JP3823556B2 - Wave winding coil of rotating electric machine and method for manufacturing the same - Google Patents

Wave winding coil of rotating electric machine and method for manufacturing the same Download PDF

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Publication number
JP3823556B2
JP3823556B2 JP23762498A JP23762498A JP3823556B2 JP 3823556 B2 JP3823556 B2 JP 3823556B2 JP 23762498 A JP23762498 A JP 23762498A JP 23762498 A JP23762498 A JP 23762498A JP 3823556 B2 JP3823556 B2 JP 3823556B2
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Japan
Prior art keywords
conductor
coil
slot
transition
wave winding
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Expired - Fee Related
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JP23762498A
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JP2000069701A (en
Inventor
敏一 加藤
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株式会社デンソー
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Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a wave winding of a rotating electrical machine and a method for manufacturing the same.
[0002]
[Prior art]
As a method of winding a stator winding or rotor winding of a rotating electrical machine such as a motor / generator, a predetermined number of conductors are wound around one magnetic pole, and after winding is completed, concentrated winding that moves to the next magnetic pole There are known a method and a wave winding method in which a conductor is wound in a wave shape.
[0003]
[Problems to be solved by the invention]
However, in the case of concentrated winding, since winding is performed for each magnetic pole, production takes time. Also, in the case of wave winding, when winding a three-phase coil widely used in rotating electrical machines, the winding work becomes complicated, and it is difficult to use a coil conductor having a large cross-sectional area for the winding work. Therefore, the resistance power loss of the coil conductor is large, and it is not easy to improve the slot space factor of the coil conductor. Further, there is a problem that the coil end becomes large, the total conductor length thereof increases, and the resistance power loss at the coil end increases.
[0004]
In order to solve these problems in wave winding, the present inventors formed a coil conductor with a thin plate-like conductor, and connected the end of the forward conductor portion inserted into the slot and the end of the return conductor portion. The connecting conductor part to be connected is formed in a mountain shape on the substantially circumferential surface, and one half part of the connecting conductor part is formed in the other half part by folding or forming a step at the tip part (the peak part) of the connecting conductor part. In comparison with, we have developed a wave winding structure for a rotating electrical machine (hereinafter referred to as a plate-shaped mountain-shaped cross-conductor wave winding coil) having a coil end that is displaced by a thickness in the thickness direction.
[0005]
However, the coil end of this plate-shaped mountain-shaped crossover conductor-type wave winding coil has a problem that heat dissipation is inferior because each crossover conductor portion overlaps with a very high density. Moreover, the pitch (circumferential width) of the transition conductor portion needs to be shortened as it moves inward, but such pitch adjustment of the transition conductor portion requires a shortening of the length of the transition conductor portion, and the coil conductor The work of creating the fold was complicated.
[0006]
The present invention has been made in view of the above problems, and it is possible to reduce the coil end space and resistance power loss of the plate-shaped mountain-shaped crossover conductor-type wave winding coil, and it is excellent in cooling performance and produced. It is an object of the present invention to provide a wave winding and a winding method for a rotating electrical machine that are easy to handle.
[0007]
[Means for Solving the Problems]
The wave winding of the rotating electrical machine according to the present invention includes a slot conductor portion composed of a forward conductor portion and a return conductor portion alternately inserted into each slot of the core, and the forward conductor portion formed integrally with the slot conductor portion. In a wave winding of a rotating electrical machine having a coil conductor composed of a transition conductor portion connecting the same side end portions of the return conductor portion, a thin plate shape extending in a posture in which the thickness direction is the radial direction of the core A plurality of the transition conductor portions each made of a conductor have a coil end formed by laminating in the radial direction, and the lengths of the plurality of the transition conductor portions laminated in the radial direction are different from each other in the radial direction. The crossing conductor portion is characterized in that it protrudes in the axial direction from the crossing conductor portion outside the diameter.
Since the wave winding of the rotating electric machine of the present invention has the above-described plate-shaped mountain-shaped crossing conductor type wave winding coil structure, winding can be completed simply by inserting a pre-formed coil into the slot. Work becomes easy. In addition, since there is no coil conductor plastic deformation work such as bending during the winding work, a coil conductor having a large cross-sectional area can be used, and the slot space factor of the coil conductor can be improved. Since the total conductor length can be shortened, the resistance power loss of the coil can be reduced.
[0008]
Furthermore, the required space at the coil end can be remarkably reduced as compared with the conventional wave winding.
Further, in this configuration, since the lengths in the axial direction of the plurality of crossover conductor portions stacked in the radial direction are different, the exposed surface area of the crossover conductor portion, particularly the crossover conductor portion located in the central portion in the radial direction (other crossover portions) The surface area of the portion that does not overlap the conductor portion can be increased, and the cooling performance can be improved.
[0009]
According to the configuration of the second aspect, in the wave winding of the rotating electrical machine according to the first aspect, each bridging conductor portion has a bent end portion formed by bending a thin plate-like conductor, one on each of the axial end portions. Since the structure (bending structure) is adopted, the transition conductor portion of the plate-shaped chevron transition conductor type wave winding coil can be easily manufactured. In addition to the bent structure, the transition conductor portion of the plate-shaped mountain-shaped transition conductor type wave winding coil is approximately the thickness of the transition conductor portion in the radial direction in the radial direction at the tip end portion in the axial direction of the transition conductor portion. A displacement structure (hereinafter referred to as a step structure) may be employed.
[0010]
According to the configuration of the third aspect, in the wave winding of the rotating electrical machine according to the first or second aspect, the crossing conductor portions have the same length.
In this way, the wave winding winding, that is, the coil manufacturing operation can be simplified. That is, of the two transition conductor portions adjacent in the radial direction at the coil end, the pitch of the transition conductor portion on the inner diameter side, that is, the circumferential width Li, is the thickness of the transition conductor portion t and the transition conductor portion on the inner diameter side. When the radius from the center of the core is r, it is shorter than the pitch of the transition conductor portions outside the diameter, that is, the circumferential width Lo, at a rate of r / (r + t). However, in this configuration, the lengths of the respective transition conductor portions are equal, and as a result, the inner diameter transition conductor portion protrudes in the axial direction from the outer diameter transition conductor portion.
[0011]
In other words, even if each of the transition conductors is created at an equal pitch before the slot is inserted, the axial tip of the inner diameter transition conductor is projected in the axial direction as compared with that of the outer diameter transition conductor. Thus, the slot conductor portion can be inserted into the slot without any problem by readjusting the pitch of the crossing conductor portion, that is, the circumferential width.
Therefore, according to this embodiment, the simplification of the manufacturing work can be realized in addition to the improvement of the coil end cooling effect according to the first aspect.
[0012]
The manufacturing method according to claim 4 is a method for manufacturing a wave winding having an equal-length transition conductor portion according to claim 3 described above, after each of the transition conductor portions is formed at an equal pitch, and Before inserting each transition conductor portion into the slot, the pitch of each transition conductor portion is adjusted by plastic deformation of the transition conductor portion so that each slot conductor portion can be adjacent in the radial direction within the slot. A plate-shaped chevron crossing conductor type wave winding coil can be created.
[0013]
The pitch adjustment may be performed by plastic deformation of the transition conductor portion or may be performed by elastic deformation. In addition, it is possible to adjust by pulling the axial tip portion of the transition conductor portion on one end side of the slot conductor portion and the axial tip portion of the transition conductor portion on the other end side of the slot conductor portion in opposite directions. In addition to this configuration, the cross-sectional tip portion of the cross-conductor portion may be bent at an appropriate angle all at once.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
Preferred embodiments of the invention are illustrated by the following examples.
[0015]
[Example 1]
An embodiment of a three-phase motor in which the wave winding of the present invention is applied to a stator winding will be described. FIG. 1 shows a plan view of the stator of this motor, FIG. 2 shows a front view, FIGS. 3 to 10 show a procedure for making a stator coil, and FIG. 11 shows a transition conductor portion located outside the diameter of the coil end. FIG. 12 shows the transition conductor portion 21 located on the inner diameter side of the coil end.
[0016]
Reference numeral 1 denotes a stator core in which thin plate steel plates are laminated, and has a large number of slots opened on the inner diameter side. In each slot, a star-connected three-phase two-layer wave-type stator coil (hereinafter also simply referred to as a coil) 2 is wound. A plate-like wedge 4 for preventing the protrusion is fitted. An insulator 3 that insulates the coil 2 from the core 1 is inserted in the inner periphery of the slot.
[0017]
The coil 2 has a linear slot conductor portion 21 inserted into a slot and a transition conductor portion 22 formed integrally with the slot conductor portion 21, and both ends of the transition conductor portion 22 are sandwiched by two slots. They are individually connected to the same end of the pair of slot conductors 21 inserted into the slots on both sides. As shown in FIG. 1, the coil 2 is composed of three phase coils 2a, 2b, and 2c. As shown in FIG. 3, the slot conductor portion 21 is formed from the start ends 23 to 25 of the phase coils 2a, 2b, and 2c. It consists of a forward conductor portion 21a extending in the forward direction, and a return conductor portion 21b extending in the return direction approaching from the start ends 23 to 25 of the phase coils 2a, 2b, 2c. Therefore, the coil end portions 2d on both sides of the slot are precisely constituted by the end portions on both sides of the slot conductor portion 21 and the transition conductor portions 22, and each of the transition conductor portions 22 is formed of a slot conductor portion as shown in FIG. 21 is bent obliquely in the circumferential direction, is bent at the center of the crossover conductor 22, and has a chevron shape at the tip in the axial direction.
[0018]
More specifically, each has one bent end portion 22a that is folded in the radial direction at the tip end portion in the axial direction and overlaps. Therefore, the folding of the tip end portion 22a in the axial direction of the transition conductor portion 22 imparts a radial displacement equal to the thickness of the pair of slot conductor portions 21 extending from both ends of the transition conductor portion 22. Even if the step portion is formed by plastic deformation instead of folding the tip end portion 22a in the axial direction of the cross conductor portion 22, the thickness of the pair of slot conductor portions 21 extending from both ends of the cross conductor portion 22 is similarly reduced. A radial displacement equal to the thickness can be applied. And since this axial direction front-end | tip part 22a of the crossing conductor part 22 does not overlap with the adjacent crossing conductor part 22 in radial direction, the said radial direction bending or level | step difference provision can be implemented without trouble.
[0019]
Hereinafter, the coil 2 will be described in more detail.
As shown in FIG. 3, the coil 2 includes six coil conductors 201 to 206 arranged in parallel at a distance of one slot pitch, and the coil conductors 201 and 204 constitute the phase coil 2 a, and the coil conductor 203 , 206 constitute the phase coil 2b, and the coil conductors 202, 205 constitute the phase coil 2c. Each of the coil conductors 201 to 206 has a substantially square cross-sectional shape that is thin in the radial direction of the stator core 1 and wide in the circumferential direction.
[0020]
The nth (n is an integer) slot conductor portion 21 of the mth (m is an integer) coil conductor is the (n−1) th or (n + 1) th slot conductor portion 21 of the mth coil conductor. Are accommodated in slots that are 180 degrees apart from the slots in which the electrical angle is accommodated. In addition, the slots separated by the three-slot pitch are accommodated together with the slot conductor portion 21 of the m-3th or m + 3th coil conductor.
[0021]
Further, among the starting ends of the six coil conductors 201 to 206, the second, fourth, and sixth starting ends are short-circuited with each other to become a neutral point, and the remaining first, third, and fifth starting ends are three-phase star types. It forms the terminal of each connected phase coil 2a, 2b, 2c.
A specific method for manufacturing the coil conductors 201 to 206 will be described with reference to the manufacturing procedure shown in FIGS.
[0022]
First, as shown in FIG. 3, the six coil conductors 201 to 206 are arranged in parallel at a distance of one slot pitch. The slot conductor portion 21 and the transition conductor portion 22 are each formed in a straight strip shape, and the transition conductor portion 22 is obliquely provided with respect to the slot conductor portion 21 at an appropriate angle (here, about 60 degrees). Reference numeral 23 denotes a start end of the coil conductor 201, 24 denotes a start end of the coil conductor 203, 25 denotes a start end of the coil conductor 205, 26 denotes a start end of the coil conductor 202, and 27 denotes a start end of the coil conductor 204. Yes, 28 is the starting end of the coil conductor 206.
[0023]
Next, as shown in FIG. 4, the first six crossing conductor portions 22 counted from the start ends 23 to 28 of the coil conductors 201 to 206 are the first slot conductors at the center (shown by broken lines in FIG. 3). Bend so that part 21 is at the bottom (by valley fold). In FIG. 3, the first slot conductor portion 21 and the next slot conductor portion 21, which are counted from the start ends 23 to 28 of the coil conductors 201 to 206, are formed at a three-slot pitch, thereby the coil conductor 201. The second slot conductor portion 21 of the coil conductor 204 overlaps with the first slot conductor portion 21 of the coil conductor 204, and similarly, the second slot conductor portion 21 of the coil conductor 202 is the first slot conductor portion 21 of the coil conductor 205. The second slot conductor portion 21 of the coil conductor 203 overlaps the first slot conductor portion 21 of the coil conductor 206.
[0024]
Next, as shown in FIG. 5, the second six transition conductor portions 22 counted from the start ends 23 to 28 of the coil conductors 201 to 206 are arranged at the center (shown by broken lines in FIG. 4), and the second The slot conductor portion 21 is folded so as to be above the third slot conductor portion 21 (in a mountain fold, that is, in the same rotational direction as the first bending direction). As a result, the third slot conductor portion 21 of the coil conductor 201 overlaps below the second slot conductor portion 21 of the coil conductor 204, and the third slot conductor portion 21 of the coil conductor 202 is similarly connected to the coil conductor 205. The third slot conductor portion 21 of the coil conductor 203 overlaps below the second slot conductor portion 21 of the coil conductor 206. As a result, the third slot conductor 21 is reasonably accommodated at the same depth (deepest position) in the slot as the first slot conductor 21.
[0025]
Hereinafter, as shown in FIG. 6, six coil conductors 201 to 206 are accommodated in two layers in each slot by sequentially bending in the same rotational direction as valley folding, mountain folding, and valley folding. As a result, by bending the number of times of subtracting 1 from the number of magnetic poles of the rotor, each of the coil conductors 201 to 206 makes one round, and a coil for two turns is formed in two layers in the slot.
[0026]
Next, as shown in FIG. 7, the sheet is bent in the opposite direction of rotation (that is, the final folding of the first two turns is a valley fold so that it is again a valley fold). Thereby, the subsequent slot conductor portions 21 can be smoothly arranged in the third and fourth layers in the slot.
Hereinafter, as shown in FIG. 8, the six coil conductors 201 to 206 are accommodated in four layers in each slot by sequentially bending the valley fold, the mountain fold, and the valley fold in the direction opposite to the first two turns. . As a result, the coil conductors 201 to 206 perform the next round by bending the number of times obtained by subtracting 1 from the number of rotor magnetic poles, and coils for four turns are formed in four layers in the slot. . Thereafter, the necessary number of turns is produced by the same procedure as described above.
[0027]
Next, after making a predetermined turn, as shown in FIG. 8, the final transition conductor portion 22 b of the coil conductors 201 to 206 is about half the length of the conventional transition conductor portion 22, and the coil The last transition conductor portion 22b of the conductors 204 to 206 is obliquely arranged in a line symmetrical direction with the other transition conductor portion 22 and the last transition conductor portion 22b. As a result, as shown in FIG. 10, the end portions of the last transition conductor portions 22b of the coil conductors 201 and 204 overlap, the end portions of the last transition conductor portions 22b of the coil conductors 202 and 205 overlap, and the coil conductors 203 and 206 The leading end portion of the final crossover conductor portion 22b overlaps, and a three-phase stator coil is formed by welding these overlapping portions. More specifically, the coil conductors 201 to 203 are bent as shown in FIG. 9, and then the coil conductors 204 to 206 are bent as shown in FIG. do it.
[0028]
Next, the coil 2 manufactured as described above is inserted into each slot of the stator core 1, and next or before the slot is inserted, the starting ends of the coil conductors 202, 204, 206 are short-circuited to obtain a neutral point.
Hereafter, the principal part of a present Example is demonstrated below with reference to FIG. 11, FIG.
FIG. 11 shows the outermost slot conductor portion 21 and the transition conductor portion 22 among the slot conductor portions 21 and the transition conductor portions 22 adjacent to the five layers in the radial direction as shown in FIG. The innermost slot conductor portion 21 and the transition conductor portion 22 are shown.
[0029]
The pitch, that is, the circumferential width Li of the transition conductor portion 22 (see FIG. 12) on the inner diameter side is t when the thickness of the transition conductor portion 22 is t, and the radius from the core center of the transition conductor portion 22 on the inner diameter is r. It is shorter at a rate of r / (r + t) than the pitch of the crossover conductor portions 22 on the outer diameter side, that is, the circumferential width Lo.
The change in the circumferential width of the transition conductor portion 22 is made by creating the coil 2 having the same circumferential width in the transition conductor portion 22 in the steps of FIGS. What is necessary is just to hold | grip 22 with a jig | tool and pull it at a stretch in the mutually opposite direction to the direction where the slot conductor part 21 extends, and to adjust the angle of the crossing conductor part 22, ie, the circumferential direction width | variety, to a required value now.
[0030]
As a result, the circumferential width of each transition conductor portion 22 is equal to the pitch of the slot into which it is inserted, and the slot conductor portion 21 can be smoothly inserted into the slot lot. Since it protrudes in the axial direction from the crossover conductor portion 22 on the outer diameter side, the tip end portion of each crossover conductor portion 22 is cooled by the cooling air flow better than before.
[0031]
In addition, this pitch adjustment may be performed by plastic deformation of the crossing conductor 22 or may be performed by elastic deformation. That is, the slot conductor portion 21 may be inserted into the slot while pulling the crossover conductor portions 22 and 22 in the extending direction of the slot conductor portion 21 with the jig.
[0032]
[Modification]
First, a plurality of conductors may be arranged in the circumferential direction to form one coil conductor.
In addition, the coil conductors 201 to 206 may be bent at the time of bending to form the transition conductor part 22 instead of obliquely providing the transition conductor part 22 with respect to the slot conductor part 21 in advance.
[0033]
Further, for example, coils of even number of turns (coil group referred to in the present invention) are formed by six coil conductors 201 to 206, and coils of even number of turns (coil group referred to in the present invention) are formed by further six coil conductors. ) And the coil groups may be connected to each other by, for example, a method of overlapping and welding the conductor portions 22 having a half length.
The coil conductors 201 and 204, the coil conductors 202 and 205, the coil conductors 203 and 206, and the above-described final transition conductor portions may be bent and formed, and then the coils may be formed in order from FIG.
[0034]
Furthermore, instead of short-circuiting the starting ends of the coil conductors 202, 204, 206, it is possible to make a delta connection.
[Brief description of the drawings]
FIG. 1 is a plan view of a stator in an embodiment of a three-phase motor in which a wave winding of the present invention is applied to a stator winding.
FIG. 2 is a front view of the stator shown in FIG.
FIG. 3 is a process diagram showing a procedure for creating the stator coil shown in FIGS. 1 and 2;
FIG. 4 is a process diagram showing a procedure for creating the stator coil shown in FIGS. 1 and 2;
FIG. 5 is a process diagram showing a procedure for creating the stator coil shown in FIGS. 1 and 2;
6 is a process diagram showing a procedure for creating the stator coil shown in FIGS. 1 and 2. FIG.
7 is a process diagram showing a procedure for creating the stator coil shown in FIGS. 1 and 2. FIG.
8 is a process diagram showing a procedure for creating the stator coil shown in FIGS. 1 and 2. FIG.
FIG. 9 is a process diagram showing a procedure for creating the stator coil shown in FIGS. 1 and 2;
FIG. 10 is a process diagram showing a procedure for creating the stator coil shown in FIGS. 1 and 2;
FIG. 11 is a development view of the coil 2 showing a slot conductor portion 21 inserted outside the slot diameter and a transition conductor portion 22 extending therefrom.
12 is a development view of the coil 2 showing the slot conductor portion 21 inserted inside the slot and the transition conductor portion 22 extending therefrom. FIG.
[Explanation of symbols]
1 is a stator core, 2 is a coil, 21 is a slot conductor, 22 is a transition conductor, and 22a is a bent end.

Claims (4)

  1. A slot conductor portion composed of a forward conductor portion and a return conductor portion that are alternately inserted into each slot of the core and an end portion on the same side of the forward conductor portion and the return conductor portion that are formed integrally with the slot conductor portion. In the wave winding of a rotating electrical machine having a coil conductor composed of a transition conductor part,
    A coil end configured by laminating a plurality of the transition conductor portions each formed of a thin plate-like conductor extending in a posture in which the thickness direction is the radial direction of the core;
    The axial lengths of the plurality of crossover conductor portions stacked in the radial direction are different ,
    The wave winding of a rotating electrical machine, wherein the transition conductor part on the inner diameter side protrudes in the axial direction from the transition conductor part on the outer diameter side .
  2. In the wave winding of the rotating electric machine according to claim 1,
    Each of the bridging conductor portions has a bent end portion formed by bending the thin plate-like conductor, one at each end portion in the axial direction.
  3. In the wave winding of the rotating electrical machine according to claim 1 or 2,
    Each said crossing conductor part has the mutually equal length, The wave winding of the rotary electric machine characterized by the above-mentioned.
  4. In the manufacturing method of the wave winding of the rotary electric machine according to claim 3,
    Each slot conductor portion is finally inserted into the slot after each of the transition conductor portions radially adjacent in the slot is formed at an equal pitch and before each of the transition conductor portions is inserted into the slot. A method of manufacturing a wave winding of a rotating electrical machine, wherein a circumferential width of the transition conductor portion is adjusted so as to be adjacent in a radial direction.
JP23762498A 1998-08-24 1998-08-24 Wave winding coil of rotating electric machine and method for manufacturing the same Expired - Fee Related JP3823556B2 (en)

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JP23762498A JP3823556B2 (en) 1998-08-24 1998-08-24 Wave winding coil of rotating electric machine and method for manufacturing the same

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Application Number Priority Date Filing Date Title
JP23762498A JP3823556B2 (en) 1998-08-24 1998-08-24 Wave winding coil of rotating electric machine and method for manufacturing the same

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JP3823556B2 true JP3823556B2 (en) 2006-09-20

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103236749A (en) * 2009-10-23 2013-08-07 株式会社电装 Methods of manufacturing a stator for an electric rotating machine

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4688003B2 (en) 2007-03-05 2011-05-25 株式会社デンソー Rotating electric machine stator and rotating electric machine using the same
JP5532319B2 (en) 2009-07-17 2014-06-25 株式会社デンソー Stator for rotating electric machine and method for manufacturing the same
JP5704418B2 (en) * 2009-07-17 2015-04-22 株式会社デンソー Rotating electric machine stator
JP5488421B2 (en) * 2009-12-09 2014-05-14 株式会社デンソー Rotating electric machine stator

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103236749A (en) * 2009-10-23 2013-08-07 株式会社电装 Methods of manufacturing a stator for an electric rotating machine
CN103236749B (en) * 2009-10-23 2015-08-26 株式会社电装 For stator and the manufacture method thereof of electric rotating machine

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