JP2018160955A - Rotary electric machine coil, and manufacturing method of rotary electric machine coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotary electric machine coil capable of reducing energy consumption required for fixing a winding, and of suppressing thermal deterioration; and to provide a manufacturing method of the rotary electric machine coil.SOLUTION: According to a rotary electric machine coil C comprising a cylindrical insulator 12 surrounding a core member (stator core 11), and a winding 14 cylindrically wound around an outer circumference of the insulator 12; a fusion layer 14c made of a thermosetting resin is provided on a surface of the winding 14. After the winding 14 is wound around the insulator 12, electricity is carried to the winding 14, and the fusion layer 14c is cured with Joule heat by carrying the electricity thereto to fix windings 14 adjacent to each other.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a coil constituting a stator or the like of a rotating electrical machine.

In a rotating electrical machine, a winding is fixed in a wound state so that the winding constituting the coil does not loosen or shift in position during operation.
For example, in Patent Document 1, after winding a coil coated with a thermosetting resin and forming a coil, the coil is heated, the thermosetting resin (crosslinked precursor resin) is melted and thermoset, The winding is fixed.

JP 2004-242414 A

By the way, Patent Document 1 discloses a technique in which a stator around which a winding is wound is put into an electric heating furnace, and the coil is heated to thermally cure the thermosetting resin.
In the case of such a heating method, since the configuration other than the winding such as the stator core must be heated, there is a problem that the energy consumption required for the heating becomes larger than necessary.
In addition, in heating by a heating furnace, it takes time for the inside of the stator to reach a set temperature, so that the surface of the stator is exposed to a high temperature environment in the furnace for a longer time, and thermal degradation is promoted. There's a problem.

  The present invention has been made in view of the foregoing points, and reduces the energy consumption required for fixing the windings, and can manufacture a coil for a rotating electrical machine that can suppress thermal degradation and a coil for a rotating electrical machine. It aims to provide a method.

  In order to achieve the above object, a coil for a rotating electrical machine according to the present invention includes an insulator having a cylindrical shape surrounding the periphery of a core member, and a winding wound in a cylindrical shape on the outer periphery of the insulator. The winding is provided with a fusion layer made of a thermosetting resin on the surface, and after being wound around the insulator, the fusion layer is cured by Joule heat by energization, and the adjacent windings are fixed. It is characterized by that.

  ADVANTAGE OF THE INVENTION According to this invention, while reducing the energy consumption required for fixation of a coil | winding, the manufacturing method of the coil for rotary electric machines which can suppress thermal deterioration, and the coil for rotary electric machines can be provided.

It is a disassembled perspective view which shows the structure which concerns on one Embodiment. It is a disassembled perspective view which shows the stator segment which concerns on one Embodiment. It is a front view which shows the stator segment which concerns on one Embodiment. It is sectional drawing along the axial direction of the coil | winding which concerns on one Embodiment. The coil for rotary electric machines which concerns on one Embodiment is shown, (a) is the winding start of winding, (b) is the winding end of winding, (c) is sectional drawing along the Vc-Vc line of (b). is there. 3A and 3B are enlarged views of a main part showing a VI part of FIG. 3, in which FIG. 3A shows a state in which the winding is inserted into the narrow groove, and FIG. 3B shows a state in which the winding is accommodated in the wide groove. 6A is a cross-sectional view taken along the line VIIa-VIIa in FIG. 6A, showing a state where the winding is inserted into the narrow groove, and FIG. 6B is a cross-sectional view taken along the line VIIb-VIIb in FIG. In the figure, the winding is shown in the wide groove. It is a graph which shows the heating pattern at the time of energization heating. The coil for rotary electric machines which concerns on 1st another aspect is shown, (a) is the winding start of winding, (b) is the winding end of winding, (c) is the cross section along the IXc-IXc line of (b) FIG. The coil for rotary electric machines which concerns on 2nd another aspect is shown, (a) is the winding start of winding, (b) is the winding end of winding, (c) is the cross section along the Xc-Xc line of (b) FIG.

An embodiment of the present invention will be described in detail with reference to the drawings. In the description, the same elements are denoted by the same reference numerals, and redundant description is omitted.
FIG. 1 is an exploded perspective view showing a structure 102 provided with a rotating electrical machine coil according to the present embodiment. The rotating electrical machine 101 is a three-phase AC type, and is mounted on a vehicle such as a hybrid vehicle or an electric vehicle, and functions as a traveling motor when electric power is supplied from the outside, and as a generator during regenerative braking. Function.
In addition, the coil C for rotary electric machines of this embodiment is applicable not only to the rotary electric machine 101 for vehicles but to a fixed motor, a motor for other uses, and a generator.
Moreover, the upper and lower in the description indicate the upper and lower in the drawing, and do not indicate the upper and lower in a state where the rotating electrical machine 101 is assembled to the vehicle.

As shown in FIG. 1, the structure 102 constitutes the stator 104 side when the rotating electrical machine 101 is divided into a rotor (not shown) side and a stator 104 side.
The structure 102 includes a stator 104, a stator holder 105, and a case 106.
The stator 104 has a substantially cylindrical shape, and a rotor (not shown) is disposed in the cylinder. Details of the stator 104 will be described later.
The stator holder 105 has a substantially cylindrical shape, and holds the stator 104 in the cylinder.
The case 106 has a substantially cylindrical shape, and holds the stator holder 105 holding the stator 104 in the cylinder. Further, the case 106 rotatably supports a rotor (not shown) disposed in the cylinder of the stator 104.

Next, the stator 104 will be described again.
As shown in FIG. 1, the stator 104 includes a plurality of stator segments 10 having a substantially fan shape, and the stator segments 10 are arranged in an annular shape. The plurality of stator segments 10 arranged in an annular shape are integrally held by being inserted into the cylinder of the stator holder 105. As a result, the plurality of stator segments 10 can be handled as a single component stator 104.
The stator segment 10 includes a stator core 11, an insulator 12, and a coil body 13 as shown in FIG.
The rotating electrical machine coil C includes an insulator 12 and a coil body 13.

  As shown in FIG. 2, the stator core (core member) 11 is configured by laminating thin plate-like magnetic steel plates 11 a punched in a substantially T shape. The stator core 11 is set to a yoke 11b that forms a T-shaped horizontal side and a tooth 11c that forms a T-shaped vertical side.

The insulator 12 is formed of an insulating resin material. The insulator 12 has a substantially rectangular tube shape that can be divided into two along the axial direction of the stator 104, and the teeth 11c of the stator core 11 are sandwiched in the tube.
The insulator 12 includes a winding tube portion 12a, an inner diameter side jaw portion 12b, an outer diameter side jaw portion 12c, a partition wall portion 12d, and a collecting wiring housing portion 12e.

The wound cylinder portion 12a mainly forms a rectangular tube shape of the insulator 12, and is formed so as to surround the teeth 23b without a gap.
The inner diameter side jaw portion 12b is erected in a flange shape at the inner diameter side end portion (the upper end portion in FIG. 2) of the winding tube portion 12a.
The outer diameter side jaw portion 12c is erected in a flange shape at the outer diameter side end portion (lower end portion in FIG. 2) of the winding tube portion 12a.
The inner diameter side jaw portion 12b, the winding tube portion 12a, and the outer diameter side jaw portion 12c form a winding groove 12f having a rectangular cross section. And the coil | winding 14 which comprises the coil main body 13 is wound in this winding groove | channel 12f. That is, the coil body 13 is accommodated in the winding groove 12f.

The partition wall portion 12d is configured by a front portion of the outer-diameter side jaw portion 12c in FIG. 3, and partitions the wiring collection housing portion 12e and the winding groove 12f.
Moreover, the terminal fixing | fixed part 12h is formed in 12d of partition walls.

The terminal fixing portion 12h is engaged with the lead wire 13a (the winding start and winding end of the coil main body 13 in the winding 14) so that the wound winding 14 does not loosen or unwind before being fixed by fusion. Accommodates while matching.
Further, as shown in FIGS. 2 and 3, the terminal fixing portion 12h is formed by a notch groove that penetrates the partition wall portion 12d and communicates the collecting wiring housing portion 12e and the winding groove 12f.
As shown in FIGS. 7A and 7B, the terminal fixing portion 12h has a substantially T-shape with a narrow groove 12h1 and a wide groove 12h2.
The width of the narrow groove 12h1 is set similarly to the width dimension of the narrow surface 14n of the winding 14 described later.
The width of the wide groove 12h2 is set similarly to the width dimension of the wide surface 14w of the winding 14.

As shown in FIG. 3, the collection wiring housing portion 12 e is located on the radially outer side (upward in FIG. 3) of the winding tube portion 12 a in the front portion of the stator segment 10, and has a rectangular shape with the partition wall portion 12 d as the inner wall. It has a cross-sectional groove shape.

In addition, the collecting and wiring accommodating portion 12e forms a groove that is connected in an annular shape with the partition wall portion 12d as an inner wall in a state where the stator segments 10 are assembled in an annular shape (state of the stator 104). And the collection wiring accommodation part 12e accommodates the collection wiring (not shown) provided for every three phases (U phase, V phase, W phase), and a neutral wire (not shown).
The collecting wiring and the neutral wire are used for collecting the lead wires 13a of the coil main bodies 13 for each phase, and electrically connecting the power circuit (not shown) provided outside the rotating electrical machine 101 and the coil main bodies 13 to each other. Connect to.

As shown in FIGS. 2 and 3, the coil body 13 is formed of a so-called concentrated winding coil in which a winding 14 is wound around the teeth 11 c for each stator segment 10. Further, the lead wire 13a of the coil body 13 has both the winding start side and the winding end side drawn out to the wiring collection portion 12e (outside in the radial direction) and fixed to the terminal fixing portion 12h.
In addition, the coil | winding 14 which comprises the coil main body 13 is comprised by the flat wire which has a rectangular cross section.

  The coil | winding 14 which comprises the coil main body 13 is comprised by the flat wire which consists of a copper material which has a cross-sectional substantially rectangular shape, as shown in FIG. As shown in FIG. 4, an enamel layer 14b as an insulating film is formed on the surface of the core wire 14a. Further, a fusion layer 14c is formed outside the enamel layer 14b. In other words, the winding 14 has the fusion layer 14c formed on the enameled wire.

The fusing layer 14c is made of a thermosetting resin made of an epoxy resin that melts and cures at about 150 ° C. or higher.
The rotating electrical machine 101 of the present embodiment rises to about 135 ° C. when the installed vehicle is in a general traveling state, and reaches about 160 ° C. in a severe traveling state.
That is, the fusion layer 14c is made of a thermosetting resin that melts and cures at a temperature lower than the maximum temperature that the rotating electrical machine 101 reaches during operation.
Further, the fusion layer 14 c is formed on the entire winding 14 including the start and end of winding of the coil body 13. That is, the entire winding 14 including the start and end of winding of the coil body 13 is fixed by melting and curing the fusion layer 14c.

Next, the assembly procedure of the structure 102 will be described.
First, the coil body 13 is formed for each stator segment 10 (winding process). In this step, first, a predetermined number of magnetic steel plates 11a are laminated to form the stator core 11, and the insulator 12 is assembled to the stator core 11 (see FIG. 2).
Next, the coil 14 is wound around the winding groove 12 f of the insulator 12 to form the coil body 13. When winding the winding 14, the winding 14 is wound from the upper side to the lower side so that the wide surface 14w of the winding 14 faces the outer peripheral surface of the winding tube portion 12a (FIG. 5A). (See (b)).

When the winding 14 reaches the lower end of the winding groove 12f, the winding 14 is rewound upward. The winding groove 12f is reciprocated several times up and down, and when the winding 14 having a set length is wound, the winding is finished.
Next, the winding start portion and winding end portion of the lead wire 13a are engaged with and accommodated in the terminal fixing portion 12h. When accommodating, the winding 14 is first twisted so that the narrow surface 14n of the winding 14 faces the terminal fixing portion 12h. Then, the twisted winding 14 is inserted from the narrow groove 12h1 into the wide groove 12h2. Further, the winding 14 in the wide groove 12h2 is twisted back to engage the lead wire 13a with the terminal fixing portion 12h (see FIGS. 6A, 6B, 7A, and 7B).
As described above, the slack of the winding 14 is prevented and the winding process is completed.

Next, as shown in FIG. 1, the stator segments 10 are temporarily assembled in an annular shape so that they can be inserted into the stator holder 105 (coil fixing step).
Next, the stator segment 10 is inserted into the cylinder of the stator holder 105 (holder press-fitting process). Further, in this step, the stator segment 10 is assembled into the case 106 together with the stator holder 105.
Next, the lead wire 13a, the collecting wiring (not shown), and the terminal (not shown) are connected for each of the three phases and the neutral wire (terminal processing step).
Next, the winding 14 is energized, heated by Joule heat generated by energization (energization heating), the fusion layer 14c is melted and cured, and the winding 14 is fixed (heating step). . Further, the windings 14 are fixed to each other by energization heating, and the fusion layer 14c is fused and hardened in the wide groove 12h2, and the winding 14 is fixed in the wide groove 12h2.

As shown in FIG. 8, the heating pattern in the heating process follows a predetermined temperature increase rate (temperature increase gradient) at a rate of temperature increase per time, and is constant at a set curing temperature (150 ° C. in this embodiment). And And the electric energy which supplies with electricity is controlled so that it may become such a heating pattern.
When energization heating is started and the temperature of the winding 14 reaches the set curing temperature (150 ° C.), the fusion layer 14 c starts to melt.
When the winding 14 is maintained at the set curing temperature, the melted fusion layer 14c is gradually cured from the melted state by a crosslinking reaction.
Further, when the winding 14 is maintained at the set curing temperature, the fusion layer 14c is integrated with the fusion layer 14c of the winding 14 adjacent to the periphery when the winding 14 is cured, and the winding 14 is fixed.
The thermosetting resin is not cured after all is melted, but is cured from the melted position, so that the winding 14 is not loosened during energization heating.

The set curing temperature is set according to the employed thermosetting resin.
Moreover, in this embodiment, in order to suppress the thermal deterioration of the coil main body 13 due to energization heating, the rate of temperature increase per unit time (temperature increase gradient) is constant regardless of the set curing temperature. For this reason, the lower the set curing temperature, the shorter the time from the start of energization heating until the set curing temperature is reached. As a result, it is possible to reduce energy consumption required for fixing the winding 14 while suppressing thermal degradation.

On the other hand, when a thermoplastic resin is used for the fusion layer 14c, a resin that melts and softens at about 200 ° C. must be selected.
This is because the temperature of the coil body 13 reaches 160 ° C. in a severe running state, and in the thermoplastic resin that melts at a temperature lower than this, the fusion layer may melt during operation and the winding may be loosened. Because there is.
However, since the coil body 13 is heated to promote thermal degradation, it is desirable to avoid heating the coil body 13 to a temperature higher than that reached during operation during the assembly process.
That is, the fusion layer 14c is required to be a material that is fused and cured at a lower temperature. In FIG. 8, a thermosetting resin that melts and cures at 100 ° C. is described as a reference example for comparison of energization time.

Next, the effect of the coil C for rotary electric machines which concerns on this embodiment is demonstrated.
In the present embodiment, when the winding 14 is fixed, the fusion layer 14c made of a thermosetting resin is melted and cured by Joule heat generated by energization of the winding.
By using such a method, it is possible to heat only the winding 14 provided with the fusion layer 14c. Thereby, energy consumption can be reduced compared with the conventional method of heating the whole stator using a heating furnace (not shown).
Further, since the fusion layer 14c is directly heated, the heating time for curing the fusion layer 14c can be shortened, and thermal deterioration of the coil body 13 can be suppressed.

Further, since the epoxy resin employed in the present embodiment is solidified without stickiness at room temperature, it does not hinder the winding 14 from being wound. And since the fusion | melting layer 14c is formed into a film and solidified by the uniform thickness, it can wind orderly without a gap. This makes it difficult for heat to escape to the surroundings during energization heating, so that melting and curing can be performed more efficiently.
Further, since the fusion layer 14c is formed and solidified with a uniform thickness, the winding 14 can be fixed with a uniform fixing force by melting and curing (FIGS. 5B and 5C). reference).

In the present embodiment, the fusion layer 14 c is formed on the entire winding 14 including the winding start portion and the winding end portion. As a result, it is possible to prevent the winding 14 from slacking and to reliably fix the winding start portion and the winding end portion whose positions are likely to shift.
It is also possible to add (add) the same thermosetting resin as that of the fusion layer 14c to the terminal fixing portion 12h and melt and harden the lead wire 13a more firmly during energization heating.

In the present embodiment, a resin that melts and cures at a temperature lower than the maximum temperature that the rotating electrical machine 101 reaches during operation is employed as the thermosetting resin that constitutes the fusion layer 14c. Thereby, the energization heating time can be further shortened.
Moreover, since it is not necessary to heat excessively, the thermal deterioration of the coil main body 13 can be suppressed.

  In addition, although the coil C for rotary electric machines of this embodiment is wound around the stator core 11 as a core member and comprises a part of stator 104, it is not limited to this. For example, it is possible to employ a rotating electrical machine in which a rotating electrical machine coil is wound around a rotor (not shown) and a permanent magnet is disposed on the stator. By setting it as such a structure, while being able to obtain the effect similar to this embodiment, rotation of the rotor at the time of operation | movement is stabilized and a noise and a vibration can be suppressed.

In this embodiment, an epoxy resin that is solidified at room temperature and melted and cured at a predetermined temperature (about 150 ° C.) is used as the thermosetting resin constituting the fusion layer 14c. It is not limited to the layer 14c.
For example, it is also possible to adopt a method in which, after the formation of the fusion layer, the resin is heated and energized in a soft state before the thermosetting resin is solidified. Even with such a method, the same effects as those of the present embodiment can be obtained.

Next, the 1st another aspect of the coil for rotary electric machines is demonstrated, referring drawings. The same components as those in the above-described rotating electrical machine coil C are denoted by the same reference numerals, and redundant description is omitted.
As shown in FIGS. 9A to 9C, the configuration that is greatly different between the rotating electrical machine coil CA of this aspect and the rotating electrical machine coil C of the first embodiment described above is the cross-sectional shape of the winding 14A. .
The winding 14A of this aspect is configured by a round wire having a substantially circular cross section. Since the winding 14A is formed of a round wire, it is not necessary to align the direction of the winding 14A strictly when the winding 14A is wound around the winding groove 12f.
As a result, in addition to the effects obtained in the above-described embodiment, the winding process is simplified, and the manufacturing cost can be reduced.

Next, a second alternative embodiment of the rotating electrical machine coil will be described with reference to the drawings. The same components as those in the above-described rotating electrical machine coil C are denoted by the same reference numerals, and redundant description is omitted.
As shown in FIGS. 10A to 10C, the configuration of the rotating electrical machine coil CB of this aspect and the rotating electrical machine coil C of the first embodiment described above are substantially different from each other in the cross-sectional shape of the winding 14A, It is the shape of winding cylinder part 12aB.
The winding 14A of this aspect is configured by a round wire having a substantially circular cross section, as in the first different aspect.
Moreover, in this aspect, the winding cylinder part 12aB which comprises the outer cylinder surface of the insulator 12 is provided with the shape which followed the inner cylinder surface of the coil main body 13 wound by the cylinder shape. That is, a semicircular groove is formed in a spiral shape on the outer cylinder surface of the wound cylinder portion 12aB.

  In this way, in addition to the operational effects obtained in the above-described embodiment and the first alternative aspect, it is possible to suppress loosening and deviation of the winding 14 during winding and after winding until energization heating. .

C Coil for rotating electrical machine 11 Core member (stator core)
12 Insulator 14 Winding 14c Fusing Layer 101 Rotating Electric Machine

Claims (5)

An insulator having a cylindrical shape surrounding the periphery of the core member;
A winding wound in a cylindrical shape on the outer periphery of the insulator;
With
The winding is
A fusion layer made of a thermosetting resin is provided on the surface,
A coil for a rotating electrical machine, characterized in that after being wound around the insulator, the fusion layer is cured by Joule heat by energization, and adjacent windings are fixed. The winding is
2. The coil for a rotating electrical machine according to claim 1, wherein the fusion layer is provided in at least one of a portion that is a winding start portion and a winding end portion of the insulator. 3. The coil for a rotating electrical machine according to claim 1, wherein an outer cylindrical surface of the insulator has a shape that follows an inner cylindrical surface of a winding wound in the cylindrical shape. The fusion layer is
The coil for a rotating electrical machine according to any one of claims 1 to 3, wherein the coil is made of a thermosetting resin that is cured at a temperature lower than a maximum temperature that the rotating electrical machine reaches during operation. An insulator having a cylindrical shape surrounding the periphery of the core member;
Winding comprising a fusion layer made of a thermosetting resin on the surface, and being wound in a cylindrical shape around the outer periphery of the insulator;
In the manufacturing method of the coil for rotating electrical machines comprising:
A coil for a rotating electrical machine, comprising: a step of hardening the fusion layer by Joule heat by energization and fixing adjacent windings after the step of winding the windings around the insulator Production method.

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