JP4852073B2 - Wave coil - Google Patents

Description

The present invention relates to a wave Maki coil for use in motors and generators.

  2. Description of the Related Art In recent years, an electric motor used for an electric vehicle or a hybrid vehicle is composed of a cylindrical stator coil, a columnar rotor disposed inside the stator coil, and a shaft connected to the rotor. .

  As this stator coil, there is a stator coil in which an inner tooth of a stator iron core having an inner tooth shape is wound with a winding line from the radial inner side of the stator iron core.

  In a hybrid vehicle, the rotating shaft of the electric motor is directly connected to the crankshaft of the engine. In the case of such an electric motor, the length in the crankshaft direction when the electric motor is assembled to the engine is And the total length of the electric motor in the crankshaft direction.

  Therefore, in order to store such an engine and an electric motor in the engine room, it is necessary to make the length of the electric motor in the crankshaft direction as short as possible. In other words, in the case of the electric motor configured as described above, the coil end (the portion of the connecting wire coming out from the slot until the coil inserted through the slot comes out of the slot and enters the next slot) must be made as short as possible. Don't be.

  As a configuration of such an electric motor, there has been proposed a configuration in which a short conductor segment is used and a winding wire of a looped wire and a winding wire of a winding wire are connected in parallel to form a winding wire of each phase of the stator wire. (For example, refer to Patent Document 1).

  FIG. 31 is a perspective view for explaining the arrangement of the strands constituting the stator winding proposed in Patent Document 1. In FIG. FIG. 32 shows a parallel connection diagram of the stator windings applied to the electric motor.

  This conventional stator winding uses three types of conductor segments 331, 332, and 333 formed by bending a rectangular conductor into a substantially U shape. Then, the conductor segments 331, 332, 333 are inserted from one end side in the axial direction of the stator core into each set of slots separated by 3 slots (one magnetic pole pitch), and on the other end side in the axial direction of the stator core. The extending ends are joined to each other by welding or the like, and formed into a coil that makes four turns around the stator core.

  In each slot, six conductors constituting the slot insertion portions 331a, 332a, 333a of the conductor segments 331, 332, 333 are arranged in a row in the radial direction of the stator core. Here, the conductor position in the slot is referred to as address 1, address 2,... Address 6, from the inner peripheral side. Further, on one end side of the stator core in the axial direction, the turn part 332 c of the conductor segment 332 surrounds the turn part 333 c of the conductor segment 333, and the turn part 331 c of the conductor segment 331 surrounds the turn part 332 c of the conductor segment 332. It is out.

  Then, on the other end side in the axial direction of the stator iron core, the end portion 333d of the conductor segment 333 extending from the third address of one slot is a conductor segment extending from the fourth address of the other slot which is three slots apart. Joined to the end portion 333e of 333, two corrugated wires 311 and 313 of one turn per slot are formed. Also, the end 331d of the conductor segment 331 extending from the first address of one slot is joined to the end 332d of the conductor segment 332 extending from the second address of another slot separated by three slots, and further, The end 332e of the conductor segment 332 extending from address 5 is joined to the end 331e of the conductor segment 331 extending from address 6 of the other slot 3 slots away, and the winding line 312 having two turns per slot. Two 314 are formed.

Then, as shown in FIG. 32, the winding wire 311 and the winding wire 312 are connected in series, the winding wire 313 and the winding wire 314 are connected in series, and both are connected in parallel. Connected to form a three-turn stator winding group. These stator coil groups are AC-connected to form a stator cable consisting of a set of three-phase AC cables.
JP 2000-92766 A

  However, in the electric motor using the above-described conventional stator winding, the coil end becomes long.

  That is, looking at the conductor segment 331 of the stator winding described in Patent Document 1, as shown in FIG. 31, the slot insertion portion 331a and the end portion 331d are connected by the end connection portion 331f, The insertion part 331a and the turn part 331c are connected by a turn part connection part 331g. Similarly, the slot insertion portion 331b and the end portion 331e are connected by an end connection portion 331i, and the slot insertion portion 331b and the turn portion 331c are connected by a turn portion connection portion 331h.

  These end connection parts 331f and 331i and turn part connection parts 331g and 331h are all arranged at the coil end outside the slot.

  Accordingly, the length of the coil end at the upper part of the stator iron core in this case is the total length of the end connection part 331f and the end part 331d, and the length of the coil end at the lower part of the iron core is the turn part connection part 331h. And the length in the axial direction of the turn portion 331c, and the length of any coil end becomes long.

  As a result, when an electric motor using a stator winding is used for a vehicle, a large installation space is required in the engine room.

The present invention, in consideration of the conventional problems, and an object thereof is to provide a short-wave Maki coil of the coil end than before.

In order to solve the above-described problem, the first aspect of the present invention provides:
It is a wave coil provided with each phase coil of U phase, V phase, and W phase,
Each phase coil is a flat wire having an even number of layers ;
The main part of the crossover part at the coil end of each phase coil is such that the main surface of the rectangular wire is parallel to the rotation axis,
Each phase coil is arranged in parallel with each other in the radial direction in the main part of the crossover portion ,
The length obtained by averaging the lengths of the plurality of layers of the phase coils in each of the phase coils is substantially the same in the U phase, the V phase, and the W phase,
When the three phase coils are a first phase coil, a second phase coil, and a third phase coil,
The main part of the crossover portion of the half layer of the first phase coil is arranged on the outermost side in the radial direction, and the main part of the crossover portion of the remaining half layer of the first phase coil is The innermost radial direction,
The main portion of the crossover portion of the half layer of the second phase coil is adjacent to the main portion of the crossover portion of the half layer of the first phase coil arranged on the outermost side, and the diameter The main part of the crossover portion of the remaining half layer of the second phase coil, which is arranged inside the direction, is the main part of the crossover portion of the remaining half layer of the first phase coil arranged on the innermost side. Adjacent to the main part, disposed outside the radial direction,
The main part of the crossover part of all the layers of the third phase coil is the main part of the crossover part of the half layer of the second phase coil and the remaining half layer of the second phase coil. It is a wave coil arrange | positioned between the main parts of the said crossover part .

The second of the present invention,
The plurality of layers of each phase coil are divided into a plurality of adjacent slots and inserted,
The plurality of layers inserted through the adjacent slots, the crossover portion is formed in the same direction,
The main portion of the crossover portion of the layer inserted into one slot and the main portion of the crossover portion of the layer inserted into the other slot are stacked in the direction of the rotation axis. It is a wave coil of the invention.

The third present invention,
At least a part of the crossover portion from the slot of each phase coil to enter the next slot is bent in a direction perpendicular to the rotation axis,
Both ends of the bent portion are the undulating coils of the first aspect of the present invention that protrude to the center of the core portion forming the slot at the maximum.
The fourth aspect of the present invention is
A plurality of layers of the same phase coil are inserted into one slot formed in the core, and the plurality of layers inserted into the one slot are layers close to the bottom of the groove forming the slot. The wave coil according to the first aspect of the present invention is so thin and wide that the cross-sectional areas of the respective layers are equal.

The first invention related to the present invention is:
It is a wave coil provided with each phase coil of U phase, V phase, and W phase,
Each phase coil is a flat wire,
The main part of the crossover part at the coil end of each phase coil, the main surface of the rectangular wire is orthogonal to the rotation axis,
Each of the phase coils is a coiled coil arranged in parallel with each other in the direction of the rotation axis in the main part of the crossover portion.
The second invention related to the present invention is:
A molten copper supply step for pouring molten copper into the mold from a molten copper supply nozzle while heating and rotating the rotating mold with the mold formed on the rotating surface;
A scraping step of scraping off the excess molten copper poured into the mold by a scraping portion provided on the downstream side of the molten copper supply nozzle,
A solidification step of supplying cold air to the mold by the cooling section provided on the downstream side of the scraping section, and solidifying the molten copper poured into the mold;
And a winding step of winding the solidified molten copper from the mold by a winding unit provided on the downstream side of the cooling unit.

In addition, the third invention related to the present invention is:
A semi-solid copper supply step of supplying semi-solid copper from the semi-solid copper supply nozzle to the mold while relatively rotating the rotating mold having the mold formed on the rotating surface;
A semi-solid copper supplied to the mold while a pressing roller having a rotating surface in contact with the rotating surface of the rotating mold is rotated in the same direction as the rotating mold on the downstream side of the semi-solid copper supply nozzle. An adsorption step for adsorbing to the rotating surface;
A winding step of winding the adsorbed semi-solid copper from the iron rotating surface by a winding unit provided on the downstream side of the pressing roller;
In the suction step, the semi-solid copper is attracted to the rotating surface of the pressing roller in the suction step by using different materials for the rotating surface of the rotating mold and the pressing roller.

The fourth invention related to the present invention is:
The mold is a method for manufacturing a rectangular wire according to the second or third aspect of the present invention, which has a shape of a wave coil.

The fifth invention related to the present invention is:
The wave coil produced is
It is each phase coil of U phase, V phase, and W phase. Each phase coil has a plurality of layers, and a plurality of layers of the same phase coil are inserted into one slot. The method for producing a rectangular wire according to the fourth aspect of the present invention is such that the plurality of layers inserted into the one slot are thinner and wider as the layer is closer to the bottom of the groove forming the slot. is there.

The present invention can provide a short-wave Maki coil of the coil end than before.

Embodiments of the present invention and the invention related to the present invention will be described below with reference to the drawings.

(Embodiment 1)
The stator according to the first embodiment, which is an example of the winding coil according to the present invention, will be described below.

  FIG. 1 is a perspective view of the stator according to the first embodiment, FIG. 2 is a top view of the stator according to the first embodiment, and FIG. 3 is a side view of the stator according to the first embodiment.

  As shown in FIG. 1, the stator iron core 11 constituting the stator 10 of the first embodiment has 48 internal teeth of the stator iron core 11 having an internal tooth shape, and 48 internal teeth are formed by these internal teeth. A slot 13 is formed. Here, each internal tooth portion of the stator iron core 11 is referred to as a core 12. Further, the 48 slots 13 are referred to as a first slot, a second slot,..., A 48th slot in order counterclockwise as viewed from above in FIG. In addition, the numerals 1-48 currently described in the inner periphery of each phase coil of the upper part of the stator 10 of FIG. 1 have shown the slot number.

  The center axis 17 corresponds to an example of the rotation axis of the present invention.

  The stator 10 is composed of three phase coils of a U-phase coil 14, a V-phase coil 15, and a W-phase coil 16, and these three phase coils 14, 15, 16 are each formed by a wave formed by a rectangular wire. It is a burning coil. In FIG. 1, the U-phase coil 14 portion is shown with a dark fill, and the V-phase coil portion 15 is shown with a thin fill.

  Each phase coil has eight layers, each layer corresponding to one turn, and is arranged so that each phase passes through two adjacent slots 13. Therefore, four layers of the same phase are inserted into one slot 13.

  In each figure, the eight layers of the U-phase coil 14 are shown as 1T to 8T, respectively. Of the two adjacent slots 13 through which the U-phase coil 14 is inserted, layers of 1T, 3T, 5T, and 7T are inserted into one of the slots from the bottom, that is, the side farther in the radial direction from the central axis 17. ing. In the other adjacent slot 13, layers of 2T, 4T, 6T, and 8T are inserted in order from the bottom of the slot. 1 to 3, four layers of 2T, 4T, 6T, and 8T of the U-phase coil 14 are inserted into the first slot, and 1T, 3T, 5T, and 7T of the U-phase coil 14 are inserted into the second slot. Four layers are inserted. The same applies to the V-phase coil 15 and the W-phase coil 16.

  In the case of the stator 10 according to the first embodiment, the two slots 13 are alternately arranged in the order of the U-phase coil 14, the V-phase coil 15, and the W-phase coil 16 counterclockwise as viewed from above in FIG. It is inserted through one by one. That is, the U-phase coil 14 is inserted in the first slot and the second slot, the V-phase coil 15 is inserted in the next third slot and the fourth slot, and the fifth slot and the second slot are further inserted. A W-phase coil 16 is inserted into six slots. Then, the U-phase coil 14 protruding from the first slot to the coil end 20 portion above the stator core 11 passes through the crossover portion bent in the counterclockwise direction when viewed from above the stator 10, and then Insert into 8 slots. Similarly, the U-phase coil 14 that has come out from the second slot to the coil end 20 portion above the stator iron core 11 is inserted into the seventh slot next through the crossover portion. The U-phase coil 14 inserted downward through the seventh slot and the eighth slot now passes through the crossover portion of the coil end 20 portion below the stator core 11, and then the 14th slot and 13th respectively. Insert into the slot.

  As shown in FIGS. 1 to 3, at the crossover portion of each phase coil 14, 15, 16, the main surface, that is, the wide surface of the flat wire is parallel to the central axis 17.

  FIG. 3 is a side view of the stator 10 shown in FIG. 1 viewed from the front side. That is, it is the side view which looked at the open side of the groove of the first slot from the front.

  In the coil end 20, the 1T and 2T crossover portions (W-phase 1T crossover wire 25 and W-phase 2T crossover wire 26) of the W-phase coil 16 are arranged on the farthest side from the central axis 17. That is, in the side view of FIG. 3, the W-phase 1T connecting wire 25 and the W-phase 2T connecting wire 26 are arranged on the most front side.

  As shown in FIG. 3, the W-phase 1T crossover line 25 and the W-phase 2T crossover line 26 are located between two adjacent slots through which the W-phase coil 16 is inserted and two adjacent slots through which the W-phase coil 16 is inserted next. Is a two-tiered configuration in the direction of the central axis 17. At this time, of the two slots inserted adjacently, the layer farther to the next slot to be inserted is arranged on the outer side (the far side) of the two-tiered stack with respect to the stator core 11. Therefore, as shown in FIG. 3, the W-phase 1T connecting wire 25 and the W-phase 2T connecting wire 26 are arranged on the outer side (upper side) of the W-phase 2T connecting wire 26 at the upper coil end 20. In the lower coil end 20, the W-phase 1T crossover wire 25 is arranged on the outer side (lower side) of the two-tiered stack.

  Similarly, the U-phase 1T crossover line 21 and the U-phase 2T crossover line 22 are also configured in a two-tiered manner in the direction of the central axis 17, and the V-phase 1T crossover line 23 and the V-phase 2T crossover line 24 are also in the direction of the central axis 17 It has a two-tiered structure.

  Similarly, two layers of each phase coil 14, 15, 16 that are inserted through the same position from the bottom of two slots that are inserted adjacent to each other are arranged in the coil end 20 so as to overlap each other at their crossover portions. It has become. That is, the 3T and 4T layers, the 5T and 6T layers, and the 7T and 8T layers each have a structure in which the crossover portions are two-tiered.

  Further, in the coil end 20, the crossover portion of the V-phase coil 15 is disposed between the plurality of crossover portions of the U-phase coil 14, and further outside the plurality of crossover portions of the U-phase coil 14, the W-phase A crossover portion of the coil 16 is disposed.

  As shown in FIG. 2, the connecting wire portions of 1T to 8T of the V-phase coil 15 are arranged adjacent to each other in the radial direction. As described above, the 1T and 2T layers, the 3T and 4T layers, the 5T and 6T layers, and the 7T and 8T layers have a configuration in which the crossover portions are two-tiered in the direction of the central axis 17, respectively. In the top view of FIG. 2, only the upper layer (2T, 4T, 6T, and 8T layers) of two layers is visible, so that the crossover portions of the four layers appear to be adjacent to each other.

  And the 1T-4T crossover part of the U-phase coil 14 is arrange | positioned adjacent to the radial direction outer side of the crossover part which the V-phase coil 15 adjoins. And the 5T-8T crossover part of the U-phase coil 14 is arrange | positioned adjacent to the radial inside of the crossover part which the V-phase coil 15 adjoins.

  Further, the 1T to 4T crossover portion of the W-phase coil 16 is disposed adjacent to the 1T to 4T crossover portion of the U-phase coil 14, and is adjacent to the 5T to 6T crossover portion of the U-phase coil 14. Thus, the crossover portion of 5T to 8T of the W-phase coil 16 is disposed.

  Therefore, the 1T and 2T crossover portions of the W-phase coil 16 are arranged on the outermost side in the radial direction, and the 7T and 8T crossover portions of the W-phase coil 16 are arranged on the innermost side in the radial direction. Has been.

  Thus, the connecting wire portions of the respective phases of the respective phase coils 14 to 16 are arranged such that their main portions (surfaces parallel to the central axis 17) are parallel to each other in the radial direction.

  The coil end 20 on the lower side of the stator core 11 in FIG. 3 has the same configuration as the top view shown in FIG. 2, and the connecting wire portion of the V-phase coil 15 is sandwiched between the connecting wire portions of the U-phase coil 14. In addition, the connecting wire portion of the U-phase coil 14 is sandwiched between the connecting wire portion of the W-phase coil 16.

  FIG. 4 is a perspective view showing U-phase coil 14 in a state assembled to stator iron core 11 of stator 10 shown in FIG.

  U phase 1T coil part 30, U phase 2T coil part 31, U phase 3T coil part 32, U phase 4T coil part 33, U phase 5T coil part 34, U phase 6T coil part 35, U phase 7T coil part 36 and U The phase 8T coil part 37 has shown the coil part of each layer of 1T-8T of the U-phase coil 14, respectively.

  The slot insertion portion 27 indicates a linear portion that is inserted into the slot 13 of each of the U-phase 1T coil portion 30 to the U-phase 8T coil portion 37.

  As shown in FIG. 4, from the side far from the central axis 17 in the radial direction, the U-phase 1T coil unit 30, the U-phase 2T coil unit 31, the U-phase 3T coil unit 32, the U-phase 4T coil unit 33, and the U-phase 5T coil The part 34, the U-phase 6T coil part 35, the U-phase 7T coil part 36, and the U-phase 8T coil part 37 are arranged in this order.

  FIG. 5 shows a perspective view of only the U-phase 2T coil portion 31, and FIG. 6 shows a side view of only the U-phase 2T coil portion 31.

  As shown in FIG. 5, the U-phase 2T coil portion 31 is a portion where the slot insertion portion 27 protrudes from the slot 13, and bends in a direction orthogonal to the central axis 17 in the radial outward direction to form a horizontal bent portion 28. Forming. Further, the horizontal bent portion 28 is bent in the direction of the central axis 17 to form a crossover main surface portion 29. As described above, the U-phase 2T connecting wire 22 includes the horizontal bent portion 28 in which the main surface of the flat wire is orthogonal to the central axis 17 and the connecting wire main surface portion 29 in which the main surface of the flat wire is parallel to the central shaft 17. ing.

  In addition, the crossover main surface part 29 is an example of the main part of the crossover part of this invention.

  Further, the U-phase 2T coil portion 31 has an open end 38, and two end portions of the open end 38 are one of the open ends 38 of the U-phase 1T coil portion 30 and the U-phase 3T coil portion 32, respectively. Joined to the end. The open ends 38 of the U-phase 1T coil part 30 to the U-phase 8T coil part 37 are joined together in order to form the U-phase coil 14 in which the U-phase 1T coil part 30 to the U-phase 8T coil part 37 are connected. The

  Further, as shown in FIG. 6, the width W2 of the flat wire of the horizontal bent portion 28 and the width W3 of the flat wire of the crossover main surface portion 29 are both larger than the width W1 of the flat wire in the slot insertion portion 27. ing. On the other hand, the cross-sectional area of the flat wire in the horizontal bent portion 28 and the crossover main surface portion 29 is configured to be the same as the cross-sectional area of the flat wire in the slot insertion portion 27. Therefore, the thickness of the flat wire in the horizontal bent portion 28 and the crossover main surface portion 29 is smaller than the thickness of the flat wire in the slot insertion portion 27.

  By making the cross-sectional areas of the rectangular wires equal in each of the slot insertion portion 27, the horizontal bending portion 28, and the crossover main surface portion 29, it is possible to suppress a change in impedance associated with a change in the cross-sectional shape of the U-phase 2T coil portion 31. Yes.

  Further, by reducing the thickness of the rectangular wire of the horizontal bent portion 28, it contributes to shortening the length of the coil end 20. Further, by reducing the thickness of the flat wire of the crossover main surface portion 29, it contributes to reducing the radial width of each phase coil 14-16.

  The width W2 of the rectangular wire in the horizontal bent portion 28 is inserted into the adjacent slot 13 even if the width W1 of the rectangular wire in the slot insertion portion 27 is widened to the central portion of the core 12 between the adjacent slots. It does not interfere with the horizontal bent portion 28 of the coil to be operated. Therefore, the width W2 of the horizontal bent portion 28 can be increased to ½ of the width W4 of the core 12 at the maximum on both sides of the width W1 of the slot insertion portion 27, respectively. That is, the maximum width W2 of the horizontal bent portion 28 can be (the width W1 of the slot insertion portion 27 + the width W4 of the core 12).

  FIG. 7 is a partial development view of the U-phase 1T coil unit 30 and the U-phase 2T coil unit 31 for explaining the relationship with the inserted slot. FIG. 7 shows a plan view of the U-phase 1T coil portion 30 and the U-phase 2T coil portion 31 before bending the rectangular wires. In FIG. 7, the U-phase 2T coil portion 31 is indicated by a solid line that is thicker than the U-phase 1T coil portion 30.

  The U-phase 2T coil portion 31 is inserted into the next eighth slot via the U-phase 2T crossover 22 at the coil end 20 portion after the slot insertion portion 27 is inserted through the first slot. Thereafter, the U-phase 2T coil portion 31 is inserted in the order of the thirteenth slot, the twentieth slot, the twenty-fifth slot, the thirty-second slot, the thirty-seventh slot, and the forty-fourth slot.

  On the other hand, the U-phase 1T coil portion 30 is inserted into the next seventh slot via the U-phase 1T crossover wire 21 at the coil end 20 portion after the slot insertion portion 27 is inserted through the second slot. Thereafter, the U-phase 1T coil unit 30 is inserted in the order of the 14th slot, the 19th slot, the 26th slot, the 31st slot, the 38th slot, and the 43rd slot.

  As shown in FIG. 1, the 2T and 1T coils of the V-phase coil 15 are provided in the third and fourth slots, and the 2T and 1T coils of the W-phase coil 16 are provided in the fifth and sixth slots. Each part is inserted.

  FIG. 8 is a partially enlarged top view of the U-phase coil 14 for explaining the relationship between each layer and the slot insertion position. And the lower figure of FIG. 8 shows the cross-sectional part which expanded further the 1st slot and the 2nd slot part. In addition, the broken line shown in FIG. 8 has shown the crossover part of the coil end 20 of the lower surface side.

  On the bottom side of the groove of the first slot, that is, the side farthest from the central axis 17 in the radial direction, the slot insertion part 27 of the U-phase 2T coil part 31 is arranged so that the main surface of the rectangular wire faces the central axis 17. It is inserted. In other words, the flat wire of the slot insertion portion 27 is inserted in a direction in which the width direction coincides with the circumferential direction of the stator core 11. And the slot insertion part of the U-phase 4T coil part 33, the U-phase 6T coil part 35, and the U-phase 8T coil part 37 toward the rotation center so as to be stacked on the slot insertion part 27 of the U-phase 2T coil part 31 27 are inserted in order.

  The U-phase 2T coil portion 31 and the U-phase 4T coil portion 33 are arranged so that the connecting wire main surface portions 29 are adjacent to each other in the radial direction, and at a predetermined interval from these connecting wire main surface portions 29, the U-phase 6T The crossover main surface part 29 of the coil part 35 and the U-phase 8T coil part 37 is arrange | positioned so that it may adjoin to radial direction. Therefore, the radial lengths of the horizontal bent portions 28 of the U-phase 6T coil portion 35 and the U-phase 8T coil portion 37 are the radial lengths of the horizontal bent portions 28 of the U-phase 2T coil portion 31 and the U-phase 4T coil portion 33. It is shorter than the length.

  FIG. 9A is an enlarged cross-sectional view of the coil end 20 in FIG. 2A, FIG. 9B is an enlarged cross-sectional view of VV ′, and FIG. 9B is an enlarged cross-sectional view of WW ′. Each is shown in c). As shown in FIG. 2, the U-U ′ cross section, the V-V ′ cross section, and the WW ′ cross section are cross sections at the 44th slot, the 40th slot, and the 29th slot, respectively.

  As shown in FIGS. 9A to 9C, the horizontal bending portion 28 has a relationship between the radial position of the slot insertion portion 27 inserted into the slot 13 and the radial position of the crossover main surface portion 29. The radial length is different.

  As shown in FIG.9 (c), the crossover main surface part 29 is arrange | positioned at two innermost rows, W phase 5T coil part 52, W phase 6T coil part 53, W phase 7T coil part 54, W phase 8T. Regarding the coil portion 55, the horizontal bent portion 28 is not formed because of the relationship with the radial position of the slot insertion portion 27. Thus, the structure without the horizontal bending portion 28 may be used depending on the positional relationship with the crossover main surface portion 29.

  FIG. 10A is a schematic cross-sectional view for explaining the order of insertion of the U-phase coil 14 into the slot of the coil of each layer. In FIG. 10A, only the layers of the U-phase coil 14 are shown for easy understanding. FIG. 10A shows the positions of the layers (1T to 8T) of the crossover main surface portion 29.

  When a coil of each layer is inserted into the slot 13 of the stator iron core 11 formed with the internal tooth-shaped core 12, the coil of the layer inserted through the bottom side of the slot 13, that is, the side farthest from the central axis 17 in the radial direction. Will be inserted from.

  As shown in FIG. 10A, since the coils of the 1T and 2T layers are inserted in the radial direction farthest from the central axis 17, the coils of the 1T and 2T layers are first inserted into the slots 13. . After that, 3T and 4T layers, 5T and 6T layers, and 7T and 8T layers are inserted into the slot 13 in this order.

  In addition, regarding the two layers in which the crossover main surface portion 29 is arranged in two layers in the direction of the central axis 17, the coil of any layer may be inserted into the slot 13 first. For example, a 2T coil may be inserted after a 1T coil is inserted, or a 1T coil may be inserted after a 2T coil is inserted.

  FIG. 10B is a schematic cross-sectional view of the crossover main surface portion 29 for explaining the insertion order of the coils of the respective layers of the phase coils 14 to 16 into the slots of the coils. In FIG. 10B, as in FIG. 10A, the right side of the drawing is shown to be the outermost layer side (the side far from the central axis 17 in the radial direction).

  The coil of the layer arranged on the outermost side in the radial direction of the crossover main surface portion 29 is first inserted into the slot, and the coil of the layer in which the crossover main surface portion 29 is aligned in the radial direction is inserted in this order. Become.

  Therefore, the connecting wire main surface portion 29 has the 1T to 4T layers of the W-phase coil 16 disposed outside the 1T and 2T layers of the U-phase coil 14 in the radial direction. Before inserting the 2T layer coil, the 1T to 4T layer coil of the W-phase coil 16 is inserted. In addition, since the 1T to 8T layers of the V-phase coil 15 are arranged between the 3T and 4T layers of the U-phase coil 14 and the 5T and 6T layers, the 3T and 4T layers of the U-phase coil 14 are After inserting into the slot 13, the coils of the 1T to 8T layers of the V-phase coil 15 are inserted into the slot 13, and then the 5T and 6T layers of the U-phase coil 14 are inserted.

  That is, it inserts in order from the coil of the layer currently described in the outermost layer side in FIG.10 (b). That is, 1T and 2T layers of W-phase coil 16 → 3T and 4T layers → 1T and 2T layers of U-phase coil 14 → 3T and 4T layers → 1T and 2T layers of V-phase coil 15 → 3T and 4T → 5T and 6T layers → 7T and 8T layers → 5T and 6T layers of U-phase coil 14 → 7T and 8T layers → 5T and 6T layers of W-phase coil 16 → 7T and 8T layers Insert in order.

  The order of insertion described above is the order in the case of the manufacturing method in which the coils of each layer are inserted into the slots 13 of the stator iron core 11 on which the internal tooth-shaped core 12 is formed in advance. In the case of the manufacturing method in which the cores 12 are inserted between the slot insertion portions 27 adjacent to each other in the circumferential direction of the phase coils 14 to 16 after the 16 layers are configured, the layers are arranged in the same insertion order as described above. The coil may be assembled, or may be assembled in the reverse order, that is, sequentially from the layer closer to the central axis 17 in the radial direction.

  FIG. 11 is a partial cross-sectional view taken along the line AA ′ of FIG. In FIG. 11, for ease of explanation, the V-phase coil 15 and the W-phase coil 16 are omitted, and only the U-phase coil 14 is illustrated. And the lower figure of FIG. 11 shows the cross-sectional part which expanded further the 1st slot and the 2nd slot part.

  As shown in FIG. 11, each slot 13 has a width at the bottom of the groove wider than the width of the opening of the groove. That is, the cross-sectional area of the slot 13 increases from the opening portion toward the outer diameter direction. Since the circumferential lengths of the outer periphery and inner periphery of the circular stator iron core 11 are different, the cross-sectional shape of the slot 13 is thus trapezoidal.

  Each of the phase coils 14 to 16 of the first embodiment is formed such that the cross-sectional shape of the rectangular wire of the slot insertion portion 27 becomes wider and thinner as the layer is inserted into the bottom side of the slot 13. That is, regarding the slot insertion portion 27 of each layer coil of the U-phase coil 14 inserted into the first slot, the U-phase 2T coil portion 31 has the widest and thinnest cross-sectional shape and is directed toward the opening side. In the order of the U-phase 4T coil portion 33, the U-phase 6T coil portion 35, and the U-phase 8T coil portion 37, the cross-sectional shapes of the rectangular wires are narrower and thicker.

  At this time, by making the cross-sectional areas of the slot insertion portions 27 of the respective layers equal, it is possible to suppress a change in impedance due to a difference in cross-sectional shape.

  Thus, the space factor of the coil in the slot 13 space can be increased by changing the cross-sectional shape of the slot insertion portion 27 in accordance with the space shape of the slot 13 for every number of slots inserted into the slot 13. .

  By increasing the space factor of the coil in the slot 13 space, the outer diameter of the stator 10 can be reduced, and the motor using the stator 10 can be reduced in size and weight.

  FIG. 12A shows a schematic outline of the winding line representing the joining relationship between the layers of the U-phase coil 14. Also, FIGS. 12B and 12C are schematic diagrams of the winding lines representing the bonding relationship between the layers of the V-phase coil 15 and the W-phase coil 16, respectively.

  In FIG. 12 (a), the U-phase 1T coil portion 30 and the U-phase 2T coil portion 31 are indicated by solid lines, the U-phase 3T coil portion 32 and the U-phase 4T coil portion 33 are indicated by broken lines, and the U-phase 5T coil portion 34 and the U-phase are indicated. The 6T coil portion 35 is indicated by a two-dot chain line, and the U-phase 7T coil portion 36 and the U-phase 8T coil portion 37 are indicated by a one-dot chain line. The same applies to the outline diagrams of the V-phase coil 15 and the W-phase coil 16 of FIGS. 12B and 12C.

  One end of the open end 38 of the U-phase 1T coil unit 30 and one end of the open end 38 of the U-phase 2T coil unit 31 are joined by a connection unit 152. Then, the other end portion of the open end 38 of the U-phase 2T coil portion 31 and one end portion of the open end 38 of the U-phase 3T coil portion 32 are joined at the connection portion 153. Similarly, the U-phase 3T coil part 32 and the U-phase 4T coil part 33 are the connection part 154, the U-phase 4T coil part 33 and the U-phase 5T coil part 34 are the connection part 155, and the U-phase 5T coil part 34 and the U-phase. The 6T coil portion 35 is a connection portion 156, the U phase 6T coil portion 35 and the U phase 7T coil portion 36 are connection portions 157, and the U phase 7T coil portion 36 and the U phase 8T coil portion 37 are joined by a connection portion 158, respectively. Is done.

  The other end of the open end 38 of the U-phase 1T coil portion 30 becomes a U-phase start 150, and the other end of the open end 38 of the U-phase 8T coil portion 37 becomes a U-phase end 151. .

  For each layer of the V-phase coil 15, as shown in FIG. 12B, the slots 13 (third slot, fourth slot, ninth slot, 10 slots,...) Have the same joining relationship as each layer of the U-phase coil 14. Similarly, for each layer of the W-phase coil 16, as shown in FIG. 12C, the slots 13 (fifth slot, sixth slot, eleventh slot) in which the slots through which the U-phase coil 14 is inserted are shifted by four slots. The slot, the twelfth slot,...) Have the same joining relationship as each layer of the U-phase coil 14.

  FIG. 13A shows an enlarged perspective view of the coil end 20 portion on the upper side of the first and second slots shown in FIG. In FIG. 13 (a), only the U-phase coil portion is shaded for easy understanding.

  In the above, the U-phase 3T coil part 32 and the U-phase 4T coil part 33, the U-phase 7T coil part 36 and the U-phase 8T coil part 37, respectively, the connecting wire main surface part 29 is stacked in two steps in the direction of the central axis 17. Although described with the arrangement | positioning arrange | positioned, you may make it the structure which overlaps the crossover main surface part 29 of each layer not less than 2 steps | paragraphs in 3 steps or more in the direction of the central axis 17.

  Further, the crossover main surface portion 29 of each layer may not be stacked in the direction of the central axis 17. In that case, for example, the crossover main surface portion 29 is thinned and arranged in parallel in the radial direction.

  FIG. 13B shows an enlarged perspective view of the coil end 20 portion at the upper part of the first and second slots in a configuration in which the crossover main surface portion 29 is thinned and juxtaposed in the radial direction.

  The thickness of the crossover main surface portion 29 of the U-phase 1T coil portion 60 to the U-phase 8T coil portion 67 shown in FIG. 13B is thinner than the crossover main surface portion 29 having the configuration shown in FIG. Instead of a two-tiered configuration, all layers are arranged in parallel in the radial direction.

  Similar to the U-phase coil 14 having the configuration shown in FIG. 13A by doubling the width and halving the thickness of the crossover main surface portion 29 having the configuration shown in FIG. 13A. With the same impedance characteristic, the same coil end 20 height and the same outer diameter stator can be obtained.

  When the thickness of the crossover main surface portion 29 is reduced as shown in FIG. 13B, the processing step and the assembling step are affected. As shown in FIG. Thus, the thickness of the crossover main surface portion 29 may be increased.

  Next, FIG. 14 is a perspective view of the stator having the second configuration according to the first embodiment, FIG. 15 is a top view of the stator having the second configuration according to the first embodiment, and FIG. 16 is the present embodiment. The side view of the stator of the 1st 2nd composition is shown, respectively. The same reference numerals are used for the same components as in FIGS.

  Similar to the stator 10 shown in FIG. 1, the stator 70 is configured by three phase coils of a U-phase coil 71, a V-phase coil 72, and a W-phase coil 73, and these three phase coils 71 to 73 are configured as follows. These are coiled coils each formed by a rectangular wire.

  U-phase coil 71, V-phase coil 72, and W-phase coil 73 have the same shape as U-phase coil 14, V-phase coil 15, and W-phase coil 16 shown in FIGS. The only difference is that the position of the slot 13 into which the phase coils 71 to 73 are inserted is different. Therefore, the U-phase coil 71 has the same shape as the U-phase coil 14 shown in FIG.

  The stator 70 has a configuration in which the positions of the slots through which the V-phase coil and the W-phase coil of the stator 10 shown in FIG. The U-phase coil 71 is inserted into the first slot and the second slot in the same manner as in the stator 10, but in the stator 10, the V-phase coil 15 is inserted into the third slot and the fourth slot. In 70, the W-phase coil 73 is inserted. The V-phase coil 72 is inserted through the fifth slot and the sixth slot.

  As shown in FIGS. 14 and 15, the radial arrangement order of the connecting wire main surface portions 29 of the respective layers of the respective phase coils 71 to 73 is the same as that of the stator 10, and U is provided on both sides of all the layers of the V-phase coil 72. Four layers of phase coil 71 are arranged, and four layers of W phase coil 73 are arranged on both sides thereof.

  Next, FIG. 17 is a perspective view of the third configuration stator of the first embodiment, FIG. 18 is a top view of the third configuration stator of the first embodiment, and FIG. 19 is the present embodiment. The side view of the stator of the 1st 3rd composition is shown, respectively. The same reference numerals are used for the same components as in FIGS.

  Similar to the stator 10 shown in FIG. 1, the stator 80 is configured by three phase coils of a U-phase coil 81, a V-phase coil 82, and a W-phase coil 83, and these three phase coils 81 to 83 include These are coiled coils each formed by a rectangular wire.

  The insertion positions of the phase coils 81 to 83 of the stator 80 in the slots 13 of the respective layers are the same as the insertion positions of the phase coils 14 to 16 of the stator 10 shown in FIGS. That is, the U-phase coil 81 is inserted into the first slot and the second slot, the V-phase coil 82 is inserted into the third slot and the fourth slot, and the W-phase coil 83 is inserted into the fifth slot and the sixth slot.

  The crossover main surface portions 29 of two layers inserted in the same radial position of two adjacent slots 13 are arranged in two stages in the direction of the central axis 17 as in the case of the stator 10.

  That is, as shown in FIG. 19, U-phase 1T crossover 84 and U-phase 2T crossover 85, V-phase 1T crossover 86 and V-phase 2T crossover 87, W-phase 1T crossover 88 and W-phase 2T crossover 89. However, each has a structure of two-tiers in the direction of the central axis 17.

  However, the arrangement order in the radial direction of the crossover main surface portion 29 of each layer of each phase coil 81 to 83 is different from that of the stator 10.

  In the stator 80, in the coil end 20, the connecting wire main surface portion 29 is a set of two layers stacked in two steps in the direction of the central axis 17, and the 1T and 2T layers of the U-phase coil 14 are arranged on the outermost side in the radial direction. A crossover main surface portion 29 of a pair of layers is alternately arranged in the order of the V phase, the W phase, and the U phase.

  Therefore, the connecting wire portions of the layers of the phase coils 81 to 83 in the coil end 20 are, from the outside in the radial direction, the 1T and 2T layers of the U-phase coil 81, the 1T and 2T layers of the V-phase coil 82, and the W phase. 1T and 2T layers of coil 83, 3T and 4T layers of U phase coil 81, 3T and 4T layers of V phase coil 82, 3T and 4T layers of W phase coil 83, 5T and 6T of U phase coil 81 Layers, 5T and 6T layers of V-phase coil 82, 5T and 6T layers of W-phase coil 83, 7T and 8T layers of U-phase coil 81, 7T and 8T layers of V-phase coil 82, W-phase coil The layers are arranged in the order of 83 7T and 8T layers.

  The order in which the layers of the phase coils 81 to 83 are inserted into the slots 13 of the stator iron core 11 is sequentially inserted from the layers arranged outside the connecting wire portion. Each layer will be inserted in order.

  FIG. 20 is a perspective view showing U-phase coil 81 in a state assembled to stator iron core 11 of stator 80 shown in FIG.

  In the coil end 20, a pair of two-layer layers of the V-phase coil 82 and the W-phase coil 83 are arranged between different sets of layers of the U-phase coil 81 that are stacked in two stages. The connecting wire main surface portions 29 of the respective layers are arranged at intervals corresponding to the thicknesses of these layers.

  For example, the U-phase 1T coil unit 90 and the U-phase 2T coil unit 91 are arranged in two layers, and the U-phase 3T coil unit 92 and the U-phase 4T coil unit 93 are arranged in two layers. Between the two sets of two-layered layers, the two-layered layers of V-phase 1T and 2T and the two-layered layers of W-phase 1T and 2T are arranged.

  In the case of the stator 10 shown in FIG. 1, half the layers (four layers) of the U-phase coil 14 are arranged on the outer side and the inner side of the crossover portion of all layers of the V-phase coil 15 at the coil end 20, respectively. Furthermore, since half the layers (four layers) of the W-phase coil 16 are arranged on the outer side and the inner side, the average lengths in the circumferential direction of the crossover portions of the phase coils 14 to 16 are equal. Therefore, in the configuration of the stator 10, the difference in impedance between the phase coils 14 to 16 can be suppressed.

  In the case of the stator 80, the circumferential length is different between the outer peripheral side and the inner peripheral side, so that the average length in the circumferential direction of the crossover portion of each phase coil 81 to 83 is the highest in the U-phase coil 81. The length becomes longer, the W-phase coil 83 becomes the shortest, and a difference occurs between the phases. Due to the difference in the averaged length, a difference in impedance occurs between the phase coils 81 to 83.

  Even in the configuration like the stator 80, the impedance difference between the phase coils can be suppressed by changing the arrangement order of the phase coils in the crossover portion. For example, the arrangement of the crossover portion of each layer of 1T to 4T is as shown in FIG. 17, and the arrangement of the crossover portion of each layer of 5T to 8T is in reverse order to FIG. 17 (from the outside in the radial direction, W phase, V phase, By arranging them in the order of the U phase), the average lengths of the crossover portions in the circumferential direction can be made equal.

  The arrangement of the connecting wire portions of the phase coils in the coil end 20 is a predetermined phase coil (V-phase coil 15 in the stator 10) when each phase coil has an even number of layers as in the stator 10 of FIG. ) Are arranged adjacent to each other, and half the layers (four layers in the stator 10) of another phase coil (U-phase coil 14 in the stator 10) are respectively arranged outside and inside thereof, and further outside and inside thereof. When half the layers (four layers in the stator 10) of another phase coil (the stator 10 in the stator 10) are respectively arranged, the average length in the circumferential direction of the connecting wire portion of each phase coil is Can be equal.

  In the first embodiment, each phase coil is described as having a configuration of 8 layers. However, for example, when each phase coil has 12 layers, the arrangement of the crossover portion of each phase coil at the coil end 20 is described. Is arranged so that 12 layers of a predetermined layer coil are adjacent to each other, and 6 layers of crossover wires of another phase coil are adjacently arranged on the outside and inside thereof, and further on the outside and inside thereof, another phase is arranged. What is necessary is just to arrange | position 6 crossover wires of a coil adjacent to each other.

  Next, FIG. 21 is a perspective view of the stator having the fourth configuration according to the first embodiment, FIG. 22 is a top view of the stator having the fourth configuration according to the first embodiment, and FIG. 23 is the present embodiment. The side view of the stator of 1st 4th structure is each shown. The same reference numerals are used for the same components as in FIGS.

  Similarly to the stator 80 shown in FIG. 17, the stator 100 is configured by three phase coils of a U-phase coil 101, a V-phase coil 102, and a W-phase coil 103, and these three phase coils 101 to 103 are These are coiled coils each formed by a rectangular wire.

  U-phase coil 101, V-phase coil 102 and W-phase coil 103 have the same shape as U-phase coil 81, V-phase coil 82 and W-phase coil 83 shown in FIGS. The only difference is that the positions of the slots 13 into which the phase coils 101 to 103 are inserted are different. Therefore, the U-phase coil 101 has the same shape as the U-phase coil 81 shown in FIG.

  Stator 100 has a configuration in which the positions of slots through which the V-phase coil and W-phase coil of stator 80 shown in FIG. The U-phase coil 101 is inserted into the first slot and the second slot in the same manner as in the stator 80. In the stator 80, the V-phase coil 82 is inserted into the third slot and the fourth slot. In 100, the W-phase coil 103 is inserted. The V-phase coil 102 is inserted into the fifth slot and the sixth slot.

  As shown in FIGS. 21 and 22, the radial arrangement order of the crossover main surface portions 29 of the layers of the phase coils 101 to 103 is the same as that of the stator 80.

  As described above, since the stator having a short coil end can be realized by using the winding coil of the first embodiment, the motor and the generator can be downsized.

  Moreover, the difference of the impedance between each phase coil can be suppressed by adjusting arrangement | positioning of the crossover part of each phase coil in a coil end.

  In the first embodiment, each phase coil has been described as having eight layers. However, each phase coil has not only eight layers, but each phase coil has two or more layers. The present invention can be applied.

(Embodiment 2)
FIG. 24 is a perspective view of a stator according to a second embodiment of the invention related to the present invention, FIG. 25 is a top view of the stator of the second embodiment, and FIG. 26 is a side view of the stator of the second embodiment. Each is shown.

  As shown in FIG. 24, the stator iron core that constitutes the stator 110 of the second embodiment is the same as the stator iron core 11 that constitutes the stator 10 of the first embodiment, and has 48 cores 12. And a slot 13.

  The stator 110 is composed of three phase coils, a U-phase coil 111, a V-phase coil 112, and a W-phase coil 113, and these three phase coils 111, 112, 113 are each formed by waves formed by rectangular wires. It is a burning coil.

  Each phase coil has four layers in which each layer is for one turn, and each phase is arranged so as to be inserted into every third slot 13. In each slot 13, four layers of the same phase are inserted.

  24 to 26, the four layers of the U-phase coil 111 are denoted as 1T to 4T, respectively. Each slot 13 is inserted with 1T to 4T layers in order from the bottom of the slot, that is, from the side far from the central axis 17 in the radial direction.

  In the case of the stator 110 of the second embodiment, the W-phase coil 113, the V-phase coil 112, and the U-phase coil 111 are alternately inserted into the slots 13 that are anticlockwise when viewed from above in FIG. ing. A W-phase coil 113 is inserted in the first slot, a V-phase coil 112 is inserted in the next second slot, and a U-phase coil 111 is inserted in the next third slot. Then, the W-phase coil 113 protruding from the first slot to the upper coil end 20 portion of the stator core 11 passes through the connecting wire portion bent in the counterclockwise direction when viewed from above the stator 110, and then Insert into 4 slots. Similarly, the V-phase coil 112 that has come out from the second slot to the upper coil end 20 portion of the stator core 11 is inserted into the fifth slot through the crossover portion. The W-phase coil 113 inserted downward in the fourth slot is now inserted into the eighth slot through the connecting wire portion of the lower coil end 20 portion of the stator core 11.

  As shown in FIGS. 24 to 26, in the crossover portion of each phase coil 111, 112, 113, the main surface, that is, the wide surface of the flat wire is oriented in a direction perpendicular to the central axis 17.

Note that the main surface of the crossover portion corresponds to an example of a main portion of the crossover portion of the invention related to the present invention.

  FIG. 26 is a side view of the stator 110 shown in FIG. 24 viewed from the front side. That is, it is the side view which looked at the open side of the groove of the first slot from the front.

  In the coil end 20, the main surface of the 1T connecting wire portion (U phase 1T connecting wire 114) of the U phase coil 111 is disposed at a position closest to the stator iron core 11.

  The main surfaces of the U-phase 1T connecting wire 114 are arranged in this order so that the main surfaces of the U-phase 2T connecting wire 115, the U-phase 3T connecting wire 116, and the U-phase 4T connecting wire 117 overlap each other in the direction of the central axis 17. It is arranged adjacent to.

  Thus, the connecting wire portions of the respective phases of the respective phase coils 111 to 113 are arranged in parallel to each other in the direction of the central axis 17 on their main surfaces.

  Next, it is arranged adjacent to the U-phase 4T crossover line 117 so that the main surface of the V-phase 1T crossover line 118 overlaps in the direction of the central axis 17. The main surfaces of the V-phase 1T connecting wire 118 are arranged in this order so that the main surfaces of the V-phase 2T connecting wire 119, the V-phase 3T connecting wire 120, and the V-phase 4T connecting wire 121 overlap in the direction of the central axis 17. It is arranged adjacent to.

  Further, in order of the V-phase, the principal surfaces of the W-phase 1T connecting wire 122, the W-phase 2T connecting wire 123, the W-phase 3T connecting wire 124, and the W-phase 4T connecting wire 125 overlap in the direction of the central axis 17. It is arranged adjacent to the main surface of the 4T crossover line 121.

  FIG. 27 is a perspective view showing U-phase coil 111 in a state assembled to stator iron core 11 of stator 110 shown in FIG.

  The U-phase 1T coil portion 126, the U-phase 2T coil portion 127, the U-phase 3T coil portion 128, and the U-phase 4T coil portion 129 respectively indicate the coil portions of the 1T to 4T layers of the U-phase coil 111.

  The slot insertion part 160 indicates a straight part that is inserted into the slot 13 of each of the U-phase 1T coil part 126 to the U-phase 4T coil part 129.

  As shown in FIG. 27, the U-phase 1T coil portion 126, the U-phase 2T coil portion 127, the U-phase 3T coil portion 128, and the U-phase 4T coil portion 129 are inserted next to the end portion of the slot insertion portion 160 and the next. A U-phase 1T crossover wire 114, a U-phase 2T crossover wire 115, a U-phase 3T crossover wire 116, and a U-phase 4T crossover wire 117 are formed to connect the end portions of the slot insertion portion 160. The U-phase 1T connecting wire 114, the U-phase 2T connecting wire 115, the U-phase 3T connecting wire 116, and the U-phase 4T connecting wire 117 are bent radially outward at the end of the slot insertion portion 160 so that the main surface of the rectangular wire is A shape that is perpendicular to the central axis 17, is bent in the circumferential direction toward the slot to be inserted next while the main surface is orthogonal to the central axis 17, and is bent toward the rotation center at the radial position of the slot to be inserted next. is doing.

  Further, as shown in FIG. 25, the width W6 of the rectangular wire of the W-phase 4T connecting wire 125 is larger than the width W5 of the rectangular wire in the slot insertion portion 160. The cross-sectional area of the rectangular wire in the W-phase 4T connecting wire 125 is configured to be the same as the cross-sectional area of the rectangular wire in the slot insertion portion 160. Therefore, the thickness of the rectangular wire in the W-phase 4T connecting wire 125 is thinner than the thickness of the rectangular wire in the slot insertion portion 160.

  The connecting wires (U-phase 1T connecting wire 114 to W-phase 3T connecting wire 124) of the other layers of each phase coil have the same shape as the W-phase 4T connecting wire 125.

  By making the cross-sectional area of the rectangular wire in the slot insertion portion 160 equal to the cross-sectional area of the rectangular wire in the connecting wire of each layer of each phase coil, the impedance change accompanying the change in the cross-sectional shape of each layer of each phase coil is suppressed. is doing.

  Further, the length of the coil end 20 determined by the sum of the thicknesses of the crossover wires of the respective layers in which the principal surfaces are superposed in the direction of the central axis 17 by reducing the thickness of the flat wire of the crossover wire of each layer of each phase coil. Can be shortened.

  As described above, since the stator having a short coil end can be realized by using the winding coil of the second embodiment, the motor and the generator can be downsized.

In the second embodiment, each phase coil is described as having four layers. However, each phase coil is not limited to four layers, and each phase coil has two or more layers. The invention of Embodiment 2 can be applied.

(Embodiment 3)
Next, as a third embodiment of the invention related to the present invention , a method for manufacturing a rectangular wire used in the wave coil of the present invention will be described.

  The manufacturing method of the third embodiment is a method of manufacturing a rectangular wire before bending a coil of each phase of the present invention as shown in, for example, the developed view of FIG.

  FIG. 28 is a view showing a part of the rotating surface on which the mold is formed of the mold roller used in the third embodiment. FIG. 28 shows a portion corresponding to a rectangular wire used for U-phase 1T coil portion 30 and U-phase 2T coil portion 31 of the first embodiment.

  FIG. 29 is a diagram for explaining the first method for manufacturing a flat wire according to the third embodiment.

  In Embodiment 3, a rectangular wire is continuously produced by rotating a mold roller having a mold formed on a rotating surface.

  A mold 131 as shown in FIG. 28 is formed on the mold surface 130 of the mold roller 136. This mold 131 is in the shape of a rectangular wire before the wave coil of the present invention is bent. For example, the portion of the mold 131 described as “2T coil development area” in FIG. 28 corresponds to a rectangular wire before the U-phase 2T coil portion 31 in FIG. 5 is bent.

Incidentally, the mold roller 136 to an example of a rotary mold of the present invention relating to the present invention, the mold surface 130 corresponds to an example of a rotary mold of the rotating surface of the invention relating to the present invention.

  In FIG. 28, the mold 131 is provided with three connection portions 132 to 134.

  The connection part 132 is a connection part for continuously manufacturing a rectangular wire. The casting material can be continuously poured into the mold 131 through the connecting portion 132. Since this connecting portion 132 is a portion that becomes the end of the U-phase 1T coil portion 30, a portion obtained by cutting this connecting portion 132 after producing a continuous rectangular wire is a U-phase winding shown in FIG. The first is 150.

  Connection portion 133 is a joint between a portion corresponding to U-phase 1T coil portion 30 and a portion corresponding to U-phase 2T coil portion 31. After producing a continuous rectangular wire, this portion becomes one end of the open end 38 of the U-phase 2T coil portion 31 shown in FIG.

  In the case of the U-phase coil 14 according to the first embodiment, the U-phase 2T coil portion 31 is inserted next to the U-phase 1T coil portion 30. In this case, the U-phase coil 14 is not cut at the connection portion 133. It can also be processed into a rectangular wire in a state where the phase 1T coil portion 30 and the U phase 2T coil portion 31 are connected, and can be assembled to the stator iron core 11. In this case, this connection part 133 at the time of producing the rectangular wire becomes the connection part 152 shown in FIG. 12A after the coil is assembled.

  Similarly to the connection part 133, the connection part 134 is a connection part with a flat wire that becomes a coil part of the next layer. When the insertion order into the slot 13 is continuous, the connection part 134 is not cut. Can be processed and assembled.

  Further, by adjusting the depth of the mold 131, a rectangular wire having a required thickness can be manufactured. 28, the depth corresponding to the thickness required for each of the slot insertion portion 27 and the W-phase 2T connecting wire 26 of the U-phase 2T coil portion 31 of the first embodiment. A mold 131 is formed so that

  Therefore, by producing a flat wire using such a mold 131, a wave coil is completed only by cutting and bending.

  Next, the 1st manufacturing method of the flat wire of this Embodiment 3 is demonstrated concretely.

  By moving the supply port of the molten copper supply nozzle 137 in a direction perpendicular to the moving direction of the mold surface 130 according to the moving speed of the rotating mold surface 130, the mold surface 130. The molten copper can be continuously supplied to the mold 131.

  As shown in FIG. 29, the mold roller 136 is rotated while the mold surface 130 is heated. The molten copper is continuously poured from the molten copper supply nozzle 137 into the mold 131 that is moved by the rotating operation.

  Then, the excess molten copper poured into the mold 131 is scraped off by the scraping portion 138 provided on the downstream side of the mold roller 136.

  The molten copper poured into the mold 131 is solidified by blowing cold air toward the mold surface 130 from the cooling unit 139 provided further downstream of the mold roller 136.

  Then, the winding wire 140 provided further on the downstream side of the mold roller 136 winds up the rectangular wire that is solidified by solidification of the molten copper.

  Next, a second method for manufacturing a flat wire according to the third embodiment will be described.

  FIG. 30 is a diagram for explaining a second method of manufacturing a rectangular wire according to the third embodiment.

  In the second method for producing a flat wire, semi-solid copper is poured into a mold, and a flat wire is continuously produced by utilizing the peelability and adsorptivity to the semi-solid copper.

  The metal roller 141 used in the second manufacturing method has a rotating surface 147 made of ceramic that is highly peelable from semi-solid copper. A mold 131 similar to the mold surface 130 is formed on the rotating surface 147.

Incidentally, the mold roller 141 corresponds to an example of a rotary mold of the present invention relating to the present invention, the rotation surface 147 corresponds to an example of a rotating surface of a rotating mold invention relating to the present invention.

  The semi-solid copper supply nozzle 142 also supplies semi-solid copper continuously to the mold 131 on the rotating surface 147 by moving the semi-solid copper supplying nozzle 142 in a direction perpendicular to the moving direction of the rotating surface 147, similarly to the molten copper supplying nozzle 137. can do.

  As shown in FIG. 30, semi-solid copper is continuously supplied from a semi-solid copper supply nozzle 142 into a mold 131 that is moved by the rotation operation of the mold roller 141.

  A pressing roller 144 that rotates in the same direction as the mold roller 141 and presses the rotating surface 147 of the mold roller 141 by the surface 145 is provided on the downstream side of the mold roller 141.

  The material of the surface 145 of the pressing roller 144 is made of iron having a high adsorptivity to semi-solid copper.

  When the rotating surface 147 of the mold roller 141 is pressed by the surface 145 of the pressing roller 144, the semi-solid copper supplied to the mold 131 on the rotating surface 147 is adsorbed on the surface 145 of the pressing roller 144.

  Then, the rectangular solid semi-solid copper adsorbed on the surface 145 of the pressing roller 144 is wound up by the winding portion 146 provided on the downstream side of the pressing roller 144.

  Here, although the material of the rotating surface 147 of the mold roller 141 is ceramic and the material of the surface 145 of the pressing roller 144 is iron, it is not limited to these materials.

  As the material of the rotating surface 147 and the surface 145, the rotating surface 147 may be a material that has a higher peelability to semi-solid copper than the surface 145, and the surface 145 has a higher absorbability to semi-solid copper than the rotating surface 147. That's fine.

  In addition, in the method for manufacturing a rectangular wire according to the third embodiment, a rectangular wire in which the coils of each layer are continuous can be produced. Therefore, for the coils of the layers that are continuously inserted into the slots when assembled to the stator iron core, Since it can be bent and assembled while the connection portions of the layer coils are connected, the joining step between these layer coils becomes unnecessary, and the subsequent steps can be simplified.

  For example, in the case of the first embodiment shown in FIG. 1, all the layers (1T to 8T) are inserted into the stator iron core 11 in a continuous order for the V-phase coil 15, so these eight layers. The rectangular wire produced in a state where the rectangular wires corresponding to the coils are connected can be bent and inserted into the stator iron core 11 without cutting. Similarly, in the case of the stator 10 in FIG. 1, the coils of the 1T to 4T layer of the U phase coil 14, the coils of the 5T to 8T layer of the U phase coil 14, and the 1T to 4T layers of the W phase coil 16. For each of the coils of the 1T to 4T layers of the coil and the W-phase coil 16, the rectangular wire produced in a state where the rectangular wires are connected is bent without being cut and inserted into the stator iron core 11. Can do.

  Thus, the joint part between layer coils can be reduced significantly.

  As described above, by using the method for manufacturing a rectangular wire according to the third embodiment, it is possible to continuously produce a rectangular wire that can be easily processed thereafter.

  In this specification, the example in which the wave coil of the present invention is applied to the stator side has been described. However, the structure of the wave coil of the present invention can also be applied to the rotor side as it is.

  Further, in this specification, the description about the insulation of the coil wire is omitted, but of course, processing between the wires is necessary in the present invention. Recently, abundant insulation processing technologies such as cationic coating and electrodeposition coating have been established, and coatings with excellent pressure resistance and heat resistance are provided.

Wave Maki coil according to the present invention has an effect capable of shortening the coil end than conventional useful as a wave Maki coil for use in motors and generators.

The perspective view of the stator of Embodiment 1 of this invention Top view of the stator of Embodiment 1 of the present invention Side view of the stator of Embodiment 1 of the present invention The perspective view of the U phase coil of the state assembled | attached to the stator of Embodiment 1 of this invention The perspective view of the U-phase 2T coil part of Embodiment 1 of this invention Side view of U-phase 2T coil section according to Embodiment 1 of the present invention The partial expanded view of the U-phase 1T coil part and U-phase 2T coil part of Embodiment 1 of this invention Partially enlarged top view of the U-phase coil according to Embodiment 1 of the present invention (A) U-U 'enlarged sectional view of the coil end portion of Embodiment 1 of the present invention, (b) VV' enlarged sectional view of the coil end portion of Embodiment 1 of the present invention, (c) ) Enlarged cross-sectional view of the coil end portion of the first embodiment of the present invention. (A) Schematic cross-sectional view for explaining the insertion sequence of each layer of the U-phase coil into the slot according to the first embodiment of the present invention, (b) Each layer of each phase coil according to the first embodiment of the present invention. Cross-sectional schematic diagram of the crossover main surface for explaining the insertion order into the slot AA 'partial sectional view of a stator according to Embodiment 1 of the present invention FIG. 3 is a schematic diagram of a winding line representing the joining relationship of each layer of the U-phase coil according to the first embodiment of the present invention. Outline diagram of the winding line showing the joining relationship of each layer of the V-phase coil according to the first embodiment of the present invention. Outline diagram of the winding line representing the joining relationship of each layer of the W-phase coil according to the first embodiment of the present invention. (A) Enlarged perspective view of the slot end portion of the stator according to the first embodiment of the present invention, (b) Enlarged perspective view of the slot end portion of the stator of another configuration according to the first embodiment of the present invention. The perspective view of the stator of the 2nd structure of Embodiment 1 of this invention The top view of the stator of the 2nd structure of Embodiment 1 of this invention Side view of the stator having the second configuration according to the first embodiment of the present invention. The perspective view of the stator of the 3rd structure of Embodiment 1 of this invention The top view of the stator of the 3rd composition of Embodiment 1 of the present invention. Side view of the stator having the third configuration according to the first embodiment of the present invention. The perspective view of the U phase coil of the state assembled | attached to the stator of the 3rd structure of Embodiment 1 of this invention. The perspective view of the stator of the 4th structure of Embodiment 1 of this invention Top view of the stator having the fourth configuration according to the first embodiment of the present invention. Side view of the stator having the fourth configuration according to the first embodiment of the present invention. A perspective view of a stator according to a second embodiment of the invention related to the present invention Top view of a stator according to a second embodiment of the invention related to the present invention Side view of a stator according to a second embodiment of the invention related to the present invention The perspective view of the U phase coil in the state assembled | attached to the stator of Embodiment 2 of the invention relevant to this invention The figure which showed a part of rotating surface in which the casting_mold | template was formed of the metal mold | die roller used with the manufacturing method of the flat wire of Embodiment 3 of the invention relevant to this invention The figure explaining the 1st manufacturing method of the flat wire of Embodiment 3 of the invention relevant to this invention The figure explaining the 2nd manufacturing method of the flat wire of Embodiment 3 of the invention relevant to this invention The perspective view of the strand for demonstrating the arrangement | sequence of the strand which comprises the stator strand used for the conventional electric motor Parallel connection diagram of stator windings used in conventional electric motors

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Stator 11 Stator iron core 12 Core 13 Slot 14 U-phase coil 15 V-phase coil 16 W-phase coil 17 Central axis 20 Coil end 21 U-phase 1T connecting wire 22 U-phase 2T connecting wire 23 V-phase 1T connecting wire 24 V-phase 2T Crossover 25 W-phase 1T crossover 26 W-phase 2T crossover 27 Slot insertion part 28 Horizontal bending part 29 Crossover main surface part 30 U-phase 1T coil part 31 U-phase 2T coil part 32 U-phase 3T coil part 33 U-phase 4T coil Part 34 U phase 5T coil part 35 U phase 6T coil part 36 U phase 7T coil part 37 U phase 8T coil part 38 Open end 40 V phase 1T coil part 41 V phase 2T coil part 42 V phase 3T coil part 43 V phase 4T Coil part 44 V phase 5T coil part 45 V phase 6T coil part 46 V phase 7T coil part 47 V phase 8T coil part 48 W phase 1T coil Part 49 W phase 2T coil part 50 W phase 3T coil part 51 W phase 4T coil part 52 W phase 5T coil part 53 W phase 6T coil part 54 W phase 7T coil part 55 W phase 8T coil part 60 U phase 1T coil part 61 U phase 2T coil part 62 U phase 3T coil part 63 U phase 4T coil part 64 U phase 5T coil part 65 U phase 6T coil part 66 U phase 7T coil part 67 U phase 8T coil part 70 Stator 71 U phase coil 72 V phase Coil 73 W-phase coil 74 U-phase 1T crossover wire 75 U-phase 2T crossover wire 76 V-phase 1T crossover wire 77 V-phase 2T crossover wire 78 W-phase 1T crossover wire 79 W-phase 2T crossover wire 80 Stator 81 U-phase coil 82 V-phase Coil 83 W phase coil 84 U phase 1T crossover line 85 U phase 2T crossover line 86 V phase 1T crossover line 87 V phase 2T crossover line 88 W phase 1T crossover line 89 W phase 2 Crossover 90 U-phase 1T coil section 91 U-phase 2T coil section 92 U-phase 3T coil section 93 U-phase 4T coil section 94 U-phase 5T coil section 95 U-phase 6T coil section 96 U-phase 7T coil section 97 U-phase 8T coil section 100 Stator 101 U-phase coil 102 V-phase coil 103 W-phase coil 104 U-phase 1T crossover wire 105 U-phase 2T crossover wire 106 V-phase 1T crossover wire 107 V-phase 2T crossover wire 108 W-phase 1T crossover wire 109 W-phase 2T crossover wire 110 Stator 111 U-phase coil 112 V-phase coil 113 W-phase coil 114 U-phase 1T connecting wire 115 U-phase 2T connecting wire 116 U-phase 3T connecting wire 117 U-phase 4T connecting wire 118 V-phase 1T connecting wire 119 V-phase 2T connecting wire 120 V-phase 3T connecting wire 121 V-phase 4T connecting wire 122 W-phase 1T connecting wire 123 W-phase 2T connecting wire 124 W-phase 3 T crossover wire 125 W phase 4T crossover wire 126 U phase 1T coil part 127 U phase 2T coil part 128 U phase 3T coil part 129 U phase 4T coil part 130 Mold surface 131 Mold 132-134 Connection part 136 Mold roller 137 Melting Copper supply nozzle 138 Scraping part 139 Cooling part 140 Winding part 141 Mold roller 142 Semi-solid copper supply nozzle 144 Pressing roller 145 Surface 146 Winding part 150 Beginning of winding 151 Finishing 152-158 Connection part 160 Slot insertion part

Claims (4)

It is a wave coil provided with each phase coil of U phase, V phase, and W phase,
Each phase coil is a flat wire having an even number of layers ;
The main part of the crossover part at the coil end of each phase coil is such that the main surface of the rectangular wire is parallel to the rotation axis,
Each phase coil is arranged in parallel with each other in the radial direction in the main part of the crossover portion ,
The length obtained by averaging the lengths of the plurality of layers of the phase coils in each of the phase coils is substantially the same in the U phase, the V phase, and the W phase,
When the three phase coils are a first phase coil, a second phase coil, and a third phase coil,
The main part of the crossover portion of the half layer of the first phase coil is arranged on the outermost side in the radial direction, and the main part of the crossover portion of the remaining half layer of the first phase coil is The innermost radial direction,
The main portion of the crossover portion of the half layer of the second phase coil is adjacent to the main portion of the crossover portion of the half layer of the first phase coil arranged on the outermost side, and the diameter The main part of the crossover portion of the remaining half layer of the second phase coil, which is arranged inside the direction, is the main part of the crossover portion of the remaining half layer of the first phase coil arranged on the innermost side. Adjacent to the main part, disposed outside the radial direction,
The main part of the crossover part of all the layers of the third phase coil is the main part of the crossover part of the half layer of the second phase coil and the remaining half layer of the second phase coil. A wavy coil disposed between the main portion of the crossover portion of the coil. The plurality of layers of each phase coil are divided into a plurality of adjacent slots and inserted,
The plurality of layers inserted through the adjacent slots, the crossover portion is formed in the same direction,
The main part of the connecting wire portion of the layer that is inserted into the main portion and the other slot of the crossover wire portion of the layer which is inserted into one of the slots, and is stepped overlap in the rotation axis direction, to claim 1 Wavy coil as described. The out of phase coil slots of the connecting wire portions for entering the next slot, the portion exiting from the slot of the at least a portion of the phase coils are bent in a direction perpendicular to the rotation axis,
The wave coil according to claim 1 , wherein both side ends of the bent portion protrude to the center of the core portion forming the slot to the maximum. A plurality of layers of the same phase coil are inserted into one slot formed in the core, and the plurality of layers inserted into the one slot are layers close to the bottom of the groove forming the slot. The wave coil according to claim 1, wherein the coil is thinner and wider and the cross-sectional areas of each layer are equal.