JP5341621B2 - Rotating electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve the reliability on connection of the coil of a rotary electric machine. <P>SOLUTION: The rotary electric machine has: a stator 100 which has a stator core 101 around which winding is wound, a coil 102 which has an insulating film on its surface and whose sectional form is rectangular, and a lead wire 103 whose tip is formed columnar; and a cylindrical rotor 200 which is held rotatably through an rotating gap to the stator 100. The lead wire 103 has a terminal, the end of which is shaped like a flat annulus, and for the terminal, insulating films are peeled off the annular flat topside and downside thereof that is molded flat, and also an insulating film is left at a section different from the topside and the downside. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a rotating electrical machine.

  In recent years, global warming has become a problem, and there is a demand for energy saving in electrical equipment and automobiles. For example, it is said that about 70% of the total power consumption in Japan is consumed by the motor, and increasing the efficiency of the motor can greatly contribute to energy saving.

  Therefore, the shape of the electric wire used in the motor is now a rectangle (flat wire) instead of a circle (round wire), thereby improving the space factor compared to the round wire and realizing a smaller size and higher output density. doing. A plurality of round wires are wound together and a connection terminal such as a crimp terminal is used for connection to the terminal block.

  As a method for connecting the connection terminal and the coil, methods such as fusing and resistance welding are known (for example, Patent Document 1). A connection terminal such as a crimp terminal may be used for a flat wire. However, since the flat wire has a larger size than a round wire, the coil can be directly connected to the terminal block by forming the flat wire into a circular shape. .

JP 2006-190662 A

  As a problem of connection reliability between the connection terminal and the coil, there has been, for example, the possibility of dropping and electrical contact. However, in the prior art, these were not fully considered.

  The present invention is to improve the connection reliability of a coil.

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. For example, a stator core around which a winding is wound, a coil having an insulating film on the surface and a rectangular cross section, and a tip portion A stator having a lead wire formed into a circular shape, and a cylindrical rotor that is rotatably held with respect to the stator through a rotation gap, and the lead wire has a flat end portion. A circularly shaped terminal part, and the terminal part has a flatly shaped insulating film on the upper and lower surfaces of the circular shape peeled off, and has a portion different from the upper and lower surfaces. An insulating film is left , a plurality of parallel windings are provided, and a plurality of lead wires are provided per phase, and the lead wires are rotating electric machines that are overlapped and fixed .

  The present invention can improve the connection reliability of a coil.

The perspective view of the rotary electric machine which makes one Embodiment of this invention is shown. FIG. 2 shows an axial sectional view of FIG. 1. It is explanatory drawing of a coil cutting process. It is explanatory drawing of a lead wire terminal part shaping | molding process. The perspective view of the lead wire which shape | molded the front-end | tip part in circular shape is shown. The perspective view of the lead wire which has a linear shape at the front-end | tip part is shown. The perspective view of the lead wire which peeled the film | membrane of the linear part near a terminal part is shown. The perspective view of the lead wire which rolled the terminal part is shown. The perspective view of the lead wire piled up in multiple in the fixing | fixed part is shown. The perspective view of the lead wire whose terminal part is elliptical is shown.

  Embodiments of a motor including a stator according to the present invention will be described below. Note that the same or corresponding portions are denoted by the same reference numerals, and the description thereof may not be repeated.

  In this embodiment, a rotating magnetic field is generated in the stator by inserting a coil into a number of slots provided so as to open to the inner peripheral side of the stator core and supplying an alternating current to the stator coil. A rotating electrical machine that generates rotational torque in the rotor by this rotating magnetic field is used. These rotary electric machines include, for example, an induction motor using a cage rotor and a synchronous motor having a permanent magnet on the rotor. Since these induction motors and synchronous motors can also be used as generators, both of them are referred to as rotating electric machines.

  FIG. 1 shows an example of a rotating electrical machine according to the present invention. The rotating electrical machine is roughly composed of a stator 100 and a rotor 200. FIG. 2 is a view of the stator 100 and the rotor 200 as viewed from the axial direction side, and is a cross-sectional view taken in a direction orthogonal to the axial direction.

  In the stator 100, a coil 102 having a rectangular cross-sectional shape is wound around a stator core 101, and the coil 102 is inserted into a slot provided in the axial direction of the inner peripheral portion of the stator core 101. This coil 102 is a three-phase winding as a multiphase winding. This coil has a coil end exposed on both sides of the stator core 101, and is provided with a coil end insulator for the purpose of insulating the coils of the coil end portion. In order to supply electric power to the stator 100, the lead wire 103 inserted into the slot as in the coil 102 is connected to the terminal block. Inside the slot of the stator core 101, a slot insulator 104 is installed for the purpose of insulating the stator core 101 from the coil 102 and the lead wire 103.

  The stator core 101 is formed by laminating thin plate-shaped steel plates formed by punching. The stator core 101 is provided with slots at an equal pitch in the axial direction of the inner peripheral portion of the stator core 101, and is 72 slots in this embodiment. Inside each slot, there is installed a slot insulator 104 formed by bending an insulator of about 0.1 to 1 mm such as paper or film. Since the slot insulator 104 is installed to prevent direct contact between the coil and the core and between the coils, the slot insulator 104 has a shape such that the coil and the core or the coils do not contact directly.

  The coil 102 is cut to a required length, and the insulating coating on both ends of the coil is peeled off after being formed into a U-shape or before being formed. The insulating coating is peeled off using a cutter or chemicals. It is inserted so as to be interposed in a slot insulator 104 installed in each slot in the inner peripheral portion of the stator core 101.

  In this embodiment, four coils 102 are inserted into one slot, and the insertion direction is inserted into the stator core 101 from the axial direction, and the coil 102 is inserted into the slot from the part where the insulating coating is peeled off. Is done.

  After the coil 102 is inserted into the stator core 101, the coil 102 is twisted in the opposite direction to the insertion side coil, and the insulation coating of the terminal portion of the coil 102 inserted into the slots several pitches apart is peeled off by TIG welding or plasma welding. The wound cores are wound around the stator core 101.

  The lead wire 103 is made of the same material as the coil 102 and has the same cross section. Thereby, the coil 102 can be manufactured using the same member without using a special part for the lead wire 103.

  First, in order to manufacture the lead wire 103, the same member as the coil 102 is used, and for example, it is cut into a required length using a jig having a cutter 301 as shown in FIG. The coil may be cut after the lead wire 103 is formed or after the insulating coating 402 is peeled off.

  The above-mentioned cutting jig may be the same as the jig for cutting the coil 102. The length of the coil to be cut may be changed and the lead wire coil may be cut.

  Next, in order to fix to a terminal block, the coil end part cut | disconnected using the jig | tool of FIG. 4 is shape | molded circularly. As a method of forming into a circular shape, for example, a jig having a circular guide 302 and a pin 303 moving along the guide 302 shown in FIG. 5 is used. The coil cut between the guide 302 and the pin 303 is fixed, and the pin 303 is moved along the guide 302 to bend the coil along the guide 302 to form a circular terminal portion. The lead wire 103 after molding is shown in FIG.

  When the end portion of the lead wire 103 is formed into a circular shape, the linear portion 401 may be left at the tip of the coil as shown in FIG. Depending on the jig, it may be difficult to form a complete circular shape up to the tip shape, so a straight portion may remain at the coil tip portion.

  After the end portion of the lead wire 103 is formed into a circular shape, the upper and lower two curved surfaces of the lead wire 103 are peeled off from the insulating film 402 by a cutter or chemicals in the same manner as the coil 102 to form a peeled portion 403. . In general, the process of peeling off all four plane insulating films including the coil 102 can be simplified to two planes by using the manufacturing method.

  The insulation film of the lead wire 103 may be peeled before being formed into a circular shape, and the insulating film on the inner peripheral side and the outer peripheral side of the lead wire formed into a circular shape is not peeled off. This is to ensure insulation between the lead wire 103 and other parts or foreign matters by not peeling off the circumferential insulating coating.

  Not only the curved part formed at the end of the lead wire 103 but also a straight part near the curved part as shown in FIG. This is to increase the area where the contact surface of the bolt or terminal block and the terminal part come into contact, but if the peeling distance is increased by 2 mm or more, the insulation from other parts and foreign matters becomes a problem. .

  Further, when it is desired to increase the peeled area of the terminal part formed into a circular shape and the insulating film is peeled off, the terminal part is rolled as shown in FIG. 8, for example, by pressing the upper and lower surfaces of the terminal part. And coil width can be enlarged compared with before a press. As a result, the area of contact between the conductive surface of the bolt or the terminal block and the terminal portion from which the insulating coating has been peeled can be made larger than before rolling by pressing.

  In the rotating electrical machine having a plurality of windings in parallel like the 2Y and 3Y connections in the stator connection structure, a plurality of the lead wires 103 are used, and a terminal block or the like is used to fix the terminal portion of the lead wire 103. As shown in FIG. 9, it can fix so that the site | part which peeled the insulating film of the terminal part of each in-phase lead wire may overlap.

  After forming and peeling as described above, the lead wire 103 is inserted into the slot of the stator core 101 like the coil 102, and the lead wire 103 terminal portion is also joined like the coil 102. The lead wire 103 may be formed and peeled after being inserted into the slot, and the lead wire 103 and the coil 102 may be inserted into the stator core 101 at the same time.

  After the coil 102 and the lead wire 103 are joined, the lead wire 103 is fixed to the terminal block. At the time of fixing, the peeled portion formed in the circular shape of the lead wire 103 contacts the terminal block conductive portion and the fixing bolt. To fix. Thereby, the terminal block and the bolt and the lead wire 103 not only ensure electrical contact, but also do not use a component such as a crimp terminal, so there is no possibility of dropping off. Further, since the lead wire 103 peels the insulating film only at the portions that come into contact with the terminal block and the bolts, the other parts of the lead wire 103 can also have an insulating effect from other parts and foreign matters.

  In the lead wire 103 of Example 1, the tip shape formed was a circular shape. In the second embodiment, the shape of the tip to be molded is an ellipse, which facilitates alignment with the terminal block. The shape of the lead wire 105 is shown in FIG. The lead wire 105 can be used for the rotating electrical machine described in the first embodiment instead of the lead wire 103.

  Since the manufacturing method of the lead wire 105 is the same as that of the said FIG.3, FIG.4, FIG.5, FIG.6, description is abbreviate | omitted. However, the guide 301 in FIG. 5 is not circular but elliptical, and by using this, the tip shape becomes an elliptical lead line.

  The coil insulating film is peeled off after the tip shape is formed into an elliptical shape or before forming, but the peeling method and the peeling distance of the straight portion are the same as those in the first embodiment, and the description thereof is omitted.

  In the rotating electrical machine having a plurality of windings arranged in parallel like the 2Y and 3Y connections in the stator connection structure, a plurality of lead wires 105 are used and fixed as in the first embodiment. The description of the fixing method is omitted.

  After forming and peeling as described above, the lead wire 105 is inserted into the stator core 101. Since the insertion is the same as in the first embodiment, description thereof is omitted. Further, since the rolling of the terminal portion by pressing or the like is the same as that in the first embodiment, the description thereof is omitted.

  After the coil 102 and the lead wire 105 are joined, the lead wire 105 is fixed to the terminal block, but since the terminal portion shape of the lead wire 105 is elliptical, alignment with the terminal block is facilitated, Easy to manufacture. Further, the lead wire 105 also peels off only the curved portion of the two upper and lower planes in the same manner as the lead wire 105 of the first embodiment, so that it is possible not only to ensure electrical contact with the terminal block, but also to drop off. Nor. Furthermore, since the lead wire 105 peels the insulating film only at the portions that come into contact with the terminal block and the bolts, the other portions of the lead wire 105 can also have an insulating effect from other parts and foreign matters.

DESCRIPTION OF SYMBOLS 100 Stator 101 Stator core 102 Coil 103, 105 Lead wire 104 Slot insulator 200 Rotor 301 Cutter 302 Guide 303 Pin 401 Coil front end straight part 402 Insulating film part 403 Insulating film peeling part

Claims (8)

A stator having a stator core around which the winding is wound, a coil having an insulating film on the surface and a rectangular cross-sectional shape, and a lead wire having a tip formed in a circular shape,
A cylindrical rotor rotatably held with respect to the stator via a rotation gap;
The lead wire has a terminal portion whose end is shaped into a flat circle,
The terminal portion has the insulating film on the flat upper surface and the lower surface formed in a flat shape peeled off, and the insulating film in a portion different from the upper surface and the lower surface remains .
A rotating electrical machine having a plurality of parallel windings, wherein a plurality of lead wires are provided per phase, and the lead wires are overlapped and fixed . The rotating electrical machine according to claim 1,
The coil is a rotating electrical machine whose end is a flat oval shape. The rotating electrical machine according to claim 1,
The lead wire is a rotating electric machine that is an end portion of the coil formed. The rotating electrical machine according to claim 1,
The lead wire is a rotating electrical machine that is a terminal for inputting or outputting electric power. The rotating electrical machine according to claim 1,
A rotating electrical machine in which an insulating film on a straight portion of the lead wire is peeled off. The rotating electrical machine according to claim 1,
A rotating electrical machine in which the lead wire terminal portion is rolled and the width is increased by reducing the thickness of the terminal portion to increase the peeled area or the contact area with the conductive surface. The rotating electrical machine according to claim 1,
A rotating electrical machine with a straight line at the tip of a circular lead wire terminal. The rotating electrical machine according to claim 1 ,
The lead wires provided in plural per phase are rotating electric machines in which the portions where the insulating coating is peeled off at the terminal fixing portions are in contact with each other and fixed.

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