JP4241321B2 - Rotating electric machine stator - Google Patents

Description

  The present invention relates to a rotating electrical machine including a stator and a rotor composed of permanent magnets, and more particularly to the structure of the stator.

  Usually, in the structure of a motor, a coil is fixed to a stator core. In particular, in the structure of a motor used in an EV (Electric Vehicle) or an HV (Hybrid Vehicle), a very large force is applied to the coil due to the inertial force caused by acceleration / deceleration or turning of the vehicle. Therefore, it is necessary to fix the coil to the stator core by performing a varnish process or a resin molding process so that the coil does not move relative to the stator core. That is, in the conventional motor structure, first, insulating paper is inserted into the slots of the stator core. Then, the coil is wound around the stator core. Thereafter, a varnish treatment is applied to the coil to secure the insulation or coil to the stator core. Alternatively, in addition to insulation or fixing of the coil to the stator core, there is a motor in which the coil is subjected to a molding process in order to further improve heat dissipation.

  FIG. 26 shows a manufacturing process of a conventional motor in which a coil is varnished.

  In step (hereinafter, step is abbreviated as S) 2000, enamel-coated copper wire is wound around the stator core. In S2100, so-called coil end molding is performed in which the shape of the coil end portion of the coil wound around the stator core is molded into a preset shape. In S2200, the coil is varnished. In S2300, a heat curing process is performed to heat the varnish-treated coil. In S2400, the stator core that has been heat-cured is assembled to the housing.

  Further, there is a technique disclosed in Patent Document 1 below regarding a motor structure in which a plurality of flat plate U-shaped coils are stacked in a slot of a stator core.

  Japanese Patent Laying-Open No. 2001-292548 (Patent Document 1) discloses a stator for a rotating electrical machine that significantly shortens the length of a coil end portion. The stator of this rotating electrical machine is mounted in a plurality of slots of the stator core. In this stator, a straight rectangular wire is formed in advance so as to be U-shaped. Then, two straight sides are inserted into adjacent slots across the stator tooth portion. Thereafter, the coil is formed so as to form a one-turn closed circuit by connecting both ends of the coil opposite to the U-shaped side with a thin bar-shaped piece. Then, a plurality of such coils are inserted, and a predetermined number of turns is formed by connecting the opposite ends of the U-shaped side. When the anti-U-shaped side end face and the thin plate bar-like piece are overlapped and connected, the thickness of the overlapping portion is reduced by half. And when both overlap, it is made to correspond to the plate | board thickness of a flat wire coil. The surface that halves the plate thickness halves the plate thickness of the surface toward the stator inner diameter at the left side of the coil piece end. A coil is previously formed on the right side end so as to halve the plate thickness of the surface toward the stator outer diameter. On the other hand, the thin plate-like piece halves the plate thickness of the surface opposite to the coil. And when both are piled up, it connects and comprises so that a thin bar piece may be pinched | interposed into two linear parts of a U-shaped coil.

According to the stator of the rotating electrical machine disclosed in Patent Document 1, the straddling width of the coil is determined by the adjacent slot width. Therefore, the axial length of the U-shaped portion protruding from the stator core is equivalent to the adjacent slot width. On the other hand, the axial length of the portion protruding from the stator core on the half U-shaped side of the coil is connected by a thin bar-shaped piece. Therefore, only the width of the thin plate connecting piece is occupied in the axial direction. As a result, a stator in which the length of the coil end portion is reliably shortened can be provided.
JP 2001-292548 A

  However, in the varnish treatment as shown in FIG. 26, a heat treatment furnace is required for the step of curing the varnish after impregnating the coil with the varnish. Further, in the molding process using a resin or the like, a furnace or an injection molding machine for the process of injection molding by putting an object to be molded into a mold and raising the temperature is necessary. For this reason, there is a problem in that the manufacturing cost increases when the relative movement between the coil and the stator core is suppressed by varnishing or molding.

  On the other hand, if the coil is not fixed to the stator core and the coil can move relative to the stator core, the enamel coating of the coil may be damaged by friction with the stator core. Alternatively, the enamel coating of the coil can be damaged by the edges of the stator core. As a result, there is a problem that the insulation performance of the coil cannot be secured.

  Further, Patent Document 1 described above does not disclose a technique for fixing a coil against a force due to an inertial force from the outside.

  The present invention has been made to solve the above-described problems, and an object thereof is to provide a stator for a rotating electrical machine having a simple structure for suppressing relative movement of a coil with respect to a stator core. It is.

  According to a first aspect of the present invention, there is provided a stator for a rotating electrical machine, wherein a stator core having a plurality of slots in a direction parallel to a rotation axis of the rotating electrical machine and an open end of a metal conductor inserted into the plurality of slots are closed. A coil wound around the iron core, a casing covering an outer peripheral side surface parallel to the rotation axis of the stator core, a side surface orthogonal to the rotation axis, a fastening member for fastening the stator core to the casing, and a casing And an elastic member that is provided between the coil and the coil and generates an elastic force when the fastening member is fastened.

  According to the first invention, a rotating electrical machine (for example, a synchronous motor) including a rotor and a stator closes open ends of metal conductors inserted into a plurality of slots included in a plurality of hollow cylindrical stator cores. Coil is wound. Further, the outer peripheral side surface of the stator core parallel to the rotation axis and the side surface orthogonal to the rotation axis are covered with the casing. The stator of the synchronous motor includes a fastening member (for example, a bolt) that fastens the stator iron core to the housing, and an elastic member (for example, that generates an elastic force when the bolt is fastened between the housing and the coil). , A disc spring). The stator core is fastened to the casing with bolts. Therefore, an elastic force against the fastening force of the bolt is generated in the disc spring provided between the housing and the coil. This elastic force can suppress the relative movement of the coil with respect to the stator core. That is, the relative movement of the coil can be suppressed with a simple structure in which a disc spring is provided between the housing and the coil. Therefore, the conventional varnish processing or mold processing can be abolished. As a result, productivity is improved. And manufacturing cost can also be reduced. Furthermore, by loosening the fastening of the bolt, the copper of the coil and the stator core can be easily distinguished and disassembled. Therefore, the recyclability of the coil and stator core is improved. Further, since the disc spring is provided between the housing and the coil, the relative movement of the coil can be suppressed without increasing the axial dimension of the motor. By suppressing the relative movement of the coil in this way, it is possible to prevent the insulation performance from being deteriorated due to peeling off or damage of the insulating coating of the coil.

  According to a second aspect of the present invention, there is provided a stator for a rotating electrical machine, wherein a stator core having a plurality of slots in a direction parallel to the rotation axis of the rotating electrical machine and an open end of a metal conductor inserted into the plurality of slots are closed. A casing that covers a coil wound around the iron core, an outer circumferential side surface parallel to the rotation axis of the stator core, and one side surface orthogonal to the rotation axis, and a side surface opposite to the surface covered by the casing In this plane, an elastic member provided in contact with the coil, a holding portion for holding the elastic member, and a holding portion in the direction parallel to the rotating shaft are fixed so that an elastic force is generated in a direction parallel to the rotating shaft. And a fastening member fastened to the core.

  According to the second invention, a rotating electrical machine (for example, a synchronous motor) including a rotor and a stator closes metal conductors inserted into a plurality of slots included in the stator core, and a coil is wound around the stator core. Worn. Moreover, one surface of the outer peripheral side surface parallel to the rotation axis in the stator core and the side surface orthogonal to the rotation axis is covered with the casing. The stator of the synchronous motor is provided with an elastic member (in contact with the coil so that an elastic force is generated in a direction parallel to the rotation axis on the surface opposite to the surface covered with the casing on the side surface ( For example, a disc spring), a holding portion that holds the disc spring (for example, an elastic member holder), and a fastening member (for example, a bolt) that fastens the elastic member holder to the stator core in a direction parallel to the rotation axis are provided. . Then, by fastening the elastic member holder to the stator core with a bolt, an elastic force is generated in the disc spring provided between the elastic member holder and the coil, which is against the fastening force of the bolt. This elastic force can suppress the relative movement of the coil with respect to the stator core. That is, the relative movement of the coil can be suppressed with a simple structure in which a countersunk screw is provided between the elastic member holder and the coil. Therefore, the conventional varnish processing or mold processing can be abolished. As a result, productivity is improved. And manufacturing cost can also be reduced. Furthermore, by loosening the fastening of the bolt, the copper of the coil and the stator core can be easily distinguished and disassembled. Therefore, the recyclability of the coil and the stator core is improved. In addition, by suppressing the relative movement of the coil in this way, it is possible to prevent the insulation performance from being deteriorated due to peeling off, scratching, or the like of the coil. Further, the assembly of the stator core including the fixing of the coil can be performed before the stator core is assembled to the casing. Therefore, the assembly property of the stator core to the housing is improved. Furthermore, the stator core can be easily conveyed during coil manufacture.

  In the stator of the rotating electrical machine according to the third invention, in addition to the configuration of the second invention, the fastening member fastens the holding portion to the housing in addition to the stator core.

  According to the third invention, the fastening member (for example, the bolt) adds the holding portion (for example, the elastic member holder) to the stator core, and further fastens to the casing. Therefore, the assembly of the stator core including the fixing of the coil can be performed before the stator core is assembled to the casing. Therefore, the assembly property of the stator core to the housing is improved. Furthermore, the stator core can be easily conveyed during coil manufacture. In addition, the elastic member holder is added to the stator core by the bolt and fastened to the housing, thereby suppressing an increase in the number of parts and suppressing the relative movement of the coil with respect to the stator core.

  In the stator of the rotating electrical machine according to the fourth aspect of the invention, in addition to the configuration of the first or second aspect, the metal conductor is a predetermined number of metal flat plates of a U-shaped or U-shaped conductor. It is formed of a laminated body that is laminated only.

  According to the fourth invention, the metal conductor (for example, the laminated coil) is formed of a laminated body in which a predetermined number of metal flat plates of a conductor press-molded into a U-shape or U-shape are laminated. In a conventional motor, an enameled wire is wound around a stator core to form a coil. At this time, the shape of the coil end portion includes a concavo-convex portion. Therefore, in order to suppress the relative movement of the coil with respect to the stator core, it is necessary to apply a larger load to the coil end portion. For this reason, the assemblability deteriorates. Furthermore, stress is concentrated on a part of the coil by applying a large load. As a result, the enamel coating of the coil is damaged. As a result, the insulation of the coil may be deteriorated. However, the coil is formed of a laminate in which metal flat plates having substantially the same shape punched by the press as described above are laminated. Therefore, the shape of the coil end portion can be designed to an arbitrary shape. That is, the shape of the coil end portion can be formed on a flat surface by changing the shape of the metal flat plate formed in the pressing step to a U shape or a U shape. Therefore, when a load is applied to the coil due to the fastening force of a fastening member (for example, a bolt), the coil and the disk spring are uniformly contacted to the coil via an elastic member (for example, a disk spring). Stress can be applied. As a result, damage to the enamel coating can be prevented. Further, by forming the coil by press molding, the shape of the coil end is determined at the stage of winding the coil. Therefore, the coil end molding process can be abolished. As a result, the manufacturing cost can be reduced.

  In the stator of the rotating electrical machine according to the fifth invention, in addition to the configuration of the first or second invention, the elastic member is a disc spring.

  According to the fifth invention, by providing the disc spring as the elastic member, the relative movement of the coil with respect to the stator core can be suppressed.

  In the stator of the rotating electrical machine according to the sixth invention, in addition to the configuration of the first or second invention, the elastic member is a coil spring.

  According to the sixth invention, by providing the coil spring as the elastic member, the relative movement of the coil with respect to the stator core can be suppressed.

  In the stator of the rotating electrical machine according to the seventh invention, in addition to the configuration of any one of the first to sixth inventions, a plurality of end surfaces of the stator having a hollow cylindrical shape are symmetrical about the rotation axis. The elastic member is provided.

  According to the seventh invention, a plurality of elastic members (for example, disc springs or coil springs) are provided on the stator end surface having a hollow cylindrical shape so as to be symmetric about the rotation axis. For example, a plurality of disc springs or coil springs are provided on each of the coils wound around the stator core so as to be symmetric about the rotation axis at the stator end surface, so that the disc springs or coil springs are provided. A uniform stress can be applied to each of the coils in contact with the coil. For this reason, it is possible to prevent the insulation performance from being deteriorated due to peeling, scratching or the like of the coil due to stress concentration.

  Hereinafter, a synchronous motor stator will be described as an example of a stator of a rotating electrical machine according to an embodiment of the present invention with reference to the drawings. In the following description, the same parts are denoted by the same reference numerals. Their names and functions are also the same. Therefore, detailed description thereof will not be repeated.

<First Embodiment>
The synchronous motor is composed of a stator and a rotor composed of permanent magnets. As shown in FIG. 1, the stator 100 includes a stator core (hereinafter referred to as a stator core) 102, a coil 112, a bus bar 110, a bus bar positioning block 104, and a transition member 106.

  The stator core 102 has a hollow cylindrical shape in which a plurality of electromagnetic steel plates are laminated. The stator core 102 has a predetermined number of grooves (hereinafter referred to as slots) in a direction parallel to the rotation axis of the synchronous motor. The predetermined number of slots has a number corresponding to the number of poles. The number of poles is not particularly limited, but is 21 for example in the present embodiment. In addition, teeth (hereinafter referred to as teeth) 108 are provided between the slots. The number of teeth corresponds to the number of poles as well as the slot. Therefore, in the present embodiment, the stator core 102 having 21 poles has 21 slots formed between the 21 teeth.

  A laminated coil (not shown) in which a plurality of metal plates (not shown) having a predetermined shape whose ends are open so as to be wound is laminated on the teeth 108 is rotated by a synchronous motor. It is inserted into the slots on both sides of the teeth 108 so as to straddle the teeth 108 in a direction parallel to the axis. In the slots on both sides of the tooth 108, a plurality of laminated coils are inserted in the radial direction of the synchronous motor. The number of laminated coils to be inserted is not particularly limited. For example, in the present embodiment, ten laminated coils are inserted in the radial direction so as to straddle the teeth 108.

  The open end of the laminate coil is joined to both ends of the bus bar 110, which is a linear conductor. At this time, one end of the bus bar 106 is joined to one of the open ends of the multilayer coil. The other end of the bus bar 106 is joined to one of the open ends of the multilayer coil adjacent to the multilayer coil. Similarly, one of the open ends of the 10 laminated coils is connected to one of the open ends of the adjacent laminated coils via the bus bar, whereby the coil is wound around the tooth 108 10 times. It becomes a state. That is, a 10-turn coil 112 is formed.

  In the tooth 108, a plurality of bus bars for connecting the open ends of the plurality of laminated coils are positioned and fixed to the bus bar positioning block 104. Therefore, when the bus bar positioning block 104 is installed at a predetermined position and pressed, the bus bars corresponding to the open ends of the plurality of laminated coils are assembled. Then, the assembled bus bar and the open end are joined by a joining process such as laser welding or TIG (Tungsten Inert Gas arc) welding.

  The coil 112 to which the plurality of bus bars are connected and wound around the teeth 108 is not connected to the bus bar on the inner peripheral side of one slot and the outer peripheral side of the other slot on both sides of the teeth 108. Part. Each of the coil end portions is connected to a coil wound around another tooth by a crossover member 106. Similarly, in other teeth included in the stator core 102, a 10-turn coil is formed. And as for the connection between the coils of each tooth, the coil edge part for every 3 teeth is connected using a crossover member. The coil end portions 140, 142, and 144 are connected to each other by a crossover member. In this way, the stator 100 of the three-phase synchronous motor is formed. A magnetic field is generated by controlling the phase of AC power to be supplied to each of the coil ends 134, 136, and 138. The rotor of the synchronous motor obtains a rotational force based on the generated magnetic field.

  Although the material of the metal flat plate which comprises a laminated body coil will not be specifically limited if it is a metal flat plate of a conductor at least, In this Embodiment, it is a copper rolling raw material, for example. By using a copper rolled material as the metal flat plate, copper has a high heat transfer coefficient, so that the heat dissipation of the coil can be further improved. Copper also has a low internal resistance and a high conductivity as a conductor. Therefore, heat generation when the current density is improved can be reduced. And the surface treatment of the insulation coating of a copper oxide is given to the surface of the metal flat plate of a copper rolling raw material.

  In addition, the metal flat plate having a predetermined shape that is open to be wound around the stator core that constitutes the laminated body coil has an open end, parallel upper and lower bases, and a connecting end that connects the upper and lower bases. It is a shape which has a part. In the present embodiment, the laminated body coil is formed, for example, by laminating U-shaped metal flat plates. That is, the laminated body coil is formed by laminating metal flat plates press-molded in a U-shape in a pressing step. However, the shape of the press-molded metal flat plate is not particularly limited to the U-shape. For example, the metal flat plate may be press-molded into a U shape.

  As shown in FIG. 2, the laminated body coil 114 in this Embodiment is formed by laminating a plurality of U-shaped metal flat plates. At this time, the upper base and the lower base parallel to the open end of the multilayer coil 114 are inserted into the slots 146 and 148 on both sides of the tooth 108. Moreover, the connection end part which connects an upper base and a lower base forms a coil end part. At this time, in the laminated coil 114, a cross section of an upper base and a lower base inserted into the slots 146 and 148 is shown in FIG. Further, FIG. 3B shows a cross section of the connection end portion forming the coil end portion. Comparing FIG. 3A and FIG. 3B, the cross-sectional area of the connection end portion forming the coil end portion in the multilayer coil 114 is the cross-sectional area of the upper base and the lower base inserted into the slots 146 and 148. Bigger than.

  Therefore, the volume of the coil forming the coil end portion is increased as compared with the case where the cross-sectional areas of the laminated body coil 114 in the coil end portion and the slots 146 and 148 are the same. Therefore, the heat capacity in the coil end portion is improved. The heat generated in the slot is transmitted to the coil end portion of the same turn having almost no thermal resistance. As a result, heat dissipation from the coil in the slot to the coil end portion is improved. Therefore, the current density can be improved in the coil in the slot having a small space. That is, the stator core can be miniaturized as much as the current density is improved.

  Hereinafter, as described with reference to FIG. 2, the cross-sectional area of the connection end portion forming the coil end portion in the multilayer coil 114 is made larger than the cross-sectional area of the upper base and the lower base inserted into the slot. The principle that can improve the current density is described.

  The short-term thermal rating of the coil is considered as follows. 1) Assume that all the heat generated by the coil is used to increase the temperature of the coil. 2) The temperature of the coil should be uniform everywhere. Further, the thermal resistance inside the multilayer coil in the same turn is sufficiently smaller than the heat radiation resistance to the outside.

At this time, the total calorific value Q of the multilayer coil is Q = 2 × (Ra (resistance of the upper and lower bases of the multilayer coil 114) + Rb (resistance of the connection end of the multilayer coil 114)) × I ² It can be expressed as (current) × dt (energization time). That is, Q = γ (copper specific heat) × ρ (copper density) × 2 × (Aa (cross-sectional area of upper and lower base) × La (length of upper and lower base) + Ab (cross-sectional area of connecting end) ) × Lb (length of connection end)) × dT (temperature increase).

  On the other hand, the coil resistance R can be expressed as R = 2 × (Ra + Rb) = 2 × α (specific resistance) × (La / Aa + Lb / Ab).

That is, Q = 2 × α × (La / Aa + Lb / Ab) × I ² × dt = γ × ρ × 2 × (Aa × La + Ab × Lb) × dT. Here, when Lb = X × La and Ab = Aa, the above formula is rearranged, and (I / Aa) ² = γ × ρ / α × (dT / dt) × (X × Y ² + Y) / ( X + Y). That is, in the general motor, the term of γ × ρ / α × (dT / dt) on the right side of the above-described equation is the cross-sectional area of the upper and lower bases on the slot side and the cross-sectional area of the connection end on the coil end side. This is a substantial expression when and are the same. That is, the temperature rise dT at the rated time is proportional to the square of the current density (I / Aa). The term (X × Y ² + Y) / (X + Y) is a concern when the length and cross-sectional area of the upper and lower bases on the slot side are different from the length and cross-sectional area of the connection end on the coil end side. It should be a term. For example, when Lb is 0.3 times the length of La (X = 0.3) and Ab is 3 times the cross-sectional area of Aa (Y = 3), (X × Y ² + Y) / (X + Y) The term is 1.314. That is, the current density in the slot can be improved by about 1.3 times under the same temperature condition. This means that a size of about 30% is possible. From the above, in the multilayer coil 114, by making the cross-sectional area of the connection end part forming the coil end part larger than the cross-sectional area of the upper base and the lower base inserted into the slot, the current density in the slot can be increased. Can be improved.

  Further, the coil in the slot is in contact with the stator core. Therefore, it is easy to keep the temperature low by dissipating heat generated by copper loss to the stator core. On the other hand, the coil at the coil end portion is exposed to air. For this reason, it is difficult to dissipate heat generated by copper loss to the outside. Therefore, in the present embodiment, the U-shape is formed so that the metal flat plate forming the coil end contacts the stator core. As a result, heat can be radiated from the coil end portion to the stator core. Therefore, the heat dissipation of the coil end part can be enhanced. That is, for example, when the slot is formed orthogonally to the end face of the stator core, the angle inside the upper and lower bases and the connecting end is set to a right angle when the U-shaped coil is viewed from the stacking direction. Therefore, the metal flat plate which forms a coil end can be made to contact a stator core. For example, even when the slot is formed with a skew angle, the angle inside the connection end portion with the upper base and the lower base is set to an angle corresponding to the skew angle. Therefore, the metal flat plate which forms a coil end can be made to contact a stator core.

  The axial length of the physique of the motor is defined by the physique of the stator core and the coil end portion wound around the stator core. Therefore, the space factor of a coil end part can be raised by forming a metal flat plate and a laminated body coil in a U shape. As a result, the stator can be miniaturized.

  Next, a plurality of U-shaped metal flat plates forming the multilayer coil 114 are provided with three protruding portions as shown in the multilayer coil 114 of FIG. And in order to form the laminated body coil 114, each other is fixed by what is called lamination caulking which press-fits the convex part of the protrusion part of another metal flat plate to the concave part of the protrusion part of a metal flat plate. Similarly, the laminated body coil 114 is formed by fixing by a laminated caulking to a predetermined number of metal flat plates. The metal flat plates forming the laminated body coil 114 are fixed to each other, so that the laminated body can be transported. As a result, workability at the time of assembling the laminated body coil 114 to the stator is improved. Although the predetermined number is not particularly limited, in the present embodiment, laminated coil 114 is formed by laminating three or four metal flat plates.

  FIG. 4A is a cross-sectional view cut in the stacking direction so as to include the protruding portion of the U-shaped metal flat plate 116. Then, as shown in FIG. 4B, the protrusions of the protrusions of the metal flat plate 116 are press-fitted into the recesses of the protrusions of the metal flat plate 120 by lamination caulking. And the convex part of the metal flat plate 120 is press-fitted in the hole provided in the metal flat plate 122 and fixed to each other. In this way, the laminated body coil 114 as shown in FIG. 4C is formed.

  Moreover, you may use an adhesive agent for fixation with an adjacent laminated body coil. That is, the laminate coil 114 and the laminate coil 124 may be bonded as shown in FIG. 4D by applying the concave portion of the protruding portion of the metal flat plate as an adhesive tray. When the laminate coils are bonded to each other, the caulking portion can be used as an adhesive tray. Therefore, workability at the time of assembling the coil can be improved.

  In the following description, a process of forming the stator 100 from a copper rolled material will be described based on the configuration of the stator 100 described above.

  FIG. 5 is a view showing an appearance of a metal flat plate 126 made of a rolled copper material. The surface of the metal flat plate 126 made of a rolled copper material is subjected to a surface treatment with an insulating coating of copper oxide. In the pressing process, the metal flat plate 126 of the copper rolled material is press-molded into a U-shape. And the metal flat plate press-molded in the U-shape is laminated by a predetermined number as described in FIG. Then, by fixing the metal flat plates to each other by lamination caulking, the laminated body coil 114 is formed as shown in FIG. Then, as shown in FIG. 6B, the laminated coil 114 is subjected to an insulation process for the adjacent laminated coil. Insulation with the adjacent laminated body coil is not particularly limited. For example, an inorganic material such as glass may be interposed, and enamel treatment may be performed for each laminated body. Then, as shown in FIG. 6C, the laminate coil 114 can be bonded to another laminate coil by applying an adhesive at a predetermined position on the insulator. Or you may use the recessed part of the mutual protrusion part of a laminated body coil as a receiving tray of an adhesive agent as demonstrated using FIG.4 (D).

  By bonding a plurality of laminated coils with an insulator interposed, a coil 112 is formed as shown in FIG. At this time, a U-shaped metal flat plate having different dimensions is laminated in each of the laminated coils forming the coil 112. Thus, the cross-sectional shape of the laminated body coil inserted into the slot can be freely set. That is, in accordance with the shape of the slot, the width of the metal flat plate inserted into the U-shaped slot is increased from the inner peripheral side to the outer peripheral side in the radial direction of the synchronous motor (from the top to the bottom in FIG. 7). To do. Therefore, the space factor of the coil 112 in the slot can be increased.

  As shown in FIG. 8, the coil 112 formed by a plurality of laminated coils is inserted across the teeth 108 of the stator core 102. That is, the respective open ends corresponding to the upper and lower bases of the coil 112 are inserted into the slots 146 and 148 on both sides of the tooth 108 in a direction parallel to the rotational axis direction of the synchronous motor.

  FIG. 9 shows the open end of coil 112 inserted into slots 146 and 148. As shown in FIG. 9, the laminated body coil which forms the coil 112 has a junction part of a different shape in each laminated body coil. Therefore, when the bus bar is assembled, an assembly error can be prevented. Different shapes of the joint portions can be realized by changing the number of metal flat plates having notches of a predetermined shape in the metal flat plate forming the laminated body coil.

  In addition, as shown in FIG. 10, when assembling a plurality of bus bars corresponding to the joint portions of each multilayer coil, the shape of the joint portions in at least the adjacent multilayer coils is different. Since the shapes of the joint portions of the adjacent laminated coils are different, it is possible to prevent an assembly error of the bus bar.

  In particular, as shown in FIG. 11, when performing a work such as assembling at the same time with a positioning block to which a plurality of bus bars are fixed, at least one of the joints of the open ends of the laminated coils in the coil 112 has a different shape. By having it, it is possible to prevent an assembly error when the bus bar is assembled. Furthermore, since the joining location is specified, the joining process can be performed without a jig for positioning. In the present embodiment, the joint portions of the three laminated coils on the inner peripheral side, the three laminated coils on the center, and the four laminated coils on the outer peripheral side have different shapes.

  When the bus bar is assembled to the laminated body coil, as shown in FIG. 12, the joint between the bus bar assembled to the coil 112 and the open end of each laminated body coil is laser-welded or TIG at each point. Multi-point joining is performed by welding.

  When the bus bar and the open end of each laminated body coil are joined, the coil wound for each tooth is connected using the transition member. That is, since the synchronous motor of the present embodiment is a three-phase AC synchronous motor, the coil end on the outer peripheral side of the coil and the coil end on the inner peripheral side are shown in FIG. They are connected using a transition member. Then, as shown in FIG. 14, the coil 112 and the transition member 106 are joined by laser welding or TIG welding. As a result, the stator 100 as shown in FIG. 1 is formed. Then, the coil end portion is subjected to a molding process using a resin or the like to form a stator 100 as shown in FIG.

  The molding process for the coil end portion is performed to suppress relative movement of the coil with respect to the stator core. In particular, in a motor used for HV, a very large force is applied to the coil due to an inertial force caused by acceleration / deceleration or turning of the vehicle. Therefore, in order to suppress the relative movement of the coil, a varnish process or a mold process is performed. However, in the varnish treatment, heat treatment is necessary because the varnish is cured after the coil is impregnated with the varnish. In the molding process, a furnace or injection molding is required for the process of putting an object in a mold and increasing the temperature for injection molding. As a result, if the relative movement of the coil and the stator core is suppressed by varnishing or molding, the manufacturing cost increases.

  Therefore, in the present embodiment, the molding process for the coil end portion as shown in FIG. 15 is abolished. That is, an elastic member is provided between the outer peripheral side surface of the stator core that is parallel to the rotation axis of the motor, the casing that covers one of the upper and lower surfaces orthogonal to the rotation axis, and the coil. The elastic member is not particularly limited, but one disc spring is used as an example in the present embodiment. However, the elastic member and the coil are insulated. Although it does not specifically limit as a method to insulate, For example, you may insulate the surface of an elastic member by coating etc., and you may provide insulating paper between a coil and an elastic member.

  The stator core is fastened to the casing in the direction of the rotation axis of the motor by a fastening member. Although a fastening member is not specifically limited, For example, it is a volt | bolt. Then, by providing a disc spring between the coil and the housing, an elastic force is generated in the disc spring against the fastening force caused by fastening the bolt. This elastic force suppresses relative movement of the coil with respect to the stator core.

  As shown in FIGS. 16 and 17, in this embodiment, synchronous motor 200 includes stator core 102, coil 112, rotor 208, bolt 210, housing 202, and disc spring 212. .

  A coil 112 is wound around the stator core 102. The stator core 102 is fastened to the housing 202 by bolts 210. A disc spring 212 is provided between the housing 202 and the coil 112.

  The disc spring 212 has a surface that is inclined with respect to a surface orthogonal to the rotation axis of the synchronous motor 200. The shape of the disc spring 212 is not particularly limited. For example, in the present embodiment, the disc spring 212 includes a conical elastic portion centered on the rotation axis. That is, when a load is applied in the rotation axis direction, the conical elastic portion of the disc spring 212 is deformed so as to bend in a direction parallel to the rotation axis. In response to the deformation, an elastic force is generated in the disc spring 212 so as to return to the original shape in a direction parallel to the rotation axis.

  The housing 202 is provided with a holding portion for holding the disc spring 212. Although a holding part is not specifically limited, In this Embodiment, the seat which hold | maintains a disc spring is provided in the housing | casing 202, for example. When the stator core 102 is fastened to the housing 202 with the bolts 210, the disc spring 212 comes into contact with all the coils wound around the stator core 102. The disc spring 212 is sandwiched between the casing 202 and the coil 112 and deforms in the direction of the rotation axis of the synchronous motor 200 according to the fastening force. At this time, the deformed disc spring 212 generates an elastic force to return to the original shape in the direction of the rotation axis. By this elastic force, the relative movement of the coil 112 with respect to the stator core 102 is suppressed.

  Moreover, it is not specifically limited to the shape of a disc spring like the disc spring 212 demonstrated using FIG. For example, as shown in FIG. 18, a diaphragm spring or a Belleville spring can be used as the disc spring 213.

  FIG. 19 shows a manufacturing process of the synchronous motor 200 in which a disc spring is provided between the casing 202 and the coil 112 as described above.

  In S1000, the coil 112 is assembled to the stator core 102. As described with reference to FIG. 7, the press coil 112 is formed by a plurality of laminated coils in which a predetermined number of U-shaped metal flat plates are laminated. As described with reference to FIG. 8, the coil 112 is inserted into the slots 146 and 148 so as to straddle the teeth 108.

  At S1100, bus bar 110 is assembled to coil 112 and joined. At this time, as described with reference to FIG. 11, the plurality of bus bars are fixed to the bus bar positioning block 104. Then, the positioning block 104 to which the plurality of bus bars are fixed is assembled to the open end portion of the coil 112. The assembled bus bar and the open end of the coil 112 are joined by laser welding or TIG welding.

  In S1200, the stator core 102 around which the coil 112 is wound is assembled to the housing 202 together with the disc spring 212. At this time, as described with reference to FIGS. 16 and 17, the disc spring 212 is installed on a seat for holding the disc spring 212 provided in the housing 202. Then, the stator core 102 around which the coil 112 is wound is assembled to the casing 202, and the stator core 102 is fastened to the casing 202 with a bolt 210.

  As described above, according to the synchronous motor according to the present embodiment, the coil is wound around the synchronous motor through two of the plurality of slots included in the plurality of hollow cylindrical stator cores. Further, one surface of the outer peripheral side surface parallel to the rotation axis of the stator core and the side surface orthogonal to the rotation axis is covered with the casing. The synchronous motor includes a bolt that penetrates in a direction parallel to the rotation axis and fastens the stator core to the housing, and a disc spring that generates an elastic force that is against the fastening force of the bolt between the housing and the coil. And are provided. Then, by fastening the stator core to the housing with bolts, an elastic force is generated in the disc spring provided between the housing and the coil in a direction parallel to the rotation axis of the motor, which is opposite to the fastening force of the bolts. This elastic force can suppress the relative movement of the coil with respect to the stator core.

  That is, the relative movement of the coil can be suppressed with a simple structure in which a disc spring is provided between the housing and the coil. Therefore, the varnish process or the mold process applied to the conventional coil can be abolished. As a result, productivity can be improved and manufacturing costs can be reduced. Further, by loosening the fastening of the bolt, the copper of the coil and the stator core can be easily distinguished and disassembled, so that recyclability is improved. Further, since the disc spring is provided between the casing and the coil, the coil can be fixed without increasing the axial dimension of the motor. In addition, by suppressing the relative movement of the coil in this way, it is possible to prevent the insulation performance from being deteriorated due to peeling off, scratching, or the like of the coil.

  The coil wound around the stator core is formed of a laminate in which a predetermined number of conductive metal flat plates press-molded in a U-shape are laminated. In a conventional motor, an enameled wire is wound around a stator core to form a coil. And the shape of the coil end part becomes a shape including an uneven part. Therefore, in order to suppress the relative movement of the coil with respect to the stator, it is necessary to apply a larger load to the coil end portion. For this reason, the assemblability deteriorates. Furthermore, stress is concentrated on a part of the coil by applying a large load. As a result, the enamel coating of the coil is damaged. As a result, the insulation of the coil may be deteriorated. However, the coil according to the present embodiment is formed of a laminated body in which metal flat plates having substantially the same shape punched by the press as described above are laminated. Therefore, the shape of the coil end portion can be designed to an arbitrary shape. That is, in the coil according to the present embodiment, the shape of the coil end portion can be formed on a flat surface by using a laminate of metal flat plates formed in a U shape by a pressing process. Therefore, stress can be uniformly applied to the coil at the portion where the coil and the disc spring come into contact with each other via the disc spring when a load due to the fastening force of the bolt is applied to the coil. As a result, damage to the enamel coating can be prevented. Further, by forming the coil by press molding, the shape of the coil end is determined at the stage of winding the coil. Therefore, the coil end molding process can be abolished. As a result, the manufacturing cost can be reduced.

  In addition, although the one disc spring which contacts all the coils wound around a stator core was used as an elastic member which concerns on this Embodiment, it is not specifically limited. For example, you may provide several disc springs which each fix each coil. At this time, the plurality of disc springs are provided so as to be symmetric about the rotation axis of the motor on the end face of the stator having a hollow cylindrical shape. Therefore, a uniform elastic force can be applied to the coil that contacts each of the plurality of disc springs. Therefore, it is possible to prevent a decrease in insulation performance due to damage to the enamel coating of the coil due to concentration of stress.

<Modification of First Embodiment>
Hereinafter, a synchronous motor according to this modification will be described. The configuration of the synchronous motor according to this modification is the same as that of the synchronous motor according to the first embodiment except for the elastic member. Therefore, the same reference numerals are assigned to the same components as those of the synchronous motor according to the first embodiment. Their functions are the same. Therefore, detailed description thereof will not be repeated here.

  The elastic member according to this modification uses a coil spring instead of the aforementioned disc spring. As shown in FIGS. 20 and 21, the synchronous motor 500 according to the present modification includes a stator core 102, a coil 112, a rotor 208, a bolt 210, a housing 502, and a coil spring 512.

  A coil 112 is wound around the stator core 102. The stator core 102 is fastened to the housing 502 by bolts 210. A plurality of coil springs 512 are provided between the housing 502 and the coil 112. When a load is applied to the plurality of coil springs 512 in a direction parallel to the rotation axis of the synchronous motor 500, an elastic force is generated to return to the original shape in response to contraction of the coils forming the plurality of coil springs 512. . That is, the plurality of coil springs 512 fixes each coil. At this time, the plurality of coil springs 512 are provided so as to be symmetric about the rotation axis of the motor on the stator end surface having a hollow cylindrical shape.

  The housing 502 is provided with a holding portion for holding a plurality of coil springs 512. Although the holding portion is not particularly limited, in the present modification, for example, a plurality of seats for holding a plurality of coil springs are provided in the housing 502. When the stator core 102 is fastened to the casing 502 with the bolts 210, the plurality of coil springs 512 are sandwiched between the casing 502 and the coil 112 and deformed by a fastening force in a direction parallel to the rotation axis of the synchronous motor 500. . At this time, an elastic force is generated in the deformed coil springs 512 to return to the original shape in a direction parallel to the rotation axis. By this elastic force, the relative movement of the coil 112 with respect to the stator core 102 is suppressed.

  As described above, according to the synchronous motor according to this modification, by providing a plurality of coil springs as elastic members between the housing and each of the coils wound around the stator core, the coil with respect to the stator core can be provided. Relative motion can be suppressed. In addition, although the several coil spring which fixes each coil wound by the stator core was used as an elastic member which concerns on this modification, it is not specifically limited. For example, as shown in FIG. 22, one coil spring 513 that contacts all the coils wound around the stator core may be used. By fixing the coil with one coil spring 513, it is possible to apply an elastic force uniformly to the coil. Therefore, it is possible to prevent a decrease in insulation performance due to damage to the enamel coating of the coil due to concentration of stress.

<Second Embodiment>
Hereinafter, a synchronous motor according to a second embodiment of the present invention will be described. The configuration of the synchronous motor according to the present embodiment is different from the configuration of the synchronous motor according to the first embodiment described above in that it includes an elastic member holder as a holding portion for holding the elastic member. Other than that is the structure of the synchronous motor which concerns on 1st Embodiment. The same reference numerals are assigned to the same components. Their functions are the same. Therefore, detailed description thereof will not be repeated here.

  The synchronous motor according to the present embodiment includes an elastic member holder for holding the elastic member. The elastic member is covered with the casing, and is provided so as to contact the coil on the surface opposite to the side surface orthogonal to the rotation axis of the synchronous motor in the stator core. Although the elastic member is not particularly limited, in the present embodiment, for example, one disc spring is used. And an elastic member holder is provided as a holding part holding a disc spring. The disc spring holding method is realized in this embodiment by forming the disc shape of the elastic member holder so as to cover the whole disc spring and fastening the elastic member holder to the stator core at a plurality of locations by fastening members. The The elastic member holder is fixed to the stator core using a fastening member that fastens in a direction parallel to the rotation axis of the synchronous motor. The elastic member holder is not particularly limited, and may be any member that can transmit a fastening force generated by fastening to the elastic member when the elastic member holder is fastened to the stator core by a fastening member.

  Although a fastening member is not specifically limited, In this Embodiment, a volt | bolt is used, for example. When the elastic member holder is fastened to the stator core by the bolt, the disc spring is deformed according to the fastening force by the bolt. In response to the deformation of the disc spring, an elastic force is generated in which the disc spring attempts to return to its original shape against the fastening force in a direction parallel to the rotation axis. This elastic force suppresses the relative movement of the coil in contact with the disc spring with respect to the stator core.

  At this time, the position at which the elastic member holder is fixed to the stator core is not particularly limited. For example, as shown in FIG. 23, the elastic member holder is fixed to a fastening end portion 304 for fastening the stator core 102 to the housing. The Further, the number of positions at which the elastic member holder is fixed to the stator core is not particularly limited, but the elastic member holder is fixed at equal intervals so that a load is evenly applied to the disc spring. In the present embodiment, for example, the elastic member holder is fastened to the stator core 102 by three fastening end portions of the stator core 102 for fastening to the housing.

  Next, the structure of the synchronous motor in the present embodiment will be described in detail with reference to the drawings.

  FIG. 24 shows a cross section when the synchronous motor 300 is cut along the line AA shown in FIG. As shown in FIG. 24, in the present embodiment, the synchronous motor 300 includes a stator core 102, a coil 112, a rotor 208, a bolt 310, a housing 302, a disc spring 212, and an elastic member holder 314. It is configured.

  A coil 112 is wound around the stator core 102. Further, an elastic member holder 314 is fastened to the housing 302 by a bolt 310 so as to penetrate the stator core 102. That is, the elastic member holder is fixed to the stator core 102 by fastening the bolt 310. A disc spring 212 is provided between the elastic member holder 314 and the coil 112.

  When the elastic member holder 314 passes through the stator core 102 in the housing 302 and is fastened by the bolt 310, the disc spring 212 comes into contact with all the coils wound around the stator core 102. The disc spring 212 is deformed according to the fastening force sandwiched between the elastic member holder 314 and the coil 112 and parallel to the rotation axis of the synchronous motor 200. At this time, the deformed disc spring 212 is subjected to an elastic force to return to the original shape in a direction parallel to the rotation axis. By this elastic force, the relative movement of the coil 112 with respect to the stator core 102 is suppressed.

  As described above, according to the synchronous motor according to the present embodiment, the synchronous motor includes the elastic member holder that holds the disc spring and the bolt that fastens the elastic member holder to the stator core in a direction parallel to the rotation axis. Is done. Then, by fastening the elastic member holder to the stator core with a bolt, an elastic force is generated in the disc spring provided between the elastic member holder and the coil, which is against the fastening force of the bolt.

  This elastic force can prevent relative movement of the coil with respect to the stator core. That is, the relative movement of the coil can be suppressed with a simple structure in which a countersunk screw is provided between the elastic member holder and the coil. Therefore, the conventional varnish processing or mold processing can be abolished. As a result, productivity is improved. And manufacturing cost can also be reduced. Furthermore, by loosening the fastening of the bolts, the copper of the coil and the stator core can be easily distinguished and disassembled. Therefore, recyclability is improved. In addition, by suppressing the relative movement of the coil in this way, it is possible to prevent the insulation performance from being deteriorated due to peeling off, scratching, or the like of the coil. In addition, before the stator core is assembled to the housing, the stator core can be assembled including fixing the coil. Therefore, the assembly property of the stator core to the housing is improved. Furthermore, the stator core can be easily transported during coil manufacture.

  Further, the fixing position of the elastic member holder is not limited to fixing to the fastening end portion of the stator core. For example, the elastic member holder may be fixed to the stator core with bolts. At this time, the number of positions at which the elastic member holders are fixed is not particularly limited, but the elastic member holders are fixed to the circumference of the stator core at equal intervals so that a load is evenly applied to the disc springs. For example, as shown in FIG. 23, it is assumed that the circumference of the stator core 102 is fastened with bolts 410, 412, and 414 at a part that divides the circumference into three equal parts.

  FIG. 25 shows a cross section of the synchronous motor 300 taken along the line BB shown in FIG. As shown in FIG. 25, the synchronous motor 300 includes a stator core 102, a coil 112, a rotor 208, a bolt 410, a casing 302, a disc spring 212, and an elastic member holder 314.

  The elastic member holder 314 is fastened to the stator core 102 with bolts 410. A disc spring 212 is provided between the elastic member holder 314 and the coil 112. The disc spring 212 is sandwiched between the elastic member holder 314 and the coil 112 and deformed in the direction parallel to the rotation axis by the fastening force in the direction parallel to the rotation axis due to the fastening of the bolt 410. In response to the deformation, the disc spring generates an elastic force to return to its original shape. By this elastic force, the relative movement of the coil 112 with respect to the stator core 102 is suppressed.

  In addition to suppressing the relative movement of the coil 112 with respect to the stator core 102 by using the fixed position of the elastic member holder described with reference to FIG. 25, before assembling the stator core 102 to the housing 302, the disc spring 212 and the elastic member holder Since 314 can be assembled, workability is improved.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

It is a figure which shows the external appearance of a stator. It is a figure which shows the external appearance of a U-shaped laminated body coil. It is a figure which shows the cross section of a laminated body coil. It is a figure which shows the lamination | stacking cross section of the lamination direction of a laminated body coil. It is a figure which shows the external appearance of the metal flat plate of a copper rolling raw material. It is a figure which shows progress of the insulation process of a laminated body coil. It is a figure which shows the external appearance of the coil formed with a some laminated body coil. It is a figure which shows the assembly | attachment progress of the coil inserted in a stator core. It is a figure which shows the external appearance of the coil assembled | attached to the stator core. It is a figure which shows the external appearance of the coil by which the bus bar was assembled | attached. It is a figure which shows the external appearance of the coil by which the bus-bar positioning block to which the several bus bar was fixed was assembled | attached. It is a figure which shows joining of the bus-bar assembled | attached to the open end part of the coil. It is a figure which shows progress of assembling a bridge member to the edge part of a coil. It is a figure which shows joining of the edge part of the crossover member assembled | attached to the edge part of a coil. It is a figure which shows the external appearance of the stator by which the coil end part was mold-processed. It is a figure which shows the cross section of the synchronous motor which concerns on 1st Embodiment. It is a perspective view (the 1) of a synchronous motor concerning a 1st embodiment. It is a perspective view (the 2) of the synchronous motor which concerns on 1st Embodiment. It is a figure which shows the manufacturing process of the synchronous motor which concerns on 1st Embodiment. It is a figure which shows the cross section of the synchronous motor which concerns on the modification of 1st Embodiment. It is a perspective view of the synchronous motor which concerns on the modification of 1st Embodiment. It is a perspective view of the synchronous motor which fixes a coil with one coil spring. It is a figure which shows the fixed position of the elastic member holder in a stator core. It is a figure which shows the cross section cut | disconnected by the AA line of FIG. It is a figure which shows the cross section cut | disconnected by the BB line of FIG. The manufacturing process of the conventional motor which performs a varnish process on a coil is shown.

Explanation of symbols

  100 Stator, 102 Stator core, 104 Busbar positioning block, 106 Transition member, 108 Teeth, 110 Busbar, 112 Coil, 114, 124 Laminate coil, 116, 120, 122, 126 Metal flat plate, 134, 136, 138, 140, 142, 144 Coil end, 146, 148 slot, 200, 300, 500 Synchronous motor, 202, 302, 502 Housing, 208 Rotor, 210, 310, 410, 412, 414 Bolt, 212, 213 Disc spring, 304 Fastening End part, 314 Elastic member holder, 512 Multiple coil springs, 513 Coil springs.

Claims (7)

A stator of a rotating electric machine,
A stator core having a plurality of slots in a direction parallel to the rotation axis of the rotating electrical machine;
A coil that is wound around the stator core by closing open ends of metal conductors inserted into the plurality of slots;
A casing that covers an outer peripheral side surface of the stator core parallel to the rotation axis and a side surface orthogonal to the rotation axis;
A fastening member for fastening the stator core to the housing;
A stator for a rotating electrical machine, comprising: an elastic member that is provided between the housing and the coil and generates an elastic force when the fastening member is fastened. A stator of a rotating electric machine,
A stator core having a plurality of slots in a direction parallel to the rotation axis of the rotating electrical machine;
A coil that is wound around the stator core by closing open ends of metal conductors inserted into the plurality of slots;
A casing that covers an outer peripheral side surface of the stator core parallel to the rotation axis and one surface of the side surface orthogonal to the rotation axis;
An elastic member provided in contact with the coil so that an elastic force is generated in a direction parallel to the rotation axis on a surface of the side surface opposite to the surface covered with the housing;
A holding portion for holding the elastic member;
A stator for a rotating electrical machine, comprising: a fastening member that fastens the holding portion to the stator core in a direction parallel to the rotation axis.   The stator of the rotating electrical machine according to claim 2, wherein the fastening member fastens the holding portion to the housing in addition to the stator core.   The stator of a rotating electrical machine according to claim 1, wherein the metal conductor is formed of a laminate in which a predetermined number of metal flat plates of a conductor press-molded into a U-shape or a U-shape are stacked.   The stator of the rotating electrical machine according to claim 1, wherein the elastic member is a disc spring.   The stator of a rotating electrical machine according to claim 1, wherein the elastic member is a coil spring.   The stator of the rotating electrical machine according to any one of claims 1 to 6, wherein a plurality of the elastic members are provided on the end face of the stator so as to be symmetric about the rotation axis.

Images