JP2020205724A - Stator of rotary electric machine and rotary electric machine - Google Patents

Abstract

To easily penetrate even a small amount of impregnating material into the entire conductor segment, and prevent the resonance vibration of a stator core.SOLUTION: A stator of a rotary electric machine includes a cylindrical stator core with a plurality of slots arranged in the circumferential direction, and a plurality of conductor segments inserted into the slots, having a protrusion extending from both ends of the stator core in the axial direction of the stator core, and arranged in the radial direction of the stator core, the plurality of conductor segments inserted into the slots are fixed by an impregnating material applied to the protrusion of the conductor segment, and the conductor segment includes an inclined portion whose cross-sectional area changes continuously from one end side to the other end side of the stator core.SELECTED DRAWING: Figure 10

Description

The present application relates to a stator of a rotary electric machine and a rotary electric machine provided with the stator.

Stator used in rotary electric machines such as AC generators for vehicles has a structure in which a plurality of wound conductor segments are inserted into a plurality of slots arranged in the circumferential direction of a cylindrical stator core. There is.
This stator may induce resonance vibration of the stator core when the rotary electric machine is driven, and an impregnating material such as varnish is injected into the slot to fix the stator core and the conductor segment.

As a method of injecting the impregnating material into the slot of the stator core, a method of immersing the stator of the rotary electric machine in the impregnating material tank (Patent Document 1), an impregnating material is applied from the inner peripheral side of the stator core, and the slot is A method of infiltrating the stator (Patent Document 2) and a method of applying an impregnating material while rotating the stator in the horizontal direction and then drying and curing the stator while rotating the stator vertically (Patent Document 3) are known. There is.

Japanese Unexamined Patent Publication No. 2006-262541 Japanese Unexamined Patent Publication No. 2012-39719 Japanese Unexamined Patent Publication No. 2011-62036

In the stator of a conventional rotary electric machine, a large amount of impregnating material is required for impregnation (Patent Document 1), and the impregnating material adheres to unnecessary parts and parts that should not be applied (Patent Document 2). There is a problem that it is difficult to control the coating amount and control the adhesion amount of the impregnating material (Patent Document 3).

The present application has been made to solve the above-mentioned problems, and a stator that securely fixes the slot of the stator core and the conductor segment by dropping a small amount of an impregnating material and prevents resonance vibration. The purpose is to obtain.

The stator of the rotary electric machine of the present application has a cylindrical stator core having a plurality of slots arranged in the circumferential direction, and a protruding portion inserted into the slot and extending from both end faces of the stator core in the axial direction of the stator core. A plurality of conductor segments arranged in the radial direction of the stator core, and a plurality of conductor segments inserted in the slots are fixed by an impregnating material applied to the protruding portion of the conductor segment. It is a stator of a rotary electric machine, and the conductor segment is characterized by having an inclined portion whose cross-sectional area continuously changes from one end side to the other end side of the stator core.

The stator of the rotary electric machine of the present application has high permeability of the impregnating material into the slot of the stator core, can surely fix the stator core and the conductor segment, and can prevent resonance vibration.

It is sectional drawing of the alternator for a vehicle which concerns on Embodiment 1. FIG. It is a partial perspective view of the stator which concerns on Embodiment 1. FIG. It is a partial sectional view of the stator which concerns on Embodiment 1. FIG. It is a manufacturing flow figure of the stator which concerns on Embodiment 1. FIG. It is a block diagram of the conductor segment manufacturing apparatus which concerns on Embodiment 1. FIG. It is sectional drawing of the conductive material which concerns on Embodiment 1. FIG. It is the schematic of the flat-angle molded part of the conductive material which concerns on Embodiment 1. FIG. It is a figure which shows the conductor segment which concerns on Embodiment 1. FIG. It is a figure which shows the processing process of the conductor segment which concerns on Embodiment 1. FIG. It is sectional drawing which shows the impregnating material coating state of the stator which concerns on Embodiment 1. FIG. It is sectional drawing which shows the impregnating material coating state of the stator which concerns on Embodiment 2. FIG. It is sectional drawing which shows the impregnating material coating state of the stator which concerns on Embodiment 3. FIG.

In the description of the embodiment and each figure, the parts with the same reference numerals indicate the same or corresponding parts.

Embodiment 1.
The present embodiment will be described with reference to FIGS. 1 to 10.
First, the structure of the stator 9 will be described with reference to FIGS. 1 to 3.
FIG. 1 is a cross-sectional view showing the structure of a vehicle alternator 100 to which the stator 9 according to the present embodiment is applied, and FIG. 2 is a partial perspective view showing a state in which the conductor segment 20 is inserted into the stator 9. Is. FIG. 3 is a partial cross-sectional view showing slot 11 of the stator core 10 into which the conductor segment 20 is inserted.

<Structure of AC generator for vehicles>
FIG. 1 is a cross-sectional view showing the structure of an alternator 100 for a vehicle, which is an example of a rotary electric machine. In the vehicle alternator 100, a rotor 5 attached to a rotating shaft 4 is arranged in a case 3 composed of a front bracket 1 and a rear bracket 2, and a stator 9 is provided so as to cover the outer peripheral side thereof. It has an attached structure.

The rotor 5 is composed of a pair of iron pole cores 6 and 7 and a rotor coil 8 wound around the rotor coil 8. A current is passed through the rotor coil 8 to generate a magnetic flux, and the generated magnetic flux causes the pole cores 6 and 7 to be generated. A magnetic pole is formed at.
The stator 9 is composed of a stator core 10 made of a cylindrical laminated iron core and a stator winding wound around the stator core 10, and coil ends on the front side are provided at both ends of the stator winding. A portion 13 and a coil end portion 14 on the rear side are formed.

2 and 3 show the structure of the stator 9, FIG. 2 shows a part of the stator 9, and FIG. 3 shows a cross-sectional structure of a part of the stator core 10.
As shown in the partial perspective view of FIG. 2, a plurality of slots 11 penetrating to the other end face are formed on the end face of the stator core 10, and a plurality of conductor segments 20 are inserted into each slot 11. ing. Each conductor segment 20 is twisted and joined at the coil end portion 13 which is not covered by the stator core 10.

FIG. 3 is a part of a cross-sectional view of the stator core 10, and the lower part of the drawing is arranged so as to face the rotor 5. A plurality of slots 11 surrounded by broken lines are formed in the stator core 10. A plurality of conductor segments 20 are inserted as an aggregate in each slot 11. Further, a paper insulator 21 that electrically insulates both of the slot 11 and the conductor segment 20 is provided. In the present embodiment, the paper insulator 21 is used, but the present invention is not limited to this, and any impregnating material 73 described later can be used as long as it can penetrate.

In the present embodiment, the conductor segment 20 inserted into the slot 11 is the smallest unit constituting the stator winding, and the conductor segments 20 are twisted, joined, and formed at the coil end portions 13 and 14. The entire coil is called a stator winding. Further, an aggregate of a plurality of conductor segments 20 inserted into the same slot 11 may be collectively referred to as a conductor segment aggregate.

<Manufacturing process flow of stator>
The outline of the manufacturing process flow of the stator 9 will be described with reference to FIG.
Step S001
This is a conductor segment manufacturing process.
A copper conductive material 50 wound around a bobbin is used. The cross section of the conductive material 50 having a round cross section is crushed into a flat plate, and the insulating coating at the end is peeled off. Further, in this step, the end portion is subjected to plastic working to make the shape easy to join by welding.
Since this step is an important step of the present application, it will be described in detail in the next section with reference to FIG. 5 and the like, separately from the description of the manufacturing process flow.

Step S002
This is a conductor segment insertion process.
The conductor segment 20 manufactured in the previous process is inserted into the conductor segment holding jig as a preparatory step for inserting it into the slot 11. When inserting the conductor segment 20 into the conductor segment holding jig, a predetermined number of conductor segments 20 to be inserted into the slot 11 are bundled in advance, and then the conductor segments 20 are inserted in order from the end. A notch is formed in the conductor segment holding jig, which serves as a guide when the conductor segment holding jig is inserted into the insulator 21, and can be smoothly performed.
The amount of protrusion of the conductor segment 20 is adjusted so that the length of the conductor segment 20 protruding in the axial direction from both end faces of the conductor segment holding jig is longer on the other end side where twisting is not performed.

Step S003
Conductor segment twisting process (one end side).
The conductor segment of the conductor segment holding jig is supported by a flat plate from below, the amount of protrusion of the conductor segment 20 is adjusted, and the upper tip portion is twisted. Even if the adjacent conductor segments 20 are in contact with each other, the surface is coated with enamel so that there is no short circuit. However, in order to improve reliability, it is preferable to arrange them so that they do not come into contact with each other. Therefore, by twisting the adjacent conductor segments 20 apart from each other in the same slot 11, it is possible to avoid contact with each other. Further, even when the adjacent conductor segments 20 are twisted in the same direction, a gap is formed by changing the height, and contact can be avoided.

Next, the operation of the conductor segment twisting process (one end side) will be described.
The conductor segment holding jig in which the conductor segment 20 is inserted in the slot 11 is set in the conductor segment holding jig receiver. The outer peripheral portion of the conductor segment holding jig is fixed by a clamper, and the upper part of the conductor segment holding jig is suppressed by the conductor segment holding jig holder, and the vertical movement of the conductor segment holding jig is suppressed.
The conductor segment holding jig is fixed by the clamper and the conductor segment holding jig holder, the annular jig which is a torsion molding portion is lowered, and the end portion of the conductor segment 20 is inserted into the conductor segment insertion portion formed in the annular jig. Will be done. Of the tip portion of the conductor segment 20, only the portion that becomes the joint portion can be inserted into the conductor segment insertion portion. Further, a taper is formed at the end of the conductor segment 20 to facilitate insertion into the conductor segment insertion portion. On the other hand, a conductor segment insertion portion capable of accommodating a member longer than the conductor segment 20 is formed in the twist-molded portion of the conductor segment in which the lead type conductor segment is arranged.

The annular jig, which is a torsionally formed portion in which the end portion of the conductor segment 20 is inserted into the conductor segment insertion portion, is rotationally driven and lowered. The twist forming is performed on all of the conductor segments 20 at the same time. Further, the torsion molding portion is rotated by a predetermined angle so that the adjacent ring jigs are rotated in different directions.

Step S004
This is the insulator insertion process.
The end of the insulator 21 on the side where the conductor segment 20 is inserted is formed in a trumpet shape, facilitating the insertion of the conductor segment 20. On the other hand, the other end has a flat shape.
Since the insulator 21 and the conductor segment 20 are inserted in the same direction, even if a large force is applied in the axial direction of the stator core 10 when the conductor segment 20 is inserted, the insulator 21 is stopped at the end face of the stator core 10 and the insulator is inserted. There is no misalignment between 21 and the conductor segment 20.

Step S005
This is a one-end molded conductor segment insertion process in which one end is twisted and integrated.
The conductor segment 20 having one end formed is pulled out from the conductor segment holding jig, a lead type conductor segment having a wiring portion prepared separately is mixed, and the conductor segment 20 is inserted into the slot 11 of the stator core 10. After inserting into all the slots 11, the process proceeds to the next step.
Further, it is preferable that the step of extracting from the conductor segment holding jig and the step of inserting the conductor segment 20 into the stator core 10 are performed as a series of operations in one facility. As an example, a regulation jig in which the regulation pieces are arranged in a circumferential shape at the same interval as the slot 11 is used, and the regulation pieces are arranged between the straight portions of the conductor segments 20 arranged in an annular shape. In this state, by moving the stator core 10 and the regulating jig in the axial direction, the conductor segments 20 arranged in an annular shape can be inserted into the slot 11 of the stator core 10.

Step S006
This is the conductor segment twisting process (the other end side).
The twisting operation on the other end side is the same as the twisting operation of the conductor segment 20 in step S003.
The stator core 10 on which the conductor segment 20 inverted by the reversing machine is arranged is set on the stator core receiver so that the other end side faces upward. The lower part of the stator core 10 is supported by a jig that matches the shape of the conductor segment 20 on one end side for which the twisting process has been completed, and the tips of the other ends of all the conductor segments 20 are held at the same height.
The outer peripheral portion of the stator core 10 is fixed by a clamper, and the upper portion of the stator core 10 is pressed by the stator core retainer to suppress the vertical movement of the stator core 10.

After the stator core 10 is fixed by the clamper and the stator core retainer, the annular jig, which is a torsion molding portion, is lowered, and the other end of the conductor segment 20 is inserted into the conductor segment insertion portion formed in the annular jig. The tip part is inserted.
At the end of the conductor segment 20, only the tip portion serving as the joint can be inserted into the conductor segment insertion portion. Further, a taper is formed at the end portion of the conductor segment 20 to facilitate insertion into the conductor segment introduction portion.

The annular jig, which is a torsionally formed portion in which the end portion of the conductor segment 20 is inserted into the conductor segment insertion portion, is rotationally driven and lowered. The twist forming is performed on all of the conductor segments 20 at the same time. Further, the torsion molding portion is rotated by a predetermined angle so that the adjacent ring jigs are rotated in different directions.

Step S007
It is a welding process.
The parts twisted up to the previous process are joined by welding with a laser welder.
The joining process between the conductor segments 20 will be described. In this method, a plurality of conductor segments 20 are used to join the ends of different conductor segments 20 in order to form a rotating coil, and the method differs depending on the shape of the conductor segments 20, the winding method, and the like. In some cases, a method is used.

The joining process here will be described separately in two steps.
The first step is an end alignment step.
The two conductor segments 20 to be joined are held so that the side surfaces of the adjacent ends of the conductor segments 20 are in contact with each other. In the end alignment step of the conductor segment 20, the stator 9 which has been twisted at both ends is set, and the conductor segment 20 in the slot 11 is moved in the circumferential direction by using a conical taper pin. Hold the edge of. In the conductor segment 20 to be joined, the insulating coating in a predetermined region is removed from the tip portion.

The second step is a laser beam irradiation step of irradiating two adjacent ends with laser light at an inclination angle inclined to a predetermined angle and welding and joining the ends of the conductor segments 20 to each other. Here, the laser beam is applied to one of the two adjacent ends, and then the laser beam is moved to the other.
By this laser light irradiation, first, a part of the two adjacent ends irradiated with the laser light is melted. Since the gap between the two adjacent ends is fine, the molten conductor on one end fills the gap with the other end and then drives the laser beam. As a result, the laser beam is transferred from one end irradiated with the laser beam to the other end, and the other adjacent end is also melted. As a result, the ends of the conductor segments 20 can be welded to each other.

Step S008
This is a wiring and connection step of the lead type conductor segment mixed in step S005.
After welding between the terminals of the conductor segment 20, the end of the lead conductor segment is placed at a predetermined position between the output wire from the stator 9 and the neutral point of the Y connection or the interphase connection point of the delta connection. A conductor segment assembly is formed by forming and connecting a plurality of lead type conductor segments by welding or the like.

Step S009
This is a neutral point joining process.
The ends of the lead type conductor segments formed so that they can be joined as neutral points in the lead conductor segment forming step of step S008 are joined using a laser welder.

Step S010
This is a powder coating process.
Powder coating is performed to insulate the welded part.
The conductor is exposed at the end of the conductor segment 20 welded in the previous step, and in this step, insulation treatment with an insulating member is also performed.
Step S011
This is a step of applying an impregnating material to the conductor segment 20.
An impregnating material 73 is applied to improve the vibration resistance of the conductor segment 20, the heat dissipation of the conductor segment 20 in the slot 11, and the insulation between the conductor segments 20.
Since this process is also an important process of the present application, it will be described in detail with reference to FIG. 9 and the like separately from the manufacturing process flow.

<Step S001 Conductor segment manufacturing process>
The conductor segment manufacturing process of step S001, which is an important process of the present application, will be described.
In this step, the copper conductive material 50 used for the conductor segment 20 is processed into a shape, thickness, etc., and the conductive material 50 having a round cross section used for the conductor segment 20 is pressed into a flat shape having an angle R. Alternatively, the corners are flat and square, and at the same time, the thickness is also changed. Further, peeling and cutting of the insulating coating are also performed in the same process.

FIG. 5 is a configuration diagram of a conductor segment manufacturing apparatus 101 used for processing the conductor segment 20. Further, FIG. 6 shows the cross-sectional shape of the copper conductive material 50 supplied to the conductor segment manufacturing apparatus 101. As shown in the figure, the cross-sectional shape is round, the insulating coating 52 is on the outside, and the conductive portion is on the inside. It is equipped with 51.

The conductive material 50 for the conductor segment is supplied from the left side of FIG. 5, and first, in the straightening portion 53 of the conductor segment manufacturing apparatus 101, the conductive material 50 is straightened to have a shape suitable for processing.
Next, in the flat square forming portion 54, the round conductive material 50 is processed into a flat shape.

FIG. 7 shows a schematic view of the flat forming portion 54. The supplied conductive material 50 is fed from the back side to the front side of the paper surface, and pressure is applied to the feed path from the vertical direction and the horizontal direction as shown by the arrow 58 to form a round shape. The conductive material 50 of the above is made flat.
In FIG. 7, an example of a flat angle having an angle R is shown, but the same effect can be obtained even if the angle is a right angle.

The flat-angled conductive material 50 is sent to the coating stripping portion 56 via the conductive material feeding portion 55, and peels off the insulating coating at positions that become both end portions when cut into individual conductor segments 20. ..
Finally, the conductive material cutting portion 57 cuts at a predetermined cutting position, and the conductor segment manufacturing process is completed.

FIG. 8 shows the conductor segment 20 manufactured through the conductor segment manufacturing step of step S001. FIG. 8 shows a state in which the arrangement of the conductor segments 20 when processed by the conductor segment manufacturing apparatus 101 shown in FIG. 5 is observed from the side surface.

As shown in FIG. 8, the conductor segment 20 obtained in the present embodiment has a large thickness at both ends, and as a result, the cross-sectional area at both ends is large and the cross-sectional area at the center is small. The length of the conductor segment 20 is the sum of the lengths of the coil end portions 13 and 14 of the conductor segment 20 and the stator core 10.

In the processing of the conductor segment 20, when the conductive material 50 is pressed to form the conductor segment 20, it is necessary to extrude the surplus copper material from the mold to the outside in the portion to be thinly processed.
Assuming that the entire conductor segment 20 having a thin central portion shown in FIG. 8 is molded by using a single mold, a mold having a thin central portion was used. However, when it is difficult to completely extrude the excess copper material from the central portion to the outside of the mold, the central portion has a bulging shape as compared with the design value, and a good conductor segment 20 cannot be formed. There is.

Therefore, as shown in FIG. 9, when molding is performed by the flat forming portion 54 and the conductive material 50 is moved in the feed direction 28 for processing, the right side of the two conductor segments 20 arranged side by side is on the right side. The left half of the conductor segment 20 located at 1 and the right half of the conductor segment 20 located on the left side are integrally molded by one mold 26.
At this time, the thinly processed portion of the conductor segment 20 can be both ends of the mold 26, and the surplus copper material due to the processing can be smoothly moved to the outside of the mold 26. A good conductor segment 20 can be obtained by processing as described above and finally cutting at the cutting portion 27.

However, in the processing of the conductor segment 20 shown in FIG. 9, the processing pattern 25 due to the movement of the surplus copper material is formed. Since the processed pattern 25 may have lower strength and reliability than other parts, when used as the conductor segment 20, the processed pattern 25 is arranged in the slot 11 of the stator core 10. Therefore, good characteristics can be obtained.

<Step S011 Impregnated material coating process>
Next, the impregnating material coating step of step S011 will be described in detail with reference to FIG.
FIG. 10 shows a schematic cross-sectional view of the stator 9 of the vehicle alternator 100, and the slot 11 portion so that the arrangement state of the plurality of conductor segments 20 inserted into the slots 11 of the stator core 10 can be understood. Is shown in a cross section cut in the radial direction.

An insulator 21 is arranged in the slot 11 of the stator core 10, and a plurality of conductor segments 20 are arranged so as to overlap each other in the radial direction.
In the present embodiment, the conductor segment 20 is processed so that the cross-sectional area is small at the center, and the cross-sectional area is increased from the right end to the center of the conductor segment 20 in a state of being arranged in the slot 11. It includes a first inclined portion 63 that becomes smaller, and a second inclined portion 64 that becomes smaller in cross-sectional area from the left end portion to the center.

The conductor segment 20 protrudes in the axial direction from the slot 11 portion of the stator core 10 and forms the coil end portions 13 and 14, which are surrounded by broken lines, respectively. The impregnating material 73 is dropped onto the coil end portions 13 and 14 from the impregnating material discharge ports 71 of the two nozzles 70 arranged outside from both end faces of the stator core 10.
In the actual coating process, the impregnating material 73 is applied to the coil end portions 13 and 14 while rotating the cylindrical stator core 10 in which a plurality of conductor segments 20 are inserted into the slots 11 in the circumferential direction about the axis thereof. It can be dropped continuously.

The plurality of conductor segments 20 inserted into the slot 11 and arranged so as to overlap in the radial direction of the stator core 10 are the first inclined portion 63 and the second inclined portion 63 toward the center from both ends of the slot 11 as described above. Since the impregnating material 73 having the inclined portion 64 and having a small cross-sectional area at the central portion, the impregnating material 73 dropped on the coil end portions 13 and 14 efficiently enters the slot 11 in the direction of the arrow 72 indicating the permeation direction. It penetrates the whole and penetrates the paper insulator. As a result, the impregnating material 73 can be permeated into the entire conductor segment 20 with a small amount of the impregnating material 73, and the conductor segment 20 and the stator core 10 can be reliably fixed.

Further, in the present embodiment, since the insulator 21 is arranged in the slot 11 and covers the conductor segment 20, even when the impregnating material 73 is dropped while rotating the stator core 10 around its axis. Although the insulator 21 is made of paper and permeates, the impregnating material 73 does not spill around, and the impregnating material 73 can be prevented from adhering to the periphery of the stator core 10.

As described above, by infiltrating the impregnating material 73 between the conductor segments 20 in the slot 11, the insulating property between the conductor segments 20 can be enhanced and the resonance vibration can be suppressed. Further, the thermal conductivity from the conductor segment 20 to the stator core 10 is also improved, and the temperature rise in the conductor segment 20 can be reduced.

Embodiment 2.
The stator 9 of the rotary electric machine of the present embodiment has basically the same manufacturing process, twisting process, joining process, etc. of the conductor segment 20 as compared with the first embodiment, but the conductor segment 20 is a stator. When arranged in the slot 11 of the iron core 10, the arrangement of the inclined portion is different.

FIG. 11 shows a schematic cross-sectional view of a part of the stator 9 of the vehicle alternator 100, in which the cylindrical stator 9 is arranged with its axis oriented in the vertical direction, and the slot 11 portion in the radial direction. Shows the state of the cross section when the An insulator 21 is arranged in the slot 11 of the stator core 10, and a plurality of conductor segments 20 are arranged so as to overlap each other in the radial direction.

The conductor segment 20 used in the present embodiment has a different arrangement of inclined portions from the first embodiment, and in the conductor segment 20 of the present embodiment, the cross-sectional area at the center is processed to be larger than the cross-sectional area at both ends. There is. In the state of being arranged in the slot, the third inclined portion 65 whose cross-sectional area increases from one upper end to the center of the slot 11 and the fourth inclined portion 65 whose cross-sectional area increases from the lower other end to the center. The inclined portion 66 is provided.

The conductor segment 20 is similar to the first embodiment in that the conductor segment 20 projects axially from the slot 11 portion of the stator core 10 and forms the coil end portions 13 and 14 surrounded by the broken line. In the present embodiment, as shown in FIG. 10, a nozzle 70 is installed above the coil end portion 13, and the impregnating material 73 is dropped from the impregnating material discharge port 71.

The plurality of conductor segments 20 inserted into the slot 11 and arranged so as to overlap in the radial direction have a third inclined portion 65 and a fourth inclined portion 66 having a larger cross-sectional area from both ends toward the center. Therefore, the dropped impregnating material 73 can efficiently permeate into the slot 11 in the direction indicated by the arrow 72, and the impregnating material 73 can be permeated into the entire conductor segment 20 with a small amount of dropping.
Further, since the conductor segment 20 has a large cross-sectional area in the central portion, the impregnating material 73 can be held in the central portion, and the amount of the impregnating material 73 flowing downward can be suppressed. Can be prevented from leaking in the opposite direction.

As described above, by infiltrating the impregnating material 73 between the conductor segments 20 in the slot 11, the insulation between the conductor segments 20 can be improved and resonance vibration can be prevented, and the conductor segment 20 can be used as a stator. The thermal conductivity to the iron core 10 is also improved, and the temperature rise in the conductor segment 20 can be reduced.

Embodiment 3.
The stator 9 of the rotary electric machine of the present embodiment has basically the same manufacturing process, twisting process, joining process, etc. of the conductor segment 20 as compared with the first and second embodiments, but the conductor. When the segment 20 is arranged in the slot 11 of the stator core 10, the shape of the inclined portion is different.

FIG. 12 shows a schematic cross-sectional view of the stator 9 of the vehicle alternator 100, and similarly to FIG. 11, the cylindrical stator 9 is arranged with its axis oriented in the vertical direction, and is arranged in the radial direction. The state of the cross section when the slot 11 portion is cut is shown. An insulator 21 is arranged in the slot 11 of the stator core 10, and a plurality of conductor segments 20 are arranged so as to overlap each other in the radial direction.

Unlike the first and second embodiments, the conductor segment 20 used in the present embodiment has a fifth aspect in which the cross-sectional area increases from one upper end of the slot 11 toward the lower other end. The inclined portion 67 is provided.

The conductor segment 20 projects axially from the slot 11 portion of the stator core 10 to form the coil end portions 13 and 14. As shown in FIG. 12, a nozzle 70 is installed above the coil end portion 13, and the impregnating material 73 is dropped from the impregnating material discharge port 71.

The conductor segment 20 inserted into the slot 11 and arranged so as to overlap in the radial direction has a fifth inclined portion 67 whose cross-sectional area increases from one upper end to the lower other end, and thus drops. The impregnating material 73 efficiently permeates into the slot 11 in the direction indicated by the arrow 72, and the impregnating material 73 can permeate the entire conductor segment 20 with a small amount of dropping.
Further, since the conductor segment 20 has a large cross-sectional area on the lower side, the impregnating material 73 can be held and leakage of the impregnating material 73 can be prevented.

As described above, by infiltrating the impregnating material 73 between the conductor segments 20 in the slot 11, the insulation between the conductor segments 20 can be improved and resonance vibration can be prevented, and the conductor segment 20 can be used as a stator. The thermal conductivity to the iron core 10 is also improved, and the temperature rise in the conductor segment 20 can be reduced.

Although various exemplary embodiments and examples have been described in the present application, the various features, embodiments, and functions described in one or more embodiments may be applied to the application of a particular embodiment. Not limited, it can be applied to embodiments alone or in various combinations.
Therefore, innumerable variations not illustrated are envisioned within the scope of the techniques disclosed herein. For example, it is assumed that at least one component is modified, added or omitted, and further, at least one component is extracted and combined with the components of other embodiments.

1 Front bracket, 2 Rear bracket, 3 Case, 4 Rotating shaft, 5 Rotor, 6 Pole core, 7 Pole core, 8 Rotor coil, 9 Fixture, 10 Conductor core, 11 slot, 13 Coil end, 14 Coil end Part, 20 Conductor segment, 21 Insulator, 25 Processing pattern, 26 Mold, 27 Cut part, 28 Feed direction, 50 Conductive material, 51 Conductive part, 52 Insulation coating, 53 Straightening part, 54 Flat angle molding part, 55 Conductive material feed Part, 56 Coating peeling part, 57 Conductive material cutting part, 58 Arrow, 63 First inclined part, 64 Second inclined part, 65 Third inclined part, 66 Fourth inclined part, 67 Fifth inclined part , 70 nozzles, 71 impregnated material discharge port, 72 arrows, 73 impregnated material, 100 vehicle alternators, 101 conductor segment manufacturing equipment.

Claims (11)

A cylindrical stator core with multiple slots arranged in the circumferential direction,
A plurality of conductor segments inserted into the slot, having protrusions extending in the axial direction of the stator core from both end faces of the stator core, and arranged in the radial direction of the stator core.
A stator of a rotary electric machine in which the plurality of conductor segments inserted into the slots are fixed by an impregnating material applied to the protruding portion of the conductor segments.
The conductor segment
Stator A stator of a rotary electric machine having an inclined portion whose cross-sectional area continuously changes from one end side to the other end side of the stator core. The conductor segment
A first inclined portion whose cross-sectional area continuously decreases from one end side to the central portion of the stator core,
The stator of a rotary electric machine according to claim 1, further comprising a second inclined portion whose cross-sectional area continuously decreases from the other end side of the stator core toward the central portion. The stator of a rotary electric machine according to claim 2, wherein a processing pattern resulting from the molding of the conductor segment is provided between the first inclined portion and the second inclined portion of the conductor segment. .. The second aspect of claim 2, wherein the decrease in the cross-sectional area of the first inclined portion and the second inclined portion is a decrease in the size of the conductor segment in the radial direction of the stator core. Stator of rotary electric machine. The conductor segment
A third inclined portion whose cross-sectional area continuously increases from one end side to the central portion of the stator core, and a third inclined portion.
The stator of a rotary electric machine according to claim 1, further comprising a fourth inclined portion whose cross-sectional area continuously increases from the other end side of the stator core toward the central portion. The fifth aspect of claim 5, wherein the increase in the cross-sectional area of the third inclined portion and the fourth inclined portion is an increase in the size of the conductor segment in the radial direction of the stator core. Stator of rotary electric machine. The conductor segment
The stator of a rotary electric machine according to claim 1, further comprising a fifth inclined portion whose cross-sectional area continuously increases from one end side to the other end side of the stator core. The stator of a rotary electric machine according to claim 7, wherein the increase in the cross-sectional area of the fifth inclined portion is an increase in the size of the conductor segment in the radial direction of the stator core. The stator of a rotary electric machine according to any one of claims 1 to 8, wherein the conductor segment has a rectangular cross-sectional shape. The stator of a rotary electric machine according to any one of claims 1 to 9, wherein an insulator is provided between the conductor segment and the slot. The stator of the rotary electric machine according to any one of claims 1 to 10,
A rotary electric machine characterized by having a rotor rotatably attached to a rotary shaft and arranged on the inner diameter side of the stator.

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