JP2019075906A - Segment coil split conductor and manufacturing method for the same - Google Patents

Abstract

To provide a segment coil split conductor which enables edges of split conductors to be easily welded and can be easily handled and to provide a manufacturing method for the segment coil split conductor.SOLUTION: A split conductor 5 has a split section 8 made up of a plurality of wire sections 7 at a portion other than both edge sections 9. Each wire section 7 has a conductor section 11 and an insulation layer 13 which covers the conductor section 11. That is, the split section 8 is made up of the plurality of conductor sections 11 and the insulation layers 13 formed between the conductor sections 11. Both edge sections 9 of the split conductor 5 are integrated with the conductor sections 11. That is, at least both edge sections 9 of the split conductor 5 are not provided with the insulation layer 13 so that the conductor section 11 is exposed without being split into plural pieces.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a segmented coil segment conductor used for a motor and a method of manufacturing the same.

  For example, as a winding used for a stator of a motor for vehicles, conventionally, enameled wire of round section was used. However, in recent years, rectangular coils of rectangular cross section have come to be used to increase the space factor. Also, conventionally, there have been many cases where the manufacturing method of winding the winding around the core of the stator has often been adopted, but with the adoption of the flat winding, the winding is configured as a short segment coil and assembled after being assembled to the stator A method of forming a coil has come to be adopted by welding and connecting ends of segment coils.

  However, since the rectangular winding has a large cross-sectional area per winding, there is a problem that the winding loss increases due to the generation of the eddy current when the motor rotation number is increased and the frequency is increased.

  On the other hand, a split conductor in which a plurality of conducting wires are integrated has been proposed. That is, the influence of an eddy current can be suppressed by using a divided conductor constituted by a plurality of conducting wires as a segment coil.

  The divided conductors are formed, for example, by bundling together a plurality of strands having an insulating layer such as an oxide film on the surface and integrating them into a substantially rectangular cross section. According to such a divided conductor, the filling efficiency of the conductor to the slot of the stator can be enhanced, and each wire can be insulated by the oxide film, and an increase in AC resistance due to the skin effect and eddy current can be suppressed. .

  As such a divided conductor, for example, there is a collective conductor in which a plurality of conductor wires having a rectangular conductor wire and a covering layer provided on the outer periphery of the conductor wire are integrated (PTL 1).

  Further, there is a coil in which a single wire is joined alternately in the longitudinal direction with a collective wire made of a plurality of linear conductors, and a portion exposed from a slot of the stator is constituted by a single wire (Patent Document 2).

JP 2007-227266 A JP, 2013-39000, A

  However, as in Patent Document 1, when a normal divided conductor is used, there is a problem that each conductor wire is separated at the time of handling. In particular, when arranging the divided conductors in the stator core, it is necessary to bend the divided conductors into a predetermined shape, which causes the conductor wires to slip, causing deviation or separation during bending.

  Moreover, when using a division | segmentation conductor as a segment coil of a motor, it is necessary to join the edge parts of each division | segmentation conductor by welding. Under the present circumstances, in the welding part, the coating layer of the outer periphery of each conductor strand becomes an impurity, and there exists a possibility of reducing the reliability of a welding part.

  On the other hand, in the method of Patent Document 2, since it is necessary to join the single wire and the collective wire in the longitudinal direction, the manufacture is extremely difficult. For example, if the two are welded together in the usual manner, the cross-sectional area of the connection portion may be reduced due to, for example, a shrinkage at the time of welding of the collective wire, which may cause breakage. In addition, at the time of welding of both of them, spheroidization may occur due to surface tension, and the joint portion may partially expand, making it difficult to insert the joint into the slot.

  Further, since all the portions exposed from the slot are formed by a single wire, the conducting wires are conducted at the single wire portion at the upper and lower sides of the slot to form a loop, which may increase AC resistance due to eddy current. When the eddy current is generated as described above, the eddy current loss reduction effect, which is a merit of using the divided conductor, is reduced.

  The present invention was made in view of such a problem, and it is possible to easily weld the ends of the divided conductors to each other, and to provide a segmented coil divided conductor which is easy to handle and a method of manufacturing the same. With the goal.

  According to a first aspect of the present invention, there is provided a split conductor for a segment coil, wherein the split conductor includes a split portion including a plurality of wire portions, and the wire portions include a conductor portion An insulating layer for covering the conductor portion, wherein the divided conductor is integrally formed without a joint portion connecting the conductor portion in the longitudinal direction, and at least both ends of the divided conductor are made of resin type And the conductor portion is exposed without forming the insulating layer.

  It is desirable that the conductor portion be integrated in a range in which the resin type insulating layer is not formed at both end portions of the divided conductor.

  The insulating layer of the resin type may not be formed only at both ends of the divided conductor, and the portion excluding the both ends of the divided conductor may be the divided portion.

  The conductor portion may be exposed without forming the resin type insulating layer in a range of 30 mm or less from both ends of the divided conductor.

  The conductor portion at both ends of the divided conductor does not have a joint portion in which a plurality of conductors are joined to each other, and the divided conductor has a joint portion between conductors in any of the longitudinal direction, thickness direction and width direction It may be an integral structure that does not have

  The number of divisions of the central portion in the longitudinal direction of the divisions may be smaller than that of other portions of the divisions.

  A plurality of the wire parts may be integrated via the insulating layer, and the insulating layer of the wire parts may be removed at both ends of the divided conductor.

  According to the first aspect of the invention, since the divided conductors are integrally formed without the joint in the longitudinal direction, it is not necessary to join a plurality of types of conducting wires. Therefore, there is no joint in the longitudinal direction of the divided conductors, and the reliability is high over the entire length in the longitudinal direction. Moreover, since it is not necessary to join a plurality of conducting wires in the longitudinal direction, manufacture is easy.

  In addition, since the insulating layer is removed at least at both end portions of the divided conductor, there is no mixing of the insulating layer when welding and joining the end portions of the divided conductors, and the reliability of the connection portion is also high. .

  In addition, if the conductor portions are integrated at both ends of the divided conductor, the separation of the end does not occur at the time of welding, and the deviation and separation of the conductor during bending of the divided conductor are suppressed. And handleability is good.

  Further, by not forming the insulating layer only at both ends of the divided conductor, it is possible to suppress an increase in alternating current resistance due to eddy current at other portions.

  Under the present circumstances, if an insulating layer is removed in the range of 30 mm or less from the both ends of a division | segmentation conductor, it is enough for welding and it can suppress that the effect of dividing | segmenting a strand part becomes small.

  Moreover, it is not necessary to bundle and unify a plurality of strands by making it the integral structure which does not have a joined part of conductors in the longitudinal direction, thickness direction, and width direction of a division conductor. In addition, since the both ends are originally integrated, the insulating layer is not internally wound at the ends.

  Further, by making the number of divisions of the central portion in the longitudinal direction of the divided portions smaller than that of the other portions, it is possible to suppress dispersion near the substantially central portion in the longitudinal direction of the divided conductors.

  The same effect can be obtained even if the insulating layer is removed at both ends of the litz wire in which the plurality of strand portions are integrated through the insulating layer in the dividing portion.

  A second invention is a method of manufacturing a segmented conductor for a segment coil, in which at least a portion excluding one end of an integral conductor material is divided along the longitudinal direction to form a plurality of conductor portions. An insulating layer is formed on the surface of the separated conductor portion to form a plurality of wire parts, and the divided conductors are characterized in that the conductor is integrally formed at least at both end portions in the longitudinal direction. It is a manufacturing method of the division conductor for.

  According to the second invention, it is possible to easily manufacture a split conductor in which both ends are integrated. At this time, since there is no joint in the longitudinal direction of the divided conductors, the reliability is also high.

  ADVANTAGE OF THE INVENTION According to this invention, it is possible to weld the edge parts of a division | segmentation conductor easily, and can provide the division coil for segment coils which is easy to handle, and its manufacturing method.

FIG. 2 is a partial perspective view showing a stator core 1; The top view which shows the division | segmentation conductor 5. FIG. It is a sectional view showing divided conductor 5, and (a) is an AA line sectional view of Drawing 2, and (b) is an BB line sectional view of Drawing 2. As shown in FIG. FIG. 10 is a conceptual view showing a state in which divided conductors 5 are arranged in slots 3; (A) is a conceptual diagram which shows the state which welded edge part 9 comrades, (b) is a conceptual diagram which shows the state which welded division part 8 comrades. (A), (b) is a figure which shows the method to divide | segment the conductor part 11. FIG. The top view which shows the division | segmentation conductor 5a. It is sectional drawing which shows the division | segmentation conductor 5a, Comprising: (a) is a CC sectional view taken on the line of FIG. 7, (b) is a DD sectional view taken on the line of FIG. The figure which shows the state which has arrange | positioned the division | segmentation conductor 5a to the slot 3. FIG. The top view which shows the division | segmentation conductor 5b. It is sectional drawing which shows the division | segmentation conductor 5b, Comprising: (a) is the GG sectional view taken on the line of FIG. 10, (b) is the HH sectional view taken on the line of FIG.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a partial perspective view showing a stator core 1. The stator core 1 has a substantially cylindrical shape, and is formed, for example, by laminating electromagnetic steel sheets. A plurality of slots 3 are provided on the inner peripheral side of stator core 1. A conductor is disposed in each slot 3 and a coil is formed by joining the conductors.

  FIG. 2 is a plan view of segmented conductor 5 for segment coil disposed in slot 3. The divided conductor 5 has a divided portion 8 composed of a plurality of wire portions 7 at least at portions other than both end portions 9. In the illustrated example, the entire portion between the end portions 9 is the divided portion 8 except for the end portion 9.

  Fig.3 (a) is the sectional view on the AA line of FIG. Each wire portion 7 has a conductor portion 11 and an insulating layer 13 covering the conductor portion 11. That is, the division part 8 consists of the several conductor part 11 and the insulating layer 13 formed between each conductor part 11 comrades. The conductor portion 11 is made of, for example, copper or copper alloy, and the insulating layer 13 is either an oxide film type insulating layer made of a conductor oxide or a resin type insulating layer made of a resin such as enamel or an adhesive It is. That is, the insulating layer 13 is made of a material having a lower conductivity than the conductor portion 11. The insulating layer 13 in the dividing portion 8 is preferably a resin type insulating layer from the viewpoint of the insulation between the conductor portions 11 and the eddy current suppressing effect thereby. The dividing unit 8 is, for example, substantially rectangular as a whole. The number, the shape, and the arrangement of the strand portions 7 in the dividing portion 8 are not limited to the illustrated example.

  FIG.3 (b) is the BB sectional drawing of FIG. The conductor portion 11 is integrated with both ends 9 of the divided conductor 5. That is, the insulating layer 13 is not formed at at least both end portions 9 of the divided conductor 5, and the conductor portion 11 is exposed without being divided into a plurality of portions. In the present invention, the end 9 includes the foremost end of the divided conductor 5, and “the end 9 is integrated” means that the end surface of the divided conductor 5 is a plurality of strands It means that it is not divided into seven. Further, "the insulating layer 13 is not formed at the end 9" means that the insulating layer 13 of the resin type described above is not formed at the end 9, and it is formed on the surface of the conductor portion 11. It does not mean that the oxidized film is completely removed. That is, “the conductor portion 11 is exposed” also includes that the oxide film formed on the surface layer of the conductor portion 11 is exposed.

  FIG. 4 is a conceptual view showing a state in which divided conductors 5 are arranged in slots 3 when stator core 1 is viewed from the inner surface side. In the drawings, only a part of the stator core 1 is shown. As described above, the divided conductors 5 are bent into a predetermined shape to form segment coils and disposed in the slots 3. At this time, the end portion 9 of the divided conductor 5 protrudes above the stator core 1, and the bent portion of the divided conductor 5 is exposed at the lower portion of the stator core 1.

  At this time, all the end portions 9 of the divided conductors 5 protruding above the stator core 1 become the divided portions 8. That is, all of the divided conductors 5 disposed inside the slot 3 are divided portions 8, and the bent portions of the divided conductors 5 exposed below the stator core 1 also become the divided portions 8 as a whole.

  The end 9 of the divided conductor 5 protruding above the stator core 1 is joined by welding to the end 9 of another adjacent divided conductor 5 (not shown). A coil is formed by connecting all the divided conductors 5 to each other.

  Fig.5 (a) is a conceptual diagram which shows the state which welds edge part 9 comrades. As described above, the end 9 is formed only of the conductor portion 11 and does not have the insulating layer 13. For this reason, when the end portions 9 of the divided conductors 5 to be connected are welded, the conductor portion 11 can be made substantially integral. For this reason, the reliability of a junction part is high and end part 9 comrades can be connected certainly.

  On the other hand, as shown in FIG. 5B, if the divided portion 8 is present at the tip (end face) of the divided conductor 5, when the two are welded, the residue 13a derived from the insulating layer 13 is inside the connection portion. mixing. In particular, when such a residue 13a derived from a resin is present, the electrical resistance of the connecting portion becomes high, and there is a possibility that the connecting portion may be broken or the like. In addition, when the divided conductor 5 is bent or the like, the wire portion 7 at the end of the divided conductor 5 may be separated, which may make the welding operation difficult. As described above, by preventing the resin type insulating layer 13 from being provided at the end portion 9, the connection operation becomes easy, and the reliability of the connection portion can be improved.

  In addition, in order to obtain sufficient weldability, the end 9 should be about 30 mm from the tip. If the length at which the conductor portion 11 is integrated is made longer than this, the effect of suppressing an increase in alternating current resistance due to the eddy current is reduced. Therefore, the end 9 is preferably 30 mm or less from the tip. Moreover, in order to weld reliably, as for the edge part 9 with which the conductor part 11 was integrated, it is desirable that it is 5 mm or more from a front end.

  Next, an example of a method of manufacturing the divided conductor 5 will be described. First, a conductor material cut into a predetermined length is prepared. A conductor material is a member constituted by one. The cross-sectional shape of the conductive material is, for example, rectangular, and is manufactured by cutting a wire made of, for example, copper or copper alloy.

  Next, at least a part of the portion excluding the both ends of the integral conductor material is divided along the longitudinal direction. The divided range is the dividing unit 8. For this reason, for example, in the case where the entire portion other than the both end portions is the dividing portion 8, the entire portion excluding the both end portions is divided along the longitudinal direction.

  FIG. 6A is a conceptual view showing a state in which the conductive material is cut by the laser 12. For example, by dividing the conductive material by the laser 12, it is possible to form a plurality of conductor portions 11 which are divided from one another. The method of dividing the conductor portion 11 is not limited to the laser 12, and any method such as mechanical cutting or chemical etching may be used.

  Moreover, the dividing method of the conductor part 11 can be arbitrarily changed by changing the direction and the position of the laser 12. For example, as shown in FIG. 6 (b), the conductor portion 11 may be divided obliquely by irradiating the laser 12 obliquely.

  Next, the insulating layer 13 is formed on the surface of the separated conductor portion 11 to form a plurality of wire portions 7. The insulating layer 13 is formed, for example, by applying a resin such as enamel on the surface of each conductor portion 11. By the above, the division | segmentation conductor 5 can be manufactured.

  As described above, according to the present embodiment, since the portions other than the end portions 9 of the divided conductors 5 are the divided portions 8, a high eddy current loss reduction effect can be obtained. In particular, since the divided portion 8 continues to the bent portion exposed to the lower side of the stator core 1, this effect is large.

  Moreover, since the original conductor material is integrated in the longitudinal direction, the obtained divided conductor 5 does not have a joint portion connecting the conductor portions 11 in the longitudinal direction, and the conductor portions of both ends 9 11 also does not have a junction where multiple conductors are joined together. That is, each of the divided conductors 5 has an integral structure in which none of the longitudinal direction, the thickness direction, and the width direction has a joint between the conductors. For this reason, compared with the case where a plurality of members are joined in the longitudinal direction to manufacture a divided conductor of a predetermined length, the reliability is high, and the shape (cross sectional area) of the joint portion is changed or welding defects etc. There is no influence such as disconnection. In addition, since uniform conductor resistance can be obtained in the longitudinal direction, the quality of the obtained segment coil is stabilized.

  Further, since the original conductor material is integrally formed, the conductor portions 11 of at least both end portions 9 in the longitudinal direction of the divided conductor 5 are also integrally formed. Therefore, in the manufacturing process, it is not necessary to integrate the end portions 9 by welding or the like. Therefore, the manufacture is easy and the quality of the end 9 can be enhanced.

  Next, a second embodiment will be described. FIG. 7 is a view showing a divided conductor 5a according to the second embodiment. In the following description, about the composition which plays the same function as division conductor 5, the same numerals as Drawing 1-Drawing 6 are attached, and overlapping explanation is omitted.

  The divided conductor 5a has substantially the same configuration as the divided conductor 5, but the aspect of the divided portion 8 is different. In the divided conductor 5a, as in the divided conductor 5, the conductor portion 11 is integrated at only the end portion 9, and in the divided portion 8, the conductor portion 11 is divided into a plurality of wire portions 7.

  The dividing unit 8 is divided into a plurality of regions in which the number of divisions of the wire portion 7 is different. In FIG. 7, the number of divisions of the wire portion 7 is different between the vicinity of the approximate center of the divided conductor 5 a (F in the drawing) and the region E on both sides thereof and between the end 9 and the region F. .

  8A is a cross-sectional view taken along the line C-C in FIG. 7 and is a cross-sectional view taken along the region E, and FIG. 8B is a cross-sectional view taken along the line D-D in FIG. FIG. As shown to Fig.8 (a), in the area | region E of the division part 8, the cross section of the division | segmentation conductor 5a is the same as that of the division | segmentation conductor 5 mentioned above. On the other hand, as shown in FIG. 8B, the division number of the conductor portion 11 in the region F of the division portion 8 (the number of the wire portions 7) is the division number of the conductor portions 11 in the region E (the wire portion 7). Number less than). That is, the number of divisions of the central portion in the longitudinal direction of the division portion 8 is smaller than that of the other portions.

  FIG. 9 is a conceptual view showing a state in which divided conductors 5 a are arranged in slots 3 of stator core 1. In the present embodiment, the end 9 of the divided conductor 5 a protrudes above the stator core 1, and the portion disposed inside the slot 3 is the region E of the divided portion 8. Further, the area F of the divided portion 8 is positioned at the curved portion of the divided conductor 5 a exposed below the stator core 1.

  According to the second embodiment, the same effect as that of the first embodiment can be obtained. Moreover, since the area | region F with few division | segmentation numbers is formed in the approximate center part of the longitudinal direction of the division | segmentation conductor 5a, in the case of a bending process, the strand part 7 does not disperse easily. Moreover, since the said part is not necessarily completely integrated, the influence of the eddy current mentioned above can also be suppressed.

  Note that the region F having a relatively small number of divisions does not have to be formed over substantially the entire range exposed from the lower side of the slot 3 and is, for example, only a part of the approximate center of the divided conductor 5a in the longitudinal direction It is also good. Moreover, if it is only a part like this, the number of divisions may be further reduced and the conductor part 11 may be integrated. Even in this case, the insulating layer 13 is formed on the outermost periphery of the conductor portion 11 integrated with the portion. That is, the conductor portion 11 is not exposed to the outside by the insulating layer 13 except for the end portion 9.

  Next, a third embodiment will be described. FIG. 10 is a view showing a divided conductor 5b according to a third embodiment. The divided conductor 5b has substantially the same configuration as the divided conductor 5, but the structure of each part is different.

  11 (a) is a cross-sectional view taken along the line G-G in FIG. 10, and is a cross-sectional view of the divided portion 8. FIG. 11 (b) is a cross-sectional view taken along the line H-H in FIG. FIG. In the dividing unit 8, a plurality of strand portions 7 are bundled. Further, the insulating layer 14 is further provided on the outermost periphery of the bundle structure of the plurality of wire portions 7. That is, in the dividing portion 8, the plurality of wire portions 7 are integrated via the insulating layer 13.

  On the other hand, at the end portion 9, all the insulating layers 13 and 14 are removed, and the end portion 9 is formed only of the conductor portion 11. In addition, although conductor part 11 comrades mutually contact and can conduct, metallographically unifying is not carried out. Moreover, "consisting only of the conductor portion 11" means that it does not have the resin type insulating layer described above, and also includes one having an oxide film on the surface layer.

  Divided conductor 5b is manufactured, for example, as follows. First, the plurality of wire portions 7 are bundled, and the entire shape is formed by, for example, a die, and the insulating layer 14 is coated on the outermost periphery by extrusion or the like. The insulating layer 14 is, for example, a resin. Even in this case, since the respective wire portions 7 are integral with the longitudinal direction, no joint portion is formed in the longitudinal direction of the divided conductor 5b.

  Next, the insulating layers 13 and 14 are removed only at both ends 9. The insulating layers 13 and 14 are removed by mechanical methods such as grinding or chemical methods such as etching. As described above, when the divided conductors 5b are connected to each other, the residue 13a of the insulating layers 13 and 14 is mixed in the connection portion by removing the insulating layers 13 and 14 at the end portion 9 as described above. Can be suppressed. As described above, in the divided conductor 5b, as long as the end portion 9 is formed of only the conductor portion 11, the conductor portion 11 may not necessarily be integrated in a metallographic manner.

  In addition, as shown in FIG.11 (c), in the edge part 9 from which the insulating layers 13 and 14 were removed in this way, conductor part 11 comrades may be fuse | melted and integrated. That is, the end 9 may have a joint between the conductors in the width direction or the thickness direction. By doing so, a structure substantially similar to that of the divided conductors 5 can be obtained. As described above, by performing bending or the like of the divided conductors 5b in a state in which the conductor portions 11 are integrated, it is possible to suppress the separation of the wire portions 7 (conductor portions 11).

  According to the third embodiment, the same effect as that of the first embodiment can be obtained. As described above, if the conductor portion 11 is exposed without forming the insulating layers 13 and 14 at least at the end portion 9 of the divided conductor 5 b, the conductor portions 11 do not necessarily have to be integrated at the end portion 9 .

  Although the embodiments of the present invention have been described above with reference to the attached drawings, the technical scope of the present invention is not influenced by the above-described embodiments. It is apparent that those skilled in the art can conceive of various changes or modifications within the scope of the technical idea described in the claims, and they are naturally also within the technical scope of the present invention. It is understood that it belongs.

1 ... ... Stator core 3 ... ... Slots 5, 5a, 5b ... ... Divided conductor 7 ... ... Wire part 8 ... ... Divided part 9 ... ... End part 11 ... ... Conductor part 12 ... ... Laser 13, 14 ......... Insulating layer 13a ... ... residue

Claims (8)

Split conductor for segment coil,
The divided conductor includes a divided portion including a plurality of strand portions,
The wire portion includes a conductor portion and an insulating layer covering the conductor portion.
The divided conductors are integrally formed without having a joint that connects the conductor portions in the longitudinal direction,
A segmented coil segmented conductor characterized in that the conductor portion is exposed without forming a resin type insulating layer at least at both end portions of the segmented conductor.   The segment coil split conductor according to claim 1, wherein the conductor portion is integrated in a range in which the resin type insulating layer is not formed at both end portions of the split conductor.   The segment according to claim 1 or 2, wherein the insulating layer of the resin type is not formed only at both ends of the divided conductor, and a portion excluding the both ends of the divided conductor serves as the divided portion. Split conductor for coil.   4. The segment coil according to claim 1, wherein the conductor portion is exposed without forming the resin type insulating layer in a range of 30 mm or less from both ends of the divided conductor. Divided conductor.   The conductor portion at both ends of the divided conductor does not have a joint portion in which a plurality of conductors are joined to each other, and the divided conductor has a joint portion between conductors in any of the longitudinal direction, thickness direction and width direction The segmented coil for a segment coil according to any one of claims 1 to 4, characterized in that it has an integral structure that does not have a.   The segment coil split conductor according to claim 5, wherein the number of divisions of the central portion in the longitudinal direction of the division portion is smaller than that of other portions of the division portion.   In the divided portion, a plurality of the wire portions are integrated via the insulating layer, and the insulating layer of the wire portion is removed at both ends of the divided conductor. The segment coil split conductor according to any one of claims 1 to 4. A method of manufacturing a segmented conductor for a segment coil, comprising:
At least a part except one end of the integral conductor material is divided along the longitudinal direction to form a plurality of conductor parts, and an insulation layer is formed on the surface of the separated conductor parts to form a plurality of strands Make up the department,
The method of manufacturing a segmented coil segmented conductor, wherein the conductor segments are integrally formed at at least both end portions in the longitudinal direction.

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