JP4457785B2 - Stator structure of disk type rotating electrical machine - Google Patents

Description

  The present invention belongs to the technical field of a stator structure of a disk-type rotating electrical machine in which a stator and a rotor are arranged to face each other in the axial direction.

  The permanent magnet synchronous motor (IPMSM: Interior Permanent Magnet Synchronus Motor) with a permanent magnet embedded in the rotor and the surface magnet synchronous motor (SPMSM: Surface Permanent Magnet Synchronus Motor) with a permanent magnet attached to the rotor surface have low loss. Due to its high efficiency and high output (in addition to magnet torque, reluctance torque can also be used), its application range has been expanded to applications such as electric vehicle motors and hybrid vehicle motors.

Such a permanent magnet synchronous motor, in which a stator and a rotor are opposed to each other in the axial direction, can be thinned and used for applications where layout is limited (for example, Patent Documents) 1).
Japanese Patent Laid-Open No. 11-187635

  However, in the conventional disk type motor, the stator coil plate is fixed to the bracket (corresponding to the case) at the outer peripheral portion thereof by tightening in the axial direction with a through bolt (through bolt). There is a problem that the diameter of the disk type motor is unavoidable because it is necessary to set a flange portion for opening the outer periphery of the stator.

In order to achieve the above object, in the present invention, a rotor having a permanent magnet disposed thereon, a stator disposed on the axial direction side with respect to the permanent magnet , having a stator core and a stator coil, and better in thermal conductivity than resin. A cylindrical outer case made of metal, and the stator core has a flat portion at a position facing the inner periphery of the outer case, and the outer case is an inner peripheral side of the outer case and the plane A protrusion projecting toward the inner peripheral side of the outer peripheral case at a position opposed to the outer peripheral case, the distal end of the protrusion being planar, and surrounding the stator with a resin mold made of the resin. Was constrained to the inner surface of the outer peripheral case .

In order to achieve the above object, in the present invention, a disk-type rotating electrical machine comprising a rotor having a permanent magnet disposed therein, a stator having a stator core and a stator coil, and the rotor and the stator are disposed in the axial direction.
The stator was wrapped around with a resin mold, and the resin mold was restrained in at least one of an axial direction and a circumferential direction with respect to the inner surface of the case.

Therefore, in the disc-type rotary electric machine of the present invention, configured with the improved cooling performance of the stator, by constraining the stator casing without using bolts or the like, the rotary electric machine without enlargement of the diameter can do.

  BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the best mode for carrying out a stator structure of a disk-type rotating electrical machine of the present invention will be described based on Examples 1 to 5 shown in the drawings.

First, the configuration will be described.
FIG. 1 is an overall cross-sectional view showing a disk-type rotating electrical machine having a two-rotor / one-stator structure to which the stator structure of the first embodiment is applied.
The disk-type rotating electrical machine according to the first embodiment includes a rotating shaft 1, rotors 2, 2, a stator 3, and a rotating electrical machine case 4 (case). The rotating electrical machine case 4 includes a front side case. 4a, a rear side case 4b, and an outer peripheral case 4c bolted to both side cases 4a and 4b.

  The rotary shaft 1 is rotatably supported by a first bearing 5 provided on the front side case 4a and a second bearing 6 provided on the rear side case 4b.

  The rotors 2 and 2 are fixed at two positions with the stator 3 sandwiched between the rotating shaft 1 and generate reaction force on the permanent magnets 9 and 9 with respect to the rotating magnetic flux applied from the stator 3. A plurality of permanent magnets 9, 9 partially embedded in the facing surfaces of the rotor bases 8, 8 made of electromagnetic steel plates (ferromagnetic material) fixed to the rotating shaft 1 so as to rotate about the center and the stator 3. And is configured. The plurality of permanent magnets 9 are arranged such that adjacent surface magnetic poles (N pole, S pole) are different from each other. Here, gaps called air gaps 10 and 10 exist between the rotors 2 and 2 and the stator 3 and do not contact each other.

  The stator 3 is fixed to the inner surface of the outer peripheral case 4c and includes a stator core 11 and a stator coil 12. The stator coil 12 is wound around the stator core 11 via insulating paper or an insulator not shown.

  FIG. 2 is a longitudinal sectional view at the stator position of the disk-type rotating electrical machine of the first embodiment, and the stator structure of the first embodiment will be described based on FIGS. 1 and 2.

  The stator structure of Example 1 includes rotors 2 and 2 having permanent magnets 9 and 9 disposed therein, and a stator 3 having a stator core 11 and a stator coil 12, and the rotors 2 and 2 and the stator 3 are arranged in the axial direction. In the disk-type rotating electrical machine arranged, the stator 3 is wrapped around by a resin mold 13 to restrain the resin mold 13 in the axial direction and the circumferential direction with respect to the inner surface of the outer case 4c.

  That is, the stator 3 is provided with a concavo-convex portion on the inner surface of the case where the resin mold 13 abuts, the stator core 11 around which the stator coil 12 is wound is disposed, and the outer peripheral case 4c is a part of the mold. The stator 3 is positioned integrally with the outer case 4c by resin molding.

  Here, as shown in FIG. 1 and FIG. 2, the concavo-convex portion provided on the inner surface of the outer peripheral case 4 c is a cross-sectional square shape provided on the inner surface of the outer peripheral case 4 c that matches the position where the stator core 11 is set. The constraining square convex portion 14. And the said restraining square convex part 14 has the axial direction opposing surfaces 14a and 14a which restrain the resin mold 13 to an axial direction with respect to a case inner surface, and the circumferential direction opposing surface 14b which restrains the resin mold 13 with respect to a case inner surface in the circumferential direction. , 14b. In addition to the constraining square convex part 14, a constraining square convex part 14 ′ whose inner protrusion amount is larger than that of the constraining square convex part 14 is provided at a case inner surface position coinciding with the position between the adjacent stator cores 11, 11. Provided. This constraining square convex portion 14 ′ also has an axially facing surface and a circumferentially facing surface, and is further enhanced in the restraining performance in the axial direction and the circumferential direction.

  In addition, a cooling gallery 15 is provided at the position of the outer case 4c where the stator core 11 wrapped by the resin mold 13 abuts. As shown in FIG. 2, the cooling gallery 15 has an elliptic cross-section refrigerant passage shape, and is positioned between a radial position coincident with the position of the stator core 11 around which the stator coil 12 is wound and the adjacent stator cores 11, 11. It is formed at a radial position that matches the position of.

Next, the operation will be described.
First, when the stator is tightened and fixed to the case in the axial direction with a through bolt as in the prior art, the flange portion that opens the bolt hole of the through bolt protrudes in the outer diameter direction, avoiding the diameter increase of the rotating electrical machine. I can't. Incidentally, when the stator is fastened and fixed with a through bolt, the length obtained by adding two through bolt diameters to the outer diameter of the stator core around which the stator coil is wound and the length due to the tightening allowance in the radial direction are added.

  On the other hand, in the stator structure of the first embodiment, an uneven portion is provided on the inner surface of the case with which the resin mold 13 abuts, the stator core 11 around which the stator coil 12 is wound is disposed, and the outer case 4c is formed as a mold. The stator 3 is positioned integrally with the outer case 4c by resin molding.

  Thus, since the resin mold 13 enclosing the stator core 11 with the stator coil 12 is restrained in the axial direction and the circumferential direction with respect to the inner surface of the outer case 4c, an axial force and a torque reaction force due to a magnetic force. Therefore, the stator 3 can be constrained to the outer case 4c without using bolts or the like, and a disk-type rotating electrical machine without increasing the diameter can be configured.

  Furthermore, the concavo-convex portion provided on the inner surface of the outer case 4c is a constraining square convex portion 14 having a rectangular cross section provided on the inner surface of the outer case 4c, and the axially facing surfaces 14a and 14a and the circumferentially facing surface 14b, 14b, the resin mold 13 is secured against the inner surface of the case in the axial direction and the circumferential direction is secured, and the displacement of the stator 3 can be reliably restrained during operation.

  In addition, the constraining square convex portion 14 provided on the inner surface of the outer case 4c is set at a case inner surface position that coincides with a position where the plurality of stator cores 11 are set, so that it is closer to the stator coil 12 that is a heat source. The metal part of the outer peripheral case 4c having better thermal conductivity than the resin is present at the position, and the cooling performance is improved.

  Further, since the cooling gallery 15 is provided at the position of the outer peripheral case 4c where the stator core 11 wrapped by the resin mold 13 abuts, heat transfer is favorably performed from the resin mold 13 to the outer peripheral case 4c → the cooling medium. The cooling performance of the rotating electrical machine can be improved.

Next, the effect will be described.
In the stator structure of the disk-type rotating electrical machine according to the first embodiment, the effects listed below can be obtained.

  (1) A disk having rotors 2 and 2 having permanent magnets 9 and 9 disposed thereon and a stator 3 having a stator core 11 and a stator coil 12, wherein the rotors 2 and 2 and the stator 3 are disposed in the axial direction. In the type rotating electric machine, the stator 3 is wrapped around by the resin mold 13 and the resin mold 13 is restrained in the axial direction and the circumferential direction with respect to the inner surface of the rotating electric machine case 4. By constraining the rotating electrical machine case 4, it is possible to configure a rotating electrical machine that does not increase in diameter.

  (2) The stator 3 is provided with a concavo-convex portion on the inner surface of the case with which the resin mold 13 abuts, the stator core 11 around which the stator coil 12 is wound is disposed, and the outer case 4c is a part of the mold. Since the stator 3 is integrally positioned with the outer case 4c by resin molding, the stator 3 can be strongly restrained to the rotating electrical machine case 4 by concave-convex fitting while simplifying the mold.

  (3) The constraining square convex portion 14 includes axial facing surfaces 14a and 14a that restrain the resin mold 13 in the axial direction with respect to the inner surface of the case, and a circumferential facing surface that restrains the resin mold 13 in the circumferential direction with respect to the inner surface of the case. 14b, 14b, the displacement of the stator 3 can be reliably restrained against the axial force caused by the magnetic force and the circumferential force caused by the torque reaction force.

  (4) Since the concavo-convex portion provided on the inner surface of the outer peripheral case 4c is a constraining square convex portion 14 having a rectangular cross section provided on the inner surface of the outer peripheral case 4c coinciding with the position where the stator core 11 is set, The stator coil 12 which is a heat source and the outer case 4c are close to each other via the constraining square convex portion 14, and the stator cooling performance can be improved.

  (5) Since there is a cooling gallery 15 at the position of the outer peripheral case 4c where the stator core 11 wrapped by the resin mold 13 abuts, the resin mold 13 → the outer peripheral case 4c → the heat to the cooling medium (in the cooling gallery 15). A transmission path is ensured, and the cooling performance of the stator 3 can be further improved.

  Example 2 is an example in which the cross-sectional shape of the uneven portion provided on the inner surface of the case is different from Example 1.

  That is, as shown in FIG. 3, the concave and convex portions provided on the inner surface of the outer peripheral case 4 c are constrained square concave portions 16 having a rectangular cross section provided on the inner surface of the case coinciding with the position where the stator core 11 is set, It was set as the combination with the restraint T-shaped convex part 17 of T-shaped cross section. The constraining rectangular recesses 16 and the constraining T-shaped protrusions 17 are alternately formed for each of the plurality of stator cores 11 so as to appear at symmetrical positions via the rotating shaft 1 as shown in FIG. Since other configurations are the same as those of the first embodiment, the corresponding components are denoted by the same reference numerals and description thereof is omitted.

  Next, the operation will be described. In Example 2, the constrained T-shaped convex portion 17 provided on the inner surface of the outer case 4c is set to the case inner surface position that matches the position where the plurality of stator cores 11 are set. Therefore, the metal portion of the outer peripheral case 4c having better thermal conductivity than the resin is present at a position closer to the stator coil 12 that is a heat generation source, and like the constraining square convex portion 14 of the first embodiment, The cooling performance is improved, and the concave and convex fitting with the resin mold 13 is performed in a complicated shape, so that the restraining function in the axial direction and the circumferential direction is improved. Further, with respect to the restraining function in the axial direction and the circumferential direction, an improvement can also be desired by combining the restraining square recess 16 and the restraining T-shaped protrusion 17. Other operations are the same as those in the first embodiment.

  Next, the effect will be described. In addition to the effects (1), (2), (3), (5) of the first embodiment, the following structure is provided for the stator structure of the disk-type rotating electrical machine of the second embodiment. An effect can be obtained.

  (6) A concavity and convexity portion provided on the inner surface of the outer peripheral case 4c includes a constraining square concave portion 16 having a rectangular cross section provided on the case inner surface coinciding with the position where the stator core 11 is set, and a constraining portion having a T-shaped cross section. Since it is a combination with the T-shaped convex part 17, a high restraining function in the axial direction and the circumferential direction can be achieved.

  The third embodiment is an example in which the cross-sectional shape of the concavo-convex portion provided on the inner surface of the case is different from the first and second embodiments.

  That is, as shown in FIG. 4 and FIG. 5, the uneven portion provided on the inner surface of the outer peripheral case portion 4 c is a rectangular cross section provided on the case inner surface coinciding with the position where the stator core 11 is set, And it was set as the square convex part 18 with a constraining hole which has a through-hole in an axial direction. Since other configurations are the same as those of the first embodiment, the corresponding components are denoted by the same reference numerals and description thereof is omitted.

  Next, the operation will be described. Since the rectangular convex portion 18 with constraining holes of the third embodiment is set at a case inner surface position that coincides with a position where the plurality of stator cores 11 are set, the stator coil 12 as a heat source. The metal part of the outer peripheral case 4c having better thermal conductivity than the resin is present at a position closer to the same, and the cooling performance is improved in the same manner as the constraining square convex part 14 of the first embodiment. In addition, the rectangular convex portion 18 with the constraining hole and the resin mold 13 are not only simply concavo-convexly fitted, but are constrained in a locked state in which the resin mold 13 enters the through hole in the axial direction. Not only the circumferential direction but also the restraining function in all directions is improved. Since other operations are the same as those in the first embodiment, description thereof is omitted.

  Next, the effect will be described. In addition to the effects (1), (2), (3), (5) of the first embodiment, the following structure is provided for the stator structure of the disk-type rotating electrical machine of the third embodiment. An effect can be obtained.

  (7) The concavo-convex portion provided on the inner surface of the outer peripheral case portion 4c has a rectangular cross section provided on the inner surface of the case that coincides with the position where the stator core 11 is set, and has a through hole in the axial direction. Since it is the square convex part 18 with a restraint hole, while being able to improve cooling performance, the restraint function with respect to not only an axial direction and a circumferential direction but all directions can be improved.

  Example 4 is an example showing molding in a disk-type rotating electrical machine having one rotor and one stator.

  In the fourth embodiment, as shown in FIG. 6A, the rotating electrical machine case 4 is constituted by a front side case 4d and a rear side cover 4e, and one rotor 2 is fixed to the rotary shaft 1, and the front side case A set of stators 3 in which a large number of stator cores 11 are arranged on the circumference is fixed to 4d. That is, a disk-type rotating electric machine with one rotor and one stator is provided. And as shown in FIG.6 (b), it has the positioning pin 19 (positioning means) between stator core base 11 'and the front side case 4d. In FIG. 6B, reference numeral 20 denotes a mold. Since other configurations are the same as those of the first embodiment, the corresponding components are denoted by the same reference numerals and description thereof is omitted.

Next, the operation will be described. When the resin mold 13 of the stator 3 is formed,
1) The stator core 11 with the stator coil 12 is positioned using the positioning pins 19 with respect to the front side case 4d.
2) The mold 20 is positioned and set with respect to the front case 4d where the stator core 11 is positioned. The positioning of the mold 20 is set in the axial direction and the radial direction with respect to the front case 4d by fitting the positioning step 20a and the bearing step 4d ′ of the front case 4d.
3) Molten resin is supplied from the resin supply hole 20b in a state where the mold 20 is positioned and set in the front case 4d.
4) When the resin is solidified, remove the mold 20.
The resin mold 13 is formed by passing through the above process.

  Therefore, the position of the stator core 11 can be held at the time of molding the resin mold 13, and the ease of manufacturing the rotating electrical machine and the stabilization of the performance can be achieved. Since other operations are the same as those in the first embodiment, description thereof is omitted.

  Next, the effects will be described. In the stator structure of the disk-type rotating electrical machine of the fourth embodiment, the following effects can be obtained in addition to the effects of the first, second, and third embodiments.

  (8) Since the positioning pin 19 is provided between the stator core base 11 'and the front case 4d, the rotating electrical machine can be easily manufactured and the performance of the rotating electrical machine can be stabilized.

  Example 5 is an example in which the resin mold is constrained by changing the shape of the case inner surface into a polygon instead of the resin mold constrained by the uneven portions of the case inner surface in Examples 1-4.

  That is, as shown in FIG. 7, the stator 3 has a polygonal inner surface 21 as the inner surface of the rotating electrical machine case 4 with which the resin mold 13 abuts, and a stator core 11 around which the stator coil 12 is wound is disposed. The rotating electrical machine case 4 is a part of a mold, and the stator 3 is integrally positioned with the rotating electrical machine case 4 by resin molding. The polygonal inner surface 21 of the rotating electrical machine case 4 has a number of side surfaces 21a, 21b, 21c,... Corresponding to the number of stator cores 11 around which the stator coil 12 is wound. Since other configurations are the same as those of the first embodiment, the corresponding components are denoted by the same reference numerals and description thereof is omitted.

  Next, the operation will be described. By forming the inner surface of the rotating electrical machine case 4 into a polygonal inner surface 21 instead of a circular shape, a circumferential restraint state can be obtained, and it is generated in the resin mold 13 as compared with the case of an uneven portion. This is advantageous in terms of strength. Regarding the axial restraint of the resin mold 13, for example, in the case of using the disk rotor as the base of the fourth embodiment and having one rotor and one stator, the inner surface of the front side case 4 d is the shaft of the resin mold 13. It becomes a constraining surface when trying to displace in the direction.

  Next, the effects will be described. In the stator structure of the disk-type rotating electrical machine of the fifth embodiment, in addition to the effects of (1) of the first embodiment, the effects listed below can be obtained.

  (9) In the stator 3, the inner surface of the rotating electrical machine case 4 with which the resin mold 13 abuts is a polygonal inner surface 21, and the stator core 11 around which the stator coil 12 is wound is disposed. Since the stator 3 is integrally positioned with the rotating electrical machine case 4 by being molded as a part of the mold and being molded with the resin, the stress generated in the resin mold 13 is small compared to the case of the concavo-convex portion, which is advantageous in terms of strength. A reliable restrained state in the circumferential direction can be obtained.

  (10) Since the polygonal inner surface 21 of the rotating electrical machine case 4 has the number of side surfaces 21a, 21b, 21c,... Corresponding to the number of stator cores 11 around which the stator coil 12 is wound, the stator coil 12 serving as a heat source. And the rotating electrical machine case 4 are close to each other via the side surfaces 21a, 21b, 21c,..., And the stator cooling performance can be improved.

  As mentioned above, although the stator structure of the disk type rotating electrical machine of the present invention has been described based on the first to fifth embodiments, the specific configuration is not limited to these embodiments, and the scope of the claims is as follows. Design changes and additions are allowed without departing from the spirit of the invention according to each claim.

  For example, in Examples 1 to 5, as an uneven portion provided on the inner surface of the case, an example in which the displacement of the stator is reliably restrained by having a configuration having opposing surfaces in the circumferential direction or the axial direction or both, Not only the shape of the inner surface of the case but also the roughness of the inner surface of the case (for example, knurl processing) may be used, or the same effect can be obtained by driving a pin into the inner surface of the case. In short, as long as the resin mold is restrained in at least one of the axial direction and the circumferential direction with respect to the inner surface of the case, the specific means is not limited to the first to fifth embodiments.

  In Examples 1-5, although the example which provides the cooling gallery in which a cooling medium exists in the case wall which a resin mold contacts was shown, a refrigerant path may be formed in the convex part provided in the case inner surface. Compared to the cooling gallery in the case wall, better cooling performance can be obtained.

  In Example 4, although the example which has a positioning means between a stator core and a case was shown, you may make it have a positioning means between a stator core and a shaping | molding die.

  In the first to fifth embodiments, as an example of the disk-type rotating electrical machine, an example in which an axial air gap is provided between the rotor and the stator has been described. However, for example, only an oil film exists between the rotor and the stator. The present invention can also be applied to a disk-type rotating electrical machine in which there is substantially no air gap.

  In the first to fifth embodiments, a disk-type rotating electrical machine is described. However, it may be applied as a disk-type motor or a disk-type generator. In the first to fifth embodiments, application examples of a two-rotor / one-stator and a one-rotor / one-stator disk-type rotating electrical machine have been described. The present invention can also be applied to a disk type rotating electrical machine having a number different from that of the embodiment.

1 is an overall cross-sectional view showing a disk-type rotating electrical machine to which a stator structure of Example 1 is applied. It is a partial cross section figure which shows the stator to which the stator structure of the disk type rotary electric machine of Example 1 was applied. It is a figure which shows the whole cross section and stator partial cross section of the disk type rotary electric machine to which the stator structure of Example 2 was applied. It is a whole sectional view showing a disk type rotating electrical machine to which the stator structure of Example 3 is applied. It is a partial cross section figure which shows the stator to which the stator structure of the disk type rotary electric machine of Example 3 was applied. It is a figure which shows the whole cross section of the disk type rotary electric machine to which the stator structure of Example 4 was applied, and a resin mold molding state. It is a partial cross section figure which shows the stator to which the stator structure of the disk type rotary electric machine of Example 5 was applied.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Rotating shaft 2 Rotor 3 Stator 4 Rotating electrical machine case 5 1st bearing 6 2nd bearing 8 Rotor base 9 Permanent magnet 10 Air gap 11 Stator core 12 Stator coil 13 Resin mold 14 Restraint square convex part (concavo-convex part)
15 Cooling gallery 16 Restraint square recess (concave part)
17 Constrained T-shaped convex part (concave part)
18 Square convex part with constraining holes (concave part)
19 Positioning pin (Positioning means)
20 Molding die 21 Polygonal inner surface 21a, 21b, 21c Side surface

Claims (9)

A rotor with permanent magnets,
A stator disposed on the axial direction side with respect to the permanent magnet, and having a stator core and a stator coil;
A cylindrical outer case made of metal having better thermal conductivity than resin;
Have
The stator core has a flat surface at a position facing the inner periphery of the outer case,
The outer peripheral case has a protruding portion that protrudes toward the inner peripheral side of the outer peripheral case at a position facing the flat portion on the inner peripheral side of the outer peripheral case, and the tip of the protruding portion has a flat shape. ,
Around the stator wrapped by a resin molding by the resin, the disc-type rotary electric machine, characterized by constraining the resin molding to the outer circumferential inner surface of the case. In the disk-type rotating electrical machine according to claim 1,
The protrusion, in axial and circumferential direction, the disc-type rotary electric machine characterized by having a facing surface to restrain the resin mold to the inner surface of the outer peripheral casing. Oite the disc-type rotary electric machine according to claim 2,
The protrusion, the disc-type rotary electric machine, which is a constraint rectangular protrusion sectional rectangular shape. Oite the disc-type rotary electric machine according to claim 2,
The protrusion, the disc-type rotary electric machine, characterized in that the restraint rectangular recess sectional rectangular shape, a combination of T-shaped cross-section of the restricted T Tokitotsu unit. Oite the disc-type rotary electric machine according to claim 2,
The protrusion is a cross-sectional rectangular shape, and a disk-type rotary electric machine, which is a square with convex portions restraining bore having an axial to the through hole. Oite the disc-type rotary electric machine according to claim 1,
The stator has a polygonal inner surface that contacts the resin mold, a stator core around which a stator coil is wound is disposed, and the outer peripheral case is part of the molding, and is resin molded. disc-type rotary electric machine, characterized in that positioned integrally with the stator to the case by. Oite the disc-type rotary electric machine according to claim 6,
Polygonal inner surface of said case, disk-type rotary electric machine, characterized in that it has a side surface of the number corresponding to the number of stator core wound stator coils. Oite the disc-type rotary electric machine according to any one claims 1 to 7,
The stator core and the outer peripheral casing or a disk-type rotary electric machine, characterized in that it comprises a positioning means between the stator core and the shaping mold. Oite the disc-type rotary electric machine according to any one claims 1 to 8,
Disc-type rotary electric machine, wherein a stator core wrapped by the resin mold has a cooling gallery abuts casing position.

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