JP6332150B2 - Stator structure of axial gap type rotating electrical machine and method for manufacturing the same - Google Patents

Description

  The present invention relates to a stator structure of an axial gap type rotating electrical machine (motor, generator, or motor / generator) and a method for manufacturing the same.

  Conventionally, an axial gap type rotating electrical machine having a structure in which a stator and a rotor are arranged so as to face each other in the axial direction of the rotor via an air gap and the stator and the rotor are housed in a hollow cylindrical housing is known.

  Patent Document 1 discloses an example of an axial gap type motor. The axial gap type motor described in Patent Document 1 includes a stator having a coil (hereinafter, referred to as “flatwise winding coil”) formed by flatwise winding a rectangular wire.

  A plurality of flatwise winding coils are provided for each phase (U phase, V phase, W phase). The flatwise winding coils of the same phase are connected to each other via an electric connection line different from the rectangular wire. It is connected.

  Since the motor described in Patent Document 1 includes a flatwise winding coil, the space factor of the coil can be increased.

JP-A-7-67307

  However, as shown in FIG. 5 of Patent Document 1, the U-phase electrical connection line, the V-phase electrical connection line, and the W-phase electrical connection line are arranged so as to overlap in the radial direction of the stator. There is a problem that the diameter of the stator becomes large and the motor becomes large in the radial direction.

  The present invention has been made in view of the above-described circumstances, and can increase the space factor of the coil and suppress the increase in the diameter of the stator, thereby making it possible to configure the rotating electric machine compactly. It is an object of the present invention to provide a stator structure for a rotating electrical machine.

In order to solve the above-described problems, the present invention provides an axial gap type including a rotating shaft, a rotor that rotates together with the rotating shaft, and a stator that is disposed opposite to the rotor in the axial direction of the rotating shaft. A stator structure of a rotating electrical machine, wherein the stator includes a plurality of stator cores arranged in the circumferential direction, a plurality of coils having a plurality of coils having the same phase, and a plurality of coils having the same phase. And a connecting portion that connects the coils adjacent to each other along the outer periphery of the stator at a position outside the coils in the radial direction of the stator, and the coil has a rectangular wire whose thickness direction is in the axial direction. The connecting portion of each phase is formed of a rectangular wire that is flat in the axial direction. Rutotomoni for connection of other phases in the vicinity at the same position in the circumferential direction, characterized in that overlap in the axial direction, to provide a stator structure.

  In the present invention, “a flat wire wound in the axial direction with the thickness direction directed in the axial direction” means a so-called “edgewise wound” flat wire.

  According to the present invention, the connecting portion of each phase is configured by a flat wire that is flat in the axial direction of the rotating shaft, and the shaft is connected to the connecting portion of another phase that is adjacent at the same position in the circumferential direction of the stator. Since they overlap in the direction, it is possible to avoid the overlapping of the connecting portions of the respective phases in the radial direction of the stator, and to configure the axial gap type rotating electric machine in a compact manner. Furthermore, since the connecting portion can be configured by the same rectangular wire as the rectangular wire constituting the coil, it is not necessary to provide a connecting line different from the rectangular wire, and the number of parts and the manufacturing process can be reduced. In addition, the coil is formed by winding the rectangular wire around the stator core with no gap in the axial direction with the thickness direction of the coil oriented in the axial direction, so that the space factor of the coil can be increased. it can. In addition, the connection part in this invention includes both the case where it comprises with the flat wire extended from the coil, and the case where it comprises with the flat wire provided separately from the coil.

  In this invention, it is preferable that the said connection part is comprised by connecting the rectangular wire each extended from the coil of the same phase.

  According to this structure, since a connection part can be comprised only by connecting the flat wire each extended from the coil of the same phase, a number of parts and a manufacturing process can be reduced.

  In this invention, it is preferable to further provide the clip which supports the said connection part of a different phase in the state mutually spaced apart in the said axial direction.

  According to this structure, the connection part of a different phase can be supported by a clip, preventing the connection part of a different phase from contacting each other.

  In the present invention, the axial gap rotating electrical machine includes a plurality of coil groups each including a coil group arranged in the order of the first phase coil, the second phase coil, and the third phase coil in the circumferential direction as the circumferential direction. A three-phase rotating electrical machine configured by being arranged in a direction, wherein the connecting portion alternately connects adjacent coils of the same phase in the circumferential direction at one end side and the other end side in the axial direction, A first connecting portion that is a connecting portion that connects the first phase coils, a second connecting portion that is a connecting portion that connects the second phase coils, and a connecting portion that connects the third phase coils. The connecting points of the rectangular wires in each of the three connecting portions are provided at different positions in the circumferential direction, and the connecting points in the first connecting portion and the connecting points in the third connecting portion are Same in circumferential direction It is preferably provided at a position not overlapping with the connecting portion of the other phases in location.

According to this configuration, the connection points between the rectangular wires in the connection portions of the phases are provided at different positions in the circumferential direction of the stator, and the connection points in the first connection portion and the connection points in the third connection portion are respectively Since it is provided at a position that does not overlap with the connecting portion of the other phase at the same position in the circumferential direction, in the process of manufacturing the stator, when performing the connection work between the coils after arranging the coils of each phase at a predetermined position, The second connecting portion and the third connecting portion do not obstruct the connection work between the rectangular wires in the first connecting portion, and the first connecting portion and the second connecting portion are not in the rectangular wires in the third connecting portion. Does not interfere with connection work. Therefore, it is possible to easily connect the coils in the stator manufacturing process.
The present invention is a stator structure of an axial gap type rotating electrical machine that includes a rotating shaft, a rotor that rotates together with the rotating shaft, and a stator that is disposed opposite to the rotor in the axial direction of the rotating shaft. The stator includes a plurality of stator cores arranged in the circumferential direction, a multi-phase coil having a plurality of in-phase coils and a plurality of in-phase coils, and a plurality of in-phase coils. The coil is wound around the stator core in the axial direction with the flat wire oriented in the axial direction. The connecting portions of the respective phases are formed by connecting rectangular wires extending from coils of the same phase, and are connected at the same position in the circumferential direction. In the axial direction, the axial gap type rotating electrical machine is in the order of the first phase coil, the second phase coil, and the third phase coil in the circumferential direction. Is a three-phase rotating electrical machine configured by arranging a plurality of coil groups having one coil group arranged in the circumferential direction as a unit, and the connecting portion connects adjacent coils of the same phase to one end side in the axial direction. And the other end side are alternately connected in the circumferential direction, and a first connecting portion that is a connecting portion that connects the first phase coils, and a second connecting portion that is a connecting portion that connects the second phase coils. , And a third connecting portion that is a connecting portion that connects the third phase coils, the connection points of the rectangular wires are provided at different positions in the circumferential direction, and the connection in the first connecting portion. Point and the third series Said connection point in section, respectively, or may be provided at a position not overlapping with the connecting portion of the other phases at the same position in the circumferential direction.

  In the present invention, at the predetermined position in the circumferential direction where the first connecting portion, the second connecting portion, and the third connecting portion overlap in the axial direction, the second connecting portion is connected to the first connecting portion and the first connecting portion. It is preferable that the connection point in the second connection portion is provided at the predetermined position, and is disposed between the third connection portion and the third connection portion.

  According to this configuration, when the second phase rectangular wire is connected in the stator manufacturing process, the first phase rectangular wire and the third phase rectangular wire are separated from the second phase rectangular wire in the axial direction. By making the second phase rectangular wire connection in this state, the rectangular wire connection can be easily made.

  When manufacturing the stator having this configuration, the connection between the rectangular wires in the second connecting portion is the connection between the flat wires in the first connecting portion and the connection between the rectangular wires in the third connecting portion. It is preferable to be performed before (stator manufacturing method).

  According to this manufacturing method, before the first-phase rectangular wire connection and the second-phase rectangular wire connection are performed, the first-phase rectangular wire and the third-phase rectangular wire are moved from the second-phase rectangular wire to the above-mentioned axis. The rectangular wire connection can be easily performed by pulling apart in the direction and performing the second phase rectangular wire connection in that state.

  In this invention, it is preferable that the said connection part of each phase is arrange | positioned in the state which waves in the said axial direction from the edge part of the said coil in the said axial direction.

  According to this configuration, it is possible to easily prevent the connecting portions of the respective phases from interfering with each other, and in particular, easily prevent the end portions of the connecting portions of the respective phases from interfering with the connecting portions of the other phases. can do.

  In the present invention, it is preferable that a single stator core is provided with a plurality of coils composed of a plurality of rectangular wires independent from each other.

  According to this configuration, the strength of the magnetic field generated in the coil can be easily adjusted according to the state of the vehicle.

  As described above, according to the stator structure of an axial gap type rotating electrical machine according to the present invention, the rotating electrical machine can be configured in a compact manner while suppressing an increase in the stator diameter while increasing the coil space factor. it can.

1 is a perspective view showing an outline of a stator structure of an axial gap type rotating electrical machine according to an embodiment of the present invention. It is the II-II sectional view taken on the line in FIG. It is sectional drawing which expands and shows the III section in FIG. It is the figure which looked at the coil and connection part in embodiment of this invention from the radial direction outer side of the stator. (A) is the schematic which looked at the coil and connection part in embodiment of this invention from the axial direction one side of the stator, (b) is the perspective view which shows the clip in embodiment of this invention, ( (c) is a front view which shows the state by which the connection part was supported by the clip shown by (b). (A) is a figure which shows the coil at the time of providing two coils in one stator core, (b) is a figure which shows the clip which supports the coil shown by (a). It is a figure which shows the coil at the time of providing four coils in one stator core.

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In addition, in FIG. 1, illustration of the connection part 50 mentioned later is abbreviate | omitted.

  First, a schematic configuration of the axial gap type rotating electrical machine in the present embodiment will be described.

  The axial gap type rotating electrical machine in the present embodiment includes a rotating shaft 10, a rotor 2 that rotates together with the rotating shaft 10, a stator 4 that is disposed in the axial direction of the rotating shaft 10 so as to face the rotor 2, the rotor 2, and And a housing 6 (see FIG. 2) for housing the stator 4.

  This axial gap type rotating electrical machine is a three-phase rotating electrical machine. As shown in FIGS. 1 and 4, the stator 4 has a U-phase coil 23u in the circumferential direction (corresponding to the “first phase coil” of the present invention). A plurality of coil groups 23G arranged in the order of the V-phase coil 23v (corresponding to the “second-phase coil” of the present invention) and the W-phase coil 23w (corresponding to the “third-phase coil” of the present invention). Coil groups 23G are arranged in the circumferential direction S.

  That is, one V-phase coil 23v and one W-phase coil 23w are interposed between U-phase coils 23u and 23u adjacent to each other in the circumferential direction S. Similarly, one W-phase coil 23w and one U-phase coil 23 are interposed between the V-phase coils 23v and 23v adjacent to each other in the circumferential direction S, and the W-phase coils 23w and 23w adjacent to each other in the circumferential direction S. In between, one U-phase coil 23u and one V-phase coil 23v are interposed.

  In the following description, as shown in FIG. 1, the direction parallel to the rotation shaft 10 is “axial direction Y”, the radial direction of the stator 4 (direction perpendicular to the rotation shaft 10) is “radial direction X”, The circumferential direction of the stator 4 is referred to as “circumferential direction S”.

  As shown in FIG. 1, the rotor 2 includes a pair of disk-shaped rotor bodies 12A and 12B that are arranged to face each other with a predetermined interval. Each of the rotor main bodies 12A and 12B has a rotor disk that also serves as a back yoke and a plurality of permanent magnets that are fixed to the rotor disk in a state of being arranged in the circumferential direction. Each of the rotor bodies 12A and 12B is fixed to the rotating shaft 10, and the rotating shaft 10 is supported by the stator 4 via a bearing 28 (see FIG. 2). With this configuration, the rotor 2 is rotatably supported with respect to the stator 4.

  In the following description, when the U-phase coil 23u, the V-phase coil 23v, and the W-phase coil 23w are collectively referred to, these coils are referred to as the coil 23.

  Next, the structure of the stator 4 will be described in detail.

  The stator 4 is disposed between the rotor bodies 12A and 12B. As shown in FIGS. 1 and 2, the stator 4 is a three-phase coil that includes a plurality of stator cores 22 arranged in the circumferential direction S and a rectangular wire wound around the stator core 22, and includes a plurality of coils 23 in the same phase. 23 and a coupling portion 50 that couples adjacent coils 23 in the same phase along the outer periphery of the stator 4 and a clip 51 that supports the coupling portions 50 of different phases in a state of being separated from each other in the axial direction Y (see FIG. 5), a pair of support members 26 that support the stator core 22 from both sides in the axial direction Y (see FIGS. 2 and 3), and an inner cylinder that is disposed inside the plurality of stator cores 22 and connects the pair of support members 26 The member 20 and the sealing member 24 interposed between each support member 26 and the stator core 22 are included.

  As shown in FIGS. 2 and 3, the stator core 22 includes a core body 40 and a bobbin 44 attached to the core body 40. The core body 40 has a block-like structure in which a plurality of electromagnetic steel plates 41 (see FIG. 1) pressed into a predetermined shape are stacked in the radial direction X. More specifically, as shown in FIG. 1, the core body 40 is formed in a substantially trapezoidal shape that tapers from the outside in the radial direction X to the inside in a plan view.

  The core body 40 is integrally held by a bobbin 44. The bobbin 44 is formed of an insulating resin material. For example, the stator core 22 is molded by insert molding using the core body 40 as a metal part and the bobbin 44 as a resin part. That is, the core body 40 and the bobbin 44 are integrally molded so as to surround the core body 40 with the bobbin 44. As shown in FIG. 3, the bobbin 44 has a shaft portion 44a on which the coil 23 is mounted (a rectangular wire is wound), and flange portions 44b provided at both ends of the shaft portion 44a. . The flange portion 44b is separated in the axial direction Y from a portion where the coil 23 is mounted in the shaft portion 44a.

  As shown in FIGS. 1 to 4, each coil 23 is formed by winding a rectangular wire around the stator core 22 without any gap in the axial direction Y in a state where the thickness direction thereof is directed to the axial direction Y. . This winding method (winding method) is so-called “edgewise winding”.

  The winding direction of each coil 23 is the same for each coil group 23G, and is opposite to each other between adjacent coil groups 23G and 23G. In the example shown in FIG. 4, the winding direction in the left coil group 23G is right-handed (clockwise) from the upper side to the lower side in the figure, and the winding direction in the right coil group 23G is , Left-handed (counterclockwise) from the upper side to the lower side of the figure. Each coil 23 has the same position of one end portion (upper end portion in FIG. 4) in the axial direction Y, and the same position of the other end portion (lower end portion in FIG. 4) in the axial direction Y.

  As shown in FIGS. 4 and 5, the connecting portion 50 is configured by connecting the rectangular wires respectively extending from the in-phase coils 23. Specifically, as shown in FIGS. 3 and 4, the connecting portion 50 of each phase is composed of a flat rectangular wire that is flat in the axial direction Y, and other phases that are close to each other at the same position in the circumferential direction S. The connecting portion 50 overlaps the axial direction Y.

  That is, as shown in FIG. 4, the U-phase connecting portion 50 is a U-phase connecting portion 50 u (corresponding to the “first connecting portion” of the present invention), and the V-phase connecting portion 50 is a V-phase connecting portion 50 v (this When the W-phase connecting portion 50 is referred to as the W-phase connecting portion 50w (corresponding to the “third connecting portion” in the present invention), the U-phase connecting portion 50u is The V-phase coupling portion 50v and the W-phase coupling portion 50w that are close to each other at the same position in the direction S overlap in the axial direction Y. The same applies to the V-phase connecting portion 50v and the W-phase connecting portion 50w.

  As shown in FIG. 4, the connecting portion 50 is configured so that the in-phase coils 23 adjacent to each other have a circumferential direction S between one end side (upper side in FIG. 4) and the other end side (lower side in FIG. 4). Are alternately connected. In other words, the U-phase coupling portion 50u alternately couples the U-phase coils 23u and 23u adjacent to each other in the circumferential direction S at one end side and the other end side in the axial direction Y. The same applies to the V-phase connecting portion 50v and the W-phase connecting portion 50w.

  By connecting the coils 23 of the same phase in this way, the number of connecting portions 50 overlapping at the same position in the circumferential direction S differs depending on the position in the circumferential direction S. Specifically, as shown in FIG. 4, a region where only the U-phase coupling portion 50 u exists on each of the one end side and the other end side of the coil 23 in the axial direction Y (a region where the coupling portions 50 do not overlap). A region where only the U-phase connecting portion 50u and the V-phase connecting portion 50v overlap (a region where the two connecting portions 50 overlap), and a region where the U-phase connecting portion 50u, the V-phase connecting portion 50v, and the W-phase connecting portion 50w overlap. (Regions where the three connecting portions 50 overlap) are arranged in this order along the circumferential direction S, and a plurality of region groups are arranged in the circumferential direction S with these three regions as a unit region group. .

  The connecting point Pu between the rectangular wires in the U-phase connecting portion 50u, the connecting point Pv between the rectangular wires in the V-phase connecting portion 50v, and the connecting point Pw between the rectangular wires in the W-phase connecting portion 50w are different positions in the circumferential direction S. Is provided. In the example shown in FIG. 4, the connection point Pu is provided between the U-phase coil 23 u and the V-phase coil 23 v on one end side and the other end side of the coil 23 in the axial direction Y, and the connection point Pv is W Provided between phase coil 23u and U-phase coil 23u, and connection point Pw is provided between V-phase coil 23v and W-phase coil 23w.

  Furthermore, the connection point Pu of the U phase is provided at a position where it does not overlap with the other phase connecting portions 50 (the V phase connecting portion 50v and the W phase connecting portion 50w) at the same position in the circumferential direction S. The point Pw is provided at the same position in the circumferential direction S at a position where it does not overlap with the other phase connecting portions 50 (the U-phase connecting portion 50u and the V-phase connecting portion 50v).

  As shown in FIG. 4, the connecting portions 50 of each phase are undulated in the axial direction Y so as to avoid interference with the connecting portions 50 of other phases starting from the end of the coil 23 in the axial direction Y. Is arranged in. In the example shown in FIG. 4, the U-phase coupling portion 50 u on one end side (upper side in the figure) in the axial direction Y is arranged in a state of being convex downward (valley) as a whole. The V-phase coupling portion 50v on the one end side is arranged in a state of being convex downward (valley) on the left side and convex upward (crest) on the right side. The W-phase connecting portion 50w on the one end side is arranged in a state of being convex upward (mountain) as a whole. Then, the upwardly convex portion (mountain portion) of the V-phase coupling portion 50v and the entire W-phase coupling portion 50w are protruded upward from the end portion on the one end side of each coil 23. The U-phase coupling portion 50u, the V-phase coupling portion 50v, and the W-phase coupling portion 50w on the other end side (the lower side in the figure) in the axial direction Y are arranged in a wavy state that is convex in the direction opposite to the one end side. ing.

  The peak portion of the V-phase connecting portion 50v and the W-phase connecting portion 50w protrude above the end portion on the one end side of each coil 23. The protruding portion of the connecting portion 50 is accommodated in a space SP1 (see FIG. 4) between the flange portion 44b and the coil 23. This space SP1 is a part of a closed space SP described later.

  As shown in FIG. 4, a predetermined position in the circumferential direction S where the U-phase coupling portion 50u, the V-phase coupling portion 50v, and the W-phase coupling portion 50w overlap in the axial direction Y (the W-phase coil 23w and the U-phase coil 23u V region connecting portion 50v is disposed between U phase connecting portion 50u and W phase connecting portion 50w. The V-phase connection point Pv is provided at the predetermined position.

  As shown in FIGS. 5B and 5C, the clip 51 is a rectangular plate-like member that extends in the width direction from the long side on one end side in the width direction and extends in the longitudinal direction. There are six slit portions 52 provided at a predetermined interval from each other. Three of the six slit portions 52 are provided on one end side in the longitudinal direction, and the other three are provided on the other end side in the longitudinal direction.

  As shown in FIG. 5A, in the closed space SP, a plurality of clips 51 are arranged at predetermined intervals along an inner peripheral surface of a cylindrical housing 7 described later. Each clip 51 is arranged such that its longitudinal direction is along the axial direction Y and its width direction is along the radial direction X. Each clip 51 is arranged in a state where the slit portion 52 is located outside the radial direction X shown in FIG. 5A, but may be arranged in a state where the slit portion 52 is located inside the radial direction X. .

  Further, as shown in FIG. 5A, in the closed space SP, the plurality of guide plates 53 are arranged along the outer peripheral surface of the inner cylinder member 20 at a predetermined interval. The guide plate 53 is a rectangular member. The guide plate 53 is arranged such that its longitudinal direction is along the axial direction Y and its width direction is along the radial direction X. The clips 51 and the guide plates 53 are alternately arranged in the circumferential direction S. In the example shown in FIG. 5A, two coils 23 are interposed between two clips 51, 51 adjacent to each other. Two coils 23 are interposed between two guide plates 53 and 53 adjacent to each other.

  A W-phase connecting portion 50w, a V-phase connecting portion 50v, and a U-phase connecting portion 50u arranged on one end side in the axial direction Y are inserted into the three slit portions 52 on one end side in the longitudinal direction of the clip 51, thereby Three slit parts 52 support the connection part 50 of each phase. A W-phase connecting portion 50w, a V-phase connecting portion 50v, and a U-phase connecting portion 50u arranged on the other end side in the axial direction Y are inserted into the three slit portions 52 on the other end side in the longitudinal direction of the clip 51, Thereby, the three slit parts 52 support the connection part 50 of each phase. In FIG. 5C, six connecting portions 50 are illustrated for convenience, but in actuality, the number of connecting portions 50 supported by the clips 51 differs depending on the arrangement position of the clips 51. .

  The pair of support members 26 are disk-shaped members made of a nonmagnetic material (austenite stainless steel, aluminum, etc.). As shown in FIG. 2, the support member 26 has an outer diameter dimension equivalent to an inner peripheral surface (an inner peripheral surface other than the small-diameter portion 7a) of a cylindrical housing 7 described later. A shaft hole 30 through which the shaft 10 passes is formed. A boss portion 32 protrudes outward from the surface of the support member 26 facing the rotor main bodies 12 </ b> A and 12 </ b> B so as to surround the shaft hole 30, and a bearing 28 is provided in the boss portion 32. It is press-fitted.

  Each support member 26 is provided so as to sandwich an annularly connected stator core 22 (hereinafter referred to as “stator core connection body” for convenience) from both sides in the axial direction Y. More specifically, the support member 26 includes a plurality of window portions 34 having a shape corresponding to the core body 40 around the shaft hole 30. On the other hand, the core body 40 of the stator core 22 is provided with a tooth portion 40 a that protrudes outward in the axial direction Y from the bobbin 44, and the tooth portion 40 a is fitted to the window portion 34.

  A seal member 24 that seals between each support member 26 and the stator core connection body is sandwiched between each support member 26 and the stator core connection body.

  An inner cylinder member 20 is disposed inside the stator core coupling body. The inner cylinder member 20 is formed of a nonmagnetic material (austenitic stainless steel, aluminum, or the like) like the support member 26. As shown in FIG. 2, the inner cylinder member 20 is disposed between a pair of support members 26, and is fixed to each support member 26 via a seal member 24 with a bolt B.

  The housing 6 includes a cylindrical housing 7 to which the stator 4 is assembled, and a pair of disk-shaped end covers (not shown) that close both ends of the cylindrical housing 7 in the axial direction. A shaft hole (not shown) is formed at the center of the end cover, and the rotating shaft 10 is led out of the housing 6 through each shaft hole.

  As shown in FIGS. 2 and 3, a small-diameter portion 7a having an inner diameter set smaller than other portions is formed inside the cylindrical housing 7 and in the central portion in the axial direction Y. The stator 4 is assembled to the portion 7a. Specifically, the stator core coupling body (stator core 22) is disposed inside the small diameter portion 7a, and a pair of support members 26 are overlapped so as to sandwich the stator core coupling body and the small diameter portion 7a from both sides in the axial direction. The support members 26 are fixed to the small diameter portion 7a by bolts B from both sides in the axial direction Y.

  In the rotary electric machine configured as described above, a closed space SP having an annular shape in plan view is formed inside the housing 6 by the bobbin 44, the inner cylindrical member 20, and the housing 6 (small diameter portion 7a). A coolant introduction port IP and a lead-out port OP are provided in the cylindrical housing 7 at positions opposite to each other in the radial direction across the closed space SP, and cooling of the closed space SP with oil or the like. Liquid is supplied. By providing the clip 51 and the guide plate 53 in the closed space SP, the coolant flows in the circumferential direction S while meandering in the annular closed space SP, whereby the coil 23 is efficiently cooled.

  Next, a method for manufacturing the stator 4 will be described.

  First, a coil 23 of each phase is manufactured by winding a rectangular wire around the stator core 22. Next, the inner cylinder member 20 is prepared, and the coils 23 of the respective phases are arranged in an annular shape in the arrangement order shown in FIGS. 1 and 4 around the inner cylinder member 20, and the flange portions of the coils 23 adjacent to each other. By connecting 44b, a stator core coupling body is comprised.

  Next, the stator core coupling body is fitted into the window 34 of the support member 26 with the stator core coupling body superimposed on the seal member 24 and the support member 26 in the axial direction Y.

  Next, as shown in FIG. 4, by connecting (for example, welding) the rectangular wires extending from the adjacent in-phase coils 23, the U-phase connection portion 50 u, the V-phase connection portion 50 v, and the W-phase connection are connected. The part 50w is formed. In this connection work, in the state where the flat wire extends from the coil 23 of each phase along the outer periphery of the stator coupling body, first, the connection work of the V-phase flat wire is performed, and then the U-phase wire is connected. Perform flat wire work and W-phase flat wire connection work. More specifically, the rectangular wires extending from the coil 23 of each phase are arranged in a state where the rectangular wires of each phase are undulated in the axial direction Y (see FIG. 4). Then, between the U-phase coil 23u and the W-phase coil 23w adjacent to each other, the U-phase rectangular wire and the W-phase rectangular wire are separated from the V-phase rectangular wire in the axial direction Y, and in this state, the V-phase rectangular wire is separated. (See the connection point Pv in FIG. 4). Next, a U-phase rectangular wire is connected between the U-phase coil 23u and the V-phase coil 23v that are adjacent to each other (see the connection point Pu in FIG. 4), and the V-phase coils 23v and W that are adjacent to each other. The W-phase rectangular wire is connected between the phase coils 23w (see the connection point Pw in FIG. 4).

  Next, the connection part 50 of each phase is inserted into the slit part 52 of the clip 51, so that the connection part 50 of each phase is supported by the clip 51.

  Next, the stator core coupling body fitted into one of the support members 26 is set at the mounting position along the inner peripheral surface of the cylindrical housing 7, and the support member 26 is coupled to the cylindrical housing 7 with the bolt B.

  Next, the other sealing member 24 and the support member 26 are set along the inner peripheral surface of the cylindrical housing 7 so that the window 34 is fitted into the stator core coupling body and set at the mounting position, and the support member 26 is bolted to the cylindrical housing 7. Connect with B.

  Thereby, the stator 4 is manufactured.

  According to the stator 4 according to the present embodiment, each phase connecting portion 50 is formed of a flat wire that is flat in the axial direction Y, and is connected to the connecting portion 50 of another phase that is close at the same position in the circumferential direction S. On the other hand, since it overlaps with the axial direction Y, it can avoid that the connection part 50 of each phase overlaps with the radial direction X, and an axial gap type rotary electric machine can be comprised compactly. Furthermore, since the connecting portion 50 can be configured by the same rectangular wire as the rectangular wire constituting the coil 23, it is not necessary to provide a connecting line different from the rectangular wire, and the number of parts and the manufacturing process can be reduced. . In addition, the coil 23 is formed by winding the rectangular wire in the axial direction Y around the stator core 22 with the thickness direction of the coil 23 directed in the axial direction Y, so that the space factor of the coil 23 is increased. Can do.

  Moreover, according to this embodiment, since the connection part 50 can be comprised only by connecting the flat wire each extended from the coil 23 of the same phase, a number of parts and a manufacturing process can be reduced.

  Moreover, according to this embodiment, the connection part 50 of a different phase can be supported by the clip 51, preventing the connection part 50 of a different phase from contacting each other.

  Further, according to the present embodiment, the connection points Pu, Pv, and Pw between the rectangular wires are provided at different positions in the circumferential direction S, and the connection point Pu and the connection point Pw are respectively the same position in the circumferential direction S. Since it is provided at a position that does not overlap with the connecting portion 50 of the other phase, when connecting the coils 23 to each other after the coils 23 of the respective phases are arranged at predetermined positions in the manufacturing process of the stator 4, the V-phase connection is performed. The portion 50v and the W-phase connecting portion 50w do not obstruct the connection work between the U-phase flat wires, and the U-phase connecting portion 50u and the V-phase connecting portion 50v are used for the connection work between the W-phase flat wires. It will not get in the way. Therefore, in the manufacturing process of the stator 4, the connection work between the coils 23 can be easily performed.

  Further, according to the present embodiment, at the predetermined position in the circumferential direction S where the U-phase coupling portion 50u, the V-phase coupling portion 50v, and the W-phase coupling portion 50w overlap in the axial direction Y, the V-phase coupling portion 50v Since the V-phase connection point Pv is disposed at the predetermined position, the V-phase rectangular wire connection is performed in the manufacturing process of the stator 4. In this case, by connecting the V-phase rectangular wire to the U-phase rectangular wire and the W-phase rectangular wire in the axial direction Y from the V-phase rectangular wire, the rectangular wire connection can be easily performed. it can. Further, if the connection between the V-phase rectangular wires is made before the connection between the rectangular wires in the U-phase and the connection between the W-phase rectangular wires, in the process of manufacturing the stator 4, Since the rectangular wire of the phase and the rectangular wire of the W phase can be easily separated in the axial direction Y, the rectangular wire connection of the V phase can be more easily performed.

  Further, according to the present embodiment, each phase connecting portion 50 is arranged in a state of undulating in the axial direction Y starting from the end of the coil 23 in the axial direction Y. Interference with each other can be easily prevented, and in particular, it is possible to easily prevent the end portions of the connecting portions 50 of each phase from interfering with the connecting portions 50 of other phases.

  Although the structure of the stator 4 has been described above, the following configuration (modified example) can be applied to the stator 4.

  In the above embodiment shown in FIGS. 1 to 5, one coil 23 composed of one rectangular wire is provided in one stator core 22, but in this modified example, as shown in FIG. As shown, two coils 23, 23 composed of two rectangular wires that are independent of each other are provided on a single stator core in a state of being aligned on the same straight line along the axial direction Y.

  In this modification, coils 23 and 23 as shown in FIG. 6A are provided for each phase. In the following description, the upper coil 23 in FIG. 6A is referred to as “upper coil 23a”, and the lower coil 23 is referred to as “lower coil 23b”.

  In the example shown in FIG. 6A, the flat wire h1 extends from one end of the upper coil 23a in the axial direction Y (the upper end in FIG. 6A) and the other end (the lower end in FIG. 6A). The flat wire h2 extends from the section. Similarly, a flat wire h3 extends from one end portion (upper end portion in FIG. 6A) of the lower coil 23b in the axial direction Y, and a flat wire h4 extends from the other end portion (lower end portion in FIG. 6A). It is extended.

  The U-phase coupling portion 50u1 is configured by connecting the rectangular wires h1 and h1 of the upper coils 23a and 23a adjacent to each other in the U-phase. Similarly, the U-phase coupling portion 50u2 is configured by connecting the rectangular wires h2 and h2. The U-phase coupling portion 50u3 is configured by connecting the rectangular wires h3 and h3, and the U-phase coupling portion 50u4 is configured by connecting the rectangular wires h4 and h4. Similarly to the case of the U phase, the V phase coupling portions 50v1, 50v2, 50v3, and 50v4 and the W phase coupling portions 50w1, 50w2, 50w3, and 50w4 are configured for the other phases.

  The connection part of each phase is supported by being inserted into 12 slit parts 52, as shown in FIG. 6 (b). In FIG. 6B, twelve connecting portions are shown for convenience, but actually, the number of connecting portions supported by the clip 510 differs depending on the position where the clip 510 is disposed.

  According to this modification, the strength of the magnetic field generated in the coil is easily adjusted by switching the connection state of the upper coil 23a and the lower coil 23 to serial connection or parallel connection according to the state of the vehicle. be able to.

  In the modification shown in FIG. 6, two coils 23a and 23b composed of two rectangular wires are provided in one stator core. However, as shown in FIG. Four coils 23a, 23b, 23c, and 23d configured by four rectangular wires independent from each other may be provided. Also in this case, the rectangular wires extending from adjacent coils in the same phase are connected to each other.

2 Rotor 4 Stator 10 Rotating shaft 22 Stator core 23 Coil 23G Coil group 23u U-phase coil (first phase coil)
23v V phase coil (second phase coil)
23w W phase coil (third phase coil)
50 connection part 50u U-phase connection part (first connection part)
50v V-phase connecting part (second connecting part)
50w W phase connecting part (third connecting part)
51 clip Pu U-phase connection point Pv V-phase connection point Pw W-phase connection point S Stator circumferential direction Y Axis direction of rotation axis

Claims (9)

A stator structure of an axial gap type rotating electrical machine comprising: a rotating shaft; a rotor that rotates together with the rotating shaft; and a stator that is disposed opposite to the rotor in the axial direction of the rotating shaft,
The stator includes a plurality of stator cores arranged in the circumferential direction, consist of rectangular wire wound on the stator core, and a coil of a plurality of phases having a plurality of coils of the same phase, the coils adjacent to each other in the same phase, the stator A connecting portion connected along the outer periphery of the stator at a position outside the coil in the radial direction of
The coil is formed by winding the rectangular wire around the stator core in the axial direction with the thickness direction of the coil oriented in the axial direction.
The connecting portion of each phase is configured by a flat wire that is flat in the axial direction, and overlaps in the axial direction with respect to a connecting portion of another phase that is adjacent at the same position in the circumferential direction. A stator structure.   2. The stator structure according to claim 1, wherein the connecting portion is configured by connecting rectangular wires extending from coils of the same phase. In the axial gap type rotating electrical machine, a plurality of coil groups each including a coil group arranged in the order of the first phase coil, the second phase coil, and the third phase coil in the circumferential direction are arranged in the circumferential direction. A three-phase rotating electric machine configured,
The connecting portion connects adjacent in-phase coils alternately in the circumferential direction on one end side and the other end side in the axial direction,
A first connecting portion that is a connecting portion that connects the first phase coils; a second connecting portion that is a connecting portion that connects the second phase coils; and a connecting portion that connects the third phase coils. The connecting points of the rectangular wires in each of the third connecting portions are provided at different positions in the circumferential direction, and the connecting points in the first connecting portions and the connecting points in the third connecting portions are respectively The stator structure according to claim 2, wherein the stator structure is provided at a position that does not overlap with the connecting portion of another phase at the same position in the circumferential direction. A stator structure of an axial gap type rotating electrical machine comprising: a rotating shaft; a rotor that rotates together with the rotating shaft; and a stator that is disposed opposite to the rotor in the axial direction of the rotating shaft,
The stator is composed of a plurality of stator cores arranged in the circumferential direction, a rectangular wire wound around the stator core, and a plurality of coils having a plurality of in-phase coils, and in-phase coils adjacent to each other. A connecting portion for connecting along the outer periphery of the stator,
The coil is formed by winding the rectangular wire around the stator core in the axial direction with the thickness direction of the coil oriented in the axial direction.
The connecting portion of each phase is configured by connecting the rectangular wires respectively extending from the coils of the same phase, and with respect to the connecting portion of another phase that is adjacent at the same position in the circumferential direction, Overlapping in the axial direction,
In the axial gap type rotating electrical machine, a plurality of coil groups each including a coil group arranged in the order of the first phase coil, the second phase coil, and the third phase coil in the circumferential direction are arranged in the circumferential direction. A three-phase rotating electric machine configured,
The connecting portion connects adjacent in-phase coils alternately in the circumferential direction on one end side and the other end side in the axial direction,
A first connecting portion that is a connecting portion that connects the first phase coils; a second connecting portion that is a connecting portion that connects the second phase coils; and a connecting portion that connects the third phase coils. The connecting points of the rectangular wires in each of the third connecting portions are provided at different positions in the circumferential direction, and the connecting points in the first connecting portions and the connecting points in the third connecting portions are respectively The stator structure, wherein the stator structure is provided at a position that does not overlap with the connecting portion of another phase at the same position in the circumferential direction. The stator structure according to any one of claims 1 to 4 , further comprising a clip that supports the connecting portions of different phases while being separated from each other in the axial direction. At the predetermined position in the circumferential direction where the first connecting portion, the second connecting portion, and the third connecting portion overlap in the axial direction, the second connecting portion includes the first connecting portion and the third connecting portion. Placed between
The stator structure according to claim 3 or 4, wherein the connection point in the second connecting portion is provided at the predetermined position. The stator according to any one of claims 1 to 6 , wherein the connecting portion of each phase is arranged in a state of undulating in the axial direction starting from an end of the coil in the axial direction. Construction. The stator structure according to any one of claims 1 to 7 , wherein a plurality of the coils composed of a plurality of rectangular wires independent from each other are provided on one stator core. It is a manufacturing method of the stator structure according to claim 6 ,
The connection between the rectangular wires in the second connecting portion is performed before the connection between the rectangular wires in the first connecting portion and the connection between the rectangular wires in the third connecting portion. .