JP6660606B2 - Rotating electric machine, method for manufacturing rotating electric machine - Google Patents

Description

  An embodiment of the present disclosure relates to a rotating electric machine and a method for manufacturing the rotating electric machine.

  In Patent Literature 1, a stator core is configured by arranging a plurality of divided core elements in a circumferential direction, and each of a plurality of coils has one circumferential portion on one side of one of a plurality of slots. And the other part in the circumferential direction is housed in another slot different from the one slot, and the circumferential position of each coil is sequentially shifted and overlapped and wound.

International Publication No. WO 2013/183188

  In the above prior art, when a coil formed in a predetermined shape is used in advance, the stator core has an open slot structure for the convenience of assembly, and thus there are problems in terms of cogging and quietness. On the other hand, when a segment type coil is used in order to form a fully-closed slot structure, it is necessary to connect the coil sides, which increases the size and cost and makes it difficult to ensure reliability. There was a problem that.

  The present invention has been made in view of such a problem, and provides a rotating electric machine and a method of manufacturing the rotating electric machine that can realize a stator core having a fully-closed slot structure without using a segment-type coil. The purpose is to do.

In order to solve the above problems, according to one aspect of the present invention, an annular first stator core having a first slot portion is connected to an outer peripheral surface of the first stator core, and the first stator core is connected to a rotation axis. A second stator core including a plurality of iron core pieces arranged in a circumferential direction, a second stator core including a second slot between the adjacent iron core pieces, and the first slot and the second slot being the rotary shaft. a plurality of stator coils housed in a plurality of slots that are configured in communication with the radial direction with respect to heart, was closed, the stator coil has a first coil side portions housed in said first slot portion A second coil side portion accommodated in the second slot portion, wherein the radial dimension of the first slot portion is smaller than the radial dimension of the first coil side portion, The radial dimension of the second slot portion is the second coil side. Large rotary electric machine is applied than the dimension of the radial direction.
According to another aspect of the present invention, first coil side portions of a plurality of stator coils are mounted on a plurality of first slot portions formed on an outer peripheral surface of an annular first stator core, respectively. A plurality of core pieces are respectively inserted into the air core portions of the plurality of stator coils and connected to the outer peripheral surface of the first stator core, and between the core pieces adjacent in the circumferential direction around the rotation axis. A rotating electric machine in which the formed second slots accommodate the second coil sides of the plurality of stator coils, respectively.

  According to another aspect of the present invention, the first coil side portions of the plurality of stator coils are respectively mounted on the plurality of first slot portions formed on the outer peripheral surface of the annular first stator core. A plurality of core pieces are respectively inserted into the air core portions of the plurality of stator coils and connected to the outer peripheral surface of the first stator core, and the core pieces adjacent to each other in a circumferential direction around a rotation axis are provided. The second coil side portions of the plurality of stator coils are respectively accommodated in the second slot portions formed therebetween, and the ends of the plurality of stator coils are connected to form a predetermined connection pattern. And a method for manufacturing a rotating electric machine having the following.

  ADVANTAGE OF THE INVENTION According to this invention, a highly efficient and quiet rotary electric machine can be implement | achieved by making a stator iron core the slot structure of a fully closed type.

It is a longitudinal section showing an example of the whole composition of the rotary electric machine of a 1st embodiment. FIG. 2 is a transverse sectional view taken along the line II-II in FIG. 1. It is the figure which looked at only a stator core from the side in the direction of an axis. It is a perspective view showing an example of a structure of a stator coil. FIG. 5 is a cross-sectional view taken along a line VV in FIG. 1. It is explanatory drawing which shows an example of the state which inserts a 1st coil side part into an inner side slot part. It is explanatory drawing which shows an example that it is difficult to insert a 1st coil side part into an inside slot part, when the radial dimension of an inside slot part is larger than the radial dimension of a 1st coil side part. It is explanatory drawing which shows an example which can insert a 1st coil side part into an inside slot part appropriately, when the radial dimension of an inner slot part is smaller than the radial dimension of a 1st coil side part. It is explanatory drawing which shows an example of the state which connects an iron core piece to the inner stator iron core with which the stator coil was assembled. It is a process figure showing an example of a manufacturing method of a rotating electrical machine. It is a schematic diagram for demonstrating an example of the connection pattern of a stator coil. It is a longitudinal section showing an example of the whole composition of the rotary electric machine of a 2nd embodiment. It is a perspective view showing an example of the structure of a coil end cover. It is a cross-sectional view showing an example of a structure in which a core piece has a concave portion and a convex portion on a circumferential side surface.

<1. First Embodiment>
Hereinafter, the first embodiment will be described with reference to the drawings. In the following, directions such as up, down, left, right, front and rear may be appropriately used for convenience of description of the configuration of the rotating electric machine and the like, but the positional relationship of each configuration of the rotating electric machine and the like is not limited.

(1-1. Example of Overall Configuration of Rotating Electric Machine)
First, an example of the entire configuration of the rotating electric machine according to the first embodiment will be described with reference to FIGS. 1 and 2.

  The rotating electric machine 1 is used as a motor or a generator. As shown in FIGS. 1 and 2, the rotating electric machine 1 includes a rotor 2 having a shaft 21, a stator 3, a frame 4, a load-side bracket 5, a load-side bearing 6, and a non-load-side bracket. 8 and a non-load-side bearing 9.

  In this specification, the direction along the rotation axis AX (the left-right direction in FIG. 1) of the shaft 21 (the rotor 2) is referred to as “axial direction”, and the radial direction around the rotation axis AX is referred to as “radial direction”. And the direction along the circumference around the rotation axis AX is referred to as the “circumferential direction”. In this specification, the “load side” refers to a side on which a load is attached to the rotary electric machine 1, that is, a side on which the shaft 21 protrudes (the right side in FIG. 1) in this example, and a “non-load side”. Refers to the side opposite to the load side (left side in FIG. 1).

  The frame 4 (an example of a housing) has a substantially cylindrical shape, and the stator 3 is fixed to an inner peripheral portion 4a. The load-side bracket 5 (an example of a housing) is provided at a load-side end of the frame 4. The non-load side bracket 8 (an example of a housing) is provided at the non-load side end of the frame 4. The non-load-side bracket 8, the frame 4, and the load-side bracket 5 are fixed to each other by bolts (not shown).

  The load-side bearing 6 is provided on the load-side bracket 5. The non-load side bearing 9 is provided on the non-load side bracket 8. The shaft 21 is rotatably supported by the load-side bearing 6 and the non-load-side bearing 9 around the rotation axis AX. A hole is formed at the end on the non-load side of the shaft 21 by boring or the like, and a rotation position detection unit 22 that detects the rotation position of the rotor 2 is provided inside the hole.

  The rotor 2 includes a shaft 21, a substantially cylindrical rotor core 24 having an inner peripheral portion 23, and a plurality (eight poles in this example) embedded in the rotor core 24 for each pole in a substantially V shape. And a permanent magnet 25. The shaft 21 is fitted to the inner peripheral portion 23 of the rotor core 24.

  The stator 3 is fixed to the inner peripheral portion 4 a of the frame 4 so as to surround the rotor core 24 in the radial direction with a magnetic gap therebetween. The stator 3 includes a substantially annular stator core 32 in which a plurality of (in this example, 48) slots 31 are arranged along the entire circumference, and a two-layer lap winding method (so-called distributed winding method) on the plurality of slots 31. And a plurality (48 in this example) of stator coils 41 housed in one form; The detailed configuration of the stator 3 will be described later.

  A connection portion 45 that connects the ends of the plurality of stator coils 41 in a predetermined connection pattern is disposed radially outside the second coil end portion 53 on the non-load side of the stator coil 41. .

  The above is an example, and the configuration of the rotating electric machine 1 is not limited to the examples illustrated in FIGS. 1 and 2. For example, in the rotor 2, the permanent magnets 25 may be radially arranged on the rotor core 24, or the permanent magnets 25 may be fixed to the outer peripheral surface of the rotor core 24. The rotating electric machine 1 may be a slot combination other than the eight poles and 48 slots shown in FIG.

(1-2. Detailed Configuration of Stator)
Next, an example of a detailed configuration of the stator 3 will be described.
(1-2-1. Detailed configuration of stator core)
FIG. 3 shows a view of only the stator core 32 viewed from the side in the axial direction. In FIG. 3, the stator core 32 has a double annular structure which is divided coaxially in the radial direction as a whole. Of the outer stator core 32b located on the outer peripheral side, a plurality (48 in this example) of core pieces 33 (also referred to as split cores) are arranged along the entire circumference in the circumferential direction along the inner peripheral portion 4a of the frame 4. As a result, the whole is formed in a ring shape. In other words, when viewed as a whole of the stator core 32, the outer peripheral surface of the substantially cylindrical inner stator core 32 a (an example of a first stator core) on the inner peripheral side is formed into a substantially cylindrical shape by connecting a plurality of core pieces 33. Is disposed so as to cover the outer stator core 32b (an example of a second stator core).

  The inner stator core 32a includes a substantially annular inner peripheral portion 34 arranged on the inner peripheral side, and a plurality of substantially rectangular inner radial portions (radially arranged radially outward from the outer peripheral surface of the inner peripheral portion 34). In the example, the inner teeth portion 35 of 48) is provided. The inner peripheral portion 34 and the plurality of inner teeth portions 35 are formed integrally. The interval between the inner teeth portions 35 adjacent in the circumferential direction is constant, and this interval portion forms the inner slot portion 36 (an example of the first slot portion). Also, each core piece 33 is provided in the same number as the inner teeth portion 35, and in this example, each core piece 33 has a substantially T-shaped radial cross-sectional shape, and has a substantially rectangular radial cross-sectional shape radially inward. An outer teeth portion 37 is provided. An outer slot portion 38 (an example of a second slot portion) is formed between the outer tooth portions 37 of the iron core pieces 33 adjacent in the circumferential direction. In this example, each of the inner teeth portions 35 and the outer teeth portions 37 have substantially the same circumferential dimension in the radial direction. A concave portion 35a is formed at an outer peripheral end of each inner tooth portion 35, and a convex portion 37a is formed at an inner peripheral end of each outer tooth portion 37.

  Each core piece 33 is connected to the inner stator core 32a by the convex portion 37a of the outer tooth portion 37 being housed in the concave portion 35a of the inner tooth portion 35. Thereby, a pair of corresponding inner teeth portions 35 and outer teeth portions 37 are radially connected to form one tooth portion 39. In this state, the corresponding inner slot portion 36 and outer slot portion 38 communicate with each other in the radial direction, and all of them form a so-called fully-closed (not open in either the radial direction or the circumferential direction) slot 31. I do. In this example, each slot 31 is formed so as to have a substantially trapezoidal radial cross-sectional shape whose circumferential dimension gradually narrows inward in the radial direction.

(1-2-2. Detailed configuration and arrangement of stator coils)
Next, an example of the configuration and arrangement of the stator coil 41 will be described with reference to FIGS. 2, 4, and 5. FIG. In FIG. 4, the upper side corresponds to the load side, and the lower side corresponds to the non-load side. In FIGS. 2 and 5, the near side of the sheet corresponds to the opposite side, and the far side of the sheet corresponds to the load side. In FIGS. 2 and 5, only one stator coil 41 exemplifies a coil end portion described later for convenience of description.

  Each stator coil 41 is a coil whose outer shape is formed into a predetermined shape by pressure molding. The stator coil 41 is formed by winding a conducting wire 42 which is originally a round wire having a substantially circular cross section. The conducting wire 42 is formed of, for example, a round enameled wire covered with an appropriate fusion coating. Specifically, in each stator coil 41, the conductor 42 is wound a plurality of times in, for example, a substantially rectangular frame shape, and each part is press-formed, so that an outer shape as shown in FIG. It is formed as an air core coil having a core part 43. Note that the stator coil 41 may be formed of a conductor (a rectangular wire or the like) having a shape other than the conductor 42. As shown in FIG. 4, each stator coil 41 includes a first coil side 50, a second coil side 51, a first coil end 52, and a second coil end 53.

  The first coil side portion 50 extends in the axial direction, and is accommodated in the inner slot portion 36 of one slot 31. The first coil side portion 50 is pressure-formed so as to have a predetermined shape. As shown in FIG. 2, in the first coil side portion 50, the conductive wires 42 are stacked in the radial direction and the circumferential direction. The first coil side portion 50 is formed by pressing in the radial direction and the circumferential direction so as to correspond to the cross-sectional shape of the inner slot portion 36 of the slot 31, so that the circumferential dimension is radially inward. It has a substantially trapezoidal cross-sectional shape that narrows toward the bottom.

  The second coil side portion 51 extends in the axial direction at a position separated from the first coil side portion 50 by a predetermined distance X (see FIG. 2), and is different from the one slot 31 (in this example, It is accommodated in the outer slot portion 38 of another slot 31 (six spaced apart in the circumferential direction). That is, the number N of the slots 31 between the one slot 31 in which the first coil side 50 is accommodated and the other slot 31 in which the second coil side 51 is accommodated is 4 in this example. It is. Therefore, the so-called “slot jump number” of the stator coil 41 indicated by N + 2 is 6 in this example. In the present embodiment in which the plurality of stator coils 41 are accommodated in the plurality of slots 31 in a two-layer lap winding system, N + 2 = M, and the number of the plurality of stator coils 41 is N + 2 (six in this example). ) Are accommodated in the plurality of slots 31 so that the first coil end portions 52 and the second coil end portions 53 overlap in the radial direction while their positions in the circumferential direction are sequentially shifted (see FIG. 5).

  The second coil side portion 51 is pressure-formed so as to have a predetermined shape. As shown in FIG. 2, in the second coil side portion 51, the conductive wires 42 are laminated in the radial direction and the circumferential direction. The second coil side portion 51 is pressed in the radial and circumferential directions so as to correspond to the cross-sectional shape of the outer slot portion 38 of the slot 31, so that the circumferential dimension is radially inward. It has a substantially trapezoidal cross-sectional shape that narrows toward the outside (the radial dimension is smaller than the first coil side part 50 and the circumferential dimension is larger).

  The first coil side portion 50 of one stator coil 41 is housed in the inner slot portion 36 of each slot 31, and the inner slot portion 36 of the slot 31 which is spaced six in the circumferential direction is accommodated in the outer slot portion 38. The second coil side 51 of the other stator coil 41 in which the first coil side 50 is housed is housed. In order to realize such an arrangement, the distance L (see FIG. 4) between the coil side portions 50 and 51 of each stator coil 41 is set to be equal to the above-mentioned inner slot portion 36 of the slot 31 which is spaced six in the circumferential direction. The distance X from the outer slot 38 (see FIG. 2) is substantially equal to the distance X.

  As shown in FIG. 4, when the stator coil 41 is mounted on the stator core 32, the outer diameter do of the first coil side portion 50 with respect to the rotation axis AX of the rotor 2 is equal to the rotation of the rotor 2. The inner diameter di of the second coil side portion 51 with respect to the axis AX is equal to or smaller than di. That is, in a state where the stator coil 41 is mounted on the stator core 32, the storage ranges of the respective first coil side portions 50 and the respective second coil side portions 51 are arranged so as to be close to each other in the radial direction or not to overlap. ing. The coil side portions 50 and 51 of each stator coil 41 are accommodated in each slot 31 in a laminated and pressure-formed shape as described above, and the respective accommodation ranges are closely in the radial direction (do = di). In this case, the space factor of the stator coil 41 (coil side portions 50, 51) in each slot 31 is, for example, 85% or more.

  The first coil end portion 52 extends so as to connect between the respective load-side ends of the coil side portions 50 and 51 at a portion of the stator coil 41 which is separated from the slot 31 of the stator core 32 on the load side. (See FIG. 4). The first coil end portion 52 is pressure-formed so as to have a predetermined shape. That is, the first coil end portion 52 extends in the axial direction from the load-side end of the first coil side portion 50, and extends in the axial direction from the load-side end of the second coil side portion 51. A third extending portion that connects the extended second extending portion 52b and the respective load-side ends of the first extending portion 52a and the second extending portion 52b in a substantially arc shape along the separation distance X. 52c. In this example, the third extending portion 52c is formed by pressing in the radial direction and the axial direction, and its load-side end surface is a flat portion 52d. The second extending portion 52b is formed by pressing in the radial direction, and the radially outer end face is a flat portion 52e. As shown in FIG. 1, the first coil end portion 52 is disposed such that the flat portions 52d and 52e contact the load side bracket 5 via a resin or an insulating sheet (not shown).

  The second coil end portion 53 connects the respective non-load-side ends of the coil side portions 50 and 51 in a portion of the stator coil 41 that is separated from the slot 31 of the stator core 32 on the non-load side. (See FIG. 4). The second coil end portion 53 is pressure-formed so as to have a predetermined shape. That is, the second coil end portion 53 is formed by a first extending portion 53 a that extends in the axial direction from the non-load side end of the first coil side portion 50, and a shaft extending from the non-load side end of the second coil side portion 51. A third arc connecting the second extending portion 53b extending in the direction and the respective non-load-side ends of the first extending portion 53a and the second extending portion 53b in a substantially arc shape along the separation distance X. And an extending portion 53c. In this example, the third extending portion 53c is formed by pressing in the radial direction and the axial direction, and the end face on the non-load side is a flat portion 53d. The second extending portion 53b is formed by pressing in the radial direction, and the radially outer end surface is a flat portion 53e. As shown in FIG. 1, the second coil end portion 53 is arranged such that the flat portion 53d contacts the non-load-side bracket 8 via a resin or an insulating sheet (not shown).

  In each of the stator coils 41, both the winding start side end 54 and the winding end side end 55 of the conductive wire 42 are drawn out from the vicinity of the radially outer end of the second coil end 53. For this reason, as shown in FIG. 1, a connection portion 45 is formed radially outside a ring-shaped coil end group including a plurality of second coil end portions 53 arranged in a circumferential direction at a position on the non-load side of the stator core 32. Are arranged easily.

  The stator coil 41 configured as described above is disposed in a two-layer lap winding manner with respect to the plurality of slots 31 provided in the stator core 32. That is, as shown in FIG. 4, the stator coil 41 in which the first coil side portion 50 is housed in the inner slot portion 36 of one slot 31 is attached to the second coil side portion 38 in the outer slot portion 38 of the other slot 31. 51 are stored. In other words, the first coil side portions 50 and the second coil side portions 51 of the different stator coils 41 are arranged adjacent to each other in the same slot 31 in the radial direction.

  By arranging the coil end portions 52 and 53 of each of the stator coils 41 in a two-layer lap winding manner in a laminated and pressure-formed shape as described above, the load side portion and the anti-load The space factor of the coil end portions 52 and 53 in each of the side portions is, for example, 80% or more.

  The configuration and arrangement of the stator coil 41 described above is merely an example, and other configurations and arrangements may be used. For example, the space factor of the stator coil 41 in each slot 31 may be less than 85%, and the coil end portions 52, 53 at the load side portion and the non-load side portion of the stator core 32 may be smaller than 85%. The space factor may be less than 80%. Further, the projecting positions of the ends 54 and 55 of each stator coil 41 may be positions other than those described above. Further, in this example, a case where M = 6 is described as an example, but M may be a number other than 6 as long as M is a natural number of 3 or more. Further, only one of the coil end portions may be configured as described above to reduce the size.

(1-3. Stator assembly process)
As described above, in the stator 3 provided in the rotating electric machine 1 of the present embodiment, the plurality of stator coils 41 are arranged in a two-layer lap winding with respect to the plurality of fully closed slots 31 provided in the stator core 32. It is provided in. Here, since the slot 31 of the integrated stator core 32 is a fully closed type, the operation of forming the stator coil 41 by winding the conductive wire 42 as the coil wire around each of the teeth 39 in the connected state is not necessary. It is very complicated and impractical. Therefore, in the present embodiment, a plurality of stator coils 41 which are pressurized and formed in the above-described configuration are attached to the inner stator core 32a from which the outer stator core 32b (the plurality of core pieces 33) is removed. Then, the stator 3 is assembled by sequentially connecting the plurality of iron core pieces 33.

  This will be specifically described with reference to FIGS. FIG. 6 is an enlarged view of the outer peripheral portion of the inner stator core 32a viewed from the axial side surface. As shown in FIG. 6, the first coil side portion 50 of the stator coil 41 is inserted into one inner slot portion 36 in the radial direction and assembled. The work of assembling the stator coil 41 is performed on all the inner slot portions 36 (see FIG. 9 described later).

At this time, if the radial dimension A of the inner slot portion 36 is larger than the radial dimension B of the first coil side portion 50, as shown in FIG. 7, for example, the stator coil 41 is assembled to the inner stator core 32a. You will not be able to do it. This is because the inner teeth portion 35 and the inner slot portion 36 extend radially around the rotation axis AX, and the distance between the adjacent inner teeth portions 35 (the circumferential direction of the inner slot portion 36) increases toward the outside in the radial direction. Width) is increased. That is, as described above, when the stator coil 41 whose outer shape is fixed (hard to deform) by pressure molding including the coil end portions 52 and 53 is used, the first coil side portion 50 and the It cannot be deformed so as to increase the distance L between the two coil sides 51 (see FIG. 4 ). For this reason, even though the first coil side portion 50 can be inserted into the inner slot portion 36 first, the second coil side portion 51 facing the second coil side portion 51 during the insertion to the radially inner end of the inner slot portion 36 may be inserted. As a result, the stator coil 41 interferes with the inner teeth portion 35, and the entire stator coil 41 cannot be mounted on the inner stator core 32a like the stator coil 41S in the figure.

  In order to avoid the above problems, in the present embodiment, as shown in FIG. 8, the radial dimension A of the inner slot portion 36 (the inner tooth portion 35) is smaller than the radial dimension B of the first coil side portion 50. It is set as follows. In this case, even if the first coil side portion 50 is inserted into the inner slot portion 36 first and the radially inner end portion of the inner slot portion 36 is inserted, the opposing second coil side portion 51 is formed halfway. It does not interfere with the inner teeth portion 35 and can be mounted in a normal arrangement. This is because the outer diameter do of the first coil side portion 50 with respect to the rotation axis AX is equal to or smaller than the inner diameter di of the second coil side portion 51 (do) when the stator coil 41 is normally mounted as described above. ≦ di), and the inner teeth portion 35 is within the range of the inner peripheral diameter di (see FIG. 4).

  In order to increase the space factor of the stator coil 41 (coil sides 50, 51) in the slot 31, the radial dimension of the first coil side 50 and the radial dimension of the second coil side 51 are required. Desirably, the total is equal to the radial dimension of the entire slot 31. Accordingly, as described above, in response to the radial dimension A of the inner slot portion 36 (the inner tooth portion 35) being smaller than the radial dimension B of the first coil side portion 50, the outer slot portion 38 (the outer tooth portion) The radial dimension of 37) is set to be larger than the radial dimension of the second coil side portion 51.

  In a state where the stator coil 41 is assembled to all the inner slot portions 36 in this manner, the outer teeth portion 37 of the iron core piece 33 is inserted into the air core portion 43 of the stator coil 41 as shown in FIG. The stator 3 is assembled by being connected to the inner teeth portion 35 in the radial direction while being performed. At this time, the core pieces 33 are also connected in the circumferential direction, and the outer slot portion 38 and the inner slot portion 36 between the adjacent core pieces 33 communicate with each other in the radial direction to form the respective slots 31. The first coil side portion 50 and the second coil side portion 51 are arranged adjacent to each other in the radial direction.

(1-4. Example of manufacturing method of rotating electric machine)
Next, an example of a method for manufacturing the rotating electric machine 1 will be described with reference to FIG.

  As shown in FIG. 10, in the manufacturing process of the stator coil 41, first, the conductive wire 42, which is the conductive wire of the stator coil 41, is set in a jig (not shown). Then, the conductive wire 42 is wound a plurality of times, for example, in a substantially rectangular frame shape to form a wound body (not shown). At this time, the conductive wire 42 is wound so that the shape of the wound body is substantially the same as the completed shape of the stator coil 41 (see FIG. 4). Then, after each corner of the wound body is bent, each of the coil side portions 50 and 51 and the coil end portions 52 and 53 are pressed in a predetermined direction by a mold (not shown) to complete the stator coil 41.

  Next, the first coil side portions 50 of the stator coil 41 are housed in all the inner slot portions 36 of the inner stator core 32a to which the iron core pieces 33 are not connected, and all the stators are attached to the inner stator core 32a. The coil 41 is arranged (see FIG. 6). Then, the iron core piece 33 is assembled to the inner stator iron core 32a so that the outer tooth parts 37 are connected to all the inner tooth parts 35 (constituting the stator iron core 32). At this time, the second coil side portion 51 of each stator coil 41 is housed in the outer slot 38, and the stator coils 41 are arranged in the above-described two-layer lap winding method (see FIG. 9). Here, the stator coil 41 and the stator core 32 may be integrally molded with a molding resin.

  Next, the ends 54 and 55 of the plurality of stator coils 41 are subjected to connection processing by the connection portions 45 in a connection pattern as shown in FIG. 11, and the stator 3 is completed. In FIG. 11, "# 1" to "# 48" are the numbers of the slots 31, and the stator coil 41 is composed of three systems (U, V, W) of coils in total. U bar ("U" is underlined in the figure) "V" "V bar (" V "is underlined in the figure)" "W" "W bar (in the figure “W” is underlined) ”is the phase of the stator coil 41. Also, in the figure, the U-phase stator coil 41 is a thick line, the V-phase stator coil 41 is a thin line, and the W-phase stator coil 41 is a middle line between the thick line and the thin line. Each line is shown. In the plurality of stator coils 41 subjected to the connection processing as shown in FIG. 11, for example, at a certain moment, the current input from the U phase is set to the neutral point (N), (Equivalent to the arrow tip side of the arrow).

  Thereafter, the stator 3 manufactured as described above is attached to the load side bracket 5. At this time, the flat portions 52d and 52e of the first coil end portion 52 of each stator coil 41 come into contact with the load-side bracket 5 via a resin or an insulating sheet. Then, the frame 4 is attached to the load-side bracket 5 so as to cover the outer periphery of the stator 3. Then, the shaft 21 and the rotor 2 are inserted and fixed inside the stator core 32. After that, the anti-load side bracket 8 is attached to the non-load side end of the frame 5. At this time, the flat portion 53d of the second coil end portion 53 of each stator coil 41 comes into contact with the non-load-side bracket 8 via a resin or an insulating sheet or the like. Thereby, the rotating electric machine 1 is completed.

  Note that the method of manufacturing the rotating electric machine 1 described above is merely an example, and the method of manufacturing the rotating electric machine 1 includes not only the steps performed in time series in the order described above, but also necessarily the time series. It also includes steps that are not performed but are performed in parallel or individually. In addition, even in the steps performed in time series, the order can be appropriately changed in some cases.

(1-5. Effect of First Embodiment)
As described above, the rotating electric machine 1 of the present embodiment includes an annular inner stator core 32a having an inner slot portion 36, and a plurality of annular stators connected to the outer peripheral surface of the inner stator core 32a and arranged in the circumferential direction. An outer stator core 32b having an outer slot 38 between adjacent core pieces 33, and a plurality of inner stators 32 and outer slots 38 formed in radial communication with each other. And a plurality of stator coils 41 housed in the slots 31. Such a rotating electric machine 1 can be manufactured as follows. That is, the first coil side portions 50 of the stator coil 41 are sequentially mounted on the inner slot portions 36 formed in the inner stator core 32a, and then the core pieces 33 are sequentially mounted on the air core portions 43 of the stator coils 41. The second coil side portion 51 of the stator coil 41 is sequentially housed in the outer slot 38 formed between the circumferentially adjacent iron core pieces 33 while being inserted and sequentially connected to the outer peripheral surface of the inner stator core 32a. I do. Thus, a non-segmented annular stator coil 41 can be used, and a fully closed slot structure can be provided by the annular inner stator core 32a. Therefore, a highly efficient and quiet rotating electric machine 1 can be realized.

  In the present embodiment, particularly, the radial dimension A of the inner slot portion 36 (the inner tooth portion 35) is smaller than the radial dimension B of the first coil side portion 50 to be accommodated (see FIG. 8). Thus, even when the stator coil 41 having a fixed outer shape is used, it is possible to avoid the interference of the second coil side portion 51 facing the first coil side portion 50 with the inner teeth portion 35, and It can be properly mounted on the stator core 32a.

  In the present embodiment, in particular, the radial dimension of the outer slot portion 38 (the outer tooth portion 37) is larger than the radial dimension of the second coil side portion 51 to be accommodated. Thereby, in the stator coil 41, a part of the first coil side part 50 is housed in the inner slot part 36, the remaining part is housed in the outer slot part 38, and the whole of the second coil side part 51 is It is accommodated in the outer slot portion 38. In this manner, the rotating electric machine 1 having a high space factor in each slot 31 can be realized by housing the stator coil 41 in a two-layer lap winding system.

  In the present embodiment, the outer stator core 32 b has the same number of the core pieces 33 as the slots 31. Since the number of core pieces 33 is the same as the number of slots 31, each core piece 33 has a single tooth (outer tooth portion 37). Thereby, the electromagnetic characteristics can be improved as compared with the case where the iron core piece 33 includes a plurality of teeth. Further, at the time of the assembling work, the core piece 33 is easily inserted into the air core 43 of the stator coil 41, so that the working efficiency can be improved.

  In the present embodiment, in particular, the inner stator core 32a has the same number of recesses 35a as the number of the core pieces 33 on the outer peripheral surface, and the core piece 33 has the convex portions 37a housed in the recesses 35a. Thereby, at the time of assembling work, the connection can be performed by inserting the convex portion 37a of the core piece 33 into the recess 35a of the inner stator core 32a, so that the connection and positioning work of the core piece 33 become easy, and the work efficiency is improved. it can.

  In the rotating electric machine 1 of the present embodiment, the first coil side portions 50 of the plurality of stator coils 41 are respectively mounted on the plurality of inner slot portions 36 formed on the outer peripheral surface of the annular inner stator core 32a. In the process, a plurality of core pieces 33 are inserted into the air core portions 43 of the plurality of stator coils 41 and connected to the outer peripheral surface of the inner stator core 32a, and are formed between the circumferentially adjacent core pieces 33. The process of accommodating the second coil side portions 51 of the plurality of stator coils 41 in the outer slot portions 38, respectively, and forming the end portions 54 and 55 of the plurality of stator coils 41 into a predetermined connection pattern (see FIG. 11). And a connecting step as described above. Thus, a non-segmented annular stator coil 41 can be used, and a fully closed slot structure can be provided by the annular inner stator core 32a. Therefore, a highly efficient and quiet rotating electric machine 1 can be realized.

  In the method for manufacturing the rotating electric machine 1 according to the present embodiment, the first coil side portion 50, the second coil side portion 51, and the coil end portions 52 and 53 of the stator coil 41 are added to have a predetermined shape. It has a step of pressing. Thereby, the space factor of the stator coil 41 can be improved and the winding resistance can be reduced, so that a highly efficient rotating electric machine 1 can be realized.

<2. Second Embodiment>
Next, a second embodiment will be described with reference to the drawings.

(2-1. Example of Overall Configuration of Rotating Electric Machine)
An example of the entire configuration of the rotating electric machine according to the second embodiment will be described with reference to FIGS. 12 and 13.

  When the respective coil end portions 52 and 53 of the stator coil 41 are brought into direct contact with the load-side bracket 5 and the non-load-side bracket 8 as in the first embodiment described above, the respective coil end portions 52 and 53 are set due to dimensional tolerances. It is difficult to bring the brackets 52, 53 and the brackets 5, 8 into close contact with each other. In order to ensure insulation between the coil end portions 52 and 53 and the brackets 5 and 8, it is preferable to prevent damage to the insulating film of the conductor 42 of the stator coil 41, and labor is required. Further, when the specification of the stator coil 41 is changed, it is necessary to change the shape of each of the brackets 5 and 8, which leads to an increase in cost.

  Therefore, as shown in FIG. 12, the rotating electric machine 100 according to the second embodiment has a load-side coil end cover 107 and a non-load-side coil end cover 110. The load side coil end cover 107 (corresponding to an example of a cover member) is disposed between the load side bracket 105 and the frame 104 and the first coil end portion 52 of the stator coil 41. The load side coil end cover 107 covers at least a part of the first coil end portion 52, in this example, the load side end and the radially outer end. The load-side coil end cover 107 is disposed so as to be in contact with the flat portions 52d and 52e (see FIG. 1) of the first coil end portion 52 on the inner side in the axial direction and the radial direction. The load-side coil end cover 107 is in contact with the load-side bracket 105 and the frame 104 on the outside in the axial direction and the radial direction.

  The non-load side coil end cover 110 (corresponding to an example of a cover member) is disposed between the non-load side bracket 108 and the frame 104 and the non-load side coil end portion 53 of the stator coil 41. The anti-load side coil end cover 110 covers at least a part of the second coil end portion 53, in this example, the anti-load side end and the radially outer end. Further, the anti-load side coil end cover 110 is disposed so as to be in contact with the above-mentioned flat portions 53d and 53e (see FIG. 1) of the second coil end portion 53 on the inner side in the axial direction and the radial direction. The non-load side coil end cover 110 is in contact with the non-load side bracket 108 and the frame 104 on the outside in the axial direction and the radial direction.

  As shown in FIG. 13, the load-side coil end cover 107 has a disk portion 107A having a substantially constant plate thickness and a cylindrical portion 107B. The surface on the non-load side of the disk portion 107A contacts the surface (flat portion 52d) of the first coil end portion 52 on the outside in the axial direction. The load-side surface of the disk portion 107A contacts the inner wall surface of the load-side bracket 105. The inner peripheral surface of the cylindrical portion 107B is in contact with a radially outer surface (flat portion 52e) of the first coil end portion 52. The outer peripheral surface 107b of the cylindrical portion 107B contacts the load-side bracket 105 and the inner peripheral surface of the frame 104. The anti-load side coil end cover 110 has the same configuration as that of the load side coil end cover 107, and a description thereof will be omitted.

  The material of the load-side coil end cover 107 and the non-load-side coil end cover 110 is not particularly limited, but may be made of a metal such as aluminum. In this case, an insulating film (an anodic oxide film or the like) is formed on at least the surface facing (contacting) the coil end portions 52 and 53. Further, the insulating film may be formed so as to cover at least a part of the inner peripheral surface 107a and the outer peripheral surface 107b of the coil end covers 107 and 110. Thereby, it becomes easy to secure the creepage distance between the coil end portions 52, 53 and the coil end covers 107, 110. Further, the coil end covers 107 and 110 may be made of ceramic or resin which is an insulator. In this case, a resin whose thermal conductivity is improved by adding a filler such as a carbon nanotube may be used.

  Inside the frame 104, a cooling channel 104b through which cooling water (or oil) is passed is formed. The configuration of the rotating electric machine 100 other than the above is the same as that of the rotating electric machine 1 described above, and thus the description is omitted.

(2-2. Effect of Second Embodiment)
The rotating electric machine 100 according to the second embodiment described above includes the coil end covers 107 and 110. The shape of the coil end covers 107 and 110 can be freely designed independently according to the shapes of the coil end portions 52 and 53, the frame 104, and the brackets 105 and 108. It is possible to highly adhere to 52 and 53. Therefore, the heat of the stator coil 41 can be efficiently transferred to the frame 104 and the brackets 105 and 108 via the coil end covers 107 and 110, so that the heat radiation can be improved. In addition, by forming the coil end covers 107 and 110 from an insulating material or providing an insulating film on the coil end covers 107 and 110, insulation can be ensured regardless of whether the stator coil 41 is damaged. Further, even when the specification of the coil is changed, it can be dealt with only by changing the coil end covers 107 and 110, and the frame 104 and the brackets 105 and 108 can be shared, so that the cost can be reduced.

  In the present embodiment, in particular, the coil end covers 107 and 110 are brought into contact with the flat portions 52d, 52e, 53d and 53e of the coil end portions 52 and 53, so that the conductors of the coil end covers 107 and 110 and the stator coil 41 are formed. Since the contact area with 42 can be increased, the heat dissipation can be further improved. Further, such coil end portions 52 and 53 are obtained by press-molding the stator coil 41 into a predetermined shape. Therefore, since the space factor of the stator coil 41 can be improved and the winding resistance can be reduced, a highly efficient rotating electric machine 100 can be realized.

  By pressing the coil end portions 52 and 53, flat portions other than the flat portions 52d, 52e, 53d and 53e can be formed. For example, a flat portion can be formed also at a radially inner end of the first extending portions 52a and 53a. The coil end covers 107 and 110 may be shaped so as to be able to contact these flat portions.

<3. Modification>
The embodiments of the disclosure are not limited to the above, and various modifications can be made without departing from the gist and the technical idea.

  For example, as shown in FIG. 14 corresponding to FIG. 3, a plurality of core pieces 33 constituting the outer stator core 32b have a concave portion 135a on one circumferential side and a convex portion 137a on the other circumferential side. Is also good. The plurality of core pieces 33 are connected in the circumferential direction by fitting the concave portion 135a and the convex portion 137a. In this case, the positioning in the radial direction between the iron core pieces 33 is ensured, the connection strength of the entire stator iron core 32 is improved, and the assembling work is facilitated.

  In the above description, when there is a description such as “vertical”, “parallel”, and “plane”, the description is not strictly meaning. That is, the terms “vertical”, “parallel”, and “plane” mean tolerances and errors in design and manufacturing, and mean “substantially vertical”, “substantially parallel”, and “substantially plane”. .

  Further, in the above description, when there is a description such as “identical”, “same”, “equal”, “different”, and the like in terms of external dimensions, size, shape, position, and the like, the description is not strictly meaning. That is, the terms “identical”, “equal”, and “different” mean that tolerances and errors in design and manufacture are allowed, and that “substantially the same”, “substantially the same”, “substantially the same”, “substantially the same” Is different. "

  Further, in addition to those already described above, the methods according to the above-described embodiment and each modified example may be appropriately combined and used. In addition, although not illustrated one by one, the above-described embodiment and each modified example are implemented with various changes added thereto without departing from the gist thereof.

REFERENCE SIGNS LIST 1 rotating electric machine 2 rotor 3 stator 21 shaft 22 encoder 23 inner peripheral part 24 rotor core 25 permanent magnet 31 slot 32 stator core 32a inner stator core (an example of first stator core)
32b Outer stator core (example of second stator core)
33 core piece 35 inner teeth 35a recess 36 inner slot (an example of a first slot)
37 outer teeth portion 37a convex portion 38 outer slot portion (an example of a second slot portion)
39 teeth portion 41 stator coil 42 conducting wire 43 air core portion 50 first coil side portion 51 second coil side portion 52 first coil end portion 52d flat portion 52e flat portion 53 second coil end portion 53d flat portion 53e flat portion 54 Winding start side end 55 Winding end side end 100 Rotating electric machine 104 Frame (an example of a housing)
105 Load side bracket (example of housing)
107 Load side coil end cover (example of cover member)
108 Anti-load side bracket (example of housing)
110 Non-load side coil end cover (example of cover member)
135a recess 137a protrusion AX rotation axis

Claims (8)

An annular first stator core having a first slot portion,
A second stator core connected to an outer peripheral surface of the first stator core, provided with a plurality of core pieces arranged in a circumferential direction with respect to a rotation axis, and provided with a second slot between the adjacent core pieces; When,
A plurality of stator coils housed in a plurality of slots configured such that the first slot portion and the second slot portion communicate with each other in a radial direction with respect to the rotation axis;
Have a,
The stator coil includes:
A first coil side portion housed in the first slot portion,
A second coil side portion housed in the second slot portion,
With
The radial dimension of the first slot portion is smaller than the radial dimension of the first coil side portion,
The rotating electric machine according to claim 1, wherein the radial dimension of the second slot portion is larger than the radial dimension of the second coil side portion . The second stator core includes:
The rotating electric machine according to claim 1 , comprising the same number of the core pieces as the number of the slots. The first stator core includes:
The outer peripheral surface has the same number of recesses as the iron core pieces,
The iron core piece,
Electric rotating machine according to claim 1 or claim 2, wherein characterized in that it has a convex portion which is accommodated in the recess. The stator coil includes:
Having a coil end portion disposed outside the slot,
The rotating electric machine,
A housing,
Wherein the housing is disposed between the coil end portion, of the claims 1 to 3, characterized by further comprising a cover member which is in contact with the casing covering at least a portion of the coil end portion The rotating electric machine according to claim 1. The coil end portion,
An end in the axial direction with respect to the rotation axis, and at least one end on the outside or inside in the radial direction have a plurality of flat portions,
The cover member,
The rotating electric machine according to claim 4 , wherein the plurality of flat portions are arranged so as to be in contact with the respective flat portions. First coil sides of a plurality of stator coils are mounted on a plurality of first slots formed on an outer peripheral surface of an annular first stator core, respectively.
A plurality of core pieces are respectively inserted into the air core portions of the plurality of stator coils and connected to the outer peripheral surface of the first stator core;
Second coil sides of the plurality of stator coils are respectively accommodated in second slots formed between the iron core pieces adjacent in the circumferential direction around the rotation axis.
A rotating electric machine characterized by the above-mentioned. Mounting the first coil sides of the plurality of stator coils in the plurality of first slots formed on the outer peripheral surface of the annular first stator core,
A plurality of core pieces are respectively inserted into the air core portions of the plurality of stator coils and connected to the outer peripheral surface of the first stator core, and between the core pieces adjacent in the circumferential direction around the rotation axis. Accommodating the second coil sides of the plurality of stator coils in the formed second slots, respectively;
Connecting the ends of the plurality of stator coils so as to have a predetermined connection pattern;
A method for manufacturing a rotating electric machine, comprising: The first coil side portion, the second coil side portion, and the coil end portion connecting the first coil side portion and the second coil side portion of the stator coil are pressed so as to have a predetermined shape. The method for manufacturing a rotating electric machine according to claim 7 , further comprising: forming.

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