JP2022031993A - Rotary electric machine, stator for rotary electric machine and method of manufacturing the same - Google Patents

Abstract

To provide a rotary electric machine, a stator for the rotary electric machine, and a manufacturing method thereof, in which noise is suppressed.SOLUTION: A stator 3 is connected between a plurality of magnetic poles. The stator 3 is divided into three parts and provides a three-phase generator or a three-phase motor generator. The stator 3 includes an inter-pole member 30 disposed between a plurality of magnetic poles. The inter-pole member 30 includes a plurality of inter-teeth members 31 disposed between all of a plurality of core teeth tips 11. The inter-pole member 30 can include a plurality of inter-coil members disposed between all of a plurality of coil parts 12. The plurality of inter-coil members can be an adhesive.SELECTED DRAWING: Figure 1

Description

The disclosure in this specification relates to a rotary electric machine, a stator of a rotary electric machine, and a method for manufacturing the same.

Patent Document 1 discloses a rotary electric machine. The contents of the prior art documents listed as prior art are incorporated by reference as an explanation of the technical elements in this specification.

Japanese Unexamined Patent Publication No. 2013-162726

The rotary electric machine has a basic configuration necessary to satisfy the required performance. At the same time, the rotary electric machine is required to suppress noise. Further improvements are required in the rotary electric machine, the stator of the rotary electric machine, and the manufacturing method thereof in the above-mentioned viewpoints or in other viewpoints not mentioned.

One object disclosed is to provide a noise-suppressed rotary machine, a rotary machine stator, and a method of manufacturing the same.

Another object disclosed is to provide a rotary electric machine in which magnetic noise due to magnetic action is suppressed, a stator of the rotary electric machine, and a method for manufacturing the same.

The stator of the rotary electric machine disclosed here is connected between a plurality of magnetic poles.

According to the stator of the rotary electric machine disclosed here, it is possible to suppress noise caused by vibration of a plurality of magnetic poles.

The rotary electric machine disclosed here includes the above-mentioned stator and a rotor facing the stator.

A plurality of methods for manufacturing a stator of a rotary electric machine disclosed herein include a partial stator forming step of forming a plurality of partial stators having magnetic poles including a partial core, a partial insulator, and a partial coil, and a plurality of partial stators by combining the plurality of partial stators. It has an annular body assembly step of assembling an annular body including the magnetic poles of the above, and a step of arranging an interpole member between a plurality of magnetic poles at the same time as or after the annular body assembly step.

The disclosed embodiments herein employ different technical means to achieve their respective objectives. The claims and the reference numerals in parentheses described in this section exemplify the correspondence with the parts of the embodiments described later, and are not intended to limit the technical scope. The objectives, features, and effects disclosed herein will be further clarified by reference to the subsequent detailed description and accompanying drawings.

It is a perspective view of the rotary electric machine which concerns on 1st Embodiment. It is a top view which shows the seating surface of a body. It is a perspective view of the rotary electric machine which concerns on 2nd Embodiment. It is a waveform diagram which shows the noise of a rotary electric machine. It is a perspective view which shows the manufacturing process of a stator. It is a perspective view which shows the manufacturing process of a stator. It is a perspective view which shows the stator. It is an exploded perspective view which shows the stator. It is a perspective view which shows the stator. It is a waveform diagram which shows the luc acting on a stator.

A plurality of embodiments will be described with reference to the drawings. In a plurality of embodiments, functionally and / or structurally corresponding parts and / or related parts may be designated with the same reference code or reference numerals having different hundreds or more digits. References can be made to the description of other embodiments for the corresponding and / or associated parts.

1st Embodiment In FIG. 1, the rotary electric machine 1 includes a rotor 2 and a stator 3. The rotor 2 is arranged so as to face the stator 3. The rotor 2 is arranged on the radial outer side of the stator 3. The rotary electric machine 1 is an outer rotor type.

The stator 3 is connected between a plurality of magnetic poles. The stator 3 is connected between a plurality of core teeth portions 10 or between a plurality of coil portions 12.

In this embodiment, another part is inserted between the teeth. Separate parts are glued or press-fitted between the teeth. In the illustrated example, another component is inserted from one side of the stator 3. Separate parts may be inserted on both sides of the stator 3.

The stator 3 is divided into three parts and provides a three-phase generator or a three-phase motor generator. For the stator 3, Japanese Patent Application No. 2018-022650 can be referred to, the content of which is incorporated by reference as the description of this application.

The stator 3 includes an interpole member 30 arranged between a plurality of magnetic poles. There is an interpole gap between the plurality of magnetic poles. The interpole gap allows displacement of multiple magnetic poles. Specifically, an interpolar gap is opened between the plurality of core teeth tip portions 11 which are the tips of the plurality of core teeth portions 10. The pole-to-pole member 30 suppresses the displacement of the plurality of magnetic poles against the displacement of the plurality of magnetic poles. The magnetic poles may be displaced with respect to the circumferential direction of the stator 3. The pole-to-pole member 30 resists displacement of the magnetic poles in the circumferential direction. The magnetic poles may be displaced with respect to the axial direction of the stator 3. The pole-to-pole member 30 resists axial displacement of the magnetic poles. In order to resist the displacement of the magnetic poles, it is desirable that the pole-to-pole member 30 is fixed to the magnetic poles. The pole-to-pole member 30 is fixed to a magnetic pole in both the circumferential direction and the axial direction of the stator 3. The pole-to-pole member 30 does not project out of the virtual cylinder defined by the maximum diameter and maximum axial height of the stator 3. The interpole member 30 is also referred to as a separate part or a separate member.

In this embodiment, the interpolar member 30 includes a plurality of intertooth members 31 arranged between all of the plurality of core teeth tip portions 11. The plurality of inter-teeth members 31 are all connected. In the illustrated example, the two tooth-to-teeth members 31a and 31b adjacent to each other in the circumferential direction are connected by a circumferential extending portion 31c located at the axial end portion of the stator 3. The circumferential extending portion 31c is C-shaped or annular.

The plurality of inter-teeth members 31 are molded products made of resin. The plurality of inter-teeth members 31 are provided as a series of integrally molded products. The plurality of inter-teeth members 31 have a comb-teeth shape that can be easily inserted between the plurality of magnetic pole gaps.

In FIG. 2, the stator 3 is fastened to the body 5 by three bolts. The body 5 is provided by an engine, a mission case, or the like. The body 5 has a body hole 6 through which a rotation shaft for rotating the rotor 2 passes. The body 5 has a fixed seat 7 for the stator 3 around the body hole 6. The fixed seat 7 generally has a shape as shown in the figure. The fixed seat 7 provides a seat surface 8. The seat surface 8 contacts the end surface of the stator core and supports the stator 3. The seat surface 8 is formed slightly wider around the bolt hole 9. Since the seat surface 8 is wide around the bolt hole 9, the vibration of the teeth around the seat surface 8 is easily transmitted to the body 5 side. The bolt holes 9 are generally spaced at 120 degrees. In this case, different teeth of the same phase are arranged in the vicinity of each of the plurality of bolt holes 9. As a result, the vibration generated in that phase is easily transmitted to the body 5 side.

In this embodiment, a plurality of inter-teeth members 31 connect the plurality of teeth. As a result, the vibration and noise of the teeth caused by the trisection are suppressed. In addition, vibration and noise of a specific phase caused by the fixed seat 7 are suppressed.

Second Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In the above embodiment, the interpole member 30 is provided by a plurality of inter-teeth members 31. Instead, in this embodiment, the interpole member 30 is provided by a plurality of intercoil members 32.

In FIG. 3, also in this embodiment, the rotary electric machine 1 includes an interpole member 30 arranged between a plurality of magnetic poles. The inter-pole member 30 includes a plurality of inter-coil members 32 arranged between all of the plurality of coil portions 12. The plurality of coil-to-coil members 32 are adhesives. The inter-coil member 32 is provided by an epoxy adhesive or the like arranged between the plurality of coils 12. The coil-to-coil member 32 is slightly impregnated into the coil 12.

The coil-to-coil member 32 is a cured resin. In the step of applying the coil-to-coil member 32, the coil-to-coil member 32 before curing has a fluidity that can be called high viscosity. The inter-coil member 32 before curing is cured immediately after being applied between the coils 12. The inter-coil member 32 has a viscosity that does not flow out of the stator 3 in the axial direction and hang down during the curing process. For example, when the stator 3 is placed horizontally on a workbench and the coil-to-coil member 32 before curing is applied from the upper end surface of the stator 3, the coil-to-coil member 32 hangs down from the lower surface of the stator 3. It stays between the coils 12 without any problems. As a result, the inter-coil members 32 are connected to each other between the magnetic poles, that is, between the coils while adhering along the coil 12. As described above, the high-viscosity resin does not easily drip and has good coatability.

The intercoil member 32 may be connected between the insulators 42, that is, between the bobbins. The inter-coil member 32 may be connected between the core teeth tip portions 11. The intercoil member 32 is applied to the stator 3 in a state of still having fluidity, and is subsequently cured. The inter-coil member 32 connects the two coils 12 in the circumferential direction by filling the space between the two coils 12 adjacent to each other in the circumferential direction with respect to the circumferential direction. The inter-coil member 32 has a raised shape that slightly rises on the axial end surface of the stator 3 or a wraparound shape that wraps around the axial end face of the stator 3 with respect to the surfaces of the two coils 12 that are adjacent to each other in the circumferential direction. As a result, the inter-coil member 32 connects the two coils 12 with respect to the axial direction of the stator 3. The inter-coil member 32 connects the two coils 12 in the axial direction of the coil 12 by entering the groove between the strands of the two coils 12 adjacent to each other in the circumferential direction. The inter-coil member 32 firmly connects not only the coil 12 but also the magnetic poles adjacent to each other in the circumferential direction. The coil-to-coil member 32 firmly connects all the magnetic poles.

In FIG. 4, the vertical axis represents noise NOISE (dB), and the horizontal axis represents the rotation speed REV (r / min) of the rotary electric machine 1. Overall noise (Overall) and specific components (12th: 12th-order component) are shown in the figure. In the case of an integrated core (UNI-CORE), a double-line waveform can be obtained. On the other hand, in the case of the three-divided core (TRI-CORE), a broken line waveform is obtained. The three-piece core produces a large amount of noise. On the other hand, according to this embodiment (EMB), a waveform shown by a solid line can be obtained. According to this embodiment, it is possible to realize a noise waveform close to that of an integrated core.

Manufacturing Method of Embodiment In the first embodiment and the second embodiment, the interpole member 30 can be added by using the stator described below as a basic configuration. The stator 3 has a plurality of partial stators 40. These plurality of partial stators 40 are in contact with each other in a plane perpendicular to the axial direction. These plurality of partial stators 40 may be tightened and connected by rivets. Further, these plurality of partial stators 40 are tightened and connected to the body 5 by a plurality of bolts. Further, in the first embodiment and the second embodiment, the plurality of partial stators 40 are also connected by the interpole member 30. The partial stator 40 has a partial core 41, a partial insulator 42, and a partial coil 43. The partial core 41 has a central annular portion that occupies approximately 1/3 of the thickness and a tooth of each phase. The partial insulator 42 provides a bobbin for a plurality of teeth and an insulating member at both ends. The partial coil 43 has a plurality of end coils.

In FIG. 5, the U-phase partial stator 40u is shown. The partial stator 40u has a partial core 41u, a partial insulator 42u, and a partial coil 43u.

In FIG. 6, the V-phase partial stator 40u is shown. In the figure, a state in which the U-phase partial stator 40u and the V-phase partial stator 40u are assembled is shown. The partial stator 40v has a partial core 41v, a partial insulator 42v, and a partial coil 43v.

In FIG. 7, the W phase partial stator 40w is shown. In the figure, a state in which the U-phase partial stator 40u, the V-phase partial stator 40u, and the W-phase partial stator 40w are assembled is shown. FIG. 7 is also a perspective view of the annular body 50. The tubular body partial stator 40w has a partial core 41w, a partial insulator 42w, and a partial coil 43w.

In FIG. 8, the three partial stators 40u, 40v, and 40w are combined so that their plurality of magnetic poles mesh with each other in the axial direction. As a result, the three partial stators 40u, 40v, and 40w come into contact with each other by the contact portions. The three partial stators 40u, 40v, 40w are in contact at the two contact points. One contact is provided by two planes that are axially opposed and in contact. The three partial stators 40u, 40v, 40w are also fixed by rivets penetrating them axially.

In FIG. 9, the axial end face of the stator 3 is shown. 1, FIG. 3, FIG. 7, and FIG. 8 illustrate the end face facing the body 5, so to speak, the back surface. FIG. 9 illustrates an end face, so to speak, a surface that accepts a plurality of bolts.

In FIG. 10, the vertical axis represents the torque TQ (Nm), and the horizontal axis represents the angle (degrees) in the circumferential direction. U is a torque waveform applied to the magnetic pole of the U phase, V is a torque waveform applied to the magnetic pole of the V phase, and W is a torque waveform applied to the magnetic pole of the W phase. The amplitude A in the figure is the sum of the torques applied to each phase (U + V + W). When the torque of each phase is added up at the mounting portion by the integrated core, the torque appears as the amplitude A. The amplitude A appears in the central annular portion (mounting portion to the body 5) of the integral core. B in the figure is the amplitude of the torque applied to each phase. If the torque summing is successful, the vibration due to torque fluctuation will be greatly reduced, and the resulting noise will also be reduced. However, the split core does not work, so noise may occur.

The method for manufacturing a rotary electric machine includes a step of forming a rotor 2, a step of forming a stator 3, and a step of positioning the rotor 2 and the stator 3 on the body 5 so as to face each other.

The method of manufacturing the stator 3 includes a partial stator forming step of forming a plurality of partial stators 40 having magnetic poles including a partial core 41, a partial insulator 42, and a partial coil 43. Here, the plurality of partial stators 40u, 40v, 40w shown in FIGS. 5, 6 and 7 are formed.

The method for manufacturing the stator 3 includes an annular body assembly step of assembling an annular body 50 including a plurality of magnetic poles by combining a plurality of partial stators 40.

The method for manufacturing the stator 3 further includes a step of arranging the pole-to-pole member 30 between a plurality of magnetic poles at the same time as the annular body assembly step or after the annular body assembly step. The interpole member 30 may be arranged in the process of assembling the three partial stators 40u, 40v, 40w. The interpole member 30 may be arranged after the step of assembling the three partial stators 40u, 40v, 40w. For example, the plurality of inter-teeth members 31 in the first embodiment are mounted on the stator 3 assembled in the state of FIG. The plurality of inter-teeth members 31 are inserted and adhered between the plurality of polar gaps. As a result, all the magnetic poles of the stator 3 are connected. For example, the intercoil member 32 in the second embodiment is attached to the stator 3 assembled in the state of FIG. The inter-coil member 32 is applied between a plurality of polar gaps and cured. As a result, all the magnetic poles of the stator 3 are connected.

Comparative example Operation explanation of the comparative example The comparative example is a three-phase rotary electric machine. A comparative example is a magneto generator having a starter function. This rotary electric machine is also called a motor generator or ACG-S. The comparative example may be a magneto generator. Magnet generators are also called ACGs. In the comparative example, the stator core is divided into phases. This main rotary electric machine is also called a split core or a three-split core.

In the comparative example, the winding is performed in a split state. Therefore, in the winding process, the gap (clearance) obtained around the coil is large. When winding around an integral core, the clearance between adjacent coils is limited. As a result, the space factor of the coil can be increased. On the other hand, when an aluminum or aluminum alloy wire is used for the coil, it is necessary to increase (thicken) the wire diameter in order to obtain the same resistance as the copper or copper alloy wire. The split core is suitable for coils made of aluminum or aluminum alloy because it can increase the space factor.

The stator core is fastened to the body, for example, with three bolts at 120 degree intervals. Occasionally, the tightening seat surface is provided with a seat. This tightening seat provides a mounting portion on the body side. On the other hand, the stator core has three through holes in the central annular portion for receiving bolts. Therefore, the stator has a central annular portion as a mounting portion.

The tripartition core has a plurality of cores divided for each phase. The torque applied to each phase becomes smaller by adding up. If it is an integrated core, the torque is added up at the integrated part of the core. As a result, the torque applied to the mounting portion is significantly smaller than that of the teeth. However, due to the split structure of the three-split core, the three phases do not exist at the same time in one core sheet, so that the sum of the torques does not go well. Only in-phase teeth are integrated in the mounting portion of each split core. The remaining two phases are not integrated in each cross section, but are added to the torque of the other phase via the sheet integrated with the mounting portion.

As a result, the torque is summed through the rivets penetrating the core and the frictional force between the phases, and is not summed up in one core sheet as in the case of the integrated core. Therefore, the torque applied to the split core is not completely added up, and the exciting force remains. As a result, the remaining exciting force may vibrate the rotor and other parts via the stator body, body, engine body, and engine to generate noise.

In ACGG-S, which is not a split core, the amplitude of the torque applied to each tooth becomes smaller when they are added together. However, for example, when the mounting bolts, which are a general configuration, are spaced by 120 degrees, the teeth of the same phase are arranged so as to be closest to the mounting bolt portions. This is because in the case of a three-phase winding, the teeth and magnetic poles of the same phase appear every 120 degrees. In the vicinity of the mounting bolt, the contact surface with the engine side is generally wide. Therefore, the vibration due to the torque of the teeth near the mounting bolt is easily transmitted to the engine side. From another point of view, the stator core is strongly pressed toward the body (engine) side by tightening. Therefore, the vibration due to the torque of the teeth near the mounting bolt is easily transmitted to the engine side. Due to these, noise may be generated. Such a phenomenon is not limited to the split core. Such a phenomenon is also observed in the integrated core. Noise is also called magnetic sound.

Other Embodiments The disclosure in this specification, drawings and the like is not limited to the exemplified embodiments. Disclosures include exemplary embodiments and modifications by those skilled in the art based on them. For example, the disclosure is not limited to the parts and / or combinations of elements shown in the embodiments. Disclosure can be carried out in various combinations. The disclosure can have additional parts that can be added to the embodiment. Disclosures include those in which the parts and / or elements of the embodiment are omitted. Disclosures include the replacement or combination of parts and / or elements between one embodiment and another. The technical scope disclosed is not limited to the description of the embodiments. Some technical scopes disclosed are indicated by the claims description and should be understood to include all modifications within the meaning and scope equivalent to the claims description.

Disclosure in the description, drawings, etc. is not limited by the description of the scope of claims. The disclosure in the description, drawings, etc. includes the technical ideas described in the claims, and further covers a wider variety of technical ideas than the technical ideas described in the claims. Therefore, various technical ideas can be extracted from the disclosure of the description, drawings, etc. without being bound by the description of the scope of claims.

1 rotary machine, 2 rotor, 3 stator, 4 magnetic poles,
5 body, 6 body hole,
7 fixed seat, 8 seat surface, 9 bolt hole,
10 core teeth, 11 core teeth tips,
20 coil part,
30 pole-to-pole member,
31 Inter-teeth member, 32 Inter-coil member,
40, 40u, 40v, 40w partial stator,
41, 41u, 41v, 41w partial core,
42, 42u, 42v, 42w partial insulator,
43, 43u, 43v, 43w partial coil,
50 annular body.

Claims (10)

A stator of a rotary electric machine in which multiple magnetic poles are connected. The stator of a rotary electric machine according to claim 1, wherein the stators of the rotary electric machine are connected between a plurality of core teeth portions or between a plurality of coil portions. The stator of a rotary electric machine according to claim 1 or 2, wherein the stator is divided into three parts and provides a three-phase generator or a three-phase motor generator. The stator of a rotary electric machine according to any one of claims 1 to 3, further comprising an interpole member arranged between the plurality of magnetic poles. The stator of a rotary electric machine according to claim 4, wherein the inter-pole member includes a plurality of inter-teeth members arranged between all of the plurality of core teeth tips. The stator of a rotary electric machine according to claim 5, wherein the plurality of inter-teeth members are all connected. The stator of a rotary electric machine according to claim 4, wherein the inter-pole member includes a plurality of inter-coil members arranged between all of the plurality of coil portions. The stator of a rotary electric machine according to claim 7, wherein the plurality of coil-to-coil members are adhesives. A rotary electric machine including the stator according to any one of claims 1 to 8 and a rotor facing the stator. A partial stator forming step of forming a plurality of partial stators having magnetic poles including a partial core, a partial insulator, and a partial coil.
An annular body assembly step of assembling an annular body including the plurality of magnetic poles by combining the plurality of the partial stators,
A method for manufacturing a stator of a rotary electric machine, which comprises a step of arranging an interpole member between a plurality of the magnetic poles at the same time as the annular body assembly step or after the annular body assembly step.

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