JP5151309B2 - Rotating electric machine - Google Patents

Description

  The present invention relates to a rotating electrical machine, and more particularly to a rotating electrical machine in which a stator core coil is resin-molded.

  A coil is wound around the stator of the rotating electrical machine, and the winding portion or the coil end may protrude from the stator core. Resin molding is performed in order to fix and protect portions such as the coil ends.

  For example, Patent Document 1 discloses a configuration in which a concentrated winding is used as a servo motor stator, a plurality of coils and wiring portions are resin-molded, and a heat dissipating frame is provided on the outer periphery of the stator core. It is stated that this makes it possible to improve the heat dissipation against the heat generated during the servo lock.

  In Patent Document 2, in the resolver stator structure, an outer surface molding portion by BMC (Bulk Molding Compound) molding using a thermosetting resin material such as unsaturated polyester is formed on the outer surface of the resin mold portion of the thermoplastic resin. By forming the outer surface forming portion, a positioning portion having an outer surface protruding shape of the connector portion is formed. Here, unsaturated polyester has a linear expansion coefficient close to that of iron and lower than that of other thermoplastic resins. Further, it is stated that the strength can be improved by this double molding.

JP 2004-289928 A JP 2003-294488 A

  Such a resin mold type rotating electrical machine improves the handleability, but on the other hand, there may be a problem related to heat generation due to the operation of the rotating electrical machine. For example, the heat dissipation characteristics deteriorate at a thick part of the mold resin.

  The objective of this invention is providing the resin mold type rotary electric machine which can improve a thermal radiation characteristic.

Rotating electrical machine of the present onset Ming, a coil having a stator core, a coil wound around the stator core, a coil end portion protruding from the stator core in the axial direction, a shape which is uneven in the axial direction of the plane of the stator core as a reference And a connector part for a terminal drawn from the coil, the connector part provided on the outer diameter side of the stator core, and a resin mold part covering at least the coil part, the resin mold part being a coil of the coil integrated along the outer shape of the concavo-convex shape of the end portion covering the coil with a uniform thickness, a coil mold part for chromatic axial become uneven shape the face of the stator core as a reference, and a connector mold covering the connector portion Thus, a mold resin layer is formed.

The rotary electric machine according to the present onset Ming, a plurality of coils wound around the stator core, each coil has an outer peripheral shape that is in contact with the linear in the back yoke side of the stator core, by connecting the outer peripheral shape of a plurality of coils yuku When forming a polygonal shape, a resin mold portion is had contact to the back yoke side of the stator core to cover the plurality of coils with a uniform thickness along the polygonal shape formed by the outer peripheral shape of the plurality of coils, a plurality of preferably molded resin layer is formed having a shape which is polygonal on the outer peripheral side of the coil.

The upper Ki構 formation, the resin molded part, the mold resin layer is formed to have an uneven shape along the outer shape of the coil. Thereby, the thickness of the resin mold part which covers a coil can be made substantially uniform, and heat dissipation can be improved. In addition, the amount of resin for forming the resin mold portion can be suppressed, and the amount can be made efficient.
Further, a connector portion is provided on the outer diameter side of the stator, and the connector portion is integrated with the coil portion to form a mold resin layer. Thereby, the thickness of the resin mold part which covers a coil including a connector part can be made substantially uniform, and heat dissipation can be improved. In addition, the amount of resin for forming the resin mold portion can be suppressed, and the amount can be made efficient. In addition, compared to the case where the connector portion is provided along the axial direction of the stator, the rotating electrical machine has a reduced axial length.

Further, the upper Ki構 formation, the resin molded part, the mold resin layer is formed to have a polygonal shape along the outer peripheral shape of the coils in the back yoke side of the stator core. Thereby, the thickness of the resin mold part which covers the outer peripheral part of a coil can be made substantially uniform, and heat dissipation can be improved.

  Embodiments according to the present invention will be described below in detail with reference to the drawings. In the following, a multiphase concentrated winding rotary electric machine will be described as the rotary electric machine, but any rotary electric machine in which a plurality of coils are wound around the stator may be used. For example, a distributed winding type rotating electrical machine may be used. Moreover, the shape of the resin mold part demonstrated below is an example for description, Comprising: It can change suitably with the shape of a stator, the winding shape of a coil, etc.

  FIG. 1 is a diagram showing an external appearance of a stator 10 in a multiphase concentrated winding electric rotating machine. The multi-phase concentrated winding rotary electric machine is configured by housing a stator 10 in which a multi-phase winding is wound around each of multi-phase poles by concentrated winding and a rotor (not shown) in a case. Below, the part of the stator 10 which is a characteristic matter of the multiphase concentrated winding rotary electric machine will be extracted and described.

  As shown in FIG. 1, the stator 10 includes a stator core 20 and a resin mold part 30. FIG. 2 is a diagram illustrating a state where the resin mold portion 30 is removed from the stator 10, that is, a state of the semi-finished stator 6 before the resin molding is performed.

  As shown in FIG. 2, the semi-finished stator 6 includes a stator core 20 and a plurality of coils 22 wound around the stator core 20. In the example of FIG. 2, twelve coils are shown as the semi-finished stator 6 for a three-phase, twelve-pole multiphase concentrated winding rotary electric machine.

  The stator core 20 is an annular member made of a magnetic material having a plurality of protrusions called teeth from the outer peripheral side toward the inner peripheral side. The stator core 20 can be obtained by laminating a plurality of thin electromagnetic steel sheets punched into a shape having a plurality of protrusions called teeth 24 from the outer peripheral side toward the inner peripheral side. it can.

  The coil 22 is obtained by winding a conductor wire in a concentrated winding manner for each tooth 24 of the stator core 20. In FIG. 2, the teeth 24 are covered with the coil 22 and are not shown except for the tip portion. Concentrated winding is a winding form in which a conductor wire is wound around a plurality of times for one phase around one tooth 24 to form a coil 22. In the case of a three-phase rotating electrical machine, one of the U-phase, V-phase, and W-phase windings is wound around one tooth 24. In the example of FIG. 2, since there are 12 teeth 24, a total of 12 coils of 4 U-phase coils, 4 V-phase coils, and 4 W-phase coils are formed for each tooth 24. Become.

  Thus, the coil 22 is intensively wound around the teeth 24 of the stator core 20 a plurality of times, so that the coil 22 has a shape protruding in the axial direction of the stator core 20. Although this protruding portion is sometimes called a coil end, when viewed from the whole semi-finished stator 6, the coil end portion protrudes in the axial direction of the stator core 20, and in the circumferential direction of the stator core 20, the number of the coils 22. It has a shape with corresponding irregularities.

  Returning to FIG. 1 again, the resin mold portion 30 is a stator 10 in which the coil end portion is covered with a mold resin layer, and has a function of fixing the coil end portion. And this resin mold part 30 has the uneven | corrugated shape along the external shape of the coil 22 demonstrated in FIG. 2, and the mold resin layer is formed. In other words, the mold resin layer is formed in an appropriate thickness with the uneven shape of the coil described in FIG.

  The effect of this structure is demonstrated using FIGS. 3-5. In the following, the same elements as those in FIGS. 1 and 2 are denoted by the same reference numerals, and detailed description thereof is omitted. In the following, description will be made using the reference numerals in FIGS. 3 is a view showing a state of a resin molded stator 8 that has been generally used conventionally, FIG. 4 is a cross-sectional view of a resin mold stator of the prior art, and FIG. 5 is a cross-sectional view of the stator 10 described in FIG. is there.

  As shown in FIG. 3, in the conventional resin mold stator 8, the resin mold portion 28 is formed with a mold resin layer in an annular shape. In other words, the resin mold portion 28 in this case has an annular shape with a certain thickness from the surface of the stator core 20, and the surface thereof is flat regardless of the uneven shape of the coil 22 inside.

  As shown in the cross-sectional view of FIG. 4, the conventional resin-molded stator 8 has a rectangular cross-section in the side view regardless of the concave-convex shape of the internal coil 22. Therefore, the thickness of the mold resin layer has a thin part and a thick part depending on the outer shape of the coil 22. In other words, the thickness of the mold resin layer is uneven depending on the location.

  On the other hand, the stator 10 described in FIG. 1 has a concavo-convex shape along the concavo-convex outer shape of the coil 22 protruding in the axial direction of the stator core 20 as shown in FIG. 5 which is a sectional view. In other words, the mold resin layer has a substantially uniform thickness over the entire area covering the coil 22. According to this structure, it can prevent that heat dissipation falls in the part where a mold resin layer is too thick like the prior art. Further, as can be seen by comparing FIG. 4 and FIG. 5, the amount of resin required for forming the resin mold portion is less than that of the prior art, so that it is less expensive and economical. It is.

  In the above description, the example in which the mold resin layer is formed with an uneven shape along the outer shape of the coil has been described. Here, the uneven shape refers to a portion protruding in the axial direction of the stator. Here, even when the outer peripheral shape of the coil on the outer peripheral side of the stator is a polygon, it is preferable to form the mold resin layer along the polygon. FIG. 6 is a view showing such a stator 12.

  The stator 12 includes a stator core 20 and a resin mold portion 32 having a polygonal shape on the outer peripheral side and a circular outer shape on the inner peripheral side. The semi-finished stator from which the resin mold portion 32 is removed is the same as that described in FIG. As shown in FIG. 2, the twelve coils 22 are in contact with each other on the outer peripheral side of the stator core 20, but the contacted portions are often linear. Here, the portion on the outer peripheral side of the stator core 20 corresponds to a portion that is not the tooth 24 and may be called a back yoke. That is, the portion where each coil 22 is in contact with the back yoke of the stator core 20 is often linear. Or even if it is not linear, if the outer peripheral shape of the 12 coils 22 is tied in the outer peripheral side of the stator core 20, it will become a shape close | similar to a dodecagon.

  The resin mold part 32 has a polygonal shape along a dodecagonal shape connecting the outer peripheral shapes of the twelve coils 22, and a mold resin layer is formed. In other words, the mold resin layer is formed with a substantially uniform thickness on the outer peripheral side of the coil 22 on the outer peripheral side in the radial direction of the stator core 20.

  The effect of this structure is demonstrated using FIG. 7, FIG. In the following, the same elements as those in FIGS. 1 to 6 are denoted by the same reference numerals, and detailed description thereof is omitted. In the following, description will be made using the reference numerals in FIGS. 7 is a cross-sectional view of the prior art resin-molded stator 8 described in FIG. 3, and FIG. 8 is a cross-sectional view of the stator 12 described in FIG.

  Since the conventional resin-molded stator 8 has an annular resin-molded portion 28, as shown in the cross-sectional view of FIG. 7, the cross-section in the plan view regardless of the outer peripheral shape of the internal coil 22. Is an annular shape. Therefore, a portion A in which the thickness of the mold resin layer is thinner on the outer peripheral side of the coil 22 than in other portions is generated. Here, although the back yoke 21 of the stator core 20 is illustrated, the outer peripheral side of the coil 22 is the side in contact with the back yoke of the stator core 20. In the resin mold portion 28, it can be seen that the portion A in which the thickness of the mold resin layer is thinner than the other portions is generated at both ends where the coil 22 is in contact with the back yoke 21.

  On the other hand, the stator 12 described in FIG. 6 has a polygonal shape along the outer peripheral shape of the coil 22 on the outer peripheral side in the radial direction of the stator core 20 as shown in FIG. In other words, on the outer peripheral side of the stator core 20, the mold resin layer of the resin mold portion 32 has a substantially uniform thickness over the entire area covering the coil 22. According to this configuration, the portion A in which the mold resin layer is thinner than the other portions as pointed out in the prior art in FIG. 7 does not occur. That is, in FIG. 8, the part B corresponding to the part A in FIG. 7 has the same thickness of the mold resin layer as the other parts. Therefore, heat dissipation can be made uniform.

  6 and the content described in FIG. 1 are combined, and the stator core has an uneven shape along the outer shape of the coil in the axial direction, and the outer peripheral side of the stator core follows the outer peripheral shape of the coil. A stator having a polygonal shape may also be used.

  Although the connector connected to each coil is not described above, a connector connected to each coil is provided in an actual stator. In a resin mold type stator, a part of the connector is also included in the resin mold part, and integrated molding is often performed.

  In this case, as described with reference to FIG. 3, the conventional technique uses an annular resin mold portion, and thus the connector portion is often provided so as to protrude in the axial direction of the annular resin mold portion. By doing so, the flat surface of the stator core 20 can be used as the sealing surface of the resin molding die, and the resin molding can be easily performed. On the other hand, since the stator has an outer shape in which the connector protrudes in the axial direction, the dimension in the axial direction increases.

  FIG. 9 is a diagram showing the stator 14 that is provided with a connector on the outer diameter side of the stator, part of the connector is included in the resin mold portion, and is integrally formed to reduce the axial dimension and reduce the size. . In the following, the same elements as those in FIGS. 1 to 8 are denoted by the same reference numerals, and detailed description thereof is omitted. In the following, description will be made using the reference numerals in FIGS.

  In the stator 14, a connector portion 40 for a terminal drawn from the coil 22 is provided on the outer diameter side of the stator core 20. The stator 14 includes a stator core 20 and a resin mold part 34. The semi-finished stator from which the resin mold portion 34 is removed has a configuration in which a connector portion 40 is added to the content described in FIG. Therefore, the resin mold part 34 includes a coil mold part 36 that covers the coil 22 and a connector mold part 38 that covers a part of the connector part 40.

  The content of the coil mold portion 36 may have a concavo-convex shape along the outer shape of the coil in the axial direction of the stator core, similarly to the content described with reference to FIG. 6, and is the same as the content described with reference to FIG. Thus, the outer peripheral side of the stator core may have a polygonal shape along the outer peripheral shape of the coil. Moreover, it is good also as what combined the content demonstrated in FIG. 6, and the content demonstrated in FIG.

  The connector mold part 38 is formed by covering a part of the connector part 40, preferably all other parts except the part of the conductor terminal connected to the outside, with a mold resin. And the connector mold part 38 is integrated with the coil mold part 36, and a mold resin layer is formed with the same resin.

  FIGS. 10 and 11 are views for explaining a mold configuration for integrally forming the connector mold portion 38 and the coil mold portion 36. 10 is a plan view, and FIG. 11 is a cross-sectional view taken along the line DD of FIG. In the following, the same elements as those in FIGS. 1 to 9 are denoted by the same reference numerals, and detailed description thereof is omitted. In the following, description will be made using the reference numerals in FIGS.

A mold for integrally forming the connector mold part 38 and the coil mold part 36 includes a first mold 50 and a second mold 52. The first mold 50 is a mold for forming the entire coil mold part and the upper half of the connector mold part 38. The second mold is a slide mold and is a mold for mainly molding the lower half of the connector mold portion 38. Both molds cooperate to resin-mold the connector mold portion 38 and the coil mold portion 36 together. Here, as shown in FIG. 11, the connector portion 40 is disposed further outward than the outer peripheral portion of the stator core 20.

  The first mold 50 is used such that the lower surface is in contact with the upper surface of the stator core 20. That is, the upper surface of the stator core 20 is used as a seal surface. The first mold 50 is similar to the mold for forming the substantially annular resin mold portion as described with reference to FIGS. 1, 3, and 6, but covers the upper half of the connector portion 40. The portion is overhanging for resin molding. That is, if only the molding of the coil mold part 36 is performed, the connector mold part 38 is the same as the mold for forming the substantially annular resin mold part as described in FIGS. Therefore, the mold has a shape protruding from the outer periphery of the stator core 20.

  The second mold 52 is a slide mold that is used because the connector portion 40 is disposed further outside the outer periphery of the stator core 20. The second mold 52 is used to form the connector lower mold part 39 corresponding to the lower half part of the connector mold part 38. In this case, it is desirable to have a structure in which the lower part of the second mold 52 projects partially so that the upper surface of the stator core 20 can be used as a seal surface. In the example of FIG. 11, in part C, a part of the lower surface of the second mold 52 is in contact with the upper surface of the stator core 20, where a seal against the molding resin is secured.

  As described above, the first mold 50 and the second mold 52 are used, the upper surface of the stator core 20 is used as a sealing surface for the molding resin, and the coil portion and the connector portion are integrated to form a mold resin layer. be able to.

In embodiment which concerns on this invention, it is a figure which shows the external appearance of the stator in a multiphase concentrated winding type rotary electric machine. In embodiment which concerns on this invention, it is a figure which shows the mode of the semi-finished stator before performing resin molding. It is a figure which shows the mode of the resin mold stator generally used conventionally. It is sectional drawing of the resin mold stator of FIG. It is sectional drawing of the stator in embodiment which concerns on this invention. It is a figure which shows the stator in other embodiment. It is sectional drawing of the resin mold stator of FIG. It is sectional drawing of the stator in other embodiment. In another embodiment, it is a figure which shows the connector part integral molding stator. It is a top view explaining the metal mold | die structure for the stator of FIG. It is sectional drawing explaining the metal mold | die structure for the stator of FIG.

Explanation of symbols

  6 Semi-finished stator, 8 Resin molded stator, 10, 12, 14 Stator, 20 Stator core, 21 Back yoke, 22 Coil, 24 teeth, 28, 30, 32, 34 Resin mold part, 36 Coil mold part, 38 Connector mold part , 39 Connector lower mold part, 40 Connector part, 50 1st metal mold, 52 2nd metal mold.

Claims (2)

A stator core;
A coil wound around the stator core, the coil end portion protruding in the axial direction from the stator core has a shape that is uneven in the axial direction with respect to the surface of the stator core ; and
A connector portion for a terminal drawn from the coil, the connector portion provided on the outer diameter side of the stator core;
A resin mold part covering at least the coil part;
Have
The resin mold part is
Along the outer shape of the concavo-convex shape of the coil end portion of the coil covers the coil with a uniform thickness, a coil mold part for chromatic axial become uneven shape the face of the stator core as a reference, the connector mold covering the connector portion And a mold resin layer is formed. In the rotating electrical machine according to claim 1,
A plurality of coils are wound around the stator core,
Each coil has an outer peripheral shape that is in linear contact with the back yoke side of the stator core, and forms a polygonal shape by connecting the outer peripheral shapes of a plurality of coils.
The resin mold part is
Covering the plurality of coils in a plurality of uniform thickness along the polygonal shape formed by the outer peripheral shape of the coil have you back yoke side of the stator core, has a shape which is polygonal on the outer circumferential side of the plurality of coils A rotating electric machine characterized in that a mold resin layer is formed.

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