JP5174485B2 - Rotating electric machine - Google Patents

Description

  The present invention relates to a rotating electrical machine such as an electric motor or a generator.

  Developments in electric vehicles and hybrid electric vehicles using rotating machines such as motors and generators have become active as the price of crude oil rises and regulations on exhaust gas emissions against global warming are tightened.

  In these distributed winding stators, a flat wire is wound around a single oval coil, the whole is solidified, the coil is twisted and deformed, and the coil end is made into a non-interfering shape of two-layer winding. There is known a structure in which two coils are sequentially assembled from the inner peripheral side of a stator into a slot to constitute a rectangular winding coil stator (see, for example, Patent Document 1).

Japanese Patent Laid-Open No. 2005-51981

  The two slot insertion pieces of the lap coil are disposed in different slots of the stator and cannot be incorporated into the slot unless elastically deformed during insertion. Further, when the lap winding coil is continuously wound, the difficulty of the coil insertion work into the slot is further increased by pulling the plurality of coils together. For these reasons, in order to incorporate a rectangular continuous winding coil with insulation into the stator slot, a certain amount of air gap (0.1 to 0.2 mm or more) is required between them. There were limits to the volume factor and heat dissipation.

  In view of the above, the object of the present invention is to reduce the gap between the insulated rectangular wire-wound coil and the slot, improve the space factor and heat dissipation, and realize further miniaturization and higher output of the motor. It is in.

In order to solve the above problems, for example, the configuration described in the claims is adopted. The present application includes a plurality of means for solving the above-mentioned problems. To give an example, a coil wire has a substantially quadrangular cross section, and a plurality of two-layer winding coils that are continuous via a jumper are incorporated. And a stator provided rotatably on the stator via a gap. The slot of the stator extends outwardly from the insertion portion of the coil and the insulator to the inner peripheral side. The rotating electrical machine is configured such that the slot is smaller in width than the total dimension of the coil and the insulator in the slot width direction before being inserted into the slot.

  According to the present invention, the motor can be further reduced in size and output.

  Hereinafter, an embodiment of the present invention will be described.

  Rotating machines used in automobiles are extremely demanded for miniaturization in order to be mounted on a moving body. In addition, in order to make maximum use of the limited input power from the battery and to produce a high output torque, a much higher level of output density is required than a rotating machine for general industrial use or home appliances. For this reason, there is a movement to increase the current density and heat dissipation by using a square wire for the stator coil, and to promote a significant reduction in size and output of the rotating machine.

  On the other hand, there are two types of winding methods for the stator of a rotating machine: concentrated winding and distributed winding. Concentrated winding has a non-sinusoidal magnetomotive force waveform and is inferior to distributed winding in rotational characteristics such as noise and torque pulsation. In addition, the heat dissipation of the coil end is lower than that of the distributed winding, and the efficiency of the motor is deteriorated as the temperature rises. Until now, due to restrictions on the mounting space of the vehicle system, concentrated winding stators were unavoidably used. However, in the future, the distributed winding stator will be shortened with a coil end, and the movement to apply it to in-vehicle rotating machines will become stronger. I think that the.

  From the above development trend, it is easy to think that the development of a short-coil-end distributed winding stator using a square coil for a rotating machine of an electric vehicle or a hybrid electric vehicle is advanced.

  However, distributed winding stators are wound and deformed one by one, so the total number of coil end wires is twice the total number of coils. There was a need to do. For this reason, in order to reduce the man-hour which processes a terminal wire, and to shorten a coil end, it is necessary to wind the coil of the same phase continuously.

  Furthermore, the two slot insertion pieces of the lap winding coil are disposed in different slots of the stator, and cannot be incorporated into the slot unless accompanied by elastic deformation at the time of insertion. Further, when the lap winding coil is continuously wound, the difficulty of the coil insertion work into the slot is further increased by pulling the plurality of coils together. For these reasons, a certain amount of gap (0.1 to 0.2 mm or more) is required between the two in order to incorporate a rectangular continuous winding coil with insulation into the stator slot. Therefore, in order to realize further miniaturization and higher output of the motor, it is necessary to reduce the gap between the insulated rectangular wire-wound coil and the slot and to improve the space factor by another rank.

  Therefore, in the present embodiment, in the rectangular winding stator, the compact terminal wires are wound and connected, the stator of the rotating machine is reduced in the axial direction, and the slot occupation of the rectangular winding stator is achieved. The purpose is to reduce the copper loss by improving the volume factor, reducing the electrical resistance of the coil, and improving the heat dissipation, and to realize a small and high output motor.

  In the present embodiment, a plurality of lap winding coils are continuously wound and deformed into a turtle shell shape. As a result, the number of terminal connection points of the lap winding stator of the rectangular wires is reduced, the space for arranging the terminal wires is reduced, and the axial length required for connecting the terminal wires is shortened (for example, connecting terminals are connected). If it is used, the length in the axial direction is required, and when the wire itself is melted and connected by TIG welding, etc., in order to prevent the terminal wires from being fixed and the insulation film of other coils from being burned out. In addition, the connection position must be separated from the coil end).

  On the other hand, the coil and the insulator are press-fitted into the slot or assembled in a dimensional relationship close to that by attaching an outwardly extending slope to the inner circumferential side of the stator slot coil and the insulator insertion portion. Also improve slot space factor and heat dissipation.

  Since the number of connection points of the terminal is smaller than that of the conventional single coil winding stator, the space for arranging the terminal wire is reduced and the shaft required for connecting the terminal wire is smaller. The length of the direction can be shortened. That is, the axial dimension of the motor can be reduced.

  Further, by adding an outwardly extending inclination to the slot, the gap between the coil + insulator and the slot can be reduced or eliminated, and the space factor of the continuous winding stator with a square line can be dramatically improved. As a result, it is possible to realize a rotating machine that is smaller and has a higher output than conventional motors.

  Furthermore, the continuous lap winding stator of the present invention has a higher density coil mounting in both the slot and the coil end, but the number of connection points is reduced, and the risk of damage to the insulation film during coil assembly is reduced. Therefore, the insulation reliability is improved.

  The details of this embodiment will be described below with reference to the drawings.

  FIG. 7 shows a stator 4 having a continuous winding of square lines, which constitutes an embodiment of the present invention. The stator iron core 412 is formed by punching and laminating silicon steel sheets and the like, and a rectangular wire lap coil in which the periphery is protected by insulating paper in slots (grooves) provided radially at equal intervals on the inner circumference of the iron core. A stator coil 413 is incorporated. In the stator coil 413, two or more different coils are connected via a crossover wire 4132.

  The stator of FIG. 7 has three phases, 48 slots, NSPP (number of slots per pole per phase) = 2, 2Y connection, and 8 series coils in the same phase are continuous. In this case, there are 12 terminal wires of the coil before connection.

  Here, the number of continuously wound coils is not limited to eight. For example, as in the stator of FIG. 7, three-phase, 48-slot, NSPP (number of slots per pole per phase) = 2, 2Y connection, and in-phase square overlap inserted in adjacent slots as shown in FIG. Two winding coils may be wound in succession. In this case, the two element coils 4131a and 4131b are wound in opposite directions with the connecting wire 4132 as an intermediate, and both terminal wires 90 are arranged on the outer peripheral side of the coil. FIG. 48 shows a state where 24 sets of the two continuous coils are incorporated in the stator core 2. In the case of two continuous coils, there are 48 terminal lines of the coil before connection.

  A permanent magnet rotor (described later) or a squirrel-cage copper rotor (described later) is coaxially incorporated in the continuous winding stator 4 of this rectangular wire, and both ends of the rotor are rotatably supported by bearings. Alternatively, a generator is configured.

  The coil of this embodiment is formed by a generation method described in detail later, but finally has a shape as shown in FIG. Here, in the case where the two slot insertion portions of the original coil with insulating paper are gripped and opened in a direction to separate them and plastically deformed, as shown in FIG. 50, the two slot insertion portions 90 of the same coil are formed. The angle θ is preferably substantially equal to the angle formed by the two slots of the core to be inserted.

  The obtained rectangular continuous winding coil is inserted into the slot 411 from the inside of the stator 4. Here, as shown in FIG. 51, in the slot 411 of the stator, a slope 120 that spreads outward is provided on the inner peripheral side of the position where the coil 3 and the insulating paper 91 are inserted. This absorbs variation in the opening amount of both slot insertion portions of the coil and displacement due to pulling between the coils due to the continuous winding, and even if the gap between the coil 413 + insulating paper 91 and the status lot 411 is small, Easy to assemble. As shown in FIG. 52, the total width A of the coil 413 and the insulating paper 91 before assembly can be made larger than the width B of the slot 411 of the coil insertion portion, and both can be assembled in a press-fit relationship. Therefore, the slot space factor of the rectangular wire-wound coil can be dramatically increased as compared with the conventional case, and the heat dissipation is improved by increasing the adhesion between the coil + insulating paper and the core. Furthermore, since the coil is not forcibly deformed when assembled into the core, high insulation reliability can be obtained.

  Further, when the insertion groove 140 of the slot wedge 130 is provided in order to prevent the coil from jumping out, as shown in FIG. 53, an outwardly inclined slope 120 is provided on the inner peripheral side of the wedge insertion groove 140 to insert the wedge. The corner 150 where the groove 140 and the slot 411 intersect is formed in an R shape, or as shown in FIG. 54, an outwardly extending slope 120 is provided on the inner peripheral side and the outer peripheral side of the insertion groove 140 of the slot wedge 130. Thereby, with and without the insertion groove 140 of the slot wedge 130, the coil assembly property, the slot space factor, and the heat dissipation property can be improved as in the case where there is no insertion groove 140.

  By the above method, the gap between the coil 413 + insulating paper 91 and the slot 411 can be made small or negative. However, there is a high possibility of damaging the coil and the insulator at the corners in the radial direction of the slots on the stator end face during the coil insertion operation. Therefore, as another embodiment of the present invention, the concave portion 160 is formed by plastically deforming the coil conductor and the insulating paper at a position in contact with the radial corner of the slot before inserting the coil (FIG. 55). . Thus, the coil + insulating paper is not damaged at the corner of the slot on the core end surface.

  As described above, according to the present invention, it is possible to obtain a rectangular continuous lap winding stator having a high slot space factor and excellent insulation performance. By shortening the coil end by continuous winding and improving the motor characteristics and heat dissipation due to the slot space factor exceeding the conventional method, a small and high output rotating electrical machine can be realized.

  The said Example is suitable for the rotary electric machine shown next.

  A rotating electrical machine that constitutes an embodiment of the present invention will be described based on an electric motor used in a hybrid vehicle. The electric motor for a hybrid vehicle according to the present embodiment has both a function of a driving motor for driving wheels and a function of a generator for generating power, and the functions are switched depending on the running state of the vehicle. ing. Here, an induction type rotating electrical machine will be described as an example, but it may be applied to other types, for example, a synchronous rotating electrical machine.

  FIG. 1 is a side sectional view of an induction type rotating electrical machine. FIG. 2 is a perspective view of a cross section of the rotor. FIG. 3 is an exploded perspective view of each part related to the induction type rotating electrical machine of the present embodiment.

  The induction type rotating electrical machine includes a bottomed cylindrical housing 1 that is open at one end in the axial direction, and a cover 2 that seals the open end of the housing 1. A water channel forming member 22 is provided inside the housing 1, one end of the water channel forming member 22 is fixed between the housing 1 and the cover 2, and a water channel 24 is formed between the stator 4 and the housing 1. Is done. Cooling water is taken into the water channel 24 from the cooling water inlet 32, and the cooling water is discharged from the water channel 24 to the outlet 34 to cool the rotating electrical machine. The housing 1 and the cover 2 are fastened by a plurality of, for example, six bolts 3.

  A water channel forming member 22 is provided on the inner periphery of the housing 1, and the stator 4 is fixed inside the water channel forming member 22 by shrink fitting or the like. As shown in FIG. 6, the stator 4 includes a stator core 412 having a plurality of slots 411 and three-phase stator windings 40 wound in the slots 411 at equal intervals in the circumferential direction. And is composed of. In this embodiment, there are 8 poles and 48 slots, and the stator winding 40 is connected by star connection, and each phase is a 2Y connection in which a pair of stator coils 413 are connected in parallel as shown in FIG. It has become.

  In addition, the rotor 5 is disposed on the inner periphery of the stator core 412 so as to be rotatable through a minute gap so as to face the stator core 412. The rotor 5 is fixed to the shaft 6 and rotates integrally with the shaft 6. The shaft 6 is rotatably supported on both sides thereof by ball bearings 7a and 7b acting as bearings provided on the housing 1 and the cover 2, respectively. Among these ball bearings 7 a and 7 b, the ball bearing 7 a on the cover 2 side is fixed by a substantially rectangular fixing plate 8 shown in FIG. 3, and the ball bearing 7 b on the bottom side of the housing 1 is fixed to the housing 1. It is being fixed to the recessed part provided in the bottom part. For this reason, the rotor 5 is rotated relative to the stator 4, and the pulley 6 attached to the cover 2 side end of the shaft 6 by the nut 11 via the sleeve 9 and the spacer 10 is used for the shaft 6. A rotational force is output to the outside, or a rotational force from the pulley 12 is input to the shaft 6. Since the outer periphery of the sleeve 9 and the inner periphery of the pulley 12 are slightly conical, the pulley 12 and the shaft 6 are firmly integrated by the tightening force of the nut 11 so that they can rotate integrally. It has become.

  The rotor 5 has conductor bars 511 extending in the rotation axis direction at equal intervals over the entire circumference in the circumferential direction, and a pair of short-circuit rings 512 are provided to short-circuit each conductor bar 511 at both ends in the rotation axis direction. It is a connected cage rotor. The conductor bar 511 is embedded in a rotor core 513 made of a magnetic material. FIG. 2 shows a cross-sectional structure taken along a plane perpendicular to the rotation axis to clearly show the relationship between the rotor core 513 and the conductor bar 511, and the short-circuit ring 512 and the shaft 6 on the pulley 12 side are visible. Absent.

  The rotor core 513 is formed of a laminated steel plate formed by punching or etching an electromagnetic steel plate having a thickness of about 0.05 to 1 mm and laminating the formed electromagnetic steel plates. As shown in FIGS. 2 and 3, substantially fan-shaped cavities 514 are provided at equal intervals in the circumferential direction on the inner peripheral side for weight reduction. A plurality of spaces in which the respective conductor bars 511 are arranged are provided on the outer peripheral side. The rotor core 513 has a conductor bar 511 on the stator side, and a rotor yoke 530 for forming a magnetic circuit inside the conductor bar 511.

  In this embodiment, the stator has an 8-pole stator winding, and the thickness of the magnetic circuit formed in the rotor yoke 530 in the radial direction is larger than that of an induction motor having two or four poles. Can be thinned. The thickness can be reduced by increasing the number of poles compared to 8 poles, but there is a problem in that the output and efficiency are lowered if 12 poles or more. Accordingly, the rotating electric machine for running the vehicle including the engine start function is preferably 6 to 10 poles, particularly 8 or 10 poles.

  Each conductor bar 511 and short-circuit ring 512 of the rotor 5 are made of aluminum, and are formed so as to be integrated with the rotor core 513 by die casting. The short-circuit rings 512 arranged at both ends of the rotor core are provided so as to protrude from the rotor core 513 to both ends in the axial direction. The conductor bar and the short-circuit ring 512 may be made of, for example, copper. In that case, the conductor bar and the short-circuit ring 512 can be formed by die casting. The conductor bar and the short-circuit ring 512 may be joined and fixed by joining.

  A detection rotor 132 is provided on the bottom side of the housing 1, and the rotation sensor 13 for detecting the rotation speed and the rotor position detects the teeth of the detection rotor 132 to detect the position and rotation of the rotor 5. An electric signal for detecting the rotation speed of the child 5 is output. The rotation sensor 13 may use a resolver.

  Next, the operation of the induction motor according to the present embodiment will be described with reference to FIGS.

  First, the power running operation of the rotating electrical machine that functions as a driving motor for driving the wheels and the engine will be described. FIG. 4 shows a system for explaining electrical connection. For example, a secondary battery 612 for high voltage corresponding to a voltage of 100 V to 600 V and a DC terminal of the inverter device 620 are electrically connected. The AC terminal of the inverter device 620 is electrically connected to the stator winding 40. As will be described later, each phase of the stator winding 40 has a stator coil 413 connected in parallel.

  In the power running operation, DC power is supplied from the secondary battery 612 to the inverter device 620, and AC power is supplied from the inverter device to each stator coil 413 of the three-phase stator winding 40 wound around the stator core 412. Is done. Due to this AC power, a rotating magnetic field having a rotational speed based on the frequency of the AC power is generated in the stator core 412, and a magnetic flux having the rotor 5 as a magnetic path is generated by the rotating magnetic field as shown in FIG. 5. FIG. 5 shows the state of the rotating magnetic field generated by the stator winding 40. The winding structure of the stator winding 40 is, for example, an 8-pole distributed winding as described in the following embodiment. FIG. 5 shows a simulation result when a general iron core virtually having no conductor bar is arranged in a state where the influence of the rotor is removed. A core back 430 is provided on the outer peripheral side of the slot of the stator core 412 to form a magnetic circuit for the rotating magnetic field. In this simulation, since the stator winding 40 has eight poles and a large number of poles, the radial thickness of the magnetic circuit in the core back 430 can be reduced. The radial thickness of the magnetic circuit on the rotor 5 side is also thin. The rotating magnetic field shown in FIG. 5 rotates based on the AC frequency supplied to the stator winding 40.

  In FIG. 4, the inverter device 620 generates an alternating current necessary for generating the torque required for the rotating electrical machine and supplies the alternating current to the stator winding 40. In a state where the rotation speed of the rotor 5 is slower than the rotation speed of the rotating magnetic field, the conductor bar 511 is linked to the rotating magnetic field generated in the stator core 412, and current flows through the conductor bar 511 according to Fleming's right-hand rule. . Further, when a current flows through the conductor bar 511, rotational torque is generated in the rotor 5 according to Fleming's left-hand rule, and the rotor 5 rotates. Since the difference between the rotational speed of the rotor 5 and the rotational speed of the rotating magnetic field of the stator 4 affects the magnitude of the torque, it is necessary to appropriately control the speed difference, that is, “slip”. For this reason, the rotational speed of the rotor 5 is detected based on the output of the rotation sensor 13 to control the switching frequency of the inverter, thereby controlling the frequency of the alternating current supplied to the stator 4.

  FIG. 6 is a simulation result showing the state of magnetic flux when the rotation speed of the rotor 5 having the conductor bar 511 is slower than the rotation speed of the rotating magnetic field generated in the stator core 412. The rotation direction of the rotor 5 is counterclockwise. Magnetic flux generated by the stator winding 40 disposed in the slot 411 passes through a magnetic circuit including the core back 430 and the rotor yoke 530 of the rotor core 513. The magnetic flux of the rotor core 513 is shifted to the delay side in the rotation direction of the rotor from the magnetic flux of the stator core 412. Since the number of poles of the stator winding is as large as eight, the magnetic flux of the rotor's rotating yoke 530 is coarser on the rotating shaft side than on the conductor bar 511 side.

  Next, a case where the rotating electrical machine operates as a generator that generates electric power will be described. When operating as a generator, the rotational speed of the rotor 5 rotated by the rotational force input from the pulley 12 is higher than the rotational speed of the rotating magnetic field generated in the stator core 412. When the rotational speed of the rotor 5 exceeds the rotational speed of the rotating magnetic field, the conductor bar 511 is linked to the rotating magnetic field, so that a braking force acts on the rotor 5. By this action, electric power is induced in the stator winding 40, and power generation is performed. In FIG. 4, when the frequency of the AC power generated by the inverter device 620 is lowered and the rotational speed of the rotating magnetic field generated in the stator core 412 is made slower than the rotational speed of the rotor 5, the inverter device 620 changes to the secondary battery 612. DC power is supplied. Since the electric power generated by the rotating electric machine is based on the difference between the rotation speed of the rotating magnetic field and the rotation side of the rotor 5, the generated electric power can be controlled by controlling the operation of the inverter device. If the loss or reactive power of the rotating electrical machine is ignored, if the rotating magnetic field of the rotating electrical machine is made faster than the rotational speed of the rotor 5, electric power is supplied from the secondary battery 612 to the rotating electrical machine via the inverter device 620. If the rotating magnetic field of the rotating electrical machine is the same as the rotational speed of the rotor 5, power is not transmitted and received between the secondary battery 612 and the rotating electrical machine, and if the rotating magnetic field of the rotating electrical machine is slower than the rotational speed of the rotor 5. Electric power is supplied from the rotating electrical machine to the secondary battery 612 via the inverter device 620. However, since the loss or reactive power of the rotating electrical machine cannot be ignored in practice, power is not supplied from the secondary battery 612 to the rotating electrical machine when the rotating magnetic field of the rotating electrical machine is slightly slower than the rotational speed of the rotor 5.

  Next, details of the stator 4 will be described with reference to FIGS. 4 and 7 to 13.

  FIG. 7 is a perspective view of the stator 4 as described above. The stator 4 shown in FIG. 7 includes a plurality of stators that constitute a stator core 412 having 48 slots 411 formed at equal intervals in the circumferential direction and a stator winding 40 wound around the slots 411. And a coil 413. The stator core 412 is made of a laminated steel plate formed by, for example, punching or etching a magnetic steel plate having a thickness of about 0.05 to 1 mm and laminating the formed magnetic steel plates, and is equally spaced in the circumferential direction. A plurality of slots 411 arranged radially are formed. In this embodiment, the number of slots is 48. Teeth 414 are provided between these slots 411, and each tooth 414 is integrated with an annular core back 430. That is, each tooth 414 and the core back 430 are integrally formed. Further, the inner peripheral side of the slot 411 is open, and the stator coil 413 constituting the stator winding 40 is inserted from this opening. The circumferential width of the opening of the slot is substantially equal to the width of the slot at the position where the coil is mounted, that is, the width of the coil mounting portion of each slot, or slightly larger than the coil mounting portion of the slot. It is formed as follows. Each slot is formed into an open slot, and a holding member 416 is provided at the distal end side of each tooth 414 in order to prevent the coil inserted in each slot from moving toward the outlet side of the slot, that is, the inner peripheral side of the stator. Is to be installed. The holding member 416 is made of a non-magnetic material such as resin or a non-magnetic metal material, and has a shaft in a holding groove 417 formed on the both sides in the circumferential direction on the tip side of the teeth 414 so as to extend in the axial direction. It comes to be mounted from the direction.

  Next, the stator coil 413 constituting the stator winding 40 will be described with reference to FIGS. 8 and 9. FIG. 8 is a perspective view of a stator coil 413 made up of one continuous insulated conductor constituting the stator coil 40. FIG. 9 is a perspective view of the stator coil 413 for one phase. In the present embodiment, the three-phase stator winding 40 is provided. First, one phase will be described. In addition, the stator coil 413 of this embodiment uses a conductor whose cross-sectional shape called a flat wire is substantially rectangular and whose outer periphery is covered with an insulating film, and the cross-section of the conductor in a wound state is used. In the rectangular shape, the circumferential direction of the stator core 412 is long and the radial direction is short. Further, as described above, the surface of the conductor of the stator coil 413 is coated for insulation.

  Before describing FIG. 8, the connection of the stator winding 40 will be described with reference to FIG. In this embodiment, the stator winding 40 has two star connections in a system constituted by two stator coils 413 in which windings of respective phases constituting the stator winding 40 are connected in parallel. doing. If the two star connections are a Y1 connection and a Y2 connection, the Y1 connection has a U-phase winding Y1U, a V-phase winding Y1V, and a W-phase winding Y1W. The Y2 connection has a U-phase winding Y2U, a V-phase winding Y2V, and a W-phase winding Y2W. The Y1 connection and the Y2 connection are connected in parallel, and each neutral point is also connected.

  The coil Y1U includes a coil U11, a coil U12, a coil U13, and a coil U14 connected in series. The coil Y2U includes a coil U21, a coil U22, a coil U23, and a coil U24 connected in series. The coil Y1V includes a coil V11, a coil V12, a coil V13, and a coil V14 connected in series. The coil Y2V includes a coil V21, a coil V22, a coil V23, and a coil V24 connected in series. The coil Y1W includes a coil W11, a coil W12, a coil W13, and a coil W14 connected in series, and the coil Y2W includes a coil W21, a coil W22, a coil W23, and a coil W24 connected in series. As shown in FIG. 4, the coils U11 to W24 each further include two sets of coils. For example, the coil U11 is configured by connecting the coil 2 and the coil 1 in series. Here, the numbers of the coils 2 and 1 indicate the slot numbers on the rotor side in which the coils are inserted. That is, the coil U11 is a series connection of a slot number 2 coil and a slot number 1 coil. Similarly, the coil U12 is a series connection of a coil of slot number 38 and a coil of slot number 37. Similarly, the coil number in FIG. 4 represents the number of the inserted rotor side slot. The last coil W24 is a series connection of a coil with slot number 11 and a coil with slot number 12. It should be noted here that each series coil is inserted in the adjacent slot. As described below, this makes it easy to manufacture and further reduces torque pulsation. The winding state of each coil will be described in detail later.

  Since the coils Y1U, Y1V, Y1W, Y2U, Y2V and Y2W have the same structure, the coil Y1U will be described as a representative example with reference to FIG.

  If the structure of the stator coil 413 is described as a representative of the coil Y1U, the coil Y1U is constituted by a series connection of a coil U11, a coil U12, a coil U13, and a coil U14. Since the coils are arranged at equal intervals, the coils are arranged at a mechanical angle of 90 °. The coil U11 has two element coils 4131a and 4131b, and the element coil 4131a has a structure that goes around the rotor side of the slot 2 and the bottom side of the slot 7. In this embodiment, the slot 2 and the slot 7 are paired a plurality of times, and in this embodiment, the slot 2 and the slot 7 are rotated three times. Since these laps are performed by continuous conducting wires, there is no need for connection work in the lap of the coil 4131.

  The element coil 4131b constituting the coil U11 has a structure in which the rotor side of the slot 1 and the bottom side of the slot 6 are rotated three times. The element coil 4131a and the element coil 4131b each have a structure that circulates between two slots, and these coils are arranged on the rotor side in one slot of each coil, and the bottom of the slot in the other slot. Arranged on the side. The element coil 4131a and the element coil 4131b are connected in series by an inter-coil connection line 4134. This serially connected portion is also composed of continuous conductors, and no special connection work is required. The coil 4131, which is a circulating part of the two slots, has a substantially turtle shell shape when attached to the stator core 412, and has an inner circumference on the rotor side of one slot 411 at the coil end. It is wound so as to straddle the outer peripheral side which is the bottom side of the side and the other slot. The interval between the slot 2 or slot 1 as one slot and the slot 7 or slot 6 as another slot is wound by a distributed winding method determined based on the number of slots and the number of poles of the stator.

  As described above, the element coils 4131a and 4131b having a circular structure are made of continuous conductors, and the number of places requiring connection work can be reduced. Further, according to the following method, the two element coils 4131a and the element coil 4131b can be made of a continuous conductor in the inter-coil connection line 4134 that connects them. For this reason, in this embodiment, the number of turns of the stator coil 413 is increased, but an increase in the number of connection points requiring connection work is suppressed.

  Further, a set is formed by two element coils 4131a and 4131b which are rotating portions, and arranged at a plurality of positions spaced apart in the circumferential direction by using this set as a unit, in this embodiment, at four positions at intervals of 90 °. The coil extending from the inner peripheral side of the spiral portion in the set of element coils 4131a and 4131b and the coil extending from the outer peripheral side in the set of other element coils 4131a and 4131b are connected to each top of the coil end. They are connected by a crossover 4132. In the present embodiment, the coil extending from the inner peripheral side of the spiral portion in the set of element coils 4131a and 4131b and the coil extending from the outer peripheral side of the spiral portion in the set of the other element coils 4131a and 4131b are wound continuously. As a result, a set of four pairs of rotating portions formed so as to be adjacent to each other is formed by a coil made of one continuous conductor. The connecting wire 4132 is provided only on one axial end side of the stator 4 and converges so as to cross from the outer peripheral side of the stator core 412 to the inner peripheral side of the stator core 412. .

  One coil shown in FIG. 8 is half of one phase of the stator winding, and the stator winding constituting one phase is the winding Y1U described in FIG. 8 as shown in FIG. The winding Y2U having the same structure is arranged at a mechanical angle of 45 ° with respect to the winding Y1U in the circumferential direction. A set of element coils 4131a and 4131b of a coil molded body formed in the same manner is arranged with a 45 ° shift in mechanical angle. The element coil 4131a constituting the coil U11 is arranged on the rotor side of the slot 2, and the element coil 4131b constituting the coil U11 is arranged on the rotor side of the slot 1. The element coil 4131a that constitutes the coil U21 that is shifted by 45 ° by the mechanical angle has a structure that goes around the rotor side of the slot 44 and the bottom side of the slot 1. The element coil 4131b constituting the coil U21 has a structure that goes around the rotor side of the slot 43 and the bottom side of the slot 48.

  A stator coil 413, which is a three-phase coil molded body, is formed by disposing the stator coil 413, which is a coil molded body formed as shown in FIG. 9, so as to be shifted by 15 ° and 30 ° in the circumferential direction. The Thus, in this embodiment, the stator coils 413 for three phases can be wound around the stator core 412 with a structure that reduces the number of connection points that require connection work.

  FIG. 10 is a front view of the stator. FIG. 11 is a side view of the stator. 12 is a connection diagram, and is a connection diagram of the 2Y-connected stator winding 40 shown in FIG. As shown in FIG. 10, the connecting wire 4132 in each coil molded body is disposed so as to straddle the outer peripheral side and the inner peripheral side of the stator core 412, so that the connecting wire 4132 is substantially spiral as a whole. Will be configured. For the neutral point of the star connection, it is necessary to connect the terminal of each coil and the connecting wire provided separately from each other by TIG welding or the like instead of the continuous coil 4132. Note that the connecting wire serving as the neutral point is also arranged so as to straddle the outer peripheral side and the inner peripheral side of the stator core 412. By adopting such a structure, the stator coils 413 are arranged in a regular structure, and space is efficiently used. As a result, the rotating electrical machine can be miniaturized.

  FIG. 13 is a diagram showing the relationship between the slot numbers of the stator and the coils constituting the stator coil, and the arrangement relationship between the slots and the surrounding portions of the stator coil 413 constituting the stator winding 40. In the figure, a slot number column 442 indicates a slot number, and 48 slots are given as a reference, and numbers are assigned in order from that slot. Each of the coils U11 to W24 constituting the stator coil 413 of FIG. 4 is composed of a coiled portion with a slot number arranged on the rotor side, and these configurations are related to the slots in the column 442. Shown below. In the column 442, the coil W13 has slot numbers 29 and 30. This indicates that the coil W13 is constituted by a serial connection of the coil portion disposed on the rotor side of the slot number 29 and the coil portion disposed on the rotor side of the slot number 30. . This is also indicated by coil numbers 29 and 30 constituting the coil W13 of FIG. In the column 442 of FIG. 13, the coil U22 has slot numbers 31 and 32, and the coil portion arranged on the rotor side of the slot number 31 and the coil portion arranged on the rotor side of the slot number 32 It shows that the coil U22 is configured in series connection. This is also indicated by coil numbers 31 and 32 constituting the coil U22 of FIG. Looking at the coil U11 described with reference to FIG. This indicates that the coil U11 is constituted by a series connection of the coiled portion arranged on the rotor side of the slot number 1 and the coiled portion arranged on the rotor side of the slot number 2. This can also be seen from the fact that the coil numbers 1 and 2 constituting the coil U11 of FIG.

  A column 444 in FIG. 13 indicates the phase of the stator coil 413 and the order of arrangement in the phase. In column 442, coil U11 is slot numbers 1 and 2. As shown above, this indicates that the coil is arranged in series at the coil portions arranged in the slot numbers 1 and 2. This coil U11 is marked “U1” in column 444. This indicates that the stator coil 413 is disposed at the first position of the U phase, that is, at the reference position of the U phase. Coil U21 is labeled "U2" in column 444. This indicates that the second U-phase of the stator coil, that is, a mechanical angle of 45 ° from the U-phase reference position is arranged. Similarly, coil U12 is labeled “U3” in column 444. This indicates that the stator coil is arranged at the third position of the U phase, that is, at a mechanical angle of 90 ° from the reference position of the U phase. This is as already described with reference to FIG.

  With respect to the coil U11, the coil V11 is shifted by 15 ° in mechanical angle. Accordingly, the coil V21 of “V2” shown in the column 444 is positioned at a position shifted by 45 ° from the position of the coil V11 with respect to the coil V11 at a position shifted by 15 ° by the mechanical angle with respect to the reference position of the coil U11. is there. Hereinafter, since all the V-phase coils are based on the coil V11, they are shifted by 15 ° with respect to the U-phase coil. Similarly, since the coil W11 is shifted by 30 ° in mechanical angle from the position of the coil U11, all the W-phase coils are shifted by 30 ° with respect to the U-phase coils.

  Next, the column 446 will be described. In this embodiment, the coil 4131 that circulates has a structure that circulates through two slots. That is, the element coil 4131a shown in FIG. 8 circulates through the slot 2 and the slot 7, the element coil 4131a is arranged on the rotor side, the second slot is the element coil 4131a, and the other slot is arranged on the back side. No. 7. The column 442 shows the one slot number, whereas the column 446 shows the other slot number. That is, the column 446 of the slot number 2 in the column 442 is “7”. This indicates that the coil is circulating with slot number 2 as one slot and slot number 7 as the other slot. The following columns 442 and 446 show one and the other slots of the coil that similarly circulates.

  A column 448 indicates the phase of the coil located behind the slot number shown in the column 442 and the order of arrangement of the coils in the phase. A column 450 indicates a slot around the coil described in the column 448. For example, the coil arranged behind slot number 2 in column 442 indicates that it is the second coil located in the V phase. In addition, the description “45” in the column 450 indicates that the coil arranged behind slot number 2 circulates through two slots with one slot number “45” and the other slot number “2”. Show. Looking at the slot number 45 in the column 442, the column 446 is described as “2”. This description refers to the same coil as above. That is, it is indicated that the coil that circulates through one slot number “45” and the other slot number 2 is the second coil arranged in the V phase.

  FIG. 12 shows the connection state of the final stator winding 40 thus connected. In addition, although the winding part of the coil 4131 in FIG. 12 is displayed for one round, in fact, as described above, the coil 4131 is turned for three rounds. In addition, the number displayed in the center of the winding portion of the coil 4131 in FIG. 12 is the slot number, and the portion where the coil is a broken line is the coil located on the inner peripheral side in the slot 411, that is, on the slot opening side. The portion where the coil is a solid line is a coil located outside the slot 411, that is, on the slot bottom side. Furthermore, the places where the intersections of the lines are displayed as circles are the places where connection work such as welding is necessary. As can be seen from FIG. 12, only nine locations need to be connected by welding.

  In the structure described with reference to FIGS. 4 and 13, a plurality of conductors are arranged in the radial direction in each slot, and a coil having a shape in which these conductors circulate through two slots is formed. Since this circulating coil is composed of continuous conductors, in this embodiment, the number of turns is increased, but the increase in the number of connection points is suppressed. Further, only one conductor is inserted in the circumferential direction of each slot, and this structure is easy to manufacture as described below. Further, since the conductor has a shape that is wide in the circumferential direction and thin in the radial direction, an eddy current generated in the conductor in the slot due to leakage magnetic flux is suppressed. For this reason, the efficiency of the rotating electrical machine is improved and heat generation is suppressed.

  Further, as shown in FIG. 11, these connecting wires 4132 are positioned on substantially the same plane on one end side in the axial direction of the stator 4, so that the coil end can be shortened. As described above, in the present embodiment, the crossover wires are arranged outside the coil ends in the rotation direction, and the arrangement is orderly as a whole, and the entire rotating electrical machine is downsized. In addition, reliability can be ensured in terms of electrical insulation. In particular, recently, rotating electric machines for driving automobiles have a high operating voltage, and many of them exceed 100V. Depending on the case, a voltage of 400V or 600V may be applied, and the reliability between the lines of the stator coil is important.

  Furthermore, in the above-described embodiment, the element coil 4131b wound a plurality of times is connected to the element coil 4131b wound a plurality of times by the inter-coil connection line 4134. Crossover wires are arranged outside the inter-coil connection wires 4134, and the arrangement is orderly as a whole. As described above, this reduces the overall size of the rotating electrical machine. In addition, reliability can be ensured in terms of electrical insulation.

  The rotating electrical machine described in the present embodiment has a structure that can provide a relatively large output and improve productivity even though it is relatively small applied to a drive motor of an automobile. As a conductor of the stator winding, not only a conductor having a circular cross section but also a conductor having a substantially rectangular cross section can be used, and the space factor in the slot can be improved, so that the efficiency of the rotating electrical machine is improved. In a conventional rotating electrical machine, when a conductor having a substantially rectangular cross section is used, there are many places to be electrically connected after inserting the conductor into the slot of the stator, which has a problem in terms of productivity. In the following embodiments, since a coil in which a conductor whose surface is insulated is continuously wound can be inserted into the slot, the number of electrical connection points is small and productivity is improved.

  In the present embodiment, one side of each of the plurality of circulation portions of the coil is inserted into the back side of the slot, and then the other side of each of the circulation portions and the one side By adjusting the distance to a predetermined distance and inserting the other side into the slot entrance side, the continuously wound coil can be efficiently inserted into the slot, and the productivity is improved.

  In this embodiment, the overlapped portion of the continuous winding coil is formed of a continuous line, and when one side constituting the coil of the overlapped portion is inserted into one slot, the other side constituting the coil is predetermined. It is arranged to be inserted into another slot that is spaced apart, and is arranged radially inside in the one slot, outside in the radial direction in the other slot, and from the inside to the outside of the slot at the coil end or It is structured to be wound so as to move from the outside to the inside. With such an arrangement, the continuously wound coils are regularly arranged, the number of turns of the coil can be increased, and an increase in electrical connection points with respect to an increase in the number of turns of the coil can be suppressed. Moreover, even if the number of turns of the coil is increased, the increase in the size of the rotating machine can be suppressed.

  In this embodiment, each slot has a structure in which a plurality of conductors constituting a coil are arranged in a row in the radial direction with respect to the rotation axis in a circumferential direction. With such a structure, the process of inserting the continuously wound coil into the slot becomes relatively simple, and the productivity is improved. In addition, since the coil is disposed so that currents in the same phase flow in the slots adjacent to each other in the circumferential direction, a rotating electrical machine having a structure that leads to an improvement in productivity can be provided. In addition, stator windings are made by connecting in-phase windings arranged in adjacent slots in series, and electrically connecting a stator coil with the series-connected windings as unit windings, This has the effect of easily balancing the electrical characteristics.

  The stator winding described in the present embodiment can be used for both a permanent magnet type rotating machine and an induction type rotating electrical machine. As an example in the case of being used as an induction type rotating electrical machine, in the following embodiment, the induction type rotating electrical machine has 8 poles. By setting the number of poles of the induction rotating electrical machine to 6 poles or more, particularly 8 poles or 10 poles, the radial thickness of the magnetic path of the core back of the stator core can be reduced. Similarly, with respect to the rotor, the thickness in the radial direction of the magnetic path of the rotor yoke can be reduced by using 6 poles or more, particularly 8 poles or 10 poles. In the case of an induction motor, if the number of stator poles is increased, the efficiency will be reduced due to the relationship with the rotor cage conductor, and 6 to 10 poles are preferred as a rotating electrical machine for use in an automobile drive system. Among them, 8 to 10 are better, and 8 is very good. A rotating electrical machine used for a drive system of an automobile is a rotating electrical machine that starts a stopped engine, generates a torque for traveling a vehicle together with the engine, or travels a vehicle with a single torque.

  Next, a method for manufacturing a rotating electrical machine will be described with reference to FIGS. One of the features of this embodiment is a method of inserting a coil into a slot of a stator, and this method will be described. FIG. 14 is a flowchart showing the manufacturing process of this embodiment. FIG. 15A is a perspective view of a state where a coil is wound around a core. FIG. 15B is an enlarged view of the portion (B) in the diagram of FIG. FIG. 16 is a perspective view of a state in which a coil wound around a core is further press-formed. FIG. 17 is a perspective view of a preformed coil. FIG. 18A and FIG. 18B are side views in which the preformed coil is further deformed. FIG. 19 is a perspective view showing a state in which the preformed coil is mounted in the slot of the stator core. FIG. 20 is a perspective view illustrating a state in which the pushing portion of the inner jig is retracted. FIG. 21 is a perspective view illustrating a state in which the extruded portion of the inner jig protrudes. FIG. 22 is a cross-sectional perspective view of the stator core with the teeth support jig attached, with the upper portion in the figure cut away. (A) in FIG. 23 is a perspective view showing a state in which the preformed coil is mounted in the slot of the stator core, and the inner jig and the support jig are further mounted. FIG. 23B is an enlarged partial cross-sectional view of FIG. FIG. 24 is a partial cross-sectional perspective view of a state in which the pressing jig is mounted. FIG. 25 is a perspective view of a stator that has been temporarily formed. FIG. 26 is a diagram showing deformation of the coiled portion in the insertion step. FIG. 27 is a perspective view showing a state where the coil is inserted into the slot of the stator core.

  In the manufacturing method of the present embodiment, in step 111 in the flowchart of FIG. 14, first, a wire having an insulating coating on its surface, for example, an enameled wire, is wound around the core wire 14 a plurality of times, and the element coil 4131a and the element coil 4131b are thereby connected. to make. As shown in FIG. 15 (B), the core glass 14 has a thin flat plate shape with rounded corners as shown in FIG. 15 (A), and is adjacent to the thin surface on the long side as shown in FIG. 15 (B). Four pairs of the two pinned pins 15 provided at substantially equal intervals are provided.

  Here, the insulation-coated wire is wound a plurality of times (in this embodiment, 3 times so that the element coil 4131a and the element coil 4131b are spirally hooked on one side surface of the curled pin 15 on one end side in the long side direction of the core rod 14. Lap) lap. Thereafter, the pair of element coils 4131a and 4131b are formed by further rotating the insulation-coated wire a plurality of times (in this embodiment, three laps) so as to be hooked on the side surface of the adjacent curled pin 15. Since the pair of element coils 4131a and 4131b formed in this way are both spirally wound from the inner peripheral side to the outer peripheral side, the two element coils 4131a and 4131b are adjacent to each other from the outer peripheral side of the spiral portion. Continuing on the inner peripheral side of the spiral portion in the circular portion.

  In addition, the coil terminals on the winding end side of the pair of element coils 4131a and 4131b are on the outer peripheral side of the spiraling part that circulates, and the terminal part of the stator coil 413 on the outer peripheral side is tangled in the core rod 14. Along the thin surface on the long side where the pins 15 are provided, the element coils 4131a and 4131b are separated by a slot pitch × 11 which is a length corresponding to the mechanical angle of 90 ° in the circumferential direction. Then, it is hooked on the next curled pin 15 and the insulation coated wire is circulated in the same manner. That is, four pairs of the tangled pins 15 provided adjacent to each other are provided for every length necessary for the pair of element coils 4131a and 4131b to shift in the circumferential direction by 90 ° in mechanical angle. The stator coil 413 wound around the core rod 14 is formed as shown in FIG. 15A by repeating the same operation four times in order to form four pairs of rotating portions.

  Next, as shown in step 112 in the flowchart of FIG. 14, the stator coil 413 is pressure-molded to complete the preforming. In addition, the process 111 and the process 112 in the flowchart of FIG. 14 become a preforming process. In order to press-form the stator coil 413 wound around the core rod 14, first, as shown in FIG. The two blocks 16 are sandwiched and pressurized, and the bulges on both sides of the stator coil 413 are removed. In order to facilitate the subsequent molding, it is preferable to use a self-bonding wire for the stator coil 413 and harden it to be integrated by energization. Alternatively, insulating paper may be disposed around the slot insertion portion in the circumferential portion of the stator coil 413 so that the stator coil 413 and the insulating paper are fixed together when the stator coil 413 is energized and fixed. By integrating the stator coil 413 and the insulating paper in this way, the subsequent formation of the stator coil 413 can be facilitated, and damage to the coating on the coil surface during insertion into the slot 411 can be avoided.

  Next, the stator coil 413 wound around the core rod 14 is removed from the core rod 14. In order to take out the stator coil 413 from the core rod 14, it is possible to make the pin 15 detachable, or to divide the core rod 14 in the height direction so as to reduce the distance in the height direction after winding. It is only necessary that the tapping pin 15 can be withdrawn into the core glass 14. The stator coil 413 removed from the core rod 14 as described above includes a linear portion 4133 that forms a pair of sides that are spirally wound a plurality of times (three in this embodiment) as shown in FIG. There are four pairs of oval-shaped element coils 4131a and 4131b, and the pairs of the surrounding portions are continuous via a crossover 4132.

  Here, as shown in FIG. 49, the insulating paper 91 may be fixed to the original coil by wrapping the slot insertion portion of the original coil with the insulating paper 91 and energizing and heating the coil again. There is also a method using an electric wire that does not have a self-bonding layer. A resin film such as PET is used in place of the insulating paper 91, the slot insertion part of the original coil is wrapped with a resin film, and the overlapping part of the film is welded by ultrasonic bonding or the like, so that the electric wire and the insulation of the slot insertion part are fixed. You may use for.

  Next, as shown in FIG. 18A, the straight portion 4133 in each of the revolving portions 4131 formed into an oval shape is pressed from the side surface. The apparatus used for pressing is a flat die 17 on one side and a substantially trapezoidal punch 18 on the other side, so that the oval-shaped circumferential portion 4131 in the stator coil 413 is the die 17. And is punched by the punch 18, and is formed into a substantially P-shape in which the side surface on one end side on the coil end side is recessed. In this way, by forming the oval-shaped circumferential portion 4131 of the stator coil 413 into a substantially P-shape and disposing the recessed side on the outer peripheral side of the stator core 412, the stator coil 413 is disposed on the inner peripheral side. And the hindrance to the insertion of the rotor 5 is eliminated.

  As another means for preventing the stator coil 413 from projecting to the inner peripheral side, the one shown in FIG. 18B can be considered. FIG. 18B shows that when the stator coil 413 is sandwiched between the punches 18 by forming a substantially trapezoidal recess in the die 171 in the longitudinal direction longer than the punch 18, and the stator coil 413. The oval-shaped circumferential portion 4131 in 413 is formed into a substantially U-shaped cross section in which the coil ends are deformed in one direction, that is, both ends connecting the linear portions 4133 in the circumferential portion. If the deformed side of the molded portion 4131 formed here is arranged on the outer peripheral side of the stator core 412, the stator coil 413 protrudes more toward the inner peripheral side than in FIG. This can be surely prevented, and the height of the coil end can be lowered.

  Thus, the preforming step 112 of the stator coil 413 is completed. Next, as shown in step 113 in the flowchart of FIG. 14, the outer peripheral straight portion 4133 a is inserted into the slot 411 of the stator core 412 so that the outer peripheral straight portion 4133 a of the preliminarily formed peripheral portion 4131 is inserted into the circumference. An arrangement step of arranging in the direction is performed. That is, it arrange | positions so that the short-axis direction in the oval-shaped surrounding part 4131 may become radial. Here, since the pair of the element coils 4131a and 4131b is connected by the crossover wire 4132, it is necessary to arrange them while deforming the crossover wire. A series of these operations is an arrangement process. FIG. 19 shows a state where one side of the rotating portion 4131, for example, the outer peripheral side straight portion 4133a, is inserted into the slot 411 of the stator core 412. Note that FIG. 19 shows a state in which only some of the coils 4131 are inserted into the slots 411 for easy understanding, and the connecting wire 4132 is also omitted.

  Further, in the arranging step 113, the protruding portion deformed in FIG. 18 (A) or FIG. 18 (B) is inserted so as to face the outer peripheral side of the stator core 412 and continuously preformed. In the stator coil 413, a pair of element coils 4131 a and 4131 b wound next to each other is inserted into an adjacent slot 411 and a pair of other element coils 4131 a and 4131 b that are continuous by a crossover 4132. Each of the outer peripheral side straight portions 4133a is inserted into a slot 411 shifted by 90 ° in mechanical angle. Further, the outer peripheral side straight portion 4133a of the continuous circulation portion 4131 preliminarily formed also in the other slots 411 is inserted from the axial direction, and the outer peripheral side straight portion 4133a of the stator coil 413 for three phases is entirely the slot 411. Inserted inside.

  Further, the crossover 4132 portion connecting the pair of element coils 4131a and 4131b in the stator coil 413 is substantially spiral so as to straddle the outer peripheral side and the inner peripheral side of the stator core 412 as shown in FIG. However, it is desirable to form in a projecting shape in a substantially V shape or a substantially U shape in the axial direction in preparation for an insertion process to be performed later.

  Next, as shown in step 114 in the flowchart of FIG. 14, the inner jig 19 is mounted from the axial direction of the stator core 412 on the other side of the rotating portion 4131, for example, the inner peripheral linear portion 4133 b. Note that the steps 113 and 114 in the flowchart of FIG. 14 are the placement steps. Here, details of the inner jig 19 will be described with reference to FIGS. 20 and 21. FIG.

  As shown in FIG. 20, the inner jig 19 has the same number of outer peripheral opening grooves 191 as the slots 411 of the stator core 412 on the outer periphery, and these outer peripheral opening grooves 191 can be opposed to the slots 411. It has become. In addition, the circumferential width of the outer circumferential opening groove 191 is smaller than or equal to the circumferential width of the inner circumferential opening of the slot 411, and the axial length of the outer circumferential opening groove 191 is 411 is longer than the axial length. In addition, slits 192 are formed at the bottom of each outer peripheral opening groove 191, and a plate-like extrusion member 193 is provided from these slits 192 so as to be able to appear and exit in the inner and outer peripheral directions, that is, radially. . Further, an expansion member 194 is provided on the inner peripheral side of these push-out members 193 so as to be movable in the axial direction. The enlarged member 194 is provided with a tapered portion having a continuously small diameter in the inserting direction. When the enlarged member 194 is inserted into the inner periphery of each pushing member 193, the cam action by the tapered portion is shown in FIG. Thus, the pushing member 193 is pushed out from the slit 192.

  The inner jig 19 is inserted from the axial direction of the stator core 412 so that the inner circumferential linear portion 4133b of each circumferential portion 4131 is inserted into each outer circumferential opening groove 191 of the inner jig 19 configured as described above. . 23 (A) and 23 (B) show a state where the inner jig 19 is inserted into the inner periphery of the stator core 412, but for ease of understanding, FIG. 23 (A) shows only a part of the coils 4131. The state inserted in the slot 411 is shown, and the detailed shape of the inner jig 19 and the connecting wire 4132 are omitted. As described above, as clearly shown in FIG. 23B, the axial dimension of the inner jig 19 is longer than the axial dimension of the slot 411 of the stator core 412. That is, the axial length of the outer peripheral opening groove 191 is longer than the axial length of the slot 411.

  Next, as shown in step 115 in the flowchart of FIG. 14, the support member 20 and the teeth support jig 21 are attached to the stator core 412. First, the substantially rod-shaped teeth support jig 21 along the slot 411 is inserted from the axial direction of the stator core 412 into the gap between the bottom of each slot 411 and the outer straight portion 4133a of the circumferential portion 4131. FIG. 22 is a cross-sectional view of the stator core 412 in the upper side in the figure. As shown in this figure, all the slots 411 include the teeth support jig 21 and the linear portion on the outer circumference side of the coil 4131. 4133a is inserted as a pair. Here, when a force in the rotational direction of the stator core 412 is applied to each of the outer peripheral side straight portions 4133a of the coil 4131, a force to tilt the teeth 414 in the circumferential direction acts, but the teeth support treatment is applied to all the slots 411. Since the tool 21 is inserted, the teeth 414 cannot be tilted in the circumferential direction. For this reason, even if a force in the rotational direction of the stator core 412 is applied to the outer peripheral side straight portion 4133a of the coil 4131 in a temporary forming step performed later, the teeth 414 can be prevented from falling.

  Further, as shown in FIG. 23, at both ends in the axial direction of the stator core 412, rod-like support members 20 formed in a taper shape slightly tapered toward the inner periphery at all locations corresponding to the teeth 414 from the outer periphery side. The coil 4131 is mounted between the outer peripheral straight portions 4133a. As shown in FIG. 23 (B), the support member 20 is configured so that the height in the axial direction is substantially equal to the inner jig 19 in the mounted state. What is the contact surface with the stator core 412? Both sides in the circumferential direction on the opposite side have a generally rounded shape that forms a gentle curved surface.

  Next, as shown in step 116 in the flowchart of FIG. 14, the pressing jig 23 is attached to the stator core 412. As shown in FIG. 24, the pressing jig 23 is attached to both ends of the stator core 412 in the axial direction, and both ends connecting the linear portions 4133 of the rotating portion 4131, that is, the top portions of the coil ends, It is comprised so that it can press from the direction both sides. For this reason, the pressing jig 23 includes a pressing jig 23a on the side where the crossover 4132 is provided and a pressing jig 23b on the opposite side, and the pressing jigs 23a and 23b are arranged on the inner periphery. It has a ring shape having a hole 231 into which the inner jig 19 can be inserted. Further, the pressing jig 23a on the side where the connecting wire 4132 is provided is formed with grooves 232 along the shape of the connecting wire 4132. By inserting the connecting wires 4132 into these grooves 232, the connecting wire 4132 is inserted. While adjusting the shape of 4132, a pressing force can be applied to the top of the coil end.

  Next, as shown in step 117 in the flowchart of FIG. 14, the inner jig 19 is rotated with respect to the stator core 412 to widen both ends of the circumferential portion 4131, and as a result, the circumferential portion 4131 that has an oval shape is substantially omitted. Molded into a turtle shell shape. This operation is a temporary molding process. Specifically, in a state in which a fixing member is fixed to a groove for welding a plurality of electromagnetic steel plates provided on the outer periphery of the stator core 412, both ends of the stator core 412 in the axial direction of the top end of the coil end are pressed by the pressing jig 23. The inner jig 19 is rotated by a predetermined angle in the clockwise direction while pressing from above, and the inner circumferential straight portion 4133b in the circumferential portion 4131 overlaps with the outer circumferential linear portion 4133a in another circumferential portion 4131 to form a line in the radial direction. Mold as follows. In the present embodiment, the inner peripheral straight portion 4133b in the rotating portion 4131 is rotated by an angle that is shifted by five slots 411 in the stator core 412. That is, the stator core 412 is arranged so that the inner peripheral side straight portion 4133b of the coil 4131 inserted into the five slots 411 overlaps the inner side of the outer peripheral side linear portion 4133a of the coil 4131 formed in a turtle shell shape. The slot 411 and the outer peripheral opening groove 191 of the inner jig 19 are opposed to each other. In the present embodiment, the inner jig 19 is rotated with respect to the stator core 412, but the stator core 412 may be rotated with respect to the inner jig 19.

  FIG. 25 shows a state in which all the circumferential portions 4131 are spread out in an aligned state, that is, a state in which they are formed in a substantially turtle shell shape, but for the sake of clarity, the detailed shape of the inner jig 19 and the crossovers are shown. 4132 and the pressing jig 23 are omitted. As for the crossover 4132, since the tops of the coil ends are connected to each other, the shape of the crossover 4132 is not changed even if the winding portion 4131 is formed in a substantially turtle shell shape, and the entire crossover 4132 is maintained while maintaining the shape. Only rotates. That is, the pressing jigs 23 a and 23 b with the connecting wire 4132 inserted follow the inner jig 19 and rotate.

  Thus, in this embodiment, since it forms in a turtle shell shape, pressing the rotation part 4131 with the pressing jig 23, the stress which acts when the rotation part 4131 deform | transforms can be disperse | distributed, and shaping | molding is easy. In addition, the insulating coating such as varnish applied to the surface of the stator coil 413 can be prevented from being damaged. Furthermore, the axial length of the coil end can be shortened.

  Next, as shown in step 118 in the flowchart of FIG. 14, the inner peripheral side straight portion 4133 b of the rotating portion 4131 is inserted into the slot 411 of the stator core 412. This operation is an insertion process. After the provisional molding process is completed and before the insertion process is performed, first, the support member 20 and the teeth support jig 21 are removed. Thereafter, the enlarged member 194 of the inner jig 19 is inserted into the inner periphery of each pusher member 193, and the pusher member 193 is pushed out from the slit 192 as shown in FIG. Into the slot 411. Here, the circumferential width of the slot 411 and the outer circumferential side opening groove 191 is the same, or the circumferential width of the slot 411 is larger, and each of the circumferential portions 4131 is larger than the axial length of the slot 411 in the stator core 412. Since the length in the axial direction of the straight portion 4133 is long, the rotating portion 4131 can be prevented from being caught by the tip of the tooth 414 in the stator core 412. Therefore, in the state where the stator coil 413 is inserted into the slot 411 of the stator core 412, as shown in FIG. 26, the extending portion 418 extending in the continuous direction from the slot 411 of the stator core 412 has a slot. 411 extends to both ends in the axial direction.

  Further, since the slots 411 are formed in a radial shape, it is necessary to widen the space between the pair of linear portions 4133 in the rotating portion 4131 as shown in FIG. Therefore, as in the temporary molding step, the stator coil 413 is inserted by inserting the inner peripheral side straight portion 4133b while pressing the top of the coil end from both axial sides of the stator core 412 with the pressing jig 23. This can be facilitated, and the axial length of the coil end can also be shortened. Further, as the distance between the pair of straight portions 4133 widens, it is necessary to increase the length of the crossover 4132 in the radial direction. However, in the arrangement process, the projecting shape becomes a substantially V shape or a substantially U shape in the axial direction. The length of the connecting wire 4132 in the radial direction can be extended by deforming the connecting wire 4132 that has been formed into a substantially identical surface in the axial direction.

  Next, as shown in step 119 in the flowchart of FIG. 14, the pressing jig 23 and the inner jig 19 are taken out from the inner circumference of the stator core 412, and both circumferential sides on the distal end side of the teeth 414 in the stator core 412. A holding member 416 is mounted in each holding groove 417 provided on the surface from the axial direction of the stator core 412. 27 and 28 show the stator core 412 from which the pressing jig 23 and the inner jig 19 have been removed. 27 and 28 are also shown with the crossover 4132 omitted for easy understanding. In the present embodiment, since the temporary forming step and the insertion step are performed while pressing the top of the coil end in the circumferential portion 4131 with the pressing jig 23, the width α between the respective linear portions 4133 in the coil 4131 is clear from FIG. Rather, the width β between the coils 4131 at the coil end inclined with respect to the axial direction of the stator core 412 is smaller. Thus, the axial length of the coil end in this embodiment can be shortened.

  The holding member 416 has substantially the same length in the axial direction of the stator core 412, and the holding member 416 has a substantially trapezoidal cross section with a short inner peripheral side. On the other hand, since each holding groove 417 is also formed in a shape that matches the holding member 416, the holding member 416 has as large an area as possible when a force that causes the stator coil 413 to be pulled toward the inner peripheral side is generated. And the holding groove 417 can be brought into contact with each other.

  Next, as shown in step 120 in the flowchart of FIG. 14, the terminals of each stator coil 413 are not continuous with the stator coil 413 as shown in FIG. 10 in order to connect the terminals as shown in FIGS. The four connecting wires 4132a provided separately are connected by welding, for example, TIG welding. This operation is a connection process. The connecting wire 4132a provided separately converges so as to straddle the outer peripheral side and the inner peripheral side of the stator core 412, so that the entire connecting wire 4132 is arranged in a substantially spiral shape.

  As described above, the stator 4 is completed. As shown in step 121 in the flowchart of FIG. 14, as the rotating electric machine, the stator 4 is fixed in the housing 1 in which each component is assembled. It is manufactured by rotatably supporting the rotor 5 on the circumferential side using ball bearings 7a and 7b as bearings. This operation is an attachment process that is an assembly process of the rotating electrical machine.

  Although the first embodiment has been described above, the operational effects of the first embodiment are described below.

  The insulation-coated conductor is formed into a continuous coil shape, and then the coil is placed inside the stator 4, and one side of each turn constituting the coil is opened in each slot 411 of the stator 4. Are inserted into the slots, and the other side of each turn constituting the coil is inserted into the slots from the openings of the slots 411 of the stator 4 and the continuous coils are inserted into the stator. A rotating electrical machine is produced by inserting the coil into the slot, and then electrically connecting the coil ends, rotating the stator 4 inside, and rotatably mounting 4. In this production method, since continuously wound coils are mounted in the slots, the number of connection points that require electrical connection work can be reduced, and productivity is improved. Here, the coil may be turned once or plural times. In particular, since the effect is greater in a plurality of times, the embodiment has a structure in which a turn portion having a plurality of turns is placed in each slot. As described above, it is possible to reduce the number of connection points that require connection work for the entire stator winding even if the number of turns is one.

  The manufacturing method of the rotating electrical machine according to the first embodiment includes a preforming step of performing a preforming by rotating a continuous coil in a spiral shape including a pair of opposing linear portions a plurality of times, and the preformed coil An arrangement step of arranging a plurality of circumferential portions in the circumferential direction so that the respective linear portions are located on the inner peripheral side and the outer peripheral side, and relative rotation of the linear portions on the inner peripheral side and the outer peripheral side in the peripheral portion of the coil A temporary forming step, and the linear portion on the outer peripheral side of the temporarily formed coil is positioned on the bottom side of the slot, and the linear portion on the inner peripheral side is positioned on the coil insertion portion side. An insertion step for inserting the rotor, a connection step for connecting a terminal portion of the coil to each location according to the application, and an attachment for mounting the rotor in the stator so as to be relatively rotatable by a bearing. It is characterized in that it consists of a degree. In this way, the number of connection portions does not increase regardless of how many turns around the coil, so that the coil can be easily wound around the stator core with as few connection points as possible. For this reason, reduction of connection man-hours, reduction of insulation processing, and improvement of strength reliability can be realized. In addition, since the coil ends are wound so as to straddle the inner and outer peripheral sides of the slots, the coil ends extending from different slots are not aligned in the axial direction of the stator core, but do not interfere in the circumferential direction. Therefore, the axial length of the coil end and thus the rotating electric machine can be reduced. Further, the cooling performance of the coil can be improved. Further, since the coils are continuously circulated, the number of coils in the slot can be increased, so that loss due to harmonics can be reduced. In addition, since the coil can be easily mounted on the stator core, the manufacturing can be automated and the mass production can be realized.

  Further, in the method of manufacturing the rotating electrical machine according to the first embodiment, when performing the temporary forming step, before performing the temporary forming step so that both ends of the linear portion of the coil are positioned away from the slot. The linear portions on the inner peripheral side and the outer peripheral side are relatively rotated with support jigs inserted at both ends of the linear portion. For this reason, it is possible to prevent the bent portion of the coil from being caught by the teeth tip of the stator core in the insertion step, so that the straight portion can be easily inserted into the slot.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that the said linear parts of the other said surrounding parts may overlap an inner periphery in a temporary formation process. For this reason, it is easy to insert the straight portion into the slot, and furthermore, since the coils are aligned in the radial direction, the space factor of the coil in the slot can be improved. In particular, in this embodiment, since a coil having a substantially rectangular cross section is used, the space factor can be further improved. For this reason, high output and good rotation characteristics can be achieved.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that a pair of said circumference | surroundings part arrange | positioned by the circumferential direction at the said preliminary shaping process may continue via a crossover. For this reason, the surrounding part in each phase can be arrange | positioned efficiently, and a connection location can be reduced as much as possible.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that the said connecting wire may be provided only in the axial direction one end side in the said stator at the said pre-forming process. For this reason, the axial direction length of a stator can be shortened rather than the connecting wire in the axial direction both ends in a stator.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that it may become a substantially spiral shape so that the said crossover might straddle the outer peripheral side and inner peripheral side of the said stator core at the said preliminary forming process. For this reason, the number of places where the crossovers overlap in the axial direction of the stator can be reduced as much as possible, and the axial length of the stator can be shortened.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that the said crossover wire may be located on the axial direction substantially the same surface in the said stator at the said preforming process. For this reason, the axial direction length of the stator can be further shortened.

  Further, in the method of manufacturing the rotating electrical machine according to the first embodiment, the linear portion on the outer peripheral side of the coil is arranged in the slot of the stator core in the arranging step, and the inner portion in the coil is arranged in the temporary forming step. Temporary molding is performed by relatively rotating the linear portion on the circumferential side and the slot by an inner jig. This eliminates the need to take out the temporarily formed coil from the jig and rearrange it in the stator core. For this reason, workability | operativity can be improved and a manufacturing process can be shortened.

  Further, in the method of manufacturing the rotating electrical machine according to the first embodiment, before performing the temporary forming step, a tooth support jig is inserted between the bottom of each slot and the coil, and temporary forming is performed in that state. Like to do. For this reason, when pre-molding, a force in the rotational direction is applied to the coil and a force to tilt the teeth in the circumferential direction acts, but since the teeth support jigs are inserted in all slots, the teeth are tilted in the circumferential direction. I can't do that. For this reason, even if a rotational force is applied to the coil, it is possible to prevent the teeth from falling.

  In addition, the rotating electrical machine manufacturing method according to the first embodiment includes the same number of outer peripheral opening grooves as the slots so that the inner jig faces the coil insertion portion, and extends from the bottom of the outer peripheral opening groove to the inner and outer periphery. A push-out part capable of appearing and retracting is provided, and the inserting step is performed by projecting the push-out part. For this reason, it is sufficient to arrange the inner jig in the stator core from the temporary molding process to the insertion process. As described above, in this embodiment, the number of work steps can be reduced as much as possible by minimizing the insertion and removal of the jig. Moreover, even if this inner jig | tool changes the inner / outer diameter of a stator core, it can respond with the same inner jig | tool.

  In the method for manufacturing a rotating electrical machine according to the first embodiment, a holding member having an insulating function is fixed to the coil insertion portion in the slot after the insertion step and before the connection step. For this reason, even if a magnetic flux is generated between the rotor and the rotor, the coil can be prevented from jumping out of the slot toward the rotor.

  Moreover, the manufacturing method of the rotating electrical machine according to the first embodiment is performed while pressing both end portions connecting the linear portions of the coil in the temporary forming step and the inserting step. For this reason, stress acting on the coil can be dispersed in the provisional molding step and the insertion step, so that molding is facilitated and it is possible to prevent damage to the insulating coating such as varnish applied to the surface of the coil. . Furthermore, the axial length of the coil end can be shortened.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that a pair of said surrounding part may adjoin by the coil which continued in the said preforming process. For this reason, since adjacent surrounding portions are inserted into adjacent slots, the number of slots can be increased as compared to the case where adjacent surrounding portions are inserted into the same slot. For this reason, since the waveform which synthesize | combined the magnetomotive force of each phase can be made into a smooth waveform, it becomes possible to reduce a torque pulsation and noise. Moreover, since the number of slots can be increased, eddy current loss due to harmonics can be reduced. Furthermore, since the surrounding parts in the coil are separated from each other in the circumferential direction, the cooling performance can be improved.

  Further, in the method for manufacturing the rotating electrical machine according to the first embodiment, both end sides connecting the linear portions in the circumferential portion are formed in a substantially P shape in the preliminary forming step, and the substantially P-shaped convex portion is formed in the arranging step. Is arranged on the outer peripheral side of the stator. For this reason, the coil does not protrude to the inner peripheral side, and it does not become an obstacle when the rotor is inserted in the attachment process. In addition, if both end sides connecting the straight line portions in the circular portion are deformed in one direction, and the arranging step is arranged so that the deformed direction is the outer peripheral side of the stator, the coil It can prevent more reliably that it protrudes to an inner peripheral side.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment adheres each wire material integrally after performing the said preforming process. For this reason, the coil wires are not separated from each other in the steps after the preforming step, and can be easily inserted into the slot. Moreover, since the coil laminated | stacked can be integrally deformed when shape | molding the surrounding part of the preformed coil in a substantially turtle shell shape, a moldability is also improved.

  In the rotating electrical machine according to the first embodiment, the coil cross section has a substantially rectangular shape in which the normal direction of the stator core is long and the radial direction is short. For this reason, the number of coils in the slot can be increased as much as possible, and the loss reduction effect due to harmonics can be further increased. Moreover, since the length of the side protruding to the coil end side is shortened also in terms of space, the protruding amount of the coil end can be further reduced. Furthermore, although it is difficult to form thin coils by deforming them one by one, in this embodiment, they can be easily formed because they are overlapped and bundled.

  In the rotating electrical machine of the first embodiment, since the connecting wire connects the terminals drawn to the outer peripheral side of the rotating portion, the connecting wire and the rotating portion do not cross each other. For this reason, the axial direction length of a stator can be shortened.

  In the rotating electrical machine of the first embodiment, the coil insertion portion in the slot is an open slot having a circumferential width that is substantially equal to or greater than the portion where the coil is mounted in the slot. The coil can be easily inserted from the slot insertion portion, and the space factor of the coil in the slot is not reduced.

  Next, 2nd Embodiment in the manufacturing method of a rotary electric machine is described based on FIGS. FIG. 30 is a simplified representation of how to wind a pair of winding portions in the coil of the second embodiment. FIG. 31 is a diagram for explaining a preforming method in the second embodiment. FIG. 31 (A) is a view of the state where the preforming is performed as viewed from the front, and FIG. 31 (B) is a view of FIG. 31 (A) as viewed from the side AA. FIG. 32 is a perspective view of a coil molded using the preforming method of the second embodiment. In addition, about the site | part which is common in 1st Embodiment, it represents with the same name and the same code | symbol.

  Although the first embodiment and the second embodiment are different in how the pair of element coils 4131a and 4131b wound in a spiral shape in the stator coil 413 are continuously formed, the preforming process is different. Since other processes are the same as those in the first embodiment, description thereof is omitted. In the first embodiment, the first element coil 4131a is wound so that the coil terminal at the beginning of winding is on the inner peripheral side and spirals on the outer peripheral side, and then the coil extending to the outer peripheral side is the second element coil. The second element coil 4131b is wound so as to extend to the inner peripheral side of the 4131b and further spiral on the outer peripheral side. That is, since the inter-coil connection line 4134 for connecting the first element coil 4131a and the second element coil 4131b is directed from the outer peripheral side to the inner peripheral side, a portion where the coil lines intersect with each other. Will occur.

  On the other hand, in the second embodiment, as shown in FIG. 30, the first element coil 4131a is wound so that the winding start is on the outer peripheral side of the first element coil 4131a and spirals on the inner peripheral side. Next, the coil extending to the inner peripheral side is extended to the inner peripheral side of the second element coil 4131b, and the second element coil 4131b is wound so as to form a spiral on the outer peripheral side. That is, since the inter-coil connection line 4134 for connecting the first element coil 4131a and the second element coil 4131b is connected on the inner peripheral side, a portion where the coil lines intersect does not occur. Such a winding method is generally referred to as α winding, and by adopting this winding method, the coil end can be further simplified and the axial length of the stator 4 can be shortened. In FIG. 30, only one pair of element coils 4131a and 4131b is shown, but actually, as shown in FIG. 32, four pairs of rotating portions are formed by continuous lines.

  Next, a preforming process for preforming such a pair of rotating portions will be described.

  In the pre-forming step of the second embodiment, as shown in FIG. 31A, first, a continuous coil is formed so as to be substantially U-shaped irregularities. At this time, the length between the vertices of the concavo-convex portion, that is, the length in the vertical direction in FIG. 31A, is the length corresponding to the pair of element coils 4131a and 4131b, and finally the concavo-convex portion that becomes the connecting wire 4132 The length of the apex, that is, the length in the left-right direction in FIG. Further, all the intermediate positions between the vertices of the concave and convex portions are bent in a crank shape by the length of the cross section of the coil, and the inter-coil connection portion 4134 is formed.

  Next, the coil formed in the concavo-convex shape is mounted on the α-winding forming jig 25 having the oval shaped forming groove 253 on the outer periphery. The α-winding forming jig 25 has a plurality of partitions 252 that are detachably attached to the plate-like member 251, and a plurality of forming grooves 253 are configured by each partition 252. These forming grooves 253 are arranged adjacent to each other as a pair, and further, the pair of forming grooves 253 adjacent to the four positions in the longitudinal direction of the plate-like member 251 are spaced apart by the length of the crossover line 4132. Is provided. Further, the partition 252 between the forming grooves 253 in the pair of adjacent forming grooves 253 is provided with an insertion groove 254 into which one coil can be inserted, and the insertion groove 254 has one end in the long axis direction of an oval shape. Located on the side. In addition, although detailed description is abbreviate | omitted, the plate-shaped member 251 can be expanded-contracted.

  The inter-coil connecting portion 4134 of the coil is inserted through the insertion groove 254 of the α winding forming jig 25 configured as described above. FIG. 31 shows a state where the inter-coil connecting portion 4134 of the coil is inserted into the insertion groove 254.

  Next, the rotating portion is formed by rotating the coil while pressing the coil against the forming groove 253 side with a roller 255 as shown in FIG. 31B provided in each forming groove 253. In addition, the direction of the circumference | surroundings of the roller 255 provided in each pair of the adjacent shaping | molding groove | channel 253 differs.

  Next, all the partitions 252 on both sides of each forming groove 253 are removed, and the coil formed by expanding and contracting the plate-like member 251 is removed from the α-winding forming jig 25. In this way, the coil shown in FIG. 32 is formed. Further, similarly to the first embodiment, the operation 112 in FIG. 14 is performed to complete the preforming process. In addition, processes other than a preforming process are performed similarly to 1st Embodiment.

  Thus, the manufacturing method of the rotary electric machine of 2nd Embodiment is shape | molded so that a pair of said surrounding parts may continue in the terminal of an inner peripheral side at a preforming process. For this reason, since the inter-coil connection lines for connecting the pairs of the surrounding portions 4131 are connected to each other on the inner peripheral side, a portion where the coil lines intersect does not occur. Therefore, the coil end can be further simplified, and the axial length of the stator can be shortened.

  Further, in the method of manufacturing the rotating electrical machine according to the second embodiment, in a state where the unevenness is previously formed in the preliminary forming step, the top of the unevenness is formed so as to circulate along the forming die. For this reason, it is possible to easily form a pair of circulation parts that are formed so that the circulation parts are continuous with each other on the inner peripheral side, and it is also possible to automate the manufacture.

  Next, based on FIGS. 33-41, 3rd Embodiment in the manufacturing method of a rotary electric machine is described. FIG. 33 is a flowchart showing the manufacturing process from the placement process to the insertion process, which is a feature of the present embodiment. FIG. 34 is a perspective view of a state where a coil is arranged on a slide jig. FIG. 35 is a perspective view of a state where the slide jig is slid to form the coiled portion in a substantially turtle shell shape. FIG. 36 is an enlarged perspective view of a fixed groove portion in the slide jig. FIG. 37 is a perspective view showing a state in which the fixing groove on one side in FIG. 36 is inclined. FIG. 38 is a perspective view of a state in which a substantially turtle-shaped coil molded body is wound around the inner jig. FIG. 39 is a perspective view of a state in which the inner jig with the coil mounted is disposed in the stator core. FIG. 40 is a perspective view of a state where the insertion process has been performed. FIG. 40A is an overall view. FIG. 40B is a perspective view showing a state where the pushing member of the inner jig is retracted, and FIG. 40A is a perspective view showing a state where the pushing member of the inner jig is protruding. . FIG. 41 is a perspective view showing a state where the inner jig is taken out. In addition, about the site | part which is common in other embodiment, it represents with the same name and the same code | symbol.

  This embodiment is different from the second embodiment from the placement step to the insertion step, but the other steps are the same as those of the second embodiment. For this reason, this embodiment demonstrates from an arrangement process to an insertion process.

  In the manufacturing method of the present embodiment, the preforming step is performed in the same manner as in the second embodiment, and a coil molded body extending in the longitudinal direction is mounted on the slide jig 35 as shown in Step 221 in the flowchart of FIG. This operation is an arrangement process. The slide jig 35 is divided into a fixed side jig 35a and a movable side jig 35b, each of which is formed in a substantially plate shape extending in the longitudinal direction, and the movable side jig 35b is fixed to the fixed side jig 35a. Can be moved in the longitudinal direction. The movement side jig 35b moves along a guide 352 as shown in FIGS.

  Further, fixing grooves 351 as the same number of fixing portions as the stator cores 412 extending in the short side direction are provided in parallel at equal intervals on each surface where the fixing jig 35a and the moving jig 35b face each other. The lengths of the fixing grooves 351 are longer than the lengths of the slots 411 of the stator core 412. Further, as shown in FIGS. 36 and 37, the moving side jig 35b is configured such that each fixed piece 353 constituting the fixed groove 351 is movable, and each fixed piece 353 is moved with respect to the bottom surface shown in FIG. As shown in FIG. 37, the fixed pieces 353 are simultaneously movable from the vertical state to the state in which each fixed piece 353 is inclined. Although a detailed description of the structure of the movable mechanism is omitted, the fixed pieces 353 can be moved simultaneously by employing a link mechanism, a cam mechanism, or the like.

  In the slide jig 35 configured as described above, first, as shown in FIG. 34, all the fixed grooves 351 of the fixed side jig 35a and the movable side jig 35b face each other, and the short side of the slide jig 35 is set. From the direction, an oval-shaped circumferential portion 4131 of a coil that has been preformed is inserted into each fixed groove 351. Note that, in FIG. 34, for the sake of clarity, only one coil molded body in which a pair of rotating portions of the four coils 4131 is formed by a continuous coil is shown inserted in the fixed groove 351. , The winding portion of the coil 4131 is inserted into all the fixing grooves 351.

  Next, as shown in step 222 in the flowchart of FIG. 33, the moving side jig 35b is slid in the longitudinal direction with respect to the fixed side jig 35a, and the coiled portion 4131 is temporarily formed into a substantially turtle shell shape. FIG. 35 shows a state in which the moving side jig 35b is slid in the longitudinal direction with respect to the fixed side jig 35a. Finally, the moving side jig 35b is moved from the state of FIG. The fixed groove 351 is moved to a position facing the fifth fixed groove 351 in the fixed jig 35a. Although not shown, as in the first embodiment, when the moving jig 35b is slid while pressing the coil top of the coil 4131, the coil 4131 is easily formed into a substantially turtle shell shape. can do.

  Next, as shown in step 223 in the flowchart of FIG. 33, the linear portion 4133 on the moving side jig 35b side in the winding portion of the substantially tortuous-shaped coil 4131 is bent so that the cross section has a predetermined angle. Note that step 222 and step 223 in the flowchart of FIG. 33 are temporary forming steps. As a method of bending, as shown in FIG. 37, all the fixing pieces 353 of the moving side jig 35b are inclined simultaneously. Here, since the stator coil 413 employs a rectangular wire having a rectangular cross section, the stator coil 413 is formed so that the cross section of the linear portion 4133 of the coil is inclined as the fixing piece 353 is inclined. The inclination angle is set such that when the coil molded body is formed into an annular shape in the next step, the cross sections of the linear portions 4133 of the coils respectively inserted in the fixed side jig 35a and the moving side jig 35b overlap radially. Good.

  Next, as shown in step 224 in the flowchart of FIG. 33, a coil molded body in which the circumferential portion 4131 is formed in a turtle shell shape is attached to the inner jig 36. Similar to the inner jig 19 in the first embodiment, the inner jig 36 includes outer peripheral side opening grooves 361 similar to the number of slots 411 of the stator core 412 on the outer periphery, and the periphery of these outer peripheral side opening grooves 361. The width in the direction is smaller than or equal to the width in the circumferential direction of the inner circumferential side opening of the slot 411, and the axial length of the outer circumferential side opening groove 361 is longer than the axial length of the slot 411. Yes. In addition, as shown in FIG. 40, slits 362 are formed at the bottom of each outer peripheral opening groove 361, and from these slits 362, plate-like extrusion members 363 are arranged in the inner and outer peripheral directions, that is, radially. It is provided so that it can appear and disappear. Although a detailed description of the structure is omitted, the pushing member 363 appears and disappears radially from the slit 362 by rotating the lever 364 provided on one end side in the axial direction of the inner jig 36 in the circumferential direction. .

  As shown in FIG. 38, winding is performed so that the linear portions 4133 of the circumferential portion of the coil 4131 are inserted into the respective outer opening grooves 361 of the inner jig 36 thus configured. At this time, the linear portions 4133 of the coils respectively inserted into the fixed side jig 35a and the moving side jig 35b are overlapped and inserted into the respective outer peripheral opening grooves 361, but at both ends of the coil molded body extending in the longitudinal direction. The five straight portions 4133 are inserted into the outer peripheral opening groove 361 so as to overlap each other. Here, the cross section of the linear portion 4133 of the coil inserted into the moving side jig 35b and the cross section of the linear portion 4133 of the coil inserted into the fixed side jig 35a are shown in the step 223 in the flowchart of FIG. Since the coils are angled with each other, the coil cross-sections formed on the flat wire can be radially overlapped only by winding the coil molded body extending in the longitudinal direction around the inner jig 36. Thus, the temporary molding process is completed. In FIG. 38, the detailed structure of the inner jig 36 and the coil connecting wire 4132 are omitted for the sake of clarity.

  Next, as indicated by step 225 in the flowchart of FIG. 33, each linear portion 4133 of the coil is inserted into the slot 411 of the stator core 412. This operation is an insertion process. As shown in FIG. 39, the inner jig 36 around which the stator coil 413 is wound in the temporary forming step is arranged on the inner peripheral side of the stator core 412. The slots 411 of the stator core 412 in the present embodiment are different from those in the first embodiment, and each slot 411 is inclined in one circumferential direction. In this manner, by inclining the slot 411 in the circumferential direction, the stator coil 413 formed in an annular shape can be easily inserted. In FIG. 39, the coil crossover 4132 is omitted for the sake of clarity.

  Next, as shown in FIG. 40A, the lever 364 of the inner jig 36 is rotated in the circumferential direction. As described above, by rotating the lever 364, the state in which the pushing member 363 in FIG. 40B is retracted from the slit 362 and the state in which the pushing member 363 in FIG. 40C is projected from the slit 362 can be switched. . More specifically, when the lever 364 is in the state shown in FIG. 40A, the pushing member 363 is retracted from the slit 362 as shown in FIG. 40B, and the lever 364 is moved in the direction of the arrow in FIG. As shown in FIG. 40C, the pushing member 363 protrudes from the slit 362 and pushes each linear portion 4133 of the coil into the slot 411 of the stator core 412. By rotating the lever 364 in this manner, the stator coil 413 is inserted into the slot 411. Further, as shown in FIG. 41, the lever 364 is rotated in the direction of the arrow to cause the pushing member 363 to retract from the slit 362. The inner jig 36 is taken out from the inner periphery of the stator core 412. Thereafter, the joining step and the attaching step may be performed as in the first embodiment. 40 and 41 also omit the coil crossover 4132 for the sake of clarity.

  As mentioned above, although 3rd Embodiment was demonstrated, the manufacturing method of the rotary electric machine of 3rd Embodiment preliminarily shape | molds the continuous coil by carrying out multiple turns to the spiral shape containing a pair of opposing linear part. A step of separately fixing to a fixing portion provided opposite to each of the different molds so that the linear portions of the preformed coils are aligned in the axial direction; and Temporary molding in which at least one of the fixed separate molding dies is linearly moved relative to each other to form a coil molded body extending in the longitudinal direction, and then annularly molded so that both longitudinal ends of the coil molded body overlap. And the slot of the coil so that the linear portion on the outer peripheral side of the temporarily formed coil is positioned on the bottom side of the slot and the linear portion on the inner peripheral side is positioned on the coil insertion portion side. An insertion step of inserting within a connecting step of connecting to the location of people each according to the application of the terminal portion in the coil, becomes the rotor within the stator and a mounting step of mounting to be relatively rotatable by bearings. For this reason, this embodiment can prevent force from acting on the teeth of the stator core in addition to the effects of the first embodiment. For this reason, even if the width | variety of a tooth | gear is small and it is what is easy to fall down, the continuous lap winding coil can be inserted.

  Further, in the method of manufacturing the rotating electrical machine according to the third embodiment, when the coil is formed using a rectangular wire having a rectangular cross section and the coil molded body is formed into an annular shape in the temporary forming step, the linear portion of the coil is formed. The fixed part of at least one of the molding dies is moved in a state where the coil molded body is fixed to the fixed part of the molding die so that the cross section is radial. For this reason, when the coil molded body is formed into an annular shape, the linear portion on the outer peripheral side and the linear portion on the inner peripheral side can be overlapped, and the insertion work in the insertion step can be facilitated.

  Moreover, the manufacturing method of the rotary electric machine of 3rd Embodiment winds the said linear part in the said coil molded object around the inner side jig | tool provided with the some outer periphery opening groove | channel at the said temporary forming process, and is shape | molded cyclically | annularly. For this reason, a coil molded object can be made cyclic | annular along the inner periphery of a stator iron core, and the insertion operation | work in an insertion process can be made easy.

  Further, in the method of manufacturing the rotating electrical machine according to the third embodiment, the inner jig is provided with an extruding portion that can be projected and retracted from the bottom of the outer peripheral opening groove to the inner and outer peripheries, and the inserting step projects the extruding portion I do that. For this reason, the number of jigs can be reduced as much as possible, and the jigs can be kept in and out of the stator core to a minimum.

  The above is an embodiment of the method for manufacturing a rotating electrical machine according to the present invention. Other embodiments of the coil and other embodiments of the rotor will be described below.

  Next, a fourth embodiment will be described with reference to FIG. FIG. 42 is a diagram showing connecting a set of coils including the element coil 4131a and the element coil 4131b, that is, connecting the connecting wires connecting the coil pairs. In addition, about the site | part which is common in other embodiment, it represents with the same name and the same code | symbol.

  As shown in FIG. 8, the stator coil 413 of the first embodiment is formed of four sets, that is, four pairs of element coils 4131a and 4131b formed by continuous wires. A different stator coil 413 is formed for each pair of rotating parts, and finally a pair of element coils 4131a and 4131b is connected by welding or the like. Specifically, one end side of the coil terminal of the pair of element coils 4131a and 4131b is lengthened by a length corresponding to the connecting wire 4132, and the connecting wire 4132 is inserted into the slot 411 of the stator core 412. It is deformed and connected to another pair of surrounding parts by TIG welding or the like.

  Thus, if the connecting wire 4132 can be connected later, it is not necessary to consider the deformation of the connecting wire 4132 when the coil molded body is inserted into the slot 411 of the stator core 412 while expanding the diameter. For this reason, although a connection location increases a little, the arrangement | positioning freedom degree of the crossover 4132 can be improved. In addition, since the connecting wire 4132 is a coil terminal on one side of the winding portion 4131, the number of parts and the connection points can be reduced as compared with the case where only the connecting wire is configured by another wire. Note that the pair of winding portions in FIG. 42 are wound by the winding method described in the second embodiment.

  Next, a fifth embodiment will be described with reference to FIG. FIG. 43 is a perspective view of the stator of the fifth embodiment. In addition, about the site | part which is common in other embodiment, it represents with the same name and the same code | symbol.

  The fifth embodiment is different from the first embodiment in the way of connecting the crossover 4132, and further, a pair of element coils 4131a and 4131b are wound by α winding as in the second embodiment. However, the other configuration is the same. Although the connecting wire 4132 of the first embodiment is configured to extend from the top of the coil end in each of the surrounding portions 4131, the connecting wire 4132 of the fifth embodiment is formed from the bottom side of the slot 411 in each of the surrounding portions 4131. It is provided so as to straddle the coil insertion part side. More specifically, the coil terminal positioned on the bottom side of the slot 411 among the coil terminals positioned on the outer peripheral side of each of the rotating portions 4131 is deformed in a stepped manner from the rotating portion 4131 toward the outer peripheral side of the stator core 412. Extend to the top of the end. Furthermore, it extends in a substantially spiral shape from the outer peripheral side to the inner peripheral side of the coil end in the same manner as in the first embodiment, and continues to the coil insertion portion side in the other rotating portion 4131. Similarly to the bottom side of the slot, this coil insertion part side is also deformed stepwise toward the inner peripheral side of the stator core 412 and is continuous with the top side of the coil end. In FIG. 43, the portion connecting the coil molded bodies formed of the crossover lines that are neutral points and the continuous lines is omitted.

  As described above, in the fifth embodiment, since the connecting wire 4132 does not extend from the top of the coil end, the axial length of the stator 4 can be further reduced. Further, since the connecting wire is configured such that the long side direction of the flat wire is directed to the axial direction of the stator 4, the connecting wire can be sufficiently arranged even with the stator core 412 having a small diameter.

  Note that the crossover 4132 of the fifth embodiment does not extend from the top of the coil end, but extends from the slot insertion portion, so that the length greatly changes when the coiled portion 4131 has a substantially turtle shell shape. End up. For this reason, as described in the first embodiment, before forming the winding portion 4131 into a substantially turtle shell shape, the connecting wire 4132 is folded into a substantially V shape or a substantially U shape in the axial direction or the radial direction. Then, the folded crossover 4132 may be extended when it is molded into a substantially turtle shell shape or inserted into the slot 411 of the stator core 412. The pair of element coils 4131a and 4131b may be wound not only by the winding method described in FIG. 30 but also by the winding method as in the first embodiment described above.

  Next, a sixth embodiment will be described with reference to FIG. FIG. 44 is a perspective view of the stator according to the sixth embodiment. In addition, about the site | part which is common in other embodiment, it represents with the same name and the same code | symbol.

  The sixth embodiment is the same as the fifth embodiment except for the shape and arrangement of the crossover 4132 compared to the fifth embodiment. The crossover wire 4132 of the sixth embodiment is spiral in the tip side from the top of the coil end as in the fourth embodiment, but the crossover wire 4132 of the sixth embodiment is not spiral but the bottom of the slot 411. It is formed in a spiral shape on the side, that is, on the outer peripheral side of the stator core 412, and is connected to another rotating portion 4131. In the sixth embodiment, the connecting wire 4132 is formed in a spiral shape on the outer peripheral side of the stator core 412 and connected to the coil terminal of the rotating portion 4131 at the coil end portion. The state before welding coils is shown. However, actually, since the wires protruding in the axial direction of the stator 4 are melted and joined from the state of FIG. 44 using TIG welding or the like, the portion protruding in the axial direction almost reaches the position of the coil end. It will melt and leave.

  As described above, in the sixth embodiment, although the number of connection points is slightly increased, the connecting wire 4132 can be disposed without protruding so much in the axial direction of the stator 4 from the top of the coil end. In addition, the axial direction of the stator 4 can be further shortened. In addition, if a shaping | molding method is devised, it is also possible to comprise the connecting wire 4132 by the line which followed the surrounding part 4131. FIG. Furthermore, the portion to be formed in a spiral shape may be spiral on the coil insertion portion side, that is, on the inner peripheral side of the stator core 412, and both the inner peripheral side and the outer peripheral side of the stator core 412 It does not matter if it is spiral.

  As mentioned above, although the effect of each embodiment was demonstrated, in the present invention, various other composition can be adopted. For example, in the above embodiment, a rectangular wire having a substantially rectangular rectangular cross-sectional shape is adopted, but it may not be a complete rectangular shape, for example, finally in the slot. Each side may be a deformed curve instead of a straight line. The coil may have a substantially circular, elliptical, or substantially polygonal shape other than the four sides. When a rectangular shape is used, the coil may have a substantially square cross section or a stator. The core may have a substantially rectangular shape with a short normal direction and a long radial direction.

  In the above embodiment, an induction motor has been described as an example of a rotating electrical machine. However, a magnetic synchronous motor having a permanent magnet in the circumferential direction of the rotor may be used. When such a magnet synchronous motor is employed, a surface magnet rotor in which a plurality of magnets are arranged on the surface of the rotor and fixed by a non-magnetic ring or the like on the inner peripheral side of the rotor. It is conceivable to employ a built-in magnet rotor in which holes extending in the axial direction are formed at a plurality of locations in the direction and magnets are built in the holes. Furthermore, when used as an AC generator for a vehicle, a Landell type rotor having a field coil wound therein can be used.

  Moreover, in the said embodiment, although the magnetic body part in a stator iron core and a rotor was comprised with the laminated steel plate, even if it employ | adopts the powder iron core which compressed and hardened the iron powder by which the insulation coating was given to the surface Good. Further, the stator core may be a split stator core configured by fixing a plurality of members.

  Moreover, in the said embodiment, although the conductor bar and the short circuit ring were comprised with aluminum, you may make it use copper. If copper is used for the conductor bar and the short-circuit ring, the electric resistance can be lowered as compared with the case where aluminum is used, so that the efficiency of the electric motor can be improved.

  In the above embodiment, the number of slots of the stator core is 48, but the number of slots can be changed according to the specification. When the number of slots is changed in this way, it is necessary to change the arrangement of the coiled portion.

  Moreover, in the said embodiment, although the surrounding part of the coil was comprised with the continuous line 1 pair so that it might adjoin, if it may increase the number of connection points, it may connect by welding etc. after inserting in a stator core. Is possible. Furthermore, the number of adjacent winding portions of the coil is not limited to two, and the number of times of spiral winding can be freely set according to the specification.

  Moreover, in the said embodiment, although it adhered to the coil using the self-bonding wire, it is also possible to adhere using other members, such as an adhesive agent and a tape. Further, depending on the molding method, it is possible to mold without fixing.

  In the above embodiment, the insulating paper is integrally fixed to the coil and then inserted into the slots of the stator core. However, the coil may be inserted after the insulating paper is arranged in each slot. In that case, the coil can be easily inserted by projecting the insulating paper so as to spread from the inner peripheral side opening in the slot.

  Moreover, in the said embodiment, although the slot was set as the open slot, you may comprise so that the inner peripheral end in each teeth may extend in the circumferential direction. Further, in the case of an open slot, a holding member is provided, but the holding member may be configured so that the inner peripheral end of the teeth is molded with resin or the like.

  Moreover, in the said embodiment, although the surrounding part of the coil was inserted in the fixed iron core as a substantially tortoiseshell shape, it may not be a tortoiseshell shape but a large oval shape.

  In the above embodiment, the stator winding is a 2Y connection in which a pair of stator coils are connected in parallel. However, a 1Y connection in which a plurality of stator coils are connected in series is also possible. is there. When such 1Y connection is employed, the number of connection points can be further reduced.

  The above-described stator winding can be used not only for an induction motor but also for a permanent magnet rotating electric machine. A permanent magnet rotating electric machine using the above-described stator winding will be described with reference to FIGS. 45 and 46. FIG. 45 is a cross-sectional view of the permanent magnet rotating electric machine 200. 46 is an AA cross section of the stator 230 and the rotor 250 shown in FIG. In this figure, the housing 212 and the shaft 218 are not shown.

  A stator 230 is held inside the housing 212, and the stator 230 includes a stator core 232 and the above-described stator winding 238. A rotor 250 having a permanent magnet 254 is arranged with respect to the stator core 232 through a gap 222. The housing 212 has end brackets 214 on both sides in the rotation axis direction of the shaft 218, and the shafts 218 having the rotor core 252 are rotatably held by bearings 216 on the end brackets 214.

  The shaft 218 is provided with a rotor position sensor 224 that detects the position of the rotor pole and a rotation speed sensor 226 that detects the rotation speed of the rotor. Based on the outputs of these sensors, the three-phase alternating current supplied to the stator winding is controlled.

  A specific structure of the stator 230 and the rotor 250 shown in FIG. 45 will be described with reference to FIG. The stator 230 has a stator core 232, and the stator core 232 has a large number of slots 234 and teeth 236 equally in the circumferential direction as in the above-described structure, and the slot 234 has the above-described structure. The stator coil 238 is provided. As shown in FIG. 46, in this embodiment, the number of slots of the stator core is 48, but is not limited to this.

  The rotor core 252 is provided with permanent magnet insertion holes for inserting permanent magnets 254 and 256, and the permanent magnets 254 and 256 are inserted into the permanent magnet insertion holes. The magnetization direction of the permanent magnets 254 and 256 is a direction in which the side surface of the stator of the magnet is an N pole or an S pole, and the magnetization direction is reversed for each pole of the rotor.

  In the embodiment shown in FIG. 46, the permanent magnets 254 and 256 act as one pole of the rotor 250. The poles of the rotor 250 including the permanent magnets 254 and 256 are arranged at equal intervals in the circumferential direction of the rotor 250, and in this embodiment, there are eight poles. However, it is not fixed to 8 poles, but may be 10 poles or more and 30 poles or more in some cases, and the number of poles is determined by conditions such as output required for the rotating electrical machine. Further, when the number of poles is increased, the number of magnets increases and workability decreases. In some cases, it may be 8 poles or less. The portion of the rotor core existing on the stator side of the permanent magnets 254 and 256 acting as each pole of the rotor 250 acts as a magnetic pole piece 280, and the magnetic lines of force entering and exiting the permanent magnets 254 and 256 are fixed through this magnetic pole piece 280. Enter and exit the child core 232.

  As described above, the permanent magnets 254 and 256 acting as the poles of the rotor 250 are magnetized in the opposite directions for each pole so that the magnets 254 and 256 of a certain pole are the N pole on the stator side and the S pole on the shaft side. Are magnetized such that the permanent magnets 254 and 256 acting as poles on both sides thereof are S-pole on the stator side and N-pole on the shaft side. A portion acting as an auxiliary magnetic pole 290 exists between the poles of the rotor 250, and the reluctance is determined by the difference in magnetic resistance between the q-axis magnetic flux passing through the auxiliary magnetic pole 290 and the d-axis magnetic flux passing through the magnet. Generate torque. Between the auxiliary magnetic poles 290 and the magnetic pole pieces 280, there are bridge portions 282 and 284, respectively. In the bridge portions 282 and 284, the magnetic circuit 262 and 264 narrow the cross-sectional area of the magnetic circuit. Yes. For this reason, a magnetic saturation phenomenon occurs in each of the bridge portions 282 and 284, and the amount of magnetic flux passing between the magnetic pole piece 280 and the auxiliary magnetic pole 290, that is, passing through the bridge portions 282 and 284 is suppressed to a predetermined amount or less.

  45 and 46, the switching operation of the inverter device shown in FIG. 4 is controlled based on the outputs of the rotation speed sensor 226 and the rotor position sensor 224 of the rotor. The operation of converting the supplied DC power into three-phase AC power is controlled. The three-phase alternating current power is supplied to the stator coil 238 shown in FIGS. 45 and 46, and the frequency of the three-phase alternating current is controlled based on the detection value of the rotational speed sensor 226, and the detection of the rotor position sensor 224 is performed. Based on the value, the phase of the three-phase alternating current with respect to the rotor is controlled.

  A rotating magnetic field based on the phase and frequency is generated in the stator 230 by the three-phase alternating current. The rotating magnetic field of the stator 230 acts on the permanent magnets 254 and 256 of the rotor 250, and magnet torque based on the permanent magnets 254 and 256 is generated in the rotor 250. The rotating magnetic field acts on the auxiliary magnetic pole 290 of the rotor 250, and the reluctance torque is applied to the rotor 250 based on the difference in magnetic resistance between the magnetic circuit passing through the magnets 254 and 256 of the rotating magnetic field and the magnetic circuit passing through the auxiliary magnetic pole 290. Is generated. The rotational torque of the rotor 250 is a value determined based on both the torque of the magnet based on the permanent magnet and the reluctance torque based on the auxiliary magnetic pole.

  The reluctance torque is generated by the difference between the magnetic resistance that the rotating magnetic field generated by the stator winding passes through the magnet and the magnetic resistance that passes through the auxiliary magnetic pole 290. Therefore, the inverter device 620 shown in FIG. The resultant vector of the armature magnetomotive force by 238 is controlled so as to be on the advance side in the rotation direction from the center position of the auxiliary magnetic pole, and reluctance torque is generated by the advance side phase of the rotating magnetic flux with respect to the auxiliary magnetic pole 290 of the rotor.

  Since the reluctance torque is generated in the rotor 250 in the direction added to the magnet torque by the permanent magnets 254 and 256 in the start-up state and the low-speed operation state of the rotating electrical machine, the reluctance torque rotates with the addition torque of the magnet torque and the reluctance torque. The required torque that the electric machine must generate can be created. Therefore, the generation of magnet torque can be reduced by the amount corresponding to the reluctance torque, and the magnetomotive force of the permanent magnet can be lowered. By lowering the magnetomotive force of the permanent magnet, it is possible to suppress the induced voltage caused by the permanent magnet during high-speed operation of the rotating electrical machine, and it becomes easy to supply power to the rotating electrical machine during high-speed rotation. Furthermore, the amount of magnets can be reduced by increasing the reluctance torque. Since rare earth permanent magnets are expensive, it is desirable from an economical viewpoint that the amount of magnets used can be reduced.

  The stator winding can be applied to induction type rotating electric machines and permanent magnet type rotating electric machines. By using these stator windings, it is possible to obtain rotating electric machines that are easy to produce and have high reliability. Further, by having one conductor in the circumferential direction of the slot, it is possible to obtain a rotating electrical machine that can reduce torque pulsation and is excellent in productivity. In the above-described embodiment, it is possible to produce a coil that circulates a plurality of times with a continuous conductor, and it is possible to obtain a rotating electrical machine with few connection points and excellent productivity.

It is side surface sectional drawing of an electric motor. The cross section of a rotor is made into the perspective view. It is a perspective view of each component in an electric motor. It is a system diagram for demonstrating electrical connection. It is a figure which shows the state of the rotating magnetic field which generate | occur | produces with a stator winding | coil. It is a figure which shows the mode of the magnetic flux in case the rotational speed of a rotor is slower than the rotational speed of the rotating magnetic field which generate | occur | produces in a stator core. It is a perspective view of a stator. It is a perspective view of one continuous coil for constituting a stator winding. It is a perspective view of the coil for 1 phase. It is a front view of a stator. It is a side view of a stator. It is a connection diagram of a stator winding. It is a figure which shows the relationship between the coil which comprises the slot number of a stator, and a stator winding. It is a flowchart which shows the manufacturing process of 1st Embodiment. It is a figure explaining the method of shape | molding an oval-shaped coil in 1st Embodiment. It is a perspective view of the state which further press-molded the oval-shaped coil in 1st Embodiment. It is a perspective view of the coil preformed by the method of a 1st embodiment. It is the side view which deform | transformed further the coil preformed by the method of 1st Embodiment. It is a perspective view of the state where the coil preformed by the method of the first embodiment is mounted in the slot of the stator core. It is a perspective view explaining the state which the extrusion part of the inner side jig | tool used in 1st Embodiment has retracted. It is a perspective view explaining the state which the extrusion part of the inner side jig | tool used in 1st Embodiment protrudes. It is a section perspective view in the state where the upper part in a figure of a stator iron core which equipped with a tooth support jig in a 1st embodiment was cut off. It is a figure of the state which mounted | wore with the coil previously preform | molded in 1st Embodiment in the slot of a stator core, and also mounted | worn the inner side jig | tool and the support jig | tool. It is a partial section perspective view in the state where a pressing jig was equipped in a 1st embodiment. It is a perspective view of the stator which performed temporary molding by the method of a 1st embodiment. It is a figure which shows the deformation | transformation of the surrounding part of the coil in the insertion process of 1st Embodiment. It is a perspective view of the state where the coil was inserted in the slot of a stator core by the method of a 1st embodiment. It is the perspective view which expanded the coil end of the stator manufactured by the method of 1st Embodiment. It is front sectional drawing of the stator manufactured by the method of 1st Embodiment. It is a simplified representation of how to wind a pair of winding portions in the coil of the second embodiment. It is a figure explaining the preforming method in 2nd Embodiment. It is a perspective view of the coil shape | molded using the preforming method of 2nd Embodiment. It is a flowchart which shows the manufacturing process from the arrangement | positioning process used as the characteristic of 3rd Embodiment to an insertion process. It is a perspective view in the state where a coil was arranged in a slide jig used in a 3rd embodiment. It is a perspective view of the state where the slide jig used in a 3rd embodiment is slid and the circumference part of a coil is shape | molded in the substantially turtle shell shape. It is the perspective view which expanded the part of the fixed groove in the slide jig | tool used by 3rd Embodiment. FIG. 37 is a perspective view of a state in which a fixing groove on one side in FIG. 36 is inclined. It is a perspective view in the state where the substantially turtle shell-shaped coil molding is wound around the inner jig in the third embodiment. It is a perspective view of the state which arrange | positions the inner side jig | tool equipped with the coil in 3rd Embodiment in a stator core. It is a perspective view of the state which performed the insertion process of 3rd Embodiment. It is a perspective view in the state where an inner side jig is taken out in a 3rd embodiment. It is a figure which shows connecting the connecting wire which connects coil pairs in 4th Embodiment. It is a perspective view of the stator of 5th Embodiment. It is a perspective view of the stator of 6th Embodiment. It is sectional drawing of a permanent magnet rotary electric machine. It is an AA cross section of the stator and rotor shown in FIG. Two continuous rectangular winding coils. The perspective view of the stator incorporating 2 continuous square wire winding coils. Eight continuous original coil of square wire with insulating paper attached to the slot insertion part. The figure which shows the positional relationship of the slot insertion part of a square wire-wound coil. The slot shape of the present invention when there is no slot wedge groove. The figure which shows the relationship between the width | variety of a coil + insulating paper, and slot width. The slot shape of the present invention when there is a slot wedge groove. Another shape of the slot of the present invention when there is a slot wedge groove. The figure which shows the state which provided the recessed part in the coil + insulating paper which contacts a slot radial direction corner | angular part by a stator end surface.

Explanation of symbols

4 Stator 5 Rotor 7a, 7b Ball bearing
19, 36 Inner jig 20 Support member 21 Teeth support jig 23 Press jig 35 Slide jig 191,361 Outer opening groove 193,363 Extrusion member 351 Fixed groove (fixed portion)
411 Slot 412 Stator core 413 Stator coil 416 Holding member 4131 Coiled portion 4132 Crossover wire 4133 Straight line portion

Claims (6)

A stator in which a coil wire has a substantially quadrangular cross section and a plurality of two-layer winding coils that are continuous via a jumper wire are incorporated, and a rotor that is rotatably provided to the stator via a gap A rotating electric machine having
The stator slot is provided with an outwardly extending slope on the inner peripheral side from the coil and insulator insertion portion ,
A rotating electrical machine having a slot width smaller than a total dimension of the coil and the insulator in the slot width direction before being inserted into the slot. A stator in which a coil wire has a substantially quadrangular cross section and a plurality of two-layer winding coils that are continuous via a jumper wire are incorporated, and a rotor that is rotatably provided to the stator via a gap A rotating electric machine having
The stator slot is provided with an outwardly extending slope on the inner peripheral side from the coil and insulator insertion portion ,
A rotating electrical machine in which a concave portion is formed by plastically deforming a coil conductor and insulating paper at a position in contact with a radial corner of a slot on an axial end face of the stator. A stator in which a coil wire has a substantially quadrangular cross section and a plurality of two-layer winding coils that are continuous via a jumper wire are incorporated, and a rotor that is rotatably provided to the stator via a gap A rotating electric machine having
The slot of the stator is provided with an outwardly inclined slope on the inner peripheral side of the wedge insertion groove, and the corner portion where the wedge insertion groove and the slot groove intersect is R-shaped ,
A rotating electrical machine having a slot width smaller than a total dimension of a coil and an insulator in a slot width direction before being inserted into the slot. A stator in which a coil wire has a substantially quadrangular cross section and a plurality of two-layer winding coils that are continuous via a jumper wire are incorporated, and a rotor that is rotatably provided to the stator via a gap A rotating electric machine having
The slot of the stator is provided with an outwardly inclined slope on the inner peripheral side of the wedge insertion groove, and the corner portion where the wedge insertion groove and the slot groove intersect is R-shaped ,
A rotating electrical machine in which a concave portion is formed by plastically deforming a coil conductor and insulating paper at a position in contact with a radial corner of a slot on an axial end face of the stator. A stator in which a coil wire has a substantially quadrangular cross section and a plurality of two-layer winding coils that are continuous via a jumper wire are incorporated, and a rotor that is rotatably provided to the stator via a gap A rotating electric machine having
The stator slot is provided with an outwardly extending slope on the inner peripheral side and the outer peripheral side from the wedge insertion groove ,
A rotating electrical machine having a slot width smaller than a total dimension of a coil and an insulator in a slot width direction before being inserted into the slot. A stator in which a coil wire has a substantially quadrangular cross section and a plurality of two-layer winding coils that are continuous via a jumper wire are incorporated, and a rotor that is rotatably provided to the stator via a gap A rotating electric machine having
The slot of the stator is provided with an outwardly inclined slope on the inner peripheral side of the wedge insertion groove, and the corner portion where the wedge insertion groove and the slot groove intersect is R-shaped ,
A rotating electrical machine in which a concave portion is formed by plastically deforming a coil conductor and insulating paper at a position in contact with a radial corner of a slot on an axial end face of the stator.

Images