JP2022157251A - stator - Google Patents

Abstract

To provide a stator capable of improving workability during assembly.SOLUTION: A stator has two joint parts 42a to 45a each joined to end parts 31a of different coil wires used for the same phase, and connection parts 42b to 45b that connect the two joint parts 42a to 45a to each other, and includes a plurality of connection members 42 to 45 electrically connecting the joined end parts 31a. The connection members 42 to 45 connecting the end parts 31a of the coil wires used in the same phase are arranged on the same plane over one circumference in a circumferential direction to form a single bus ring 40 as a group. The bus ring 40 is formed for each phase and provided in layers on a first side D1 with respect to a stator core 10. The joint parts 42a to 45a of the connection members 42 to 45 of the bus ring 40 of each phase do not overlap the connection parts 42b to 45b of the connection members 42 to 45 of the other bus ring 40, respectively, and are exposed axially when viewed from the first side D1.SELECTED DRAWING: Figure 4

Description

The present disclosure relates to a stator used in a rotating electric machine mounted on a vehicle such as an electric vehicle.

2. Description of the Related Art Conventionally, a stator used in a rotating electrical machine mounted on a vehicle such as an electric vehicle has a ring-shaped stator core in which a plurality of slots are arranged in the circumferential direction, and a coil wire accommodated in the stator core. is known (see Patent Document 1). In this stator, the protrusions of the coil wire protruding from the stator core in the axial direction are connected by connecting members (bus bars), and the coil wire and the connecting member form a coil. In this stator, a plurality of connection members for connecting coil wires of the same phase are arranged in the circumferential direction, and these are held by an annular holder made of resin (bus ring). ) is used.

When assembling the stator, a connecting ring is axially installed on the stator core housing the coil wire, and the connecting member and the coil wire are joined to form a single phase coil. Then, another connection ring is stacked and installed on top of this connection ring, and the connection member and the coil wire are joined to form a coil of another phase. This operation is repeated according to the number of phases to form coils for all phases.

JP 2008-148479 A

However, in the stator described in Patent Document 1, it is necessary to repeat the steps of installing a connection ring and joining with the coil wire, and stacking another connection ring and joining with the coil wire for the number of phases. Therefore, there is a problem that the number of man-hours is increased and workability during assembly is poor.

Accordingly, it is an object of the present invention to provide a stator capable of improving workability during assembly.

A stator according to the present disclosure is a stator used in a rotating electrical machine, and includes: a stator core having a ring shape in which a plurality of slots are arranged in a circumferential direction; a first slot accommodating portion accommodated in the slot; a first protruding portion continuously protruding to one side in the axial direction of the central axis of the stator core; and a second slot accommodating portion accommodated in the slot different from the slot accommodating the first slot accommodating portion. and a second protruding portion continuously protruding from the second slot accommodating portion and protruding toward one side of the stator core in the axial direction, and connecting the first slot accommodating portion and the second slot accommodating portion to form the and a coil end portion arranged on the other side in the axial direction opposite to the one side in the axial direction, wherein the first projecting portion and the second projecting portion each have an end portion. a coil wire, two joints respectively joined to the ends of the different coil wires used for the same phase, and a connecting portion connecting the two joints; and a plurality of connecting members for electrically connecting the joined ends, wherein the plurality of coil wires housed in the same slot are used for the same phase, and the slots used for the same phase are the same. The plurality of the plurality of sprockets are arranged along one circumference at predetermined intervals in the circumferential direction, are arranged with different phases with respect to the slots of different phases, and are accommodated in the plurality of slots used for the same phase. The coil wires are connected by the plurality of connecting members to form a coil wound by wave winding over one turn in the circumferential direction, and the end portions of the plurality of coil wires used for the same phase are formed. The plurality of connection members connecting each other are arranged on the same plane over one circumference in the circumferential direction to form a single annular connection portion as a group, and the plurality of annular connection portions are arranged for each phase. formed and stacked in layers on the one axial side of the stator core, and when viewed from the one axial side, each of the joint portions of the connection members of the annular connection portions of each phase, It is exposed in the axial direction without overlapping with the connecting portion of the connecting member of the other annular connecting portion.

According to this stator, workability during assembly can be improved.

It is a perspective view of the stator which concerns on embodiment, (a) is the state seen from the top, (b) is the state seen from the bottom. (a) is a side view of a stator according to the embodiment, and (b) is a schematic diagram. (a) is a plan view of a bus ring according to the embodiment, and (b) is a plan view of a connection unit. (a) is a perspective view of a layered bus ring according to the embodiment, and (b) is a plan view of the layered bus ring. (a) is an exploded perspective view showing the shape of the end portion and the joint portion according to the embodiment, (b) is a perspective view showing the joint state, and (c) is the shape of the end portion and the joint portion according to the modification. and (d) is a perspective view showing the joined state. (a) is an exploded perspective view showing the shape of an end portion and a joint portion according to another modification, (b) is a perspective view showing the joint state, and (c) is an end portion according to still another modification. FIG. 4D is an exploded perspective view showing the shape of the joint, and (d) is a perspective view showing the joint state. 1 is a schematic diagram showing a coil wire according to an embodiment; FIG.

The disclosed embodiments will be described in detail below with reference to FIGS. 1(a) to 7. FIG. In this embodiment, the stator is used for a three-phase AC motor as a rotating electrical machine, for example. This three-phase AC motor has six phases U1, U2, V1, V2, W1, and W2.

[Stator configuration]
First, the configuration of the stator 1 will be described with reference to FIGS. 1(a) and 1(b). The stator 1 is formed in a substantially annular shape and has a stator core 10, a coil set 20 which is an example of a coil, busbar terminals (not shown), and hardened varnish (not shown). The stator core 10, the coil set 20 and the busbar terminals are integrally fixed with varnish. 1(a) to 2(b) show the state after the coil set 20 is formed on the stator core 10 and before the busbar terminals are provided.

The stator core 10 is formed by laminating substantially annular electromagnetic steel sheets, and has ribs 11 and bolt holes 12 for fixing the stator core 10 to a motor case (not shown) on the outer peripheral side thereof, and an inner peripheral surface side. and a plurality of teeth 13 arranged in the circumferential direction. A plurality of slots 14 for accommodating the coil sets 20 are arranged and formed in the circumferential direction between the adjacent teeth 13 . In this embodiment, the upper side in FIG. Let it be side D2.

In this embodiment, one wave winding coil is formed for each of the six phases, and the coil set 20 has six coils. Each coil has a plurality of coil wires 30 and a bus ring 40 that is an example of an annular connection.

As shown in FIG. 7, each coil wire 30 is formed of a flat conductor wire having a rectangular cross section and being coated with insulation. One coil wire 30 has a substantially U-shape as a whole, and includes a first slot accommodating portion 33A accommodated in the slot 14 and a first side of the stator core 10 that is continuous with the first slot accommodating portion 33A. A first projecting portion 31A projecting to D1, a second slot accommodating portion 33B accommodated in a slot 14 different from the slot 14 in which the first slot accommodating portion 33A is accommodated, and a a second protruding portion 31B protruding to the first side D1 of the stator core 10; ,have. Each coil wire 30 has an end portion 31a on each of the first projecting portion 31A and the second projecting portion 31B. Further, the coil end portion 32 is continuous with the first slot accommodation portion 33A and the second slot accommodation portion 33B, and is provided by bending with respect to the first slot accommodation portion 33A and the second slot accommodation portion 33B. For example, the coil end portion 32 may have a shape that linearly connects the first slot accommodation portion 33A and the second slot accommodation portion 33B, or may have a shape that allows a lane change with respect to the coil wire 30 of another phase. It has a curved or partially bent shape, and the shape is not limited. In the present embodiment, the first slot accommodating portion 33A and the second slot accommodating portion 33B are collectively referred to as the slot accommodating portion 33, and the first projecting portion 31A and the second projecting portion 31B are collectively referred to as the projecting portion 31. .

As shown in FIGS. 1A and 1B, in this embodiment, each slot 14 accommodates eight coil wires 30 of the same phase. In addition, in the present embodiment, the slot accommodating portion 33 of the coil wire 30 employs a modified cross-section coil having a different cross-sectional shape depending on the position, thereby achieving a high space factor within the slot 14 . However, the coil wire 30 is not limited to the modified cross-section coil, and may be a coil having the same cross-sectional shape depending on the position. Also, the coil wire 30 is covered by resin extrusion molding. Thereby, cost reduction can be achieved.

The bus ring 40 has an annular shape, is provided for each phase, and electrically connects the coil wires 30 of the same phase. In this embodiment, six bus rings 40 are formed for each phase and provided in layers on the first side D<b>1 of the stator core 10 . A detailed configuration of the bus ring 40 will be described later.

The slots 14 used for the same phase are arranged along one circumference at predetermined intervals in the circumferential direction, and the slots 14 for different phases are arranged with different phases. A plurality of coil wires 30 housed in a plurality of slots 14 used for the same phase are connected by a bus ring 40 to form a coil wound by wave winding over one turn in the circumferential direction. is doing.

Next, the configuration of the bus ring 40 will be described in detail with reference to FIGS. 3(a) to 4(b). First, the single bus ring 40 will be described. As shown in FIG. 3(a), one bus ring 40 consists of an assembly of a plurality of (eight in this embodiment) connection units 41, and as shown in FIG. 3(b), each connection unit 41 has four connecting members 42-45. These four connecting members 42 to 45 are arranged in parallel along the circumferential direction, and from the outer diameter side, the first outer diameter side connecting member 42, the second outer diameter side connecting member 43, the first inner diameter side connecting member 44 and a second inner diameter side connecting member 45 .

The first outer diameter side connecting member 42 includes two joint portions 42a each joined to one end portion 31a of each different coil wire 30 used in the same phase, and a connection connecting the two joint portions 42a. It has a portion 42b and electrically connects the joined ends 31a (ends). The first outer diameter side connection member 42 is made of, for example, an aluminum plate formed into a flat plate shape by press molding, and the joint portion 42a has a hole shape through which the end portion 31a penetrates. The cost is reduced by using an aluminum plate. An insulating coating is applied to the first outer diameter side connecting member 42, and the coating is removed only at the joint portion 42a to expose it so that it can be connected to the end portion 31a. Similarly, the second outer diameter side connecting member 43 has two joint portions 43a and a connecting portion 43b, the first inner diameter side connecting member 44 has two joint portions 44a and a connecting portion 44b, The second inner diameter side connecting member 45 has two joint portions 45a and a connecting portion 45b. That is, these connection members 42 to 45 connect the end portions 31a of the coil wires 30 used in the same phase, and are arranged on the same plane over one circumference in the circumferential direction to form a single layer as a set group. A bus ring 40 is formed. Moreover, in order to avoid the electrical resistance of the connecting members 42 to 45 from increasing, the cross-sectional areas of the connecting members 42 to 45 are preferably larger than the cross-sectional area of the coil wire 30 .

Further, as shown in FIGS. 5A and 5B, the end portion 31a is formed in a stepped shape having a stepped portion 31b at the tip of the projecting portion 31. For example, the joint portion 42a is The hole portion is fitted into the end portion 31a, and the stepped portion 31b supports in the axial direction. After the assembly, a laser welding machine or the like is used from the first side D1 to join by welding at the welded portion 50 . That is, the end portion 31a has a step portion 31b as an example of a positioning portion against which the joint portion 42a abuts and is positioned, for example, when the connecting member 42 is assembled axially. In the present embodiment, the end portion 31a and the joint portion 42a are joined by welding, but the present invention is not limited to this.

As shown in FIGS. 3(a) and 3(b), the connecting portion 42b of the first outer diameter side connecting member 42 and the connecting portion 43b of the second outer diameter side connecting member 43 are closer to each other than the joint portion 42a. Located on the outer diameter side. The connecting portion 44b of the first inner diameter side connecting member 44 and the connecting portion 45b of the second inner diameter side connecting member 45 are arranged on the inner diameter side of the joint portion 45a.

One bus ring 40 is formed by arranging eight connection units 41 having the same shape in the circumferential direction. For the eight coil wires 30 accommodated in the same slot 14, the joint portions 42a to 45a of the connection unit 41 arranged on one side in the circumferential direction of the slot 14 and the joint portions 42a to 45a arranged on the other side in the circumferential direction of the slot 14 The joint portions 42a to 45a of the connection unit 41 are arranged alternately in the radial direction and joined to the end portion 31a (see FIG. 4B).

Next, a configuration in which bus rings 40 are layered will be described. As shown in FIGS. 4A and 4B, bus rings 40 are provided in six layers on the first side D1 of the stator core 10 . Here, a U1-phase bus ring 40 _U1 , a U2-phase bus ring 40 _U2 , a V1-phase bus ring 40 _V1 , a V2-phase bus ring 40 _V2 , a W1-phase bus ring 40 _W1 , and a W2-phase bus ring 40 , and the bus ring 40 _W2 are stacked in order.

The U1-phase bus ring 40 _U1 is joined to the end surface 10a of the stator core 10 while being supported by the end portion 31a with a predetermined gap S (see FIG. 2(a)). As a result, it is possible to prevent the U1-phase bus ring 40 _U1 from interfering with the end portion of the first side D1 of the insulating paper (not shown) provided in the slot 14 . The bus rings 40 on the first side D1 of the U1-phase bus ring 40 _U1 are all laminated with insulating coating interposed therebetween. That is, the bus rings 40 are not in direct contact with each other, but are supported.

In this embodiment, the end portion 31a of the coil wire 30 is set to be at the same height as the bus ring 40 to be joined when viewed from the radial direction of the stator core 10 . That is, the end portions 31a of the plurality of coil wires 30 accommodated in the same slot 14 overlap one layer of the bus ring 40 connected to the end portions 31a when viewed from the radial direction of the stator core 10. As shown in FIG. In addition, since the distance from the end surface 10a of the stator core 10 to the bus ring 40 differs for each phase, as shown in FIG. 31 have different lengths.

In this embodiment, as shown in FIG. 7, in each coil wire 30, a first leg length L1, which is the total length of the first slot accommodating portion 33A and the first protruding portion 31A, and a second slot accommodating portion The second leg length L2, which is the total length of 33B and the second protrusion 31B, is the same length. The plurality of coil wires 30 used for the same phase are all made to have the same first leg length L1 and second leg length L2.

As shown in FIGS. 4(a) and 4(b), the bus rings 40 formed for each phase have the same shape and are stacked in layers with a phase shift so that the plane crossing of the wiring is Realized. The connecting portions 42b and 43b are arranged on the outer diameter side of the joint portion 42a, and the connecting portions 44b and 45b are arranged on the inner diameter side of the joint portion 45a. Accordingly, when viewed from the first side D1, the joint portions 42a to 45a of the connection members 42 to 45 of the bus ring 40 of each phase are connected to the connection portions 42b of the connection members 42 to 45 of the other bus ring 40. 45b and is exposed on the first axial side D1.

When assembling the stator 1, the slot 14 is provided with insulating paper and the coil wire 30 is assembled. Then, the assembly 46 of the six-layer bus ring 40 is attached to all the ends 31a of the coil wire 30 from the first side D1, and all the joints 42a to 45a are joined by welding or the like. . At this time, when viewed from the first side D1, since the joint portions 42a to 45a of the connection members 42 to 45 of the bus ring 40 of each phase are exposed in the axial direction, all the joint portions 42a to 45a are exposed. On the other hand, it is possible to perform the work from one direction at a time without intervening another work such as stacking a new bus ring 40 . As a result, workability during assembly of the stator 1 can be improved. After that, attach the busbar and harden it with varnish.

As described above, according to the stator 1 of the present embodiment, when the stator 1 is viewed from the first side D1, the joint portions 42a to 45a of the connection members 42 to 45 of the bus ring 40 of each phase are connected to each other. The bus ring 40 is exposed in the axial direction without overlapping the coupling portions 42b to 45b of the connection members 42 to 45 of the bus ring 40. As shown in FIG. Therefore, when assembling the stator 1, all the joints 42a to 45a can be assembled in one direction at once without intervening another work such as stacking the bus ring 40 again. As a result, the workability is improved compared to the case where a bus ring is placed and joined to the coil wire, and another bus ring is laminated and joined to the coil wire, which is repeated for the number of phases. be able to. Also, after assembly, since the joints 42a to 45a are exposed, inspection can be easily performed.

Further, according to the stator 1 of the present embodiment, the bus rings 40 formed for each phase have the same shape, so parts can be shared. Furthermore, since the connection unit 41 also has the same shape, parts can be shared.

Further, according to the stator 1 of the present embodiment, the coil wires 30 accommodated in the same slots 14 have the same length. As a result, the length of the coils in the same phase can be made the same, so the occurrence of a difference in resistance can be suppressed.

Further, according to the stator 1 of the present embodiment, each bus ring 40 is flat and the length of the protruding portion 31 is changed for each phase, so that the overall height in the axial direction can be kept low. . That is, there is no cross point between different bus rings 40, and even if the bus ring is multi-layered, the thickness can be reduced to the sum of the thicknesses of the layers. Therefore, the size of the stator 1 can be reduced. In addition, since the planar bus ring 40 is attached from the first side D1, there is no need to bend or twist the projecting portion 31, and the positional accuracy of the end portion 31a and peeling of the coating of the coil wire 30 are taken into consideration. No need. Further, by making the bus ring 40 planar, the shapes of all the joints 42a to 45a can be unified.

Further, according to the stator 1 of the present embodiment, during assembly, the joint portion 42a is axially supported by the stepped portion 31b by fitting the hole portion into the end portion 31a. Therefore, workability can be improved as compared with the case where the joining work is performed while the bus ring 40 is held by some jig without the stepped portion 31b.

In the stator 1 of the present embodiment described above, the bus ring 40, that is, the connecting members 42 to 45, has been described as a case where an aluminum plate formed into a flat plate shape by press molding is applied. Alternatively, it may be formed by cutting a linear member. For example, an aluminum wire, a coated aluminum wire, a copper plate, a copper wire, a copper-coated wire, etc. can be applied.

In addition, in the stator 1 of the present embodiment, the bus ring 40 is arranged on both the outer diameter side and the inner diameter side. It can be changed as appropriate according to the number of 30 or the like. For example, when four coil wires 30 are accommodated in the slot 14, they may be provided only on the outer diameter side or only on the inner diameter side.

Also, in the stator 1 of the present embodiment, the stacking order of the six layers is U1, U2, V1, V2, W1, W2, but it is not limited to this. For example, by using U1, V1, W1, W2, V2, and U2, the length of the coil wire 30 for each phase of the UVW phases can be made the same, so the difference in resistance value between the UVW phases can be reduced.

Also, in the stator 1 of the present embodiment, as shown in FIGS. However, as shown in FIGS. 5(c) and 5(d), the end portion 131a may have a shape in which both sides in the thickness direction and both sides in the width direction of the projecting portion 131 are cut off. Also in this case, the joint portion 142a of the first outer diameter side connecting member 142 can be supported by the stepped portion 131b and welded at the weld portion 150. As shown in FIG. Alternatively, as shown in FIGS. 6(a) and 6(b), the end portion 231a may have a shape in which one side in the width direction of the second projecting portion 231 is cut. Also in this case, the joint portion 242a of the first outer diameter side connecting member 242 can be supported by the stepped portion 231b and welded at the weld portion 250. As shown in FIG. Alternatively, as shown in FIGS. 6(c) and 6(d), the end portion 331a may have a shape in which one side in the width direction and one side in the thickness direction of the second projecting portion 331 are cut. Also in this case, the joint portion 342a of the first outer diameter side connecting member 342 can be supported by the stepped portion 331b and welded at the weld portion 350 .

Reference Signs List 1 Stator 10 Stator core 14 Slot 20 Coil set (coil) 30 Coil wire 31 Projection (first projection, second projection) 31A First projection 31a, 131a, 231a, 331a end portion 31B second projecting portion 31b, 131b, 231b, 331b stepped portion (positioning portion) 33 slot accommodating portion (first slot accommodating portion, second slot accommodating portion), 33A... First slot accommodation portion, 33B... Second slot accommodation portion, 40... Bus ring (annular connection portion), 42... First outer diameter side connection member (connection member), 42a, 43a, 44a, 45a, 142a, 242a, 342a... Joint portion 42b, 43b, 44b, 45b... Connecting portion 43... Second outer diameter side connecting member (connecting member) 44... First inner diameter side connecting member (connecting member) 45... Second inner diameter Side connecting member (connecting member), D1... first side (one side in axial direction), D2... second side (other side in axial direction)

Claims (4)

In a stator used in a rotating electric machine,
an annular stator core in which a plurality of slots are arranged in the circumferential direction;
A first slot accommodating portion accommodated in the slot, a first protruding portion continuously protruding from the first slot accommodating portion and protruding to one side in the axial direction of the central axis of the stator core, and the first slot accommodating portion are accommodated. a second slot accommodating portion accommodated in the slot different from the slot in which the first a coil end portion connected to the slot accommodating portion and the second slot accommodating portion and arranged on the other axial side of the stator core opposite to the one axial side of the stator core, a plurality of coil wires having ends on each of the first projecting portion and the second projecting portion;
two joints respectively joined to the ends of the different coil wires used for the same phase, and a connecting portion connecting the two joints, and a plurality of connection members that electrically connect the ends,
The plurality of coil wires housed in the same slot are used for the same phase, the slots used for the same phase are arranged along the circumference at predetermined intervals in the circumferential direction, and the coil wires of different phases The plurality of coil wires accommodated in the plurality of slots arranged with different phases with respect to the slots and used for the same phase are connected by the plurality of connection members, so that one turn in the circumferential direction forming a coil wound by wave winding over the
The plurality of connection members for connecting the ends of the plurality of coil wires used in the same phase are arranged on the same plane over one circumference in the circumferential direction to form a single annular connection portion as a group. form,
the plurality of annular connection portions are formed for each phase and provided in layers on one side in the axial direction with respect to the stator core,
When viewed from one side in the axial direction, each of the joint portions of the connection members of the annular connection portions of each phase does not overlap the connection portion of the connection member of the other annular connection portion, and exposed to
stator. In each coil wire, a first leg length that is the total length of the first slot accommodation portion and the first protrusion, and a second leg length that is the total length of the second slot accommodation portion and the second protrusion The two leg lengths are the same length,
The plurality of coil wires used for the same phase have the same first leg length and the second leg length,
A stator according to claim 1 . The end portion has a positioning portion against which the joint portion abuts and is positioned when the connecting member is assembled from the axial direction.
A stator according to claim 1 or 2. The annular connection portions formed for each phase have the same shape, and are stacked in layers with a phase shift so that the joint portions are exposed in the axial direction.
A stator according to any one of claims 1 to 3.

Images