JP2015177656A - Stator for rotary electric machine, and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator for a rotary electric machine capable of securing a distance between coils and improving coil insulation and radiation properties by forming uneven insulators in the coils using round wires, and a manufacturing method thereof.SOLUTION: A resin insulator 16 is mounted to teeth 7 of a divided core 5, and ring-shaped first-stage protrusions 13 are disposed continuously at predetermined intervals in an axial direction of a round wire 9. The round wire 9 with which an uneven part 12 is formed is wound around an insulation part of teeth of the insulator 16 while being aligned in a layer shape, and a coil 3 is wound around the divided core 5. In the coil 3, the uneven parts 13 circumferentially and radially neighboring to each other are fitted to each other and fixed while maintaining a distance between the coils and securing a distance between lead wire parts 11. On an outermost layer surface of the coil 3, the round wire 9 is wound around the insulation part of the teeth in a stairway shape while decreasing the number of layers from a yoke 6 to a flange part 8.

Description

  The present invention relates to a stator for a rotating electrical machine and a method for manufacturing the same, and more particularly to a stator for a rotating electrical machine that can improve heat dissipation of a stator coil wound around an outer peripheral surface of a stator core and a method for manufacturing the same.

  Conventionally, in stators used in rotating electrical machines such as electric motors and generators, stator coils (windings, hereinafter referred to as coils) are attached to insulating bobbins (insulators) attached to teeth extending from an annular yoke of the stator core. Is wound. As the coil, for example, a coil made of a round wire having a circular cross section in which an insulating film is coated around a copper wire or a coil made of a rectangular wire having a substantially rectangular cross section is used as a wire. A stator formed by winding these coils around a tooth portion of an insulating bobbin and a winding method thereof have been proposed (for example, see Patent Document 1).

  In Patent Document 1, a rectangular wire is aligned and wound in layers on a tooth portion having a rectangular cross section that is parallel to each other of an insulating bobbin, and the protrusion protrudes from the yoke portion of the insulating bobbin along the inner surface of the end portion of the tooth portion. The number of layers is reduced toward the part. The stator is formed by winding a rectangular wire stepwise around the teeth of the stator core, and the outermost layer surface of the coil is an outer peripheral surface inclined in the axial direction of the teeth.

Japanese Patent No. 3786931

  However, when the coil as described above is rolled down from the yoke part of the insulating bobbin in the direction of the extension part, the coil slips from the winding position and the coil is rubbed due to collapse or motor vibration, and the insulating film Prone to damage. For this reason, a liquid varnish etc. may be permeate | solidified between coils and a coil may be fixed. In addition, since the coil generates heat due to Joule heat during energization, the temperature at which the coil is in contact with the coil rises as compared with the coil part in contact with the stator core. If the heat becomes extremely high, the insulation film may be broken due to damage to the insulation film, and the insulation performance of the coil may not be maintained. Moreover, there is a possibility that a decrease in motor output or the like due to an increase in coil resistance value occurs.

  Furthermore, when a rectangular wire is used for the stator coil, the rectangular wire can increase the space factor and has a high cooling effect, but it has a high cost and is difficult to bend in the width direction of the rectangular wire at the time of winding. Yes. For this reason, the stator which can improve the heat dissipation of a coil using an inexpensive round wire is desired.

  The present invention has been made in order to solve the above-described problems. The object of the present invention is to form a concavo-convex insulator on a coil using a round wire, thereby ensuring the distance between the coils and the insulation of the coil. Another object of the present invention is to provide a stator for a rotating electrical machine that can improve heat dissipation and a method for manufacturing the same.

  In order to solve the above-mentioned problem, the invention described in claim 1 is a stator for a rotating electrical machine, wherein the stator is formed by a plurality of laminated ferromagnetic plates and extends from an annular yoke to the inner peripheral side. A coil having a stator core having teeth, an insulator disposed around the teeth, and a coating layer in which the periphery of the conductor is insulation-coated, and a circular wire having a circular cross section wound around the winding surface of the insulator The round wire has an insulator having a plurality of irregularities disposed at predetermined intervals in the axial direction of the round wire on the outer peripheral surface of the coating layer, and the coil includes the round wire The gist is that the concavo-convex parts of the round lines adjacent to each other are wound so that the lines fit each other.

  According to the above configuration, the concave and convex portions formed of the insulator are provided at predetermined intervals on the outer peripheral surface of the round wire around which the coil is wound, and the coils of the stator core are fitted so that the adjacent concave and convex portions are fitted to each other. It winds around the insulator attached to. As a result, the coil can be reliably wound without being wound around the insulator, and coil collapse that occurs during winding or motor vibration can be prevented. Further, it is possible to secure a distance between the wound coils, suppress a temperature rise due to heat generation of the coils, and improve the insulation and heat dissipation of the coils.

  According to a second aspect of the present invention, in the stator for a rotating electrical machine according to the first aspect, the concavo-convex portion has a concave portion formed on an outer peripheral surface of the round wire, and a ring shape extending in a radial direction from the concave portion. And a convex portion, and is formed continuously and integrally in the axial direction of the round wire. According to the said structure, since a recessed part and a ring-shaped convex part are integrally formed, an uneven | corrugated | grooved part can be continuously formed on the outer peripheral surface of a round wire. As a result, it is possible to secure a distance between the wound coils, suppress a temperature rise due to heat generation of the coils, and improve the insulation and heat dissipation of the coils.

  According to a third aspect of the present invention, in the stator for a rotating electrical machine according to the first aspect, the concave and convex portions include a concave portion formed of an outer peripheral surface of the round wire and a convex portion extending in a radial direction from the outer peripheral surface. And the flat insulator is spirally and integrally formed in the axial direction of the round wire. According to the said structure, since a flat insulator is helically formed integrally, an uneven | corrugated | grooved part can be continuously formed on the outer peripheral surface of a round wire. Thereby, it is possible to secure a distance between the wound coils, and to improve the insulation and heat dissipation of the coil due to the temperature rise due to the heat generation of the coil.

  According to a fourth aspect of the present invention, in the method for manufacturing a stator for a rotating electrical machine, a stator core having a plurality of teeth formed from a plurality of laminated ferromagnetic plates and extending from an annular yoke to the inner peripheral side; An insulator disposed around the teeth, and a coil having a coating layer in which the periphery of the conductor is insulation-coated, and a circular wire having a circular cross section wound around the winding surface of the insulator, The coil has a forming step of forming a plurality of concave and convex portions in which insulators are arranged at predetermined intervals in an axial direction of the round wire on an outer peripheral surface of the coating layer of the round wire, and the round wire is adjacent to the forming step. The gist is provided with a winding step of winding so that the concavo-convex portions of the matching round wires fit each other.

  According to the above configuration, the concave and convex portions formed of the insulator are provided at predetermined intervals on the outer peripheral surface of the round wire wound with the coil, and the adjacent concave and convex portions are fitted to each other so that the stator core is interposed with the insulator. The stator is formed by winding the coil. As a result, the coil can be reliably wound without being wound around the stator core, and the coil can be prevented from being collapsed during winding or during motor vibration. Further, it is possible to secure a distance between the wound coils, suppress a temperature rise due to heat generation of the coils, and improve the insulation and heat dissipation of the coils.

  According to the present invention, there is provided a stator for a rotating electrical machine capable of securing a distance between coils and improving the insulation and heat dissipation of the coil by forming a concavo-convex insulator on a coil using a round wire, and a method for manufacturing the same. Can be provided.

1 is an overall cross-sectional view of a stator for a rotating electrical machine according to an embodiment of the present invention. FIG. 2 is an axial sectional view showing a schematic structure of the coil of FIG. 1 according to the first embodiment of the present invention. The figure which looked at the coil of the split core of FIG. 1 from the stator side surface. FIG. 4 is a partial cross-sectional view of the coil of FIG. 3 as viewed from the front of the stator. The figure which looked at the uneven part formed in the spiral of the coil concerning the 2nd Embodiment of the present invention from the stator side. The figure which looked at the uneven part of the coil concerning other embodiments of the present invention from the stator side.

  Below, the stator for rotary electric machines (henceforth a stator) 1 used for the rotary electric machine of embodiment of this invention is demonstrated based on the figure of the stator of an electric motor. In the following description, the radial direction and the axial direction refer to the radial direction and the axial direction of the stator 1 (stator core 2).

FIG. 1 is an overall cross-sectional view of a stator 1 according to an embodiment of the present invention.
The rotating electrical machine is mounted on a vehicle, for example, an electric power steering device for assisting a steering operation, or an electric motor for a driving source such as a rear wheel driving device for an electric four-wheel drive vehicle that travels by generating a driving force on a rear wheel (for example, Used as a three-phase brushless motor). As shown in FIG. 1, the electric motor is an inner rotor type brushless motor. The electric motor includes a cylindrical rotor 19 coupled to a rotary shaft 18 so as to be integrally rotatable, an annular stator 1 surrounding the rotor 19, and a cylindrical motor housing 20 that houses the rotor 19 and the stator 1. I have.

  The stator 1 includes an annular stator core 2 and a plurality (12 in this embodiment) of stator coils (coils) 3 wound around the stator core 2. The stator core 2 is a laminate in which a plurality of thin plates formed by punching out electromagnetic steel plates into a predetermined shape are laminated and fixed in the axial direction of the stator core 2. That is, the stator core 2 is formed of a material containing iron, and as the electromagnetic steel plate, for example, a ferromagnetic plate such as a silicon steel plate whose surface is subjected to insulation treatment can be used.

  Here, the stator core 2 is composed of a plurality of (in this embodiment, 12) divided cores 5 in which a plurality of T-shaped plates 4 divided at a predetermined angle are stacked and integrally connected. Are arranged in an annular manner at equal intervals in the circumferential direction and fastened. The split core 5 includes an arcuate yoke 6 and teeth 7 having a substantially rectangular cross section extending from the yoke 6 to the inner peripheral side (inner side in the radial direction). It is comprised so that it may mutually contact | abut in radial direction. At the tip of the tooth 7 facing the outer peripheral surface of the rotor 19, a flange portion 8 is provided extending to both sides in the circumferential direction.

  An insulator (not shown) (see FIG. 3) that insulates the tooth 7 from the coil 3 is mounted on the tooth 7, and the coil 3 is wound along a winding surface (see FIG. 3) of the insulator. A so-called round wire 9 having a circular cross section is used for the coil 3. Further, when the electric motor is a high output motor, an insulating material (for example, aramid paper) that electrically insulates the phases of adjacent coils 3 in order to prevent dielectric breakdown due to a high voltage applied to the coil 3. 21) may be provided.

  The motor housing 20 is formed of a material containing iron such as carbon steel or aluminum. In the stator core 2, the split cores 5 arranged in an annular shape are inserted into the motor housing 20, and the outer peripheral surface of the split core 5 is fixed to the inner peripheral surface of the motor housing 20 by press-fitting. A slot in which the coil 3 is disposed is provided between the teeth 7 of the adjacent split cores 5. In the present embodiment, the number of slots is 12.

  A plurality of permanent magnets (not shown) are embedded in the rotor 19 (not shown) or bonded to the rotor core surface by bonding or the like. The electric motor configured as described above has a rotor that generates magnetic attraction and repulsion between a magnetic field formed by supplying driving power to each coil 3 of the stator 1 and the magnetic flux of the permanent magnet. 19 and the rotating shaft 18 are configured to rotate.

(First embodiment)
2 is an axial sectional view showing a schematic structure of the coil 3 of FIG. 1 according to the first embodiment of the present invention, and FIG. 3 is a side view of the stator 1 of the coil 3 of the split core 5 of FIG. 4 is a partial cross-sectional view of the coil 3 of FIG. 3 as viewed from the front of the stator 1.

  As shown in FIG. 2, the coil 3 includes a round wire 9 in which an outer periphery of a conducting wire portion (conductor, for example, copper wire) 10 having a circular cross section is coated with an insulating film (film layer) 11 that is electrically insulated. Consists of. A plurality of concavo-convex portions 12 made of a highly heat-conductive insulating member (a thermosetting molding material such as unsaturated polyester (BMC) or a thermoplastic molding material such as a resin such as PPS) is provided on the outer periphery of the insulating film 11. Formed (molding process). The uneven portion 12 has, for example, a ring-shaped first-stage convex portion 13 and second-stage convex portion 14 and a concave portion 15 formed on the outer periphery of the insulating film 11 in a predetermined direction in the axial direction of the round line 9. They are continuously arranged at intervals and are integrally formed with high dimensional accuracy.

  As shown in FIG. 3, an insulator 16 made of resin (for example, an insulator such as PPS) is attached to the teeth 7 of the split core 5. For example, the round wire 9 formed with the concavo-convex portion 12 composed of the ring-shaped first-stage convex portion 13 and concave portion 15 is aligned and wound in layers on the teeth insulating portion of the insulator 16 (winding step), and divided. A coil 3 is wound around the core 5. In the coil 3, the concave and convex portions 12 arranged adjacent to each other in the circumferential direction (front and rear in the figure) and the radial direction (up and down in the figure) of the split core 5 are fitted to each other, and the distance between the coils 3 is maintained. It is fixed in a state where the distance between the portions 10 is secured. Note that, on the outermost layer surface of the coil 3 (not shown), the number of layers is reduced from the yoke 6 toward the flange portion 8 and the round wire 9 is wound around the tooth insulating portion in a stepped manner so as to be inclined in the axial direction of the tooth 7.

  Specifically, as shown in FIG. 4, the insulator 16 is disposed so as to surround the side surface of the tooth 7 of the split core 5, and the coil 3 made of the round wire 9 is formed on the winding surface 17 of the insulator 16 having a rectangular cross section. It is aligned and wound in layers. For example, the first-stage coil 3 is wound in a state where the ring-shaped first-stage convex portion 13 is in contact with the winding surface 17, and the first-stage convex portion 13 is radially insulated. 11 (see FIG. 2) are wound around and fixed to the outer peripheral surface of each other. In the upper second stage coil 3, the ring-shaped second stage convex portion 14 is in contact with the outer peripheral surface of the insulating film 11 (see FIG. 2) of the first and second stage coils 3 adjacent to each other. And wound around the outer layer (upper stage) of the coil 3 at the first stage.

  As described above, the stator 3 is formed by winding the coil 3 through the molding process and the winding process. In the molding process, first and second projections 13 and 14 made of ring-shaped insulating members are arranged on the outer peripheral surface of the insulating film 12 of the round wire 9 at predetermined intervals in the axial direction of the round wire 9. Then, the plurality of concave and convex portions 12 are formed continuously and integrally. Subsequently, in the winding step, the round wire 9 is wound so that the uneven portions 12 adjacent to each other in the circumferential direction and the radial direction of the split core 5 are fitted to each other.

  As described above, by providing the concave and convex portion 12 made of a ring-shaped insulating member on the outer peripheral surface of the round wire 9 around which the coil 3 is wound, the insulating film thickness can be increased and the insulating property of the coil 3 can be improved. . Further, the heat generated in the coil 3 propagates to the motor housing 20 via the stator core 2. Therefore, the temperature rise of the coil 3 on the outer layer side that is far from the stator core 2 and is wound around the insulator 16 is highest. For this reason, the distance between the coils 3 is ensured by winding the coil 3 around the teeth insulating portion of the insulator 16 attached to the stator core 2 so that the adjacent concavo-convex portions 12 are fitted to each other. Thereby, the temperature rise by the heat_generation | fever of the coil 3 can be suppressed and the heat dissipation of the coil 3 can be improved.

  Further, the coil 3 can be reliably wound without being wound around the insulator 16, and the coil 3 can be prevented from collapsing during winding or motor vibration, and the insulating film 11 can be damaged by rubbing between the coils 3. Can be prevented.

(Second Embodiment)
Next, FIG. 5 is a view of the concavo-convex portion 12 formed in a spiral shape of the coil 3 according to the second embodiment of the present invention as seen from the side surface of the stator 1.
As shown in FIG. 5, a flat insulating member (a thermosetting molding material such as unsaturated polyester (BMC), or a thermoplastic molding material such as, for example, A resin such as PPS) is integrally formed in a spiral shape, and the convex portions 22 are continuously formed. A plurality of concave and convex portions 12 having spiral convex portions 22 are wound and arranged adjacent to each other in the circumferential direction (front and rear in the drawing) and radial direction (up and down in the drawing) of the split core 5 (see FIG. 3). It is fixed by being fitted to the uneven portion 12. Thereby, since the uneven parts 12 adjacent to each other can be fitted in the same manner as the provision of the ring-shaped first-stage and second-stage convex parts 13, 14, the insulation and heat dissipation of the coil 3 are improved. It becomes possible.

  Next, the operation and effect of the stator 1 according to the embodiment of the present invention configured as described above will be described.

  According to the first and second embodiments, a plurality of irregularities formed on the outer peripheral surface of the round wire 9 around which the coil 3 is wound by an insulating member made of thermosetting resin or thermoplastic resin at a predetermined interval. A portion 12 is provided. Since the coil 3 is wound around the stator core 2 via the insulator 16 so that the adjacent concavo-convex portions 12 are fitted to each other, the coil 3 can be reliably wound around the stator core 2 without slipping.

  According to the first embodiment, the concave portion 15 formed on the outer peripheral surface of the round wire 9 forming the coil 3 and the ring-shaped convex portions 13 and 14 extending in the radial direction from the concave portion 15 are integrally formed. A plurality of concave and convex portions 12 can be formed continuously on the outer peripheral surface of the line 9. In addition, according to the second embodiment, since the insulating member made of a plate-like thermosetting resin or thermoplastic resin is integrally formed on the outer peripheral surface of the round wire 9 in a spiral shape, a plurality of concavities and convexities are continuously formed. The portion 12 can be formed.

  As a result, the coil 3 can be reliably wound without being wound around the stator core 2, the coil 3 is prevented from being collapsed during winding or when the motor vibrates, and the insulating film 11 due to friction between the coils 3 is prevented. Damage and dielectric breakdown can be prevented. Further, by securing the distance between the coils 3, it is possible to suppress the temperature rise due to the heat generation of the coils 3, and to improve the insulation and heat dissipation of the coils 3.

  Furthermore, according to the manufacturing method according to the first and second embodiments, the stator 3 is formed by reliably winding the coil 3 around the teeth insulating portion of the insulator 16 attached to the stator core 2 by the molding and winding process. be able to. On the outer peripheral surface of the round wire 9, a molding process for forming a plurality of uneven portions 12 formed by a resin member at predetermined intervals, and then the stator core 2 is rounded so that the adjacent uneven portions 12 are fitted to each other. The coil 3 is wound by the winding process of winding the wire 9.

  As a result, the coil 3 can be reliably wound without being wound around the stator core 2, the coil 3 is prevented from being collapsed during winding or when the motor vibrates, and the insulating film 11 due to friction between the coils 3 is prevented. Damage and dielectric breakdown can be prevented. Further, by securing the distance between the coils 3, it is possible to suppress the temperature rise due to the heat generation of the coils 3, and to improve the insulation and heat dissipation of the coils 3.

  As described above, according to the embodiment of the present invention, a stator that can secure the inter-coil distance by forming a concavo-convex insulator in a coil using a round wire, and improve the insulation and heat dissipation of the coil, and A manufacturing method thereof can be provided.

  As mentioned above, although embodiment which concerns on this invention was described, this invention can also be implemented with another form.

  In the first embodiment, the case has been described in which the first and second ring-shaped convex portions 13 and 14 made of resin are provided on the coil 3 at equal intervals so as to fit each other. Instead, the interval between the first and second convex portions 13 and 14 may be widened.

FIG. 6 is a view of the concavo-convex portion 13 of the coil 3 according to another embodiment of the present invention as seen from the side surface of the stator 1.
As shown in FIG. 6, the concavo-convex portion 12 includes ring-shaped first and second ridges 13, 14 and a recess 15 formed on the outer peripheral surface of the round wire 9. The concave and convex portion 12 is disposed with a double spacing in the axial direction of the round wire 9. For example, the first step protrusions 13 are arranged adjacent to each other in a state of being shifted one by one in the radial direction (up and down), and the second step protrusions 14 in the upper step are adjacent to each other so as to be further shifted one by one. Arranged in contact with the outer peripheral surface of the adjacent coils 3. As a result, the number of ring-shaped first-stage and second-stage convex portions 13 and 14 and the insulating members to be used can be reduced.

  In the first embodiment, the concave and convex portion 12 has been described as an example in which the concave portion 15 and the ring-shaped first and second convex portions 13 and 14 are integrally formed of an insulating member. For example, the recess 15 may be formed as an outer peripheral surface of the round wire 9 of the coil 3 and only the ring-shaped first and second protrusions 13 and 14 may be formed of an insulating member.

  In the above embodiment, the stator core 2 is formed by laminating electromagnetic steel plates using silicon steel plates in accordance with the shape of the split cores 5. However, the present invention is not limited to this, and for example, a powder containing a soft magnetic material It may be a green compact made of a material. As the soft magnetic material, iron, ferrite, permalloy, or the like can be used.

  In the above embodiment, the example in which the coil 3 is wound with the round wire 9 having a circular cross-section is not limited to this, and it is difficult to generate a gap between the layers of the coil 3 during aligned winding. For example, a polygonal wire having a regular hexagonal cross section may be used.

  In the above embodiment, one stator core 2 is formed by combining twelve divided cores 5. However, the number of divisions is not limited to this, and a plurality of teeth 7 are provided instead of division types. The present invention may be applied to the formed annular integral stator core 2.

  In the above-described embodiment, the present invention has been specifically described as an electric motor used as a drive source for an in-vehicle electric power steering device, a rear wheel drive device, and the like. However, the present invention is not limited to this, and other motor devices are used. It may be used as a drive source motor or a generator.

1: stator, 2: stator core, 3: coil, 4: plate, 5: split core,
6: yoke, 7: teeth, 8: collar, 9: round wire, 10: conductor (conductor),
11: Insulating film (film layer), 12: concavo-convex part, 13: first-stage convex part, 14: second-stage convex part, 15: concave part, 16: insulator, 17: winding surface, 18: rotation axis , 19: Rotor,
20: Motor housing, 21: Insulating paper, 22: Spiral convex part

Claims (4)

A stator core formed by a plurality of laminated ferromagnetic plates and having a plurality of teeth extending from an annular yoke to the inner peripheral side;
An insulator disposed around the teeth;
A coil having an insulating coating around the conductor, and a round wire having a circular cross section wound around the winding surface of the insulator; and
The round wire has an insulator in which a plurality of concave and convex portions are disposed at predetermined intervals in the axial direction of the round wire on the outer peripheral surface of the coating layer,
The stator for a rotating electrical machine, wherein the coil is wound so that the concavo-convex portions of the round wires adjacent to each other are fitted to each other. The stator for a rotating electrical machine according to claim 1,
The concavo-convex part has a concave part formed on the outer peripheral surface of the round line and a ring-shaped convex part extending in a radial direction from the concave part, and is formed continuously and integrally in the axial direction of the round line. A stator for a rotating electrical machine characterized by being made. The stator for a rotating electrical machine according to claim 1,
The concavo-convex portion has a concave portion formed by an outer peripheral surface of the round wire and a convex portion extending in a radial direction from the outer peripheral surface, and the flat plate-like insulator is spirally and integrally formed in the axial direction of the round wire. A stator for a rotating electrical machine, characterized in that it is formed. A stator core formed by a plurality of laminated ferromagnetic plates and having a plurality of teeth extending from an annular yoke to the inner peripheral side;
An insulator disposed around the teeth;
A coil having an insulating coating around the conductor, and a round wire having a circular cross section wound around the winding surface of the insulator; and
The coil has a forming step of forming a plurality of concave and convex portions in which insulators are arranged at predetermined intervals in an axial direction of the round wire on an outer peripheral surface of the coating layer of the round wire, and the round wire is adjacent to the forming step. And a winding step of winding so that the concave and convex portions of the matching round wires are fitted to each other.

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