JP3891062B2 - Coil end contact cooling type rotating electrical machine - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a coil end contact cooling type rotating electrical machine.
[0002]
[Prior art and problems to be solved by the invention]
2. Description of the Related Art In recent years, due to various problems associated with an internal combustion engine, technology is expected from a vehicle driving power using a motor (also referred to as a driving motor), and a hybrid vehicle that partially covers the vehicle driving power has been put to practical use. It is preferable to adopt a design that increases the current density of the stator coil as much as possible for this traveling motor as a so-called copper machine because of the demand for high output and small size and weight.
[0003]
However, such an increase in the current density of the stator coil inevitably leads to a significant increase in the stator coil temperature due to an increase in the copper loss of the stator coil. In fact, the heat resistance temperature of the insulating film of the stator coil determines the output value per unit weight of the motor.
[0004]
For this reason, conventionally, many proposals have been made to reduce the stator temperature by adjoining a liquid cooling pipe adjacent to the stator core and the stator coil. Since the coil end is exposed from the stator core, it is effective to indirectly cool the coil end by connecting a liquid cooling pipe to the coil end which is a large heat source.
[0005]
However, conventionally, in a coiled coil rotating electric machine (rotating electric machine in which a large number of round conductors are wound around a stator core to form a stator coil) generally used in motors of about 100 kW or less, an extremely large number of coil ends are used. Because it has a shape as a result of winding a round conductor, its outer surface is bumpy, and the shape differs from one piece to another, resulting in the adjoining non-flexible metal tubes, etc. However, a large gap is generated between the metal tube and the outer surface of the coil end, and the size of the gap varies locally and for each model. Even if it was interposed, good heat transfer could not be expected. In addition, since the gap is so wide and uneven, a problem arises that the heat conduction grease deviates.
[0006]
In response to this problem, Japanese Patent Laid-Open No. 6-296348 discloses a silicon tube through which a coolant flows, that is, a soft tube having good thermal conductivity, flexibility, and electrical insulation, and a coil end of a stator coil and a motor housing. It has been proposed to eliminate the irregularities and uneven shape of the outer surface of the coil end by using the flexibility of the soft tube, mainly in the gap between the inner end surface.
[0007]
However, since this soft tube is made of resin, its thermal conductivity is limited, and if it is thinned to improve the thermal conductivity, it is from a vehicle or magnetic vibration at the contact portion with the irregularities on the outer surface of the coil end. There is a problem that the soft tube breaks due to vibration due to, and if the wall thickness is large, the thermal conductivity is lowered, and the soft tube cannot cope with the shape change of the outer surface of the coil end, and a gap is generated between the two. There was a serious problem that the thermal conductivity was extremely lowered.
[0008]
As a result, there are various proposals for adjoining the liquid-cooled piping to the coil end, but it was difficult to put it to practical use because good contact between the liquid-cooled piping and the coil end cannot be expected. .
[0009]
In view of the above problems, the present invention provides a coil end contact cooling type rotating electrical machine that is excellent in coil end cooling, durability, and vibration resistance, and that can significantly reduce the size and weight of the rotating electrical machine and increase the output. Its purpose is to provide.
[0010]
[Means for Solving the Problems]
The coil end contact cooling type rotating electrical machine according to claim 1, wherein a cylindrical stator core having a slot in an inner peripheral portion and fixed to a motor housing, a rotor rotating to face an inner peripheral surface of the stator core, A stator coil having coil ends protruding from both end surfaces of the stator core and inserted into the slot, and a heat transfer cooling of the coil end by contacting the coil end in an electrically insulating manner with good heat absorption performance In a coil end contact cooling type rotating electrical machine comprising a coil end cooling member that performs
The stator coil constitutes a pair of slot conductor portions individually accommodated in a pair of slots separated in a circumferential direction by a predetermined pitch, and a head-side coil end projecting from the both slot conductor portions to one end side of the stator core A plurality of segments each having a square cross section each having a head portion and a pair of protruding end portions that project from the slot conductor portions to the other end side of the stator core to constitute an end side coil end, The head includes a substantially U-shaped head tip and a pair of head skews that are skewed circumferentially and axially from both ends of the head tip and are individually connected to the pair of slot conductors. The projecting end portions are formed at a pair of end oblique portions inclined obliquely in the circumferential direction and the axial direction from the pair of slots, and are formed at the distal ends of the end oblique portions and are adjacent to each other in the radial direction. To be different And the coil end cooling member is directly or electrically insulated on the flat surface of the head portion or the protruding end portion of the segment. It has the surface which touches indirectly, and it absorbs heat from the flat surface of the head or the protruding end.
[0011]
Hereinafter, the background of the invention will be described.
[0012]
In view of the problem of the coil end contact cooling type rotating electrical machine described above, the present inventors have a flat surface of the coil end of the segment sequential joining stator coil type rotating electrical machine which is the invention of the present applicant, and a constant with very little variation. Therefore, if liquid-cooled piping is adjacent to the coil end of this segment sequential joining stator coil type rotating electrical machine, it is not necessary to use a soft tube having various defects as described above, particularly defective vibration resistance. However, I realized that I can expect very good thermal conductivity.
[0013]
By the way, the patent No. 3118837 owned by the applicant of the present application is such that a segment, which is a conductor piece having a substantially U-shape, is individually inserted into a pair of slots separated from each other by a substantially magnetic pole pitch of a rotor. A segment sequential stator coil type rotating electrical machine is disclosed in which both protruding end portions are bent in the circumferential direction and the ends of both leg portions of each segment are sequentially joined.
[0014]
That is, the coil end contact cooling type rotating electrical machine of the present invention employs a segment sequential joining stator coil whose coil end is the invention of the present applicant, so that there is a gap between the segments at the coil end, The surface of a segment with a square cross section (usually also called a flat wire) is very flat, and the level difference between the surfaces of adjacent segments is very small (for example, approximately the same plane or approximately the same cylinder) In addition, the variation in the space arrangement and shape of the segments at the coil end and the variation of one unit is very small, and the coil ends of each motor formed by the same manufacturing process can be regarded as almost the same shape. it can.
[0015]
Therefore, a coil end cooling member that requires almost no change in shape as compared with a conventional silicon tube or the like is very close to the outer surface of the coil end of this segment sequential stator coil type rotating electrical machine (for example, less than 1 mm). The cooling efficiency of the conventional coil end can be remarkably improved by interposing thermal conductive grease, resin, or the like in these gaps.
[0016]
Note that the coil end shape of the segment sequential stator coil type rotating electrical machine has a flat surface, small steps between the segments, and small variations among the motors. The member need not be limited to the liquid cooling pipe described above, and solid heat transfer cooling using, for example, an aluminum heat sink having a flat surface can also be employed. Furthermore, even when a soft resin tube is used, it means that the soft resin tube is brought into close contact with the flat surface of the coil end segment by reducing the deformation stress applied to the soft resin tube while deforming the soft resin tube. Good coil end cooling is possible.
[0017]
In the present invention Further, the coil end cooling member has a flat surface that faces the flat surface of the head skew portion or the end skew portion while the coolant flows. Thereby, since a coil end and a coil end cooling member become surface contact, a cooling effect can be improved further.
[0018]
In the present invention Further, the coil end cooling member has a cooling pipe that extends while adjoining a flat surface of the head skew portion or the end skew portion as the coolant flows.
[0019]
The cooling pipe extends along and along the head skew portion of the head-side coil end of the segment sequential joining stator coil or the end skew portion of the end-side coil end. Since these head oblique portions or end oblique portions have four long planes that are considered to be substantially flat, a cooling pipe having a flat surface parallel to these four planes is connected to the head oblique portion or end portion. It is possible to achieve excellent heat transfer cooling adjacent to the plane of the skew portion. As described above, this excellent heat transfer cooling is substantially constant in size, position, and posture of the head skew portion or the end skew portion, and its outer surface is flat. This can be realized because the cooling pipe having a fixed shape, position and posture can be adjacent to the head skew portion or the end skew portion at a very short distance.
[0020]
In the present invention, the cooling pipe may further include a circumferential gap between the head skew portion or the end skew portion adjacent in the circumferential direction so that the head portion skew portion or the end skew portion has a flat vertical length. Skew along the surface, and then over the head oblique portion or the end oblique portion adjacent in the circumferential direction at the axial outer end and the axial inner end in the circumferential direction, and then Heat is transferred from the vertical surface of the head skew portion or the end skew portion by skewing the circumferential gap along the flat vertical surface of the head skew portion or the end skew portion. Consists of a square tube with a substantially square cross section that absorbs heat It is characterized by that.
[0021]
In this embodiment, among the four planes of the head skew portion or the end skew portion, the cooling pipe is arranged adjacent to the longitudinal surface that extends in the radial direction and skews in the circumferential direction and the axial direction. Therefore, the above effect can be realized.
[0022]
In a preferred embodiment, The cooling pipe is radially outermost or radially innermost Before The head oblique portion or the end oblique portion is wound in the circumferential direction or the axial direction while being adjacent to the head oblique portion or the end oblique portion in the circumferential direction or the axial direction. It is characterized by heat transfer and heat absorption from the flat horizontal surface of the row portion.
[0023]
In this embodiment, of the four planes of the head skew portion or the end skew portion, the cooling pipe is adjacent to the lateral surface extending in the substantially circumferential direction (tangential direction) and projecting in the substantially axial direction. Since it arrange | positions, the said effect is realizable.
[0025]
In a preferred embodiment, The cooling pipe is made of an electrically insulating soft resin pipe. The soft resin tube improves electrical insulation with the coil end, and when pressed against the flat surface of the coil end, the contact surface is easily flattened, so that the cooling effect can be improved.
[0026]
In a preferred embodiment The coil end cooling member includes a metal cooling member extending adjacent to the flat surface of the head skew portion or the end skew portion.
[0027]
That is, this metal cooling member is a solid heat conduction member such as an aluminum heat sink block, for example, the head skew portion of the head side coil end of the segment sequential joining stator coil, or the end side coil end. Adjacent to the end skewed portion, it extends along these. Since these head skew portions or end skew portions have four long planes that are considered to be substantially flat, a metal cooling member having a flat surface parallel to these four planes is connected to the head skew portion or end. Excellent heat transfer cooling can be realized by adjoining the plane of the oblique portion. As described above, this excellent heat transfer cooling is substantially constant in size, position, and posture of the head skew portion or the end skew portion, and its outer surface is flat. This can be realized because the cooling pipe having a fixed shape, position and posture can be adjacent to the head skew portion or the end skew portion at a very short distance.
[0030]
In a preferred embodiment, The metal cooling member is disposed radially adjacent to the head oblique portion or the end oblique portion on the radially outermost or radially innermost side, and is arranged on the radially outermost or radially outermost side. Heat transfer is absorbed from a flat lateral surface of the inner head skew portion or the end skew portion.
[0031]
In this embodiment, among the four planes of the head skew portion or the end skew portion, the metal cooling member is adjacent to the lateral surface extending in the substantially circumferential direction (tangential direction) and projecting in the substantially axial direction. Therefore, the above effect can be realized.
[0032]
In a preferred embodiment, The metal cooling member is composed of a plurality of vertically divided partial cylindrical members arranged adjacent to the surface of the head oblique portion or the end oblique portion on the radially outermost or radially innermost side. It is said.
[0033]
That is, in this embodiment, the outermost head part of each segment having an inner circumferential surface adjacent to the outermost head skewed part or the end skewed part of each segment is divided into a substantially cylindrical partly cylindrical member. Adjacent to the skewed part or the end skewed part. In addition, since the outer surface of the outer side in the radial direction of the head skew portion or the end skew portion of each segment is a flat surface, the inner peripheral surface of these vertically divided partial cylindrical members is in the polygon accordingly. It may be a circumferential surface, and may further have a skewed portion protruding in a circumferential gap between adjacent head skewed portions or end skewed portions.
[0034]
In a preferred embodiment, The metal cooling member protrudes into a radial gap between a pair of head skew portions or end skew portions adjacent in the radial direction.
[0035]
In other words, in this embodiment, the metal cooling member is inserted into the radial gap between the head skew portion or the end skew portion adjacent in the radial direction. Preferably, the outer end of the metal cooling member in the axial direction is fixed or integrated with the motor housing so that the heat transfer can be satisfactorily cooled to the motor housing. Thereby, the surface of the head skew portion or the end skew portion existing in the middle in the radial direction can also be satisfactorily cooled. Also in this case, the metal cooling member may be a substantially vertically divided partial cylindrical member.
[0036]
In a preferred embodiment, In the metal cooling member, a radial gap between a pair of head oblique portions or end oblique portions adjacent to each other in the radial direction is increased stepwise or continuously as the distance from the stator core increases. It is a feature.
[0037]
Accordingly, a radial gap for accommodating the metal cooling member can be secured between the head skew portion or the end skew portion adjacent in the radial direction without reducing the slot space factor.
[0038]
In a preferred embodiment, The coil end cooling member is in contact with the motor housing.
[0039]
Thereby, the heat of a metal cooling member can be dissipated favorably.
[0040]
In a preferred embodiment, Since the coil end cooling member includes the motor housing having a plane facing the plane of the head skew portion or the end skew portion, an excellent cooling effect can be realized.
[0041]
In a preferred embodiment, The coil end cooling member is made of a metal member covered with an electrically insulating insulating film.
[0042]
Thereby, the electrical insulation with respect to a motor housing and a segment can be improved, suppressing the fall of heat-transfer cooling property.
[0043]
In a preferred embodiment, A gap between the coil end cooling member and the head skew portion or the end skew portion is less than 1 mm.
[0044]
Thereby, the heat transfer between the coil end cooling member and the head skew portion or the end skew portion can be favorably performed. This gap is filled with a resin material that will be cured later, or is coated with heat conductive grease, or an electrical insulating film is interposed. Note that the coil end cooling member having an insulating film formed on the surface may be directly attached to the head skew portion or the end skew portion.
[0045]
In a preferred embodiment, The rotating electrical machine is an automobile travel motor that generates travel power of the automobile.
[0046]
By adopting the above-described configurations, it is possible to realize an automobile travel motor that has a significantly higher output per unit weight than in the past.
[0047]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a rotating electrical machine having a contact cooling type coil end according to the present invention will be described with reference to the drawings.
(Description of overall structure)
First, the overall structure of the rotating electrical machine of this embodiment will be described. FIG. 1 is an axial sectional view of this rotating electrical machine used as a traveling motor for generating traveling power of a vehicle. However, the coil end portion of the stator coil is schematically shown. FIG. 2 is a perspective view of a segment forming a part of the stator coil, and FIG. 3 is a partial cross-sectional view showing a state in which the segment is accommodated in the slot.
(Description of overall configuration)
In FIG. 1, the travel motor has a stator core 1, a rotor 2, a stator coil 3, a housing 4, and a rotating shaft 7. The stator core 1 is fixed to the inner peripheral surface of the peripheral wall of the housing 4, and the stator coil 3 is wound around each slot of the stator core 1. The rotor 2 is an IPM type rotor that is fixed to a rotating shaft 7 that is rotatably supported by the housing 4, and is disposed inside the stator core 1. The stator coil 3 is a three-phase armature winding, and is fed from a three-phase inverter fed from an external battery of about 300V.
[0048]
This travel motor is a permanent magnet type three-phase brushless DC motor (synchronous motor) that generates travel power for a secondary battery car, a fuel cell car, or a hybrid car, but the rotor structure is replaced with various known types. Is possible. Since such various types of synchronous machines are well known, description thereof will be omitted.
(Description of stator coil 3)
As shown in FIG. 2, the stator coil 3 includes a plurality of segment sets (also simply referred to as segments) 33 each including a pair of segments, which are inserted into the slots of the stator core 1 from one side of the stator core 1, and the segments 33 extending from the slots. The protruding end of each segment 33 is projected by the required length to the other side of the stator core 1, and the protruding end of each segment 33 is twisted in the circumferential direction by a substantially electrical angle π / 2, and the tip end of the protruding end of each segment 33 ( The joint portion) is welded in a predetermined combination. The segment 33 has a long plate U shape that is covered with a resin film except for a welded portion, that is, a tip end portion of the protruding end portion (also referred to as an end tip portion). This kind of segment sequential joining type stator coil itself is already known as described above.
[0049]
(Detailed description of segment set 33)
The segment set 33 will be described in more detail.
[0050]
One segment set 33 includes a substantially V-shaped head, a pair of slot conductors linearly extending from both ends of the head and housed in the slot, and a pair extending from the tips of both slot conductors. Are formed of one large segment 331 and one small segment 332 each having a protruding end portion. Thereby, the stator coil 3 exists in a ring shape as a whole on the other side of the stator core 1 and a first coil end portion (head side coil end) 311 that exists in a ring shape as a whole on one side of the stator core 1. It is divided into a second coil end (end side coil end) portion 312 and a slot conductor portion existing in the slot.
[0051]
That is, in FIG. 1, the head-side coil end 311 is configured by the head of each segment 33, and the end-side coil end 312 is configured by the protruding end of each segment 33.
[0052]
In FIG. 1, two sets of segment sets 33 are sequentially inserted in the radial direction. 3301 is the head of one segment set 33 constituting the innermost segment set group S1, 3302 is the head of one segment set 33 constituting the second segment set group S2 counted from the inner side in the radial direction. There are two heads arranged in order in the radial direction to constitute the head-side coil end 311 described above. Reference numeral 3303 denotes a total of four protruding ends constituting one segment set 33 of the segment set group S1, and 3304 denotes a total of four protruding ends of one segment set 33 constituting the segment set group S2.
[0053]
The segment set 33 will be described in more detail with reference to FIG.
[0054]
The segment set 33 includes a large large segment (also referred to as a large loop segment) 331 and a small small segment (also referred to as a small loop segment) 332. The large segment 331 and the small segment 332 surrounded by the large segment 331 are referred to as a segment set.
[0055]
In the large segment 331, 331a and 331b are slot conductor portions, 331c is a head portion, 331f and 331g are protruding end portions. Since the leading end portions 331d and 331e of the protruding end portions 331f and 331g are joint portions, they are also referred to as end tip portions or joint portions. The slot conductor portion 331a is referred to as an innermost slot conductor portion, and the slot conductor portion 331b is referred to as an outermost slot conductor portion.
[0056]
In the small segment 332, 332a and 332b are slot conductor portions, 332c is a head portion, 332f and 332g are protruding end portions. Since the leading end portions 332d and 332e of the protruding end portions 332f and 332g are joint portions, they are also referred to as end tip portions or joint portions. The slot conductor portion 332a is referred to as a middle inner layer slot conductor portion, and the slot conductor portion 332b is referred to as a middle outer layer slot conductor portion.
[0057]
The symbol 'indicates the same portion as the portion without the large segment or small segment symbol' (not shown). Accordingly, in FIG. 2, the joint portion 331 d and the joint portion 332 d ′ that are adjacent to each other in the radial direction are welded, the joint portion 332 d and the joint portion 331 d ′ that are adjacent to each other in the radial direction are welded, and are adjacent to each other in the radial direction. The joint portion 332e and the joint portion 331e ′ are welded.
[0058]
In FIG. 2, when the innermost slot conductor portion 331 a and the innermost slot conductor portion 332 a are accommodated in a predetermined slot of the rotor core 71, the outermost slot conductor portion 331 b and the inner and outer layers of the same segment 331, 332 The slot conductor portion 332b is accommodated in a slot separated from the predetermined slot by a substantially predetermined odd-numbered magnetic pole pitch T (for example, one magnetic pole pitch (electrical angle π)). The head 332c of the small segment 332 is disposed so as to be surrounded by the head 331c of the large segment 331.
[0059]
(Segment set arrangement in the slot)
The arrangement state of the segment set of the slot is shown in FIG.
[0060]
Reference numeral 35 denotes a slot. Sixteen conductor housing positions P1 to P8 are set in the slot 35 in the radial direction, and one slot conductor portion is housed in each of the conductor housing positions P1 to P8. Each slot 35 accommodates two sets of segment sets S1 to S2 in order in the radial direction, the conductor accommodation positions P1 to P4 accommodate the segment set group S1, and the conductor accommodation positions P4 to P8 accommodate the segment set group S2. ing. Each segment set group S1 to S2 includes a large number of segments 33 arranged in the circumferential direction.
[0061]
The innermost segment set group S1 will be described in detail as an example. The innermost layer slot conductor portion 331a is disposed on the radially innermost side of the slot 35 of the stator core 32. Hereinafter, the innermost layer slot conductors are sequentially arranged outward in the radial direction. The portion 332a, the slot conductor portion 332b 'of the middle and outer layers, and the slot conductor portion 331b' of the outermost layer are arranged in this order. As a result, each slot 35 accommodates four slot conductor portions in one row of four layers. In FIG. 3, the slot conductor portions 332b ′ and 332b ′ belong to a large segment 331 and a small segment 332 that are different from the large segment 331 and the small segment 332 having the slot conductor portions 332a and 331a. It goes without saying that the other segment sets S2 to S4 have the same arrangement and configuration as described above. A state in which a segment (segment set) 33 including a large segment 331 and a small segment 332 is inserted into the slot 35 is shown in FIG.
[0062]
Hereinafter, a standard manufacturing process of a normal segment sequential joining stator coil will be described first, and then a manufacturing process unique to this embodiment will be described.
(Manufacturing process of segment sequential stator coil)
(Head twisting process)
First, two types of pine needle segments having a shape before development of a necessary number of small segments 332 and large segments 331 are prepared. Both leg portions of these pine needle segments extend in a straight line substantially adjacent to each other, and their heads are bent sharply. Next, the pine needle segments are processed into U-shaped segments so that the pair of slot conductor portions of the segments are separated from each other by a substantially magnetic pole pitch in the circumferential direction, and the necessary number of segments are inserted into the slots of the stator core at the same time. The step of spatial arrangement (alignment in the circumferential direction) is performed as follows.
[0063]
This head twisting process will be described below with reference to FIGS.
[0064]
The state before the segment insertion in this head twisting process is shown in FIG. In FIG. 5, 10 is a head twisting device, 11 is a small ring, 12 is a large ring, and both are coaxially arranged so as to be relatively rotatable. The large ring 11 is provided with a pair of holes 121 and 122 arranged in the radial direction at a predetermined pitch in the circumferential direction, and the small ring 12 is paired with a pair of holes 111 arranged in the radial direction at an equal pitch in the circumferential direction. , 112 are provided. The holes 111 to 114 are arranged in a line in the radial direction. Both slot conductor portions of the large-turn segment (large segment) 331 are inserted into the innermost hole 111 and the outermost hole 122, and both slot conductor portions of the small-turn segment (small segment) 332 are located outside the innermost hole 111. And the inner hole 121 of the outermost hole 122.
[0065]
FIG. 6 shows a state in which all the large segments 331 and all the small segments 332 are inserted into the holes 111, 112, 121, 122 of the small ring 11 and the large ring 12. In FIG. 6, reference numeral 16 denotes a head pressing plate that is disposed above the small ring 11 and the large ring 12 in the axial direction. On the lower end surface of the head presser plate 16, a pair of claw portions sandwiching a pair of the top of the head of the large segment 331 and the top of the head of the small segment 332 at the same circumferential position from both sides in the circumferential direction (one Only shown) 160. That is, after each segment 33 is inserted into the holes 111, 112, 121, 122, the holding plate 16 is lowered, and each pair of claw portions 160 is smaller than the top of the head of the large segment 331 at the same position in the circumferential direction. The top of the head of the segment 332 is sandwiched from both sides in the circumferential direction.
[0066]
Thereafter, the large ring 12 and the small ring 11 are rotated in opposite directions by a half magnetic pole pitch with respect to the stationary head pressing plate 16. As a result, the Japanese legs of all the segments 33 are expanded in the circumferential direction by one circumferential magnetic pole pitch.
[0067]
When the rings 11 and 12 are rotated, the tops of the heads of the segments 33 are displaced in the axial direction toward the rings 11 and 12 as the rings 11 and 12 are rotated. Displace to. Reference numeral 17 denotes a restriction plate that restricts the large segment 331 and the small segment 332 from falling deeply. The restriction plate 17 is divided into an outer restriction plate on which two radially outer legs are placed and an inner restriction plate on which two radially inner legs are placed. The outer restriction plate may be fixed to the ring 12 and rotated integrally with the ring 12.
[0068]
Next, the small ring 11 and the large ring 12 are separated from the segments 33 while the segments 33 are held by the head pressing plate 16.
[0069]
(End insertion process)
Next, the small U-shaped segment 332 is extracted from the ring with both holes and is inserted into the middle and middle layer positions of the slot 35 of the stator core 1 as shown in FIG. The character-shaped segment 331 is extracted from the ring with both holes and inserted into the innermost layer position and the outermost layer position of the slot 35 of the stator core 1. At this time, each segment can be inserted into each slot 35 at a time by holding each segment with the head pressing plate 16 so as not to be separated. Thereafter, the head pressing plate 16 is removed.
[0070]
The steps until the small U-shaped segment 332 and the large U-shaped segment 331 are inserted into the stator core slot 35 are not limited to those described above, and various other processes may be employed. it can.
[0071]
(End twisting process)
A process of twisting the end of the segment 33 inserted into the slot as described above will be described below.
[0072]
In this embodiment, an end portion 331g (also referred to as an outer layer side end portion) connected to the outermost layer slot conductor portion 331b of the large segment 331 is twisted to one side in the circumferential direction, and an end connected to the innermost layer slot conductor portion 331a of the large segment 331. The portion 331f (also referred to as an inner layer side end) is twisted to the other circumferential side. An end portion 332f (also referred to as an inner layer side end portion) connected to the slot conductor portion 332a in the middle and inner layers of the small segment 332 is twisted to one side in the circumferential direction, and an end portion 332g (connected to the slot conductor portion 332b in the middle and outer layers of the small segment 332) Is also twisted to the other side in the circumferential direction. The total circumferential twist amount of the conductor portions 331f and 332f is one magnetic pole pitch, and the total circumferential twist amount of the conductor portions 331g and 332g is one magnetic pole pitch.
[0073]
The twist processing of the segment set composed of the large segment 331 and the small segment 332 will be described in more detail with reference to FIGS. 7 is a schematic longitudinal sectional view of the stator coil twisting device 5, and FIG. 8 is a sectional view taken along the line AA in FIG.
[0074]
First, the configuration of the stator coil twisting device 5 will be described.
[0075]
The stator coil twisting device 5 includes a workpiece receiver 51 that receives the outer periphery of the stator core 1, a clamper 52 that restricts and holds the radial movement of the stator core 32, a workpiece presser 53 that prevents the stator core 32 from being lifted, and one end of the stator core 32. A torsion shaping portion 54 for twisting the protruding leg portion of the segment 33 that has come out, an elevating shaft 54a for driving the torsion shaping portion 54 in the axial direction, and a rotational drive mechanism 541a to rotatively driving the torsion shaping portion 54 in the circumferential direction. 544a, an elevating drive mechanism 54b for moving the elevating shaft 54a in the axial direction, and a controller 55 for controlling the rotational drive mechanisms 541a to 544a and the elevating drive mechanism 54b.
[0076]
In the twist shaping section 54, four cylindrical twist jigs 541 to 544 arranged concentrically are arranged with their front end surfaces aligned. Each of the twisting jigs 541 to 544 can be independently rotated by the rotation drive mechanisms 541a to 544a, and can be lifted and lowered simultaneously by raising and lowering the lifting shaft 54a by the lifting drive mechanism 54b.
[0077]
As shown in FIG. 8, segment insertion portions for holding the respective distal ends (joining portions) of the end portions 331 f, 331 g, 332 f, and 332 g of the inserted segment 33 are provided on the distal end surfaces of the twisting jigs 541 to 544. 541b to 544b are formed. The segment insertion portions 541b to 544b are formed side by side in the circumferential direction of the twisting jigs 541 to 544 by a number equal to the total number of the slots 35 of the stator core 1.
[0078]
As shown in FIG. 8, the segment insertion portions 541 b to 544 b are provided with partition walls 541 c to 544 c, 542 d, and 543 d for preventing communication between the segment insertion portions 541 b to 544 b adjacent to each other in the radial direction. The thicknesses of the partition walls 541c to 544c, 542d, and 543d are the distance d1 formed by the partition walls 541c and 542c between the first layer and the second layer, counted from the outside in the radial direction, and between the third layer and the fourth layer. The distance d2 formed by the partition walls 542d and 543d between the second layer and the third layer is set to be larger than the distance d3 formed by the partition walls 543c and 544c.
[0079]
Next, the operation of the stator coil twisting device 5 will be described.
[0080]
The stator core 32 in which the segment 33 is disposed in the slot 35 is set on the work receiver 51. Next, the outer peripheral portion of the stator core 32 is fixed to the clamper 52. After that, the upper part of the stator core 32 and the head 331c of the large segment 331 are pressed by the work presser 53, thereby restricting the vertical movement of the stator core 32 and the segment 33.
[0081]
After the stator core 32 on which the segment 33 is disposed is fixed by the clamper 52 and the work receiver 53, the twist shaping portion 54 is raised by the lifting shaft 54a, and the segment insertion portions 541b to 544b formed on the twist jigs 541 to 544 are raised. The end portions 331f, 331g, 332f, and 332g of the segment 33 are inserted into the segments.
[0082]
Only the tip portions of the end portions 331f, 331g, 332f, 332g, and 332g of the segment 33, that is, the portions to be joined later, can be inserted into the segment insertion portions 541b to 544b. Since the end portions 331f, 331g, 332f, and 332g of the segment 33 are formed in a tapered shape, they can be smoothly inserted into the segment insertion portions 541b to 544b.
[0083]
After the end portions 331f, 331g, 332f, and 332g of the segment 33 are inserted into the segment insertion portions 541b to 544b of the twist shaping portion 54, the twist shaping portion 54 is rotated by the rotation drive mechanisms 541a to 544a and the elevation drive mechanism 54b. Lifted and lowered.
[0084]
Next, the rotation of the twist shaping unit 54 will be described.
[0085]
The twisting jig 541 and the jig 543 are rotated clockwise by a first angle, and the twisting jig 542 and the twisting jig 544 are rotated counterclockwise by a second angle. At this time, the magnitudes of the first angle and the second angle may not be equal, and the sum of both may be a required slot pitch.
[0086]
After that, of the end portions 331f, 331g, 332f, and 332g of the segment 33, the elevating drive mechanism 54b and the rotary drive mechanism are maintained so that the lengths from the outlet of the slot 35 to the inlets of the segment insertion portions 541b to 544b are kept constant. The twist shaping section 54 is raised while rotating while controlling 541a to 544a. At this time, it is preferable that the end portions 331f, 331g, 332f, and 332g of the segment 33 rise while rotating so as to draw an arcuate locus. In order to prevent the deformation of the segment 33 due to the spring back, the twist drawing the arc-shaped trajectory is preferably performed to an angle that exceeds the angle corresponding to the half magnetic pole pitch (T / 2).
[0087]
Thereafter, the elevating drive mechanism 54b and the rotary drive mechanisms 541a to 544a are rotated in the direction opposite to that in the previous step and lowered. In this way, the twisting process of the segment 33 is completed, the twist shaping portion 54 is lowered, and the end portions 331f, 331g, 332f, 332g of the segment 33 are removed from the segment insertion portions 541b-544b of the twisting jigs 541-544. . The twist shaping section 54 from which the segment 33 is removed is rotated by the rotation drive mechanisms 541a to 544a and returned to the original position. Finally, the clamper 52 and the work holder 53 are removed, and the stator with the segments 33 twisted is taken out.
[0088]
After all, in this twisting process, first, the end portion of the segment 33 is rotationally displaced only in the circumferential direction, the segment 33 is tilted in the circumferential direction, and then the end portion of the segment 33 is displaced in the circumferential direction and the axial direction. Inclining deeply, and then displacing the end of the segment 33 in the circumferential direction and the axial direction beyond a predetermined processing amount to incline the segment 33 excessively deep, and then return the end of the segment 33 to the predetermined processing amount. Is done.
[0089]
The twist shaping portion 54 moves relative to the stator core 32 not only in the circumferential direction but also in the axial direction. Therefore, of the end portions 331f, 331g, 332f, and 332g of the segment 33, the portion from the exit of the slot 35 to the entrance of the segment insertion portions 541b to 544b, that is, the end portion from the end portions 331f, 331g, 332f, and 332g (Junction part) Twist so that the edge part 331f, 331g, 332f, 332g of the segment 33 may draw an arc-shaped locus | trajectory so that the length which deducted the length of 331d, 331e, 332d, 332e may be kept constant. Accordingly, the segment 33 can be prevented from coming out of the segment insertion portions 541b to 544b.
[0090]
Further, only the end tips (joining portions) 331d, 331e, 332d, and 332e of the segment 33 are inserted into the segment insertion portions 541b to 544b, and the segment 33 is removed from the segment insertion portions 541b to 544b in the same manner as described above. Never get out.
[0091]
(Welding process)
Next, the welding process to be performed will be described below. This process is essentially the same as before.
[0092]
After twisting the end portions of the segments, as shown in FIGS. 1 and 2, the end portions (joint portions) of the first layer and the second layer are welded from the radially inner side, and three layers are formed from the radially inner side. The stator and the stator coil 31 are completed by welding the end portions (joints) of the ends of the eyes and the fourth layer. Arc welding is used for welding.
[0093]
(Description of coil end contact cooling structure)
Next, a coil end contact cooling structure which constitutes a characteristic configuration of this embodiment will be described below with reference to FIG.
[0094]
In this embodiment, the liquid cooling pipe 1000 having a substantially square cross section is attached to the head side coil end 311 and the liquid cooling pipe 2000 is in close contact with the end side coil end 312 via silicon grease (thermally conductive grease). .
[0095]
Before describing the liquid cooling pipes 1000 and 2000, the detailed structures of the head-side coil end 311 and the end-side coil end 312 will be described again in detail with reference to FIG.
[0096]
The head-side coil end 311 is formed by overlapping the head of the segment set S1 and the head of the segment set S2 in the radial direction. The heads of the segment sets S1 and S2 are arranged so that the head of the large-turn segment surrounds the head of the small-turn segment in the radial direction.
[0097]
The head of the large-turn segment has a curved large-turn head (head tip) and a pair of straight lines extending in the axial direction individually from both ends of the large-turn head toward the pair of slot conductors. The head has a skew portion. One of the pair of head skew portions constituting the head of the large-turn segment is skewed so as to advance to a substantially semi-magnetic pole pitch in the circumferential direction CW as the distance from the slot conductor portion, and constitutes the head of the large-turn segment The other of the pair of skewed head portions is disposed so as to recede to a substantially semi-magnetic pole pitch in the circumferential direction CCW as the distance from the slot conductor portion increases.
[0098]
The head of the small-turn segment includes a curved small-turn head (head tip) and a pair of skewed head portions individually extending linearly from both ends of the small-turn head toward the pair of slot conductors. have. One of the pair of head skew portions constituting the head of the small-turn segment is skewed so as to proceed to a substantially semi-magnetic pole pitch in the circumferential direction CW as the distance from the slot conductor portion, and constitutes the head of the small-turn segment The other of the pair of skewed head portions is disposed so as to recede to a substantially semi-magnetic pole pitch in the circumferential direction CCW as the distance from the slot conductor portion increases.
[0099]
The innermost head skew portion a in the radial direction is skewed in the CW direction, and the even-numbered head skew portion counted from the head skew portion a is also skewed in the CW direction. Conversely, the outermost head skew portion b in the radial direction is skewed in the CCW direction, and the even-numbered head skew portion counted from the head skew portion b is also skewed in the CCW direction.
[0100]
The end side coil end 312 is formed by overlapping the end portion (projecting end portion) of the segment set S1 and the end portion (projecting end portion) of the segment set S2 in the radial direction. The end portions of the segment sets S1 and S2 are arranged so that the pair of protruding end portions of the large loop segment sandwich the pair of protruding end portions of the large loop segment in the radial direction.
[0101]
The end portion of the large turn segment has a pair of end tip portions and a pair of end skew portions that individually extend linearly from the both end tip portions to the pair of slot conductor portions. One of the pair of skewed end portions constituting the end portion of the large-turn segment is skewed so as to advance to the substantially semi-magnetic pole pitch in the circumferential direction CW as the distance from the slot conductor portion, and constitutes the end portion of the large-turn segment The other of the pair of skewed end portions is arranged so as to recede to a substantially semi-magnetic pole pitch in the circumferential direction CCW as the distance from the slot conductor portion increases.
[0102]
The end portion of the small turn segment has a pair of end tip portions and a pair of end oblique portions extending linearly individually from the both end tips toward the pair of slot conductor portions. One of the pair of skewed end portions constituting the end of the small-turn segment is skewed so as to advance to a substantially semi-magnetic pole pitch in the circumferential direction CW as the distance from the slot conductor portion, and constitutes the end of the small-turn segment The other of the pair of skewed end portions is arranged so as to recede to a substantially semi-magnetic pole pitch in the circumferential direction CCW as the distance from the slot conductor portion increases.
[0103]
Similarly, the radially innermost end skew portion c is skewed in the CCW direction, and the even-numbered head skew portion counted from the end skew portion c is also skewed in the CCW direction. Conversely, the outermost head skew portion d in the radial direction is skewed in the CW direction, and the even-numbered head skew portion counted from the head skew portion d is also skewed in the CW direction.
[0104]
The liquid cooling pipe 1000 has an oblique pipe portion 1001 that is adjacent to and parallel to the radial side surface of the head inner skew portion a (see FIG. 1) in the radial direction with a predetermined gap in the circumferential direction. An oblique pipe portion 1002 that is adjacent to and parallel to the radial side surface of the head outermost portion skew portion b (see FIG. 1) in the circumferential direction with a predetermined gap therebetween is provided. Therefore, the oblique tube portion 1001 obliquely moves in the CW direction as it moves away from the stator core 1, and the oblique tube portion 1002 obliquely moves in the CCW direction as it moves away from the stator core 1.
[0105]
That is, a skew pipe portion 1001 is interposed in a gap between each head skew portion a, and a skew tube portion 1002 is interposed in a gap between each head skew portion b. Yes. The outer end in the axial direction of one skew pipe portion 1001 is connected to the inner end in the radial direction of the radial pipe portion 1005 extending radially inward, and the outer end in the radial direction of the radial pipe portion 1005 is the oblique pipe portion. 1002 is connected to the outer end in the axial direction, and the inner end in the axial direction of the inclined pipe portion 1002 passes over the head inclined portion b adjacent in the circumferential direction CW on the outer side in the radial direction, and next in the circumferential direction. It continues to the inner end in the axial direction of the oblique tube portion 1002. In addition, the inner end in the axial direction of the skew pipe portion 1001 passes over the head skew portion a adjacent in the circumferential direction CW on the inner side in the radial direction, and the next oblique pipe portion 1001 adjacent in the circumferential direction. It continues to the inner end in the axial direction. In this way, by interposing the skew pipe portions 1001 and 1002 adjacent to the side surfaces of the head skew portions a and b, the liquid cooling pipe 1000 substantially goes around the head side coil end 311, The both ends are connected to the inlet pipe 1006 and the outlet pipe 1007 so that the coolant from the external pump can be circulated.
[0106]
The liquid cooling pipe 2000 has an oblique pipe portion 2001 adjacent to and parallel to the radial side surface of the radially innermost head skew portion c (see FIG. 1) with a predetermined gap in the circumferential direction. An oblique pipe portion 2002 that is adjacent to and parallel to the radial side surface of the head outermost portion d (see FIG. 1) in the circumferential direction with a predetermined gap therebetween in the circumferential direction. Therefore, the skew tube portion 2001 is skewed in the CCW direction as it is away from the stator core 1, and the skew tube portion 2002 is skewed in the CW direction as it is away from the stator core 1.
[0107]
That is, a skew pipe portion 2001 is interposed in a gap between the head skew portions c, and a skew tube portion 2002 is interposed in a gap between the head skew portions d. Yes. The outer end in the axial direction of one oblique pipe portion 2001 is connected to the inner end in the radial direction of the radial pipe portion 2005 extending inward in the radial direction, and the outer radial direction end of the radial pipe portion 2005 is the oblique pipe portion. The axial inner end of the oblique pipe portion 1002 is connected to the axially outer end of 2002 and the head oblique portion d adjacent in the circumferential direction CW is overcome on the radially outer side, and the next adjacent in the circumferential direction is next. It continues to the inner end in the axial direction of the oblique tube portion 2002. In addition, the axially inner end of the skew pipe portion 2001 climbs over the head skew portion c adjacent in the circumferential direction CW on the inside in the radial direction, and the next oblique pipe portion 2001 adjacent in the circumferential direction. It is connected to the inner end in the axial direction. In this way, by interposing the skew pipe portions 2001 and 2002 adjacent to the side surfaces of the head skew portions c and d, the liquid cooling pipe 2000 makes a substantially round turn on the head side coil end 312. Both ends thereof are connected to an inlet pipe 2006 and an outlet pipe 2007 so that the coolant from an external pump can be circulated.
[0108]
The head-side coil end 311 is filled with a resin having good heat conductivity between the heads, and the end-side coil end is filled with a resin having good heat conductivity between the ends (the protruding ends). Filled. An insulating film is formed on the surfaces of the liquid cooling pipes 1000 and 2000, and the gaps between the oblique pipe portions 1001 and 1002 and the head oblique portions a and b and the planar shapes of the oblique pipe portions 2001 and 2002 are formed. The side surfaces and the planar side surfaces of the head skew portions c and d are in close contact with each other through heat conductive grease.
[0109]
Thereby, the heat of head side coil end 311 and end part side coil end 312 can be satisfactorily transmitted to liquid cooling pipes 1000 and 2000. In this embodiment, in the radial cross section of the segment, when the radial height is larger than the circumferential width, the head oblique portions a and b, the end oblique portions c and d, and the oblique pipe portion 1001, This is particularly effective because the area facing 1002, 2001, and 2002 is large.
[0110]
(Modification)
The modification will be described below with reference to FIGS.
[0111]
In this modification, a case where only a pair of slot conductor portions are inserted in each slot in the radial direction is shown. Therefore, the head-side coil end 311 has only one head in the radial direction, and the end-side coil end 312 has only a pair of protruding end portions in the radial direction. In this case, the radial pipe portions 1005 and 2005 extending in the radial direction are very short and exist at positions adjacent to the head tip e in the circumferential direction.
[0112]
FIG. 10 shows a view of the stator core 1 facing outward in the radial direction. In FIG. 10, reference numeral 1008 denotes a portion that crosses the head skew portion a adjacent in the circumferential direction radially inward and connects the axial inner ends of the pair of skew pipe portions 1001 adjacent in the circumferential direction. Is a portion that passes over the head skew portion c adjacent in the circumferential direction inward in the radial direction and connects the inner ends in the axial direction of the pair of skew pipe portions 2001 adjacent in the circumferential direction.
[0113]
A view of the head-side coil end 311 facing inward in the radial direction is shown in FIG. In FIG. 11, reference numeral 1009 denotes a portion that crosses the head oblique portion b adjacent in the circumferential direction outward in the radial direction and connects the inner ends in the axial direction of the pair of oblique tube portions 1002 adjacent in the circumferential direction.
[0114]
A view of the end side coil end 312 facing radially inward is shown in FIG. In FIG. 12, 2009 is a portion that crosses the circumferentially adjacent end tip d in the radial direction and connects the axially inner ends of the pair of oblique pipe portions 2002 adjacent in the circumferential direction.
[0115]
In this variation, the gap is reduced for each pair of head skew portions a adjacent to each other, and the gap is reduced for each pair of head skew portions b adjacent to each other, resulting in a widened circumferential direction. The oblique pipe portions 1001 and 1002 are interposed in the gap. That is, the number of the skewed pipe portions 1001 is set to be half the number of the head skewed portions a, and the number of the skewed tube portions 1002 is set to be half the number of the head skewed portions b. Similarly, the gap is reduced for each pair of end skew portions c adjacent to each other, the gap is reduced for each pair of head skew portions d adjacent to each other, and as a result, the skew is increased to the widened circumferential gap. Pipe portions 2001 and 2002 are interposed. That is, as many as the skew feeding pipe parts 2001 are arranged as many as the half of the head skewing part c, and as many as the skewing pipe parts 2002 are arranged as many as the half of the head skewing part d. If it does in this way, head side coil end 311 and end part side coil end 312 can be satisfactorily cooled like the above-mentioned embodiment.
[0116]
(Modification)
A modification is shown in FIG.
[0117]
In this modification, two segment sets S1 and S2 are arranged in the radial direction as in FIG.
[0118]
3000 is a liquid cooling pipe spirally wound in contact with the radially innermost head skew part a of the segment set S1, and 4000 is the radially outermost head skew of the segment set S2. This is a liquid cooling pipe wound in a spiral manner in contact with the part b. The liquid cooling pipes 3000 and 4000 are made of thin-walled aluminum pipes similarly to the liquid cooling pipes described above, and have a flat cross section and are in close contact with the head skew portions a and b through heat conductive grease. Since the end side coil end 312 also employs the same cooling structure, the illustration and description thereof will be omitted. If it does in this way, head side coil end 311 can be cooled favorably. This deformation mode is suitable when the radial length of the slot conductor portion is small and the circumferential width is large.
[0119]
(Modification)
A modification is shown in FIG.
[0120]
In this modified embodiment, flat liquid-cooled pipes 3000 and 4000 are arranged as in FIG. 13, and liquid-cooled pipes 5000 are similarly arranged between the segment sets S1 and S2. In order to arrange the liquid cooling pipe 5000, the segment set S1 is obliquely provided radially outward so as to extend radially outward as it moves away from the stator core 1. Since the end side coil end 312 also employs the same cooling structure, the illustration and description thereof will be omitted. If it does in this way, the contact cooling performance of a coil end can be improved further.
[0121]
(Modification)
A modification is shown in FIG.
[0122]
In this modification, as in FIG. 10, the liquid cooling pipe 6000 is axially disposed adjacent to the innermost head skew portion a of the segment set S1 and the outermost head skew portion b of the segment set S2. It is arranged.
[0123]
The liquid cooling pipe 6000 is radially overlapped with the head skew portion a skewed in the CW direction and skewed in the CW direction, and overlapped with the head skew portion b skewed in the CCW direction in the radial direction. It is skewed in the direction. The liquid cooling pipe 6000 extends in the circumferential direction while reciprocating between the axial inner end (stator core 1 side) and the axial outer end by bending. Since the end side coil end 312 also employs the same cooling structure, the illustration and description thereof will be omitted. Thereby, the head side coil end 311 can be contact-cooled satisfactorily.
[0124]
(Modification)
A modification is shown in FIG.
[0125]
In this modification, instead of the liquid cooling pipe 6000 of FIG. 15, an aluminum plate for heat sink 7000 is arranged to overlap the outermost head skew portion b of the segment set S2 in the radial direction.
[0126]
The aluminum plate 7000 has a partial cylindrical shape in which a cylinder is vertically divided into four in the axial direction, and overlaps over the entire circumference of each head skew portion b. In addition, since the radially outer surface of the head skew portion b is flat, the inner peripheral surface portion of the aluminum plate 7000 is also flattened accordingly. A groove in which the head skew portion b is fitted may be recessed in the inner peripheral surface portion of the aluminum plate 7000. Thermal conductive grease is applied between the aluminum plate 7000 and the head skew portion b. The outer peripheral surface portion of the aluminum plate 7000 is in contact with the motor housing 4 via heat conductive grease.
[0127]
Further, a cylindrical portion 8000 protrudes inward in the axial direction from the end wall of the motor housing 4, and the outer peripheral surface of the cylindrical portion 8000 is disposed on the flat surface on the radially inner side of the head skew portion a via heat conduction grease. Are in close contact. Similarly to the above, the outer peripheral surface of the cylindrical portion 8000 is flattened according to the flat surface on the radially inner side of the head skew portion a.
[0128]
Thereby, the heat of the head-side coil end 311 can be transmitted to the motor housing 4 satisfactorily, and the temperature rise of the head-side coil end 311 can be maintained within an allowable range by cooling the motor housing 4. it can. Since the end side coil end 312 also employs the same cooling structure, the illustration and description thereof will be omitted. 9000 is a resin material with good thermal conductivity, which is formed by solidifying an epoxy resin liquid mixed with copper powder or aluminum powder.
[0129]
(Modification)
The cooling pipe is a square pipe or a flat pipe in the above embodiment, but may be a circular cross section or an elliptic cross section.
[0130]
(Modification)
When a cooling pipe is used as the coil end cooling member, a soft resin pipe such as a silicon tube may be used. In this case, the silicon tube is pressed against the flat surface of the segment to be deformed and deformed, and the heat transfer resistance between the two can be satisfactorily reduced.
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view of a vehicle travel motor according to a first embodiment.
FIG. 2 is a schematic perspective view of the segment of FIG.
FIG. 3 is a partial radial cross-sectional view of the stator core of FIG. 1;
FIG. 4 is a schematic perspective view showing a state immediately before a segment set is inserted into a slot.
FIG. 5 is a schematic cross-sectional view showing a state of being inserted into a ring of a segment head twisting device.
FIG. 6 is a schematic longitudinal sectional view of a head twisting device.
FIG. 7 is a schematic longitudinal sectional view of an end twisting device.
FIG. 8 is a plan view of a ring of the end twisting device.
FIG. 9 is an axial sectional view showing a coil end contact cooling structure.
FIG. 10 is a view showing a modified coil end contact cooling structure.
FIG. 11 is a view showing a modified coil end contact cooling structure.
FIG. 12 is a view showing a modified coil end contact cooling structure.
FIG. 13 is a view showing a modified coil end contact cooling structure.
FIG. 14 is a view showing a modified coil end contact cooling structure.
FIG. 15 is a view showing a modified coil end contact cooling structure.
FIG. 16 is a view showing a modified coil end contact cooling structure.
[Explanation of symbols]
1 Stator core
3 Stator coil
4 Motor housing
1000 Liquid-cooled piping
2000 Liquid-cooled piping

Claims (9)

A cylindrical stator core having a slot on the inner periphery and fixed to the motor housing;
A rotor rotating to face an inner peripheral surface of the stator core;
A stator coil having coil ends protruding from both end faces of the stator core and inserted into the slot;
A coil end cooling member that has good heat absorption performance and contacts the coil end in an electrically insulating manner so as to transfer and cool the coil end;
Equipped with a,
The stator coil is
A pair of slot conductors individually accommodated in a pair of slots spaced apart in a predetermined pitch circumferential direction; a head that protrudes from one of the slot conductors toward one end of the stator core to form a head-side coil end; A plurality of segments each having a square cross section each having a pair of protruding end portions projecting from the both slot conductor portions to the other end side of the stator core and constituting an end side coil end are sequentially connected,
The head includes a substantially U-shaped head tip and a pair of head skews that are skewed circumferentially and axially from both ends of the head tip and are individually connected to the pair of slot conductors. And consists of
The protruding end portions include a pair of end oblique portions that are inclined in the circumferential direction and the axial direction from the pair of slots, and different segments adjacent to each other in the radial direction that are formed at the ends of the end oblique portions. It consists of an end tip part joined to the tip of the end skew part,
The coil end cooling member,
A flat surface facing the flat surface of the head skew portion or the end skew portion as the coolant flows;
The surface is
In the coil end contact cooling type rotary electric machine that directly or indirectly contacts the flat surface of the head or the protruding end of the segment so as to be electrically insulated and absorbs heat from the flat surface of the head or the protruding end .
The coil end cooling member is
A cooling pipe that extends while adjoining the flat surface of the head skew portion or the end skew portion as the coolant flows;
The cooling pipe is
The circumferential gap between the head skew portion or the end skew portion adjacent in the circumferential direction is skewed along the flat vertical surface of the head skew portion or the end skew portion, and then Cross over the circumferentially adjacent head skew portion or end skew portion in the circumferential direction at the axially outer end portion and the axially inner end portion, and then pass the next circumferential clearance to the head oblique portion. It consists of a rectangular tube with a substantially square cross section that is inclined along the flat vertical surface of the head portion or the inclined portion of the end portion and reversely inclined to absorb heat from the vertical surface of the inclined portion of the head portion or the inclined portion of the end portion. A coil end contact cooling type rotating electrical machine . In the coil end contact cooling type rotating electrical machine according to claim 1 ,
The cooling pipe is
Wrapped in the circumferential direction or the axial direction while being radially adjacent to the head oblique portion or the end oblique portion on the radially outermost side or radially innermost side, A coil end contact cooling type rotating electrical machine that absorbs heat from a flat horizontal surface of an inner head skew portion or an end skew portion . In the coil end contact cooling type rotating electrical machine according to claim 1 ,
The coil end contact cooling type rotating electrical machine, wherein the cooling pipe is made of a soft resin pipe. In the coil end contacting cooling rotary electric machine according to claim 1 Symbol placement,
The coil end cooling member is
A coil end contact cooling type rotating electrical machine comprising a metal cooling member extending adjacent to a flat surface of the head skew portion or the end skew portion . In the coil end contact cooling type rotating electrical machine according to claim 3 ,
The metal cooling member is
Before SL radially outermost or radially innermost disposed while adjoining radially on the head oblique portion or end oblique portion, the radially outermost or radially innermost of the head skew A coil end contact cooling type rotating electrical machine that absorbs heat from a flat horizontal surface of a portion or an inclined portion of an end. In the coil end contact cooling type rotating electrical machine according to claim 5 ,
The metal cooling member is
Coil end contact cooling comprising a plurality of vertically divided partial cylindrical members disposed adjacent to the surface of the head outermost part or the innermost radial part or the end oblique part. Type rotating electric machine. In the coil end contact cooling type rotating electrical machine according to claim 4 ,
The metal cooling member is
A coil end contact cooling type rotating electrical machine characterized by projecting into a radial gap between a pair of head skew portions or end skew portions adjacent in the radial direction. In the coil end contact cooling type rotating electrical machine according to claim 7 ,
The metal cooling member is
A coil end contact characterized in that a radial gap between a pair of head oblique portions or end skew portions adjacent to each other in a radial direction becomes wider stepwise or continuously as the distance from the stator core increases. Cooling type rotating electric machine. In the coil end contact cooling type rotating electrical machine according to claim 4 ,
The coil end cooling member is
A coil end contact cooling type rotating electrical machine which is in contact with the motor housing .

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