JP2016163500A - Rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator of a rotary electric machine having an excellent insulation quality and productivity, a rotator, and a rotary electric machine comprising them.SOLUTION: A stator of a rotary electric machine includes a stator core 132 to which a plurality of slots 420 are provided, and a stator coil 60 provided to the slot through insulation paper 300. N segment coils 28 (N is a positive even number) are provided to each of the slots, and the stator coil is constructed so that the plurality of segment coils is connected through a weld zone provided to a conductive end part 28E of the segment coil. The conductive end part is annularly arranged in a circumferential direction in a coil end of an axial direction, N annular lines are constructed, and the stator core is constructed so that a plurality of magnetic steel sheets 133 is laminated. A particle diameter of a crystal grain 910 of each magnetic steel sheet constructs the stator of rotary electric machine so as to be larger than a half of a plate thickness of the magnetic steel sheet.SELECTED DRAWING: Figure 12

Description

  The present invention relates to a stator of a rotating electrical machine, a rotor, and a rotating electrical machine including these.

  In response to the recent global warming, rotating electric machines, particularly rotating electric machines that generate torque for driving a car or generate electric power during braking, are required to have a small and high output. As such a rotating electrical machine, for example, it has a stator core having a large number of slots opened on the inner peripheral side, and a plurality of substantially U-shaped segment coils are inserted into each slot to improve the space factor. In order to increase the output by improving the cooling performance, it is known.

  And the stator of the vehicle alternator which prevented the dielectric breakdown by the burr | flash of a laminated steel sheet by making the insertion direction to the slot of a substantially U-shaped segment coil and the punching direction of the laminated steel sheet of a stator iron core into the same direction (For example, refer to Patent Document 1).

  In addition, the alternating current generator for a vehicle which prevents the insulation paper from shifting and prevents the insulation breakdown by reversing the insertion direction of the substantially U-shaped segment coil into the slot and the punching direction of the laminated steel sheet of the stator core. (For example, refer to Patent Document 2).

  Note that, in a rotating electrical machine in which a round wire is wound instead of a substantially U-shaped segment coil, attention is paid to the burr of the laminated steel sheet, and the insertion direction of the stator into the housing and the insertion direction of the rotor into the shaft are defined. There are some (see, for example, Patent Document 3).

Japanese Patent No. 3478182 Japanese Patent No. 3478183 JP 2008-199831 A

  Since the techniques of Patent Documents 1 and 2 are mainly intended for air-cooled and low-voltage (12 Vdc) vehicle AC generators, insulation by burr on the anti-connection side (segment insertion side) or connection side (anti-insertion side) It is only necessary to prevent destruction. However, in a rotating electric machine used for an electric vehicle or a hybrid electric vehicle, the voltage is as high as 150 to 300 Vdc (some of which are 600 Vdc by boosting), and a transformer such as direct liquid (for example, oil) cooling is used. Many are used in cases. Furthermore, since such a rotating electric machine has a high voltage, it is necessary to improve the insertion property of the segment coil, insulating paper, magnet, shaft, and housing by burr. Furthermore, it is necessary to prevent the core burr from falling off in terms of quality reliability.

  Further, in the techniques of Patent Documents 1 and 2, as shown in FIG. 1 of Patent Document 1 and FIG. 6 of Patent Document 2, the process of laminating steel sheet sheets is based on a wound core. Since all winding core burrs are in the same direction, it is only necessary to consider the direction of segment coil insertion and the direction of slot burr, but when punching and laminating steel sheet sheets using a punching die, the direction of burrs should be the same direction. Therefore, paying attention to the direction of the burrs other than the slot, it is necessary to improve the insertability and prevent the burrs from falling off. This is especially true when not only the stator core but also the rotor core is punched at the same time.

  On the other hand, since the technology of Patent Document 3 is based on a rotating electrical machine with a round wire wound, the examination of the slot burr and the coil insertion direction that are most likely to cause dielectric breakdown has not been sufficiently performed. Insufficient consideration is given to a rotating electrical machine having a voltage of 150 to 300 Vdc (some of which have a voltage of 600 Vdc due to boosting) used in an electric vehicle or a hybrid electric vehicle, in which reliability is a problem.

  Then, an object of this invention is to provide the stator of a rotary electric machine excellent in insulation and productivity, a rotor, and a rotary electric machine provided with these.

  In order to solve the above problems, for example, the configuration described in the claims is adopted.

  The present application includes a plurality of means for solving the above-described problems. To give an example, a stator core provided with a plurality of slots and a stator coil provided with insulating paper in the slots are provided. Each of the slots is provided with N segment coils (where N is a positive even number), and the stator coil is connected via a welded portion provided at a conductor end of each segment coil. In the stator of the rotating electrical machine, wherein the plurality of segment coils are connected, the conductor end is annularly arranged in the circumferential direction at one coil end in the axial direction, and an N-row annular row is configured. The stator iron core is formed by laminating a plurality of electromagnetic steel plates, and the grain size of crystal grains of the electromagnetic steel plates is larger than half of the thickness of the electromagnetic steel plates.

  ADVANTAGE OF THE INVENTION According to this invention, the stator of a rotary electric machine excellent in insulation and productivity, a rotor, and a rotary electric machine provided with these can be provided.

  Problems, configurations, and effects other than those described above will become apparent from the description of the following examples.

The schematic diagram which shows the whole structure of a rotary electric machine. The schematic diagram which shows the cross section which inserts a stator core into a housing. The perspective view which shows the stator coil for three phases wound around a stator core. It is a figure explaining the segment coil of a stator coil, (a) is a figure which shows one segment coil, (b) is a figure explaining coil formation by a segment coil, (c) is arrangement | positioning of the segment coil in a slot FIG. The perspective view which shows the stator coil of U1 phase wound around a stator core. The perspective view which shows the stator coil of U2 phase wound around a stator core. The perspective view which shows the stator coil of U phase wound around a stator core. The perspective view which shows the stator core of a rotary electric machine. The perspective view which shows the electromagnetic steel plate which comprises a stator core. Sectional drawing at the time of the press work of an electromagnetic steel plate. Sectional drawing at the time of press processing of an electromagnetic steel plate. Sectional drawing at the time of the press work of an electromagnetic steel plate. Sectional drawing at the time of the press work of an electromagnetic steel plate. Sectional drawing at the time of press processing of an electromagnetic steel plate. Sectional drawing at the time of press processing of an electromagnetic steel plate. The schematic diagram which shows the cross-sectional state of a stator core and a rotor core. The perspective view which shows the aspect which inserts insulating paper in a stator core. Sectional drawing which shows the state before combining each member. Sectional drawing which shows the state after combining each member. The perspective view which shows the aspect which inserts a stator coil in a stator iron core (another system). Sectional drawing which shows the state before combining each member (another system). Sectional drawing which shows the state after combining each member (another system). The perspective view of a rotor and a stator. The block diagram which shows the structure of the vehicle carrying a rotary electric machine.

Embodiments of the present invention will be described below with reference to the drawings.
In the following description, an electric motor used in a hybrid vehicle is used as an example of a rotating electric machine. In the following description, “axial direction” refers to a direction along the rotation axis of the rotating electrical machine. The circumferential direction refers to the direction along the rotational direction of the rotating electrical machine. The “radial direction” refers to a radial direction (radial direction) when the rotational axis of the rotating electrical machine is the center. “Inner circumference side” refers to the radially inner side (inner diameter side), and “outer circumference side” refers to the opposite direction, that is, the radially outer side (outer diameter side).

  FIG. 1 is a cross-sectional view showing a rotating electrical machine including a stator according to the present invention. The rotating electrical machine 10 includes a housing 50, a stator 20, a stator core 132, a stator coil 60, and a rotor 11.

  The stator 20 is fixed to the inner peripheral side of the housing 50. The rotor 11 is rotatably supported on the inner peripheral side of the stator 20. The housing 50 constitutes an outer casing of an electric motor that is formed into a cylindrical shape by cutting an iron-based material such as carbon steel, casting of cast steel or aluminum alloy, or pressing. The housing 50 is also referred to as a frame or a frame.

  A liquid cooling jacket 130 is fixed to the outer peripheral side of the housing 50. The inner peripheral wall of the liquid cooling jacket 130 and the outer peripheral wall of the housing 50 constitute a refrigerant passage 153 of a liquid refrigerant RF such as oil, and the refrigerant passage 154 is formed so as not to leak. The liquid cooling jacket 130 houses the bearings 144 and 145 and is also called a bearing bracket.

  In the case of direct liquid cooling, in the refrigerant RF, the liquid accumulated in the refrigerant (oil) storage space 150 passes through the refrigerant passage 153 and flows out from the refrigerant outlets 154 and 155 toward the stator 20 to cool the stator 20.

  The stator 20 includes a stator core 132 and a stator coil 60. The stator core 132 is formed by laminating thin sheets of silicon steel plates. The stator coil 60 is wound around a plurality of slots 420 provided in the inner periphery of the stator core 132. Heat generated from the stator coil 60 is transferred to the liquid cooling jacket 130 via the stator core 132 and is radiated by the refrigerant RF flowing through the liquid cooling jacket 130.

  The rotor 11 is composed of a rotor core 12 and a shaft 13. The rotor core 12 is made by laminating thin sheets of silicon steel plates. The shaft 13 is fixed to the center of the rotor core 12. The shaft 13 is rotatably held by bearings 144 and 145 attached to the liquid cooling jacket 130, and rotates at a predetermined position in the stator 20 at a position facing the stator 20. The rotor 11 is provided with a permanent magnet 18 and an end ring 19.

  As shown in FIG. 1, the rotating electrical machine 10 is disposed inside a liquid cooling jacket 130, and includes a housing 50, a stator 20 having a stator core 132 fixed to the housing 50, and this fixing. And a rotor 11 rotatably disposed in the child. The liquid cooling jacket 130 includes an engine case and a transmission case.

  The rotating electrical machine 10 is a three-phase synchronous motor with a built-in permanent magnet. The rotating electrical machine 10 operates as an electric motor for rotating the rotor 11 by supplying a three-phase alternating current to the stator coil 60 wound around the stator core 132. Further, when driven by the engine, the rotating electrical machine 10 operates as a generator and outputs three-phase AC generated power. That is, the rotating electrical machine 10 has both a function as an electric motor that generates rotational torque based on electric energy and a function as a generator that generates electric power based on mechanical energy. Functions can be used selectively.

  The stator 20 fixed to the housing 50 is fixedly held in the liquid cooling jacket 130 by fastening a flange 115 provided on the housing 50 to the liquid cooling jacket 130 with a bolt 15.

  The rotor 11 is fixed to a shaft 118 supported by bearings 144 and 145 of the liquid cooling jacket 130, and is rotatably held inside the stator core 132. A stator 20 that generates a rotating magnetic field, and a rotor 11 that is rotated by a magnetic action of the stator 20 and that is rotatably arranged via an inner peripheral side of the stator 20 and a gap 850 are provided. .

  The housing 50 and the stator 20 will be described with reference to FIG. FIG. 2 is a perspective view showing the housing 50 and the stator 20 of the rotating electrical machine 10 according to the first embodiment of the present invention.

  The housing 50 is formed in a cylindrical shape by drawing a steel plate (such as a high-tensile steel plate) having a thickness of about 2 to 5 mm. The housing 50 is provided with a plurality of flanges 115 attached to the liquid cooling jacket 130. The plurality of flanges 115 project outward in the radial direction at the periphery of one end surface of the cylindrical housing 50. Note that the flange 115 is formed by cutting away a portion other than the flange 115 at an end portion formed at the time of drawing, and is integrated with the housing 50.

-stator-
The stator 20 includes a stator coil 60 and a cylindrical stator core 132 to which the stator coil 60 is attached.

-Stator coil-
The stator coil 60 will be described with reference to FIGS. FIG. 3 is a perspective view showing a stator coil 60 for three phases. FIG. 4 is a diagram showing a winding method of the stator coil 60, and FIGS. 5-7 are U1-phase stator coil 60, U2-phase stator coil 60, and U-phase wound around the stator core 132, respectively. It is a perspective view which shows the stator coil 60 of.

  The stator coil 60 is wound in a distributed winding manner and connected in a star connection configuration. The distributed winding is a winding method in which the phase windings are wound around the stator core 132 so that the phase windings are housed in two slots 420 that are spaced apart from each other across the plurality of slots 420. In this embodiment, distributed winding is adopted as the winding method, so that the formed magnetic flux distribution is closer to a sine wave than concentrated winding, and has a feature that reluctance torque is likely to be generated. Therefore, this rotating electrical machine 10 has improved controllability using field-weakening control and reluctance torque, and can be used over a wide rotational speed range from a low rotational speed to a high rotational speed, and is suitable for an electric vehicle. Excellent motor characteristics can be obtained.

  The stator coil 60 constitutes a three-phase star-connected phase coil, and the cross section may be round or square, but the cross section inside the slot 420 is used as effectively as possible. Since a structure in which the space in the slot is reduced tends to lead to an improvement in efficiency, a square cross section is desirable in terms of improving the efficiency. The square shape of the cross section of the stator coil 60 may have a shape in which the circumferential direction of the stator core 132 is short and the radial direction is long, or conversely, the circumferential direction is long and the radial direction is short. It may be.

  In this embodiment, the stator coil 60 has a rectangular wire in which the rectangular cross section of the stator coil 60 is long in the circumferential direction of the stator core 132 and short in the radial direction of the stator core 132 in each slot 420. It is used. The rectangular wire has an outer periphery covered with an insulating film.

  The winding method of the stator coil 60 will be briefly described with reference to FIG. A copper wire insulated with enamel or the like having a substantially rectangular cross section is formed into a substantially U-shaped segment coil 28 with the apex 28C at the non-welding side coil end 61 as shown in FIG. 4A. To do. At this time, the non-welding side coil end 61 apex 28 </ b> C may have a substantially U shape so as to fold back the direction of the conductor. That is, the shape is not limited to a shape in which the apex 28C of the anti-welding side coil end 61 and the conductor skew portion 28F of the anti-welding side anti-welding side coil end 61 form a substantially triangular shape when viewed from the radial direction. For example, in a part of the apex 28C of the anti-welding side coil end 61C, the conductor is substantially parallel to the end face of the stator core 132 (when viewed from the radial direction, the apex 28C of the anti-welding side coil end 61C and the anti-welding side The shape may be such that the conductor skew portion 28F of the coil end 61 forms a substantially trapezoidal shape.

  The segment coil 28 is inserted into the status lot 420 from the axial direction. Connection is made as shown in FIG. 4B at another segment coil 28 inserted into a predetermined slot 420 away from the conductor end 28E (for example, by welding).

  At this time, the segment coil 28 has a conductor straight portion 28S that is a portion inserted into the slot 420 and a conductor skew portion 28D that is a portion inclined toward the conductor end portion 28E of the segment coil 28 to be connected. (The skewed portion 28D and the end portion 28E are formed by bending).

  2, 4, 6... (Multiple of 2) segment coils 28 are inserted into the slot 420. FIG. 4C shows an example in which four segment coils 28 are inserted in one slot 420. However, since the cross section is a substantially rectangular conductor, the space factor in the slot 420 can be improved. The efficiency of 10 is improved.

  FIGS. 5 and 6 are diagrams when the connection operation of FIG. 4B is repeated until the segment coil 28 becomes annular, and coils for one system (U1 phase and U2 phase, respectively) are formed. FIG. 7 is a diagram in which these are integrated as a U-phase coil. The coil for one phase is configured such that the conductor end 28E gathers in one axial direction, and forms a welding side coil end 62 and an anti-welding side coil end 61 where the conductor end 28E gathers. A coil for one phase is formed with a terminal for each phase at one end (U-phase terminal 41U in the example of FIG. 7) and a neutral wire 40 at the other end.

  As shown in FIG. 2, the stator coil 60 includes six coils (U 1, U 2, V 1, V 2, W 1, W 2) that are attached in close contact with the stator core 132. The six coils constituting the stator coil 60 are arranged at appropriate intervals by the slot 420.

  One coil end 140 of the stator coil 60 includes AC terminals 41 (U), 42 (V), 43 (W) which are coil conductors for input / output of the stator coils 60 of the UVW three-phase, A sex point connection conductor 40 is drawn out.

  In order to improve workability in assembling the rotating electrical machine 10, the AC terminals 41 (U), 42 (V), and 43 (W) for receiving the three-phase AC power are connected to the stator core 132 from the coil end 140. It is arranged so as to protrude outward in the axial direction. The stator 20 is connected to a power converter (not shown) via the AC terminals 41 (U), 42 (V), and 43 (W), so that AC power is supplied. .

  As shown in FIGS. 2 and 3, the coil end 140, which is a portion of the stator coil 60 that protrudes outward in the axial direction from the stator core 132, is provided with a crossover, and the overall arrangement is orderly. This has the effect of reducing the overall size of the rotating electrical machine 10. In addition, it is desirable that the coil end 140 is orderly from the viewpoint of improving the reliability with respect to the insulation characteristics.

  The stator coil 60 has a structure in which the outer periphery of the conductor is covered with an insulating film, and the electrical insulation is maintained. In addition to the insulating film, the insulation voltage is maintained by the insulating paper 300 (see FIG. 2). This is preferable because the reliability can be further improved.

  The insulating paper 300 is disposed in the slot 420 and the coil end 140. The insulating paper 300 (so-called slot liner) disposed in the slot 420 is disposed between the segment coils 28 inserted into the slot 420 and between the segment coil 28 and the inner surface of the slot 420, and between the segment coils. In addition, the withstand voltage between the segment coil 28 and the inner surface of the slot 420 is improved.

  The insulating paper 300 disposed at the coil end 140 is used by being annularly disposed between the segment coils for interphase insulation and interconductor insulation at the coil end 140. Further, the insulating paper 300 serves as a holding member that prevents dripping when a resin member (for example, polyester or epoxy liquid varnish) is dropped on the whole or a part of the stator coil 60.

  As described above, in the rotating electrical machine 10 according to the present embodiment, since the insulating paper 300 is disposed inside the slot 420 and at the coil end 140, even if the insulating coating is damaged or deteriorated, the required withstand voltage is achieved. Can be held. The insulating paper 300 is an insulating sheet of heat-resistant polyamide paper, for example, and has a thickness of about 0.1 to 0.5 mm.

  The entire stator coil is covered with a resin member to enhance insulation. Alternatively, the first resin member (for example, polyester or epoxy liquid varnish) is dropped on the whole or a part of the stator coil and cured. In order to reinforce the insulation of the welded portion, the vicinity of the welded portion may be covered with a second resin member (for example, an epoxy-based powder varnish).

-Stator core-
The stator core 132 will be described with reference to FIGS. 8 and 9. FIG. 8 is a perspective view showing the stator core 132, and FIG. 9 is a perspective view showing the electromagnetic steel sheet 133 constituting the stator core 132. As shown in FIG. 8, the stator core 132 is formed such that a plurality of slots 420 parallel to the axial direction of the stator core 132 are equally spaced in the circumferential direction.

  The number of slots 420 is 72 in the present embodiment, for example, and the stator coil 60 described above is accommodated in the slot 420. The inner circumferential side of each slot 420 is an opening, and the circumferential width of this opening is substantially the same as or slightly smaller than the coil mounting portion of each slot 420 to which the stator coil 60 is mounted. Yes.

  Teeth 430 are formed between the slots 420, and each tooth 430 is integrated with an annular core back 440. That is, the stator core 132 is an integrated core in which the teeth 430 and the core back 440 are integrally formed.

  The teeth 430 serve to guide the rotating magnetic field generated by the stator coil 60 to the rotor 11 and generate a rotating torque in the rotor 11.

  The stator iron core 132 is formed by punching a magnetic steel sheet 133 (see FIG. 9) having a thickness of about 0.05 to 1.0 mm and laminating a plurality of formed annular magnetic steel sheets 133. The welded portion 200 is provided in parallel to the axial direction of the stator core 132 at the outer peripheral portion of the cylindrical stator core 132 by TIG welding, laser welding, or the like. As shown in FIG. 8, the welded portion 200 is formed in a semicircular weld groove provided in advance on the outer peripheral portion of the stator core 132, and the welded portion 200 is formed radially outward of the stator core 132. It does not protrude.

  A punching process of the electromagnetic steel sheet 133 by a die (in this embodiment, a punch 850 and a die 860) will be described with reference to FIGS. In addition, these figures represent the state seen from the cross section of the electromagnetic steel sheet 133.

  As shown in FIG. 10, the crystal grains 910 of the electromagnetic steel sheet 133 are formed with a particle diameter that is approximately half the plate thickness. For example, when the thickness of the stator core 132 is 0.3 mm, the crystal particle diameter of this embodiment is approximately 0.15 mm. Thereby, generation | occurrence | production of the burr | flash (burr | ring) at the time of punching by a press process with the punch 850 and the die | dye 860 can be suppressed. That is, since the crystal grains 910 are large, the crystal grains are easily split, and the generation of burrs can be suppressed because the material is relatively hard, brittle, and has little elongation.

  As shown in FIG. 10, the electromagnetic steel sheet 133 is held by the die 860 and the punch 850 is lowered.

  FIG. 11 shows a state in which the punch 850 is pressed against the electromagnetic steel sheet 133. The punch 850 generates an R-shaped sag 800 on the electromagnetic steel sheet 133 to form a shear surface 801.

  As shown in FIG. 12, punching is completed in a state where the punch 850 has entered half or more of the thickness of the electromagnetic steel sheet 133. Since the grain size of the crystal grains 910 of the electromagnetic steel sheet 133 is formed to be more than half of the plate thickness of the electromagnetic steel sheet 133, the particle splitting occurs relatively easily and has a fracture surface 810. However, the generation of burrs can be suppressed.

  FIG. 13 shows a state in which the electromagnetic steel plate 133 is held by the die 860 and the punch 850 is lowered as in FIG.

  FIG. 14 shows a state where the punch 850 is pressed against the electromagnetic steel sheet 133. Therefore, an R-shaped sag 800 is generated by the punch 850 and a shearing surface 801 is formed.

  As shown in FIG. 15, punching is completed in a state where the punch 850 has entered half or more of the thickness of the electromagnetic steel sheet 133. Since the grain size of the crystal grains 910 of the electromagnetic steel sheet 133 is formed to be more than half of the plate thickness of the electromagnetic steel sheet 133, the particle splitting occurs relatively easily and has a fracture surface 810. However, the occurrence of burrs can be suppressed. For this reason, even if the clearance between the die 860 and the punch 850 is set relatively large, the generation of burrs can be suppressed.

  FIG. 16 is a cross-sectional view showing a state where the rotor core 12 is inserted on the inner peripheral side of the stator core 132 of the present embodiment. For reference, a perspective view of this state is shown in FIG.

  In the stator core 132 according to the present embodiment, as shown in FIG. 16, the direction of the sag 800 surface of the slot 420 of the stator core 132 and the inner diameter of the stator core 132 and the sag 800 surface of the outer diameter of the stator core 132. Reverse the direction. In other words, the direction of the fracture surface 810 is made different between the inner diameter side and the outer diameter side of the stator core 132.

  By reversing the sagging 800 direction (fracture surface 810 direction), the insulating paper 300 can be inserted from the sagging 800 direction as shown in FIG. 17, and from the outer diameter of the stator core 132 as shown in FIGS. When inserted into the housing 50, it can be inserted from the direction of the sag 800 that is inverted. By doing in this way, the insertability of the insulating paper 300 and the housing 50 can be improved. Further, the insulating paper 300 is not easily damaged when inserted, and the possibility that burrs and facets fall off and remain in the slot is reduced, so that the insulation is improved.

  At this time, the segment coil 28 is inserted from the direction of the fracture surface 810, but may be inserted from the direction of the sag 800 as shown in FIGS.

  Even when directly attaching to the liquid cooling jacket 130 or the like without the housing 50, by attaching the stator core 132 from the direction of the sag 800, it is possible to suppress the burrs from falling off and to suppress the generation of gaps due to burrs. Reliability is also improved.

  Further, in this embodiment, a space is formed in the insulating paper 300 and the slot 420 and the contact area is reduced, so that the insulation between the stator coil 60 and the stator core 132 is improved.

  In addition, a space is created between the insulating paper 300 and the slot 420. That is, since the contact area is reduced, the force for inserting the stator coil 60 can be reduced.

  In addition, even if the insulating paper 300 is made of aramid paper or the like and has a relatively rough surface, the contact area to the slot 420 when inserted into the slot 420 is reduced, so that the insulating paper 300 is not easily caught and the insertability is improved. To do.

  Further, in this embodiment, since a space is formed between the insulating paper 300 and the slot 420, the varnish easily penetrates between the slots 420, and the insulating paper 300 and the stator coil 60 can be fixed with the varnish between the slots 420, thereby stabilizing. . In addition, the varnish accumulates in the voids, and further, the varnish permeability is improved, so that the insulating property is also improved.

  Note that burrs can be made less likely to occur by adjusting not only the particle size 910 of the electromagnetic steel sheet 133 but also the clearance and punching pressure between the punch 850 and the die 860 during punching.

  Furthermore, it is also possible to arbitrarily change the direction of the sag 800 of the electromagnetic steel sheet 133 by changing the die punching direction in consideration of the assembling property of the rotating electrical machine 10.

  As shown in FIGS. 2, 18-19, and 21-22, the stator core 132 is fitted and fixed inside the housing 50 by shrink fitting. As a specific assembling method, for example, a stator core 132 is first arranged, and a housing 50 that has been heated in advance and expanded in inner diameter by thermal expansion is fitted into the stator core 132. Next, by cooling the housing 50 and shrinking the inner diameter, the outer periphery of the stator core 132 is tightened by the heat shrinkage.

  The stator core 132 has an inner diameter dimension of the housing 50 that is smaller than an outer diameter dimension of the stator core 132 by a predetermined value so that the stator core 132 does not idle with respect to the housing 50 due to a reaction caused by the torque of the rotor 11 during operation. The stator core 132 is firmly fixed in the housing 50 by shrink fitting.

  Here, the difference between the outer diameter of the stator core 132 at normal temperature and the inner diameter of the housing 50 is referred to as a tightening allowance. By setting this tightening allowance assuming the maximum torque of the rotating electrical machine 10, the housing 50 is predetermined. The stator core 132 is held by the tightening force.

  The welded portion 200 provided on the stator core 132 connects the laminated electromagnetic steel plates 133 and suppresses deformation of the electromagnetic steel plates 133 due to the tightening force of the housing 50.

  The stator core 132 is not limited to being fitted and fixed by shrink fitting, but may be fixed to the housing 50 by press fitting.

―Rotor―
Next, the rotor 11 will be described with reference to FIGS. FIG. 23 is a perspective view showing the rotor 11 and the stator 20. In addition, in order to avoid complexity, the stator coil 60 and the insulating paper 300 accommodated in the shaft 13 and the slot 420 are omitted.

  The rotor 11 has a rotor core 12 and a permanent magnet 18 held in a magnet insertion hole 159 formed in the rotor core 12.

-Rotor core-
In the rotor core 12, rectangular parallelepiped magnet insertion holes 159 are formed at equal intervals in the circumferential direction near the outer periphery, and permanent magnets 18 are embedded in the magnet insertion holes 159 and fixed with an adhesive or the like. ing. The circumferential width of the magnet insertion hole 159 is larger than the circumferential width of the permanent magnet 18, and magnetic gaps 156 are formed on both sides of the permanent magnet 18. The magnetic gap 156 may be embedded with an adhesive, or may be solidified integrally with the permanent magnet 18 with a resin. Furthermore, depending on use conditions, there may be a clearance in which the magnet can be inserted only by the magnet.

-permanent magnet-
The permanent magnet 18 forms the field pole of the rotor 11. In this embodiment, one magnetic pole is formed by one permanent magnet 18, but one magnetic pole may be formed by a plurality of permanent magnets. By increasing the number of permanent magnets for forming each magnetic pole to a plurality, the magnetic flux density of each magnetic pole emitted from the permanent magnet increases, and the magnet torque can be increased.

  The magnetization direction of the permanent magnet 18 faces the radial direction, and the direction of the magnetization direction is reversed for each field pole. That is, if the surface on the stator side of the permanent magnet 18 for forming a certain magnetic pole is magnetized to the N pole and the surface on the shaft side is magnetized to the S pole, the stator side of the permanent magnet 18 that forms the adjacent magnetic pole is assumed. The surface is magnetized so as to be the south pole and the shaft side surface is the north pole. In this embodiment, the 12 permanent magnets 18 are magnetized so that the magnetization direction changes alternately for each magnetic pole at equal intervals in the circumferential direction, so that the rotor 11 forms 12 magnetic poles. ing.

  The permanent magnet 18 may be embedded in the magnet insertion hole 159 of the rotor core 12 after being magnetized, or may be inserted into the magnet insertion hole 159 of the rotor core 12 before being magnetized, and then a strong magnetic field is applied thereto. It may be magnetized.

  However, the magnetized permanent magnet 18 has a strong magnetic force. If the magnet is magnetized before the permanent magnet 18 is fixed to the rotor 11, the permanent magnet 18 is strongly attracted to the rotor core 12 when the permanent magnet 18 is fixed. A force is generated, and this suction force hinders work. Further, dust such as iron powder may adhere to the permanent magnet 18 due to the strong attractive force. Therefore, it is desirable to magnetize the permanent magnet 18 after inserting it into the magnet insertion hole 159 of the rotor core 12 in order to improve the productivity of the rotating electrical machine 10. Here, neodymium-based, samarium-based sintered magnets, ferrite magnets, neodymium-based bonded magnets, and the like can be used for the permanent magnet 18, but the residual magnetic flux density of the permanent magnet 18 is 0.4-1. About 3T is desirable, and a neodymium magnet is more suitable.

  In this embodiment, the auxiliary magnetic pole 160 is formed between the permanent magnets 18 forming the magnetic pole. The auxiliary magnetic pole 160 acts so that the magnetic resistance of the q-axis magnetic flux generated by the stator coil 60 is reduced. The auxiliary magnetic pole 160 causes the magnetic resistance of the q-axis magnetic flux to be much smaller than the magnetic resistance of the d-axis magnetic flux, so that a large reluctance torque is generated.

  When a rotating magnetic field is generated in the stator 20 by supplying the three-phase alternating current to the stator coil 60, the rotating magnetic field acts on the permanent magnet 18 of the rotor 11 to generate magnet torque. That is, since the above-described reluctance torque is generated in the rotor 11 in addition to this magnet torque, both the above-described magnet torque and reluctance torque act on the rotor 11 as the rotational torque, resulting in a large rotation. Torque can be obtained.

  As shown in FIG. 16, the rotor core 12 in the present embodiment includes a magnet insertion hole 159 of the rotor core 12, a shear surface 801 (sagging 800 side) of the inner diameter of the rotor core 12, and an outer side of the rotor core 12. The direction of the shearing surface 801 having a diameter (sagging 800 side) is reversed. That is, the direction of the shear surface 801 is reversed between the inner diameter side and the outer diameter side. Thereby, the insertability of the shaft 118, the permanent magnet 18, and the stator 20 and the rotor 11 can be improved. Since the possibility of burrs falling off and remaining in the motor during insertion is reduced, reliability is also improved.

  Further, since no burrs are generated on the punched surface of the rotor core 12, the contact surface with the permanent magnet 18 is reduced. Therefore, the eddy current path is eliminated and the rotor eddy current loss can be reduced.

  Also when inserting into the stator 20, by inserting from the direction of the sag 800 of the rotor 11, the possibility of damaging the coil coating of the stator coil 60 of the stator 20 is reduced, the insulation is improved, and workability is improved. Will improve. Further, since the burrs are not peeled off at the time of insertion and the face is not generated, the reliability is improved.

  As described above, according to the present invention, it is possible to provide a stator for a rotating electrical machine that has excellent insulation properties despite its small size and high output.

  A configuration example of a vehicle when the rotating electrical machine according to the present invention is applied to the vehicle will be described with reference to FIG. FIG. 24 is a schematic diagram showing a powertrain of a hybrid vehicle on the premise of four-wheel drive. As main power on the front wheel side, an engine and a motor (the rotating electrical machine 10 described in the embodiment) are included. The power generated by the engine and the motor is shifted by the transmission and transmitted to the front wheel drive wheels. In driving the rear wheel, the motor disposed on the rear wheel side and the rear wheel side driving wheel are mechanically connected to transmit power.

  The motor starts the engine, and switches between generation of driving force and generation of electric power for recovering energy at the time of vehicle deceleration as electric energy according to the running state of the vehicle. The driving and power generation operation of the motor are controlled by the power converter so that the torque and the rotational speed are optimized in accordance with the driving situation of the vehicle. Electric power necessary for driving the motor is supplied from the battery via the power converter. Further, when the motor is in a power generation operation, the battery is charged with electric energy via the power converter.

  Here, the motor (rotating electrical machine 10), which is the power source on the front wheel side, is disposed between the engine and the transmission. As the motor that is the driving force source on the rear wheel side, the rotating electrical machine 10 can be used, or a rotating electrical machine having another general configuration can be used.

  Of course, the rotating electrical machine of the present invention can also be applied to hybrid systems other than the four-wheel drive system. As an application example of the present invention, description has been made with reference to a rotating electric machine for an electric vehicle or a hybrid electric vehicle. However, if there are similar problems, an alternator, a starter generator (including a motor generator), an electric compressor, an electric pump As a matter of course, the automobile auxiliary motors such as automobiles can be applied to industrial motors such as elevators and motors for household appliances such as air conditioner compressors.

  In the above description, the permanent magnet type rotating electric machine has been described. However, the rotor is not a permanent magnet type, but can be applied to an induction type, a synchronous reluctance, a claw magnetic pole type, or the like. In addition, the winding method is a wave winding method, but any winding method having similar characteristics can be applied. Next, the explanation is made with the inner rotation type, but the same applies to the outer rotation type.

  In addition, this invention is not limited to an above-described Example, Various modifications are included. For example, the above-described embodiments have been described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described. In addition, it is possible to add, delete, and replace other configurations for a part of the configuration of the embodiment.

DESCRIPTION OF SYMBOLS 10 Rotating electric machine 11 Rotor 12 Rotor core 13 Shaft 15 Bolt 18 Permanent magnet 19 End ring 20 Stator 28 Segment coil 28C Anti-welding side coil end vertex 28D Connection side segment coil coil skew part 28E Conductor end part 28F Anti-connection side Segment coil Coil skew section 40 Neutral point connection conductor 41 AC terminals (U), 42 (V), 43 (W)
DESCRIPTION OF SYMBOLS 50 Housing 60 Stator coil 61 Anti-welding side coil end 62 Welding side coil end 115 Flange 130 Liquid cooling jacket 132 Stator iron core 133 Electrical steel sheet 140 Coil end 144 Bearing 145 Bearing 150 Refrigerant (oil) storage space 153 Refrigerant passage 154 Refrigerant outlet 155 Refrigerant outlet 159 Magnet insertion hole 200 Welding part 201 Caulking part 210 Welding groove 300 Insulating paper 420 Slot 430 Teeth 440 Core back 800 Sag 801 Shear surface 810 Broken surface 850 Punch 860 Die 910 Crystal grain

Claims (6)

A stator core provided with a plurality of slots, and a stator coil provided with insulating paper in the slots;
Each said slot is provided with N (where N is a positive even number) segment coil,
The stator coil is configured by connecting a plurality of the segment coils via a welded portion provided at a conductor end of each segment coil,
In the stator of the rotating electrical machine, the conductor end portion is annularly arranged in the circumferential direction at one coil end in the axial direction, and an N-row annular row is configured.
The stator core is configured by laminating a plurality of electromagnetic steel plates,
A stator of a rotating electrical machine in which the grain size of the crystal grain of the electrical steel sheet is larger than half of the thickness of the electrical steel sheet. A stator for a rotating electrical machine according to claim 1,
The stator steel core electromagnetic steel sheet is a stator of a rotating electrical machine in which the direction of the sag surface on the radially outer peripheral side is different from the direction of the sag surface on the radially inner peripheral side. A rotor core provided with a plurality of magnet insertion holes;
A magnet inserted into the magnet insertion hole,
A rotor of a rotating electrical machine having an inner diameter hole for inserting a shaft or the like on the inner diameter side,
The rotor core is configured by laminating a plurality of electromagnetic steel plates,
A rotor of a rotating electrical machine in which the grain size of crystal grains of the electrical steel sheet is larger than half of the thickness of the electrical steel sheet. A rotor for a rotating electrical machine according to claim 3,
The electromagnetic steel sheet of the rotor core is a stator of a rotating electrical machine in which the direction of the sag surface on the radially outer peripheral side is different from the direction of the sag surface on the radially inner peripheral side. A stator for a rotating electrical machine according to claim 1 or 2,
A rotary electric machine comprising: the rotary electric machine rotor according to claim 3. The rotating electrical machine according to claim 5,
A rotating electrical machine in which a direction of a sag surface on the radially inner peripheral side of the stator core is different from a direction of a sag surface on a radially outer peripheral side of the rotor core.

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