JP5389108B2 - Stator for rotating electrical machine and method for manufacturing the same - Google Patents

Description

  The present invention relates to a stator for a rotating electrical machine mounted on an electric vehicle, a hybrid vehicle, and the like, and a method for manufacturing the same.

  Conventionally, a stator of a rotating electrical machine in which a coil is produced by winding a winding around a tooth of a stator core is known. Also, as a stator of other rotating electrical machines, after inserting a plurality of segments made of electric conductors formed in a U shape using segment coils into the slots of the stator core, the leg portions are bent and the ends of the segments are joined together There is also known a stator that constitutes a coil (see, for example, Patent Documents 1 and 2).

JP 2003-158840 A US Pat. No. 6,894,417

  However, in a conventional rotating electrical machine in which a coil is manufactured by winding a winding around a stator core tooth, it is necessary to use an expensive dedicated device such as a winding machine or an inserter.

  Moreover, the stator of the rotary electric machine described in Patent Documents 1 and 2 has a coil formed by U-shaped forming of an electric conductor, bending of legs, and joining (welding) of ends. The electrical conductor requires the number of turns of the coil and the number of pole pairs, and the number of steps required for forming, bending, and joining increases as the number of turns and pole pairs increases, and these processes are performed one by one. As a result, there was room for improvement in terms of production efficiency.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a stator for a rotating electrical machine that can be assembled without using dedicated equipment and has excellent mass productivity, and a method for manufacturing the same. .

In order to achieve the above object, the invention according to claim 1
A stator core having a plurality of slots (for example, a slot 23 in an embodiment described later) (for example, a stator core 21 in an embodiment described later);
A segmented multi-phase coil (for example, a coil 50 in an embodiment described later), and a stator for a rotating electrical machine (for example, a stator 10 in an embodiment described later),
A pair of base plates (for example, base plates 31L and 31R in the embodiments described later) are provided on both sides of the stator core,
The segmented multi-phase coils are respectively inserted into a plurality of slots of the stator core, and are respectively arranged on a plurality of coil bars (for example, coil bars 25 in the embodiments described later) and the base plates. A plurality of connect coils (for example, connect coils 40 in the embodiments described later) that connect the coil bars of the same phase to form a crossing part,
The stator core and the plurality of coil bars constitute a stator core assembly (for example, a stator core assembly 20 in an embodiment described later),
The base plate and the plurality of connect coils constitute a base plate assembly (for example, base plate assemblies 30L and 30R in the embodiments described later),
The stator core assembly and a base plate assembly disposed on both sides of the stator core assembly ,
The plurality of coil bars and the plurality of connect coils are connected to each other by press-fitting and caulking,
A taper portion (for example, a taper portion 26b in an embodiment described later) is formed at both ends of each coil bar, and a taper hole (which can be fitted to the taper portion) is connected to the connect coil connected to the coil bar. For example, coupling holes 43a, 44a) in the embodiments described later are formed,
The plurality of coil bars and the plurality of connect coils are joined together by press-fitting the tapered portions and the tapered holes, and then crushing and crimping the tips of the tapered portions. It is characterized by being.

In addition to the configuration of claim 1, the invention according to claim 2
At least a part of the plurality of connection coils is disposed in a region in which the stator core is projected in the axial direction.

The invention according to claim 3
A stator core having a plurality of slots (for example, a slot 23 in an embodiment described later) (for example, a stator core 21 in an embodiment described later);
A segmented multi-phase coil (e.g., a coil 50 in an embodiment described later);
A pair of base plates (for example, base plates 31L and 31R in the embodiments described later) provided on both sides of the stator core,
The segmented multi-phase coils are respectively inserted into a plurality of slots of the stator core, and are respectively arranged on a plurality of coil bars (for example, coil bars 25 in the embodiments described later) and the base plates. A stator of a rotating electrical machine (for example, a stator 10 in an embodiment to be described later) having a plurality of connect coils (for example, a connect coil 40 in an embodiment to be described later) connecting the coil bars of the same phase to each other to form a transition portion. A manufacturing method of
Inserting the coil bar into each slot of the stator core to form a stator core assembly (for example, a stator core assembly 20 in an embodiment described later);
Forming the base plate assembly (for example, base plate assemblies 30L and 30R in the embodiments described later) by disposing the connect coil on the base plate;
An assembly step of assembling the base plate assembly on both axial sides of the stator core assembly ,
In the assembly step, the plurality of coil bars of the stator core assembly and the plurality of connect coils of the base plate assembly are connected to each other by press-fitting and caulking,
Tapered portions are formed at both ends of each coil bar, and a taper hole (for example, a tapered portion 26b in an embodiment described later) can be fitted to a connect coil connected to the coil bar. For example, coupling holes 43a, 44a) in the embodiments described later are formed,
In the assembling step, the plurality of coil bars and the plurality of connect coils are squeezed and crimped at the tips of the taper portions after the taper portions and the taper holes are fitted together by press-fitting. In this case, they are joined at the same time .

  According to the invention of claim 1, there is no need to wind a winding around a stator core like a conventional stator, and a stator can be manufactured without using an expensive dedicated device such as a winding machine or an inserter. Equipment costs can be reduced. Also, multiple coil bars and connect coils are collectively compared to conventional U-shaped segmenting, where U-shaped forming, leg bending, and end-to-end joining are performed at each location. At the same time, the stator can be easily manufactured.

According to the first aspect of the present invention, the plurality of coil bars and the plurality of connect coils can be connected in a single assembling step, and the production efficiency is greatly improved.

According to the first aspect of the present invention, centering of the plurality of coil bars and the plurality of connection coils can be easily performed, and each connection by caulking can be performed at the same time, thereby greatly improving the production efficiency.

According to the invention of claim 2 , the stator can be reduced in the radial direction.

According to the invention of claim 3 , the conventional stator manufacturing process can be greatly simplified, and the stator can be manufactured easily and extremely efficiently.

According to the invention of claim 3 , a plurality of coil bars and a plurality of connect coils can be connected in one assembling step, and the production efficiency is greatly improved.

According to the invention of claim 3 , the centering of the plurality of coil bars and the plurality of connection coils can be easily performed, and each connection by caulking can be performed at the same time, thereby greatly improving the production efficiency.

It is a perspective view of the stator of the rotary electric machine which concerns on this invention. It is a disassembled perspective view of the stator shown in FIG. (A) is an exploded perspective view of one base plate assembly shown in FIG. 2, and (b) is an exploded perspective view of the other base plate assembly. It is a perspective view of a coil bar. It is a longitudinal cross-sectional view of the stator shown in FIG. 1, and is the sectional view on the AA line of FIG. FIG. 4 is a front view of one base plate assembly shown in FIG. FIG. 4 is a rear view of one base plate assembly shown in FIG. It is a perspective view of a segmented multi-phase coil of a double slot type. It is a perspective view which extracts and shows the coil for one phase from the coil of multiple phases shown in FIG. It is a schematic diagram which shows the structure of the coil of multiple phases. (A) is the elements on larger scale of FIG. 6, (b) is the BB sectional drawing of (a). (A) is a schematic diagram showing a state in which a coil bar and a connect coil are joined by caulking, and (b) shows a state in which a coil bar having a hemispherical end is press-fitted into a connect coil and joined. (C) is a schematic diagram showing a state in which a coil bar having a rectangular cross section whose end is formed in a semicircular shape is press-fitted into a hole of a connect coil and joined. FIG. 5 is a perspective view of a stator in which a cooling plate is disposed on a side surface of a base plate assembly. It is a principal part longitudinal cross-sectional view of a stator provided with the cooling plate shown in FIG. It is a perspective view which shows the coil for 1 phase of a single slot type coil. It is a perspective view which shows the coil for 1 phase of a triple slot type coil.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.

  As shown in FIGS. 1, 2, and 5, the stator 10 of the rotating electrical machine of the present embodiment includes a stator core assembly 20 and a pair of base plate assemblies 30 </ b> L and 30 </ b> R, and the base plate assemblies 30 </ b> L and 30 </ b> R are provided. The stator core assembly 20 is disposed and assembled on both sides. Between the stator core assembly 20 and the base plate assemblies 30L, 30R, for example, an insulating sheet 65 such as a silicon sheet is disposed to insulate the stator core assembly 20 from the base plate assemblies 30L, 30R.

  The stator core assembly 20 includes a stator core 21 and a plurality of (in the illustrated embodiment, 48) coil bars 25.

  The stator core 21 is configured, for example, by laminating a plurality of punched silicon steel plates, and 48 teeth 22 and 48 slots formed between adjacent teeth 22 and 22 on the radially inner side thereof. 23. The slot 23 is formed so as to penetrate in the axial direction of the stator core 21, is formed in a substantially oval shape that is long in the radial direction of the stator core 21 when viewed from the axial direction, and the opening 24 opens to the inner peripheral surface of the stator core 21. Yes.

  The coil bar 25 is also arranged in parallel with an outer diameter side coil bar 26 and an inner diameter side coil bar 27 having the same shape and the same length being shifted in the axial direction by the thickness of a connect coil 40 described later with reference to FIG. The periphery except for both ends is integrally formed by being covered with an insulating material 28 such as injection molded resin. Specifically, the lengths of the outer diameter side coil bar 26 and the inner diameter side coil bar 27 are set to be substantially equal to the sum of the axial length of the stator core 21 and the thickness of the three connection coils 40, and the both ends Are formed with small-diameter portions 26 a and 27 a having a length substantially equal to the thickness of the connect coil 40.

  A plurality (48 in the embodiment shown in the figure) of coil bars 25 including the outer diameter side coil bar 26 and the inner diameter side coil bar 27 are, as shown in FIG. 5, the stator core so that the outer diameter side coil bar 26 is radially outward. Are arranged in the radial direction of 21, inserted into the 48 slots 23 of the stator core 21, and arranged in the circumferential direction of the stator core 21 to constitute the stator core assembly 20.

  The outer-diameter side coil bar 26 has a small-diameter portion 26a protruding from one end surface 21a (left end surface in FIG. 5) of the stator core 21 by a thickness of approximately two of the connect coils 40, and the other end surface 21b (in FIG. 5). The small-diameter portion 26 a protrudes from the right end surface) by the thickness of approximately one of the connect coils 40 and is inserted into the slot 23.

  Further, the inner diameter side coil bar 27 has a small diameter portion 27a protruding from the one end face 21a of the stator core 21 by a thickness of about one sheet of the connect coil, and a thickness of about two sheets of the connect coil from the other end face 21b. The small diameter portion 26 a protrudes and is inserted into the slot 23. Between the outer diameter side coil bar 26 and the inner diameter side coil bar 27 and the slot 23 of the stator core 21, an insulating material 28 covering both the coil bars 26 and 27 is interposed to ensure insulation from the stator core 21. Therefore, the outer diameter side coil bar 26 and the inner diameter side coil bar 27 are covered with the insulating material 28 while being shifted in the axial direction so that the axial positions of the both end portions thereof are different.

  The insulating material 28 covering the outer diameter side coil bar 26 and the inner diameter side coil bar 27 has substantially the same shape slightly larger than the slot 23 and can be easily fixed to the slot 23 by press-fitting. Further, since the outer diameter side coil bar 26 and the inner diameter side coil bar 27 are thicker than the conventional coil formed by winding, the space factor in the slot 23 is also improved.

  As shown in FIGS. 1 to 7, the base plate assemblies 30 </ b> L and 30 </ b> R disposed on both sides of the stator core assembly 20 include base plates 31 </ b> L and 31 </ b> R and a plurality of connection coils 40. The base plate assembly 30R is the same as the base plate assembly 30L except for the fact that it does not include a connection terminal portion, which will be described later, and the shape of the groove and the connection coil. explain.

  As shown in FIGS. 6 and 7, the base plate 31 </ b> L is a substantially annular member that is formed of an insulating resin (nonmagnetic material) and has an inner and outer diameter substantially equal to that of the stator core 21. A developing portion 31a extending in a fan shape is provided radially outward. A connecting terminal portion for connecting to an external device or the like is formed in the developing portion 31a.

  On the inner diameter side of the base plate 31L, 48 pairs of outer diameter side through-holes 32 and inner diameter side through holes respectively correspond to the outer diameter side coil bar 26 and the inner diameter side coil bar 27 of each coil bar 25 inserted into the slot 23 of the stator core 21. A hole 33 is formed through the base plate 31L.

  The paired outer diameter side through hole 32 and inner diameter side through hole 33 are located on the same straight line L extending in the radial direction from the center O of the base plate 31L, and further on the straight line L and the outer diameter of the base plate 31L. On the side, an outer peripheral hole 34 is formed to communicate the outer surface 35 and the inner surface 36 (see FIG. 5) of the base plate 31L. Further, twelve connection terminal joint holes 39 are formed in the circumferential position where the developed portion 31a is formed, which are positioned in the developed portion 31a further radially outward than the position of the outer peripheral side hole 34.

As shown in FIGS. 5 to 7, the outer surface 35 and the inner surface 36 of the base plate 31 </ b> L have a plurality of (48) outer surface grooves each having a substantially U-shaped cross section that opens to the outer surface 35 and the inner surface 36, respectively. 37 and the inner surface groove | channel 38 are formed adjacent to the circumferential direction along the involute curve. The outer surface grooves 37 adjacent to each other and the inner surface grooves 38 are separated from each other by a wall 31b erected from the base plate 31L, and the outer surface grooves 37 and the inner surface grooves 38 facing each other in the axial direction are separated from each other. They are isolated by 31c and are electrically insulated from each other.
The base plate 31L has an axis substantially equal to the sum of the groove depths of the outer surface groove 37 and the inner surface groove 38 corresponding to the thicknesses of the outer connect coil 41 and the inner connect coil 42 described later and the thickness of the partition wall 31c. Set to the direction width.

  In the base plate assembly 30L, as shown in FIG. 6, each outer surface groove 37 of the base plate 31L is separated from the outer diameter side through hole 32 and from the outer diameter side through hole 32 in the clockwise direction in the front view. The outer circumferential side hole 34 formed on the straight line L passing through the outer diameter side through hole 32 is curved along an involute curve. However, of the plurality of outer surface grooves 37, the twelve outer surface grooves 37a extending toward the developed portion 31a pass through the outer diameter side through holes 32 that are separated from the outer diameter side through holes 32 in the clockwise direction by three. After extending in an involute shape up to the straight line L, it is bent in the radial direction and connected to the connection terminal joint hole 39.

  Further, as shown in FIG. 7, each inner surface groove 38 of the base plate 31 </ b> L has an inner diameter side through hole 33 and a clockwise direction from the inner diameter side through hole 33 (counterclockwise when viewed from the side in FIG. 6). B) The outer peripheral side hole 34 formed on the straight line L passing through the inner diameter side through hole 33 separated by three is connected to be bent while avoiding the outer diameter side through hole 32. However, of the plurality of inner side surface grooves 38, the twelve inner side surface grooves 38 a extending toward the developing portion 31 a are three in the clockwise direction from the inner diameter side through hole 33 (counterclockwise as viewed from the side in FIG. 6). After being bent and extended in a similar manner up to a straight line L passing through the inner diameter side through hole 33 that is separated, it is bent in the radial direction and connected to the connection terminal joint hole 39.

  That is, as shown in FIG. 6, the outer diameter side through hole 32 and the inner diameter side through hole 33 that are separated by six in the clockwise direction (or counterclockwise direction) are formed by an outer surface groove 37 and an inner surface groove 38. They are connected via an outer peripheral side hole 34 that is continuously connected in common. The pair of outer side surface grooves 37a and inner side surface grooves 38a connected to the common connection terminal joint hole 39 are divided into six outer diameter side through holes 32 and inner diameter side through holes that are separated by six in the clockwise direction (or counterclockwise direction). 33 is connected.

  In the base plate assembly 30R, each outer surface groove 37 of the base plate 31R has the same shape as each inner surface groove 38 of the base plate 31L described above, and each inner surface groove 38 of the base plate 31R corresponds to the above described base plate 31L. Each of the outer surface grooves 37 has the same shape.

  The connect coil 40 is formed in a plate shape with a conductive material such as copper, and is inserted into the outer connect coil 41 (41a, 41b) inserted into the outer groove 37, 37a and the inner groove 38, 38a, respectively. The inner connection coils 42 (42a, 42b) can be divided into two. The outer connect coil 41 referred to here is a connect coil 40 that is on the outer side in the axial direction of the stator 10 when the stator core assembly 20 and the base plate assembly 30 are assembled. The connecting coil 40 is the axially inner side of the stator 10.

  As shown in FIG. 6, the outer connecting coil 41a is formed along an involute curve having the same shape as the outer surface groove 37, and coupling holes 43a and 43b are formed at both ends thereof. The coupling hole 43a has a diameter substantially equal to that of the small diameter portion 26a of the outer diameter side coil bar 26, and the coupling hole 43b has a diameter substantially equal to that of a connection pin 45 that connects an outer connection coil 41a and an inner connection coil 42a described later. Have. The outer connect coil 41b is formed to be curved in the same shape as the outer surface groove 37a, and a coupling hole 43a and a connection terminal hole 43c are formed at both ends thereof.

  As shown in FIG. 7, the inner connection coil 42a is formed along an involute curve having the same shape as the inner side surface groove 38, and coupling holes 44a and 44b are formed at both ends thereof. The coupling hole 44 a has a diameter substantially equal to the small diameter portion 27 a of the inner diameter side coil bar 27, and the coupling hole 44 b has a diameter substantially equal to that of the connection pin 45. The inner connection coil 42b is formed to be bent in the same shape as the inner side surface groove 38a, and a coupling hole 44a and a connection terminal hole 44c are formed at both ends thereof.

  Therefore, except for the connection terminal joint hole 39 portion of the base plate 31L, the inner connect coil 42a and the outer connect coils 41a and 41b respectively connected to the outer diameter side coil bars 26 are formed along involute curves. The inner connect coils 42a and 42b and the outer connect coil 41a connected to the side coil bar 27 are formed along an involute curve, and the inner diameter side through hole 33 to the outer diameter side through hole 32 on the inner diameter side of the involute curve. It extends radially outward so as to detour.

  The outer connect coils 41a and 41b are inserted into the outer surface grooves 37 and 37a, respectively, and the inner connect coils 42a and 42b are inserted into the inner surface grooves 38 and 38a, respectively. Then, conductive connection pins 45 made of copper, aluminum or the like are inserted into each outer peripheral side hole 34 to electrically connect the outer connect coil 41a and the inner connect coil 42a.

As a result, the coupling hole 43a of the outer connection coil 41a and the coupling hole 44a of the inner connection coil 42a, which are separated by six in the clockwise direction (or counterclockwise direction), are connected to the outer connection coil 41a, the connection pin 45, and Base plate assemblies 30L and 30R are configured in a state of being electrically connected via the inner connection coil 42a.
Instead of providing the connection pin 45 as in the present embodiment, one of the outer connection coil 41a and the inner connection coil 42a is integrally formed with a protrusion having the same shape as the connection pin 45, and the outer connection coil 41a The outer connect coil 41a and the inner connect coil 42a may be electrically connected by being inserted into coupling holes 43b and 44b provided on the other side of the inner connect coil 42a.

  The pair of base plate assemblies 30 </ b> L and 30 </ b> R configured as described above are positioned and assembled at predetermined positions on both sides of the stator core assembly 20. As shown in FIG. 5, in the base plate assembly 30L arranged on one end face 21a side (left side in the figure) of the stator core 21, the small diameter portion 26a of the outer diameter side coil bar 26 is connected to the coupling holes of the outer connection coils 41a and 41b. The small-diameter portion 27a of the inner diameter side coil bar 27 is inserted into the coupling hole 44a of the inner connection coils 42a and 42b, and then caulked and fixed. In other words, the outer connect coils 41 a and 41 b and the inner connect coils 42 a and 42 b connect the coil bars 25 having the same phase (for example, U phase) to form a transition portion of the coil 50.

  In the base plate assembly 30R disposed on the other end surface 21b side (right side in the drawing) of the stator core 21, the small diameter portion 26a of the outer diameter side coil bar 26 is inserted into the coupling hole 44a of the inner connection coil 42a. After the small diameter portion 27a of the inner diameter side coil bar 27 is inserted into the coupling hole 43a of the outer connect coil 41a, it is caulked and fixed. In other words, the outer connect coils 41 a and 41 b and the inner connect coils 42 a and 42 b connect the coil bars 25 having the same phase (for example, U phase) to form a transition portion of the coil 50.

  Accordingly, with respect to the outer diameter side coil bar 26 and the inner diameter side coil bar 27 arranged in the same slot 23, the outer connect coil 41a connected on one end side (the left side in the figure) of the outer diameter side coil bar 26 is radially outward, and The inner connection coil 42a extending in the clockwise direction and connected to the in-phase inner connection coil 42a and connected to the other end side (the right side in the figure) of the outer diameter side coil bar 26 is radially outward and counterclockwise. And connected to the outer-phase connect coil 41a having the same phase. The inner connect coil connected on one end side (the left side in the drawing) of the inner diameter side coil bar 27 extends radially outward and counterclockwise and is connected to the same phase outer connect coil 41a. The outer connect coil 41a connected at the other end side (the right side in the figure) extends radially outward and clockwise and is connected to the in-phase inner connect coil 42a.

  Thus, the stator 10 is configured by assembling a pair of base plate assemblies 30L and 30R on both sides of the stator core assembly 20, and the segmented coils 50 have four coil loops each having the same structure. (U-phase coil 50U, V-phase coil 50V, and W-phase coil 50W) are formed. Each of the four coil loops (the U-phase coil 50U, the V-phase coil 50V, and the W-phase coil 50W) has two coil loops as one set, two U-phase coils 50U, two V-phase coils 50V, and Two W-phase coils 50W are wound in this order in the counterclockwise direction (see FIGS. 8 and 10). In addition, the outer diameter side coil bar 26 and the inner diameter side coil bar 27 which are disposed in one slot 23 and are covered with the insulating material 28 are composed of two coil loops constituting one set. FIG. 8 is a perspective view showing a segmented multi-phase (UVW phase) coil extracted from the stator for easy understanding, and FIG. 9 is a further drawing of one phase (for example, U phase) coil. FIG. 10 is a schematic view showing a configuration of a coil having a plurality of phases, FIG. 11A is a partially enlarged view of FIG. 6, and FIG. 11B is a sectional view taken along line BB of FIG. It is.

  Further, in the stator 10 configured as described above, the outer connect coils 41a and 41b and the inner connect coils 42a and 42b are arranged in a region in which the stator core 21 is projected in the axial direction, and at different positions in the axial direction. Be placed.

  In the cross section taken along line B-B of the base plate assembly 30L shown in FIG. 11A, as shown in FIG. 11B, the diameter of the small diameter portion 26a of the U-phase outer diameter side coil bar 26 on the outer surface of the base plate 31L. Two V-phase outer connect coils 41b and one W-phase outer connect coil 41b are arranged in this order from the radially inner side, and one U-phase inner connect coil 42b on the inner surface of the base plate 31L. And two W-phase inner connect coils 42b are arranged in this order from the radially inner side. Accordingly, as is apparent from FIG. 11A, the inner connect coils 42a and 42b face the outer connect coils 41a and 41b of the other phases in the axial direction, and the outer connect coils 41a and 41b The inner connection coils 42a and 42b are opposed to each other in the axial direction.

  Further, the outer surfaces of the plurality of outer connect coils 41a and 41b arranged on the outer side in the axial direction of the stator 10 are flush with the end surfaces of the base plates 31L and 31R.

  Further, as shown in FIG. 5, in the coil 50, on one end surface 21 a side of the stator core 21, the outer connect coils 41 a and 41 b connected to the outer diameter side coil bar 26 are positioned on the outer side in the axial direction. On the other end face 21b side, the outer connect coil 41a connected to the inner diameter side coil bar 27 is positioned on the outer side in the axial direction, and the stator 10 is assembled.

  FIG. 12 is a conceptual diagram showing the connection structure between the coil bar and the connect coil. In the following, the outer diameter side coil bar 26 will be described as an example, but the inner diameter side coil bar 27 can be similarly applied. The outer diameter side coil bar 26 shown in FIG. 12 (a) is formed with a tapered portion 26b tapered toward the tip at both ends, and the coupling holes 43a of the outer connect coils 41a and 41b and the inner connect coil 42a. The coupling hole 44 a is a tapered hole having a gradient substantially equal to that of the outer diameter side coil bar 26. The outer diameter side coil bar 26 and the connection coil 40 are assembled with the base plate 31L, 31R on the stator core 21, and the connecting coil 40 is moved in the axial direction with respect to the outer diameter side coil bar 26 by the pressing member 61 of the jig through the elastic force of the spring 64. By pressing, the coupling holes 43 a and 44 a of the connect coil 40 are fitted into the both tapered portions 26 b of the outer diameter side coil bar 26. The coil bar 26 and the connect coil 40 are fixed by crushing and crimping both ends of the outer diameter side coil bar 26 with the punch 62.

  At this time, since the fitting portion between the outer diameter side coil bar 26 and the connect coil 40 is formed in a tapered shape, even if there is a slight misalignment between the outer diameter side coil bar 26 and the connect coil 40, By pressing the member 61, the outer diameter side coil bar 26 and the connect coil 40 are centered, and are reliably joined and conducted at the tapered portion 26b. In addition, joining at a plurality of locations (96 locations in the present embodiment) can be performed in a single pressing step, so that joining can be performed efficiently, and production efficiency is greatly improved. The coil bar 25 and the connection coil 40 do not necessarily need to be connected by press-fitting and caulking, but may be connected by press-fitting or caulking. Below, the connection by press injection is demonstrated.

  The outer diameter side coil bar 26 shown in FIG. 12B is hemispherical at both ends, and the coupling holes 43a and 44a of the connect coil 40 are hemispherical recesses. Both ends of the shape are press-fitted into the coupling holes 43 a and 44 a of the connect coil 40, and the outer diameter side coil bar 26 and the connect coil 40 are joined. Also in this structure, the outer diameter side coil bar 26 and the connect coil 40 can be aligned by centering. In addition, bonding at a plurality of locations can be performed in a single pressing step, and bonding can be performed extremely efficiently.

  The outer diameter side coil bar 26 shown in FIG. 12C is formed in a rectangular cross section, and both end portions thereof are formed in a semicircular shape. Also, the coupling holes 43a and 44a of the connect coil 40 are similar semicircular recesses, and the end portions of the outer diameter side coil bar 26 are press-fitted into the coupling holes 43a and 44a of the semicircular recesses. Is done. In addition, since the outer diameter side coil bar 26 of the present embodiment has a rectangular shape that is formed in a rectangular cross section and approximates the slot 23, the space factor of the slot 23 can be increased.

  FIG. 13 is a perspective view of a stator in which a cooling plate is disposed on a side surface of the base plate assembly, and FIG. 14 is a longitudinal sectional view of a main part of the stator. In the stator 10 shown in FIGS. 13 and 14, a pair of cooling plates 60 are disposed in contact with the base plate assemblies 30 provided on both side surfaces of the stator 10. The cooling plate 60 is formed with a refrigerant passage 63 for circulating the refrigerant therein, and circulates the refrigerant pumped from a refrigerant supply device (not shown) in the direction of arrow C (see FIG. 13), for example. The stator 10 can be positively cooled via the outer connect coils 41a and 41b (crossover portions) of the stator 10 with which the cooling plate 60 comes into contact.

  Further, since the side surfaces of the outer connect coils 41 a and 41 b are flat, the outer connect coils 41 a and 41 b are in surface contact with the cooling plate 60. Therefore, compared with a coil around which a conventional winding is wound, the contact area with the cooling plate 60, that is, the heat transfer area is large, and cooling can be performed efficiently.

  In addition, the coil 50 has outer connect coils 41 a and 41 b connected to the outer-diameter side coil bar 26 on the one end surface 21 a side of the stator core 21, and is located on the other end surface 21 b side of the stator core 21. Since the outer connect coil 41a connected to the inner diameter side coil bar 27 is positioned on the outer side in the axial direction, the outer diameter side coil bar 26 and the inner diameter side coil bar 27 are evenly cooled via the outer connect coils 41a and 41b. The heat distribution of is suppressed. Furthermore, there is no influence of oil on the coil and the insulating material, which is a concern in the case of oil cooling in which ATF oil or the like is injected into the coil for cooling, and reliability and durability are improved.

  As described above, according to the stator 10 according to the present embodiment, the stator core assembly 20 including the stator core 21 and the plurality of coil bars 25, the base plates 31L and 31R, and the plurality of connection coils 40 are included. , And a pair of base plate assemblies 30L and 30R disposed on both sides of the stator core assembly 20, there is no need to wind a winding around the stator core as in a conventional stator, and a winding machine or inserter The stator 10 can be manufactured without using an expensive dedicated device such as the above, and the equipment cost can be reduced. Moreover, compared with the conventional coil shaping | molding by the U-shaped segment in which U-shaped shaping | molding process, the bending process of a leg part, and the joining process of edge parts are performed for every place, several coil bar 25 and the connecting coil 40 Can be simultaneously joined together, and the stator 10 can be easily manufactured.

  Further, since the plurality of coil bars 25 and the plurality of connection coils 40 are connected by press fitting or caulking, or press fitting and caulking, the plurality of coil bars 25 and the connecting coil 40 are connected in a single assembly process. Production efficiency is greatly improved.

  Furthermore, since the plurality of connect coils 40 are arranged in a region where the stator core 21 is projected in the axial direction, the stator 10 can be reduced in the radial direction.

  Further, a step of forming the stator core assembly 20 by inserting the coil bar 25 into each slot 23 of the stator core 21, a step of forming the base plate assemblies 30L and 30R by disposing the connection coil 40 on the base plates 31L and 31R, and the stator core Since the stator 10 is manufactured by the assembly process of assembling the base plate assemblies 30L and 30R on both sides in the axial direction of the assembly 20, the manufacturing process of the conventional stator 10 can be greatly simplified, and it is easy and extremely efficient. Thus, the stator 10 can be manufactured.

  In the assembling process, the plurality of coil bars 25 of the stator core assembly 20 and the plurality of connect coils 40 of the base plate assemblies 30L and 30R are connected to each other by press-fitting or caulking, or press-fitting and caulking. Therefore, a plurality of coil bars and connect coils can be connected in a single assembly process, and production efficiency is greatly improved.

In addition, this invention is not limited to embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably.
For example, in the above-described embodiment, twelve connection terminal joint holes 39 are formed. However, the present invention is not limited to this, and six connection terminal joint holes 39 may be formed to connect adjacent in-phase connect coils.
Further, an insulating cover may be disposed outside the pair of base plate assemblies 30L and 30R in the axial direction, or may be covered with a resin or the like.

  Note that the stator 10 of the present invention is not limited to the double slot type described above, and a single slot type stator showing the coil shape for one phase in FIG. 15 or a triple slot showing the coil shape for one phase in FIG. It can also be a type of stator. In the three-phase octupole winding stator, in the case of a single slot type stator, the number of slots of the stator core 21 is 24, and in the case of a triple slot type stator, the number of slots of the stator core 21 is 72. Since all the stators have the same structure as the double slot type stator 10, description thereof will be omitted.

10 Stator 20 of rotating electrical machine Stator core assembly 21 Stator core 23 Slot 25 Coil bar 26 Outer diameter side coil bar 27 Inner diameter side coil bar 28 Insulating material 30L, 30R Base plate assembly 31L, 31R Base plate 32 Outer diameter side through hole 33 Outer diameter side through hole 35 Outside Side surface 36 Inner side surface 37, 37a Outer side surface groove (groove)
38, 38a Inner side surface groove (groove)
40 Connect coil (crossover part)
41, 41a, 41b Outer connection coil (crossover part)
42, 42a, 42b Inner connect coil (crossover part)
50 Coil 50U U phase coil 50V V phase coil 50W W phase coil

Claims (3)

A stator core having a plurality of slots;
A stator of a rotating electrical machine comprising a segmented multi-phase coil,
A pair of base plates are provided on both sides of the stator core,
The segmented multi-phase coils are inserted into the plurality of slots of the stator core, respectively, and are arranged on the base plates and connected to the coil bars of the same phase. A plurality of connect coils constituting the part,
The stator core and the plurality of coil bars constitute a stator core assembly,
The base plate and the plurality of connect coils constitute a base plate assembly,
The stator core assembly and a base plate assembly disposed on both sides of the stator core assembly ,
The plurality of coil bars and the plurality of connect coils are connected to each other by press-fitting and caulking,
A taper portion is formed at both ends of each coil bar, and a taper hole that can be fitted to the taper portion is formed in the connect coil connected to the coil bar,
The plurality of coil bars and the plurality of connect coils are joined together by press-fitting the tapered portions and the tapered holes, and then crushing and crimping the tips of the tapered portions. the stator of a rotating electric machine characterized in that it is. 2. The stator for a rotating electrical machine according to claim 1, wherein at least a part of the plurality of connect coils is disposed in a region in which the stator core is projected in an axial direction. A stator core having a plurality of slots;
A segmented coil;
A pair of base plates provided on both sides of the stator core,
The segmented multi-phase coils are inserted into the plurality of slots of the stator core, respectively, and are arranged on the base plates and connected to the coil bars of the same phase. A manufacturing method of a stator of a rotating electrical machine having a plurality of connect coils constituting a part,
Inserting the coil bar into each slot of the stator core to form a stator core assembly;
Arranging the connect coil on the base plate to form a base plate assembly;
An assembly step of assembling the base plate assembly on both axial sides of the stator core assembly ,
In the assembly step, the plurality of coil bars of the stator core assembly and the plurality of connect coils of the base plate assembly are connected to each other by press-fitting and caulking,
A taper portion is formed at both ends of each coil bar, and a taper hole that can be fitted to the taper portion is formed in the connect coil connected to the coil bar,
In the assembling step, the plurality of coil bars and the plurality of connect coils are squeezed and crimped at the tips of the taper portions after the taper portions and the taper holes are fitted together by press-fitting. A method of manufacturing a stator for a rotating electrical machine, wherein the stators are joined simultaneously .

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