JP7058541B2 - Stator of rotary electric machine and its manufacturing method - Google Patents

Description

The present invention relates to a stator of a rotary electric machine such as a motor and a generator and a method for manufacturing the stator, and particularly to a vibration-resistant structure of an additional wire connection portion in a stator winding.

In a conventional stator, the coil conductor has a coil conductor extension extending in the direction of the rotation axis, the bus bar has a bus bar extension extending in the rotation axis direction, and the coil conductor extension and the bus bar extension are arranged adjacent to each other. The ends of the coil lead extension and the bus bar extension are welded to each other. The coil lead extension portion and the bus bar extension portion were welded with a resin at a position away from the welded portion (see, for example, Patent Document 1).

In other conventional stators, a fixing means for fixing between each phase winding connected by a neutral wire and each phase winding adjacent to them is provided (see, for example, Patent Document 2).

Japanese Unexamined Patent Publication No. 2013-70568 Japanese Unexamined Patent Publication No. 2016-15797

In Patent Document 1, the coil lead wire extension portion and the bus bar extension portion are fixed at a position close to the welded portion. For this reason, the area for fixing the two becomes extremely small, and it is difficult to secure a sufficient fixing force. Further, the bus bar portion other than the bus bar extension portion and the bus bar module holding the bus bar are not fixed anywhere. Therefore, when the rotary electric machine vibrates, the bus bar and the bus bar module vibrate greatly. As a result, there is a problem that a large stress acts on the welded portion and a disconnection occurs in the welded portion.

Further, in Patent Document 2, the intermediate position of the neutral line is not fixed anywhere. Therefore, when the rotary electric machine vibrates, the neutral wire vibrates greatly. As a result, there is a problem that a large stress acts on the welded portion and a disconnection occurs in the welded portion.

The present invention has been made to solve such a problem, and is a stator of a rotary electric machine capable of enhancing the vibration resistance of a joint structure by an additional wire and suppressing the occurrence of disconnection in a welded portion, and a method for manufacturing the stator. The purpose is to provide.

The stator of the rotary electric machine according to the present invention includes an annular stator core in which a plurality of slots are formed in the circumferential direction, and a stator winding having a plurality of unit coils inserted and arranged in the slots. Each of the plurality of unit coils has a terminal protruding from the slot, and the terminal has an inclined side portion protruding from the slot and extending in the circumferential direction, and a joint portion extending axially from the inclined side portion. The stator winding is configured by welding the joints of the plurality of unit coils to each other, and the first resin member is coated on each of the welds of the joints to form a second resin. The member has an additional wire of a member different from the unit coil, which is impregnated and cured in the coil end made of the terminal of the plurality of unit coils and connects between the joints, and the additional wire is the first. It is fixed to the inclined side portion by the resin member of 1.

According to the present invention, since the additional wire connecting the joint portions of the unit coil is fixed to the hypotenuse portion of the unit coil by the first resin member, a sufficient fixing force is secured and at the time of vibration. The amplitude becomes smaller. As a result, the vibration resistance of the joint structure formed by the additional wire is enhanced, the stress acting on the welded portion is reduced, and the generation of the broken line in the welded portion is suppressed.

It is one side sectional view which shows the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the main part of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the iron core block constituting the stator core of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the stator winding in the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. FIG. 5 is an end view of the first unit coil constituting the stator winding in the stator of the rotary electric machine according to the first embodiment of the present invention as viewed from the outside in the axial direction. It is a front view which looked at the 1st unit coil which constitutes the stator winding in the stator of the rotary electric machine which concerns on Embodiment 1 of this invention from the inside in the radial direction. It is a front view which looked at the 2nd unit coil which constitutes the stator winding in the stator of the rotary electric machine which concerns on Embodiment 1 of this invention from the inside in the radial direction. It is sectional drawing of the main part schematically showing the slot accommodating state of the unit coil in the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a wiring diagram of the stator winding in the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the additional line in the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view of the main part which shows around the additional line of the coil end coated with the 1st insulating member in the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a front view seen from the outside in the radial direction around the additional line of the coil end coated with the 1st insulating member in the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a front view seen from the outside in the radial direction around the additional line of the coil end coated with the 2nd insulating member in the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a front view seen from the outside in the radial direction around the additional line of the coil end coated with the 2nd insulating member of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a flow figure which shows the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a figure explaining the additional wire fixing process in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a figure explaining the additional wire fixing process in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a front view seen from the outside in the radial direction around the addition line of the 1st coil end in the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. FIG. 19 is a cross-sectional view taken along the line AA of FIG. FIG. 19 is a cross-sectional view taken along the line AA of FIG. FIG. 19 is a cross-sectional view taken along the line AA of FIG. FIG. 19 is a cross-sectional view taken along the line AA of FIG. It is a front view which looked around the additional wire of the coil end in the stator of the rotary electric machine which concerns on Embodiment 2 of this invention from the outside in the radial direction. It is a front view which shows the additional line in the stator of the rotary electric machine which concerns on Embodiment 2 of this invention. It is a front view which looked at the addition line of the coil end in the stator of the rotary electric machine of embodiment of this invention from the outside in the radial direction.

Embodiment 1.
1 is a one-sided sectional view showing a rotary electric machine according to the first embodiment of the present invention, FIG. 2 is a perspective view showing a main part of the rotary electric machine according to the first embodiment of the present invention, and FIG. 3 is the present invention. FIG. 4 is a perspective view showing the stator of the rotary electric machine according to the first embodiment of the present invention, FIG. 4 is a perspective view showing an iron core block constituting the stator core of the rotary electric machine according to the first embodiment of the present invention, and FIG. A perspective view showing a stator winding in the stator of the rotary electric machine according to the first embodiment of the present invention, FIG. 6 constitutes a stator winding in the stator of the rotary electric machine according to the first embodiment of the present invention. An end view of the unit coil viewed from the outside in the axial direction, FIG. 7 is a front view of the unit coil constituting the stator winding in the stator of the stator according to the first embodiment of the present invention as seen from the inside in the radial direction. FIG. 8 is a front view of the second unit coil constituting the stator winding in the stator of the stator according to the first embodiment of the present invention from the inside in the radial direction, and FIG. 9 is a front view of the present invention. FIG. 10 is a sectional view of a main part schematically showing a slot housing state of a unit coil in the stator of the rotary electric machine according to the first embodiment, and FIG. 10 shows a stator winding in the stator of the rotary electric machine according to the first embodiment of the present invention. 11 is a perspective view showing an additional line in the stator of the rotary electric machine according to the first embodiment of the present invention, and FIG. 12 is a perspective view showing an additional line in the stator of the rotary electric machine according to the first embodiment of the present invention. FIG. 13 is a perspective view of a main part showing the circumference of the additional line of the coil end coated with the first insulating member, in which the first insulating member in the stator of the rotary electric machine according to the first embodiment of the present invention is coated. A front view of the circumference of the additional wire of the coil end viewed from the outside in the radial direction, FIG. 14 shows the additional wire of the coil end coated with the second insulating member in the stator of the rotary electric machine according to the first embodiment of the present invention. The front view and FIG. 15 which are viewed from the outside in the radial direction are around the additional wire of the coil end coated with the second insulating member of the stator of the stator of the rotary electric machine according to the first embodiment of the present invention. It is a front view seen from the outside in the radial direction. In FIG. 8, the winding body shows only the slot accommodating portion, and 1, 2, ... 12, 13 are slot numbers assigned to the slots in the order of arrangement in the circumferential direction.

In FIGS. 1 and 2, the rotary electric machine 100 is inserted and held inside a housing 1 having a bottomed cylindrical frame 2 and an end plate 3 for closing an opening of the frame 2, and a cylindrical portion of the frame 2. The stator 5 is fixed to the stator 10 and the rotary shaft 6 rotatably supported by the bottom portion and the end plate 3 of the frame 2 via the bearing 4, and is rotatably arranged on the inner peripheral side of the stator 10. And have.

The rotor 5 is embedded in the outer peripheral surface side of the rotor core 7 fixed to the rotation shaft 6 inserted at the axial center position and arranged on the outer peripheral surface side of the rotor core 7 at an equal pitch in the circumferential direction to form a magnetic pole. It is a permanent magnet type rotor provided with a permanent magnet 8.

Next, the configuration of the stator 10 will be described with reference to FIGS. 3 to 12. For convenience of explanation, the axial direction of the rotary shaft 6 is the axial direction, the radial direction of the rotary shaft 6 is the radial direction, and the rotational direction about the axial center of the rotary shaft 6 is the circumferential direction.

As shown in FIG. 3, the stator 10 includes a stator core 11 and a stator winding 20 mounted on the stator core 11. A ground insulating member 14 that insulates the stator winding 20 and the stator core 11 is mounted in the slot 13 of the stator core 11. Further, an interphase insulating member (not shown) that insulates between the phases of the stator winding 20 is attached to the coil end of the stator winding 20.

Here, for convenience of explanation, the number of poles of the rotor 5 is 8, the number of slots of the stator core 11 is 48, and the stator winding 20 is a three-phase winding. That is, the slots 13 are formed in the stator core 11 at a ratio of two per pole and each phase.

The stator core 11 is composed of 48 iron core blocks 12. As shown in FIG. 4, the iron core block 12 includes a core back portion 12a having an arcuate cross section and a teeth 12b protruding inward in the radial direction from the inner peripheral wall surface of the core back portion 12a. The iron core block 12 is formed by laminating, for example, T-shaped core pieces punched from an electromagnetic steel sheet. The 48 iron core blocks 12 are inserted and held in the cylindrical portion of the frame 2 by press fitting, shrink fitting, or the like in a state where the side surfaces of the core back portion 12a in the circumferential direction are butted against each other and arranged in an annular shape. Forty-eight iron core blocks 12 are arranged in an annular shape to form a stator core 11. The stator core 11 has an annular core back composed of 48 core back portions 12a, and 48 core backs extending radially inward from the inner peripheral surface of the core back and arranged at equal pitches in the circumferential direction. It is composed of the teeth 12b of the above. The space formed between the adjacent teeth 12b is the slot 13.

The stator winding 20 has a plurality of unit coils 21. The unit coil 21 is composed of a first unit coil 21A and a second unit coil 21B in which the extending directions of the terminal wires are different. Here, the first unit coil 21A and the second unit coil 21B are basically the same, and are distinguished by the subscripts A and B. Further, when the unit coil is generically referred to, only the reference code is used. Further, for convenience of explanation, the coil pattern of the unit coil will be described based on the state in which the unit coil is inserted into the slot.

In the first unit coil 21A, conductor wires 19 having a rectangular cross section made of continuous copper wire, aluminum wire, etc., which are insulated and coated and have no connection, are arranged in the circumferential direction at intervals of 6 slots, the first slot and the second slot. And in the third slot, in the order of the second slot, the first slot, the second slot, the third slot, the second slot and the first slot, and from the axial direction to the first slot, the second slot and the third slot. It is configured in a coil pattern in which the insertion direction is alternately changed and the insertion position in the radial direction in the slot 13 is sequentially shifted outward in the radial direction by one layer at a time. That is, the first unit coil 21A is configured in a coil pattern in which the character "8" is turned sideways when viewed from the inside in the radial direction. The first unit coil 21A manufactured in this way is a distributed winding lap winding. Further, the 6-slot spacing is a spacing between the slots 13 located on both sides of the six teeth 12b continuous in the circumferential direction, and corresponds to one magnetic pole pitch here. Further, the insulating film of the conductor wire 19 is formed by, for example, covering a bare wire with an enamel resin.

As shown in FIGS. 6 and 7, the first unit coil 21A has three rows separated by six slots, and the first, second, third, fourth, fifth, and sixth slot accommodating portions S1. ~ S6, the first terminal T1A extending from one end of the first slot accommodating portion S1, the first coil end portion T12 connecting the other ends of the first and second slot accommodating portions S1 and S2, and the second and second. The second coil end portion T23 that connects one ends of the third slot accommodating portions S2 and S3, the third coil end portion T34 that connects the other ends of the third and fourth slot accommodating portions S3 and S4, and the fourth. A fourth coil end portion T45 that connects one ends of the fifth slot accommodating portions S4 and S5, and a fifth coil end portion T56 that connects the other ends of the fifth and sixth slot accommodating portions S5 and S6. A second terminal T6A extending from one end of the 6-slot accommodating portion S6 is provided. The first terminal T1A is the terminal wire on the inner diameter side of the first unit coil 21A, and the second terminal T6A is the terminal wire on the outer diameter side of the first unit coil 21A.

The first and second slot accommodating portions S1 and S2 are radially shifted by the radial thickness d of the conductor wire 19 by the crank portion formed at the circumferential intermediate position of the first coil end portion T12. The second and third slot accommodating portions S2 and S3 are radially shifted by d by the crank portion formed at the circumferential intermediate position of the second coil end portion T23. The third and fourth slot accommodating portions S3 and S4 are radially shifted by d by the crank portion formed at the circumferential intermediate position of the third coil end portion T34. The fourth and fifth slot accommodating portions S4 and S5 are radially shifted by d by the crank portion formed at the circumferential intermediate position of the fourth coil end portion T45. The fifth and sixth slot accommodating portions S5 and S6 are radially shifted by d by the crank portion formed at the circumferential intermediate position of the fifth coil end portion T56.

The first coil end portion T12 includes a crank portion as a top portion, an inner diameter side end portion of the crank portion, the other end of the first slot accommodating portion S1, an outer diameter side end portion of the crank portion, and a second slot accommodating portion S2. It is composed of a pair of hypotenuses connecting the ends. When the unit coil 21 is mounted on the stator core 11, one hypotenuse portion maintains a radial position from the other end of the first slot accommodating portion S1 and faces the inner diameter side end portion of the crank portion. It extends from the stator core 11 so as to be gradually separated from the core 11 and is connected to the inner diameter side end of the crank portion. Further, the other hypotenuse portion extends from the other end of the second slot accommodating portion S2 so as to maintain a radial position and gradually separate from the stator core 11 toward the outer diameter side end portion of the crank portion. It is connected to the outer diameter side end of the crank portion. The second coil end portion T23, the third coil end portion T34, ..., The fifth coil end portion T56 is also configured in the same manner as the first coil end portion T12.

The first terminal T1A is a first crank portion T1Aa extending from one end of the first slot accommodating portion S1 and is shifted inward by d in the radial direction, and then accommodating the third slot of the second coil end portion T23. It extends parallel to the hypotenuse portion connected to one end of the portion S3 while maintaining a radial position, and then is bent and extends outward in the axial direction. That is, the first terminal T1A has a first crank portion T1Aa, a first hypotenuse portion T1Ab parallel to the hypotenuse portion connected to one end of the third slot accommodating portion S3 of the second coil end portion T23, and a first hypotenuse portion. It includes a first joint T1Ac extending axially from the end of the T1Ab. The insulating film of the first joint portion T1Ac is removed.

The second terminal T6A is a second crank portion T6Aa after extending from one end of the sixth slot accommodating portion S6, is shifted radially outward by d, and then accommodates the third slot of the second coil end portion T23. It extends parallel to the hypotenuse portion connected to one end of the portion S3 while maintaining a radial position, and then is bent and extends outward in the axial direction. That is, the second terminal T6A has a second crank portion T6Aa, a second hypotenuse portion T6Ab parallel to the hypotenuse portion connected to one end of the third slot accommodating portion S3 of the second coil end portion T23, and a second hypotenuse portion. A second joint T6Ac extending axially from the end of the T6Ab is provided. The insulating film of the second joint T6Ac is removed.

As shown in FIG. 8, the second unit coil 21B has conductor wires 19 arranged in the first slot, the second slot, and the third slot in the circumferential direction at intervals of 6 slots, similarly to the first unit coil 21A. The insertion direction from the axial direction to the second slot, the first slot, the second slot, the third slot, the second slot, and the first slot, and the first slot, the second slot, and the third slot are alternately changed. In addition, the coil pattern is configured so that the insertion position in the radial direction in the slot 13 is sequentially shifted outward in the radial direction by one layer at a time. The second unit coil 21B is also configured in a coil pattern in which the figure 8 is turned sideways when viewed from the inside in the radial direction.

Specifically, the second unit coil 21B includes the first, second, third, fourth, fifth and sixth slot accommodating portions S1 to S6, and the first terminal T1B, the first, the second, and the third. , 4th and 5th coil end portions T12, T23, T34, T45, T56 and a second terminal T6B. The first terminal T1B is the terminal wire on the inner diameter side of the second unit coil 21B, and the second terminal T6B is the terminal wire on the outer diameter side of the second unit coil 21B.

The first terminal T1B extends from one end of the first slot accommodating portion S1 in parallel with the hypotenuse portion connected to one end of the fifth slot accommodating portion S5 of the fourth coil end portion T45 while maintaining a radial position. It is taken out, then bent and extends outward in the axial direction. That is, the first terminal T1B has a first hypotenuse portion T1Bb parallel to the hypotenuse portion connected to one end of the fifth slot accommodating portion S5 of the fourth coil end portion T45 and an axial direction from the end portion of the first hypotenuse portion T1Bb. It is provided with a first joint portion T1Bc extending to.

The second terminal T6B extends from one end of the sixth slot accommodating portion S6 in parallel with the hypotenuse portion connected to one end of the second slot accommodating portion S2 of the second coil end portion T23 and while maintaining a radial position. It is taken out, then bent and extends outward in the axial direction. That is, the second terminal T6B has a second hypotenuse portion T6Bb parallel to the hypotenuse portion connected to one end of the third slot accommodating portion S3 of the second coil end portion T23 and an axial direction from the end portion of the second hypotenuse portion T6Bb. It is provided with a second joint portion T6Bc extending to.

As described above, the second unit coil 21B is manufactured in the same manner as the first unit coil 21A, except that the first terminal T1B and the second terminal T6B are different.

As shown in FIG. 9, in the unit coil 21, the first slot accommodating portion S1 is inserted at the position of the first layer of the seventh slot 13, and the second slot accommodating portion S2 is the second of the first slot 13. It is inserted at the position of the layer, the third slot accommodating portion S3 is inserted at the position of the third layer of the seventh slot 13, and the fourth slot accommodating portion S4 is inserted at the position of the fourth layer of the thirteenth slot 13. , The fifth slot accommodating portion S5 is inserted at the position of the fifth layer of the seventh slot 13, and the sixth slot accommodating portion S6 is inserted at the position of the sixth layer of the first slot 13.

The unit coils 21 mounted in the slot 13 in this way are arranged in the stator core 11 in the same number as the slots 13 at a pitch of one slot in the circumferential direction. As a result, in each slot 13, the first, second, third, fourth, fifth and sixth slot accommodating portions S1 to S6 composed of the three unit coils 21 are arranged in a row in the radial direction. Is inserted into the 6th layer. The first layer is the layer at the innermost inner diameter of the six layers of the first to sixth slot accommodating portions S1 to S6 inserted in a row in the slot 13, and the sixth layer is the most. It is a layer at the outer diameter position.

Specifically, the first unit coil 21A and the second unit coil 21B are mounted on the stator core 11 in a state of being alternately arranged in the circumferential direction. That is, the arrangement state of the first unit coil 21A and the second unit coil 21B is as follows: first unit coil 21A, first unit coil 21A, second unit coil 21B, second unit coil 21B, first unit coil 21A, first. The unit coil is 21A .... This constitutes the annular stator winding 20 shown in FIG.

As a result, on one end side of the stator core 11 in the axial direction, a layer of the second coil end portion T23 in which the second coil end portions T23 are arranged in the circumferential direction at a one-slot pitch and a fourth coil end portion T45 are formed. The layers of the fourth coil end portion T45 arranged in the circumferential direction at one slot pitch and the layers of the fourth coil end portion T45 are arranged in two layers in the radial direction to form the first coil end 20a. Then, the inclination directions of the first hypotenuse portions T1Ab and T1Bb of the first terminals T1A and T1B extending from the first layer of the slot 13 are alternately opposite to each other, and the circumference is on the inner diameter side of the first coil end 20a. Arranged in the direction. Similarly, the inclination directions of the second hypotenuse portions T6Ab and T6Bb of the second terminals T6A and T6B extending from the sixth layer of the slot 13 are alternately opposite to each other, and the outer diameter side of the first coil end 20a. Are arranged in the circumferential direction.

Further, on the other end side of the stator core 11 in the axial direction, a layer of the first coil end portion T12 in which the first coil end portions T12 are arranged in the circumferential direction at a one-slot pitch and a third coil end portion T34 are located. The layer of the third coil end portion T34 arranged in the circumferential direction at one slot pitch and the layer of the fifth coil end portion T56 in which the fifth coil end portion T56 is arranged in the circumferential direction at one slot pitch are radially arranged. It is arranged in three layers and constitutes the second coil end 20b.

Then, the first joint portions T1Ac and T1Bc of the first unit coil 21A and the second unit coil 21B constituting the phase winding of the same phase are joined to each other by TIG welding or the like, and the second joint portions T6Ac and T6Bc are joined to each other by TIG welding or the like. Each phase winding is formed by joining with. In each phase winding, one first unit coil 21A is connected to a second unit coil 21B to be connected, which is inserted into slots 13 separated by 6 slots.

This gives six phase windings, such as U-phase windings, V-phase windings, W-phase windings, X-phase windings, Y-phase windings and Z-phase windings. Then, for example, as shown in FIG. 10, the U-phase winding, the V-phase winding, and the W-phase winding are star-connected, and the X-phase winding, the Y-phase winding, and the Z-phase winding are star-connected. Will be done. As a result, the stator winding 20 composed of two sets of three-phase windings is configured.

Next, the connection structure of the U-phase winding, the V-phase winding, and the W-phase winding will be described. Since the wiring structure of the X-phase winding, the Y-phase winding, and the Z-phase winding is the same as the wiring structure of the U-phase winding, the V-phase winding, and the W-phase winding, the description thereof is omitted. do.

In order to star connect the U-phase winding, the V-phase winding, and the W-phase winding, a neutral point 201 connecting the U-phase winding, the V-phase winding, and the W-phase winding is required. Therefore, when connecting the second terminals T6A and T6B on the outer diameter side of the U-phase winding, the V-phase winding, and the W-phase winding together, one of the second terminals T6A, It is necessary to lengthen T6B. This deteriorates the handleability of the unit coil 21. Further, the number of types of the unit coil 21 increases, and the manufacturing process of the unit coil 21 becomes complicated.

In the first embodiment, the additional wire 30 shown in FIG. 11 is used to prevent the second terminals T6A and T6B from becoming long and to prevent the types of the unit coil 21 from increasing. As shown in FIG. 11, the additional wire 30 is manufactured by bending and molding a conductor wire such as an insulatingly coated copper wire or an aluminum wire, and projects from an arcuate bottom portion 31 and both ends of the bottom portion 31 at a substantially right angle. It is configured in a substantially U-shape including the tip portions 32a and 32b. Then, the insulating film on the tip side of the tip portions 32a and 32b is removed.

The second joints T6Ac and T6Bc of the second terminals T6A and T6B of the U-phase winding and the V-phase winding are overlapped with each other in the radial direction as shown in FIG. Further, the tip portion 32a of the additional wire 30 is superposed on the second joint portion T6Ac of the U-phase winding in the circumferential direction. Then, the two second joint portions T6Ac and T6Bc and the tip portion 32a are collectively gripped and welded by TIG welding. Then, the tip end portion 32b of the additional wire 30 is superposed on the second joint portion T6Bc of the second terminal T6B of the W phase winding from the outside in the radial direction. The second joint portion T6Bc and the tip portion 32a are collectively gripped and welded by TIG welding. The additional line 30 becomes the neutral point 201. Further, the second terminals T6A and T6B, which are the remaining ends of the U-phase winding, the V-phase winding, and the W-phase winding, are the lead wires, respectively. As a result, the U-phase winding, the V-phase winding, and the W-phase winding are star-connected. The X-phase winding, the Y-phase winding, and the Z-phase winding are also star-connected in the same manner.

In the stator winding 20 configured in this way, as shown in FIGS. 12 and 13, the additional wire 30 has two contact portions A and B, and the second hypotenuse portion T6Bb of the second terminal T6B. And is in contact with the second hypotenuse portion T6Ab of the first terminal T6A. Further, as shown in FIG. 13, the electrically insulating first resin member 300 is coated on the axial region including the additional wire 30 of the first coil end 20a of the stator winding 20. That is, the welded portions 50a between the first joint portions T1Ac and T1Bc, the welded portions 50b between the second joint portions T6Ac and T6Bc, the welded portions 51a and 51b between the additional wire 30 and the second joint portion T6c, and the additional wire 30. The contact portions A and B with the second terminals T6A and T6B are covered with the first resin member 300.

As a result, the electricity of the welded portions 50a between the first joint portions T1Ac and T1Bc, the welded portions 50b between the second joint portions T6Ac and T6Bc, and the welded portions 51a and 51b between the additional wire 30 and the second joint portions T6Ac and T6Bc. Insulation is ensured. Further, the additional line 30 is fixed to the second terminals T6A and T6B by the first resin member 300 in a state of being in contact with the second terminals T6A and T6B at two points.

Further, after the application of the first resin member 300, an insulating second resin member, for example, a varnish 301 is applied to the first coil end 20a and the second coil end 20b. As a result, in the first coil end 20a, as shown in FIG. 14, the entire region of the first resin member 300 is covered with the varnish 301.

The varnish 301 does not need to cover the entire region of the first resin member 300. For example, as shown in FIG. 15, the varnish 301 avoids the covering region of the first resin member 300 and covers the first coil end 20a. It may be applied, or it may be applied to the first coil end 20a so as to cover a part of the covering region of the first resin member 300.

According to the first embodiment, the pair of the two second joints T6Ac and T6Bc of the U-phase winding and the V-phase winding and the one second joint T6Bc of the W-phase winding are added. Since it is connected by 30, it is not necessary to lengthen the second terminal T6B for connecting the neutral point of the W phase winding. This facilitates the handleability of the unit coil 21. Further, since the number of types of the unit coil 21 is not increased, the manufacturing process of the unit coil 21 is simplified and the unit coil 21 can be manufactured at low cost. Further, since the additional line 30 is fixed to the second terminals T6A and T6B, it is possible to suppress the relative movement of the additional line 30 and the second terminals T6A and T6B. As a result, the stress applied to the welded portions 51a and 51b between the additional wire 30 and the second terminals T6A and T6B can be reduced without providing a special fixing member, and the risk of disconnection of the welded portions 51a and 51b can be reduced.
Further, the additional wire 30 and the second terminal are used by using the first resin member 300 for insulatingly covering the welded portion 50a between the first joint portions T1Ac and T1Bc and the welded portion 50b between the second joint portions T6Ac and T6Bc. T6A and T6B are fixed. As a result, the additional wire 30 and the second terminals T6A and T6B can be fixed without using a dedicated adhesive or the like, so that the additional wire 30 and the second terminals T6A and T6B can be fixed at low cost.
Further, since the additional wire 30 coated with insulation is used, the electrical insulation between the contact portions A and B with the second terminals T6A and T6B is surely secured.

Next, the effect of fixing the additional line 30 to the second terminals T6A and T6B at two points of the contact portions A and B will be described.

When the additional wire 30 is fixed to the second terminals T6A and T6B only by the welded portions 51a and 51b, the unfixed region between the welded portions 51a and 51b of the additional wire 30 vibrates freely. .. Therefore, when the rotary electric machine 100 vibrates, the additional wire 30 is oscillated by the length from the welded portion 51a to the welded portion 51b, and the amplitude becomes large. As a result, the stress applied to the welded portions 51a and 51b becomes large, and the welded portions 51a and 5b may break.

On the other hand, when the additional wire 30 is fixed to the second terminals T6A and T6B at two contact portions A and B between the welded portions 51a and 51b, the additional wire 30 extends from the welded portion 51a to the contact portion A. It will be shaken by the length from the contact portion A to the contact portion B, and the length from the contact portion B to the welded portion 51b, respectively, and the amplitude will be small. As a result, the stress applied to the welded portions 51a and 51b is reduced, and the occurrence of breakage of the welded portions 51a and 5b is suppressed. As described above, according to the first embodiment, the vibration resistance of the joint structure formed by the additional wire 30 can be improved.

Further, the additional wire 30 is fixed to the second terminal T6A, which is different from the second terminals T6A and T6B, which are welded to the additional wire 30 at the contact portion B. As a result, the number of the second terminals T6A and T6B fixed to the additional wire 30 increases, the amplitude of the additional wire 30 when the rotary electric machine 100 vibrates can be made smaller, and the vibration resistance is further improved. ..

Further, since the varnish 301 is applied to the first coil end 20a and the second coil end 20b, the rigidity of the first coil end 20a and the second coil end 20b is increased, and the vibration resistance is improved. Further, since the varnish 301 is impregnated in the slot 13, the stator core 11 and the stator winding 20 are fixed by the varnish 301, and the vibration resistance is improved.

Next, a method for manufacturing the stator 10 will be described. FIG. 16 is a flow chart showing a method for manufacturing a stator of a rotary electric machine according to the first embodiment of the present invention, and FIG. 17 is an additional line in the method for manufacturing a stator of a rotary electric machine according to the first embodiment of the present invention. FIG. 18 is a diagram illustrating an additional line fixing process in the method for manufacturing a stator of a rotary electric machine according to the first embodiment of the present invention.

First, the insulatingly coated conductor wire 19 is bent and molded to produce the first unit coil 21A and the second unit coil 21B (S100). Then, the first unit coil 21A and the second unit coil 21B are assembled to the stator core 11 (S101). In S101, the first unit coil 21A and the second unit coil 21B are arranged in an annular shape alternately in the circumferential direction at a pitch of one slot to produce the stator winding 20 shown in FIG. .. Next, each row of the first to sixth slot accommodating portions S1 to S6 in which the teeth 12b of the iron core block 12 shown in FIG. 4 are arranged in one row in the radial direction from the outer diameter side of the stator winding 20. Insert in between. As a result, 48 iron core blocks 12 are attached to the stator winding 20, and the stator winding 20 is assembled to the stator core 11.

Next, at the first coil end 20a of the stator winding 20, the first joint portions T1Ac and T1Bc of the first terminals T1A and T1B are welded to each other, and the second joint portions T6Ac and T6Bc of the second terminals T6A and T6B are welded to each other. Welding is performed, and the tip portions 32a and 32b of the additional wire 30 are welded to the second joint portions T6Ac and T6Bc of the second terminals T6A and T6B (S102). As a result, the stator winding 20 is composed of two sets of three-phase windings. Then, at the first coil end 20a of the stator winding 20, the additional wire 30 is fixed to the second terminals T6A and T6B (S103). In S103, as shown in FIGS. 17 and 18, the stator winding 20 of the stator 10 is heated to about 150 ° C., which is the curing temperature of the powder resin 310, and the first coil end 20a is heated to the epoxy in the tank 311. Immerse in a powder resin 310 containing a resin as a main component. At this time, the first coil end 20a is immersed in the powder resin 310 until the entire additional wire 30 is submerged in the powder resin 310. As a result, the powder resin 310 coats the surface of the metal in which it is immersed and is cured. As a result, the welded portions 50a between the first joint portions T1Ac and T1Bc, the welded portions 50b between the second joint portions T6Ac and T6Bc, and the welded portions 51a and 51b between the additional wire 30 and the second joint portions T6Ac and T6Bc are formed. It is insulated and coated by the first resin member 300 made of the powder resin 310. Further, the additional wire 30 is fixed to the second terminals T6A and T6B by the first resin member 300 in a state where the additional wires 30 are in contact with the second terminals T6A and T6B at the contact portions A and B. At this time, by using a fluidized dipping tank in which compressed air is sent to the inside of the powder resin 310 to suspend the powder resin 310, that is, the induced dipping method is used for forming the first resin member 300. Therefore, the thickness of the formed first resin member 300 can be made uniform. Then, the varnish 301 is applied to the first and second coil ends 20a and 20b of the stator winding 20 (S104), and the stator 10 is manufactured.

In the first embodiment, the insulating coated additional wire 30 is used, but a bare wire such as a copper wire or an aluminum wire may be used as the additional wire. Further, in the first embodiment, the additional line 30 having a rectangular cross section is used, but an additional line having a circular cross section may be used.

Here, the effect of the form of the additional line 30 will be described with reference to FIGS. 19 to 23. 19 is a front view of the addition line of the first coil end in the stator of the rotary electric machine according to the first embodiment of the present invention as viewed from the outside in the radial direction, and FIGS. 20 to 23 are A-A of FIG. A cross-sectional view taken along the arrow. 20 is a case where the additional line 30 is a bare line having a rectangular cross section, FIG. 21 is a case where the additional line 30 is a bare line having a circular cross section, and FIG. 22 is a case where the additional line 30 is a rectangular cross section. In the case of the insulated coated wire of No. 23, FIG. 23 is a case where the additional wire 30 is an insulated coated wire having a circular cross section.

As shown in FIGS. 20 and 22, the additional line 30 of the rectangular cross section is in surface contact with the flat side surface of the second hypotenuse portion T6Ab of the rectangular cross section. On the other hand, the additional line 30 having a circular cross section makes point contact with the flat side surface of the second hypotenuse portion T6Ab having a rectangular cross section, as shown in FIGS. 21 and 23. As described above, the additional line 30 having a rectangular cross section has a large contact area with the second hypotenuse T6Ab, and the fixing force between the additional line 30 and the second hypotenuse portion T6Ab can be increased. Therefore, when it is necessary to secure a fixing force between the additional line 30 and the second hypotenuse portion T6Ab, it is desirable to use the additional line 30 having a rectangular cross section. Further, if there is a margin in the fixing force between the additional line 30 and the second hypotenuse portion T6Ab, the additional line 30 having a circular cross section may be used. In this case, the additional wire 30 can be manufactured at low cost.

As shown in FIGS. 22 and 23, the conductor 30a of the additional wire 30 of the insulating coated wire is in contact with the conductor 19a of the second hypotenuse portion T6Ab via the two layers of insulating coatings 30b and 19b. On the other hand, the conductor 30a, which is the additional line 30 of the bare wire, is in contact with the conductor 19a of the second hypotenuse portion T6Ab via the one-layer insulating coating 19b, as shown in FIGS. 20 and 21. As described above, when it is necessary to secure the electrical insulation between the additional wire 30 and the second hypotenuse portion T6Ab, it is desirable to use the additional wire 30 of the insulating coated wire.

In the first embodiment, the unit coil 21 is manufactured by using the conductor wire 19 having a rectangular cross section, but the cross section of the conductor wire is not limited to a rectangle and may be circular, for example.
Further, in the first embodiment, since the additional line 30 is fixed on the flat side surface of the second hypotenuse portion T6Ab, T6Bb, the fixed area is increased, the fixing force can be increased, and the vibration resistance is improved. From this, from the viewpoint of improving vibration resistance, it is desirable that at least one cross section of the second hypotenuse portion and the additional line is rectangular.

Embodiment 2.
FIG. 24 is a front view of the stator of the rotary electric machine according to the second embodiment of the present invention as seen from the radial outside around the additional line of the coil end, and FIG. 25 is the rotary electric machine according to the second embodiment of the present invention. It is a front view which shows the additional line in the stator of.

In FIG. 25, the additional wire 40 is manufactured by bending and molding a conductor wire such as an insulatingly coated copper wire or an aluminum wire, and includes a bottom portion 41 and tip portions 42a and 42b protruding from both ends of the bottom portion 41. It is configured in a substantially U shape. The bottom portion 41 is bent by a bottom bending portion 41a at a substantially central portion in the length direction, and both sides of the bottom bending portion 41a are hypotenuse portions 41b. Further, the insulating film on the tip side of the tip portions 42a and 42b is removed.
The second embodiment is configured in the same manner as the first embodiment except that the additional wire 40 is used instead of the additional wire 30.

Also in the second embodiment, the second joint portions T6Ac and T6Bc of the second terminals T6A and T6B of the U-phase winding and the V-phase winding are overlapped with each other in the radial direction. Further, the tip portion 42a of the additional wire 40 is superposed on the second joint portion T6Ac of the U-phase winding in the circumferential direction. Then, the two second joint portions T6Ac and T6Bc and the one tip portion 42a are collectively gripped and welded by TIG welding. Then, the tip portion 42b of the additional wire 40 is superposed on the second joint portion T6Bc of the second terminal T6B of the W phase winding from the outside in the radial direction. The second joint portion T6Bc and the tip portion 42a are collectively gripped and welded by TIG welding.

At this time, the bottom portion 41 of the additional line 40 is bent by the bottom bent portion 41a so that the hypotenuse portion 41b is along the second hypotenuse portion T6Ab of the second terminal T6A. As a result, as shown in FIG. 24, the hypotenuse portion 41b of the additional line 40 and the second hypotenuse portion T6Ab of the second terminal T6A come into surface contact with each other at the contact portion B. Further, the tip portion 42a of the additional line 40 is in contact with the second junction portion T6Bc of the second terminal T6B at the contact portion A, and the hypotenuse portion 41b of the bottom portion 41 is in contact with the second hypotenuse portion T6Bb of the second terminal T6B at the contact portion C. Contact.

As described above, according to the second embodiment, the additional wire 40 is in contact with the second terminals T6A and T6B at the three contact portions A, B, and C, and the second terminal is formed by the first resin member 300. It is fixed to T6A and T6B. Further, since the additional wire 40 and the second terminal T6A are in surface contact with each other at the contact portion B, the contact area between the additional wire 40 and the second terminal T6A can be increased. As a result, the fixing force between the additional wire 40 and the second terminal T6A can be increased without providing a special fixing member, and the vibration resistance can be further improved.

Here, in each embodiment, the case where the three-phase windings are star-connected by using the additional wires 30 and 40 is described, but the first phase winding is configured by using the additional wires 30 and 40. The unit coil 21A and the second unit coil 21B may be connected. FIG. 26 is a front view of the stator of the rotary electric machine according to the embodiment of the present invention as seen from the outside in the radial direction around the additional line of the coil end.

As shown in FIG. 26, the second joint portion T6Ac of the U-phase second terminal T6A and the tip portion 32a of the additional wire 30 are radially overlapped and welded by TIG welding. Further, the second joint portion T6Bc of the U-phase second terminal T6B and the tip portion 32b of the additional wire 30 are radially overlapped and welded by TIG welding. As a result, the U-phase second terminals T6A and T6B are connected. At this time, the additional line 30 is in contact with the second hypotenuse portion T6Ab of the second terminal T6A, which is different from the second terminal T6A welded to the additional line 30, at the contact portions A and B.

In this way, even when connecting the unit coil of the same phase using the additional wire 30, the welded portion between the additional wire and the unit coil is insulated and coated with the first resin member, and the coil end is impregnated with varnish and cured. As a result, the same effect as that of each of the above embodiments can be obtained.

In each embodiment, the stator winding 20 is configured by using the unit coil 21, but the unit coil is not limited to the unit coil 21, and is a hexagonal coil, a wave winding coil, or a U-shaped coil. A segment coil can be used.
Further, in each of the above embodiments, the stator 10 is configured with 48 slots and 8 poles, but the number of slots and the number of poles are not limited thereto. Further, the stator 10 has 2 slots per pole and each phase, but the number of slots per pole and each phase is not limited to 2, and may be 1, for example.

11 Stator core, 13 slots, 20 stator windings, 20a 1st coil end, 20b 2nd coil end, 21 unit coil, 21A 1st unit coil, 21B 2nd unit coil, 30, 40 additional wire, 41b hypotenuse Part, 300 1st resin member, 301 varnish (2nd resin member), A, B, C contact part, T1A, T1B 1st terminal, T1Ab, T1Bb 1st hypotenuse part, T1Ac, T1Bc 1st joint part, T6A, T6B second terminal, T6Ab, T6Bb second hypotenuse, TA6c, T6Bc second junction.

Claims (9)

An annular stator core with multiple slots formed in the circumferential direction,
In a stator winding of a rotary electric machine comprising a stator winding having a plurality of unit coils inserted and arranged in the slot.
Each of the plurality of unit coils has a terminal protruding from the slot and has a terminal.
The terminal has a hypotenuse portion that protrudes from the slot and is inclined and extends in the circumferential direction, and a joint portion that extends axially from the hypotenuse portion.
The stator winding is configured by welding the joints of the plurality of unit coils to each other.
The first resin member is coated on each of the welded portions of the joint portions.
The second resin member is impregnated and cured in the coil end made of the terminal of the plurality of unit coils.
It has an additional wire of a member different from the unit coil that connects the joints to each other.
The additional line is in contact with the hypotenuse at the first contact portion and the second contact portion.
The hypotenuse portion has a rectangular cross section and has a rectangular cross section.
In the first contact portion, the additional wire is in contact with the radial side surface of the stator core in the hypotenuse portion.
In the second contact portion, the additional line is in contact with the side surface of the hypotenuse portion facing in a direction different from the radial direction.
The stator of a rotary electric machine in which the additional wire is fixed to the hypotenuse portion by the first resin member. An annular stator core with multiple slots formed in the circumferential direction,
In a stator winding of a rotary electric machine comprising a stator winding having a plurality of unit coils inserted and arranged in the slot.
Each of the plurality of unit coils has a terminal protruding from the slot and has a terminal.
The terminal has a hypotenuse portion that protrudes from the slot and is inclined and extends in the circumferential direction, and a joint portion that extends axially from the hypotenuse portion.
The stator winding is configured by welding the joints of the plurality of unit coils to each other.
The first resin member is coated on each of the welded portions of the joint portions.
The second resin member is impregnated and cured in the coil end made of the terminal of the plurality of unit coils.
It has an additional wire of a member different from the unit coil that connects the joints to each other.
The additional wire is fixed to the hypotenuse portion by the first resin member .
The additional line is a stator of a rotary electric machine having an additional line hypotenuse along the hypotenuse . Claim 1 or claim that the additional line is in contact with the hypotenuse portion at two or more contact portions, and is fixed to the hypotenuse portion at the two or more contact portions by the first resin member. Item 2. The stator of the rotary electric machine according to Item 2. The stator of the rotary electric machine according to any one of claims 1 to 3, wherein the additional wire is completely covered with the first resin member. The unit coil has a rectangular cross section and has a rectangular cross section.
The stator of the rotary electric machine according to any one of claims 1 to 4 , wherein the additional wire is fixed to the flat side surface of the hypotenuse portion. The additional line is a rectangular cross section and has a rectangular cross section.
The stator of the rotary electric machine according to any one of claims 1 to 5 , wherein the hypotenuse portion is fixed to the flat side surface of the additional wire. The stator of the rotary electric machine according to any one of claims 1 to 6 , wherein the additional wire is covered with an insulating film except for a region to be welded to the joint portion. The stator of the rotary electric machine according to any one of claims 1 to 7, wherein the hypotenuse portion to which the additional wire is fixed is a hypotenuse portion of a terminal different from the terminal to which the additional wire is welded. The method for manufacturing a stator of a rotary electric machine according to any one of claims 1 to 8.
The unit coil manufacturing process for manufacturing the above-mentioned multiple unit coils, and
In the coil / core assembly process in which the plurality of unit coils are inserted and placed in the stator core,
A coil welding process for welding the joints of the plurality of unit coils, and the additional wire and the joints,
An additional wire fixing step of covering the welded portion with the first resin member and fixing the additional wire to the hypotenuse portion.
The second resin member coating step of applying the second resin member to the coil end, and
A method for manufacturing a stator of a rotary electric machine.

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