JP2014179264A - Lead wire with insulation layer, motor with use of lead wire with insulation layer, and manufacturing method of motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lead wire with insulation layer, which hardly causes heat loss even for high-currency current, capable of stably securing desired current and voltage; a motor having an improved efficiency due to use of the lead wire with insulation layer; and a method for manufacturing the motor.SOLUTION: A lead wire 5 with insulation layer is disposed in a slot 4. The lead wire includes: an insulation layer 6 made of a hollow tube-shaped insulation material having long protrusions 9 or recesses extending along the axial direction on the inner face of a hollow tube-shaped wall part 8; and a lead wire 7 disposed inside the wall part of the insulation layer, having groove parts 10 or protrusions on the surface so as to be fitted in the protrusions or the recesses.

Description

  The present invention relates to a conductive wire with an insulating layer for suppressing heat loss that occurs when a current is passed at a high voltage, a motor using the conductive wire with an insulating layer, and a method for manufacturing the motor.

Some electrical devices contain a conducting wire for passing a high-voltage current therein. For example, a motor stator has a plurality of teeth portions formed in the circumferential direction of the stator core and a slot sandwiched between the teeth portions, and a plurality of coil conductors (conductors) are accommodated in the slots. It has been known.
In such a coil conductor accommodated in the stator core slot, an insulating layer is provided by sandwiching an insulating sheet between the coil conductor and the stator core in order to prevent contact between the coil conductor and the stator core. (Patent Document 1).

JP2012-44831

By the way, as shown in FIG. 7, the conducting wire 101 used in the motor or the like as described above is formed into a thick rectangular wire having a square cross section in order to increase the occupation ratio in the slot. However, the skin effect occurs in the conductive wire 101 when the frequency of the energized current increases.
That is, in the conductive wire 101, when the frequency of the energized current increases, current flows through the surface layer portion 102, but current hardly flows through the central portion 103 (the current density is high on the surface of the conductive wire, from the surface to the center side). The phenomenon occurs when the distance is increased. When the skin effect occurs in the conductive wire 101, the amount of current flowing through the surface layer portion 102 increases, so that heat loss increases.
Therefore, when such a conducting wire is used as a coil conductor in the stator core of the motor, there is a problem that a desired current amount and voltage required by the motor cannot be obtained. In addition, since the desired current amount and voltage cannot be obtained, there is a problem of reducing the efficiency of the motor.

  Therefore, the present invention has been made in view of the above problems, and even when the current frequency is increased, heat loss is unlikely to occur, and a conductor with an insulating layer that can stably secure a desired current and voltage, It is an object of the present invention to provide a motor whose efficiency is improved by using the conductive wire with an insulating layer and a method for manufacturing the motor.

  The present invention provides an insulating layer formed of an insulating material in a hollow tube shape, and having an axially long convex portion or concave portion provided on the inner surface of the wall portion forming the hollow tube shape, and the wall portion of the insulating layer And a conducting wire having a groove or a protrusion formed on the surface so as to fit into the convex or concave portion.

  According to the present invention, the groove or protrusion is formed on the surface of the conductive wire to increase the surface area. Therefore, when the skin effect occurs, the energization range becomes large. Therefore, even if the current is concentrated on the surface layer and energized, the energization range is large, so that heat loss does not become excessive, and a desired current and voltage can be secured stably.

FIG. 1 is a partial plan view of a stator core. (Example) FIG. 2 is an enlarged plan view of a stator core in which conductive wires with insulating layers are arranged in slots. (Example) FIG. 3 is a cross-sectional view showing a current passing portion of a conducting wire with an insulating layer having a groove formed on the surface. (Example) FIG. 4 is a cross-sectional view showing a current passing portion of a conductor with an insulating layer having a protrusion formed on the surface. (Example) FIG. 5 is an enlarged plan view of a stator core in which a conductive wire with an insulating layer having an insulating coating layer formed on the surface by coating treatment is arranged in a slot. (Example) FIG. 6A is a partial perspective view of the stator core showing the process of assembling the hollow tube-shaped insulating layer into the slot, and FIG. 6B is a view showing the molten conductive material poured into the hollow tube-shaped insulating layer. FIG. 6C is a partial perspective view of the stator core showing a state in which the conductive wire is cast and molded inside the hollow tube-shaped insulating layer. (Example) FIG. 7 is a cross-sectional view showing a current passing portion of the conducting wire. (Conventional example)

According to the present invention, a groove or protrusion is formed on the surface of the conducting wire to increase the surface area, thereby enlarging the energization range when the skin effect occurs, thereby making it difficult for heat loss to occur.
Embodiments of the present invention will be described below with reference to the drawings.

1 to 6 show an embodiment of the present invention. As shown in FIG. 1, the stator core 1 in the stator of the motor has a plurality of teeth portions 3 formed at equal intervals in the circumferential direction on the inner peripheral side of a cylindrical annular portion 2 made of a magnetic material. A plurality of slots 4 are formed at equal intervals in the circumferential direction. In each slot 4, as shown in FIG. 2, a conductive wire 5 with an insulating layer is arranged.
The conducting wire 5 with an insulating layer includes an insulating layer 6 and a conducting wire 7. The insulating layer 6 is formed into a hollow tube shape having a rectangular space S by an insulating material, and a plurality of projections 9 that are long in the axial direction are provided on the inner surface facing the space S of the wall portion 8 forming the hollow tube shape. It has been. The conducting wire 7 is formed into a rectangular wire having a square cross section by a conductive material. The conducting wire 7 is disposed in an inner space S surrounded by the wall portion 8 of the insulating layer 6, and a plurality of groove portions 10 that are long in the axial direction are formed on the surface so as to fit the convex portion 9.
Thus, since the conductor 5 with an insulating layer has the groove 10 formed on the surface of the conductor 7 to increase the surface area, the energizing range is increased when a skin effect occurs due to a high-frequency current flowing. Therefore, as shown in FIG. 3, the conductor 5 with an insulating layer does not have excessive heat loss because the energization range is large even when the current is concentrated in the surface layer portion 11 rather than the central portion 12. A desired current and voltage can be secured stably.
2 and 3, a long convex portion 9 is formed in the axial direction on the inner surface facing the space S surrounded by the wall portion 8 of the insulating layer 6, and the surface of the conductor 7 is fitted to the convex portion 8. As shown in FIG. 4, a long recess 13 is formed in the inner surface of the wall portion 8 of the insulating layer 6 in the axial direction, and the surface of the conductor 7 is axially fitted to the recess 13 as shown in FIG. It is also possible to form a long protrusion 14.
As a result, the conductor 5 with an insulating layer has a protruding portion 14 formed on the surface of the conductor 7 to increase the surface area. Therefore, even if the current is more concentrated in the surface layer portion 11 than in the central portion 12, When a high current flows and the skin effect occurs, the energization range becomes large. Since the energization range is large, heat loss does not become excessive, and a desired current and voltage can be secured stably.

The conductor 5 with an insulating layer can be cast and placed when the conductor 7 is placed in the inner space S surrounded by the wall 8 of the insulating layer 6. In this case, the insulating layer 6 is formed of an insulating material having higher heat resistance than the melting point of the conducting wire 7, and the conducting wire 7 is cast and molded in the inner space S surrounded by the wall portion 8 of the insulating layer 6.
For example, when the conductive material of the conducting wire 7 is aluminum (melting temperature 600 ° C.), a tie-mold resin (melting temperature 1000 ° C.) having higher heat resistance than the melting point of the conducting wire 7 is selected as the insulating material of the insulating layer 6. The insulating layer 6 is formed in a hollow tube shape having a rectangular space S by an insulating material having a melting temperature higher than that of the conducting wire 7, and a plurality of projections 9 that are long in the axial direction are provided on the inner surface of the wall portion 8 facing the space S. It has been. The conducting wire 7 is cast-molded by pouring a molten conductive member into the inner space S surrounded by the wall portion 8 of the insulating layer 6, and a groove portion 10 is formed on the surface so as to fit the convex portion 9.
When, for example, a conductive wire with a low elongation rate is adopted as a conductive wire to be assembled to an electric device, there arises a problem that it is difficult to assemble the conductive wire.
Since the conductive wire 5 with an insulating layer uses a heat-resistant material higher than the melting point of the conductive wire 7 as the insulating material of the insulating layer 6, the insulating layer 6 formed of the insulating material having a high melting point is used as a mold for the conductive wire 7. The conductive wire 7 can be cast and molded. If it is cast molding, the above-mentioned problem of assembling property does not occur.

Further, as shown in FIG. 5, the conductive wire 5 with an insulating layer includes a conductive wire 7 having a groove portion 10 formed long in the axial direction on the surface, and an insulating coating layer 15 formed on the surface of the conductive wire 7 by coating treatment. It can be set as the structure provided with these.
For example, the conductive wire 7 is formed by extruding aluminum as a conductive material, for example, and has a rectangular rectangular wire with a cross section having a groove 10 that is long on the surface in the axial direction. The conductor 7 is subjected to anodization after formation. When the anodic oxidation treatment is performed in this manner, the surface of the conductive wire 7 is covered with the insulating film layer 15 made of aluminum oxide, so that insulation is exhibited and it is not necessary to provide a separate insulating member.
Since the conductor 5 with an insulating layer does not need to cover the periphery of the conductor 7 with an insulating material, the volume of the conductor 7 in the slot 4 can be increased. In this way, even a material with low electrical conductivity can be used as the conductive wire 7 and the surface area of the conductive wire 7 is increased by increasing the volume, so that the energization range is increased and high-frequency current is applied. In this case, heat loss can be reduced.

  The conducting wire 5 with an insulating layer is disposed in the slot 4 of the stator core 1 of the motor. As a result, the motor provided with the conductor 5 with the insulating layer can use the conductor 7 with less heat loss as the conductor disposed in the slot 4 of the stator core 1, thereby improving the magnetization efficiency and consequently the motor efficiency. Can be improved. In the case of a motor having a plurality of phases of windings formed by conducting wires 5 with insulating layers, the conducting wires 5 with insulating layers arranged in the plurality of slots 4 are connected to the same phase by bus rings.

In the case of manufacturing a motor provided with the conductive wire 5 with an insulating layer, the conductive wire 5 with an insulating layer is formed by forming the insulating layer 6 with an insulating material having a heat resistance higher than the melting point of the conductive wire 7 as described above. Casting is performed inside the wall 8 of the layer 6.
In the manufacturing method of the motor in which the conductive wire 7 is arranged in the slot 4 of the stator core 1, as shown in FIG. 6 (A), it is formed into a hollow tube shape having a space S by an insulating material to form a hollow tube shape. As shown in FIG. 6 (B), the step of assembling the insulating layer 6 in which the axially long projections 9 are provided on the inner surface of the wall 8 facing the space S in the slot 4 and the wall 8 of the insulating layer 6 A process of casting the molten conductive material from the nozzle 16 into the enclosed inner space S and performing casting is performed sequentially. As shown in FIG. 6C, the conductive wire 5 with the insulating layer is fitted into the convex portion 9 in the inner space S surrounded by the wall portion 8 of the insulating layer 6 by solidifying the poured conductive material. A conducting wire 7 having a groove 10 formed on the surface is cast.
Thus, in the manufacturing method of the motor provided with the conducting wire 5 with the insulating layer, the hollow tube-shaped insulating layer 6 provided with the convex portion 9 on the inner surface facing the space S surrounded by the wall portion 8 is formed in the slot 4. Assembling and casting the molten conductive material into the inner space S surrounded by the wall portion 8 of the insulating layer 6 to form a groove portion 10 on the surface of the conductive wire 7 to increase the surface area, resulting in a high frequency When current flows and the skin effect occurs, the energization range is large, so heat loss does not become excessive, and a desired current and voltage can be secured stably, and a motor with improved efficiency is manufactured. be able to.
In FIG. 6, a hollow tube-shaped insulating layer 6 having a convex portion 9 formed on the inner surface of the wall portion 8 facing the space S is assembled in the slot 4, and the surface is fitted to the convex portion 9 of the insulating layer 6. A conductive wire 7 having a groove 10 formed therein is cast and molded. However, a hollow tube-shaped insulating layer 6 (see FIG. 4) in which an axially long recess 13 is formed on the inner surface of the wall 8 facing the space S is formed in the slot 4. It is also possible to cast the conductive wire 7 having a projection 14 formed on the surface so as to fit into the recess 13 of the wall 8.
As in the above, when the high frequency current flows and the skin effect occurs, the energization range becomes large, and the energization range is large so that heat loss does not become excessive and the desired current and voltage are stabilized. Thus, a motor with improved efficiency can be manufactured.

  This invention is intended to increase the surface area by forming grooves or protrusions on the surface of the conducting wire, to increase the energization range when the skin effect occurs and to make it difficult to cause heat loss. The present invention can be applied to a conducting wire that carries a high voltage current.

DESCRIPTION OF SYMBOLS 1 Stator core 2 Annular part 3 Teeth part 4 Slot 5 Conductor with an insulating layer 6 Insulating layer 7 Conductor 8 Wall part 9 Projection part 10 Groove part 11 Surface layer part 12 Center part 13 Concave part 14 Protrusion part 15 Insulating film layer 16 Nozzle S space

Claims (5)

  An insulating layer that is formed into a hollow tube shape by an insulating material, and has an inner surface of the wall portion that forms the hollow tube shape provided with a convex portion or a concave portion that is long in the axial direction, and is disposed inside the wall portion of the insulating layer And a conductive wire having a groove or a protrusion formed on the surface so as to fit into the convex portion or the concave portion.   The insulating layer according to claim 1, wherein the insulating layer is formed of an insulating material having a heat resistance higher than a melting point of the conducting wire, and the conducting wire is cast-molded inside a wall portion of the insulating layer. Conducting wire.   A conducting wire with an insulating layer, comprising: a conducting wire having a groove or a protrusion formed long on the surface in the axial direction; and an insulating coating layer formed on the surface of the conducting wire by a coating treatment.   4. The motor provided with a conductor with an insulation layer according to claim 1, wherein the conductor with an insulation layer is disposed in a slot of a stator core. 5.   In a method of manufacturing a motor in which a conductor is disposed in a slot of a stator core, a hollow tube shape is formed of an insulating material, and an axially long convex portion or concave portion is provided on the inner surface of the wall portion forming the hollow tube shape. A motor having a conductive wire with an insulating layer, comprising: assembling an insulating layer into the slot; and pouring a molten conductive material into a wall portion of the insulating layer and casting the conductive wire. Manufacturing method.

Images