JP2020127316A - Electric rotating machine and method for manufacturing the same - Google Patents

Abstract

To solve the problem of impairing insertability of a segment conductor into a stator slot during assembly and manufacturing of a stator, and the problem of misalignment of the segment conductors after insertion of the segment conductors.SOLUTION: As shown in Fig. 8(A), torsion angles φx1 to φx4 are small on an end portion 36 side of a straight portion 34 of a segment conductor 30. This improves the insertability of the segment conductor 30 into a slot 15 when a stator 14 is assembled and manufactured. As shown in Fig. 8(B), the torsion angles φy1 to φy4 are large on a bent portion 35 side of the straight portion 34 of the segment conductor 30. The segment conductor 30 makes point contact with both sides of an inner wall surface of the slot 15 at corner portions of the cross-sectional shape of straight portions 34y1, 34y2, 34y3, 34y4. This prevents the segment conductor 30 from being displaced after the segment conductor 30 is inserted into the slot 15.SELECTED DRAWING: Figure 8

Description

The present invention relates to a rotary electric machine and a method for manufacturing a rotary electric machine.

BACKGROUND ART A rotary electric machine such as an electric motor or a generator mounted and used in a vehicle or the like includes a rotor that is rotatably provided and a stator that is arranged to face the rotor in a radial direction. The stator includes a stator core having a plurality of slots arranged in the circumferential direction and segment conductors fitted in the plurality of slots of the stator core.

Patent Document 1 describes a stator of a rotary electric machine that includes a stator core having a plurality of slots in the circumferential direction and a segment conductor fitted in the slots in an annular shape. Then, the end portions of the segment conductors inserted in the respective slots are joined together to form a stator winding.

JP, 2008-33238, A

The stator described in Patent Document 1 has a problem in that the insertability of the segment conductor into the stator slot at the time of assembling and manufacturing the stator is impaired, and the segment conductor is displaced after the segment conductor is inserted.

A rotating electric machine according to the present invention has a plurality of segment conductors and an iron core in which a plurality of slots are formed, a stator in which the plurality of segment conductors are arranged in the plurality of slots, and an inner peripheral side of the stator. The segment conductor includes a pair of linear portions arranged in the slot, a bent portion formed between the pair of linear portions, and the segment of the pair of linear portions. And a pair of terminal portions respectively formed on the opposite side to the bent portion, and a twist angle formed by the center line extending in the radial direction from the center of the stator and the side surface of the linear portion of the segment conductor, The side of the straight portion near the terminal portion and the side of the straight portion near the bent portion are different.
A method for manufacturing a rotary electric machine according to the present invention has a plurality of segment conductors and an iron core having a plurality of slots formed therein, and a stator in which the plurality of segment conductors are arranged in the plurality of slots, and the stator. A method of manufacturing a rotating electric machine comprising: a mover arranged on an inner peripheral side, wherein the segment conductor is inserted into the slot and a terminal part which is inserted into the slot at the time of manufacturing the stator. An unfolded portion and a straight portion arranged in the slot, and when the segment conductor is inserted into the slot, a center line extending radially from the center of the stator and the segment conductor. The twist angle formed by the side surface of the straight portion is different between the side closer to the terminal portion of the straight portion and the side closer to the bent portion of the straight portion, and the first twist portion is formed in the segment conductor. And a second step of inserting the segment conductor having the twisted portion into the slot from the terminal portion.

According to the present invention, the insertability of the segment conductor into the stator slot at the time of assembling and manufacturing the stator is improved, and it is possible to prevent the segment conductor from being displaced after the segment conductor is inserted.
Problems, configurations, and effects other than those described above will be clarified by the following description of modes for carrying out the invention.

It is an external view of a rotary electric machine. It is sectional drawing of a rotary electric machine. It is a perspective view of a stator. It is a perspective view which shows an example of a segment conductor. It is a figure which shows the cross-sectional shape of (A)-(D) segment conductor. It is a figure which shows the 1st example of the manufacturing method of (A) (B) segment conductor. (A)-(C) A perspective view and a sectional view of a segment conductor. It is sectional drawing of the state where (A) and (B) segment conductor was inserted in the slot of a stator core. It is a figure which shows the 2nd example of the manufacturing method of a segment conductor. It is a perspective view showing a segment conductor for output lines. It is a perspective view which shows a deformed segment conductor.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The following description and drawings are exemplifications for explaining the present invention, and are appropriately omitted and simplified for clarity of the description. The present invention can be implemented in various other forms. Unless otherwise specified, each component may be singular or plural.

The position, size, shape, range, etc. of each component shown in the drawings may not represent the actual position, size, shape, range, etc., for easy understanding of the invention. Therefore, the present invention is not necessarily limited to the position, size, shape, range, etc. disclosed in the drawings.

Hereinafter, the present embodiment will be described with reference to the drawings.
FIG. 1 is an external view of a rotary electric machine 100 including a segment conductor. The rotary electric machine 100 is an electric motor, a generator, or the like that is used by being mounted on a vehicle or the like, and is, for example, a motor used for electric power steering. The rotary electric machine 100 includes a housing 1 and a bracket 2. A shaft 3, which is an output shaft, projects from the bracket 2. A plurality of coil lead wires 50 extend on the opposite side of the shaft 3. A control circuit (not shown) is arranged on the opposite side of the shaft 3.

FIG. 2 is a sectional view of the rotary electric machine 100. An O-ring 6 is provided at the connecting portion between the housing 1 and the bracket 2. A front bearing 5 that supports one end of the shaft 3 is fixed to the bracket 2 with a bevel type tomewaw 4. On the other hand, the housing 1 is provided with a rear bearing 10 that supports the other end of the shaft 3. The shaft 3 is rotatably supported by a front bearing 5 and a rear bearing 10. On the inner peripheral side of the stator 14, a rotor (movable element) 12 is provided integrally with the shaft 3. The rotor (movable element) 12 has an embedded structure in which a permanent magnet 7 is provided in a rotor core 8 or a surface magnet structure.

The stator 14 is fixed to the inner peripheral surface of the housing 1 by shrink fitting or press fitting. The stator 14 inserts a plurality of segment conductors provided with an insulating film such as an enamel film in a plurality of slots (grooves) formed in the stator core 9. The segment conductor is composed of at least one straight portion arranged in the slot and a pair of end portions arranged outside the slot of the stator 14. The segment conductors are connected to each other to form a three-phase winding 20, and are drawn out to the coil end side from the plurality of coil lead wires 50.

FIG. 3 is a perspective view of the stator 14 on which the winding 20 is arranged. A plurality of coil lead wires 50 are drawn out from the coil end portion arranged on the upper side in the drawing in the axial direction of the stator core 9. On the opposite side of the stator core 9, the connecting portion 13 of the segment conductor 30 that constitutes the winding 20 is provided. Each segment conductor 30 is inserted into the slot from the upper side in the drawing of the stator core 9 in the axial direction. The end of the inserted segment conductor 30 projects from the opposite side of the slot, that is, the lower side in the axial direction in the drawing. The ends of the segment conductors 30 protruding from the lower side in the drawing in the axial direction are connected by soldering, Tig welding, laser welding, or the like to form the connecting portion 13.

FIG. 4 is a perspective view showing an example of the segment conductor 30 inserted into the slot of the stator core 9 in FIG. The segment conductor 30 has a substantially left-right symmetric shape with the head 31 at the upper part of the drawing as the center. That is, the segment conductor 30 includes a pair of left and right inclined portions 32, a pair of bent portions 33, and a pair of straight portions 34. The head portion 31 is arranged between the pair of inclined portions 32. The inclined portion 32 arranged closest to the head portion 31 has an angle of more than 0 degrees and less than 90 degrees with respect to the end surface of the stator core 9. The linear portion 34 connected to the inclined portion 32 via the bent portion 33 has a linear shape and is inserted into the slot of the stator core 9. Here, the head portion 31, the inclined portion 32, and the bent portion 33 are collectively referred to as a bent portion 35, and a portion joined to another segment conductor 30 formed on the side opposite to the bent portion 35 is a terminal portion. It is called 36. That is, the bent portion 35 is formed between the pair of linear portions 34, and the pair of terminal portions 36 is formed on the opposite side of the pair of linear portions 34 from the bent portion 35.

FIG. 5 is a diagram showing a cross-sectional shape of the segment conductor 30. 5A shows a circular cross section, FIG. 5B shows a rectangular cross section, FIG. 5C shows a barrel-shaped cross section, and FIG. 5D shows a trapezoidal cross section. FIG. FIG. 5(A) shows a cross-sectional shape before molding. 5(B) to 5(D) show cross-sectional shapes in this embodiment after molding.

As shown in FIG. 5A, a circular cross section is called a “round cross section”. Although a perfect circle is shown in FIG. 5A, an ellipse is also included in the circular cross section. As shown in FIG. 5B, a rectangular cross section is called a “rectangular cross section”. However, the corners may be rounded as shown in FIG. 5B, and the rectangular cross section in this embodiment indicates a shape including two sets of parallel sides. Further, the rectangular cross section can be said to be a shape obtained by squashing the circular cross section from both the vertical direction and the horizontal direction.

As shown in FIG. 5C, a cross section formed by a combination of a pair of parallel sides and two semicircles is called a "barrel cross section". The barrel-shaped cross section can be said to be a shape obtained by crushing a circular cross section from either the vertical direction or the horizontal direction. In FIG. 5(C), the circular cross section has a shape that is crushed only from the vertical direction in the drawing. As shown in FIG. 5D, a cross section having a pair of parallel sides and a hypotenuse connecting them is called a "trapezoid cross section". Note that although four corners are included in FIG. 5D, the corners may be rounded as in FIGS. 5B and 5C.

Next, a first example of a method of manufacturing the segment conductor 30 will be described with reference to FIG.
As shown in FIG. 6(A), a press jig 40 is used to press-mold the linear conductor piece 41 having a circular cross section shown in FIG. 5(A). The cross section of the press-formed linear conductor piece 41 may be any of the rectangular cross section shown in FIG. 5(B), the barrel cross section shown in FIG. 5(C), and the trapezoidal cross section shown in FIG. 5(D). .. In this press forming, as shown in FIG. 6(B), a twisted portion that partially changes the twist angle in the longitudinal direction of the linear conductor piece 41 is formed. Subsequently, the central portion of the linear conductor piece 41 is bent and formed to form the segment conductor 30 having the bent portion 35, the linear portion 34, and the terminal portion 36 shown in FIG. 4.

The formation of the twisted portion in the press molding will be specifically described. As shown in FIG. 6(A), the press jig 40 includes a straight portion 34 of the segment conductor 30 which is close to the end portion 36 and a straight portion 34 of the segment conductor 30 which is close to the bent portion 35. In, the molding is performed so that the twist angles are different.

Here, as described later, the angle formed by the side surface b of the linear conductor piece 41 with respect to the center line a extending in the radial direction from the center of the stator 14 through the circumferential center of the slot 15 is defined as the twist angle. As shown in FIG. 6B, when the portion Y of the linear conductor piece 41 is indicated by a dotted line, the angle formed by the side surface by of the linear conductor piece 41 and the center line a is the twist angle φy. On the other hand, when the portion X of the linear conductor piece 41 is shown by a solid line, the angle formed by the side surface bx and the center line a is the twist angle φx. Thus, the straight conductor piece 41 is formed such that the twist angle φy of the portion Y of the straight conductor piece 41 is larger than the twist angle φx of the portion X of the straight conductor piece 41.

FIG. 7 is a perspective view and a sectional view of the segment conductor 30. 7A is similar to the perspective view of FIG. 4, but the above-described twisted portion is formed in the straight portion 34 of the segment conductor 30. 7B is a YY cross-sectional view of the segment conductor 30 shown in FIG. 7A. FIG. 7C is a cross-sectional view of the segment conductor 30 shown in FIG.

As shown in FIGS. 7B and 7C, in the segment conductor 30, the opening angle θ1 of the cross section of the straight portion 34 on the side of the terminal portion 36 and the opening angle θ2 of the coil cross section on the side of the bent portion 35 are different. The opening angle θ2 is larger than the opening angle θ1, and the opening angle of the straight portion 34 of the segment conductor 30 gradually increases from the end portion 36 side toward the bent portion 35 side.

For example, when the segment conductor 30 has a rectangular cross section, the long side length α, the short return length β, the slot width γ, the end portion side straight section cross section opening angle θ1, and the bent section side straight section cross section If the opening angle is θ2, the relationship between θ1 and θ2 is determined by the following equation (1).

FIG. 8 is a sectional view showing a state in which the segment conductor 30 is inserted into the slot 15 of the stator core 9. 8A is a cross section of the straight portion 34 of the segment conductor 30 on the terminal portion 36 side (portion X), and FIG. 8B is a bent portion 35 side (portion Y) of the straight portion 34 of the segment conductor 30. The cross section of is shown.

As shown in FIG. 8A, the linear portions 34x1, 34x2, 34x3, 34x4 of the segment conductor 30 are inserted into the slots 15. ~φx4 is small. The segment conductors 30 do not make point contact with both sides of the inner wall surface of the slot 15 at the corner portions of the cross-sectional shapes of the straight portions 34x1, 34x2, 34x3, 34x4. The corner portion may be in point contact with one side of the inner wall surface of the slot 15. This improves the insertability of the segment conductor 30 into the slot 15 when the stator 14 is assembled and manufactured.

As shown in FIG. 8(B), the straight portions 34y1, 34y2, 34y3, 34y4 of the segment conductor 30 are inserted into the slots 15. ~φy4 is large. The segment conductor 30 is in point contact with both sides of the inner wall surface of the slot 15 at the corners of the cross-sectional shape of the straight portions 34y1, 34y2, 34y3, 34y4. The corner portion is not limited to the point contact with both sides of the inner wall surface of the slot 15, and may be the point contact with at least one side of the inner wall surface. Further, the contact state is not limited to the point contact, and may be a configuration in which at least the inner wall surface of the slot 15 is in contact. This prevents the segment conductor 30 from being displaced after the segment conductor 30 is inserted into the slot 15.

Thus, in the cross section of the segment conductor 30 orthogonal to the axial direction of the stator 14, the side surface of the linear conductor piece 41 with respect to the center line a extending radially from the center of the stator 14 through the circumferential center of the slot 15. The angle formed by bx and by is defined as the twist angle. The twist angle is different between the end portion 36 side of the straight portion 34 of the segment conductor 30 and the bent portion 35 side. The twist angles φy1 to φy4 on the bent portion 35 side of the straight portion 34 are larger than the twist angles φx1 to φx4 on the terminal portion 36 side of the straight portion 34. Further, in the straight portion 34 of the segment conductor 30, the twist angle gradually increases from the end portion 36 side to the bent portion 35 side.

As a result, when the segment conductor 30 is inserted into the stator core 9, the torsion angles are relatively small on the side of the terminal portion 36, which is the insertion side of the segment conductor 30, so that the segment conductor 30 can be easily inserted into the slot 15. Will get better. Further, when the segment conductor 30 is inserted into the slot 15 and approaches the bent portion 35 side, the twist angle changes and comes into contact with the inner wall surface of the slot 15 at the corner portion of the cross section of the straight portion 34. Then, the frictional force holds the position of the segment conductor 30.

Next, a second example of the method of manufacturing the segment conductor 30 will be described with reference to FIG.
As shown in FIG. 9, the end portion 36 side of the segment conductor 30 is fixed to the fixtures 45 and 46. Next, the bent portion 35 side of the segment conductor 30 is clamped by the jigs 47 and 48. Then, a twisting step of rotating the jigs 47, 48 about the central axis of the segment conductor 30 is performed to generate a twist angle in the straight portion 34 of the segment conductor 30. Accordingly, the straight portion 34 of the segment conductor 30 can be formed such that the twist angle gradually increases from the end portion 36 side to the bent portion 35 side.

The segment conductor 30 shown in FIG. 4 is a hairpin-shaped segment conductor, and the hairpin-shaped segment conductor has been described as an example in the above-mentioned example. However, the segment conductor 30 is the segment conductor 60 for the lead wire shown in FIG. The deformed segment conductor 70 shown in FIG.

The straight portions 34, 61, 71 of the plurality of hairpin-shaped segment conductors 30, the lead wire segment conductor 60, and the odd-shaped segment conductor 70 are inserted into the slots 15 of the stator core 9. The terminal portions 36, 62, 72 of the segment conductors 30, 60, 70 have linear shapes 63, 73 (dotted lines in the figure) extending from the linear portions 34, 61, 71 before being incorporated in the stator core 9. After the segment conductors 30, 60, 70 have been assembled into the stator core 9, the portion protruding from the axial end surface of the stator core 9 is bent (solid line in the figure).

Here, similarly to the segment conductor 30 described above, the portion Y of the straight line portions 61, 71 close to the bent portions 65, 75 has a larger twist angle than the portion X of the straight line portions 61, 71 close to the terminal portions 62, 72. To be molded.

According to the embodiment described above, the following operational effects can be obtained.
(1) The rotating electric machine 100 has a plurality of segment conductors 30, 60, 70 and a stator core 9 in which a plurality of slots 15 are formed, and the plurality of segment conductors 30, 60, 70 are arranged in the plurality of slots 15 And the movable element 12 disposed on the inner peripheral side of the stator 14, and the segment conductors 30, 60, 70 include a pair of linear portions 34, 61 disposed in the slot 15. 71 and the bent portions 35, 65, 75 formed between the pair of straight portions 34, 61, 71, and the bent portions 35, 65, 75 of the pair of straight portions 34, 61, 71 on the opposite side, respectively. A pair of terminal portions 36, 62, 72 are formed, and the center line extending in the radial direction from the center of the stator 14 and the side surfaces of the linear portions 34, 61, 71 of the segment conductors 30, 60, 70. The twist angle is different between the side of the straight portions 34, 61, 71 closer to the end portions 36, 62, 72 and the side of the straight portions 34, 61, 71 closer to the bent portions 35, 65, 75. This improves the insertability of the segment conductor into the stator slot during assembly and manufacture of the stator, and prevents the segment conductor from being displaced after the segment conductor is inserted.

(2) The method for manufacturing the rotating electric machine 100 includes a plurality of segment conductors 30, 60, 70 and a stator core 9 having a plurality of slots 15 formed therein, and a plurality of segment conductors 30, 60, 70. Of the segment conductors 30, 60 and 70 are provided to the slot 15 when the stator 14 is manufactured. Segment conductors 30, which have terminal portions 36, 62, 72 inserted in the slots 15, bent portions 35, 65, 75 not inserted in the slots 15, and straight portions 34, 61, 71 arranged in the slots 15. When 60 and 70 are inserted into the slots 15, the twist angle formed by the center line extending radially from the center of the stator 14 and the side surfaces of the straight portions 34, 61 and 71 of the segment conductors 30, 60 and 70 is The segment conductors 30, 60, 70 are arranged such that the side portions of the straight line portions 34, 61, 71 close to the terminal portions 36, 62, 72 differ from the side portions of the straight line portions 34, 61, 71 near the bent portions 35, 65, 75. And a second step of inserting the twisted segment conductors 30, 60, 70 into the slots 15 from the end portions 36, 62, 72. This improves the insertability of the segment conductor into the stator slot during assembly and manufacture of the stator, and prevents the segment conductor from being displaced after the segment conductor is inserted.

The present invention is not limited to the above-described embodiment, and other forms conceivable within the scope of the technical idea of the present invention are also included in the scope of the present invention as long as the characteristics of the present invention are not impaired. ..

1 Housing 2 Bracket 3 Shaft 4 Tomoe 5, 10 Bearing 6 O-ring 7 Permanent Magnet 8 Rotor Core 9 Stator Core 12 Rotor (Mover)
13 Connection part 14 Stator 15 Slot 20 Winding 30, 60, 70 Segment conductor 31 Head part 32 Inclined part 33 Bent part 34, 61, 71 Straight part 35, 65, 75 Bent part 36, 62, 72 Terminal part 40 Press Jig 41 Linear conductor pieces 45, 46 Fixtures 47, 48 Jig 50 Coil lead wire 100 Rotating electric machine

Claims (8)

A stator having a plurality of segment conductors and an iron core having a plurality of slots formed therein, and a stator having the plurality of segment conductors arranged in the plurality of slots,
A mover arranged on the inner peripheral side of the stator,
The segment conductors are respectively formed on a pair of linear portions arranged in the slot, a bent portion formed between the pair of linear portions, and on opposite sides of the pair of linear portions from the bent portions. And a pair of terminal parts,
The twist angle formed by the center line extending in the radial direction from the center of the stator and the side surface of the straight portion of the segment conductor is a side closer to the terminal portion of the straight portion and a side closer to the bent portion of the straight portion. And different rotating electric machines. The rotating electric machine according to claim 1,
The twist angle is smaller on the side closer to the terminal portion of the linear portion than on the side closer to the bent portion of the linear portion,
The segment electric conductor is a rotary electric machine in which a side of the straight portion near the bent portion is in contact with an inner wall surface of the slot. The rotary electric machine according to claim 2,
The segment electric conductor is a rotary electric machine in which a side of the straight portion near the bent portion is in contact with both sides of an inner wall surface of the slot. The rotary electric machine according to claim 1 or 2,
The rotating electric machine wherein the straight portion of the segment conductor has a rectangular, barrel-shaped, or trapezoidal cross-sectional shape. A stator having a plurality of segment conductors and an iron core having a plurality of slots formed therein, and a stator having the plurality of segment conductors arranged in the plurality of slots,
A method of manufacturing a rotating electric machine comprising a mover arranged on the inner peripheral side of the stator,
The segment conductor has a terminal portion that is first inserted into the slot, a bent portion that is not inserted into the slot, and a straight portion that is arranged in the slot when the stator is manufactured,
When the segment conductor is inserted into the slot, the twist angle formed by the center line extending in the radial direction from the center of the stator and the side surface of the straight portion of the segment conductor is at the end portion of the straight portion. A first step of forming a twisted portion on the segment conductor so as to be different on a side closer to the bent portion of the straight portion,
A second step of inserting the segment conductor having the twisted portion into the slot from the terminal portion. The method for manufacturing a rotary electric machine according to claim 5,
The first step is a method of manufacturing a rotating electric machine, which is a pressing step of crushing the segment conductors to form the twisted portions. The method for manufacturing a rotary electric machine according to claim 5,
The said 1st process is a manufacturing method of the rotary electric machine which is a twisting process which rotates the said segment conductor centering on the central axis, and forms the said twisted part. The method for manufacturing a rotary electric machine according to claim 6 or 7,
In the first step, the rotating electric machine that forms the twisted portion on the segment conductor so that the twist angle is smaller on the side of the straight portion closer to the terminal portion than on the side of the straight portion closer to the bent portion. Manufacturing method.

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