JP5741955B2 - Coil wire and coil wire bundle using the same - Google Patents

Description

  The present invention relates to a coil wire used for a rotating electrical machine and a coil wire bundle.

  Conventionally, the thing of various shapes is known as a coil wire which forms the coil of a rotary electric machine. For example, in the coil wire disclosed in Patent Document 1, a crank-shaped torsion part is formed at the center of a turn part that connects the slot accommodating parts. Thereby, it is going to suppress the thickness of the coil wire bundle formed by braiding a plurality of coil wires.

JP 2010-11715 A

  However, in the case of the coil wire of Patent Document 1, when a plurality of coil wires are knitted, both sides of the twisted portion interfere with each other between the coil wires, and the efficiency of the knitting work may be reduced or the knitting work may not be continued. There is. Further, if the braiding operation is forcibly continued with the coil wires interfering with each other, the coil wire may be deformed.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a coil wire and a coil wire bundle that can efficiently perform a knitting operation while suppressing deformation during knitting. is there.

The present invention includes a rotor that forms a plurality of magnetic poles that are alternately different in the circumferential direction, and a plurality of slots that are provided radially outside or radially inside of the rotor and that extend linearly in the axial direction in the circumferential direction. A coil wire used for a rotating electrical machine having an annular fixed core, and includes a plurality of slot accommodating portions and a plurality of turn portions. The slot accommodating portions are formed in a straight line and are accommodated in the slots of the fixed core at a predetermined interval so as to be parallel to each other. The turn portions are alternately provided on one end side or the other end portion side of the slot accommodating portions so as to connect the end portions of the plurality of slot accommodating portions.
In the present invention, the turn portion is inclined with respect to the slot accommodating portion, and two first inclined portions extending linearly from the end portion of the slot accommodating portion so as to be separated from the virtual plane orthogonal to the slot accommodating portion, And it has the connection part which connects the edge parts on the opposite side to the slot accommodating part of the said 2nd 1st inclination part. The connection portion is inclined with respect to the first inclined portion and extends from the end portion of the first inclined portion so as to be separated from the virtual plane, and the two second inclined portions and the two second inclined portions And a crank portion formed in a crank shape parallel to the imaginary plane and connected to ends opposite to the first inclined portion. The crank portion has a projecting portion formed at the center so as to project toward the virtual plane side.

In the present invention, since the connecting portion has a crank portion, the coil wire rod is formed such that a plurality of slot accommodating portions are parallel to each other and a plurality of crank portions are arranged in a straight line by braiding a plurality of coil wire rods in a spiral shape. When the bundle is formed, the thickness of the coil wire bundle can be suppressed.
Further, since the connecting portion has the second inclined portion, it is possible to prevent the crank portion and the turn portion between the coil wires from interfering with each other in a state where the coil wire is knitted as a coil wire bundle.
Furthermore, in the present invention, when a plurality of coil wire rods are knitted in a spiral shape, the coil wire rods are naturally aligned in the thickness direction by guiding the vicinity of the second inclined portion of the turn portion to the protruding portion of the other coil wire rod. Shift. Thereby, it can suppress that especially 1st inclination part of a coil wire rod interferes at the time of a braiding operation | work. Therefore, deformation at the time of weaving the coil wire can be suppressed, and the weaving operation can be performed efficiently.

  In addition, since the coil wire bundle formed of the coil wire of the present invention can be reduced in thickness, when the coil wire bundle is used as a winding of the stator, the physique in the radial direction of the stator, that is, the outer diameter is set. Can be small.

(A) is a figure which shows a part of coil wire material by one Embodiment of this invention, (B) is the figure which looked at (A) from the arrow B direction. (A) is a figure which shows the turn part of the coil wire material by one Embodiment of this invention, and its vicinity, (B) is the figure which looked at (A) from the arrow B direction. The schematic diagram for demonstrating the braiding operation | work of the coil wire material by one Embodiment of this invention. (A) is a figure which shows the state in the middle of the braiding operation | work of the coil wire material by one Embodiment of this invention, (B) is the figure which looked at (A) from the arrow B direction, (C) is a predetermined time from (A). The figure which shows the state after progress, (D) is the figure which looked at (C) from the arrow D direction, (E) is the perspective view which shows the crank part vicinity of (C). (A) is the figure which shows the coil wire bundle by one Embodiment of this invention, (B) is the figure which looked at (A) from the arrow B direction, (C) is the perspective view which shows a coil wire bundle. The schematic diagram for demonstrating the braiding operation | work of the coil wire bundle by one Embodiment of this invention. (A) is a perspective view which shows the intermediate assembly by one Embodiment of this invention, (B) is a figure which shows the crank part vicinity of an intermediate assembly. (A) is a perspective view which shows the stator of the rotary electric machine to which the coil wire bundle by one Embodiment of this invention is applied, (B) is a side view of a stator, (C) is a schematic diagram which shows a rotary electric machine. (A) is a figure which shows the state which knitted the coil wire by a 1st comparative example, (B) is the figure which looked at (A) from the arrow B direction. (A) is the figure which shows the state in the middle of the braiding operation | work of the coil wire by a 2nd comparative example, (B) is the figure which looked at (A) from the arrow B direction, (C) is after progress for a predetermined time from (A). The figure which shows the state of (C), the figure which looked at (C) from the arrow D direction, (E) is the perspective view which shows the crank part vicinity of (C).

Hereinafter, a coil wire and a coil wire bundle according to the present invention will be described with reference to the drawings.
(One embodiment)
A coil wire according to an embodiment of the present invention is shown in FIG.

  First, a schematic configuration of a rotating electrical machine manufactured by applying the coil wire 30 will be described with reference to FIG. The rotating electrical machine 1 is used as, for example, a rotating electrical machine that also serves as an electric motor and a generator for a vehicle. As shown in FIG. 8C, the rotating electrical machine 1 includes a housing 2, a stator 3, a rotor 4, a shaft member 5, and the like.

  The housing 2 is formed in a substantially cylindrical shape whose both ends are closed with metal, for example. The stator 3 is formed in a substantially annular shape, and is accommodated in the housing 2 such that the outer wall is fixed to the inner wall of the housing 2. The rotor 4 is formed in a substantially cylindrical shape and is rotatably provided inside the stator 3. The shaft member 5 is formed in a rod shape, for example, from metal, and is provided integrally with the rotor 4 so as to coincide with the rotation axis of the rotor 4. The shaft member 5 is supported by the housing 2 on both side portions of the rotor 4 in the axial direction. Thereby, the rotor 4 and the shaft member 5 can rotate relative to the housing 2 and the stator 3.

The rotor 4 forms a plurality of magnetic poles that are alternately different in the circumferential direction, for example, by providing a permanent magnet on the outer wall. That is, the magnetic pole faces the inner wall of the stator 3.
The stator 3 has a fixed core 10 and a coil assembly 20. The fixed core 10 is formed in an annular shape by, for example, laminating magnetic steel plates having a predetermined thickness in the axial direction. As shown in FIG. 8A, the fixed core 10 has a plurality of slots formed in the inner wall in the circumferential direction, with a pair of slots 11 and 12 adjacent in the circumferential direction as a set. The slots 11 and 12 are formed so as to extend linearly in the axial direction of the fixed core 10.
The coil assembly 20 formed of stator windings is a three-phase winding, and stator windings for each phase are provided in slots 11 and 12 adjacent in the circumferential direction. Stator windings of different phases are provided in three sets of slots 11 and 12 adjacent to each other in the circumferential direction with the slots 11 and 12 as a set.

Next, the configuration and manufacturing method of the coil assembly 20 will be described with reference to FIGS.
The coil assembly 20 is a coil plate bundle 21 and 22 shown in FIG. 5 that is spirally knitted into a long plate shape (intermediate assembly 23) as shown in FIG. And a predetermined number of turns (see FIG. 8A).
The coil wire bundles 21 and 22 are each formed by weaving six coil wire rods 30 in a spiral shape.

The coil wire 30 is formed, for example, by bending a wire made of a conductor having a rectangular cross section. The coil wire 30 is covered with an insulating material. As shown in FIG. 1, one coil wire 30 includes a plurality of slot accommodating portions 31 and a plurality of turn portions 32.
The slot accommodating portions 31 are formed in a straight line and are arranged at a predetermined interval so as to be parallel to each other. The turn portions 32 are alternately provided on one end side or the other end side of the slot accommodating portion 31 so as to connect the end portions of the plurality of slot accommodating portions 31 (see FIG. 1A). ).

  FIG. 2 shows one of the plurality of turn portions 32 of the coil wire 30 and the vicinity thereof. The turn part 32 includes two first inclined parts 41 extending linearly from the end of the slot accommodating part 31 so as to be inclined with respect to the slot accommodating part 31 and away from the virtual plane P orthogonal to the slot accommodating part 31. And it has the connection part 42 which connects the edge parts on the opposite side to the slot accommodating part 31 of the said 2nd 1st inclination part 41 (refer FIG. 2 (A)). The connecting portion 42 is inclined with respect to the first inclined portion 41 and two second inclined portions 51 extending linearly from the end of the first inclined portion 41 so as to be separated from the virtual plane P, and the 2 Two end portions 51 of the second inclined portions 51 opposite to the first inclined portion 41 are connected to each other and have a crank portion 52 formed in a crank shape parallel to the virtual plane P (FIG. 2A). (See (B)). The crank portion 52 has a projecting portion 53 formed at the center so as to project toward the virtual plane P (see FIG. 2A). Therefore, the connection part 42 is formed in a substantially M shape. In the present embodiment, the crank portion 52 is formed in a crank shape in which one end portion is shifted from the other end portion by the thickness w (width portion) of the coil wire 30 (FIG. 2B). )reference).

  Next, a method for manufacturing the coil wire bundles 21 and 22 (see FIG. 5) will be described with reference to FIGS. The coil wire bundle 21 and the coil wire bundle 22 are manufactured by the same manufacturing method. Therefore, the coil wire bundle 21 and the coil wire bundle 22 have the same configuration.

  As shown in FIG. 3, first, the two coil wires 30 are knitted in a spiral shape so that the plurality of slot accommodating portions 31 are parallel to each other and the plurality of crank portions 52 are arranged in a straight line. FIGS. 3A to 3C show a part of the process of weaving the two coil wire rods 30 in a spiral manner in chronological order. Here, in order to make the explanation easy to understand, one coil wire 30 is indicated by a solid line, and the other coil wire 30 is indicated by a broken line.

When shifting from the state of FIG. 3A to the state of FIG. 3B, the ends of the two coil wire rods 30 (the right side in FIG. 3) are moved closer to each other. When shifting from the state of FIG. 3B to the state of FIG. 3C, the ends of the two coil wire rods 30 are moved away from each other.
FIG. 4 shows the state of the two coil wires 30 when shifting from the state of FIG. 3 (B) to the state of FIG. 3 (C), particularly focusing on the vicinity of the crank portion 52.

4A and 4B correspond to the state of FIG. At this time, one coil wire 30 and the other coil wire 30 are in a state where they coincide with each other in the thickness direction (the direction of arrow X shown in FIG. 4).
In this embodiment, when one coil wire 30 is moved in the direction of arrow Y from the state shown in FIG. 4A (see FIG. 4C), the second inclined portion 32 of the one coil wire 30 is particularly second. The vicinity of the portion 51 is guided by the protruding portion 53 of the other coil wire 30 so that the coil wires 30 are naturally shifted in the thickness direction (arrow X direction) (see FIG. 4D). Thereby, it can suppress that especially 1st inclination part 41 of coil wire 30 interferes at the time of a braiding operation | work (refer FIG.4 (E)). Therefore, deformation at the time of weaving the coil wire 30 can be suppressed, and the weaving operation can be performed efficiently.

Similarly, coil wire bundles 21 and 22 shown in FIG. 5 can be manufactured by weaving six coil wire rods 30 in a spiral shape. As shown in FIG. 5A, the coil wire bundles 21 and 22 are formed such that a plurality of slot accommodating portions 31 are arranged in parallel with each other at equal intervals. The coil wire bundles 21 and 22 are formed so that the six crank portions 52 are arranged in a straight line at equal intervals. Further, the coil wire bundles 21 and 22 are formed with a gap S1 extending in the arrow Y direction.
As shown in FIG. 5B, the coil wire bundles 21 and 22 are formed such that the six coil wire rods 30 are aligned in the thickness direction (arrow X direction).

Next, weaving of the coil wire bundle 21 and the coil wire bundle 22 will be described with reference to FIG.
FIGS. 6A to 6C show a part of the process of weaving the coil wire bundle 21 and the coil wire bundle 22 in a spiral manner in chronological order. Here, for easy understanding, the coil wire bundle 21 is indicated by a solid line and the coil wire bundle 22 is indicated by a broken line.

As shown in FIGS. 6A to 6C, the coil wire bundle 21 and the coil wire bundle 22 are spiraled while the gap S1 portion of the coil wire bundle 21 and the gap S1 portion of the coil wire bundle 22 intersect each other. Knit into the shape.
In this embodiment, when the state of FIG. 6 (A) is shifted to the state of FIG. 6 (B), particularly the vicinity of the second inclined portion 51 of the turn portion 32 of the coil wire bundle 21 is the protruding portion 53 of the coil wire bundle 22. The coil wire bundles (21, 22) are naturally shifted in the thickness direction. Thereby, it can suppress that especially 1st inclination part 41 of coil wire bundles 21 and 22 interferes at the time of braiding. Therefore, it is possible to suppress the deformation at the time of weaving the coil wire bundles 21 and 22 and to perform the weaving work efficiently.

  By repeating the weaving work shown in FIGS. 6A to 6C, a long plate-like intermediate assembly 23 as shown in FIG. 7A can be obtained. As illustrated in FIG. 7B, the intermediate assembly 23 forms a gap S <b> 2 having a width d between the first inclined portions 41 of the plurality of coil wires 30. Further, in the state of the intermediate assembly 23, the vicinity of the second inclined portion 51 of the turn portion 32 between the adjacent coil wire members 30 and the protruding portion 53 do not interfere with each other. Therefore, the thickness of the intermediate assembly 23 can be suppressed.

The stator 3 is manufactured by providing the intermediate assembly 23 manufactured in this way so that the slot accommodating portion 31 is accommodated in the slots 11 and 12 while being wound a predetermined number of times in the circumferential direction of the fixed core 10. (See FIGS. 8A and 8B).
The height h of the coil end of the stator 3 corresponds to the length of the turn portion 32 of the coil wire 30 in the direction perpendicular to the virtual plane P.

Next, operation | movement of the rotary electric machine 1 (refer FIG.8 (C)) provided with the stator 3 manufactured using the coil wire 30 of this embodiment is demonstrated easily.
The rotating electrical machine 1 is connected to an electronic control unit (not shown) mounted on the vehicle, for example. The electronic control unit adjusts the power supplied to the coil assembly 20. When the electronic control unit supplies power to the coil assembly 20, a rotating magnetic field is generated in the fixed core 10. Thereby, the rotor 4 and the shaft member 5 rotate. As a result, torque is output from the shaft member 5. Thus, the rotary electric machine 1 functions as an electric motor.

  Further, when the shaft member 5 and the rotor 4 are rotated by an external force, electric power is generated in the coil assembly 20. Thereby, the electronic control unit can store the electric power generated in the coil assembly 20 in a battery or the like. Thus, the rotary electric machine 1 also functions as a generator.

Next, the advantages of the present embodiment will be clarified by showing two comparative examples. Note that in the present embodiment and each comparative example, substantially the same components are denoted by the same reference numerals, and description thereof is omitted.
FIG. 9 shows a coil wire 60 according to a first comparative example. Unlike the coil wire 30 of the present embodiment, the coil wire 60 does not have the second inclined portion 51 and the protruding portion 53. In the case of the first comparative example, for example, in a state where two coil wire rods 60 are spirally knitted, the first inclined portion 41 of one coil wire rod 60 and the crank portion 52 of the other coil wire rod 60 interfere with each other. A part of the coil wire 60 is displaced in the thickness direction (arrow X direction) (see FIG. 9B). Therefore, the thickness of the coil wire bundle formed by knitting a plurality of coil wire materials 60 may increase.

  FIG. 10 shows a coil wire 70 according to a second comparative example. Unlike the coil wire 30 of the present embodiment, the coil wire 70 does not have the protruding portion 53. In the case of the second comparative example, for example, in a state where two coil wire rods 70 are spirally knitted, the vicinity of the second inclined portion 51 of the turn portion 32 of one coil wire rod 70 and the crank portion 52 of the other coil wire rod 70 Does not interfere with each other, the two coil wire rods 70 are in the same state in the thickness direction (arrow X direction) (see FIG. 10B).

However, in the case of the second comparative example, since the crank portion 52 does not have the protruding portion 53 as in the embodiment, when the two coil wire rods 70 are knitted, one coil wire rod 70 is moved in the arrow Y direction. However, the turn part 32 of one coil wire 70 is not sufficiently guided to the crank part 52 of the other coil wire 70. Therefore, the deviation width in the thickness direction (arrow X direction) between the two coil wire rods 70 is small (see FIG. 10D). Therefore, the 1st inclination part 41 of one coil wire 70 interferes with the 1st inclination part 41 of the other coil wire 70 (refer FIG.10 (C), (E)). As a result, the efficiency of the knitting work may be reduced, or the knitting work may not be continued. Further, if the braiding operation is forcibly continued in a state where the coil wire rods 70 interfere with each other, the coil wire rod 70 may be deformed.
Thus, the coil wire 30 of the present embodiment is advantageous over the two comparative examples in that the thickness of the coil wire bundle can be reduced and the braiding operation can be performed efficiently.

  As described above, in the present embodiment, the rotor 4 that forms a plurality of magnetic poles that are alternately different in the circumferential direction, and the slot 11 that is provided radially outside the rotor 4 and extends linearly in the axial direction, 12 is a coil wire rod 30 used in the rotating electrical machine 1 having a plurality of annular fixed cores 10 formed in the circumferential direction, and includes a plurality of slot accommodating portions 31 and a plurality of turn portions 32. The slot accommodating portion 31 is formed in a straight line and is accommodated in the slots 11 and 12 of the fixed core 10 at a predetermined interval so as to be parallel to each other. The turn portions 32 are alternately provided on one end side or the other end portion side of the slot accommodating portions 31 so as to connect the end portions of the plurality of slot accommodating portions 31 to each other.

  In this embodiment, the turn portion 32 extends linearly from the end of the slot accommodating portion 31 so as to be inclined with respect to the slot accommodating portion 31 and away from the virtual plane P orthogonal to the slot accommodating portion 31. Each of the first inclined portions 41 and the connecting portion 42 that connects the ends of the two first inclined portions 41 opposite to the slot accommodating portions 31 are provided. The connecting portion 42 is inclined with respect to the first inclined portion 41 and two second inclined portions 51 extending linearly from the end of the first inclined portion 41 so as to be separated from the virtual plane P, and the 2 The end portions of the second inclined portions 51 opposite to the first inclined portions 41 are connected to each other, and a crank portion 52 that is formed in a crank shape parallel to the virtual plane P is provided. The crank portion 52 has a projecting portion 53 formed at the center so as to project toward the virtual plane P side.

In the present embodiment, since the connecting portion 42 has the crank portion 52, the plurality of slot accommodating portions 31 are parallel to each other by knitting a plurality of coil wire rods 30 in a spiral shape, and the plurality of crank portions 52 are straight. When the coil wire bundles 21 and 22 are formed so as to be arranged in a line, the thickness of the coil wire bundles 21 and 22 can be suppressed.
Moreover, since the connection part 42 has the 2nd inclination part 51, in the state by which the coil wire 30 was knitted as the coil wire bundles 21 and 22, the crank part 52 and the turn part 32 between the coil wires 30 interfere. Can be prevented.

  Further, in the present embodiment, when the plurality of coil wire rods 30 are spirally knitted, the vicinity of the second inclined portion 51 of the turn portion 32 is guided to the protruding portion 53 of the other coil wire rod 30, so that the coil wire rod 30. They naturally shift in the thickness direction. Thereby, it can suppress that especially 1st inclination part 41 of coil wire 30 interferes at the time of braiding. Therefore, deformation at the time of weaving the coil wire 30 can be suppressed, and the weaving operation can be performed efficiently.

In addition, since the coil wire bundles 21 and 22 formed by the coil wire 30 of the present embodiment can be reduced in thickness, the coil wire bundles 21 and 22 are fixed using the stator wire, that is, the coil assembly 20. The child 3 can reduce the physique in the radial direction.
Further, in the present embodiment, the crank portion 52 is formed in a crank shape in which one end portion is shifted from the other end portion by the thickness (width portion) of the coil wire 30. Therefore, when a plurality of coil wire rods 30 are knitted, one coil wire rod 30 and the other coil wire rod 30 can be made to coincide with each other in the thickness direction.

  In the present embodiment, the coil wire 30 has a rectangular cross section. In general, since the coil wire having a rectangular cross section has corners (edges) formed on the outer wall, when a plurality of such coil wires are knitted, the coil wires are likely to interfere with each other. Therefore, this embodiment described above is particularly suitable for a coil wire having a rectangular cross section.

(Other embodiments)
In the above-described embodiment, an example is shown in which the crank portion is formed in a crank shape in which one end portion is displaced from the other end portion by the thickness of the coil wire rod. On the other hand, in another embodiment of the present invention, the degree of crank-like displacement with respect to the other end of one end of the crank portion is not limited to the thickness of the coil wire, and can be any extent. Good.
In another embodiment of the present invention, the coil wire is not limited to a rectangular cross section, but may be a circle, a triangle, a pentagon, or a shape corresponding to another polygon.
In another embodiment of the present invention, the angle formed by the slot accommodating portion and the first inclined portion and the angle formed by the first inclined portion and the second inclined portion are set in any manner. Good.

Moreover, in the above-mentioned embodiment, the example which applies a coil wire and a coil wire bundle to the rotary electric machine which served as the electric motor and the generator was shown. On the other hand, in another embodiment of the present invention, the coil wire and the coil wire bundle may be applied to a rotating electric machine dedicated to either an electric motor or a generator.
In another embodiment of the present invention, the coil wire and the coil wire bundle may be applied not only to a three-phase rotating electric machine but also to a multi-phase rotating electric machine other than the three-phase rotating electric machine.

Moreover, in the above-mentioned embodiment, the example which applies a coil wire and a coil wire bundle to the rotary electric machine by which a rotor is provided inside a stator was shown. On the other hand, in other embodiment of this invention, you may apply a coil wire and a coil wire bundle to the rotary electric machine by which a rotor is provided in the outer side of a stator.
Thus, the present invention is not limited to the above-described embodiment, and can be implemented in various forms without departing from the gist thereof.

DESCRIPTION OF SYMBOLS 1 ... Electric rotating machine 3 ... Rotor 10 ... Fixed core 11, 12 ... Slot 30 ... Coil wire 31 ... Slot accommodating part 32 ... Turn part 41 ... 1st inclination part 42 ... Connection part 51 ... 2nd inclination part 52 ... Crank part 53 ... Projection part P ... Virtual plane

Claims (4)

A rotor that forms a plurality of magnetic poles that are alternately different in the circumferential direction, and an annular fixed core that is provided radially outside or radially inward of the rotor and has a plurality of axially extending slots formed in the circumferential direction A coil wire used for a rotating electrical machine,
A plurality of slot accommodating portions that are linearly formed and are accommodated in the slots at predetermined intervals so as to be parallel to each other;
A plurality of turn portions provided alternately on one end side or the other end side of the slot accommodating portion so as to connect ends of the plurality of slot accommodating portions;
The turn portion is inclined with respect to the slot accommodating portion, and two first inclined portions extending linearly from an end of the slot accommodating portion so as to be separated from a virtual plane orthogonal to the slot accommodating portion; and A connecting portion that connects ends of the two first inclined portions opposite to the slot accommodating portions;
The connection portion is inclined with respect to the first inclined portion, and extends from the end portion of the first inclined portion so as to be separated from the virtual plane, and the two second inclined portions, and the two second inclined portions. Connecting two end portions of the two inclined portions opposite to the first inclined portion, and having a crank portion formed in a crank shape parallel to the virtual plane;
The said crank part has a protrusion part formed in the center so that it may protrude to the said virtual plane side, The coil wire rod characterized by the above-mentioned.   2. The coil wire according to claim 1, wherein the crank portion is formed in a crank shape such that one end portion is deviated from the other end portion by a thickness of the coil wire material.   The coil wire according to claim 1 or 2, wherein a cross section is formed in a rectangular shape.   A plurality of the slot accommodating portions are parallel to each other, and the plurality of the crank portions are arranged in a straight line by weaving a plurality of the coil wire rods according to any one of claims 1 to 3 in a spiral shape. A coil wire bundle to be formed.

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