JP4522901B2 - Rotating electric machine and manufacturing method thereof - Google Patents

Description

  The present invention relates to a rotating electrical machine and a method for manufacturing the same.

  As a conventional rotating electrical machine, for example, as described in Patent Document 1, a three-phase distributed winding type is known.

JP 2002-51489 A

  As means for increasing the output of the rotating electrical machine, two types of increase in current and increase in voltage can be considered. However, in order to flow a large current, it is necessary to increase the wire diameter of the stator coil. To obtain a desired number of windings (number of turns), it is necessary to increase the slot of the stator core. As a result, the subject that the physique of a rotary electric machine enlarges arises. On the other hand, when the voltage is increased, the voltage applied to the stator coil is increased, so that it is necessary to improve the insulation resistance between the windings (coils). For example, it is conceivable to increase the thickness of an insulating material (enamel or the like) coated on the surface of a conductor such as copper to improve the insulation resistance. However, in this case, the coil becomes thick. As a result, the subject that the physique of a rotary electric machine enlarges arises. As described above, each of the means has a problem that the physique of the rotating electrical machine increases in size as the winding specification is changed.

  The present invention provides a rotating electrical machine capable of improving the dielectric strength of a winding against a voltage without changing the specifications of the winding.

  Moreover, this invention provides the manufacturing method of the said rotary electric machine.

  The basic feature of the present invention is that the winding of the winding is formed by winding the winding conductor a plurality of times so that the combined capacitance between the winding conductors in the winding mounted on the iron core is increased. The conductor is attached to the iron core.

  According to the present invention, since the winding conductors of the windings are mounted on the iron core so that the synthesis of the capacitance between the winding conductors is increased, the insulation of the windings against the voltage can be achieved without changing the specifications of the windings. Yield can be improved. Therefore, according to the present invention, it is possible to achieve a high output of the rotating electrical machine with a physique comparable to the conventional one. It is particularly suitable for a rotating electrical machine that is driven by an inverter device and in which an excessive surge voltage is applied to the winding from the inverter device.

  Hereinafter, representative best embodiments of the present invention will be listed.

A stator in which three-phase stator coils are wound in distributed winding on the salient poles of the stator core, and is rotatably supported opposite to the stator, and a plurality of permanent magnets are equally spaced in the circumferential direction. A rotating electrical machine comprising a rotor arranged, wherein the stator coil divides one stator coil into N (N = 2, 3, 4) groups, and the number of windings in each group is the same. Alternatively, the number of windings of the first group is wound on the winding frame with a gap of ((N−1) · P) with respect to the thickness P of the conducting wire. When finished, the second group of windings is wound so as to be adjacent to the first group of windings between the gaps, and when N = 3 or more, the gaps are further inserted into the gaps. The next group of windings were wound adjacent to the previous group of windings, aligned in one layer and wound on a reel. A rotating electrical machine stator inserted into a stator core slot of the stator to constitute a stator coil, and a rotor rotatably supported by being arranged opposite to the circumferential surface of the stator via a gap. The stator includes a stator core and a stator coil wound around the stator core in a distributed winding, and the stator core has a plurality of axially continuous slots formed in the circumferential direction; The stator coils are divided into N (N = 2, 3, 4) groups, and the number of windings in each group is the same or substantially the same, and the first group of windings is wound. On the frame, it is wound with a gap of ((N-1) · P) with respect to the thickness P of the conducting wire, and when the winding of the first group is finished, it is folded back and between the gaps, Adjacent to the first group of windings In this manner, the second group of windings is wound. When N = 3 or more, the next group of windings is further wound adjacently to the previous group of windings in the gap. A rotating electrical machine in which a stator coil is configured by aligning the layers and winding them around a winding frame, and then inserting them into slots in the stator core of the stator.

  A stator in which three-phase stator coils are wound in distributed winding on the salient poles of the stator core, and is rotatably supported opposite to the stator, and a plurality of permanent magnets are equally spaced in the circumferential direction. A method of manufacturing a rotating electrical machine comprising a rotor arranged, wherein one stator coil is divided into N (N = 2, 3, 4) groups, and the number of windings in each group is the same or substantially the same. Using the automatic winding machine, the first group of windings are wound on the winding frame with a gap of ((N−1) · P) with respect to the thickness P of the conducting wire, When the winding of the first group is completed, the second group of windings is wound so as to be adjacent to the first group of windings between the gaps, and when N = 3 or more, Further, the next group of windings are wound adjacent to the previous group of windings in the gap, aligned in one layer, and placed on the reel. After turning, using an automatic insertion machine, it is inserted in the slot of the stator core of the stator, the manufacturing method of a rotating electric machine so as to wind the stator coils to the stator core.

  Embodiments of the present invention will be described below with reference to FIGS.

  Initially, the structure of the rotary electric machine of 1st Example is demonstrated using FIG.1 and FIG.2.

  In the first embodiment, the rotating electric machine for driving the vehicle that constitutes the driving source of the vehicle together with the engine that is the internal combustion engine is mounted on the hybrid vehicle, and the DC power supplied from the battery that is the in-vehicle power source is converted into AC power. A rotating electric machine driven by an inverter device having a rotor with a built-in permanent magnet, the number of magnetic poles of the rotor being 8 poles, and the number of slots of the stator being 48. An example of a synchronous machine in which is used will be described.

  In an electric vehicle such as a hybrid vehicle, a synchronous machine having a permanent magnet built-in rotor and driven by an inverter device is advantageous in terms of high output and field weakening control. In this synchronous machine, in order to increase the output by increasing the voltage, the key technology is to improve the insulation resistance of the winding against the surge voltage generated during the cross current conversion operation of the inverter device.

  The configuration of the stator described below can be applied not only to the synchronous machine but also to an induction machine.

  1 and 2 are cross-sectional views showing the configuration of the rotating electrical machine of the first embodiment. FIG. 1 shows a cross-sectional shape in the direction of the rotating shaft, and FIG. 2 shows a cross-sectional shape in the direction orthogonal to the rotating shaft direction. Yes. 1 and 2 and other drawings, the same reference numerals indicate the same components.

  As shown in FIG. 1, the rotating electrical machine of the first embodiment includes a stator 10 and a rotor 20 that is disposed on the inner peripheral side of the stator 10 via a gap and is rotatably supported. The stator 10 and the rotor 20 are held in a housing 30 of a rotating electrical machine.

  The stator 10 includes a stator core 12 and a stator coil 14. The stator core 12 is formed by laminating thin steel plates into a predetermined shape by press molding. The stator core 12 is composed of an annular yoke core and a plurality of tee scores that protrude in the radial direction from the stator core and are arranged at equal intervals in the circumferential direction. The yoke core and the tee score are integrally formed. In the inner peripheral portion of the stator core 12, the inner peripheral surface side of the stator core 12 is opened, and a plurality of slots that are continuous in the axial direction are formed. This slot is a groove-shaped space portion formed between teascores adjacent in the circumferential direction. In this embodiment, 48 slots are formed. The stator coil 14 is distributed winding and wound around the tee score of the stator core 12. Here, the distributed winding is a winding method in which the coil is wound around the stator core 12 so that the coil is housed in two slots that are spaced apart across (or sandwiching) a plurality of slots.

  The stator coil 14 is composed of a U-phase stator coil wound continuously while laminating coil conductors, a V-phase stator coil, and a W-phase stator coil. The stator coil 14 is pre-wound around the winding frame in a predetermined order using an automatic winding machine, and then inserted into the slot from the entrance of the slot of the stator core 14 using an automatic insertion machine. It is rolled up. Stator coil 14 is inserted into the slot in the order of a U-phase stator coil, a V-phase stator coil, and a W-phase stator coil. The winding order of the stator coil 14 will be described later with reference to FIG. Coil end portions of the stator coil 14 protrude in both axial directions from the slots and are disposed on both axial end surfaces of the stator core 12.

  The rotor 20 includes a rotor core 22, a permanent magnet 24, and a shaft 26. The rotor core 22 is formed by laminating thin steel plates into a predetermined shape by press molding and fixing them to the shaft 26. A plurality of magnet insertion holes penetrating in the axial direction of the rotor 20 are formed in the outer circumferential portion of the rotor core 22 at equal intervals in the circumferential direction. In this embodiment, eight magnet insertion holes are formed. A permanent magnet 24 is inserted and fixed in each of the permanent magnet insertion holes. The shaft 26 is rotatably supported by end brackets 32F and 32R fixed to both sides of the housing 30 by bearings 34F and 34R.

  Next, as shown in FIG. 2, the rotor 20 is supported inside a stator 10 by a housing (not shown) so as to be rotatable. The stator coil 14 has three phases of U phase, V phase, and W phase, and there are eight for each phase, for a total of 24 stator coils U1, U2, ..., U8, V1, V2, ..., V8, W1, and so on. It consists of W2, ..., W8. Each stator coil, for example, the stator coil U1, has four slots between which other V-phase and W-phase coils are inserted, that is, in slots that are separated from each other so as to straddle the salient poles of the plurality of stator cores 12. And wound around the salient poles of the stator core 12. The salient pole of the stator core 12 indicates a core portion formed between slots adjacent in the circumferential direction. In addition, other U-phase coils, V-phase coils, and W-phase coils are also inserted into slots that are spaced apart from each other so as to straddle the salient poles of the plurality of stator cores 12 across four slots in which coils of other phases enter. Thus, distributed winding is wound around the salient poles of the stator core 12. Since it is a distributed winding configuration, it is possible to control not only a low rotational speed but also a wide rotational speed range up to a high rotational speed by utilizing field weakening control and reluctance torque.

  .., U8, V1, V2,..., V8, W1, W2,..., W8 are connected to each other by a connection ring indicated by a dotted line. Thereby, the U-phase, V-phase, and W-phase coils are Y-connected. A connection ring is comprised using the bus bar which consists of a thin plate-shaped conductor, and supplies the three-phase alternating current supplied from an inverter apparatus to the said phase coil. In place of the Y connection, a delta connection can be performed by a connection coil.

  Eight permanent magnets 24 are respectively inserted into permanent magnet insertion holes provided in the rotor core 22 of the rotor 20. The permanent magnets 24 are arranged at equal intervals in the circumferential direction of the rotor core 22. The permanent magnet 24 is magnetized so that the polarities (N pole and S pole) of adjacent permanent magnets are opposite to each other in the circumferential direction of the rotor. The region of the rotor core 22 between adjacent permanent magnets functions as an auxiliary magnetic pole. The auxiliary magnetic pole is a region that bypasses the magnetic circuit of the permanent magnet 24 and causes a magnetic flux to act directly on the stator 10 side by the magnetomotive force of the stator 10 to generate reluctance torque. The torque generated by the rotating electrical machine can be obtained as a combined torque of the torque generated by the magnetic flux of the permanent magnet 24 and the reluctance torque generated by the magnetic flux flowing through the auxiliary magnetic pole.

  In addition, in the permanent magnet insertion hole for inserting the permanent magnet 24, magnetic gap portions (slit portions) AG1, AG2 are provided at both ends in the circumferential direction of the insertion position of the permanent magnet 24. The void portion may be a void in which air exists or may be filled with a filler such as varnish. Since the magnetic permeability of the varnish is smaller than the magnetic permeability of the silicon steel plate constituting the rotor core 22, a sudden change in the magnetic flux density on the rotor surface is mitigated by providing a gap (the circumferential end of the permanent magnet and the auxiliary magnetic pole). The cogging torque can be reduced by making the gradient of the distribution of the magnetic flux density part of the permanent magnet gentle. Furthermore, since the magnetic gap is formed, the radial dimension of the bridge portion formed at the boundary between the iron core portion (magnetic pole piece) existing on the stator side of the permanent magnet and the auxiliary magnetic pole can be reduced. , Leakage magnetic flux can be reduced.

  Next, the connection state of the stator coil in the rotating electrical machine of the first embodiment will be described with reference to FIG.

  FIG. 3 is a connection diagram of stator coils in the rotating electrical machine of the first embodiment. Note that the same reference numerals in FIG. 3 and other drawings indicate the same components.

  As shown in FIG. 3, the U-phase stator coil U, the V-phase stator coil V, and the W-phase stator coil W of the stator coil 14 are Y-connected. Looking at the U-phase stator coil U, the two stator coils U1 and U2 are connected in series. Further, two other coils U3 and U4, U5 and U6, U7 and U8 are connected in series, respectively, and these four series-connected coil groups are arranged in parallel. That is, the U-phase stator coil U is connected in 2 series and 4 parallel. Similarly, for the V-phase stator coil V and the W-phase stator coil W, the stator coils V1, V2,..., V8 and W1, W2,. . For example, the AC voltage Vin is supplied from the power source to the series circuit of the U-phase stator coil U and the V-phase stator coil V. Similarly, the AC voltage Vin is supplied from the power source to the series circuit of the V-phase stator coil V and the W-phase stator coil W or the series circuit of the W-phase stator coil W and the U-phase stator coil U. The AC voltage supplied to the series circuit of U-phase stator coil U and V-phase stator coil V, the AC voltage supplied to the series circuit of V-phase stator coil V and W-phase stator coil W, and W-phase The AC voltage supplied to the series circuit of the stator coil W and the U-phase stator coil U is 120 degrees out of phase in electrical angle.

  Next, the voltage applied to each coil of the rotating electrical machine will be described with reference to FIGS.

  FIG. 4 is a schematic circuit diagram of a stator coil in the rotating electrical machine. FIG. 5 is a waveform diagram of a voltage that is orthogonally transformed and applied to the stator coil. FIG. 6 is an equivalent circuit of the stator coil. FIG. 7 is an explanatory diagram of the ground potential en when a pulse voltage is applied to the coil.

  As described with reference to FIG. 3, the AC voltage Vin is supplied from the power source to the series circuit of the 2-series and 4-parallel U-phase stator coil U and the 2-series and 4-parallel V-phase stator coil V. Therefore, when considering the voltage applied to each coil, if this series circuit is simplified, as shown in FIG. 4, a circuit in which four coils U1 ′, U2 ′, V1 ′, V2 ′ are directly connected is provided. Can be replaced. An AC voltage Vin is supplied to both ends of the four series circuits.

  Next, the waveform of the AC voltage Vin described with reference to FIG. 4 will be described with reference to FIG.

  In an electric vehicle, an output voltage of a generator driven by an internal combustion engine is converted into a DC voltage and then temporarily stored in a battery or the like. Therefore, the AC voltage supplied to the rotating electrical machine is obtained by converting a DC voltage into an AC voltage using a power conversion circuit such as an inverter. When a DC voltage is converted into an AC voltage using such a power conversion circuit, a voltage waveform as shown in FIG. 5 is obtained.

  That is, as shown in FIG. 5, when the voltage rises, the output of the power conversion circuit generates a surge voltage with a voltage peak value of voltage V1 + V2 due to the influence of the switching operation of the semiconductor switching element constituting the power conversion circuit, Thereafter, the desired voltage value V1 is obtained. For example, when the voltage value V1 is 500 Vrms, the peak value V1 + V2 of the surge voltage is a high voltage of 1300 V or more. On the other hand, the time T during which the surge voltage V1 + V2 lasts is as short as several μs, for example. The rise time of the surge voltage is, for example, several hundred ns. That is, although the peak value of the surge voltage is high, it is a short time, and therefore, by adopting a structure that does not cause dielectric breakdown against this surge voltage, the thickness of the insulation coating such as enamel coating is not increased. Surge characteristics can be improved.

  Next, the voltage applied to each coil when the aforementioned surge voltage is supplied to the four series circuit of the stator coils shown in FIG. 4 will be described with reference to FIGS.

  First, as shown in FIG. 6, a case where one end of the four series-connected coils shown in FIG. 4 is grounded and a voltage is applied from the other end will be described. Each winding for one turn of the coil has a ground capacitance Cg between the coil and the ground. Further, an interwinding capacitance Cc exists between adjacent windings of one turn.

Here, assuming that the combined capacitance of the plurality of ground capacitances Cg is C1, the ground combined capacitance C1 is obtained from the following equation (1):

C1 = ΣCg (i) (1)

As required. Here, i is 1 to n, and n is the total number of ground capacitances Cg.

Similarly, assuming that the combined capacitance of the plurality of interwinding capacitors Cc is C2, the interwinding combined capacitance C2 is obtained from the following equation (2):

C2 = 1 / ΣCc (i) (2)

As required. Here, i is 1 to n, and n is the total number of interwinding capacitances Cc . That is, it can be thought of as an LC circuit comprising the reactance L of the coil itself, the ground combined capacitance C1, the interwinding combined capacitance C2, and the ground capacitance C0 at the end of the coil.

  Here, assuming that a pulsed voltage Vp (corresponding to a surge voltage) as shown in the figure is applied from the open end of the coil, the coil has a reactance L of the coil, a ground synthetic capacitance C1, and a winding. It operates as a delay circuit composed of the line-to-line combined capacitance C2.

Therefore, the number of windings as a whole of the coil is N, and the voltage en at the n-th position, counted from the ground side, is expressed by the following equation (3)

en = (cos h (α · (n / N)) + ( C0 / (√ ( C1 · C2 ) ) )) sin h (α · (n / N))) / (cos hα + (C0 / (√ ( C1 ・ C2 ) ) ・ sin hα))… (3)

As required. Here, α = (√ (C1 / C2)), and sin h (x) and cos h (x) are hyperbolic functions.

  For the voltage en at the n-th position, the horizontal axis is the n-th position n, the V-phase is grounded and C0 = ∞, and α is changed to obtain the n-th position according to α. The voltage en is as shown in FIG.

  Here, when four coils are connected in series, the voltage applied to each coil becomes the highest on the voltage input end side of the four series circuit. For example, when α = 4, the shared voltage ΔV1 of the first coil is applied to the first coil (n / N = 75% position) counted from the input end side, whereas the input coil side The second coil's shared voltage ΔV2 is applied to the second coil, and ΔV1> ΔV2 as understood from the figure.

  Further, as α is smaller, the voltage ΔV1 applied to the first coil counted from the input end side becomes smaller. Assuming that the total applied voltage is 100%, the sharing voltage ΔV1 of the first coil when α = 4 is about 60%, whereas the sharing voltage ΔV1 of the first coil when α = 12. 'Is about 95%. That is, ΔV1 <ΔV1 ′.

  Therefore, even when a surge voltage of 1300 V or more is applied to the 4 series circuit, by reducing α, even when it is covered with an insulation coating such as enamel coating having the same film thickness as the conventional one, Insulation resistance can be improved.

  As described with reference to FIG. 6, the stator coil is considered as an LC circuit comprising the reactance L of the coil itself, the ground combined capacitance C1, the interwinding combined capacitance C2, and the ground capacitance C0 at the end of the coil. Among them, the reactance L of the coil itself, the ground capacitance C1 and the ground capacitance C0 at the end of the coil are constant values, but the present inventors change the winding configuration of the stator coil. Thus, focusing on the fact that the inter-winding combined capacitance C2 can be changed, in order to reduce α, the winding configuration is such that the inter-winding combined capacitance C2 increases.

  Next, the winding configuration of the stator coil in the rotating electrical machine of the first embodiment will be described with reference to FIGS. In the following description, the number of windings of one stator coil, for example, the stator coil U1, is assumed to be 12T.

  FIG. 8 is an explanatory diagram of a winding method of the stator coil in the rotating electrical machine of the first embodiment. FIG. 9 is a layout diagram of windings when the stator coil is wound in the rotating electrical machine of the first embodiment. FIG. 10 is an explanatory diagram of capacitance in a conventional stator coil. FIG. 11 is an explanatory diagram of the electrostatic capacity of the stator coil in the rotating electrical machine of the first embodiment.

  In the first embodiment, the winding of one stator coil is divided (grouped) into two winding groups in units of continuous winding order of winding conductors, and then a winding frame is formed using an automatic winding machine. It is wound around the VL for a predetermined number of turns while being continuously and folded back (2 divided winding = 1 reciprocating winding). That is, in the first embodiment, if the number of windings of one stator coil is 12T, the first winding group from 1T to 6T is different from the second winding group from 7T to 12T. The winding method is adopted. In the conventional method, winding is performed in order from 1T to 12T.

  That is, first, as shown in FIG. 8 (A), the conductive wire VL insulated and coated with an enamel film or the like is sequentially applied to the winding frame VF in the same direction (R direction) using an automatic winding machine. Wind for 6T. At this time, if the thickness of the conducting wire VL is P, winding is sequentially performed with a gap of P between adjacent windings. That is, the winding pitch is 2P, and winding is performed from 1T to 6T as shown in FIG.

  Then, when the winding for 6T is completed, it is folded back at the 6T, and as shown in FIG. 8B, the gap formed in the same winding direction and between the 1T to 6T windings Then, the remaining 7T to 12T are wound. As a result, as shown in FIG. 9, the coils are arranged in a single layer in the order of 1T, 12T, 2T, 11T,..., 8T, 6T, and 7T. Here, the winding wound around the winding frame cannot be inserted when the wound winding is inserted into the slot by an automatic insertion machine unless it is aligned in a single layer state. This is because the width of the slot entrance is slightly wider than the width of a single winding, so if it has two or more layers, the automatic insertion machine cannot insert the winding into the slot. is there. In addition, in the winding method using the conventional automatic winding machine, the winding is arranged in the order of 1T-2T-3T -...- 11T-12T.

  Note that the aligned portions of the windings in FIG. 9 are portions that are shifted by 90 ° in the circumferential direction from the portions where the windings of the winding frame intersect.

  Next, with reference to FIGS. 10 and 11, the capacitance of the coils wound in an aligned manner will be described. FIG. 10 shows a case of winding in order from the first T according to the conventional method, and FIG. 11 shows a case of winding by the method of the first embodiment described in FIGS. 8 and 9. . Further, here, in order to simplify the description, the number of windings of one coil will be described as 6T.

  In the conventional method, as shown in FIG. 10, in the case of a 6T coil, the interwinding capacitance Cc is between 1T and 2T, between 2T and 3T, and between 3T and 4T. , 4T-5T, 5T-6T, and these are connected in series. Therefore, the combined capacitance C2 between the windings is ((1/5) · Cc) because the combined capacitance Cc between the five windings connected in series is combined.

  On the other hand, in the system of the first embodiment, as shown in FIG. 11A, in the case of a 6T coil, the interwinding capacitance is between 1T and 6T and between 2T and 6T. , 2T-5T, 3T-5T, 3T-4T are formed. When FIG. 11A is developed, it becomes as shown in FIG. 11B, and the five interwinding capacitances Cc are connected in parallel. Therefore, the inter-winding combined capacitance C2 is obtained by synthesizing the five inter-winding capacitances Cc connected in parallel, and thus becomes (5 · Cc). The electric capacity can be increased.

  In this way, as shown in FIGS. 8 and 9, the winding of one stator coil is divided into two winding groups and then wound sequentially around the winding frame VL (two-division winding = 1). When the conducting wires of the first winding group are wound together with the reciprocating winding, the windings are sequentially wound with a gap corresponding to the winding thickness P between adjacent windings. Further, when winding the second winding group, the winding is sequentially wound so as to fill (or complement) the gap formed between the first winding groups. By adopting such a winding method, the combined capacitance C2 between the windings can be increased and α in the equation (3) can be reduced. Therefore, as described with reference to FIG. 7, the shared voltage ΔV1 of the first coil Can be reduced. Therefore, even if the surge voltage of the inverter is supplied to both ends of the stator coil composed of four series coils, the voltage sharing of the first coil can be reduced, so that the enamel coating having the same film thickness as before is applied. Even if a conductive wire is used, breakdown can be prevented.

  Next, the state of the stator coil inserted into the slot of the stator core will be described with reference to FIG. 12A shows the state of insertion into the slot when the winding method according to the first embodiment is used, and FIG. 12B shows the state when the winding method according to the conventional method is taken. The insertion state of is shown.

  FIG. 12 is a layout diagram of the windings in the slots of the stator coil in the rotating electrical machine of the first embodiment.

  As shown in FIGS. 8 and 9, in the first embodiment, the first group and the second group are divided and wound around the winding frame. Between the 1T and 2T, the 12T Comes to be located. When one layered coil wound automatically in this way is inserted into the slot of the stator core using an automatic insertion machine, it is inserted in the order of the windings on the winding frame as shown in FIG. . As a result, the winding start 1T and winding end 12T are arranged at adjacent positions. That is, the winding conductors are disposed in the slots so that different groups of winding conductors are adjacent to each other. Since the coil winding start and winding end must be electrically connected to the outside of the rotating electrical machine using a connection ring or the like, the winding start 1T and the winding end 12T are adjacent to each other. Since it can arrange | position in the position which performs, a connection process becomes easy.

  On the other hand, FIG. 12 (B) shows a state in which after winding from the 1T to the 12T in order, it is inserted into the slot by an automatic insertion machine, and the 1T at the beginning of winding and the 12T at the end of winding. The eyes are arranged at a distant position.

  In the above description, the number of windings of one stator coil has been described as 12T, but the number of windings is actually larger. For example, in the case of 44T, the number of windings of the first group and the second group is set to 22T, respectively, and the 1st to 22Tth groups of the first group have a gap corresponding to the thickness of the conductor between them on the reel. After the winding, the second group 23T to 44T is wound in order between the windings of the first group. The number of windings is not limited to an even number, and when the number of windings of one stator coil is 43T, the number of windings of the first group is 22T, the number of windings of the second group is 21T, The first group of 1T to 22T is wound around a winding frame with a gap corresponding to the thickness of the conducting wire in between, and the second group of 23T to 43T is between the windings of the first group. Wind in order.

  As described above, according to the first embodiment, one stator coil is divided into two groups, and the second group of windings is arranged between the first group of windings in one layer. After being aligned and wound on a reel, it is inserted into a slot of the stator core to form a stator coil, so that the surge voltage of the inverter was applied to the stator coil consisting of four series coils. Even in this case, the shared voltage of the first coil can be reduced, and dielectric breakdown can be prevented. Therefore, the insulation resistance against the surge voltage of the inverter is improved, and the output can be increased with the same external dimensions as the conventional one.

  Further, the winding start and the winding end of the stator coil can be adjacent to each other, and the connection work can be easily performed.

  Next, the configuration of the rotating electrical machine of the second embodiment will be described with reference to FIGS. In addition, the whole structure of the rotary electric machine of 2nd Example is the same as that shown in FIG.1 and FIG.2.

  FIG. 13 is an explanatory diagram of a stator coil winding method in the rotating electrical machine of the second embodiment. FIG. 14 is a layout diagram of windings when the stator coil is wound in the rotating electrical machine of the second embodiment. FIG. 15 is an explanatory diagram of capacitance in a stator coil in the rotating electrical machine of the second embodiment.

  In the second embodiment, the description will be made assuming that the number of windings of one stator coil, for example, the stator coil U1, is 12T in the same manner as described with reference to FIGS.

  In the second embodiment, the winding of one stator coil is divided into three winding groups and then wound around the winding frame VL using an automatic winding machine (3 divided windings = 1 reciprocal half) Winding). That is, in the second embodiment, if the number of windings of one stator coil is 12T, the first winding group from 1T to 4T, the second winding group from 5T to 8T, and 9T to The third winding group up to 12T has a different winding method.

  That is, first, as shown in FIG. 13 (A), the conductive wire VL insulated and coated with an enamel film or the like is sequentially applied to the winding frame VF in the same direction (R direction) using an automatic winding machine. Wind 4T minutes. At this time, if the thickness of the conducting wire VL is P, the winding is sequentially performed with a gap of 2P between adjacent windings. That is, the winding pitch is 3P, and winding is performed from 1T to 4T as shown in FIG.

  When the winding for 4T is completed, it turns back at the 4T, and as shown in FIG. 13B, in the same winding direction and between the 1T to 4T windings, The 5th to 8T windings of the second group are wound in a state adjacent to the 1T to 4T windings and leaving a gap for one winding.

  Further, when the winding for 8T is completed, it is folded back at the 8th T, and as shown in FIG. 13C, in the same winding direction, the 1T to 4T winding and the 5T to 8T In the meantime, the 9th to 12th T members of the third group are wound.

  As a result, as shown in FIG. 14, the coils are arranged in a single layer in the order of 1T, 8T, 9T, 2T, 7T,..., 4T, 5T, and 12T.

  Further, when the second winding frame VF2 is provided and the first stator coil and the second stator coil are connected in series (when connected in series like the stator coil U1 and the stator coil U2 in FIG. 3). Then, the second stator coil is wound around the second winding frame VF2 in the same manner as the procedure shown in FIGS. 13 (A) to 13 (C).

  Next, with reference to FIG. 15, the capacitance of the coils wound in an aligned manner will be described. Here, in order to simplify the description, and in order to be able to compare with FIGS. 10 and 11, the number of windings of one coil is described as 6T.

  In the conventional method, as described in FIG. 10, the inter-winding combined capacitance C2 is a combination of five inter-winding capacitances Cc connected in series. 5) · Cc).

  On the other hand, in the system of the second embodiment, as shown in FIG. 15, in the case of a 6T coil, the interwinding capacitance is between 1T and 4T, between 2T and 5T, and at 2T. Five pieces are formed between the -3T, the 4T-5T, and the 3T-6T. Therefore, since two circuits in which two Cc are connected in series and one Cc are arranged in parallel, the inter-winding combined capacitance C2 is (2 · Cc), The combined capacitance between windings can be increased as compared with the prior art.

  As described above, the winding of one stator coil is divided into three winding groups, and then sequentially wound around the winding frame VL (three divided windings = one reciprocating half winding), and the first winding. When winding the conducting wires of the group, the winding is sequentially performed with a gap corresponding to twice the thickness P of the winding between the adjacent windings. Further, when the second winding group is wound, the winding is sequentially wound adjacent to the first winding group in a gap formed between the first winding groups. Further, the third winding group is wound around the gap between the first group and the second group. By adopting such a winding method, the combined capacitance C2 between the windings can be increased and α in the equation (3) can be reduced. Therefore, as described with reference to FIG. 7, the shared voltage ΔV1 of the first coil Can be reduced. Therefore, even if the surge voltage of the inverter is supplied to both ends of the stator coil composed of four series coils, the voltage sharing of the first coil can be reduced, so that the enamel coating having the same film thickness as before is applied. Even if a conductive wire is used, breakdown can be prevented.

  In the above description, the number of windings of one stator coil has been described as 12T, but the number of windings is actually larger. For example, in the case of 42T, the number of windings of the first group, the second group, and the third group is 14T, respectively, and the 1st to 14Tth groups of the first group are twice the thickness of the conductor. After winding around the winding frame with a gap, the second group 15T to 28T are wound around the gap in order adjacent to the first group of windings. Further, the 29th to 44Tth members of the third group are wound in order in the gap between the windings of the first and second groups. Further, the number of windings is not limited to a multiple of 3, and when the number of windings of one stator coil is 43T, the number of windings of the first group is 15T, and the windings of the second group and the third group are set. The number of wires is 14T, and the 1st to 15th T members of the first group are wound around a reel with a gap corresponding to twice the thickness of the conductive wire between them, and then the 16th to 29T members of the second group are The windings are made in order, with a gap between them adjacent to the first group of windings. Further, the 30th to 43Tth groups of the third group are wound in turn between the windings of the first group and the second group.

  As described above, according to the second embodiment, one stator coil is divided into three groups, and the second group and third group windings are arranged between the first group windings. Since the stator coil is configured by being inserted into a slot of the stator core after being aligned in one layer and wound on a winding frame, the surge voltage of the inverter is added to the stator coil consisting of four series coils. Even when is applied, the shared voltage of the first coil can be reduced, and dielectric breakdown can be prevented. Therefore, the insulation resistance against the surge voltage of the inverter is improved, and the output can be increased with the same external dimensions as the conventional one.

  Further, when winding the two stator coils connected in series, the second winding can be easily performed using the second winding frame after the first winding.

  Next, the configuration of the rotating electrical machine of the third embodiment will be described with reference to FIG. The overall configuration of the rotating electrical machine of the third embodiment is the same as that shown in FIGS.

  FIG. 16 is a layout diagram of windings when winding a stator coil in the rotating electrical machine of the third embodiment.

  In the third embodiment, the description will be made assuming that the number of windings of one stator coil, for example, the stator coil U1, is 12T in the same manner as described with reference to FIGS. In the third embodiment, the winding of one stator coil is divided into four winding groups and then wound around the winding frame VL using an automatic winding machine (4 divided winding = 2 reciprocating winding). ). That is, in this example, if the number of windings of one stator coil is 12T, the first winding group from 1T to 3T, the second winding group from 4T to 6T, and 7T to 9T. The third winding group and the fourth winding group from 10T to 12T have different winding methods.

  That is, first, as shown in FIG. 16, a conductive wire VL that is insulation-coated with an enamel film or the like is sequentially wound around the winding frame VF by 3T in the same direction using an automatic winding machine. At this time, if the thickness of the conducting wire VL is P, the winding is sequentially performed with a gap of 3P between adjacent windings. That is, the winding pitch is 4P and winding is performed from 1T to 3T as shown in FIG.

  When the winding for 4T is completed, it is turned back at the 3T, and as shown in FIG. 16, in the same winding direction, between the 1T to 3T windings, and from 1T to The 4th to 6th windings of the second group are wound adjacent to the third winding and leaving a gap corresponding to two windings.

  Further, when the winding for 6T is completed, it is turned back at the 6T, and as shown in FIG. 16, in the same winding direction and between the 1T to 3T windings, A third group of 7T to 9T is wound adjacent to the 6T winding and leaving a gap for one winding.

  Further, when the winding for 9T is completed, it is turned back at the 9T, and as shown in FIG. 16, in the same winding direction, and between the 1T to 4T winding and the 7T to 9T, Wind the 10th to 12th T of the fourth group.

  As a result, as shown in FIG. 16, the coils are arranged in a single layer in the order of 1T-6T-7T-12T--3T-4T-9T-102T.

  The inter-winding capacitance of the coils wound in this manner can be increased as compared with the case where the conventional winding from 1T to 12T is sequentially performed.

  As described above, the winding of one stator coil is divided into four winding groups, and then sequentially wound around the winding frame VL (four divided windings = 2 reciprocating windings), and the first winding group When winding the conducting wire, the winding is sequentially performed with a gap corresponding to three times the thickness P of the winding between the adjacent windings. Further, when the second winding group is wound, the winding is sequentially wound adjacent to the first winding group in a gap formed between the first winding groups. Further, when the third winding group is wound, the winding is sequentially wound adjacent to the second winding group in the gap formed between the first winding groups. Further, the fourth winding group is wound around the gap between the first group and the third group. By adopting such a winding method, the combined capacitance C2 between the windings can be increased and α in the equation (3) can be reduced. Therefore, as described with reference to FIG. 7, the shared voltage ΔV1 of the first coil Can be reduced. Therefore, even if the surge voltage of the inverter is supplied to both ends of the stator coil composed of four series coils, the voltage sharing of the first coil can be reduced, so that the enamel coating having the same film thickness as before is applied. Even if a conductive wire is used, breakdown can be prevented.

  In the above description, the number of windings of one stator coil has been described as 12T, but the number of windings is actually larger. For example, in the case of 44T, the number of windings of the first group to the fourth group is 11T, and the 1st to 11th groups of the first group have a gap of three times the thickness of the conductor between them. After winding on the winding frame, the 12th to 24Tth members of the second group are wound in order in the gap adjacent to the windings of the first group. Further, the 25th to 36Tth groups of the third group are wound adjacent to the second group between the first group and the second group of windings. Further, the 37th to 44Tth groups of the fourth group are wound around the gap between the first group and the third group in order. Further, the number of windings is not limited to a multiple of 4, and when the number of windings of one stator coil is 43T, the number of windings of the first group to the third group is 14T, and the winding of the fourth group The number of wires is 13T, and winding is performed as described above.

  As described above, according to the third embodiment, one stator coil is divided into four groups, aligned on one layer, wound on a winding frame, and then inserted into a slot of a stator core. Since the coils are configured, even when the surge voltage of the inverter is applied to the stator coil composed of four series coils, the shared voltage of the first coil can be reduced and the dielectric breakdown can be prevented. Therefore, the insulation resistance against the surge voltage of the inverter is improved, and the output can be increased with the same external dimensions as the conventional one.

  The first embodiment (FIGS. 8, 9, and 11), the second embodiment (FIGS. 13, 14, and 15), and the third embodiment (FIG. 16) can be summarized as follows. The group is divided into N groups (N = 2, 3, 4), and the number of windings in each group is the same or substantially the same (the difference in the number of windings in each group is “1”). First, the first group of windings are wound on the winding frame with a gap of ((N−1) · P) with respect to the thickness P of the conducting wire. When the winding of the first group is completed, the second group of windings are wound around the gap so as to be adjacent to the winding of the first group. In the case of N = 3 or more, the winding of the next group is wound adjacently to the second group in the gap, and is wound around the winding frame aligned in one layer, and then into the slot of the stator core. The stator coil is configured by being inserted.

  Next, the configuration of an electric drive system (fourth embodiment) of a hybrid electric vehicle that is one of electric vehicles using the rotating electric machines of the first to third embodiments will be described with reference to FIG.

  FIG. 17 is a block diagram showing an electric drive system (fourth embodiment) of a hybrid electric vehicle that is one of electric vehicles using the rotating electric machines of the first to third embodiments.

  In the hybrid electric vehicle of the fourth embodiment, the front wheel WH-F is formed by the engine EN, which is an internal combustion engine, and the front motor / generator FMG made of the rotating electrical machine described in the first to third embodiments. The four-wheel drive type is configured such that the rear wheels WH-R are each driven by the rear side motor / generator RMG made of the rotating electric machine described in the first to third embodiments. In this embodiment, the case where the front wheel WH-F is driven by the engine EN and the front side motor / generator FMG and the rear wheel WH-R is driven by the rear side motor / generator RMG will be described. The rear wheel WH-R may be driven by the front side motor / generator FMG made of the rotating electrical machine described in each embodiment, and the front wheel WH-F may be driven by the rear side motor / generator RMG.

  A transmission TM is mechanically connected to the front wheel axle DS-F of the front wheel WH-F via a front side differential FDF. An engine EN and a motor / generator MG are mechanically connected to the transmission TM via an output control mechanism (not shown). The output control mechanism (not shown) is a mechanism that controls composition and distribution of rotation outputs. The AC side of the inverter INV is electrically connected to the stator winding of the front side motor / generator MG. The inverter INV is a power conversion device that converts DC power into three-phase AC power, and controls driving of the motor / generator MG. A battery BA is electrically connected to the DC side of the inverter INV.

  A rear side motor / generator RMG is mechanically connected to the rear wheel axles DS-R1 and DS-R2 of the rear wheel WH-R via a rear side differential RDF and a rear side reduction gear RG. The AC side of the inverter INV is electrically connected to the stator winding of the rear side motor / generator RMG. Here, the inverter INV is common to the front side motor / generator MGF and the rear side motor / generator RMG, and includes a conversion circuit unit for the motor / generator MG, a conversion circuit unit for the rear side motor / generator RMG, and And a drive control unit for driving them. The configuration of the inverter INV will be described later with reference to FIG.

  When the hybrid electric vehicle starts up and travels at a low speed (traveling region in which the operating efficiency (fuel consumption) of the engine EN decreases), the front wheels WH-F are driven by the front motor / generator FMG. In the fourth embodiment, the front wheel WH-F is driven by the front motor / generator FMG at the start of the hybrid electric vehicle and at low speed. However, the front wheel WH-F is driven by the front motor / generator FMG. The rear wheel WH-R may be driven by the rear side motor / generator RMG (four-wheel drive traveling may be performed). The inverter INV is supplied with DC power from the battery BA. The supplied DC power is converted into three-phase AC power by the inverter INV. The three-phase AC power thus obtained is supplied to the stator winding of the front motor / generator FMG. As a result, the front motor / generator FMG is driven to generate a rotational output. This rotational output is input to the transmission TM via an output control mechanism (not shown). The input rotation output is shifted by the transmission TM and input to the differential FDF. The input rotation output is distributed to the left and right by the differential FDF and transmitted to the front wheel axle DS-F on one of the front wheels WH-F and the front wheel axle DS-F on the other of the front wheels WH-F. Thereby, the front wheel axle DS-F is rotationally driven. Then, the front wheels WH-F are rotationally driven by the rotational driving of the front wheel axle DS-F.

  During normal driving of the hybrid electric vehicle (a driving region where the driving efficiency (fuel efficiency) of the engine EN is good when driving on a dry road surface), the front wheels WH-F are driven by the engine EN. For this reason, the rotational output of the engine EN is input to the transmission TM via an output control mechanism (not shown). The input rotation output is shifted by the transmission TM. The shifted rotational output is transmitted to the front wheel axle DS-F via the front differential FDF. Thereby, the front wheel WH-F is rotationally driven. Further, when it is necessary to detect the state of charge of the battery BA and to charge the battery BA, the rotational output of the engine EN is distributed to the front motor / generator FMG via an output control mechanism (not shown). The side motor generator FMG is driven to rotate. Thereby, the front side motor generator FMG operates as a generator. By this operation, three-phase AC power is generated in the stator winding of the front motor / generator FMG. The generated three-phase AC power is converted into predetermined DC power by the inverter INV. The DC power obtained by this conversion is supplied to the battery BA. Thereby, the battery BA is charged.

  During the four-wheel drive driving of the hybrid electric vehicle (when traveling on a low μ road such as a snowy road and the driving efficiency (fuel consumption) of the engine EN is good), the rear wheel WH is driven by the rear motor generator RMG. -R is driven. Further, similarly to the above normal running, the front wheels WH-F are driven by the engine EN. Further, since the amount of power stored in the battery BA decreases by driving the rear side motor / generator RMG, the front side motor / generator FMG is driven to rotate by the rotational output of the engine EN to charge the battery BA, as in the case of the normal running. . In order to drive the rear wheels WH-R by the rear motor generator RMG, DC power is supplied from the battery BA to the inverter INV. The supplied DC power is converted into three-phase AC power by the inverter INV, and the AC power obtained by this conversion is supplied to the stator winding of the rear motor generator RMG. As a result, the rear motor / generator RMG is driven to generate a rotational output. The generated rotation output is decelerated by the rear side reduction gear RG and input to the differential device RDF. The input rotational output is distributed to the left and right by the differential RDF, and the rear wheel axle DS-R1, DS-R2 in one of the rear wheels WH-R and the rear wheel axle DS-R1, in the other of the rear wheels WH-R. Each is transmitted to DS-R2. Thereby, the rear wheel axle DS-F4 is driven to rotate. Then, the rear wheels WH-R are rotationally driven by the rotational driving of the rear wheel axles DS-R1, DS-R2.

  During acceleration of the hybrid electric vehicle, the front wheels WH-F are driven by the engine EN and the front side motor / generator FMG. In the fourth embodiment, the case where the front wheels WH-F are driven by the engine EN and the front side motor / generator FMG during acceleration of the hybrid electric vehicle will be described. However, the front wheels WH are driven by the engine EN and the front side motor / generator FMG. -F may be driven, and rear wheel WH-R may be driven by rear side motor / generator RMG (four-wheel drive traveling may be performed). The rotational outputs of the engine EN and the front side motor / generator FMG are input to the transmission TM via an output control mechanism (not shown). The input rotation output is shifted by the transmission TM. The changed rotational output is transmitted to the front wheel axle DS-F through the differential FDF. Thereby, the front wheel WH-F is rotationally driven.

  During regeneration of a hybrid electric vehicle (when depressing the brake, slowing down the accelerator, or decelerating when the accelerator is stopped), the rotational output of the front wheel WH-F is converted to the front wheel axle DS-F, differential. This is transmitted to the front side motor / generator FMG via the device FDF, the transmission TM, and an output control mechanism (not shown), and the front side motor / generator FMG is rotationally driven. Thereby, the front side motor generator FMG operates as a generator. By this operation, three-phase AC power is generated in the stator winding of the front motor / generator FMG. The generated three-phase AC power is converted into predetermined DC power by the inverter INV. The DC power obtained by this conversion is supplied to the battery BA. Thereby, the battery BA is charged. On the other hand, the rotational output of the rear wheel WH-R is transmitted to the rear side motor generator RMG via the rear wheel axles DS-R1, DS-R2, the differential device RDF of the vehicle output transmission device 100, and the reduction gear RG. The rear motor generator RMG is driven to rotate. Thus, the rear side motor / generator RMG operates as a generator. By this operation, three-phase AC power is generated in the stator winding of the rear side motor / generator RMG. The generated three-phase AC power is converted into predetermined DC power by the inverter INV. The DC power obtained by this conversion is supplied to the battery BA. Thereby, the battery BA is charged.

  According to the electric drive system of the fourth embodiment, even if the output is increased, the insulation is excellent, and since the sword motor / generator (rotary electric machine) is provided, it is possible to reduce the mounting space on the vehicle. This can contribute to reducing the size, weight and cost of the vehicle.

Next, the circuit configuration of the inverter INV used in the electric drive system for the hybrid electric vehicle shown in FIG. 17 will be described with reference to FIG.
FIG. 18 is a block circuit diagram showing a circuit configuration of inverter INV used in the electric drive system of the hybrid electric vehicle shown in FIG.

  The inverter INV is composed of two inverters INV1 and INV2. The configurations of the inverters INV1 and INV2 are the same. The inverters INV1 and INV2 are each composed of a power module PM and a driver unit DU. The driver unit DU is controlled by the motor control unit MCU. The power module PM is supplied with DC power from the battery BA, and the inverters INV1 and INV2 respectively convert AC power into AC power and supply it to the motor / generator. When the motor / generator operates as a generator, the output of the generator is converted into DC power by the inverters INV1 and INV2 and stored in the battery BA.

  The power module PM of the inverter INV1 is composed of six arms, converts the direct current supplied from the battery BA, which is a vehicle-mounted direct-current power supply, into alternating current, and supplies electric power to the motor generators FMG, RMG, which are rotating machines. The six arms of the power module PM use an IGBT (Insulated Gate Bipolar Transistor) as a semiconductor switching element. As a semiconductor switching element, a power MOS-FET (Metal Oxide Semiconductor-Field Effect Transistor) can be used in addition to the IGBT.

  The IGBT has an advantage of high operating speed. In the past, the voltage that power MOS-FETs could be used was low, so high-voltage inverters were made of IGBTs. Recently, however, the voltage that can be used for power MOS-FETs has increased, and both can be used as semiconductor switching elements in vehicle inverters. In the case of the power MOS-FET, the semiconductor structure is simpler than that of the IGBT, and there is an advantage that the manufacturing process of the semiconductor is less than that of the IGBT.

  In FIG. 18, the upper arm and the lower arm of each of the U phase, V phase, and W phase are connected in series. The respective collector terminals (drain terminals when power MOS-FETs are used) of the upper arms of the U phase, the V phase, and the W phase are connected to the positive side of the battery BA. On the other hand, the respective emitter terminals (source terminals in the case of power MOS-FETs) of the U-phase, V-phase, and W-phase lower arms are connected to the negative side of the battery BA.

  The connection point between the emitter terminal of the U-phase upper arm (source terminal in the case of power MOS-FET) and the collector terminal of the U-phase lower arm (drain terminal in the case of power MOS-FET) is the motor generator FMG (RMG) ) And a U-phase current flows. When the armature winding (the stator winding of the permanent magnet type synchronous motor) is Y-connected, the current of the U-phase winding flows. The connection point between the emitter terminal of the V-phase upper arm (source terminal in the case of power MOS-FET) and the collector terminal of the V-phase lower arm (drain terminal in the case of power MOS-FET) is the motor generator FMG (RMG) ) Of the V-phase armature winding (stator winding), and a V-phase current flows. When the stator winding is Y-connected, the current of the V-phase winding flows. The connection point between the emitter terminal of the W-phase upper arm (source terminal in the case of power MOS-FET) and the collector terminal of the W-phase lower arm (drain terminal in the case of power MOS-FET) is the motor generator FMG (RMG) ) W-phase terminal. When the stator winding is Y-connected, the current of the W-phase winding flows. By converting the DC power supplied from the battery BA into AC power and supplying it to the three-phase stator coils of the U-phase, V-phase, and W-phase that constitute the stator of the motor generator FMG (RMG), three-phase The rotor is rotationally driven by the magnetomotive force generated by the current flowing through the stator coil.

  The motor control unit RM controls the driver unit DU that generates the gate signal, and the gate signal is supplied from the driver unit of each phase to the semiconductor switching element of each phase. The gate signal controls the conduction and non-conduction (cutoff) of each arm. As a result, the supplied direct current is converted into a three-phase alternating current. Since the occurrence of three-phase alternating current is already known, a detailed description of the operation is omitted.

Next, the configuration of the rotating electrical machine according to the fifth embodiment of the present invention will be described with reference to FIGS. 19 and 20. In addition, the whole structure of the rotary electric machine by a present Example is the same as that of FIG. 1, FIG. 2, and the connection diagram of the stator coil of the rotary electric machine of a present Example is the same as FIG.
FIG. 19 is a layout diagram of windings when winding a stator coil in the rotating electrical machine of the fifth embodiment of the present invention. FIG. 20 is an explanatory diagram of a winding method of the stator coil in the rotating electrical machine according to the fifth embodiment of the present invention.

  As shown in FIG. 8, after winding the first group of coils around the winding frame VF with a gap, the second group of coils is sequentially wound in the gap (in the case of one reciprocating winding), As shown in FIG. 8, the second group of coils crosses the first group of coils. Similarly, as shown in FIG. 13, after the first group of coils is wound around the winding frame VF with a gap, the second group of coils is sequentially wound around the gap, and the second group of coils is further wound into the gap. When three groups of coils are wound (in the case of one reciprocating half-turn), as shown in FIG. 13, the second group of coils crosses the first group of coils, and the second group of coils. On the other hand, the third group of coils will cross.

  In this way, when the coils are sequentially inserted into the stator slot from the slot entrance as shown in FIG. 12A with the coil crossed, the crossed portion is not in the slot but in the slot. Are produced at both ends, that is, at the coil end portion 14 of FIG. As described with reference to FIG. 2, when the stator coil is distributed winding, the axial length of the coil end portion 14 is increased in the first place, and a crossed portion is generated in the coil end portion. As a result, the axial length of the coil end portion is further increased. The coil end portions are all formed so as to be bent in the radial direction of the stator core, and then the stator 10 is inserted into the housing 30 as shown in FIG.

  Here, if the inner diameter of the housing 30 is, for example, φ214 mm, the stator 10 cannot be inserted into the housing 30 unless the outer shape of the stator 10 is less than the inner diameter of the housing 30, that is, less than φ214 mm.

  As shown in FIG. 3, when each phase coil is composed of 8 coils and a stator coil is composed of a total of 24 coils, a cross portion is generated in the aforementioned one coil. The amount of increase in the axial length of the coil end portion is slight, but for all 24 coils, when one reciprocating winding shown in FIG. 8 or one reciprocating half winding shown in FIG. The coil end length as a whole becomes considerably long. As a result, the outer diameter of the stator may be larger than the inner diameter of the housing 30 when the coil end portion is bent in the outer circumferential direction. For example, the outer diameter of the stator in the case of one reciprocating half winding shown in FIG. 13 is φ218 mm.

  In order to solve such a problem, the present embodiment is configured as follows. That is, as shown in FIG. 3, when each phase coil is composed of 8 coils in 2 series and 4 in parallel, attention is particularly paid to the 2 series coils. Then, as shown in FIG. 4, in the case where the U-phase and the V-phase form a 4-series coil, when the high voltage Vin is applied to the 4-series coil, the highest voltage is applied to the coil U1 ′. Is done. A high voltage may be applied to the coil V1 'side. That is, a high voltage is applied to the coil U1 'and the coil V1' located on the lead wire side among the phase coils. Further, in the four series coils as shown in FIG. 4, the voltage sharing ratio of each coil is highest in the first coil on the high voltage side (leading wire side).

  Therefore, in this embodiment, for example, as shown in FIG. 3, when each phase coil is composed of two series coils, the coils U1, U3, U5, U7, V1, V3, V5 located on the lead wire side are used. , V7, W1, W3, W5, and W7 have the coil winding configuration of one reciprocating half winding shown in FIG. On the other hand, for the coils U2, U4, U6, U8, V2, V4, V6, V8, W2, W4, W6, and W8 located on the neutral point N side, the coil winding of the aligned winding described later with reference to FIG. The configuration.

  Here, the coil winding configuration of the aligned winding will be described with reference to FIG. For example, when the coil U2 in FIG. 3 is configured with 12 turns, as shown in FIG. 19, a conductive wire VL, which is insulated and coated with an enamel film or the like, is used for the winding frame VF using an automatic winding machine. Then, it is wound in the same direction for 12T. At this time, if the thickness of the conducting wire VL is P, the winding is sequentially performed so as to be adjacent to each other without leaving a gap between the adjacent windings. This winding configuration is referred to as aligned winding.

  In this way, the coil winding of the aligned winding shown in FIG. 19 for the coils U2, U4, U6, U8, V2, V4, V6, V8, W2, W4, W6, and W8 located on the neutral point N side. In the case of the configuration, in the four series coils shown in FIG. 4, the voltage sharing ratio of each coil is as follows. Here, for example, the voltage sharing ratio when U1 ′, U2 ′, V2 ′, and V1 ′ constituting the four series coils of FIG. As described above, when the total applied voltage is 100%, the shared voltage ΔV1 of the first coil when α = 4 is about 60%, whereas the shared voltage ΔV2 of the second coil is About 30%. When a surge voltage of 1300 V or more is applied to four series circuits, assuming that the sharing voltage of one coil is 60%, approximately 800 V is applied to both ends of the coil. The insulation characteristic of the enamel coating that covers the coil is such that dielectric breakdown does not occur when a voltage of about 800 V is applied to both ends of the coil.

  On the other hand, in U1 ′, U2 ′, V2 ′, and V1 ′ constituting the four series coils of FIG. 4, the coils U1 ′ and V1 ′ that are located on the lead wire side are set as one reciprocating half turn, and the neutral point N side When the coils U2 ′ and V2 ′ positioned at the same position are aligned windings in FIG. 19, the voltage sharing ratio ΔV1 of the coil U1 ′, which is the first coil, is 100% as a whole. Whereas it is about 41%, the shared voltage ΔV2 of the coil U2 ′ as the second coil is about 57%. As described above, since each coil has an insulating film that does not cause dielectric breakdown even when a voltage of 60% of 1300 V is applied, as described above, the shared voltage ΔV1 is about 41%, When the shared voltage ΔV2 is about 57%, neither the first coil nor the second coil will cause dielectric breakdown. Note that the voltage applied to the third coil and the fourth coil is the remaining voltage of about 2% and, of course, does not cause dielectric breakdown.

  As described above, as shown in FIG. 3, the dielectric breakdown characteristics on the lead wire side are improved as a one-way half-turn coil winding configuration in which 12 of the half of the 24 stator coils have a cross portion. The remaining half of the twelve pieces are arranged in an aligned winding without a cross portion, so that the coil end length can be shortened and the withstand voltage can be maintained. By the way, of the 24 stator coils, half of the 12 stator coils have a reciprocating half-winding coil winding configuration having a cross portion to improve the insulation breakdown characteristics on the lead wire side, and the other half of the 12 stator coils are crossed. In the case of a coil winding configuration of an aligned winding having no part, when the coil end portion is bent in the outer diameter direction, the outer diameter of the stator can be φ214 mm and can be inserted into the housing. .

  Next, the winding method of the stator coil in the rotary electric machine of a present Example is demonstrated using FIG.

  In this example, the winding of the first stator coil of the two series coils is divided into three winding groups, and then wound around the winding frame VL using an automatic winding machine (three-division winding). = 1 reciprocating half winding). That is, if the number of windings of one stator coil is 12T, the first winding group from 1T to 4T, the second winding group from 5T to 8T, and the third winding group from 9T to 12T. The winding group has a different winding method.

  That is, first, as shown in FIG. 20 (A), the conductive wire VL, which is insulation-coated with an enamel film or the like, is sequentially applied to the winding frame VF in the same direction (R direction) using an automatic winding machine. Wind for 4T. At this time, if the thickness of the conducting wire VL is P, the winding is sequentially performed with a gap of 2P between adjacent windings. That is, the winding pitch is 3P, and winding is performed from 1T to 4T as shown in FIG.

  When the winding for 4T is completed, it turns back at the 4T, and as shown in FIG. 20B, in the same winding direction and between the 1T to 4T windings, The 5th to 8T windings of the second group are wound in a state adjacent to the 1T to 4T windings and leaving a gap for one winding.

  Further, when the winding for 8T is finished, it is folded back at the 8th T, and as shown in FIG. 20C, in the same winding direction, the 1T to 4T winding and the 5T to 8T In the meantime, the 9th to 12th T members of the third group are wound.

  As a result, as shown in FIG. 14, the coils are arranged in a single layer in the order of 1T, 8T, 9T, 2T, 7T,..., 4T, 5T, and 12T.

  Further, when the second winding frame VF2 is provided and the first stator coil and the second stator coil are connected in series (when connected in series like the stator coil U1 and the stator coil U2 in FIG. 3). Then, as shown in FIG. 19, the 12T coils are wound around the second winding frame VF2 by aligned winding so as to be adjacent to each other.

  In this way, the first coil of the two series coils has a one-reciprocation half-turn coil winding configuration, and the second coil has an aligned winding, thereby improving the insulation of each coil When the length of the end portion can be shortened and two series-connected stator coils are wound, the second winding is used after the first winding by using the second winding frame. Easy to do.

Next, the configuration of the rotating electrical machine according to the sixth embodiment of the present invention will be described with reference to FIG. In addition, the whole structure of the rotary electric machine by a present Example is the same as that of FIG. 1, FIG. 2, and the connection diagram of the stator coil of the rotary electric machine of a present Example is the same as FIG.
FIG. 21 is an explanatory diagram of a winding method of the stator coil in the rotating electrical machine according to the sixth embodiment of the present invention.

  In this example, among the series coils, the first coil has a one-turn coil winding configuration, and the second coil has an aligned winding, so that the insulation of each coil is improved and the coil end portion is improved. The length can be shortened.

  That is, as shown in FIG. 21, the winding of the first stator coil of the two series coils is divided into two winding groups and then wound around the winding frame VL sequentially using an automatic winding machine. (One reciprocating half-turn). That is, if the number of windings of one stator coil is 12T, the first winding group from 1T to 6T and the second winding group from 7T to 12T have different winding methods. Yes.

  That is, first, as shown in FIG. 21 (A), the conductive wire VL, which is insulation-coated with an enamel film or the like, is sequentially applied to the winding frame VF in the same direction (R direction) using an automatic winding machine. Wind for 6T. At this time, if the thickness of the conducting wire VL is P, the winding is sequentially performed with a gap of 1P between adjacent windings. That is, the winding pitch is 2P, and winding is performed from 1T to 6T as shown in FIG.

  Then, when the winding for 6T is completed, it is folded back at the 6T, and as shown in FIG. 21B, in the same winding direction and adjacent to the 1T to 6T windings. Then, the 7th to 12th windings of the second group are wound.

  Further, when the second winding frame VF2 is provided and the first stator coil and the second stator coil are connected in series (when connected in series like the stator coil U1 and the stator coil U2 in FIG. 3). Then, as shown in FIG. 19, the 12T coils are wound in an aligned manner so as to be adjacent to each other on the second winding frame VF2 via the connecting wire.

  In this way, the voltage sharing ratio when the first coil of the two series coils has a one-turn winding configuration and the second coil is an aligned winding will be described. In U1 ′, U2 ′, V2 ′, and V1 ′ that constitute the four series coils of FIG. 4, the coil U2 that is located on the neutral point N side with the coils U1 ′ and V1 ′ that are located on the lead wire side as one reciprocating winding. The voltage sharing ratio when ', V2' is the aligned winding of FIG. 19 is about 48% when the entire applied voltage is 100%, and the sharing voltage ΔV1 of the coil U1 ′ that is the first coil is about 48%. On the other hand, the shared voltage ΔV2 of the coil U2 ′ as the second coil was about 53%. As described above, since each coil has an insulating film that does not cause dielectric breakdown even when a voltage of 60% of 1300 V is applied, as described above, the shared voltage ΔV1 is about 48%. When the shared voltage ΔV2 is about 53%, neither the first coil nor the second coil will cause dielectric breakdown. Moreover, the voltage sharing ratio between the first coil and the second coil can be made smaller in absolute value than in the case of the one-reciprocation half-turn coil winding configuration and the aligned winding coil winding configuration shown in FIG. Therefore, when the voltage applied to the whole of the four series coils becomes higher, the voltage sharing rate of each coil can be made smaller in this example than in the example of FIG. Will do. In addition, compared with the one-return and half-turn coil winding configuration, the one-reciprocation coil winding configuration has fewer portions where the coils cross, and thus the length of the coil end portion can be shortened.

  In this manner, the first coil of the two series coils has a one-turn winding structure, and the second coil has an aligned winding, thereby improving the insulation of each coil and increasing the coil end. The length of the part can be shortened.

In the above description, the stator coils for one phase are described as being connected in series, but it may be connected in three or more series. In the case of three series connections, the first coil on the lead wire side has a coil winding configuration of one reciprocating half winding or a coil winding configuration of one reciprocating winding. The third coil on the neutral point side has a coil winding configuration of aligned winding. The intermediate second coil is either a one-way half-turn coil winding configuration, a one-way winding coil winding configuration, or an aligned-winding coil winding configuration. If you want to improve insulation resistance, use a single-reciprocation half-winding or single-rewinding coil winding structure. If you want to shorten the length of the coil end, use an aligned-winding coil winding structure. And

It is sectional drawing which shows the whole structure of the rotary electric machine of 1st Example of this invention. It is sectional drawing which shows the whole structure of the rotary electric machine of 1st Example of this invention. It is a connection diagram of the stator coil in the rotary electric machine of 1st Example of this invention. It is a schematic circuit diagram of the stator coil in a rotary electric machine. It is a wave form diagram of the voltage which is orthogonally transformed and applied to a stator coil. It is an equivalent circuit of a stator coil. It is explanatory drawing of the ground potential en when a pulse voltage is applied to a coil. It is explanatory drawing of the winding method of the stator coil in the rotary electric machine of 1st Example of this invention. FIG. 3 is a layout diagram of windings when winding a stator coil in the rotating electrical machine according to the first embodiment of the present invention. It is explanatory drawing of the electrostatic capacitance in the conventional stator coil. It is explanatory drawing of the electrostatic capacitance in the stator coil in the rotary electric machine of 1st Example of this invention. FIG. 3 is an arrangement view of windings in slots in a stator coil in the rotating electrical machine according to the first embodiment of the present invention. It is explanatory drawing of the winding method of the stator coil in the rotary electric machine of 2nd Example of this invention. It is a layout drawing of the winding at the time of winding of the stator coil in the rotating electrical machine of the second embodiment of the present invention. It is explanatory drawing of the electrostatic capacitance in the stator coil in the rotary electric machine of 3rd Example of this invention. It is a layout drawing of the winding at the time of winding of the stator coil in the rotating electrical machine of the third embodiment of the present invention. FIG. 10 is a block diagram showing an electric drive system of a hybrid electric vehicle which is a fourth embodiment of the present invention and is one of electric vehicles using the rotating electric machines of the first to third embodiments. FIG. 18 is a block circuit diagram showing a circuit configuration of an inverter INV used in the electric drive system for the hybrid electric vehicle shown in FIG. 17. It is a layout drawing of the winding at the time of winding of the stator coil in the rotating electrical machine of the fifth embodiment of the present invention. It is explanatory drawing of the winding method of the stator coil in the rotary electric machine of 5th Example of this invention. It is explanatory drawing of the winding method of the stator coil in the rotary electric machine of 6th Example of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Stator 20 ... Rotor 12 ... Stator core 14 ... Stator coil 22 ... Rotor core 24 ... Permanent magnet VF ... Reel

Claims (9)

A stator in which three-phase stator coils are wound in distributed winding on the salient poles of the stator core, and is rotatably supported opposite to the stator, and a plurality of permanent magnets are equally spaced in the circumferential direction. A rotating electric machine comprising a rotor arranged,
The stator coil is
The stator coil is divided into N (N = 2, 3, 4) groups, and the number of windings in each group is the same or almost the same.
Wind the first group of windings on the winding frame with a gap of ((N-1) · P) with respect to the thickness P of the conducting wire,
When the winding of the first group is completed, the second group of windings is wound around the gap so as to be adjacent to the winding of the first group,
In the case of N = 3 or more, after winding the next group of windings adjacent to the winding of the previous group in the gap, aligning them in one layer and winding them on the reel,
A rotating electric machine comprising a stator coil inserted into a slot of a stator core of the stator. The rotating electrical machine according to claim 1, wherein
The stator coil is
The stator coil is divided into two groups, and the number of windings in each group is the same or almost the same.
Wind the first group of windings on the winding frame with a gap of 1P with respect to the thickness P of the conducting wire,
When the winding of the first group is finished, it is folded back, and after winding the second group of windings between the gaps,
A rotating electric machine comprising a stator coil inserted into a slot of a stator core of the stator. The rotating electrical machine according to claim 1, wherein
The stator coil is
The stator coil is divided into three groups, and the number of windings in each group is the same or almost the same.
Wind the first group of windings on the winding frame with a gap of 2P with respect to the thickness P of the conducting wire,
When the winding of the first group is completed, the second group of windings is wound around the gap so as to be adjacent to the winding of the first group,
Further, a third group winding is wound between the first group and the second group in a gap between the first group winding and the second group winding, and the windings are arranged in one layer. After winding around the frame
A rotating electric machine comprising a stator coil inserted into a slot of a stator core of the stator. In the rotating electrical machine according to claim 3,
The stator coil is
It consists of a first stator coil and a second stator coil connected in series,
After winding the first group to the third group of windings of the first stator coil around the first winding frame, using a conductor continuous to the third group, A rotating electric machine characterized by continuously winding the first group to the third group of the second stator coil. The rotating electrical machine according to claim 1, wherein
The stator coil is
The stator coil is divided into four groups, and the number of windings in each group is the same or almost the same.
Wind the first group of windings on the winding frame with a gap of 3P with respect to the thickness P of the conducting wire,
When the winding of the first group is completed, the second group of windings is wound around the gap so as to be adjacent to the winding of the first group,
Further, in the gap between the first group winding and the second group winding, the third group winding is wound adjacent to the second group winding,
Further, after winding the fourth group of windings in a single layer in the gap between the first group of windings and the third group of windings,
A rotating electric machine comprising a stator coil inserted into a slot of a stator core of the stator. The rotating electrical machine according to claim 1, wherein
The stator coil of each phase is
At least a plurality of stator coils are connected in two or more series,
The one stator coil located on the lead wire side is divided into N (N = 2, 3, 4) groups, and the number of windings in each group is the same or substantially the same.
Wind the first group of windings on the winding frame with a gap of ((N-1) · P) with respect to the thickness P of the conducting wire,
When the winding of the first group is completed, the second group of windings is wound around the gap so as to be adjacent to the winding of the first group,
In the case of N = 3 or more, the next group of windings is wound adjacently to the previous group of windings in the gap, and is wound around the winding frame in a single layer,
One stator coil positioned on the neutral point side of a Y-connected three-phase stator coil is wound by aligned winding so that the coils are adjacent to each other in the winding direction. . In rotating electrical machines,
A stator,
A rotor that is rotatably arranged and opposed to the circumferential surface of the stator via a gap;
The stator is
A stator core;
A stator coil wound around the stator core by distributed winding,
The stator core is formed with a plurality of axially continuous slots in the circumferential direction,
The stator coil is
The stator coil is divided into N (N = 2, 3, 4) groups, and the number of windings in each group is the same or almost the same.
Wind the first group of windings on the winding frame with a gap of ((N-1) · P) with respect to the thickness P of the conducting wire,
When the winding of the first group is completed, the second group of windings is wound around the gap so as to be adjacent to the winding of the first group,
In the case of N = 3 or more, after winding the next group of windings adjacent to the winding of the previous group in the gap, aligning them in one layer and winding them on the reel,
A rotating electric machine comprising a stator coil inserted into a slot of a stator core of the stator. A stator in which three-phase stator coils are wound in distributed winding on the salient poles of the stator core, and is rotatably supported opposite to the stator, and a plurality of permanent magnets are equally spaced in the circumferential direction. A method of manufacturing a rotating electrical machine comprising a rotor disposed,
The stator coil is divided into N (N = 2, 3, 4) groups, and the number of windings in each group is the same or almost the same.
Using an automatic winding machine, wind the first group of windings on the winding frame with a gap of ((N−1) · P) with respect to the thickness P of the conducting wire,
When the winding of the first group is completed, the second group of windings is wound around the gap so as to be adjacent to the winding of the first group,
In the case of N = 3 or more, after winding the next group of windings adjacent to the winding of the previous group in the gap, aligning them in one layer and winding them on the reel,
A method of manufacturing a rotating electrical machine, wherein an automatic insertion machine is used to insert a stator coil into a stator core slot of the stator and wind the stator coil around the stator core. A stator in which three-phase stator coils are wound in distributed winding on the salient poles of the stator core, and is rotatably supported opposite to the stator, and a plurality of permanent magnets are equally spaced in the circumferential direction. A rotating electric machine comprising a rotor arranged,
The stator coil of each phase is
At least a plurality of stator coils are connected in two or more series,
The stator coil located on the lead wire side is divided into N (N = 2, 3, 4) groups, and the number of windings in each group is the same or substantially the same.
Wind the first group of windings on the winding frame with a gap of ((N-1) · P) with respect to the thickness P of the conducting wire,
When the winding of the first group is completed, the second group of windings is wound around the gap so as to be adjacent to the winding of the first group,
In the case of N = 3 or more, the next group of windings is wound adjacently to the previous group of windings in the gap, and is wound around the winding frame in a single layer,
One stator coil positioned on the neutral point side of the Y-connected three-phase stator coil is wound by aligned winding so that the coils are adjacent to each other in the winding direction.
A rotating electric machine comprising a stator coil inserted into a slot of a stator core of the stator.

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