JP2021093789A - Stator of rotary electric machine and method for manufacturing the same - Google Patents

Abstract

To provide a stator of a rotary electric machine in which a plurality of windings can be inserted into slots simultaneously and a skew structure can be constructed without forming a skew shape in a stator core, and to provide a method for manufacturing the stator of the rotary electric machine.SOLUTION: A stator of a rotary electric machine includes a plurality of split stator cores arranged in the axial direction. Among the plurality of split stator cores, first and second stator cores adjacent to each other are arranged so that a first slot of the first stator core and a second slot of the second stator core are displaced in the circumferential direction from the axially aligned arrangement. A winding includes a first winding inserted in the first slot and a second winding inserted in the second slot. The first winding and the second winding are connected at a position between the first stator core and the second stator core. At the position where the first and second windings are connected, a stepped portion is formed in which the first and second windings are displaced from each other in the circumferential direction.SELECTED DRAWING: Figure 3

Description

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

In Patent Document 1, the slot is skewed, the molded conductor wire is pushed inward in the radial direction of the stator core in the same direction as the skewed slot, and then the slot accommodating portion of the molded conductor wire (winding) is pushed outward in the radial direction. Disclosed is a technique for winding a stator coil made of a molded conductor wire around a stator core by urging and pushing it into a slot and performing this work sequentially from one end side of the molded conductor wire to each slot accommodating portion of the molded conductor wire. ing.

JP-A-2009-044901

However, in Patent Document 1, in order to form a skew shape, a step of laminating the laminated steel plates constituting the stator core while shifting them one by one in the circumferential direction is required, which requires a huge number of man-hours. Further, since the windings are inserted from the inside of the stator core (opening of the slot) according to the shape of the stator core, it is difficult to insert a plurality of windings into the slot at the same time.

Therefore, the present invention provides a rotary electric machine stator and a method for manufacturing a rotary electric machine stator, in which a plurality of windings can be inserted into a slot at the same time and a skew structure can be constructed without forming a skew shape in the stator core. With the goal.

The stator of the rotary electric machine according to one aspect of the present invention includes a cylindrical stator core in which slots penetrating in the axial direction are formed at a predetermined pitch in the circumferential direction, and a winding for a stator coil inserted into the slots. It is a stator of a rotary electric machine. The stator core includes a plurality of divided stator cores arranged side by side in the axial direction, and among the plurality of divided stator cores, the first stator core and the second stator core adjacent to each other are the first slot of the first stator core and the first of the second stator cores. The two slots are arranged so as to be offset from each other in the circumferential direction from the arrangement in which the two slots are aligned in the axial direction, and the windings are the first winding inserted in the first slot and the second winding inserted in the second slot. , The first winding and the second winding are connected at a position between the first stator core and the second stator core, and at the connection position between the first winding and the second winding, the first winding A step portion is formed in which the wire and the second winding are displaced from each other in the circumferential direction.

In the above embodiment, the stator has a skew formed by a step in the circumferential direction of the winding formed between the second stator cores of the first stator core. As a result, the stator core (first stator core, second stator core) does not need to have a skew shape, so that the cost can be suppressed by easily constructing the stator core without using expensive special equipment. Further, the windings (first winding, second winding) inserted into the slots of the stator core (first slot, second slot) have a linear shape, and it is necessary to form an opening of the slot on the inner peripheral surface of the stator core. Therefore, deterioration of torque ripple and magnetic loss can be suppressed. Further, since the windings (first winding, second winding) have a linear shape as described above, the windings (first winding, second winding) are wound in all the slots (first slot, second slot). Winding) can be inserted at the same time. Therefore, the manufacturing process can be simplified and the cost can be suppressed. Further, since the joint portion between the first winding and the second winding is located between the first stator core and the second stator core, the portion can be visually or image-processed, and quality control can be easily performed. .. Further, since a resin mold can be formed between the first stator core and the second stator core, the insulation treatment of the joint portion can be easily performed.

FIG. 1 is a schematic view of the stator of the first embodiment. FIG. 2 is a perspective view of the split stator core (first stator core, second stator core). FIG. 3 is a diagram showing a joining form of the first winding and the second winding. FIG. 4 is a diagram showing an arrangement form of the first winding and the second winding with respect to the slots, and FIG. 4A shows the first winding (top view with FIG. 3 as the front) and FIG. 4B. Is the second winding (bottom view with FIG. 3 as the front). 5A and 5B are modified examples of the joint form of the first winding and the second winding, FIG. 5A is a modified example of the first, and FIG. 5B is a modified example of the second. 6A and 6B are modified examples of the joint form of the first winding and the second winding, FIG. 6A is a modified example of the third winding, and FIG. 6B is a line AA of FIG. 6A. It is a sectional view. 7A and 7B are modified examples of the joint form of the first winding and the second winding, FIG. 7A is a fourth modified example, and FIG. 7B is a fifth modified example. FIG. 8 is a schematic view of the stator of the second embodiment. FIG. 9 is a plan view of the intermediate stator core. FIG. 10 is a schematic view of the stator of the third embodiment. FIG. 11 is a schematic view of the stator of the fourth embodiment.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[Basic configuration of the first embodiment]
FIG. 1 is a schematic view of the stator of the present embodiment. FIG. 2 is a perspective view of the split stator core 11 (first stator core 11A, second stator core 11B). FIG. 3 is a diagram showing a joining form of the first winding 2 and the second winding 3. FIG. 4 is a diagram showing an arrangement mode of the first winding 2 and the second winding 3 with respect to the slot 15 (first slot 15A, second slot 15B), and FIG. FIG. 3 is a top view with FIG. 3 as the front), and FIG. 4 (b) is a second winding 3 (bottom view with FIG. 3 as the front).

The "axial direction", "circumferential direction", and "radial direction" used in the present embodiment are directions orthogonal to each other, and the "axial direction" is the central axis of the cylindrical stator core 1 (divided stator core 11). It is a parallel direction, the "circumferential direction" is a direction that orbits in an arc shape about the central axis in a plane having the central axis as the normal line, and the "radial direction" is the normal line of the central axis. It is a direction linearly approaching and a direction away from the central axis in the plane to be.

The stator of the present embodiment is composed of a stator core 1 (first stator core 11A, second stator core 11B) and windings for the stator coil (first winding 2, second winding 3).

The first stator core 11A and the second stator core 11B are divided stator cores 11 in which the stator core 1 is divided into a plurality of (two in FIG. 1) in the axial direction. The "first stator core 11A" and "second stator core 11B" mean one and the other of the divided stator cores 11 adjacent to each other, and are specified even when the stator core 1 is divided into three or more as described later. It does not refer to the split stator core 11 of the above, but is a concept including all combinations having a relationship between one of the split stator cores 11 adjacent to each other and the other.

The first stator core 11A and the second stator core 11B are each formed by laminating electromagnetic steel sheets, and a common electromagnetic steel sheet is applied. The electrical steel sheet is a ring-shaped member, and forms a circular opening 141 forming an insertion hole 14 through which a rotor (not shown) is inserted in the stator core 1 and a slot 15 (first slot 15A, second slot 15B). A rectangular opening 151 is provided.

A plurality of slots 15 (openings 151) are arranged so that the radial direction is the longitudinal direction and the slots 15 (openings 151) orbit around the circumferential direction at a predetermined pitch. Further, the slot 15 (opening 151) is arranged so as to be separated from the insertion hole 14 (opening 141). As a result, the slot 15 does not open on the side surface (inner peripheral surface) of the insertion hole 14.

The first stator core 11A and the second stator core 11B have at least the same shape when viewed from the axial direction, and are arranged coaxially in the axial direction. The split stator core 11 (first stator core 11A, second stator core 11B) may be formed by dividing the stator core 1 in the axial direction, but the length of the split stator core 11 in the axial direction may be set in advance. Laminated steel plates may be independently laminated and formed.

As shown in FIGS. 1 and 3, in the first stator core 11A and the second stator core 11B, the first slot 15A formed in the first stator core 11A and the second slot 15B formed in the second stator core 11B are axially oriented. It is arranged so as to be slightly deviated (rotated) in the circumferential direction from the position where it is lined up in a straight line (it appears to overlap when viewed from the axial direction). The amount of deviation in the circumferential direction is equal to or less than the width of the windings (first winding 2, second winding 3) in the circumferential direction. Therefore, the teeth 16A between the first slots 15A adjacent to each other of the first stator core 11A and the teeth 16B between the second slots 15B adjacent to each other of the second stator core 11B are also slightly displaced in the circumferential direction.

As shown in FIGS. 3 and 4, the first winding 2 and the second winding 3 are provided with a form such that they are wound around the teeth 16A of the first stator core 11A and the teeth 16B of the second stator core 11B. , Forming a stator coil. The "first winding 2" and the "second winding 3" are the windings (for example, the first winding 2) arranged on one of the divided stator cores 11 (for example, the first stator core 11A) adjacent to each other. It means a winding (for example, the second winding 3) arranged on the other side (for example, the second stator core 11B), and refers to a specific winding even when the stator core 1 is divided into three or more as described later. Rather, it is a concept that includes all combinations having a relationship between the windings arranged on one side of the split stator cores 11 adjacent to each other and the windings arranged on the other side.

The first winding 2 and the second winding 3 are flat wires having, for example, copper as a material and having a common rectangular (square) cross section, and the outer periphery thereof is coated with an insulating material. As shown in FIG. 4, the first winding 2 and the second winding 3 are wound around the teeth 16A and 16B a plurality of times via the first slot 15A and the second slot 15B (concentrated winding). However, distributed winding is also possible. A plurality of the first windings 2 are inserted into the first slot 15A, and are arranged so as to be arranged in a row in the longitudinal direction (radial direction) of the rectangular opening 151 of the first slot 15A. Similarly, a plurality of the second windings 3 are inserted into the second slot 15B, and are arranged so as to line up in the longitudinal direction (radial direction) of the rectangular opening 151 of the second slot 15B. The circumferential widths of the first winding 2 and the second winding 3 are formed so as to be the same as or slightly smaller than the circumferential widths of the first slot 15A and the second slot 15B.

As the first winding 2, a plurality of U-shaped ones (three in FIG. 4) and two linear ones can be applied. The linear first winding 2 includes a lead wire 23 that forms an end of the stator coil and is connected to the outside. The U-shaped first winding 2 is a combination of a pair of straight portions 21 inserted into the first slot 15A and a connecting portion 22 connecting the pair of straight portions 21. The connecting portion 22 and the lead-out electric wire 23 are arranged outside the first stator core 11A. Therefore, in the first winding 2, the connecting portion 22 and the lead-out electric wire 23 can be resin-molded in advance and integrated. Therefore, the connecting portions 22 and the lead wire 23 of all the first windings 2 attached to the first stator core 11A can be integrated in advance by the resin mold, and can be simultaneously inserted into the first slot 15A of the first stator core 11A. .. For the integrated structure, refer to, for example, WO2015 / 19432A1 and the like.

As the second winding 3, a plurality of U-shaped coils (four in FIG. 4) can be applied as in the first winding 2, and the second winding 3 and the pair of straight portions 31 inserted into the second slot 15B can be applied. , A connecting portion 32 for connecting the pair of straight portions 31 is provided. Similar to the first winding 2, the connecting portions 32 of all the second windings 3 to be inserted into the second stator core 11B are integrated in advance by the resin mold, so that they can be inserted into the second slot 15B of the second stator core 11B at the same time. Can be made to.

As shown in FIG. 3, the first winding 2 is arranged so as to be inserted into the first slot 15A of the first stator core 11A and project from the first slot 15A toward the second stator core 11B. Similarly, the second winding 3 is arranged so as to be inserted into the second slot 15B of the second stator core 11B and project from the second slot 15B toward the first stator core 11A.

The first winding 2 and the second winding 3 are displaced from each other by approximately half the width of the first winding 2 (second winding 3) in the circumferential direction from the position where they overlap in a straight line when viewed from the axial direction. It is arranged. Further, when viewed from the axial direction, the first winding 2 and the second winding 3 overlap each other, and a part of the end face of the first winding 2 and a part of the end face of the second winding 3 are joined to each other. (Basic form). Then, at the joint position between the first winding 2 and the second winding 3, a step portion 4 is formed in which the first winding 2 and the second winding 3 are displaced from each other in the circumferential direction.

Examples of the joining method between the first winding 2 and the second winding 3 include, but are not limited to, cold solid phase bonding, solid phase bonding of fine particle powder, resistance welding, and laser welding. In the cold solid phase bonding, new copper surfaces (surfaces without an oxide film) are brought into contact with each other and pressed to be bonded. Solid-phase bonding of fine particle powder is performed by arranging (sandwiching) copper nano-level fine particles in a powder state at a bonding position and solidifying them by applying an impact. In resistance welding, joint portions are brought into contact with each other to be energized, and the joint portions where contact resistance is generated are preferentially generated and melted to join the joints. Laser welding is to join by directly irradiating the joint with a laser to generate heat and melt it, and it can be applied within the range that can be seen from the outside. It is desirable to remove the insulating material from the joint portion of the first winding 2 and the second winding 3 in advance before joining.

In the manufacturing process of the stator of the present embodiment, for example, the resin-molded first winding 2 is inserted into the first stator core 11A, and the resin-molded second winding 3 is inserted into the second stator core 11B. .. Then, the second stator core 11B is arranged on the work table so that the end portion of the second winding 3 joined with the first winding 2 faces upward, and the first stator core 11A is arranged on the second stator core 11B.

At that time, the first stator core 11A is arranged on the second stator core 11B so that the end portion of the first winding 2 joined to the second winding 3 faces downward, and the first winding 2 and the second winding By shifting from the position where the wires 3 overlap each other in the axial direction in the circumferential direction, a part of the end face of the first winding 2 and a part of the end face of the second winding 3 are arranged so as to overlap each other when viewed from the axial direction. , The first winding 2 is arranged so that a part of the end face is placed on a part of the end face of the second winding 3. In this state, the stator of the present embodiment having a skew is constructed by joining the first winding 2 and the second winding 3 by using the above joining method or the like.

As shown in FIG. 3, in the present embodiment (basic embodiment), the boundary line of the joint portion between the first winding 2 and the second winding 3 is arranged between the first stator core 11A and the second stator core 11B. At the same time, since it faces the radial direction (outside), the joint portion can be easily visually recognized and the quality judgment can be easily performed.

5A and 5B are modified examples of the joint form of the first winding 2 and the second winding 3, FIG. 5A is a modified example of the first, and FIG. 5B is a modified example of the second.

In the first modification and the second modification, as in the basic form, the first winding 2 (second winding 2) is located in the circumferential direction from the position where the first winding 2 and the second winding 3 are aligned in a straight line when viewed from the axial direction. The arrangement is offset (rotated) from each other by approximately half the width of the winding 3). Then, a fitting portion is formed in a part of the end portion of the first winding 2 and a part of the end portion of the second winding 3 that overlap each other when viewed from the axial direction, and the fitting portions are engaged with each other. A stator with a skew is constructed by joining in a state of being joined.

In the first modification shown in FIG. 5A, wedge portions 24 and 34 are formed as fitting portions. The wedge portions 24 and 34 are formed as notches penetrating the first winding 2 and the second winding 3 in the radial direction, respectively.

The wedge portion 24 of the first winding 2 has a vertical surface 241 formed by cutting from the center of the end portion of the first winding 2 in the longitudinal direction (axial direction) of the first winding 2, and the vertical surface 241. It is provided with an inclined surface 242 formed by being cut from the deepest portion of the first winding 2 toward a corner portion of an end portion of the first winding 2 and in contact with the second winding 3.

The wedge portion 34 of the second winding 3 has a vertical surface 341 formed by cutting from the center of the end portion of the second winding 3 in the longitudinal direction (axial direction) of the second winding 3, and the vertical surface 341. It is provided with an inclined surface 342 formed by being cut from the deepest portion of the second winding 3 toward the corner portion of the end portion of the second winding 3 and in contact with the first winding 2. The inclined surface 242 of the first winding 2 and the inclined surface 342 of the second winding 3 have substantially the same size and inclination angle.

In the first winding 2 and the second winding 3, the inclined surface 242 of the first winding 2 and the inclined surface 342 of the second winding 3 come into contact with each other, and the side surface of the first winding 2 and the second winding 3 come into contact with each other. The step portion 4 is formed by joining the vertical surface 341 of the first winding 2 in contact with the side surface of the second winding 3 and the vertical surface 241 of the first winding 2 in contact with each other.

In the second modification shown in FIG. 5B, uneven portions 25 and 35 are formed as fitting portions. The uneven portions 25 and 35 are also formed as notches penetrating the first winding 2 and the second winding 3 in the radial direction.

The concave-convex portion 25 of the first winding 2 is a concave portion formed at a position separated from the center of the end portion of the first winding 2 on the side surface of the first winding 2 and in contact with the second winding 3. 251 and a convex portion 252 that includes the side surface and has an inner wall of the concave portion 251 as an outer wall are provided, and the widths of the concave portion 251 and the convex portion 252 in the circumferential direction are substantially the same.

The concave-convex portion 35 of the second winding 3 is a concave portion formed at a position separated from the center of the end portion of the second winding 3 on the side surface of the second winding 3 and in contact with the first winding 2. A 351 and a convex portion 352 that includes the side surface and has an inner wall of the concave portion 351 as an outer wall are provided, and the widths of the concave portion 351 and the convex portion 352 in the circumferential direction are substantially the same.

In the first winding 2 and the second winding 3, the convex portion 252 of the first winding 2 is fitted into the concave portion 351 of the second winding 3, and the convex portion 352 of the second winding 3 is the first winding 2. The stepped portion 4 is formed by joining in a state of being fitted into the concave portion 251 of the above.

In the first modification and the second modification, since the first winding 2 and the second winding 3 are in a state of being engaged with each other before joining, the joining operation can be easily performed.

FIG. 6 is a modified example of the joint form of the first winding 2 and the second winding 3, FIG. 6 (a) is a modified example of the third, and FIG. 6 (b) is A-A of FIG. 6 (a). It is a cross-sectional view of line A. In the third modification, rectangular counterbore 26 and 36 are formed at the end of the first winding 2 and the end of the second winding 3, respectively, and the stepped portion 4 is formed by joining the counterbore 26 and the counterbore 36 to each other. It is formed.

The counterbore 26 (first counterbore) of the first winding 2 has a predetermined depth (approximately half the width of the first winding 2 in the radial direction) from the inside of the end portion of the first winding 2 in the radial direction. The first winding 2 is cut into a rectangular shape up to the length) to form a thin wall, and the first corner is formed so that the corner portion in contact with the second winding 3 becomes the corner of the rectangular shape. The end face and side surface of the winding 2 are open.

The counterbore 36 (second counterbore) of the second winding 3 has a predetermined depth (approximately half the width of the second winding 3 in the radial direction) from the outside in the radial direction of the end portion of the second winding 3. The second winding 3 is cut out to a rectangular shape up to the length) to form a thin wall, and the second winding is formed so that the corner portion in contact with the first winding 2 becomes the corner of the rectangular shape. The end face and side surface of the winding 3 are open.

In the third modification, the joint surface 26a facing the inside of the counterbore 26 of the first winding 2 in the radial direction is formed, and the joint surface 36a facing the outside of the counterbore 26 of the second winding 3 in the radial direction is formed. Is formed, and the joint surface 26a and the joint surface 36a are joined to each other. The joint surface 26a and the joint surface 36b are shielded from the outside. Therefore, it is possible to suppress aged deterioration of the joint portion between the first winding 2 and the second winding 3.

7A and 7B are modified examples of the joint form of the first winding 2 and the second winding 3, FIG. 7A is a fourth modified example, and FIG. 7B is a fifth modified example.

In the fourth modification shown in FIG. 7A, the arrangement of the first stator core 11A and the second stator core 11B is the same as that of the basic form, the first modification to the third modification. At the end of the first winding 2 and the end of the second winding 3, the inclined surface 27 (first inclined surface) and the inclined surface 37 (second inclined surface) are partially overlapped with each other when viewed from the axial direction, respectively. Surface) is formed. The inclined surfaces 27 and 37 are also formed as notches penetrating the first winding 2 and the second winding 3 in the radial direction.

The inclined surface 27 of the first winding 2 is formed in a manner of chamfering a corner portion of an end portion of the first winding 2 and overlapping the second winding 3 when viewed from the axial direction. The inclined surface 37 of the second winding 3 is formed in a manner of chamfering the corner portion of the end portion of the second winding 3 and overlapping the first winding 2 when viewed from the axial direction. The inclined surface 27 of the first winding 2 and the inclined surface 37 of the second winding 3 have substantially the same inclination angle. Then, the stepped portion 4 is formed by joining the inclined surface 27 of the first winding 2 and the inclined surface 37 of the second winding 3 to each other.

In the fifth modification shown in the seventh (b), in the first stator core 11A and the second stator core 11B, the first slot 15A of the first stator core 11A and the second slot 15B of the second stator core 11B are axes when viewed from the axial direction. The arrangement is offset from each other by the width of the first slot 15A (first winding 2) and the second slot 15B (second winding 3) in the circumferential direction from the positions aligned in the direction. Then, the end portion of the first winding 2 and the end portion of the second winding 3 are in contact with each other on the side surfaces facing each other, and the step portion 4 is formed by joining each other at the contact position.

In the fourth modification and the fifth modification, it is difficult for the second winding 3 to support the first winding 2 before joining the first winding 2 and the second winding 3. Therefore, a jig (spacer, not shown) can be arranged between the first stator core 11A and the second stator core 11B so that the contact state between the first winding 2 and the second winding 3 can be maintained at the time of joining. desirable. The fifth modification is an effective configuration when it is desired to increase the skew (deviation amount in the circumferential direction) of the stator core 1.

[Second Embodiment]
FIG. 8 is a schematic view of the stator of the second embodiment. FIG. 9 is a plan view of the intermediate stator core 11C. The stator of the second embodiment is the stator of the first embodiment in which the intermediate stator core 11C is inserted between the first stator core 11A and the second stator core 11B.

The intermediate stator core 11C can be formed by using, for example, an electromagnetic steel plate common to the first stator core 11A and the second stator core 11B. In the manufacturing process of the intermediate stator core 11C, the electromagnetic steel sheet is laminated by the gap between the first stator core 11A and the second stator core 11B, and an opening 152 is formed in the laminated electromagnetic steel sheet so that the slot 15 communicates with the insertion hole 14. .. Then, the laminated electromagnetic steel sheets may be divided in the circumferential direction by the number of slots 15 (48 in FIGS. 2 and 9).

On the other hand, the joint portion (step portion 4) between the first winding 2 and the second winding 3 is designed so that the width in the circumferential direction is the same as or slightly smaller than the width of the slot 15. Not only the basic configuration but also the first modification to the fifth modification can be applied to the step portion 4.

Then, the intermediate stator core 11C is inserted between the first stator core 11A and the second stator core 11B in a manner in which the step portion 4 is inserted through the opening 152 to fit the intermediate stator core 11C. Then, by inserting all the stepped portions 4 (the same number as the number of slots 15) into the intermediate stator core 11C, the space between the first stator core 11A and the second stator core 11B is closed without a gap. As a result, magnetic leakage from the stator core 1 can be reduced. Further, since the intermediate stator core 11C can be constructed by using the electromagnetic steel sheets used in the existing first stator core 11A and the second stator core 11B, the cost can be suppressed.

In FIG. 9, the electrical steel sheet is cut at a position where the tooth 16 is bisected, but the slot 15 may be cut at a position where the slot 15 is bisected. In this case, the intermediate stator core 11C is inserted between the first stator core 11A and the second stator core 11B in a manner in which the teeth 16 are inserted between the stepped portions 4 adjacent to each other in the circumferential direction.

[Third Embodiment]
FIG. 10 is a schematic view of the stator of the third embodiment. In the stator of the third embodiment, three or more stator cores 1 are arranged in the axial direction (three in FIG. 10), and a plurality of skews are formed.

The axial length of the split stator core 11 can be arbitrarily designed. For example, in FIG. 10, the split stator core 11 arranged at the center is shorter in the axial direction than the split stator core 11 arranged on the left and right. It is formed.

Also in the third embodiment, the split winding 5 (for example, the first winding 2) and the split winding 5 (for example, the second winding) are located between the split stator cores 11 (first stator core 11A, second stator core 11B) adjacent to each other. A step portion 4 is formed at the connection position with the wire 3), and this is a skew. The stator core 1 as a whole is formed with an arbitrary arrangement so that the skew is contained in a range shorter than the pitch in the circumferential direction of the slot 15.

As shown in FIG. 10, the stepped portion 4 (skew) formed on the left side of the split stator core 11 arranged in the center and the stepped portion 4 (skew) formed on the right side are divided and wound so that their positions are different in the circumferential direction. It is possible to connect the wire 5. Therefore, by arranging the divided stator cores 11 in multiple stages, it is possible to form a plurality of skews whose positions in the circumferential direction are different from each other, and by forming such skews, it is possible to further reduce torque ripple. In addition, any of the basic form and the first modified example to the fifth modified example can be applied to the step portion 4. Further, the intermediate stator core 11C can be arranged between the divided stator cores 11 adjacent to each other in the same manner as described above.

[Fourth Embodiment]
FIG. 11 is a schematic view of the stator of the fourth embodiment. In the stator of the fourth embodiment, the linear first winding 2 and the linear second winding 3 are integrally formed so as to form a step portion 4 (skew).

As an assembly procedure, all the second windings 3 are inserted through the second stator core 11B arranged on the workbench over all the second slots 15B, and all the first windings 3 are integrated with the second windings 3. The winding 2 is supported by the second winding 3 inserted through the second stator core 11B, and all the first windings 2 are simultaneously inserted through all the first slots 15A of the first stator core 11A.

When the first stator core 11A is arranged at the axial end of the split stator core 11, the connecting portion 22 is connected to the end of the first winding 2 (excluding the lead wire 23). When the second stator core 11B is arranged at the axial end of the split stator core 11, the connecting portion 32 is connected to the end of the second winding 3. The stator is constructed by the above steps.

In the fourth embodiment, since there is no joint between the first stator core 11A and the second stator core 11B, the rigidity of the entire stator is improved. The step portion 4 may be formed by simply bending the winding in the circumferential direction in a crank shape.

[Effect of this embodiment]
According to the stator of the rotary electric machine of the present embodiment, the cylindrical stator core 1 in which the slots 15 penetrating in the axial direction are formed at a predetermined pitch in the circumferential direction, and the winding for the stator coil inserted into the slots 15. The stator core 1 of the rotary electric machine comprising the above includes a plurality of divided stator cores 11 arranged side by side in the axial direction, and among the plurality of divided stator cores 11, the first stator core 11A and the second stator core 11 adjacent to each other. The 11B is arranged so that the first slot 15A of the first stator core 11A and the second slot 15B of the second stator core 11B are arranged so as to be displaced from each other in the circumferential direction from the arrangement in which they are aligned in the axial direction, and the winding is arranged in the first slot 15A. The first winding 2 and the second winding 3 include the inserted first winding 2 and the second winding 3 inserted into the second slot 15B, and the first winding 2 and the second winding 3 are the first stator core 11A and the second stator core 11B. At the connection position between the first winding 2 and the second winding 3, a step portion 4 is formed in which the first winding 2 and the second winding 3 are displaced from each other in the circumferential direction. ing.

With the above configuration, a skew is formed by a step (step portion 4) in the circumferential direction of the windings (first winding 2, second winding 3) formed between the first stator core 11A and the second stator core 11B. It becomes a stator. As a result, the stator core 1 (first stator core 11A, second stator core 11B) does not need a skew shape, so that the cost can be suppressed by easily constructing the stator core 1 (divided stator core 11) without using expensive special equipment. it can. Further, the windings (first winding 2, second winding 3) inserted into the slots 15 (first slot 15A, second slot 15B) of the stator core 1 (divided stator core 11) have a linear shape, and the stator core 1 (1st slot 15A, 2nd slot 15B) has a linear shape. Since it is not necessary to form the opening 152 (FIG. 9) of the slot 15 on the inner peripheral surface of the split stator core 11), deterioration of torque ripple and magnetic loss can be suppressed. Further, as described above, since the windings (first winding 2, second winding 3) have a linear shape, all the slots 15 (first slot 15A, second slot 15B) are wound (first). The winding 2 and the second winding 3) can be inserted at the same time. Therefore, the manufacturing process can be simplified and the cost can be suppressed. Further, since the joint portion between the first winding 2 and the second winding 3 is located between the first stator core 11A and the second stator core 11B, the portion can be visually or image-processed, and quality control can be facilitated. It can be carried out. Further, since a resin mold can be formed between the first stator core 11A and the second stator core 11B, the insulation treatment of the joint portion can be easily performed.

In the present embodiment, three or more divided stator cores 11 are arranged in the axial direction. As a result, a plurality of skews having different positions in the circumferential direction can be formed, so that torque ripple can be further reduced.

In the present embodiment, the first winding 2 and the second winding 3 are arranged so that the circumferential length of the step portion 4 is substantially the same as the circumferential width of the first winding 2 and the second winding 3. In the above, the widths of the portions to be joined to each other in the circumferential direction are narrowed. As a result, it is possible to close between the first stator core 11A and the second stator core 11B by using the intermediate stator core 11C made of the same electromagnetic steel sheet as the electromagnetic steel sheet constituting the stator core 1 (divided stator core 11), so that the magnetic flux can be reduced. Leakage can be reduced.

In the present embodiment, the winding is divided into a first winding 2 and a second winding 3, and a part of the first winding 2 and a second winding 3 when viewed from the axial direction. A part of the end face of the first winding 2 and a part of the end face of the second winding 3 are joined to each other to form a stepped portion 4. As a result, the skew can be constructed with a simple configuration. Further, for example, since the first winding 2 can be arranged on the second winding 3 with the end of the first winding 2 in contact with the end of the second winding 3, the first winding 2 can be placed on the second winding 2. It can be easily joined to 2 windings 3.

In the present embodiment, the winding is divided into a first winding 2 and a second winding 3, and a part of the first winding 2 and a second winding 3 when viewed from the axial direction. A part of the coil is arranged so as to overlap each other, and the end of the first winding 2 overlaps with the second winding 3 when viewed from the axial direction, and the end of the second winding 3 from the axial direction. Fitting portions (wedge portions 24, 34, uneven portions 25, 35) are formed at positions overlapping the first winding 2, respectively, and fitting portions (wedge portions 24, 34, uneven portions 25, 35) are formed on each other. The stepped portion 4 is formed by being fitted. As a result, the skew can be constructed with a simple configuration. Further, since the first winding 2 and the second winding 3 are engaged with each other before being joined, the first winding 2 can be joined to the second winding 3 more easily.

In the present embodiment, the winding is divided into a first winding 2 and a second winding 3, and a part of the first winding 2 and a second winding 3 when viewed from the axial direction. A first inclined surface (inclined surface 27) is formed at a position which is an end portion of the first winding 2 and overlaps with the second winding 3 when viewed from the axial direction. A second inclined surface (inclined surface 37) is formed at a position at the end of the winding 3 and overlapping the first winding 2 when viewed from the axial direction, and the first inclined surface (inclined surface 27) and the second inclined surface The stepped portion 4 is formed by joining the (inclined surfaces 37) to each other. As a result, the skew can be constructed with a simple configuration.

In the present embodiment, the winding is divided into a first winding 2 and a second winding 3, and the side surface of the first winding 2 and the side surface of the second winding 3 are joined to each other. A step portion 4 is formed. As a result, the skew can be constructed with a simple configuration. Further, since the joints are formed on the side surfaces, the stepped portion 4 can be easily formed even when the widths of the first winding 2 and the second winding 3 in the circumferential direction are small. Further, by joining on the side surface, the first winding 2 and the second winding 3 intersect in the axial direction, so that the length of the entire stator in the axial direction can be shortened accordingly.

In the present embodiment, the winding is divided into a first winding 2 and a second winding 3, and a part of the first winding 2 and a second winding 3 when viewed from the axial direction. A part of the first winding 2 is arranged so as to overlap each other, and the end of the first winding 2 is placed at a position where it overlaps with the second winding 3 when viewed from the axial direction at the end of the first winding 2 from one of the radial directions. A thin-walled first counterbore (counterbore 26) is formed, and the end of the second winding 3 is driven at a position that overlaps with the first winding 2 at the end of the second winding 3. A second counterbore (counterbore 36) that forms a thin wall is formed from the other side in the direction, and the step portion 4 is formed by joining the first counterbore and the second counterbore to each other. A joint surface 26a facing the inside of the counterbore 26 of the first winding 2 in the radial direction is formed, and a joint surface 36a facing the outside of the counterbore 26 of the second winding 3 in the radial direction is formed. The 26a and the joining surface 36a are joined to each other. The joint surface 26a and the joint surface 36b are shielded from the outside. Therefore, it is possible to suppress aged deterioration of the joint portion between the first winding 2 and the second winding 3.

In the present embodiment, of the windings, the winding inserted into the split stator core 11 arranged at the end in the axial direction is one winding inserted into the slot 15 (first slot 15A, second slot 15B). Slot 15 (first slot 15A, first slot 15A, first slot 15A, second slot 15A) different from the slot 15 (first slot 15A, second slot 15B) through which the wire (straight line portion 21, 31) and one winding (straight line portion 21, 31) are inserted. The other winding (straight portion 21, 31) inserted into the two slots 15B), one winding (straight portion 21, 31) and the other winding (straight portion 21, 31) are connected and one of them is connected. Straddle between the slot 15 through which the windings (straight portions 21, 31) of the above are inserted and the slot 15 (first slot 15A, second slot 15B) through which the other winding (straight portions 21, 31) is inserted. Includes a U-shape in which the connecting portions 22 and 32 arranged at the ends of the divided stator core 11 are integrated. As a result, it is possible to improve the work efficiency of inserting the windings (first winding 2, second winding 3) into the slots 15 (first slot 15A, second slot 15B) and the efficiency of wiring work. Further, since the U-shaped windings (first winding 2 and second winding 3) can be commonly used in the divided stator cores 11 arranged at both ends in the axial direction, the cost can be suppressed. Further, since the heights of the coil ends of the stator coils can be made uniform by the connecting portions 22 and 32, unevenness of the magnetic flux generated in the stator can be suppressed.

In the present embodiment, the split stator core 11 arranged at the end in the axial direction includes one winding (straight line portions 21, 31) inserted into the slots 15 (first slot 15A, second slot 15B). Inserted into the slot 15 (first slot 15A, second slot 15B) different from the slot 15 (first slot 15A, second slot 15B) through which the one winding (straight portion 21, 31) is inserted. The slot 15 (first slot 15A, second slot 15B) through which the other winding (straight portion 21, 31) is connected and the one winding (straight portion 21, 31) is inserted. The connecting portions 22 and 32 are arranged so as to straddle the slot 15 (first slot 15A, second slot 15B) through which the other winding (straight portion 21, 31) is inserted. As a result, the heights of the coil ends of the stator coils can be made uniform by the connecting portions 22 and 32, so that unevenness of the magnetic flux generated in the stator can be suppressed.

Further, in the method for manufacturing a stator of a rotary electric machine according to the present embodiment, a plurality of cylindrical divided stator cores 11 in which slots 15 penetrating in the axial direction are formed at a predetermined pitch in the circumferential direction are arranged so as to be arranged in the axial direction. The first stator core 11A and the second stator core 12A, which are adjacent to each other among the plurality of divided stator cores 11, are arranged so that the first slot 15A of the first stator core 11A and the second slot 15B of the second stator core 11B are aligned in the axial direction. Arranged so as to be displaced from each other in the circumferential direction, the first winding 2 for the stator coil is inserted into the first slot 15A, the second winding 3 for the stator coil is inserted into the second slot 15B, and the first winding is inserted. The ends of the first winding 2 and the ends of the second winding 3 are joined to each other in an arrangement in which the second winding 3 and the second winding 3 are displaced from each other in the circumferential direction when viewed from the axial direction.

By the above method, a skew is formed by a step (step portion 4) in the circumferential direction of the windings (first winding 2, second winding 3) formed between the first stator core 11A and the second stator core 11B. It becomes a stator. As a result, the stator core 1 (first stator core 11A, second stator core 11B) does not need a skew shape, so that the cost can be suppressed by easily constructing the stator core 1 (divided stator core 11) without using expensive special equipment. it can. Further, the windings (first winding 2, second winding 3) inserted into the slots 15 (first slot 15A, second slot 15B) of the stator core 1 (divided stator core 11) have a linear shape, and the stator core 1 (1st slot 15A, 2nd slot 15B) has a linear shape. Since it is not necessary to form the opening 152 (FIG. 9) of the slot 15 on the inner peripheral surface of the split stator core 11), deterioration of torque ripple and magnetic loss can be suppressed. Further, as described above, since the windings (first winding 2, second winding 3) have a linear shape, all the slots 15 (first slot 15A, second slot 15B) are wound (first). The winding 2 and the second winding 3) can be inserted at the same time. Therefore, the manufacturing process can be simplified and the cost can be suppressed. Further, since the joint portion between the first winding 2 and the second winding 3 is located between the first stator core 11A and the second stator core 11B, the portion can be visually or image-processed, and quality control can be facilitated. It can be carried out. Further, since a resin mold can be formed between the first stator core 11A and the second stator core 11B, the insulation treatment of the joint portion can be easily performed.

1 Stator core 11 Divided stator core 11A 1st stator core 11B 2nd stator core 15 Slot 15A 1st slot 15B 2nd slot 2 1st winding 3 2nd winding 4 Stepped portion

Claims (11)

A stator of a rotary electric machine including a cylindrical stator core in which slots penetrating in the axial direction are formed at a predetermined pitch in the circumferential direction, and a winding for a stator coil inserted into the slot.
The stator core includes a plurality of split stator cores arranged side by side in the axial direction.
Among the plurality of divided stator cores, the first stator core and the second stator core that are adjacent to each other are arranged in the circumferential direction from the arrangement in which the first slot of the first stator core and the second slot of the second stator core are aligned in the axial direction. Arranged so that they are offset
The winding is
The first winding inserted into the first slot and
Includes a second winding inserted into the second slot.
The first winding and the second winding are connected at a position between the first stator core and the second stator core.
A stator of a rotary electric machine in which a step portion is formed at a connection position between the first winding and the second winding so that the first winding and the second winding are displaced from each other in the circumferential direction. The stator of a rotary electric machine according to claim 1, wherein three or more of the divided stator cores are arranged in the axial direction. The first winding and the second winding are joined to each other so that the circumferential length of the step portion is substantially the same as the circumferential width of the first winding and the second winding. The stator of a rotary electric machine according to claim 1 or 2, wherein the width of each portion in the circumferential direction is narrowed. The winding is divided into the first winding and the second winding, and a part of the first winding and a part of the second winding are mutually formed when viewed from the axial direction. Arranged so that they overlap
The method according to any one of claims 1 to 3, wherein a step portion is formed by joining a part of the end face of the first winding and a part of the end face of the second winding to each other. Rotating electric machine stator. The winding is divided into the first winding and the second winding, and a part of the first winding and a part of the second winding are mutually formed when viewed from the axial direction. Arranged so that they overlap
A position at the end of the first winding that overlaps with the second winding when viewed from the axial direction, and a position at the end of the second winding that overlaps with the first winding when viewed from the axial direction. The stator of the rotary electric machine according to any one of claims 1 to 3, wherein the fitting portions are formed in and the fitting portions are respectively formed, and the stepped portions are formed by fitting the fitting portions to each other. The winding is divided into the first winding and the second winding, and a part of the first winding and a part of the second winding are mutually formed when viewed from the axial direction. Arranged so that they overlap
A first inclined surface is formed at a position at the end of the first winding and overlapping the second winding when viewed from the axial direction, and the end of the second winding and when viewed from the axial direction. Any of claims 1 to 3, wherein a second inclined surface is formed at a position overlapping the first winding, and the stepped portion is formed by joining the first inclined surface and the second inclined surface to each other. The stator of the rotary electric machine according to item 1. The winding is divided into the first winding and the second winding.
The stator of a rotary electric machine according to any one of claims 1 to 3, wherein a step portion is formed by joining the side surface of the first winding and the side surface of the second winding to each other. The winding is divided into the first winding and the second winding, and a part of the first winding and a part of the second winding are mutually formed when viewed from the axial direction. Arranged so that they overlap
A first counterbore is formed at a position at the end of the first winding that overlaps with the second winding when viewed from the axial direction, so that the end of the first winding is thinly formed from one of the radial directions.
A second counterbore is formed at the end of the second winding and overlapping the first winding when viewed from the axial direction to form a thin wall from the other end of the second winding in the radial direction.
The stator of a rotary electric machine according to any one of claims 1 to 3, wherein a step portion is formed by joining the first counterbore and the second counterbore to each other. Among the windings, the winding inserted through the split stator core arranged at the end in the axial direction is
One of the windings inserted into the slot, the other winding inserted into the slot different from the slot through which the one winding was inserted, and the one winding and the other. Is arranged at the end of the split stator core so as to connect the windings of the above and straddle between the slot through which the one winding is inserted and the slot through which the other winding is inserted. The stator of a rotary electric machine according to any one of claims 1 to 8, which includes a U-shape in which the connecting portion is integrated. The split stator core located at the axial end has
One of the windings inserted into the slot and the other winding inserted into the slot different from the slot into which the one winding is inserted are connected and the one winding is connected. The stator of the rotary electric machine according to any one of claims 1 to 8, wherein a connecting portion is arranged so as to straddle between the slot through which the coil is inserted and the slot through which the other winding is inserted. .. A plurality of cylindrical split stator cores having slots penetrating in the axial direction formed at a predetermined pitch in the circumferential direction are arranged so as to be arranged in the axial direction, and the first stator core and the second of the plurality of split stator cores adjacent to each other are arranged. The stator core is arranged so that the first slot of the first stator core and the second slot of the second stator core are displaced from each other in the circumferential direction from the arrangement in which the first slot of the first stator core and the second slot of the second stator core are aligned in the axial direction.
Insert the first winding for the stator coil into the first slot,
Insert the second winding for the stator coil into the second slot,
A stator of a rotary electric machine that joins the end of the first winding and the end of the second winding to each other in an arrangement in which the first winding and the second winding are displaced from each other in the circumferential direction when viewed from the axial direction. Manufacturing method.

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