US20100257722A1 - Stator of electric rotating machine - Google Patents
Stator of electric rotating machine Download PDFInfo
- Publication number
- US20100257722A1 US20100257722A1 US12/801,706 US80170610A US2010257722A1 US 20100257722 A1 US20100257722 A1 US 20100257722A1 US 80170610 A US80170610 A US 80170610A US 2010257722 A1 US2010257722 A1 US 2010257722A1
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- United States
- Prior art keywords
- core
- stator
- stator winding
- tooth portions
- portions
- Prior art date
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- 238000004804 winding Methods 0.000 claims abstract description 93
- 238000004519 manufacturing process Methods 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 21
- 239000004020 conductor Substances 0.000 claims description 7
- 230000004927 fusion Effects 0.000 claims description 5
- 229910052751 metal Inorganic materials 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 239000005300 metallic glass Substances 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 230000009477 glass transition Effects 0.000 claims description 2
- 238000005452 bending Methods 0.000 claims 3
- 238000010586 diagram Methods 0.000 description 13
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- 229910052742 iron Inorganic materials 0.000 description 4
- 230000015556 catabolic process Effects 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 239000004962 Polyamide-imide Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 229920002312 polyamide-imide Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/16—Stator cores with slots for windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/024—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with slots
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
Definitions
- the present invention relates to a stator of an electric rotating machine, and an electric rotating machine having the stator.
- an electric rotating machine mounted on a vehicle is required to generate more output power because of an increase of vehicle loads, although the space assigned to mount the electric rotating machine in an engine compartment is becoming smaller.
- This patent document describes, as an assembling method of the stator, a step of preparing a stator winding of a predetermined shape by winding pillar-conductors in the circumferential direction a plurality of times so as to be laminated in the slot direction (in the radial direction), a step of disposing a plurality of divided cores in a ring around the outer periphery of the stator winding in a state of being overlapped at their lap portions, a step of moving the divided cores radially inwardly so that they are inserted into the stator winding, and a step of fixing the divided cores to one another.
- stator of an electric rotating machine of the type in which its stator core is constituted by a plurality of divided cores has a problem in that it is difficult for the electric rotating machine to output a sufficiently large power, because the divided portions (surfaces of the divided cores) have a magnetic resistance.
- the present invention provides a stator of an electric rotating machine comprising:
- a compact and high-output electric rotating machine including a stator having less magnetic resistance in a stator core thereof.
- FIG. 1 is a diagram showing a structure of an electric rotating machine according to a first embodiment of the invention
- FIG. 2 is a diagram showing a core member constituting a stator of the electric rotating machine according to the first embodiment of the invention
- FIG. 3 is a diagram of divided core members constituting the stator of the electric rotating machine according to the first embodiment of the invention.
- FIG. 4 is a diagram showing the divided core members disposed in a ring
- FIG. 5 is an outline view of the stator of the electric rotating machine according to the first embodiment of the invention.
- FIGS. 6A and 6B are diagrams showing cross sections of phase windings constituting a stator winding of the electric rotating machine according to the first embodiment of the invention
- FIG. 7 is a diagram showing electrical connection of the phase windings of a stator winding of the electric rotating machine according to the first embodiment of the invention.
- FIG. 8 is a perspective view of the stator winding of the electric rotating machine according to the first embodiment of the invention.
- FIG. 9 is an exploded view of the stator winding of the electric rotating machine according to the first embodiment of the invention.
- FIG. 10 is a diagram for explaining a method of assembling the stator of the electric rotating machine according to the first embodiment of the invention.
- FIG. 11 is a diagram for explaining a method of assembling the stator of the electric rotating machine according to the first embodiment of the invention.
- FIG. 12 is a diagram for explaining a method of assembling a stator of the electric rotating machine according to a second embodiment of the invention.
- FIG. 13 is an outline view of the stator of the electric rotating machine according to the second embodiment of the invention.
- FIG. 14 is an outline view of the stator of the electric rotating machine according to a third embodiment of the invention.
- FIG. 15 is a diagram for explaining a method of assembling a stator of an electric rotating machine according to a fourth embodiment of the invention.
- FIG. 16 is a partially enlarged view of a core member of a stator of an electric rotating machine according to a fifth embodiment of the invention.
- FIG. 17 is a diagram showing a structure of a core member of a stator of an electric rotating machine according to a sixth embodiment of the invention.
- Fig. is a diagram showing a structure of an electric rotating machine 1 according to a first embodiment of the invention.
- the electric rotating machine 1 includes a housing 10 constituted by a pair housing members 100 and 101 each having a bottomed tubular shape and joined to each other at their opening portions, a rotor 2 fixed to a rotating shaft 20 rotatably supported by the housing 10 through bearings 110 and 111 , and a stator 3 fixed to the housing 10 so as to surround the rotor 2 inside the housing 10 .
- the rotor 2 is provided with a plurality of magnetic poles (S poles and N poles) formed in the outer periphery of the rotor 2 facing the inner periphery of the stator 3 , such that different poles alternate in the circumferential direction of the rotor 2 .
- the stator 3 includes a stator core 30 , and a three-phase stator winding 4 constituted by a plurality of phase windings.
- the stator core 30 has a shape of a circular ring formed with slots 31 at its inner periphery.
- the depth direction of each slot 31 coincides with the radial direction of the stator core 30 .
- the stator core 30 includes core members 32 .
- the core member 32 is constituted by a plurality of tooth portions 320 arranged in the circumferential direction, and a core back portion 321 having a nearly circular ring shape disposed radially outward of the tooth portions 320 and being integral with the tooth portions 320 .
- the core member 32 is formed by shaping an amorphous metal plate 25 ⁇ m thick (Optronics Co., Ltd. make, product name: METGLAS2605TCA). Since the core member 32 is made of a thin metal plate, it is flexible.
- the stator core 30 further includes divided core members 33 .
- the divided core member 33 includes two tooth portions 330 and a core back portion 331 of a roughly arc shape disposed radially outward of the tooth portions 330 and being integral with the tooth portions 330 .
- the divided core member 33 is formed by shaping an electromagnetic steel plate of 0.35 mm thick. Since the divided core member 33 is made of a relatively thick metal plate, it does not have flexibility.
- FIG. 4 is a diagram showing the divided core members 33 arranged in a circle.
- the stator core 30 is formed by laminating the core members 32 and the divided core members 33 .
- the core members 32 and the divided core members 33 are fixed to one another by fittings 34 made of stainless steel.
- the stator winding 4 is constituted by a plurality of windings 40 wound together in a given way.
- each of the windings 40 includes a conductor 41 made of copper or aluminum and an insulating film 42 constituted by an inner layer 420 and an outer layer covering the outer surface of the conductor 41 .
- the thickness of the insulating film 42 is between 100 ⁇ m and 200 ⁇ m. Since the insulating film 42 is sufficiently thick, it is not necessary to interpose insulating paper or the like between each of the wirings 40 for insulation therebetween. However, insulating paper or the like may be interposed between each of the wirings 40 .
- the outer layer 421 is made of insulating material such as nylon
- the inner layer 420 is made of insulating material having a glass transition temperature higher than that of the outer layer 421 such as thermoplastic resin or polyamideimide. Accordingly, since the outer layer 421 crystallizes at an earlier time than the inner layer 420 when the electric rotating machine 1 generates heat, the surface hardness of the winding 40 increases, and accordingly, the winding 40 is difficult to scratch.
- the outer surface of the insulating film 42 of the winding 40 may be coated with a fusion member 48 made of fusion material such as epoxy resin.
- the fusion member 43 melts at an earlier time than the insulating film 42 when the electric rotating machine 1 generates heat, and accordingly, windings 40 accommodated in the same slot 31 heat-adhere to one another through their fusion members 43 .
- the mechanical strength of the windings 40 increases.
- the stator winding 4 is constituted by two sets of three-phase windings (windings U 1 , U 2 , V 1 , V 2 , W 1 and W 2 ).
- the stator winding 4 is constituted by the windings 40 wound together in a predetermined shape.
- Each of the windings 40 is wave-wound along the circumferential direction on the side of the inner periphery of the stator core 30 .
- Each of the windings 40 includes in-slot portions 44 of a linear shape accommodated in the slots 31 , and turn portions 45 connecting the adjacent in-slot portions 44 to each other.
- the in-slot portions 44 of the same winding 40 are accommodated in every predetermined number of the slots 31 (every six slots 31 in this embodiment).
- the turn portions 45 project from the axial ends of the stator core 30 .
- Each of the windings 40 is wave-wound along the circumferential direction with one end thereof being projected from the axial end of the stator core 30 .
- One phase winding of the stator winding 4 is constituted by two of the winding 40 wave-wound along the circumferential direction and connected to each other at other ends thereof.
- the in-slot portions 44 of these two windings 40 are accommodated in the same slots 31 .
- the in-slot portions 44 of a first one of the two windings 40 hereinafter referred to as the winding 40 a
- the in-slot portions 44 of a second one of the two windings 40 hereinafter referred to as the winding 40 b
- a connecting portion 45 at which the first and second windings 40 a and 40 b are connected to each other is formed as a turn-round portion 46 constituted by a specific one of the in-slot portions 44 .
- the stator winding 4 is constituted by six phase windings (U 1 , U 2 , V 1 , V 2 , W 1 and W 2 ) each of which is constituted by the first and second windings 40 a and 40 b .
- the first and second windings 40 a and 40 b of each of the phase windings are connected in series to each other at their ends not connected to the neutral point, or phase terminals.
- the stator winding 4 is fabricated by preparing a wire assembly as shown in FIG. 9 , and convolving this wire assembly by a predetermined number of times (four times, for example) with the turn-round portions 46 being located on the axial center side. As shown in FIG. 8 , the fabricated stator winding 4 is shaped such that the in-slot portions 44 of each of the phase windings are lined in the radial direction, and spaced by a small distance along the circumferential direction.
- the stator core 30 is assembled to the stator winding 4 in the following way to manufacture the stator 3 of the electric rotating machine.
- the tooth portions 320 of the core member 32 are folded back radially outwardly toward the core back portion 321 .
- a hollow portion is formed having a diameter slightly larger than that of the stator winding 4 at the axial center portion of the core member 32 .
- the stator winding 4 is inserted into the hollow portion, and the core member 32 is slid along the axial direction of the core member 32 .
- the core member 320 reaches a position which is at a predetermined distance from the axial end of the stator winding 4 , the tooth portions 320 which have been folded back unfold and extended radially inwardly to return to their original shape (the shape of thin plate) due to their resiliency.
- each of the tooth portions 320 radially penetrates between the adjacent in-slot portions of the stator winding 4 .
- each of the in-slot portions 44 is accommodated between each adjacent two of the tooth portions 320 .
- the core member 32 is slid to a predetermined axial position of the stator winding 4 , and held there.
- the tooth portions 320 penetrate through the stator winding 4 by their self-unfolding movement when the core member 32 is assembled.
- the folded tooth portions 320 may be unfolded by use of an appropriate jig.
- the divided core members 33 are assembled to both axial ends of the laminated core members 32 .
- the divided core members 33 are assembled in a direction from radially outside of the stator winding 4 to the axial center of the stator winding 4 .
- gaps between the both end surfaces of the laminated core members 32 and the end surfaces of the stator winding 4 are filled.
- an insulating film may be inserted between each of them.
- the laminated body of the core members 32 and the divided core members 33 is fitted with band-like fittings 34 to complete the stator core 30 . It is preferable that the laminated body is compressed in the axial direction at this time.
- the stator core 30 has high rigidity because the divided core members 33 and the fittings 34 are joined together. In this embodiment, although the fittings 34 are joined to the divided core members 33 , they may be joined to the core members 32 .
- the stator 3 of the electric rotating machine 1 of this embodiment is not divided in the circumferential direction, the magnetic characteristic is not degraded unlike the conventional stator constituted by a plurality of divided cores in which its magnetic characteristic is degraded at the boundaries between each of the divided cores. Therefore, the electric rotating machine 1 of this embodiment can prevent lowering of performance due to degradation of the magnetic characteristic.
- the core member 32 is made of amorphous metal, iron loss of the stator core 30 is small, and accordingly, degradation of the magnetic characteristic of the stator core 30 due to iron loss can be also suppressed.
- the effect of the reduction of iron loss becomes large as the rotational speed of the rotor increases.
- a second embodiment of the invention differs from the first embodiment only in that the divided core members 33 are disposed at not only the axial ends of the stator core 33 , but also at a position in between the laminated core members 32 .
- the number of joint portions between the stator cores 30 and the fittings 34 is larger than that in the first embodiment. Accordingly, the rigidity of the stator core 30 can be further improved compared to the first embodiment.
- the second embodiment provides the same advantages provided by the first embodiment.
- a third embodiment of the invention differs from the first embodiment only in that the third embodiment uses a fitting 35 different from the fitting 34 used in the first embodiment to fix the core members 32 and the divided core members 33 together.
- the fitting 35 joined to the divided core members 33 is a cylindrical member into which the laminated body of the core members 32 and the divided core members 33 are fitted. Accordingly, the rigidity of the stator core 30 can be further improved compared to the first embodiment.
- the third embodiment provides the same advantages provided by the first embodiment.
- a fourth embodiment of the invention differs from the first embodiment only in that the shape of the tooth portions 320 after being folded back is different from that in the first embodiment.
- the front end portion of the tooth portion 320 is bent facing the direction in which the core member 32 is slid.
- the distance between the core back portion 321 and the outer periphery of the stator winding 4 can be reduced.
- the fourth embodiment provides the same advantages provided by the first embodiment.
- a fifth embodiment of the invention differs from the first embodiment only in that the core member 32 is formed with slits extending along the tooth portions 320 at joint portions between the teeth portions 320 and the core back portion 320 as shown in FIG. 16 .
- the tooth portions 320 can be folded back easily because of the provision of the slits, workability of assembling the core members 32 to the stator winding 4 can be improved.
- the fifth embodiment provides the same advantages provided by the first embodiment.
- a sixth embodiment of the invention differs from the first embodiment only in that the core member 32 is evenly divided in the circumferential direction into a plurality of portions as shown in FIG. 17 , while satisfying the requirement that the magnetic characteristic of the stator core 30 is not degraded.
- the sixth embodiment provides the same advantages provided by the first embodiment.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
- Manufacture Of Motors, Generators (AREA)
- Insulation, Fastening Of Motor, Generator Windings (AREA)
- Windings For Motors And Generators (AREA)
Abstract
Description
- This application is a Division of application Ser. No. 12/423,876, filed Apr. 15, 2009, which claims priority from and is based on Japanese Patent Application No. 2008-109549 filed on Apr. 18, 2008, the contents of each of which are hereby incorporated by reference.
- 1. Field of the Invention
- The present invention relates to a stator of an electric rotating machine, and an electric rotating machine having the stator.
- 2. Description of Related Art
- In recent years, there is a growing need of electric rotating machines usable as electric motors or generators which are compact in size and of high quality.
- For example, an electric rotating machine mounted on a vehicle is required to generate more output power because of an increase of vehicle loads, although the space assigned to mount the electric rotating machine in an engine compartment is becoming smaller.
- As described, for example, in Japanese Patent No. 3604326, there is known a compact and high-output electric rotating machine having a structure in which the resistance of phase windings thereof is small, the lamination factor of electric conductors accommodated in the magnetic circuit of a stator thereof is large, and the turn portions of the phase windings are in proper alignment and wound densily.
- This patent document describes, as an assembling method of the stator, a step of preparing a stator winding of a predetermined shape by winding pillar-conductors in the circumferential direction a plurality of times so as to be laminated in the slot direction (in the radial direction), a step of disposing a plurality of divided cores in a ring around the outer periphery of the stator winding in a state of being overlapped at their lap portions, a step of moving the divided cores radially inwardly so that they are inserted into the stator winding, and a step of fixing the divided cores to one another.
- However, the stator of an electric rotating machine of the type in which its stator core is constituted by a plurality of divided cores has a problem in that it is difficult for the electric rotating machine to output a sufficiently large power, because the divided portions (surfaces of the divided cores) have a magnetic resistance.
- Although the above patent discloses reducing the magnetic resistance by the provision of the lap portions, the effect is restrictive.
- In addition, there is another problem that an eddy current occurs in each lap portion, causing iron loss (core loss) to increase.
- The present invention provides a stator of an electric rotating machine comprising:
-
- a stator core having slots formed at an inner periphery thereof along a circumferential direction thereof; and
- a stator winding constituted by conductive wires wound on the slots
- the stator winding including in-slot portions accommodated in the slots and turn portions each connecting each adjacent two of the in-slot portions outside of the slots,
- the stator core including a core member having at least three first tooth portions extending in a radial direction of the stator core and a core back portion integrally connecting the first tooth portions at a radially end side thereof,
- the core member being configured such that each of the first tooth portions folded toward the core back portion is capable of unfolding to extend between a corresponding adjacent two of the in-slot portions when the core member is at a predetermined axial position with respect to the stator winding.
- According to the present invention, there is provided a compact and high-output electric rotating machine including a stator having less magnetic resistance in a stator core thereof.
- Other advantages and features of the invention will become apparent from the following description including the drawings and claims.
- In the accompanying drawings:
-
FIG. 1 is a diagram showing a structure of an electric rotating machine according to a first embodiment of the invention; -
FIG. 2 is a diagram showing a core member constituting a stator of the electric rotating machine according to the first embodiment of the invention; -
FIG. 3 is a diagram of divided core members constituting the stator of the electric rotating machine according to the first embodiment of the invention; -
FIG. 4 is a diagram showing the divided core members disposed in a ring; -
FIG. 5 is an outline view of the stator of the electric rotating machine according to the first embodiment of the invention; -
FIGS. 6A and 6B are diagrams showing cross sections of phase windings constituting a stator winding of the electric rotating machine according to the first embodiment of the invention; -
FIG. 7 is a diagram showing electrical connection of the phase windings of a stator winding of the electric rotating machine according to the first embodiment of the invention; -
FIG. 8 is a perspective view of the stator winding of the electric rotating machine according to the first embodiment of the invention; -
FIG. 9 is an exploded view of the stator winding of the electric rotating machine according to the first embodiment of the invention; -
FIG. 10 is a diagram for explaining a method of assembling the stator of the electric rotating machine according to the first embodiment of the invention; -
FIG. 11 is a diagram for explaining a method of assembling the stator of the electric rotating machine according to the first embodiment of the invention; -
FIG. 12 is a diagram for explaining a method of assembling a stator of the electric rotating machine according to a second embodiment of the invention; -
FIG. 13 is an outline view of the stator of the electric rotating machine according to the second embodiment of the invention; -
FIG. 14 is an outline view of the stator of the electric rotating machine according to a third embodiment of the invention; -
FIG. 15 is a diagram for explaining a method of assembling a stator of an electric rotating machine according to a fourth embodiment of the invention; -
FIG. 16 is a partially enlarged view of a core member of a stator of an electric rotating machine according to a fifth embodiment of the invention; and -
FIG. 17 is a diagram showing a structure of a core member of a stator of an electric rotating machine according to a sixth embodiment of the invention. - Fig. is a diagram showing a structure of an
electric rotating machine 1 according to a first embodiment of the invention. As shown in this figure, theelectric rotating machine 1 includes ahousing 10 constituted by apair housing members rotor 2 fixed to a rotatingshaft 20 rotatably supported by thehousing 10 throughbearings stator 3 fixed to thehousing 10 so as to surround therotor 2 inside thehousing 10. - The
rotor 2 is provided with a plurality of magnetic poles (S poles and N poles) formed in the outer periphery of therotor 2 facing the inner periphery of thestator 3, such that different poles alternate in the circumferential direction of therotor 2. - The
stator 3 includes astator core 30, and a three-phase stator winding 4 constituted by a plurality of phase windings. - The
stator core 30 has a shape of a circular ring formed withslots 31 at its inner periphery. The depth direction of eachslot 31 coincides with the radial direction of thestator core 30. - The
stator core 30 includescore members 32. As shown inFIG. 2 , thecore member 32 is constituted by a plurality oftooth portions 320 arranged in the circumferential direction, and acore back portion 321 having a nearly circular ring shape disposed radially outward of thetooth portions 320 and being integral with thetooth portions 320. Thecore member 32 is formed by shaping an amorphous metal plate 25 μm thick (Optronics Co., Ltd. make, product name: METGLAS2605TCA). Since thecore member 32 is made of a thin metal plate, it is flexible. - The
stator core 30 further includes dividedcore members 33. As shown inFIG. 3 the dividedcore member 33 includes twotooth portions 330 and acore back portion 331 of a roughly arc shape disposed radially outward of thetooth portions 330 and being integral with thetooth portions 330. The dividedcore member 33 is formed by shaping an electromagnetic steel plate of 0.35 mm thick. Since the dividedcore member 33 is made of a relatively thick metal plate, it does not have flexibility.FIG. 4 is a diagram showing the dividedcore members 33 arranged in a circle. - As shown in
FIG. 5 , thestator core 30 is formed by laminating thecore members 32 and the dividedcore members 33. Thecore members 32 and thedivided core members 33 are fixed to one another byfittings 34 made of stainless steel. - The stator winding 4 is constituted by a plurality of
windings 40 wound together in a given way. As shown inFIG. 6A , each of thewindings 40 includes aconductor 41 made of copper or aluminum and an insulatingfilm 42 constituted by aninner layer 420 and an outer layer covering the outer surface of theconductor 41. The thickness of the insulatingfilm 42 is between 100 μm and 200 μm. Since the insulatingfilm 42 is sufficiently thick, it is not necessary to interpose insulating paper or the like between each of thewirings 40 for insulation therebetween. However, insulating paper or the like may be interposed between each of thewirings 40. - The
outer layer 421 is made of insulating material such as nylon, and theinner layer 420 is made of insulating material having a glass transition temperature higher than that of theouter layer 421 such as thermoplastic resin or polyamideimide. Accordingly, since theouter layer 421 crystallizes at an earlier time than theinner layer 420 when the electricrotating machine 1 generates heat, the surface hardness of the winding 40 increases, and accordingly, the winding 40 is difficult to scratch. - As shown in
FIG. 6B , the outer surface of the insulatingfilm 42 of the winding 40 may be coated with afusion member 48 made of fusion material such as epoxy resin. The fusion member 43 melts at an earlier time than the insulatingfilm 42 when the electricrotating machine 1 generates heat, and accordingly,windings 40 accommodated in thesame slot 31 heat-adhere to one another through their fusion members 43. As a result, since thewindings 40 accommodated in thesame slot 31 become integrated and rigid, the mechanical strength of thewindings 40 increases. - In this embodiment, as shown in
FIG. 7 , the stator winding 4 is constituted by two sets of three-phase windings (windings U1, U2, V1, V2, W1 and W2). - As shown in
FIG. 8 , the stator winding 4 is constituted by thewindings 40 wound together in a predetermined shape. Each of thewindings 40 is wave-wound along the circumferential direction on the side of the inner periphery of thestator core 30. Each of thewindings 40 includes in-slot portions 44 of a linear shape accommodated in theslots 31, and turnportions 45 connecting the adjacent in-slot portions 44 to each other. The in-slot portions 44 of the same winding 40 are accommodated in every predetermined number of the slots 31 (every sixslots 31 in this embodiment). Theturn portions 45 project from the axial ends of thestator core 30. - Each of the
windings 40 is wave-wound along the circumferential direction with one end thereof being projected from the axial end of thestator core 30. One phase winding of the stator winding 4 is constituted by two of the winding 40 wave-wound along the circumferential direction and connected to each other at other ends thereof. The in-slot portions 44 of these twowindings 40 are accommodated in thesame slots 31. The in-slot portions 44 of a first one of the two windings 40 (hereinafter referred to as the winding 40 a) and the in-slot portions 44 of a second one of the two windings 40 (hereinafter referred to as the winding 40 b) are accommodated such that they alternate in the depth direction in the slots. A connectingportion 45 at which the first andsecond windings round portion 46 constituted by a specific one of the in-slot portions 44. - As shown in
FIG. 9 , the stator winding 4 is constituted by six phase windings (U1, U2, V1, V2, W1 and W2) each of which is constituted by the first andsecond windings second windings - The stator winding 4 is fabricated by preparing a wire assembly as shown in
FIG. 9 , and convolving this wire assembly by a predetermined number of times (four times, for example) with the turn-round portions 46 being located on the axial center side. As shown inFIG. 8 , the fabricated stator winding 4 is shaped such that the in-slot portions 44 of each of the phase windings are lined in the radial direction, and spaced by a small distance along the circumferential direction. - The
stator core 30 is assembled to the stator winding 4 in the following way to manufacture thestator 3 of the electric rotating machine. - First, the
tooth portions 320 of thecore member 32 are folded back radially outwardly toward the core backportion 321. As a result, a hollow portion is formed having a diameter slightly larger than that of the stator winding 4 at the axial center portion of thecore member 32. In the state of thetooth portions 320 being folded back, the stator winding 4 is inserted into the hollow portion, and thecore member 32 is slid along the axial direction of thecore member 32. When thecore member 320 reaches a position which is at a predetermined distance from the axial end of the stator winding 4, thetooth portions 320 which have been folded back unfold and extended radially inwardly to return to their original shape (the shape of thin plate) due to their resiliency. As a result, each of thetooth portions 320 radially penetrates between the adjacent in-slot portions of the stator winding 4. Thus, each of the in-slot portions 44 is accommodated between each adjacent two of thetooth portions 320. - In this state, the
core member 32 is slid to a predetermined axial position of the stator winding 4, and held there. - In this way, a predetermined number of the
core members 32 are assembled to the stator winding 4 successively. - In the above way, the
tooth portions 320 penetrate through the stator winding 4 by their self-unfolding movement when thecore member 32 is assembled. However, the foldedtooth portions 320 may be unfolded by use of an appropriate jig. - Thereafter, as shown in
FIG. 11 , the dividedcore members 33 are assembled to both axial ends of thelaminated core members 32. The dividedcore members 33 are assembled in a direction from radially outside of the stator winding 4 to the axial center of the stator winding 4. By assembling the dividedcore members 33, gaps between the both end surfaces of thelaminated core members 32 and the end surfaces of the stator winding 4 are filled. - At the time of laminating the
core members 32 and the dividedcore members 33, an insulating film may be inserted between each of them. - The laminated body of the
core members 32 and the dividedcore members 33 is fitted with band-like fittings 34 to complete thestator core 30. It is preferable that the laminated body is compressed in the axial direction at this time. Thestator core 30 has high rigidity because the dividedcore members 33 and thefittings 34 are joined together. In this embodiment, although thefittings 34 are joined to the dividedcore members 33, they may be joined to thecore members 32. - As apparent from the above description, since the
stator 3 of the electricrotating machine 1 of this embodiment is not divided in the circumferential direction, the magnetic characteristic is not degraded unlike the conventional stator constituted by a plurality of divided cores in which its magnetic characteristic is degraded at the boundaries between each of the divided cores. Therefore, the electricrotating machine 1 of this embodiment can prevent lowering of performance due to degradation of the magnetic characteristic. - In addition, in this embodiment, since the
core member 32 is made of amorphous metal, iron loss of thestator core 30 is small, and accordingly, degradation of the magnetic characteristic of thestator core 30 due to iron loss can be also suppressed. The effect of the reduction of iron loss becomes large as the rotational speed of the rotor increases. - As shown in
FIGS. 12 and 13 , a second embodiment of the invention differs from the first embodiment only in that the dividedcore members 33 are disposed at not only the axial ends of thestator core 33, but also at a position in between thelaminated core members 32. - In the second embodiment, the number of joint portions between the
stator cores 30 and thefittings 34 is larger than that in the first embodiment. Accordingly, the rigidity of thestator core 30 can be further improved compared to the first embodiment. - Other than this, the second embodiment provides the same advantages provided by the first embodiment.
- A third embodiment of the invention differs from the first embodiment only in that the third embodiment uses a fitting 35 different from the fitting 34 used in the first embodiment to fix the
core members 32 and the dividedcore members 33 together. - As shown in
FIG. 14 , in the third embodiment, the fitting 35 joined to the dividedcore members 33 is a cylindrical member into which the laminated body of thecore members 32 and the dividedcore members 33 are fitted. Accordingly, the rigidity of thestator core 30 can be further improved compared to the first embodiment. - Other than this, the third embodiment provides the same advantages provided by the first embodiment.
- A fourth embodiment of the invention differs from the first embodiment only in that the shape of the
tooth portions 320 after being folded back is different from that in the first embodiment. - As shown in
FIG. 15 , in this embodiment, the front end portion of thetooth portion 320 is bent facing the direction in which thecore member 32 is slid. By folding back thetooth portion 320 in a state of being bent, the distance between the core backportion 321 and the outer periphery of the stator winding 4 can be reduced. - Other than this, the fourth embodiment provides the same advantages provided by the first embodiment.
- A fifth embodiment of the invention differs from the first embodiment only in that the
core member 32 is formed with slits extending along thetooth portions 320 at joint portions between theteeth portions 320 and the core backportion 320 as shown inFIG. 16 . - In the fifth embodiment, since the
tooth portions 320 can be folded back easily because of the provision of the slits, workability of assembling thecore members 32 to the stator winding 4 can be improved. - Other than this, the fifth embodiment provides the same advantages provided by the first embodiment.
- A sixth embodiment of the invention differs from the first embodiment only in that the
core member 32 is evenly divided in the circumferential direction into a plurality of portions as shown inFIG. 17 , while satisfying the requirement that the magnetic characteristic of thestator core 30 is not degraded. Other than this, the sixth embodiment provides the same advantages provided by the first embodiment. - The above explained preferred embodiments are exemplary of the invention of the present application which is described solely by the claims appended below. It should be understood that modifications of the preferred embodiments may be made as would occur to one of skill in the art.
Claims (16)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/801,706 US7814642B1 (en) | 2008-04-18 | 2010-06-22 | Stator of electric rotating machine |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2008-109549 | 2008-04-18 | ||
JP2008109549A JP4445023B2 (en) | 2008-04-18 | 2008-04-18 | Rotating electric machine stator and rotating electric machine |
US12/423,876 US20090261684A1 (en) | 2008-04-18 | 2009-04-15 | Stator of electric rotating machine |
US12/801,706 US7814642B1 (en) | 2008-04-18 | 2010-06-22 | Stator of electric rotating machine |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US12/423,876 Division US20090261684A1 (en) | 2008-04-18 | 2009-04-15 | Stator of electric rotating machine |
Publications (2)
Publication Number | Publication Date |
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US20100257722A1 true US20100257722A1 (en) | 2010-10-14 |
US7814642B1 US7814642B1 (en) | 2010-10-19 |
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US12/423,876 Abandoned US20090261684A1 (en) | 2008-04-18 | 2009-04-15 | Stator of electric rotating machine |
US12/801,706 Active US7814642B1 (en) | 2008-04-18 | 2010-06-22 | Stator of electric rotating machine |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US12/423,876 Abandoned US20090261684A1 (en) | 2008-04-18 | 2009-04-15 | Stator of electric rotating machine |
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US (2) | US20090261684A1 (en) |
JP (1) | JP4445023B2 (en) |
Cited By (1)
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CN105723592A (en) * | 2013-11-08 | 2016-06-29 | 三菱电机株式会社 | Stator for rotary electric machine, and rotary electric machine |
Families Citing this family (12)
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JP4445023B2 (en) * | 2008-04-18 | 2010-04-07 | 株式会社日本自動車部品総合研究所 | Rotating electric machine stator and rotating electric machine |
DE102010028509A1 (en) * | 2009-12-30 | 2011-07-07 | Robert Bosch GmbH, 70469 | Stator in an electric motor |
WO2012049759A1 (en) | 2010-10-14 | 2012-04-19 | トヨタ自動車株式会社 | Motor |
US9099897B2 (en) | 2011-09-13 | 2015-08-04 | L.H. Carbide Corporation | Method for connecting end sections of an annular laminated article and articles made therefrom |
CN103023165B (en) * | 2011-09-21 | 2017-10-31 | 德昌电机(深圳)有限公司 | Stator core construction for motor and stator forming method |
CN102624105A (en) * | 2012-03-23 | 2012-08-01 | 松下·万宝(广州)压缩机有限公司 | Compound winding motor |
JP5896937B2 (en) * | 2013-02-08 | 2016-03-30 | 三菱電機株式会社 | Divided iron core, stator using the divided iron core, and rotating electric machine equipped with the stator |
US20150022044A1 (en) * | 2013-07-22 | 2015-01-22 | Steering Solutions Ip Holding Corporation | System and method for reducing torque ripple in an interior permanent magnet motor |
US20160190874A1 (en) * | 2013-08-23 | 2016-06-30 | Amotech Co., Ltd. | Single stator and motor comprising same |
CN106549512B (en) * | 2015-09-16 | 2019-06-14 | 雅马哈发动机株式会社 | Rotating electric machine |
US11228214B2 (en) | 2016-04-06 | 2022-01-18 | Mitsubishi Electric Corporation | Motor, fan, compressor, and air conditioning apparatus |
MX2018015390A (en) | 2017-12-15 | 2019-08-21 | Trinity Ind Inc | Longitudinal sliding gate for hopper car. |
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Also Published As
Publication number | Publication date |
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JP2009261188A (en) | 2009-11-05 |
US7814642B1 (en) | 2010-10-19 |
JP4445023B2 (en) | 2010-04-07 |
US20090261684A1 (en) | 2009-10-22 |
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