective view showing the structure of one phase (U phase) of four continuous winding coils (a single coil is three-stage winding) according to an embodiment of the present invention. FIG. 15 is a cross-sectional view of a first coil at the start of winding of a four-phase wound coil of one phase (U phase) according to an embodiment of the present invention (a single coil is a three-stage winding). FIG. 16 is a perspective view showing a structure of a four-phase wound coil for one phase (V phase) according to an embodiment of the present invention (a single coil is wound in three stages). FIG. 17 is a cross-sectional view of a first coil starting winding of a four-phase wound coil for one phase (V phase) according to an embodiment of the present invention (a single coil is a three-stage winding). FIG. 18 is a perspective view showing the structure of one phase (W phase) of four continuous winding coils (a single coil is three-stage winding) according to an embodiment of the present invention. FIG. 19 is a cross-sectional view of a first coil starting winding of a single-phase (W-phase) four-continuous winding coil (a single coil is three-stage winding) according to an embodiment of the present invention. FIG. 20 is a perspective view showing a state in which four continuous winding coils for three phases according to an embodiment of the present invention (a single coil is a three-stage winding) are assembled in the axial direction. FIG. 21 is a perspective view showing a state in which a position-fixing wiring block is inserted in a state where four continuous winding coils for three phases according to an embodiment of the present invention (a single coil is a two-stage winding) are assembled in the axial direction. . FIG. 22 is a cross-sectional view showing a state in which a position fixing wiring block is inserted in a state where four continuous winding coils for three phases according to an embodiment of the present invention (a single coil is a two-stage winding) are assembled in the axial direction. . FIG. 23 is a perspective view showing a state in which a position fixing wiring block is inserted in a state where four continuous winding coils for three phases according to an embodiment of the present invention (a single coil is a three-stage winding) are assembled in the axial direction. . FIG. 24 is a cross-sectional view showing a state in which a position fixing wiring block is inserted in a state where four continuous winding coils for three phases according to an embodiment of the present invention (a single coil is a three-stage winding) are assembled in the axial direction. .

  An axial gap type rotating electrical machine according to an embodiment of the present invention includes three sets of continuous winding coils in which concentrated winding coils having an even number of stages and the same winding direction are wound through a jumper. The connecting wires of two sets of continuous winding coils among the continuous winding coils are tilted at different angles in the axial direction, and three sets of the continuous winding coils are combined and formed into an annular shape.

  Further, an axial gap type rotating electrical machine according to another embodiment of the present invention comprises three sets of continuous winding coils in which the coils are odd-numbered and the winding direction is the same, and the winding is continuously wound via a crossover wire. The connecting wire of one set of continuous winding coils is diverted in the radial direction at the bottom of the coil, and the connecting wire of another set of continuous winding coils is diverted in the radial direction at the coil center. The crossover wire is detoured in the radial direction at the top of the coil, and is formed into an annular shape by combining the three sets of continuous winding coils.

  Further, in the axial gap type rotating electrical machine of another embodiment of the present invention, a plurality of fixing wiring blocks are inserted from the radial direction to the connecting wires of the three sets of the continuous winding coils, and the positions thereof are fixed. It is characterized by.

  When manufacturing the axial gap type rotating electrical machine according to the embodiment of the present invention, a concentrated winding coil in which electric wires are wound at high density, and a continuous winding coil that is continuously wound through a jumper wire, is divided into three phases (U Phase, V phase, W phase).

Thereafter, when the axial gap type rotating electrical machine according to the first aspect of the embodiment of the present invention is manufactured, the connecting wires of the continuous winding coils for two phases are tilted at different angles in the axial direction in advance and three phases The continuous winding coils are combined in the axial direction of the rotating electrical machine and formed into an annular shape.
In addition, when manufacturing the axial gap type rotating electrical machine according to the second aspect of the embodiment of the present invention, the connecting wires of the continuous winding coils for three phases are respectively detoured in the radial direction at the coil bottom, center, and top. It is formed into a shape in advance, and three-phase continuous winding coils are combined in the axial direction and formed into an annular shape.
Furthermore, when manufacturing the axial gap type rotating electrical machine according to the third aspect of the embodiment of the present invention, in the manufacture of the axial gap type rotating electrical machine according to the first and second aspects, it is located on the crossover for three phases. Manufacture by inserting a wiring block for fixing.

  Hereinafter, embodiments of the present invention will be described in more detail with reference to the drawings.

  FIG. 1 schematically shows the arrangement of connecting wires of each phase coil of a UVW of a 12-slot axial gap motor according to an embodiment of the present invention. In the axial gap type motor 100, a stator 1 is configured by annularly arranging a coil in which an electric wire is wound around an iron core 3 in a concentrated manner, and a rotor 2 is disposed above and / or below the stator 1. The rotor 2 is connected to a rotating shaft (not shown) arranged at the center, and is arranged with a certain gap from the stator 1. Further, although not shown in the drawing, a magnet alternately arranges N and S poles in the circumferential direction on the stator side of the rotor 2. Note that the axial gap type motor 100 described below is an example, and it goes without saying that the number of slots (the number of continuous turns of the coil) can be changed as appropriate without departing from the scope of the present invention.

  In FIG. 1, four U-phase coils 10a, 10d, 10g, and 10j are continuous windings through the connecting wires, and the winding directions of the coils are all the same, and all the connecting wires are coiled. It is concentrated on the inner diameter side. The four V-phase coils 10b, 10e, 10h, and 10k, and the four W-phase coils 10c, 10f, 10i, and 10l are arranged in the winding direction of the continuous winding and the arrangement of the jumper wires as described above for the U-phase coil. It is the same configuration. Therefore, if the axial gap type motor 100 is configured as described above, the neutral point 5 of the U-phase four-continuous winding coil, the V-phase four-continuous winding coil, and the W-phase four-continuous winding coil is a three-phase terminal. Lines can be placed next to each other. By connecting these three-phase terminal wires by connection terminals or welding, they function as a neutral point 5. As a result, since the number of connection points is as small as one, it is possible to reduce the price of the motor. In addition, since all the connecting wires are concentrated on the inner diameter side of the coil, the outer diameter side of the coil becomes free space. As an example, the cooling performance of the motor can be improved by contacting the outer diameter side of the coil and the motor case. Moreover, since the input line 4 of the U-phase 4-continuous winding coil, the V-phase 4-continuous winding coil, and the W-phase 4-continuous winding coil can be arranged at positions adjacent to each other, It functions as the stator 1 by rolling it so as not to contact the rotor 2 and pulling it out from the motor case.

FIG. 2 shows a connection diagram of the stator 1 of the axial gap type motor 100 of the present invention.
The U-phase coil 10U is configured by connecting an input wire 15U1, a coil 10a, a jumper wire 15U2, a coil 10d, a jumper wire 15U3, a coil 10g, a jumper wire 15U4, a coil 10j, and a terminal wire 15U5. The winding directions of the coils are all the same direction. The configurations of the V-phase coil 10V and the W-phase coil 10W are the same as those of the U-phase coil 10U, including the coil winding direction. That is, the axial gap type motor 100 of the present invention is configured by four series Y-connections using three sets of four continuous winding coils. Here, the center portion (N) of the U-phase coil 10U, the V-phase coil 10V, and the W-phase coil 10W functions as the stator 1 by connecting the neutral points.

  FIG. 3 shows a state where four continuous winding coils for three phases are simply assembled in the axial direction of the rotary electric machine. In the example shown in FIG. 3, the single coil is wound in two stages. In this example, the U-phase coil 10U, the V-phase coil 10V, and the W-phase coil 10W are each formed by four continuous windings in a straight line via a jumper, and as an example of assembly, as shown in FIG. It seems that it can be configured as the stator 1 of the axial gap type motor 100 of FIG. 1 by forming it in an annular shape after assembling in a linear state. However, this problem will be described here. As shown in FIG. 3, if the four-phase winding coils for three phases are simply combined in the axial direction of the rotary electric machine, the crossover lines for the three phases interfere with each other. As shown by the dotted lines, it is necessary to dispose the coils in different steps, so that assembling is difficult as it is. On the other hand, this solution which is the present invention will be described in FIG. In this example, two-stage winding is described as an example. However, in the case of even-numbered winding (two-stage winding, four-stage winding, six-stage winding, etc.), the input line, the jumper line, and the terminal line are all on the bottom of the coil. Similar problems occur because of concentration.

  FIG. 4 shows a state in which four continuous winding coils for three phases according to an embodiment of the present invention are assembled. A single coil is wound in three stages. Therefore, unlike the even number winding of FIG. 3, the coil winding end line is located at the top of the coil and the next coil winding start line is located at the bottom. It will be resolved. However, in this case, it is impossible to fabricate three sets of four continuous coils of this shape alone and assemble them in the axial direction of the rotary electric machine because the three-phase crossover wires interfere with each other. As a method that can be realized for this purpose, since the rotation trajectory of the nozzle can be secured, it is possible to produce the 4-continuous winding coil of FIG. This is possible only when the space factor of the coil is small because there is a sufficient gap between the cores. However, when the coil space factor is high as in the present invention, the coil adjacent to the nozzle interferes, so that the nozzle winding cannot be applied. Therefore, a method for solving this problem will be described with reference to FIG. Here, as an example, three-stage winding is used, but in the case of odd-numbered winding (one-stage winding, three-stage winding, five-stage winding,...), All the connecting wires are inclined and the same problem occurs. Occur.

A configuration capable of solving the above-described problem will be described with reference to FIGS. In addition, each of the four continuous winding coils of U phase, V phase, and W phase differs only in the angle of introduction and extension of the winding end wire and the winding start wire, and includes the length of the connecting wire between the coils. There is no difference in the length and other dimensions and configurations.
FIG. 5 shows a structure of four continuous winding coils (one coil is a two-stage winding) for one phase (a U-phase coil 10U) according to an embodiment of the present invention. A coil structure that solves the above-described problem relating to assembly when the coil has an even number of turns will be described with reference to FIG. As shown in FIG. 5, the U-phase coil 10U has four coils 10a, 10d, 10g, and 10j arranged side by side, and each coil has a crossover wire 15U2, 15U3, 15U4 in a U shape at the bottom of the coil. Arranged and continuously wound. Here, 15U5 is a terminal line, and 15U1 is an input line.

  FIG. 6 is a cross-sectional view of the first coil (10a) at the start of winding of four continuous winding coils (a single coil is a two-stage winding) for one phase (a U-phase coil 10U) according to an embodiment of the present invention. Is shown. As described above, the crossover wire 15U2 is arranged at the bottom of the coil. This coil (U-phase coil 10U) is used as a reference coil.

  FIG. 7 shows the structure of a four-phase winding coil (a single coil is two-stage winding) for one phase (V-phase coil 10V ′) according to an embodiment of the present invention. The difference from the U-phase reference coil 10U is that the connecting wires 15V2, 15V3, 15V4 of each coil are inclined at an angle φ1 in the axial direction of the rotary electric machine.

  FIG. 8 is a cross-sectional view of the first coil (10b) at the start of winding of four continuous winding coils (a single coil is two-stage winding) for one phase (V-phase coil 10V ′) according to an embodiment of the present invention. The figure is shown. As described above, the crossover line 15V2 is inclined at an angle φ1 in the axial direction.

  FIG. 9 shows a structure of four continuous winding coils (one coil is two-stage winding) for one phase (W-phase coil 10W ′) according to an embodiment of the present invention. The difference from the U-phase reference coil 10U is that the connecting wires 15W2, 15W3, 15W4 of each coil are inclined at an angle φ2 (φ2> φ1) in the axial direction of the rotary electric machine.

  FIG. 10 is a cross-sectional view of the first coil (10c) at the start of winding of four continuous winding coils (a single coil is two-stage winding) for one phase (W-phase coil 10W ′) according to an embodiment of the present invention. The figure is shown. As described above, the crossover wire 15W2 is inclined at an angle φ2 in the axial direction of the rotary electric machine.

  FIG. 11 shows a state in which three-phase four-continuous winding coils (one coil is two-stage winding) according to an embodiment of the present invention are combined in the axial direction of the rotary electric machine. The U-phase coil 10U, the V-phase coil 10V ', and the W-phase coil 10W' are combined in the state of being arranged horizontally. By connecting the connecting wires of the V-phase coil 10V ′ and the W-phase coil 10W ′ to the angles φ1 and φ2, respectively, the connecting wires can maintain the inter-phase insulation, and there is no mutual interference between the connecting wires. The cores can be aligned in a straight line, facilitating axial assembly. Furthermore, the stator 1 can be formed by forming the coil developed laterally in an annular shape.

  FIG. 12 shows a structure of four continuous winding coils (one coil is a two-stage winding) for one phase (a U-phase coil 10U) according to an embodiment of the present invention. The difference from FIG. 5 is that the U-phase coil 10U is continuously wound in an annular shape from the beginning. By creating a shape in the winding process as in this shape, the above-described annular molding process can be omitted. In this configuration, it is of course necessary to incline the connecting wires of the V-phase coil 10V 'and the W-phase coil 10W' to angles φ1 and φ2, respectively.

  FIG. 13 shows a structure of four continuous winding coils (one coil is a three-stage winding) for one phase (a U-phase coil 10U) according to an embodiment of the present invention. A coil structure that solves the above-described problem relating to assembly when the coil has an odd number of turns will be described with reference to FIG. As shown in FIG. 13, the U-phase coil 10U has four coils 10a, 10d, 10g, and 10j arranged side by side, and each coil is a continuous winding with the connecting wires 15U2, 15U3, and 15U4 inclined in parallel. Has been. Here, 15U5 is a terminal line, and 15U1 is an input line. As described above, it is not possible to assemble three sets of four continuous coils of this shape alone and simply combine them in the axial direction because the crossover wires interfere with each other. Hereinafter, the solution will be described.

  A configuration capable of solving the above-described problem will be described with reference to FIGS. As in Example 1, the four continuous winding coils of the U phase, V phase, and W phase differ only in the bending method of the winding end wire / winding starting wire and the jumper wire, There is no difference in length and other dimensions and configurations.

  FIG. 14 shows a structure of four continuous winding coils (a single coil is three-stage winding) for one phase (a U-phase coil 10U ″) according to an embodiment of the present invention. The difference from FIG. 13 is that the crossover wires 15U2, 15U3, 15U4 are detoured in the radial direction of the rotating electrical machine at the bottom of the coil. The connecting wire shape of the coil shown in FIG. 13 may be formed by forming the connecting wires 15U2, 15U3, and 15U4 of the coil in FIG. 13 through a winding process from the beginning.

  The crossover 15U2 shown in FIG. 14 will be described in detail based on FIG. FIG. 15 shows a cross-sectional view of the first coil (10a) at the start of winding of four continuous winding coils (a single coil is three-stage winding) of one phase (U-phase coil 10U ″). The connecting wire 15U2 extends the lower end bottom of the coil by extending the coil winding end line from the inner peripheral side of the coil upper base by a length h1 in the radial direction of the rotating electric machine and then bending vertically downward. A crossover wire 15U2 is formed so as to be bent to the next coil side by a predetermined length on the substantially same surface as the surface, and further bent to be a winding start wire of the next coil.

  FIG. 16 shows the structure of a four-phase winding coil (a single coil is a three-stage winding) for one phase (V-phase coil 10V ″) according to an embodiment of the present invention. The difference from the U-phase coil 10U ″ is that the connecting wires 15V2, 15V3, and 15V4 of each coil are detoured in the radial direction of the rotating electric machine at the center of the coil.

  The crossover 15V2 shown in FIG. 16 will be described in detail with reference to FIG. FIG. 17 shows a cross-sectional view of the first coil (10b) at the start of winding of four continuous winding coils (a single coil is three-stage winding) for one phase (V-phase coil 10V ″). The connecting wire 15V2 extends the coil winding end line from the inner peripheral side of the coil upper base by a length h2 in the radial direction of the rotating electric machine, and then bends vertically downward, in the longitudinal direction in the coil diagram. Bend at the center of the dimension (rotary electric machine axial direction) and extend from the inner circumference of the coil to a position where the distance is h2 ', and the electric wire is detoured from the position to the radial direction of the rotary electric machine by a predetermined length. Then, the connecting wire 15V2 of each coil is formed, the electric wire is bent downward at the same size as the winding end line, and further bent to the next coil side on the substantially same surface as the extended bottom surface of the coil. Let it be the winding start line of the next coil.

  FIG. 18 shows a structure of four continuous winding coils (a single coil is three-stage winding) of one phase (W-phase coil 10W ″) according to an embodiment of the present invention. The difference from the U-phase coil 10U ″ is that the connecting wires 15W2, 15W3, and 15W4 of each coil are detoured in the radial direction of the rotary electric machine at the top of the coil.

  The crossover 15W2 shown in FIG. 18 will be described in detail based on FIG. FIG. 19 shows a cross-sectional view of the first coil (10c) at the start of winding of four continuous winding coils (a single coil is a three-stage winding) for one phase (W-phase coil 10W ″). The connecting wire 15W2 extends the winding end line of the coil from the inner peripheral side of the coil upper base by the length h3 ′ in the radial direction of the rotating electrical machine, and from the position, the electric wire has a predetermined length to the diameter of the rotating electrical machine. The connecting wire 15W2 of each coil is formed by detouring in the direction, bent on the next coil side in a plane substantially the same as the extension of the upper bottom surface of the coil, and at a distance h3 from the inner circumference of the coil. It is bent vertically downward, and further bent on substantially the same plane as the extended bottom surface of the coil, thereby forming the winding start line of the next coil.

FIG. 20 shows a state in which four continuous winding coils for three phases (a single coil is three-stage winding) according to an embodiment of the present invention are combined in the axial direction. The U-phase coil 10U ″, the V-phase coil 10V ″, and the W-phase coil 10W ″ are combined in the order of being arranged horizontally. At this time, when the interphase insulation distance is d and the dimensions satisfy all of the following conditions, the interphase insulation can be maintained in all of the three-phase connecting wires.
h1-h2 ≧ d
h2′−h1 ≧ d
h2 '>h1> h2
h1-h3 ≧ d
h3′−h1 ≧ d
h3 '>h1> h3

  In this way, the connecting wires of the U-phase coil 10U ″, the V-phase coil 10V ″, and the W-phase coil 10W ″ are detoured in the radial direction of the rotating electric machine at the top, center, and bottom of the coil, respectively. Thus, there is no mutual interference of the crossover wires, and the cores can be aligned in a straight line, facilitating assembly in the axial direction. Further, the stator 1 can be formed by assembling the laterally expanded coils into an annular shape. Of course, in this shape as well, the coil can be continuously wound in an annular shape from the beginning as shown in FIG.

  FIG. 21 shows a state in which a position-fixing wiring block is inserted in a state in which four continuous winding coils for three phases according to an embodiment of the present invention (a single coil is a two-stage winding) are assembled in the axial direction. . As the last remaining problem, it is necessary to ensure insulation between the crossovers of the crossover wires (to restrict the position of the crossover wires and to ensure a certain spatial distance) in order to make the stator 1 function. In general radial gap type motors, the cost of parts is often high, such as the installation of resin wiring boards or connection boards. In order to reduce the price of the motor, I would like to make this part cheaper. Therefore, as shown in FIG. 21, resin wiring blocks 20 that fix the positions of the three-phase crossover wires are inserted into several places. Thereby, the material cost can be reduced by finely dividing the wiring board, which has been conventionally an integral product, into smaller pieces. As a method for fixing the wiring block 20, an adhesive, a mold, or the like can be considered.

  FIG. 22 is a cross-sectional view showing a state in which a position fixing wiring block 20 is inserted in a state where four continuous winding coils for three phases according to an embodiment of the present invention (a single coil is a two-stage winding) are assembled in the axial direction. Show. The three-phase crossover wires are arranged as shown in FIG. 22, and a substantially inverted E-shaped wiring block 20 having three grooves is suitable for positioning the three-phase connecting wires with certainty. With this shape, insertion from one direction is possible.

  FIG. 23 shows a state in which a position fixing wiring block 25 is inserted in a state where four continuous winding coils for three phases according to an embodiment of the present invention (a single coil is a three-stage winding) are assembled in the axial direction. Yes.

  FIG. 24 is a cross-sectional view of a state in which a position fixing wiring block 25 is inserted in a state where four continuous winding coils for three phases according to an embodiment of the present invention (a single coil is a three-stage winding) are assembled in the axial direction. Show. The three-phase crossover wires are arranged as shown in FIG. 24, and a substantially inverted E-shaped wiring block 25 having three grooves is suitable as in FIG. . Similarly, if it is this shape, insertion from one direction is possible.

DESCRIPTION OF SYMBOLS 1 Stator 2 Rotor 3 Iron core 4 Input wire 5 Neutral point 10a-10l Coil 10U, 10U '' U phase coil 10V, 10V ', 10V''V phase coil 10W, 10W', 10W '' W phase coil 15U1 Input line 15U2, 15U3, 15U4 Crossover line 15U5 Terminal line 15V1 Input line 15V2, 15V3, 15V4 Crossover line 15V5 Terminal line 15W1 Input line 15W2, 15W3, 15W4 Crossover line 15W5 Terminal line 20, 25 Wiring block 100 Axial gap type motor

Claims (8)

A winding end line of a coil formed by winding an electric wire is extended to form a winding start line of an adjacent coil as a connecting wire, and a plurality of winding coils are continuously formed by continuously winding U, V, and W Equipped with a continuous winding unit for three phases,
Spatial distances at the crossing portions of the crossover wires of each phase between one coil of the continuous winding unit of each U, V, and W phase and adjacent coils are predetermined in the radial direction and the axial direction of the rotating electrical machine. An axial gap type rotating electrical machine, which is arranged so as to maintain an insulation distance between phases.   The coil winding end line extends from the top or bottom of the coil in the radial direction of the rotating electric machine, and the winding start line of the next continuous coil is introduced in the axial direction from the bottom or top opposite to the winding end line. The axial gap type rotating electrical machine according to claim 1, wherein the crossover portion of the connecting wire is inclined with respect to the radial direction of the rotating electrical machine.   In the connecting wire of the U-phase continuous winding unit, the connecting wire of the V-phase continuous winding unit, and the connecting wire of the W-phase continuous winding unit, the rotating electric machine in the connecting portion of the connecting wire of each phase The introduction angle of the winding start line introduced from the transition part of each phase to the coil and the extension angle of the winding end line extending from the coil to the transition part are set so that the height in the axial direction is different. 2. The axial gap type rotating electric machine according to claim 1, wherein the winding is inclined in the axial direction of the rotating electric machine at a different angle.   In the connecting wire of the U-phase continuous winding unit, the connecting wire of the V-phase continuous winding unit, and the connecting wire of the W-phase continuous winding unit, the connecting wire of each phase extends in the radial direction of the rotating electrical machine. It is composed of an extension part and an introduction part, a vertical part extending in the axial direction of the rotating electrical machine, and a transition part extending from one coil to the next coil. The height of the transition part in the axial direction of the rotating electrical machine 2. The axial gap type rotating electrical machine according to claim 1, wherein the shafts are arranged at different heights.   A spacer block for holding a crossover portion of the U-phase continuous winding unit, a crossover portion of the V-phase continuous winding unit, and a crossover portion of the W-phase continuous winding unit. The axial gap type rotating electrical machine according to claim 1, further comprising: A winding end line of a coil formed by winding an electric wire is extended to form a winding start line of an adjacent coil as a connecting wire, and a plurality of winding coils are continuously formed by continuously winding the U winding of the same configuration , V, W 3 phase continuous winding unit is formed in advance,
The spatial distance in the crossover part of each phase between one coil and the adjacent coil of each phase continuous winding unit is maintained at a predetermined interphase insulation distance in the radial and axial directions of the rotating electrical machine. A method of manufacturing an axial gap type rotating electrical machine, characterized by being arranged and assembled as described above. A winding end line of a coil formed by winding an electric wire is extended to form a winding start line of an adjacent coil as a connecting wire, and a plurality of winding coils are continuously formed by continuously winding the U winding of the same configuration After forming continuous winding units for V, W, and W3 phases in advance,
By forming the winding end line and winding start line between the connecting wire and the coil so as to be inclined at different angles in each of the U, V, and W phases, interphase insulation between the connecting wires of each phase The method of manufacturing an axial gap type rotating electrical machine according to claim 6, wherein the distance is maintained. A winding end line of a coil formed by winding an electric wire is extended to form a winding start line of an adjacent coil as a connecting wire, and a plurality of winding coils are continuously formed by continuously winding the U winding of the same configuration After forming continuous winding units for V, W, and W3 phases in advance,
The winding end line and the winding start line are formed so as to extend from the lower bottom portion, the center portion, and the upper bottom portion of the coil for each phase, thereby maintaining the interphase insulation distance between the connecting wires of each phase. The method of manufacturing an axial gap type rotating electrical machine according to claim 6.

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