JPWO2020195580A1 - Rotating electric machine and its stator - Google Patents

Abstract

The stator (31) of the rotary electric machine includes a plurality of leader wires (43, 44). The leader wire (43, 44) is joined to the electrode (51, 52). The plurality of leaders (43, 44) are loosely wound. The plurality of leader wires (43, 44) are arranged so as to be aerial wiring between the plurality of single coils (41). The third portion (44c) of the leader wire (44) is in contact with the single coil (41) only at the contact portion (44e). As a result, the situation where the liquid adhering to the plurality of leader lines (43, 44) becomes a liquid film and accumulates for a long period of time is suppressed.

Description

Cross-reference of related applications

This application is based on Patent Application No. 2019-57168 filed in Japan on March 25, 2019, and the content of the basic application is incorporated by reference in its entirety.

The disclosure in this specification relates to a rotary electric machine and its stator.

Patent Document 1 discloses a rotary electric machine and a method for manufacturing the rotary electric machine. The contents of the prior art documents listed as prior art are incorporated by reference as an explanation of the technical elements in this specification.

International Publication No. 2018/221565 Pamphlet

Foreign matter may adhere to the rotary electric machine. The foreign matter may be a solid or a liquid. Foreign matter includes electrical conductor pieces or electrolytes. Foreign matter can cause unexpected electrical conduction or corrosion of members. Further improvements are required in the rotary electric machine and its stator in the above-mentioned viewpoint or in other viewpoints not mentioned.

One object disclosed is to provide a rotary electric machine, and a stator thereof, which are less likely to collect foreign matter.

The stator of a rotary electric machine disclosed herein includes a stator core that provides a plurality of magnetic poles, a stator coil mounted on the stator core, and an insulator as an electrically insulating member arranged between the stator core and the stator coil. The stator coil is a plurality of single coils mounted on magnetic poles, a plurality of crossovers connecting the plurality of single coils, and a leader wire providing both ends of the stator coil, and is the innermost radial inside of the plurality of single coils. It is provided with a plurality of leader lines arranged via the outer side in the radial direction from the portion.

According to the stator of the rotating electric machine disclosed, the plurality of leaders are intentionally arranged radially outside the minimum radius without passing through the minimum radius. Therefore, even if the liquid adheres to the plurality of leader wires, the situation where a liquid film is formed between the plurality of leader wires and other members is suppressed. As a result, a stator of a rotary electric machine in which foreign matter is less likely to collect is provided.

The rotary electric machine disclosed herein includes the above-mentioned stator and a rotor that provides a rotating magnetic field to the stator. According to the disclosed rotary electric machine stator, a rotary electric machine in which foreign matter is less likely to accumulate is provided.

The disclosed aspects herein employ different technical means to achieve their respective objectives. The claims and the reference numerals in parentheses described in this section exemplify the correspondence with the parts of the embodiments described later, and are not intended to limit the technical scope. The objectives, features, and effects disclosed herein will be made clearer by reference to the subsequent detailed description and accompanying drawings.

It is sectional drawing of the rotary electric machine which concerns on 1st Embodiment. It is a circuit diagram which shows the stator coil. It is a top view which shows the 2nd side surface of a stator. It is a perspective view which shows the 2nd side surface of a stator. It is a top view which shows the 1st side surface of a stator. It is a perspective view which shows the 1st side surface of a stator. It is a perspective view which shows the 1st side surface of a stator. It is a partial cross-sectional view which shows the stator. It is a partial cross-sectional view which shows the stator. It is a perspective view which shows the 1st side surface of the stator excluding a coil. It is a side view which shows the stator excluding a coil. It is sectional drawing which shows the stator excluding the coil. It is a partially enlarged sectional view which shows a leader line. It is a partially enlarged perspective view which shows the stator. It is a partially enlarged perspective view which shows the stator. It is a flowchart which shows the manufacturing method of a rotary electric machine. It is a top view which shows the stator which concerns on 2nd Embodiment. It is a perspective view which shows the stator.

A plurality of embodiments will be described with reference to the drawings. In a plurality of embodiments, functionally and / or structurally corresponding parts and / or related parts may be designated with the same reference code or reference codes having a hundreds or more different digits. For the corresponding and / or associated part, the description of other embodiments can be referred to.

1st Embodiment In FIG. 1, a rotary electric machine for an internal combustion engine (hereinafter, simply referred to as a rotary electric machine) 10 is also referred to as a generator motor or an AC generator starter. The rotary electric machine 10 is electrically connected to an electric circuit 11 including an inverter circuit (INV) and a control device (ECU). The electric circuit 11 provides a three-phase power conversion circuit. An example of the use of the rotary electric machine 10 is a generator motor of an internal combustion engine 12 for a vehicle. Vehicles are vehicles, ships, aircraft, amusement equipment, or simulation equipment. A typical example of a vehicle is a saddle-riding vehicle.

The electric circuit 11 provides a rectifying circuit that rectifies the output AC power when the rotary electric machine 10 functions as a generator and supplies power to an electric load including a battery. The electric circuit 11 provides a signal processing circuit that receives a reference position signal for ignition control supplied from the rotary electric machine 10. The electrical circuit 11 may provide an ignition controller that performs ignition control.

The electric circuit 11 provides a drive circuit that causes the rotary electric machine 10 to function as an electric motor. The electric circuit 11 receives a rotation position signal from the rotary electric machine 10 for causing the rotary electric machine 10 to function as an electric machine. The electric circuit 11 causes the rotary electric machine 10 to function as an electric motor by controlling the energization of the rotary electric machine 10 according to the detected rotation position.

The rotary electric machine 10 is assembled to the internal combustion engine 12. The internal combustion engine 12 has a body 13 and a rotating shaft 14 that is rotatably supported by the body 13 and rotates in conjunction with the internal combustion engine 12. The rotary electric machine 10 is assembled to the body 13 and the rotary shaft 14 to be attached. The body 13 is a structure such as a crankcase and a mission case of the internal combustion engine 12. The rotary shaft 14 is a crank shaft of the internal combustion engine 12, or a rotary shaft that is interlocked with the crank shaft. The rotating shaft 14 rotates when the internal combustion engine 12 is operated.

The rotary shaft 14 rotates the rotary electric machine 10 so that the rotary electric machine 10 functions as a generator. The rotating shaft 14 is a rotating shaft capable of starting the internal combustion engine 12 by the rotation of the rotating electric machine 10 when the rotating electric machine 10 functions as an electric machine. Further, the rotary shaft 14 is a rotary shaft capable of assisting the rotation of the internal combustion engine 12 by the rotation of the rotary electric machine 10 when the rotary electric machine 10 functions as an electric motor.

The rotary electric machine 10 has a rotor 21, a stator 31, and a sensor unit 37. In the following description, the term axial AD means the direction of the central axis when the stator 31 is regarded as a cylinder. The term RD in the radial direction means the radial direction when the stator 31 is regarded as a cylindrical body. The term CD in the circumferential direction means the circumferential direction when the stator 31 is regarded as a cylindrical body.

The rotor 21 is a field magnet. The stator 31 is an armature. The rotor 21 has a cup shape as a whole. The rotor 21 is positioned with its open end facing the body 13. The rotor 21 is fixed to the end of the rotating shaft 14. The rotor 21 and the rotating shaft 14 are connected via a positioning mechanism in the rotating direction such as key fitting. The rotor 21 is fixed by being tightened to the rotating shaft 14 by the fixing bolt 25. The rotor 21 rotates together with the rotating shaft 14. The rotor 21 provides a field, that is, a rotating field, by means of a permanent magnet.

The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 is connected to the rotating shaft 14 of the internal combustion engine 12. The rotor core 22 has an inner cylinder fixed to the rotating shaft 14, an outer cylinder located radially outside the inner cylinder, and an annular bottom plate extending between the inner cylinder and the outer cylinder. The rotor core 22 provides a yoke for a permanent magnet, which will be described later. The rotor core 22 is made of magnetic metal.

The rotor 21 has a permanent magnet 23 arranged on the inner surface of the rotor core 22. The permanent magnet 23 is fixed to the inside of the outer cylinder. The permanent magnet 23 is fixed with respect to the axial AD and the radial RD by the holding cup 24 arranged radially inside. The holding cup 24 is made of a thin non-magnetic metal. The holding cup 24 is fixed to the rotor core 22.

The permanent magnet 23 has a plurality of segments. Each segment is partially cylindrical. The permanent magnet 23 provides a plurality of N poles and a plurality of S poles inside the permanent magnet 23. The permanent magnet 23 provides at least a field magnet. The permanent magnet 23 provides a field of 6 pairs of N and S poles, that is, 12 poles, by 12 segments. The number of magnetic poles may be another number. The permanent magnet 23 provides a partial special magnetic pole to provide a reference position signal for ignition control. The special poles are provided by partial poles that are different from the pole arrangement for the field. As a result, the rotor 21 provides the stator 31 with a rotating magnetic field.

The stator 31 and the body 13 are connected via fixing bolts 34. The stator 31 is fixed by being tightened to the body 13 by a plurality of fixing bolts 34. The stator 31 is arranged between the rotor 21 and the body 13. The stator 31 has a virtual outer peripheral surface that faces the inner surface of the rotor 21 via a gap. The virtual outer peripheral surface is provided by a plurality of magnetic poles 35. The stator 31 is fixed to the body 13.

The stator 31 has a stator core 32. The stator core 32 has a first end surface SD1, a second end surface SD2 on the opposite side of the first end surface SD1, and an outer peripheral surface. The stator core 32 is arranged inside the rotor 21 by being fixed to the body 13 of the internal combustion engine 12. The stator core 32 has a plurality of tooth portions. One teeth portion provides one magnetic pole 35. The stator core 32 provides a plurality of magnetic poles 35. The stator core 32 provides an outer salient pole type iron core.

The stator 31 has a stator coil 33 mounted on the stator core 32. The stator coil 33 provides an armature winding. An insulator 36 is arranged between the stator core 32 and the stator coil 33. The insulator 36 is an electrically insulating member. The insulator 36 is made of an electrically insulating resin. The stator coil 33 is a three-phase winding. The stator coil 33 can selectively function the rotor 21 and the stator 31 as a generator or a motor.

The sensor unit 37 provides a rotation position detecting device for an internal combustion engine. The sensor unit 37 is provided in the rotary electric machine 10 interlocked with the internal combustion engine 12. The sensor unit 37 is provided on the stator 31. The sensor unit 37 is provided on the stator core 32 of the rotary electric machine 10. The sensor unit 37 is fixed to the first end surface SD1 of the stator core 32 by fixing bolts 39. The fixing bolt 39 penetrates from the second end surface SD2 toward the first end surface SD1. The sensor unit 37 includes a plurality of sensors 38. One sensor 38 provides a sensor for ignition control. At least one of the plurality of sensors 38 detects the rotational position of the rotor 21 for causing the rotary electric machine 10 to function as at least an electric motor. The sensor unit 37 positions the sensor 38 between the two magnetic poles 35.

The sensor unit 37 has wiring 15 for external connection for extracting signals output from one or more sensors 38 to the outside. The wiring 15 can transmit an ignition signal indicating a reference position and / or a rotation position signal indicating a rotation angle. The rotary electric machine 10 has a plurality of power lines 16 that connect the stator coil 33 and the electric circuit 11. The power line 16 is provided by a flexible cable. The power line 16 supplies the electric power induced in the stator coil 33 to the electric circuit 11 when the rotary electric machine 10 functions as a generator. The power line 16 supplies electric power for exciting the stator coil 33 from the electric circuit 11 to the stator coil 33 when the rotary electric machine 10 functions as an electric motor.

In FIG. 2, the stator coil 33 is multi-phase connected. The stator coil 33 provides a three-phase winding. The stator coil 33 may be a 5-phase winding, a 7-phase winding, or two sets of three-phase windings. The stator coil 33 is star-connected. The stator coil 33 may be ring-connected. The stator coil 33 has a plurality of phase windings 33u, 33v, 33w. The plurality of phase windings 33u, 33v, 33w are similar.

The phase winding 33u will be described as a typical example. The phase winding 33u has a plurality of single coils 41. The single coil 41 is mounted on one magnetic pole 35. The phase winding 33u has a crossover 42 extending between the single coil 41 and the single coil 41. The phase winding 33u has a plurality of crossovers 42. The plurality of crossovers 42 connect a plurality of single coils 41. The crossover line 42 is laid between the single coil 41 and the single coil 41 along the circumferential direction CD of the stator core 32. The crossover wire 42 is provided by the same wire as the wire forming the single coil 41.

The phase winding 33u has a leader wire 43 and a leader wire 44. Leaders 43 and 44 are arranged at both ends of the phase winding 33u, respectively. Therefore, the leader wires 43 and 44 provide both ends of the stator coil 33. The leader line 43 provides a leader line 43 for neutral point connection. The leader line 44 provides a leader line 44 for the power end. The leader wires 43 and 44 are provided by the same strands as the strands forming the single coil 41. The single coil 41, the crossover wire 42, and the leader wires 43, 44 are provided by continuous strands.

The stator coil 33 includes a plurality of electrodes 51, 52 to provide electrical connectivity. One electrode 51 provides an electrode 51 for neutral point connection. The electrode 51 is fixed to the stator 31. The electrode 51 is joined to a plurality of leader wires 43. The electrode 51 has a plurality of terminals to which a leader wire 43 is connected to each of the electrodes 51. One electrode 52 provides a plurality of electrodes 52 for the power end. The electrode 52 provides a connection between the leader line 44 and the power line 16. The electrode 52 is fixed to the stator 31. The electrode 52 penetrates the stator 31. The electrode 52 is connected to the leader line 44 at the second end surface SD2. The electrode 52 is connected to the power line 16 at the first end surface SD1.

The stator coil 33 is made of conductor metal. The strand of the single coil 41 is a conductor wire having a round cross section. The strand may be a conductor wire having a quadrilateral cross section or a flat cross section. The strands are covered with a resin coating film. The strands are made of aluminum or aluminum alloy. The wire may be made of copper. The plurality of electrodes 51 and 52 are made of iron alloy. The plurality of electrodes 51, 52 can be provided by various conductor metals such as brass and copper.

The wire conductor metal may be exposed due to scratches on the coating film or pinholes on the coating film. The strands are repeatedly bent in the winding process. In the winding process, the crossover wire 42 and the leader wires 43, 44 are given a bending shape different from that of the single coil 41. Therefore, the crossover line 42 and the leader lines 43 and 44 are easily damaged by the coating film. Further, the pinholes of the crossover lines 42 and the leader lines 43 and 44 are likely to be enlarged.

The foreign matter adhering to the rotary electric machine 10 may be an electrolytic solution. The salt contained in seawater or the snow melting agent forms an electrolytic solution such as a sodium chloride solution. The electrolyte may promote electrolysis of metallic materials, including aluminum. When a rotary electric machine is used in an environment where an electrolytic solution is present, it is desirable to suppress electrolytic corrosion.

Further, when the electrolytic solution adheres to the exposed portion of the wire, the metal of the wire may undergo electrolytic corrosion. When the wire is made of aluminum or an aluminum alloy, electrolytic corrosion becomes remarkable. This embodiment provides a rotary electric machine in which an electrolytic solution is less likely to accumulate, a stator of the rotary electric machine, and a method for manufacturing the same. In this embodiment, a rotary electric machine, a stator of the rotary electric machine, and a method for manufacturing the same are provided on the crossover wire 42 and / or the leader wires 43 and 44. The shape in which the electrolytic solution does not easily accumulate is also a shape in which the electrolytic solution easily flows away or a shape in which the electrolytic solution does not easily form a liquid film.

In FIG. 3, the second end surface SD2 of the stator 31 is shown. The second end face SD2 is an end face facing the rotor 21. The stator coil 33 is three-phase connected at the second end surface SD2. The stator coil 33 has a plurality of leader wires 43 and a plurality of leader wires 44. This embodiment includes three leaders 43 and three leaders 44. The three leader wires 43 are connected to the electrodes 51 in the joining container 56. The joining container 56 includes a peripheral wall member surrounding the electrode 51 and a sealing resin covering the electrode 51. Each of the three leaders 44 is connected to each of the three electrodes 52 in the junction vessel 57. The joining container 57 includes a peripheral wall member that surrounds the plurality of electrodes 52, and a sealing resin that covers the plurality of electrodes 52. Hereinafter, a detailed description is provided focusing on one of the three phase windings. Each of the three phase windings has the shape described.

The single coil 41s indicates a single coil 41s at the start of winding. The wire at the beginning of winding drawn from the single coil 41s provides a leader wire 43. The leader line 43 is also referred to as a first leader line 43. The winding start is located at the innermost radial portion of the single coil 41s. The leader wire 43 is arranged via the outermost side of the innermost radial direction of the single coil 41s at the start of winding. The leader wire 43 is led out from the innermost radial inner portion of the plurality of single coils 41 to the second end surface SD2 via the radial outer side. The leader line 43 is drawn into the joining container 56 at the second end surface SD2. In other words, the leader wire 43 is loosely wound around the other components between the single coil 41s and the joining vessel 56 so as to go through a path longer than the shortest path. As a result, the contact surface between the leader wire 43 and the other member is suppressed. Other members include a single coil 41, a crossover 42, and an insulator 36. As a result, even if the electrolytic solution adheres, it is suppressed that the electrolytic solution becomes a liquid film and accumulates for a long period of time. In other words, the leader wire 43 is arranged as an aerial wiring in at least a part in the length direction between the plurality of single coils 41. As a result, electrolytic corrosion in the leader line 43 is suppressed. The leader wire 43 may be in contact with the single coil 41 in a part in the length direction.

The single coil 41e indicates a single coil 41e at the end of winding. The end-of-winding strand drawn from the single coil 41e provides a leader 44. The leader line 44 is also referred to as a second leader line 44. The end of winding is located at the radial intermediate portion of the single coil 41e. The leader line 44 is drawn out to the second end surface SD2 again after being arranged on the first end surface SD1 from the end of winding. In the first end surface SD1, the leader line 44 is laid so as to return by approximately one pitch (distance between the three magnetic poles) along the circumferential direction CD of the stator 31. The leader wire 44 is arranged via the outermost side of the single coil 41e at the end of winding in the radial direction. The leader wire 44 is led out from the innermost radial inner portion of the plurality of single coils 41 to the second end surface SD2 via the radial outer side. The leader line 44 is drawn into the joining container 57 at the second end surface SD2. In other words, the leader line 44 is loosely wound around the other components between the single coil 41e and the joining container 56 so as to go through a path longer than the shortest path. As a result, the contact surface between the leader wire 44 and the other member is suppressed. As a result, even if the electrolytic solution adheres, it is suppressed that the electrolytic solution becomes a liquid film and accumulates for a long period of time. In other words, the leader line 44 is arranged as an aerial wiring in at least a part in the length direction between the plurality of single coils 41. As a result, electrolytic corrosion in the leader line 44 is suppressed. The leader line 44 may be in contact with the single coil 41 in a part in the length direction.

In this embodiment, a series of single strands are wound from the first leader wire 43 to the second leader wire 44. Instead of this, a plurality of strands arranged in parallel may be wound from the first leader wire 43 to the second leader wire 44. Further, there may be a joint between the first leader line 43 and the second leader line 44.

In this embodiment, the second leader line 44 is longer than the first leader line 43. The second leader line 44 passes radially outside the first leader line 43. Alternatively, the first leader line 43 may be longer than the second leader line 44. Alternatively, the first leader line 43 may pass radially outside the second leader line 44. That is, the first leader line 43 and the second leader line 44 can have different lengths. Further, the first leader line 43 and the second leader line 44 can pass through different radial positions. Instead, the first leader line 43 and the second leader line 44 may have the same length. Alternatively, the first leader line 43 and the second leader line 44 may pass through the same position in the radial direction.

The leader line 44 is arranged so as to be entwined with one or more single coils 41. The leader line 44 is arranged so as to be entangled over three single coils 41. In other words, the leader line 44 extends toward one of the circumferential CDs at the first end face SD1 and extends toward the other of the circumferential CDs at the second end face SD2. The leader line 44 has a first portion 44a, a second portion 44b, a third portion 44c, and a fourth portion 44d.

The first portion 44a is arranged so as to penetrate in the slot between the plurality of magnetic poles 35 in the axial direction AD from the end of winding of the single coil 41e on the second end surface SD2. The first portion 44a is arranged so as to pass through the inner side in the radial direction from the end of winding of the single coil 41e. The first portion 44a is arranged between the second end surface SD2 and the first end surface SD1 via the gap between the single coil 41e and the adjacent single coil 41. The first portion 44a is also referred to as an axial penetration portion.

The second portion 44b is arranged along the circumferential direction CD in the first end surface SD1. The second portion 44b is arranged for one pitch, that is, over a distance of three single coils 41. The second portion 44b extends in the circumferential direction CD between the first portion 44a and the third portion 44c. The second portion 44b also changes in the radial direction between the first portion 44a and the third portion 44c. The second portion 44b is also referred to as a circumferentially extending portion.

The third portion 44c is arranged between the first end face SD1 and the second end face SD2 via a gap between two adjacent single coils 41. The third portion 44c is arranged radially outside the innermost radial inner portion of the plurality of single coils 41. The third portion 44c is located between the plurality of single coils 41. The third portion 44c is located at the radial intermediate portion of the single coil 41 corresponding to the end of winding of the single coil 41e. The third portion 44c is also referred to as an axial penetration portion.

The fourth portion 44d extends between the radial intermediate portion of the single coil 41 and the joining vessel 57. The fourth portion 44d extends substantially straight. The fourth portion 44d is arranged along the circumferential direction CD in the second end surface SD2. The fourth portion 44d extends in the opposite direction to the second portion 44b. The fourth portion 44d is also referred to as an introduction portion introduced into the joining container 57.

The leader wire 44 is in contact with the single coil 41, the crossover wire 42, and the other leader wire 44 in the first portion 44a and the second portion 44b. The leader wire 44 is tightly wound around the single coil 41 and the crossover wire 42 arranged in the path in the first portion 44a and the second portion 44b. The leader line 44 is arranged at the third portion 44c and the fourth portion 44d away from the other members. The leader line 44 is intentionally loosely wound in the third portion 44c and the fourth portion 44d so as to be intentionally slackened. The third portion 44c and the fourth portion 44d are arranged like aerial wiring. The third portion 44c and the fourth portion 44d suppress the formation of a liquid film by the electrolytic solution by separating from the other members. As a result, the electrolytic solution easily flows away. Further, the third portion 44c and the fourth portion 44d allow fine adjustment of the leader line 44 in the joining container 57. By bending the third portion 44c, the fourth portion 44d can move back and forth in the axial direction of the fourth portion 44d. The movable distance of the fourth portion 44d extends over a range of several millimeters (0.1 mm or more and 5 mm or less) along the axial direction of the fourth portion 44d. The movable distance of the fourth portion 44d can be adjusted so as to cover a range of a maximum of a dozen millimeters (0.1 mm or more and 20 mm or less).

The leader line 44 may include a contact portion 44e at the third portion 44c. The contact portion 44e is also a portion that is inevitably generated. The contact portion 44e is a contact portion between the third portion 44c and the single coil 41.

In FIG. 4, three leader lines 44 are illustrated. One leader line 44 in the center is partially illustrated by a dashed line. Many parts of the first portion 44a are illustrated by broken lines.

In FIG. 5, the first end surface SD1 of the stator 31 is shown. The first end face SD1 is an end face facing the body 13. The stator 31 has all crossovers 42 on the first end face SD1. The intensive arrangement of the crossovers 42 on the first end surface SD1 contributes to suppressing the gap between the rotor 21 and the stator 31.

The insulator 36 has at least one radial guide plate 67, 68, 69. The radial guide plates 67, 68, and 69 are plate-shaped members that extend in the radial direction. The radial guide plates 67, 68, 69 are used to guide a plurality of crossovers 42. This embodiment has three radial guide plates 67, 68, 69. The radial guide plates 67, 68, and 69 are integrally molded with the insulator 36 by a continuous resin material. The radial guide plates 67, 68, 69 provide a reference plane for laying the crossover 42 along the circumferential CD. The crossover 42 is arranged radially outside the radial guide plates 67, 68, 69. The radial guide plates 67, 68, and 69 are plate-shaped protrusions extending along the radial RD. The radial guide plates 67, 68, 69 are also referred to as positioning members. The radial guide plates 68 and 69 are positioned on both sides of the sensor unit 37 in the circumferential direction. As a result, the radial guide plates 68 and 69 position a plurality of crossovers 42 between the sensor unit 37 and the plurality of single coils 41. The radial guide plates 67, 68, and 69 prevent the crossover wire 42 from invading inward in the radial direction.

The radial guide plates 67, 68, and 69 are plate-shaped with a thin thickness along the circumferential CD. Moreover, the radial guide plates 67, 68, and 69 extend in the radial RD with a long length. The circumferential thickness of the radial guide plates 67, 68, 69 is smaller than the radial length. Therefore, the radial guide plates 67, 68, and 69 are likely to discharge foreign matter. For example, even if a liquid foreign substance adheres to the radial guide plates 67, 68, 69, the liquid easily flows away in the radial RD. When the crossover wire 42 and the radial guide plates 67, 68, 69 are in contact with each other, the liquid foreign matter adhering to the crossover wire 42 travels along the radial guide plates 67, 68, 69 and easily flows away. In particular, when the radial guide plates 67, 68, 69 are arranged so as to spread in the direction of gravity, the discharge of the liquid is promoted by gravity.

The stator coil 33 is connected to the power line 16 at the first end surface SD1. In the figure, one power line 16 is illustrated by a broken line. The power line 16 is arranged so as to be curved along the stator 31. The power line 16 is connected to the electrode 52 at one end. The connection between the power line 16 and the electrode 52 is provided by soldering. The connection between the power line 16 and the electrode 52 can be provided by various methods such as mechanical caulking and welding.

The stator 31 has a holder 61 for holding the power line 16. The holder 61 is made of metal. The holder 61 is fixed to the stator 31. The holder 61 is fixed to the first end surface SD1. The holder 61 is fixed by being press-fitted into the stator core 32. The holder 61 holds the power line 16 at a specified position. The holder 61 has an arm portion 62 extending in the radial direction RD along the stator coil 33. The holder 61 has a press-fitting portion 63 that is press-fitted into the stator core 32 or the insulator 36.

The insulator 36 provides a bobbin for winding the stator coil 33 on the outer side in the radial direction. Further, the insulator 36 has a plate-like portion that extends in a radial direction along the end surface of the stator core 32 toward the mounting surface 32a with the body 13. The plate-shaped portion covers the range from the bobbin portion that wraps the plurality of magnetic poles 35 to the boundary line of the mounting surface 32a of the stator core 32. The mounting surface 32a is a petal-shaped surface including three bolt through holes. The radial inner edge of the insulator 36 extends to the vicinity of the mounting surface 32a. The plate-like portion of the insulator 36 provides the creepage distance of the electrically insulating member between the stator core 32 and the stator coil 33. The insulator 36 contributes to increase the creepage distance.

In FIG. 6, the holder 61 is press-fitted into the stator core 32 at the press-fitting portion 63. The insulator 36 has a cylindrical cover 64 that extends along the axial direction to receive the press-fitting portion 63. The tubular cover 64 covers the surface of the press-fitting portion 63 at the end surface of the stator core 32. The insulator 36 extends in a plate shape on the inner side in the radial direction from the cylindrical cover 64.

The adhesive resin 71 adheres the crossover wire 42 to the insulator 36. The adhesive resin 71 adheres a plurality of crossovers 42 passing through the radial outer side of the radial guide plate 67 to the radial guide plate 67. The adhesive resin 71 exists so as to bridge between the plurality of crossover wires 42 and the radial guide plate 67. The adhesive resin 71 functions as a member for fixing the plurality of crossover wires 42. As a result, damage to the plurality of crossovers 42 in the vicinity of the radial guide plate 67 is suppressed. Further, the adhesive resin 71 functions as a cover member that covers the plurality of crossover wires 42. As a result, the plurality of crossovers 42 are protected. Even if the plurality of crossovers 42 have scratches on the coating film or pinholes on the coating film, the adhesive resin 71 covers the scratches or pinholes. As a result, the plurality of crossovers 42 are protected from foreign matter adhering to the vicinity of the radial guide plate 67. The adhesive resin 71 protects the plurality of crossovers 42 from, for example, the electrolytic solution adhering to the vicinity of the radial guide plates 67, 68, 69.

In FIG. 7, the adhesive resin 71 is shown. A part of the covered crossover line 42 protrudes from the adhesive resin 71. The plurality of crossovers 42 pass through a gap between the sensor unit 37 and the plurality of single coils 41. The plurality of crossovers 42 are positioned on the radial outer side of the radial guide plate 69.

The tubular cover 64 extends from the insulator 36 along the press-fitting portion 63 in the axial direction AD of the stator 31. The tubular cover 64 is a part of the insulator 36. The tubular cover 64 provides the creepage distance of the electrically insulating member between the plurality of crossovers 42 and the holder 61. The tubular cover 64 contributes to increasing the creepage distance. Further, the insulator 36 includes an eaves portion 65 extending radially outward from the top of the tubular cover 64. The eaves 65 extends along the arms 62. The eaves portion 65 extends between the stator coil 33 and the arm portion 62. The eaves portion 65 suppresses direct contact between the plurality of single coils 41 and the plurality of crossovers 42 and the arm portion 62. When the arm portion 62 is deformed, the eaves portion 65 may come into contact with the plurality of single coils 41 and the plurality of crossover wires 42. Again, the eaves 65 provides electrical insulation between the plurality of single coils 41 and the plurality of crossovers 42 and the arm 62. Further, the eaves portion 65 provides a creepage distance of the electrically insulating member between the plurality of crossovers 42 and the holder 61. The insulator 36 extends in a radial direction from the cylindrical cover 64 and the radial guide plate 67 in a plate shape.

FIG. 8 shows a cross section taken along line VIII-VIII of FIG. FIG. 9 shows a cross section taken along line IX-IX of FIG. The adhesive resin 71 forms a resin block between the plurality of crossover wires 42 and the radial guide plate 67. The adhesive resin 71 fixes a plurality of crossover wires 42 to the radial guide plate 67. The radial guide plate 67 also functions as a target for applying the adhesive resin 71. The insulator 36 extends in a plate shape on the inner side in the radial direction from the radial guide plate 67.

FIG. 10 shows a perspective view of the stator 31 excluding the stator coil 33. FIG. 11 shows a side view of the stator 31 excluding the stator coil 33. The adhesive resin 71 has traces of a plurality of single coils 41 and traces of a plurality of crossover wires 42. The eaves portion 65 is in contact with the arm portion 62. The eaves 65 extends along the arms 62.

In FIGS. 10 and 11, the stator core 32 has an enlarged portion 35a enlarged in the circumferential direction at the radial outer end of the magnetic pole 35. The insulator 36 covers the circumferential end face of the enlarged portion 35a at many magnetic poles 35. The peripheral end faces of some of the magnetic poles 35 are exposed. The insulator 36 suppresses the exposed area of many magnetic poles 35 by covering the peripheral end surface of the enlarged portion 35a. As a result, the intrusion of foreign matter including liquid between the stator core 32 and the insulator 36 is suppressed. Further, the probability that the electrolytic solution adheres to both the wire and the stator core 32 is suppressed.

FIG. 12 shows a cross section passing through the adhesive resin 71 in FIGS. 10 and 11. The adhesive resin 71 has cavities as traces of the plurality of crossover lines 42. The insulator 36 has an axial half portion 36a and an axial half portion 36b. The insulator 36 encloses the stator core 32 at the magnetic pole 35 by the axial half portion 36a and the axial half portion 36b. The axial half portion 36a and the axial half portion 36b are butted on the mating surface 36c without a gap. The insulator 36 provides electrical insulation between the stator core 32 and the stator coil 33. The mating surface 36c without a gap suppresses the accumulation of the electrolytic solution.

The electrode 51 is arranged in the joining container 56. The electrode 51 is electrically insulated from the stator core 32 by the insulator 36. The electrode 52 is arranged in the joining container 57. The electrode 52 penetrates the stator core 32. The electrode 52 is electrically insulated from the stator core 32 by the insulator 36.

FIG. 13 shows a cross section of the stator 31 perpendicular to the axial direction AD. FIG. 13 shows a cross section of the stator core 32 in FIG. 12 at 1/2 of the thickness TH. The insulator 36 and the single coil 41 define a minimum radius R31 on the innermost radial direction in which the strands of the stator coil 33 can be arranged in the radial RD of the stator 31. The stator core 32 defines a maximum radius R32 that defines the outer peripheral surface of the stator 31.

All leader lines 44 are arranged so as to pass radially outside the minimum radius R31. The third portion 44c of the leader line 44 is located in contact with or very close to the minimum radius R31 when the leader line 44 is wound most tightly.

However, in this embodiment, all third portions 44c are arranged so as to pass through an intermediate radius R44. The intermediate radius R44 is much larger than the minimum radius R31. The intermediate radius R44 is smaller than the maximum radius R32. All third portions 44c are arranged radially outside the minimum radius R31 and radially inside the maximum radius R32 in a cross section at 1/2 the thickness TH of the stator core 32 (R31 <R44 < R32). In other words, all leaders 44 pass through an intermediate radius R44. The leader line 44 is not arranged in the minimum radius R31 of the stator core 32 in which the leader line 44 can be arranged in the stator core 32 in the cross section at 1/2 of the thickness (TH) of the stator core 32, and is in the radial direction from the minimum radius R31. It is arranged via the outer intermediate radius R44. Although the cross section at 1/2 of the thickness TH has been described here as a representative, the cross section is not limited to this, and any cross section of the thickness TH may have the above-described configuration. Therefore, the second leader line 44 is not arranged in the minimum radius R31 of the stator core 32 in which the leader line can be arranged in the stator core 32 in an arbitrary cross section in the thickness direction of the stator core 32, and is in the radial direction from the minimum radius R31. It is arranged via the outer intermediate radius R44.

14 and 15 show a leader line 43 in the vicinity of the joining container 56. The leader wire 43 is arranged so as to be entwined with one or more single coils 41. The leader wire 43 is arranged so as to be entwined with a single single coil 41. The leader line 43 has a first portion 34a and a second portion 43b.

The first portion 43a is arranged so as to penetrate in the slot between the plurality of magnetic poles 35 in the axial direction AD from the beginning of winding of the single coil 41s on the first end surface SD1. The first portion 43a is arranged so as to pass from the beginning of winding of the single coil 41s to the outside in the radial direction from the beginning of winding. The first portion 43a is arranged radially outside the innermost radial inner portion of the plurality of single coils 41. The first portion 43a is arranged between the second end surface SD2 and the first end surface SD1 via the gap between the single coil 41s and the adjacent single coil 41. The first portion 43a is also referred to as an axial penetration portion.

The second portion 43b extends between the first portion 43a and the joining vessel 56. The second portion 43b extends substantially straight. The second portion 43b is arranged along the circumferential direction CD in the second end surface SD2. The second portion 43b is also referred to as an introduction portion introduced into the joining container 57.

The leader line 43 is arranged in the first portion 43a and the second portion 43b away from the other members. The leader wire 43 is intentionally loosely wound in the first portion 43a and the second portion 43b so as to be intentionally slackened. The first portion 43a and the second portion 43b are arranged like aerial wiring. The first portion 43a and the second portion 43b suppress the formation of a liquid film by the electrolytic solution by separating from the other members. As a result, the electrolytic solution easily flows away. Further, the first portion 43a and the second portion 43b allow fine adjustment of the leader line 43 in the joining container 56. By bending the first portion 43a, the second portion 43b can move back and forth in the axial direction of the second portion 43b. The movable distance of the second portion 43b extends over a range of several millimeters (0.1 mm or more and 5 mm or less) along the axial direction of the second portion 43b. The movable distance of the second portion 43b can be adjusted so as to cover a range of a maximum of a dozen millimeters (0.1 mm or more, 20 mm or less).

The leader line 43 includes a non-contact portion 43f in the first portion 43a and the second portion 43b that is separated from the single coil 41s. The non-contact portion 43f is intentionally formed.

FIG. 16 shows a method of manufacturing the rotary electric machine 10 and a method of manufacturing the stator 31. The manufacturing method 180 includes a plurality of steps described below. Steps are also called steps. In step 181 the stator 31 is manufactured. Step 181 includes steps 181-188. In step 182, the stator core 32 is manufactured. The stator core 32 is manufactured by laminating a plurality of steel plates. In step 183, the insulator 36 is attached to the stator core 32. In step 184, the stator coil 33 is wound around the insulator 36. The wire is wound around the insulator 36 by an automatic winding machine. The strands are wound so that the single coil 41 and the crossover wire 42 are alternately formed. The plurality of electrodes 51 and 52 are mounted by step 184.

In step 185, the plurality of leader lines 43 and 44 are arranged in a large turn. Here, the plurality of leader wires 43, 44 are loosely wound around the single coil 41 and the insulator 36. The plurality of leader lines 43, 44 are introduced into the corresponding joining containers 56, 57. Step 185 is also a step of bending the plurality of leader lines 43 and 44 so as to be located outside the minimum radius R31. The plurality of leader wires 43, 44 are not tightly wound around the single coil 41, but are loosely wound around the single coil 41 so as to form many gaps. As a result, fine adjustment of the leader lines 43 and 44 is allowed in the joining containers 56 and 57. Further, when a fluid as a foreign substance adheres, the situation where the fluid forms a liquid film and accumulates for a long period of time is avoided.

In step 186, the ends of the plurality of leader lines 43, 44 are positioned at the joining vessels 56, 57. In step 187, a plurality of leader lines 43, 44 are joined to the corresponding electrodes 51, 52 in the joining containers 56, 57. In step 188, the joining containers 56 and 57 are resin-sealed. The resin sealing is performed by applying a sealing resin so as to embed the joint portion in the joining containers 56 and 57. In this way, the stator of the rotary electric machine 10 is manufactured. In step 189, the rotary electric machine 10 is manufactured by combining the rotor 21 and the stator 31.

According to the above-described embodiment, a rotary electric machine, a stator, and a method for manufacturing the same are provided. A typical example of a foreign substance is an electrolytic solution. According to this embodiment, the electrolytic solution is unlikely to accumulate. As a result, electrolytic corrosion of the components of the stator 31 is suppressed.

The leader lines 43, 44 are arranged longer than the minimum path allowed due to the shape of the components such as the plurality of single coils 41. Therefore, a gap is created between the leader lines 43 and 44 and the components. As a result, even if the liquid foreign matter adheres to the leader lines 43 and 44, it is possible to prevent the liquid film from accumulating for a long period of time.

The crossover 42 is adhered to the radial guide plates 67, 68, 69 by the adhesive resin 71. The liquid foreign matter adhering to the crossover 42 easily flows away through the radial guide plates 67, 68, 69 and the adhesive resin 71. Corrosion of the crossover 42 is suppressed due to the shapes of the radial guide plates 67, 68, 69 in which foreign matter does not easily collect and the protection provided by the adhesive resin 71.

The insulator 36 covers the end surface of the stator core 32 in a plate shape on the inner side in the radial direction of the first end surface SD1. Therefore, the creepage distance of the electrically insulating member between the stator core 32 and other components, for example, the crossover 42, can be increased. Further, the creepage distance of the electrically insulating member between the component and the body 13 can be increased. As a result, electrolytic corrosion of the components of the stator 31 is suppressed.

The insulator 36 has a cylindrical cover 64 that extends axially along the press-fitting portion 63 of the holder 61. The tubular cover 64 increases the creepage distance of the electrical insulating member between the holder 61 and other components, such as the crossover 42. As a result, electrolytic corrosion of the components of the stator 31 is suppressed.

The insulator 36 has an eaves portion 65 extending along the arm portion 62 of the holder 61. The eaves 65 suppresses direct contact between the holder 61 and other components, such as the crossover 42. Further, the eaves portion 65 increases the creepage distance of the electrically insulating member between the holder 61 and other components. As a result, electrolytic corrosion of the components of the stator 31 is suppressed.

Second Embodiment This embodiment is a modification based on the preceding embodiment. In the above embodiment, the leader wires 43, 44 may partially contact the adjacent single coil 41 in the third portion 44c. Instead, the third portion 44c and the fourth portion 44d may be managed so as not to come into contact with the single coil 41 at all.

In FIGS. 17 and 18, the leader line 44 according to this embodiment is illustrated. In addition, in FIG. 17 and FIG. 18, the state before filling the sealing resin in the joining container 57 is shown.

All leaders 44 are in partial contact with the single coil 41 at the first portion 44a and the second portion 44b. However, all leaders 44 are arranged in the third portion 44c and the fourth portion 44d without any contact with the single coil 41. The third portion 44c defines a minimum gap of 244 g as a non-contact portion even in the portion closest to the single coil 41. The minimum gap 244g is partitioned between the third portion 44c and the single coil 41 located outside the bend in the third portion 44c. Such a third portion 44c and a fourth portion 44d allow relatively free movement of the third portion 44c and the fourth portion 44d in the connection operation in the joining container 57. Further, the third portion 44c and the fourth portion 44d suppress the formation of the liquid film.

Other Embodiments The disclosure in this specification, drawings and the like is not limited to the exemplified embodiments. The disclosure includes exemplary embodiments and modifications by those skilled in the art based on them. For example, disclosure is not limited to the parts and / or element combinations shown in the embodiments. Disclosure can be carried out in various combinations. The disclosure can have additional parts that can be added to the embodiment. Disclosures include those in which the parts and / or elements of the embodiment are omitted. Disclosures include the replacement or combination of parts and / or elements between one embodiment and another. The technical scope disclosed is not limited to the description of the embodiments. Some technical scopes disclosed are indicated by the claims description and should be understood to include all modifications within the meaning and scope equivalent to the claims statement.

Disclosure in the description, drawings, etc. is not limited by the description of the scope of claims. The disclosure in the description, drawings, etc. includes the technical ideas described in the claims, and further covers a wider variety of technical ideas than the technical ideas described in the claims. Therefore, various technical ideas can be extracted from the disclosure of the description, drawings, etc. without being bound by the description of the claims.

In the above embodiment, the stator coil 33 provides a polyphase winding. Alternatively, the stator coil 33 may provide a single-phase winding. Also in this case, the stator coil 33 is provided with leader wires at both ends thereof.

In the above embodiment, the stator coil 33 includes a plurality of single coils 41 connected in series in one phase winding. Instead, the stator coil 33 may include a plurality of single coils 41 connected in parallel in one phase winding. Further, the stator coil 33 may include a plurality of groups including a plurality of single coils 41 connected in series or in parallel in one phase winding. The plurality of groups may be connected in parallel or in series with each other. In the above embodiment, one single coil 41 is formed by a series of strands wound around one magnetic pole 35. Instead of this, one single coil 41 may be formed by a plurality of strands wound around one magnetic pole 35.

The stator of a rotary electric machine disclosed herein includes a stator core that provides a plurality of magnetic poles, a stator coil mounted on the stator core, and an insulator as an electrically insulating member arranged between the stator core and the stator coil. The stator coil is a plurality of single coils mounted on magnetic poles, a plurality of crossovers connecting the plurality of single coils, and a leader wire providing both ends of the stator coil, and is the innermost radial inside of the plurality of single coils. from the fractions, e Bei a plurality of lead lines are arranged through the radially outward, the plurality of lead wires, a hard wound to have portions (44a, 44b) in the path, between a plurality of single coils Has a loosely wound portion (44c) in .

Claims (11)

A stator core (32) that provides a plurality of magnetic poles (35) and
The stator coil (33) mounted on the stator core and
An insulator (36) as an electrically insulating member arranged between the stator core and the stator coil is provided.
The stator coil is
A plurality of single coils (41) mounted on the magnetic poles and
A plurality of crossovers (42) connecting the plurality of the single coils, and
A leader wire that provides both ends of the stator coil, and includes a plurality of leader wires (43, 44) that are arranged via the radial outer side from the innermost radial inner portion of the single coil. Rotating electric machine stator. The stator of a rotary electric machine according to claim 1, wherein the plurality of leader wires (43, 44) are arranged as aerial wiring in at least a part in the length direction between the plurality of single coils. The plurality of leader wires include a first leader wire (43) at the start of winding, which is drawn from the innermost radial direction of the single coil (41s) at the start of winding.
The stator of the rotary electric machine according to claim 1 or 2, wherein the first leader wire (43) is arranged via the outermost side in the radial direction of the single coil (41s) at the start of winding. The plurality of leader lines include a second lead wire (44) at the end of winding drawn from an intermediate portion of the single coil (41e) at the end of winding.
The rotary electric machine according to any one of claims 1 to 3, wherein the second leader wire (44) is arranged via the outermost radial inner side of the single coil (41e) at the end of winding. Stator. The second leader line (44) is not arranged in the minimum radius (R31) of the stator core in which the leader line can be arranged in the stator core in an arbitrary cross section in the thickness direction of the stator core, and is the minimum. The stator of a rotary electric machine according to claim 4, which is arranged via an intermediate radius (R44) radially outside the radius. The insulator according to any one of claims 1 to 5, which has a plate-shaped portion extending in a plate shape along the end surface of the stator core toward the mounting surface (32a) with the body (13) to be mounted. The stator of the rotary electric machine described. The insulator is a plate-shaped member that extends in the radial direction, and has a radial guide plate (67, 68, 69) for guiding the crossover.
The stator of a rotary electric machine according to any one of claims 1 to 6, wherein the crossover wire and the radial guide plate are in contact with each other. Further, an adhesive resin (71) for adhering the crossover to the insulator is provided.
The stator of a rotary electric machine according to claim 7, wherein the adhesive resin adheres the crossover wire to the radial guide plate. In addition, with the power line (16) provided by the flexible cable,
A metal holder (61) for holding the power line is provided.
The stator of a rotary electric machine according to any one of claims 1 to 8, wherein the insulator has a cylindrical cover (64) extending along an axial direction to receive a press-fit portion (63) of the holder. The holder comprises an arm (62) extending along the stator coil.
The stator of a rotary electric machine according to claim 9, wherein the insulator has an eaves portion (65) extending between the stator coil and the arm portion. The stator according to any one of claims 1 to 10,
A rotary electric machine including a rotor (26) that provides a rotating magnetic field to the stator.

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