WO2011039850A1 - ステータ及びその製造方法 - Google Patents
ステータ及びその製造方法 Download PDFInfo
- Publication number
- WO2011039850A1 WO2011039850A1 PCT/JP2009/066995 JP2009066995W WO2011039850A1 WO 2011039850 A1 WO2011039850 A1 WO 2011039850A1 JP 2009066995 W JP2009066995 W JP 2009066995W WO 2011039850 A1 WO2011039850 A1 WO 2011039850A1
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- WIPO (PCT)
- Prior art keywords
- stator
- bending
- conducting wire
- conductor
- slot
- Prior art date
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
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- 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
- H02K15/0056—Manufacturing winding connections
- H02K15/0068—Connecting winding sections; Forming leads; Connecting leads to terminals
-
- 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
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
- H02K15/0478—Wave windings, undulated windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/28—Layout of windings or of connections between windings
-
- 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 distributed winding stator used for a motor or the like and a manufacturing method thereof. More specifically, the present invention relates to a stator having a multiphase coil using a conducting wire having a rectangular cross section and a method for manufacturing the same.
- a stator used for a motor or the like is provided with a coil, and a wave winding coil in which a conductor is wound in a wave shape is known as the stator coil.
- An example of this wave winding coil is disclosed in Patent Document 1.
- the wave winding coil disclosed herein includes a slot conductor portion composed of a forward conductor portion and a return conductor portion alternately inserted into each slot of the core, and a forward conductor portion and a return conductor portion formed integrally with the slot conductor portion.
- the coil conductors of each phase consisting of the transition conductor portions that constitute the coil end by connecting the same side end portions of each of the coil conductors are wound, and the transition conductor portions are radially connected to other transition conductor portions adjacent in the circumferential direction.
- a multiphase wave winding of a rotating electrical machine having an overlapping portion that overlaps with the tip portion and a tip portion that protrudes further in the axial direction than the overlapping portion, one end and the other end of the tip portion of the crossover conductor portion cross in the radial direction.
- the conductor is displaced more than the thickness in the radial direction. That is, a plurality of wave-wound coils in which a conductor is wound in a wave shape are prepared, and the coils are formed by superimposing them at different pitches. Thereby, the space of a coil end part and reduction of resistance power loss are achieved.
- the present applicant has proposed a stator and a coil rod that can increase the production efficiency by eliminating the need to braid the coil at the coil end (Japanese Patent Application No. 2009-016549).
- Japanese Patent Application No. 2009-016549 Japanese Patent Application No. 2009-016549.
- FIG. 21 when the conducting wires are overlapped to form a coil cage, bent portions of the conducting wires interfere with each other at the coil end. For this reason, there is a problem that the lane portion has two stages, and a useless space is generated at the coil end, the coil swells in the stator radial direction (back yoke side), and the size increases in the stator radial direction.
- the present invention has been made to solve the above-described problems, and a stator having a coil capable of reducing the bulge of the coil in the stator radial direction and reducing the size in the stator radial direction, and its manufacture. It aims to provide a method.
- a stator having a coil using a conducting wire having a rectangular cross section wherein the conducting wire is continuously formed in a zigzag shape, and the slot of the stator
- the conductor a plurality of in-slot conductors arranged in a circumferential direction of the stator so that the long side of the rectangle is in the radial direction of the stator, and the conductor at the coil end, the conductor A plurality of circumferential conductors arranged in the radial direction of the stator so that the short side of the rectangle is in the radial direction of the stator, and a bending connection part that connects the in-slot conductor and the circumferential conductor And a twisted portion formed in the bending connection portion, and the bending connection portion includes a first bending portion formed on the circumferential conductor portion side and a slot conductor portion side. With a second bend And wherein the are.
- the bending connection portion is provided with the first bending portion formed on the circumferential conducting wire portion side and the second bending portion formed on the slot conducting wire portion side. Since the bent portion of the conducting wire does not interfere at the coil end, the lane portion can be made one stage. Thereby, since the swelling of the coil to the stator radial direction (back yoke side) can be reduced, the size reduction in the stator radial direction can be achieved.
- a plurality of in-slot conductors can be overlapped in the circumferential direction so that the long side of the cross section is in the radial direction of the stator. Since the slots can be arranged, the slots can be connected with a minimum path, and at the coil end, a plurality of circumferential conductor portions are arranged so that the short side of the cross section overlaps in the circumferential direction of the stator. For this reason, since the occupied space at the coil end can be minimized, the coil end can be reduced. Further, since it is not necessary to braid the coil at the coil end, the production efficiency can be increased.
- the bending angle ⁇ 1 in the first bending portion is ⁇ 1 ⁇ 90 °
- the coil can be reduced in the radial direction and the height direction.
- the bending direction at the bending connection portion of the conducting wire is opposite to each coil end, so that when the coils are overlapped, one coil end (for example, the lead side) is bent.
- the connecting portion does not intersect, the bending connecting portion intersects at the other coil end (for example, the opposite lead side).
- the second bent portion on one coil end side is formed by tilting the bent connection portion toward the stator side after the twisted portion is formed.
- the bending connection portion On one coil end side, when the coils are overlapped, the bending connection portion does not intersect, so after the twist portion is formed, the bending connection portion is tilted to the stator side to form the second bending portion. be able to. Then, by bending the bending connection portion, the bending portions of the conductors can be separated from each other without interference without applying an excessive force around the twisted portion. Thereby, the swelling of the coil in the radial direction of the stator can be reduced without damaging the enamel of the conducting wire (without degrading the insulation performance).
- the second bent portion on the other coil end side is preferably formed by edgewise bending the conductive wire before the twisted portion is formed.
- the second bent portion is formed by edgewise bending the conductive wire before the twisted portion is formed, that is, the first bent portion and the second bent portion are formed by edgewise bending the conductive wire in two stages.
- Another aspect of the present invention which has been made to solve the above-described problems, is a method of manufacturing a stator having a coil using a conducting wire having a rectangular cross section, and performs edgewise bending with respect to the conducting wire at an angle smaller than 90 °.
- the bending step at least one coil end side of the conducting wire It is characterized in that edgewise bending is performed in two stages on the position.
- one step of edgewise bending is performed on a portion located on one coil end side of the conducting wire, and the twisting step is performed. It is desirable to further include a tilting step of tilting an end portion of the twisted portion of the conducting wire located on the one coil end side.
- stator can be manufactured by such a method, when the coils are overlapped with each other, the bent portion of the conducting wire does not interfere at the coil end, so that the coil bulge in the stator radial direction can be reduced. it can. Thereby, the stator which aimed at size reduction in a stator radial direction can be manufactured.
- the plurality of conducting wires subjected to the bending step are simultaneously twisted in a state where the twisting positions are overlapped in the twisting step.
- the bent portion of the conducting wire does not interfere with each other at the coil end, so that the coil bulge in the stator radial direction can be reduced. Therefore, it is possible to reduce the size in the stator radial direction.
- FIG. 15 is a plan view of FIG. 14.
- FIG. 14 It is a conceptual diagram which shows arrangement
- FIG. 1 shows the material of the conducting wire.
- FIG. 1 shows a conductor material UAXX, which is a U-phase first conductor.
- the conductor material UAXX is edgewise bent by 45 ° at a predetermined position, is formed into a substantially “ten” shape, and is crank-formed in the front-rear direction of the paper surface.
- the length of the conducting wire material UAXX is approximately one stator circumference.
- the cross section of the conductor UAXX in the present embodiment has a rectangular shape with a short side of 1 mm and a long side of 6 mm. What is visible in FIG.
- FIG. 1 is the long side and the short side is the thickness.
- the material is copper and has an enamel coating for insulation.
- the thickness of the enamel coating is set so that sufficient insulation can be maintained even when deformed as shown in FIG.
- FIG. 1 has shown the state which bent and crank-formed with respect to the conducting wire material UAXX which was linear.
- crank amounts of the conductor materials UAXX and UCXX are as shown in FIG. 2, when the numerical value is positive, the crank is attached in the outer direction of the stator diameter, and when the numerical value is negative, it means that the crank is attached in the inner direction of the stator diameter.
- a bending connection portion EL is formed on the left side of the circumferential conducting wire portion E, and a bending connection portion ER is formed on the right side of the circumferential conducting wire portion E. That is, the bending connection portions EL and ER are arranged so as to connect the in-slot conductor material portion SS and the circumferential conductor portion E.
- the bent connection portions EL and ER at positions (E2L, E2R,%) Formed on the left and right sides of the circumferential conductor portions E2, E4,. Edgewise bending is performed. Further, in the bent connection portions EL and ER, at the locations (E1L, E1R,%) Formed on the left and right sides of the circumferential conductor portions E1, E3,. The edgewise bending is performed at 45 °.
- FIG. 3 is a diagram showing each parameter in the conducting wire after bending and the conducting wire after twisting to determine the bending angle.
- FIG. 4 is a diagram illustrating the relationship between the coil end height z and the distance d with respect to the bending angle.
- the parameters for determining the bending angle include a material parameter, a design parameter, a performance design parameter, and a performance parameter.
- the material parameters include a conductor width a and a conductor thickness b shown in FIG.
- the design parameters include slot insertion portion length Ls, twisted portion length Ln, lead side twisted portion interference avoidance length L1, anti-lead side twisted portion interference avoidance length L2, anti-lead side bent connection portion linear length shown in FIG. L3, the lead-side first bending angle ⁇ 1x, and the anti-lead-side first bending angle ⁇ 1y are included.
- the performance design parameters include the size R of the bending R and the twist width c shown in FIG.
- the performance parameters include the coil end height z and the distance d shown in FIG. Note that the distance d serves as an index for determining whether or not the twisted portions formed at the ends of the in-slot conductors arranged in adjacent slots interfere with each other, and the distance d is adjacent. If the distance is smaller than the distance between the slots, it means that the twisted portions do not interfere with each other.
- Twist part length Ln is determined by Formula (2). a: Conductor width, ⁇ 1x: Lead side first bending angle, R: Bending R size
- the anti-lead-side twisted portion interference avoidance length L2 is determined by Equation (3).
- R magnitude of bending R
- L3 straight length of anti-lead-side bending connection
- ⁇ 2y anti-lead-side second bending angle
- h2 anti-lead-side crank height
- the anti-lead-side bending connection portion straight line length L3, the bending radius R, and the torsional width c may be set to minimum values within a range that satisfies the required insulation performance.
- the coil end height z is determined by equation (4).
- c Twist width
- ⁇ 1x Lead side first bending angle
- R Size of bending
- a Conductor width
- b Conductor thickness
- c Twist width
- ⁇ 1x Lead side first bending angle
- L1 Lead side twist portion interference avoidance length
- R Bending R size
- a Conductor width
- b Conductor thickness
- c Twist width
- ⁇ 1x Lead side first bending angle
- R Size of bending
- the lead-side first bending angle ⁇ 1x from the equations (5-1) and (5-2), and set the distance d so that the twisted portions do not interfere with each other between the adjacent slots.
- the distance d increases as the first bending angle ⁇ 1x decreases, and there is a possibility of interfering with the twisted portion formed at the end of the in-slot conductor portion disposed in the adjacent slot. Get higher.
- the coil end height z is low when the first bending angle ⁇ 1x is 30 ° ⁇ ⁇ 1x ⁇ 60 °.
- the lead-side first bending angle ⁇ 1x is preferably 30 ° ⁇ ⁇ 1x ⁇ 60 °.
- FIG. 5 shows a conductor UAX which is a component of the first U-phase conductor of the present invention.
- FIG. 5 shows the conductive wire UAX in a state where all of the bending process (including tilting) and the twisting process are completed.
- the in-slot conductor material portion SS of FIG. 1 is twisted in the same direction by the twist material portion HHM and the twist material portion HHN, and in FIG. 5, a twist portion HM on the upper end side and a twist portion HN on the lower end side are formed. .
- the in-slot conductor material portion SS2 is twisted clockwise as viewed from above.
- the in-slot conductor material portion SS3 is twisted counterclockwise as viewed from above. That is, when viewed from the circumferential conducting wire portion E2, the twist direction is opposite between the leftmost bent portion E2L side and the rightmost bent portion E2R side.
- Such a twisting process can be easily twisted by simply rotating the chuck claws while holding the in-slot conductor material portion SS with the chuck claws and fixing the other portions.
- the in-slot conductors S1, S2,... Have a short side and a long side located in the thickness direction in FIG.
- the thickness of the enamel coating is set so that sufficient insulation can be maintained even if the enamel coating is twisted as shown in FIG.
- the bending connection portions EL and ER that connect the in-slot conductive wire material portion SS and the circumferential conductive wire portion E have two bending portions, that is, a first bending portion EL1, a second bending portion EL2, and a first bending portion.
- a part ER1 and a second bent part ER2 are provided (see also FIG. 1).
- the first bent portions EL1, ER1 are provided on the circumferential conducting wire portion E side
- the second bent portions EL2, ER2 are provided on the in-slot conducting wire material portion SS side.
- the bending connection portions EL and ER located on the lead side include first bending portions EL1 and ER1 formed by bending performed before twisting, and tilting performed after twisting. There are provided second bent portions EL2 and ER2 formed by embedding.
- the bending connection portions EL and ER located on the opposite lead side include first bending portions EL1 and ER1 and second bending portions EL2 and ER2 formed by bending processing before twisting. And are provided.
- first bent portion E2L1 and the second bent portion E2L2 are provided for the lead-side bent connecting portion E2L
- the first bent portion E1R1 and the first bent portion E1R1 are provided for the anti-lead-side bent connecting portion E1R.
- Two bending portions E1R2 are provided.
- the conductor UAX and the conductor UCX are formed using the conductor material UAXX, which is a component of the U-phase first conductor, and the conductor UCXX, which is a component of the U-phase third conductor.
- the conductive wire material UAXX and the conductive wire material UCXX which are bent and crank-shaped into the shape shown in FIG. 1, are superposed in a state where the twist positions are aligned. Specifically, the in-slot conductor material portion SS2 of the conductor material UAXX and the in-slot conductor material portion SS1 of the conductor material UCXX are overlapped. Then, the superposed in-slot conductor material portion SS is gripped by the chuck claws, and the chuck claws are rotated and twisted while the other portions are fixed.
- the in-slot conductor material portion SS2 of the conductor material UAXX and the in-slot conductor material portion SS1 of the conductor material UCXX are twisted clockwise as viewed from above in FIG.
- the in-slot conductor material portions SS2 and SS1 that are overlapped and twisted become the in-slot conductor portions S2 and S1, and in FIG. 7, the short side can be seen, and the long side is positioned in the thickness direction. .
- the upper end portions of the in-slot conductor portions S2 and S1 are tilted downward in FIG. Specifically, the conductor material UAXX and the conductor material UCXX are bent at 45 ° at the upper ends of the in-slot conductor portions S2 and S1, respectively. At this time, the second bent portion E2L2 on the lead side is formed. Thereby, the conducting wire material UAXX and the conducting wire material UCXX have a shape as shown in FIG. 8, and the bending connecting portion E2L on the left side of the circumferential conducting wire portion E2 is formed.
- the in-slot conductor material portion SS3 of the conductor material UAXX and the in-slot conductor material portion SS2 of the conductor material UCXX are overlaid.
- the superposed in-slot conductor material parts SS3 and SS2 are gripped by the chuck claws, and the chuck claws are rotated and twisted while the other portions are fixed.
- the in-slot conductor material portion SS3 of the conductor material UAXX and the in-slot conductor material portion SS2 of the conductor material UCXX are twisted counterclockwise as viewed from above in FIG.
- the in-slot conductor material portions SS3 and SS2 that are overlapped and twisted become the in-slot conductor portions S3 and S2, and in FIG. 10, the short side can be seen, and the long side is positioned in the thickness direction. .
- the U-phase first conducting wire UA is formed by superimposing the conducting wires UAX and the conducting wire UAY formed as described above, each of which is welded at three ends (for three laps) at each end. Configured.
- the starting point side (left side) of the conducting wire corresponding to the second and third laps is different from the conducting wire corresponding to the first cycle shown in FIG. 5 on the end point side (right side) of the conducting wire corresponding to the first cycle. It is bent so that it can be connected and is in a horizontal state.
- the welded part is insulated by an insulating tape or the like.
- the length of the conducting wire is longer in the second round than the first round and in the third round from the second round.
- the third conductor UC shifted from the first conductor UA by one pitch phase is formed by superimposing three conductors UCX and three conductors UCY (3 rounds) welded at each end. Has been configured. And the 3rd conducting wire UC is overlaid on the 1st conducting wire UA, and as shown in Drawing 11, U phase 1st set conducting wire UAC is formed. In addition, 1 pitch is 1/2 length of 1 cycle of 1st conducting wire UA and 3rd conducting wire UC.
- the first conductive wire UA and the third conductive wire UC are overlapped with one pitch shifted to form a rectangular coil as shown in FIG.
- the in-slot conductor portion UACS2 includes an in-slot conductor portion UAS2 (UAS2X + UAS2Y) of the first conductor UA heading from bottom to top in the figure, and an in-slot conductor portion UCS1 (UCS1X + UCS1Y) of the third conductor UC heading from top to bottom in the figure. It is the state where it overlapped with the in-slot conductor part UCS1 facing up. That is, four conducting wires UAS2X, UAS2Y, UCS1X, and UCS1Y are overlaid in the short side direction.
- FIG. 12 is a view of the vicinity of the slot insertion portion of the U-phase first assembled conductor UAC shown in FIG. 11 as viewed from the lead side (upper side).
- the reason why the second bent portions EL2 and ER2 can be formed on the lead side by the inclining process is that the bent connection portions EL and ER that exit from the same slot to the coil end do not intersect.
- the enamel of the conductive wire is not damaged.
- the first bent portion EL1 and the second bent portion ER2 which are bent at the bent connection portions EL and ER are formed, and therefore the circumferential conductor portions UAE and UCE are formed at the coil end.
- the lane portion is formed in one stage without interference.
- the two-step edgewise bending process is performed on the non-lead side because the bending connection portion EL and ER that exits from the same slot to the coil end intersect on the non-lead side, as in the lead side. This is because the second bent part ER2 cannot be formed by the tilting process.
- the conductor UB (second U-phase conductor), conductor VA (first V-phase conductor), conductor VB (second conductor V-phase) are sequentially arranged on the conductor UA (first conductor U-phase).
- Conducting wire WA (W-phase first conducting wire), conducting wire WB (W-phase second conducting wire), conducting wire UC (U-phase third conducting wire), conducting wire UD (U-phase fourth conducting wire), conducting wire VC (V-phase third conducting wire), conducting wire VD (V-phase fourth conducting wire), conducting wire WC (W-phase third conducting wire), conducting wire WD (W-phase fourth conducting wire) are overlapped while being shifted by one slot. Indicates the state.
- the conductors UA, UB, VA, VB, WA, WB, UC, UD, VC, VD, WC, and WD arranged from the left are stacked while being shifted by one slot so as to be sequentially on the upper side. That is, the conducting wire UA is located at the bottom and the conducting wire WD is located at the top.
- FIG. 14 is a perspective view showing a state where the twelve conductive wires UA, UB, VA, VB, WA, WB, UC, UD, VC, VD, WC, and WD shown in FIG.
- a plan view of FIG. 14 is shown in FIG. Since the stator of the present embodiment includes 48 slots on the inner periphery, the U-phase first assembled conductor UAC shown in FIG. 11 includes eight in-slot conductor portions UACS1 to UACS8 in the first periphery. Similarly, the U-phase second set conductor UBD includes eight in-slot conductors UBDS1 to UBDS8 in the first round.
- the first V-phase set conductor VAC includes eight in-slot conductors VACS1 to VACS8 in the first turn.
- the V-phase second set conductor VBD includes eight in-slot conductors VBDS1 to VBDS8 in the first turn.
- the W-phase first set conductor WAC includes eight in-slot conductors WACS1 to WACS8 in the first turn.
- the W-phase second set conductor WBD is provided with eight in-slot conductor parts WBDS1 to WBDS8 in the first turn.
- Each of the six assembled conductors UAC, UBD, VAC, VBD, WAC, WBD has eight in-slot conductors S in the first round, so that 48 in-slot conductors S are formed in the first round. Is done.
- the 48 in-slot conductor portions S are located so as to be shifted by one slot.
- the three-phase coil G according to the present embodiment is completed by winding up six sets of assembly wires three times. Therefore, the in-slot conductor part (for example, UACS10) in the second round is stacked outside the in-slot conductor part S (for example, UACS2) in the first round, and further, the in-slot conductor part in the third round on the outside. (Eg, UACS 18) are stacked. That is, the in-slot conductor portions are stacked in three stages. 14 and 15 show the timing at which the second round is finished and the third round is started.
- the circumferential conductor E is overlapped in the stator radial direction.
- the bent portions of the conductive wires interfere with each other at the coil end, so that a useless space is generated at the coil end, the coil swells in the stator radial direction, and the coil increases in the stator radial direction. It was.
- the bent portion of the conducting wire does not interfere at the coil end, so that there is no useless space at the coil end, and therefore the swelling of the coil in the stator radial direction is reduced. Yes. In this way, the three-phase coil G is downsized in the stator radial direction.
- the basic configuration of the three-phase coil G is the same as that of the coil cage in the proposed technology, and details thereof are described in Japanese Patent Application No. 2009-016549, so detailed description of the three-phase coil G is omitted here. To do.
- FIG. 16 is a conceptual diagram showing the arrangement of the in-slot conductor portions in the stator. For convenience, the slots that are originally arranged on the circumference are displayed in a straight line.
- the in-slot conductors include a U1 phase composed of a first U-phase conductor UAC (conductor UA + conductor UC), a U2-phase second conductor UBD (conductor UB + conductor UD), and a V-phase first group.
- W1 phase consisting of V1 phase consisting of conducting wire VAC (conducting wire VA + conducting wire VC), V2 phase consisting of V-phase second set conducting wire VBD (conducting wire VB + conducting wire VD), W-phase first set conducting wire WAC (conducting wire WA + conducting wire WC).
- the W2 phase composed of the second set of conductive wires WBD of W phase is sequentially arranged.
- the four in-slot conductors S are arranged in close contact with each in-slot conductor S in the first round.
- the in-slot conductor UACS6 arranged in the first round of the U1 phase is circular so that the long side is in the diameter direction from the left side to UAS6Y, UAS6X, UCS5Y, UCS5X. They are arranged in close contact with each other in the circumferential direction.
- the in-slot conductor portion UCS5 (UCS5X + UCS5Y) is connected to the UACS 7 disposed in the next U1-phase slot by a circumferential conductor portion UCE5 appearing on the upper side as shown in FIG.
- the in-slot conductor portion UAS6 (UAS6X + UAS6Y) is connected to the UACS7 disposed in the next U1-phase slot by the circumferential conductor portion UAE6 hidden on the lower side.
- the in-slot conductor UBDS6 has four in-slot conductors UBS6Y, UBS6X, UDS5Y, and UDS5X sequentially stacked in close contact with each other in the circumferential direction so that the long side is in the diameter direction. Has been placed.
- the in-slot conductor UDS5 (UDS5X + UDS5Y) arranged in the first round of the U2 phase is connected to the UBDS7 arranged in the next U1 phase slot by the circumferential conductor UDE5 appearing on the upper side as shown in FIG. is doing.
- the in-slot conductor part UBS6 (UBS6X + UBS6Y) is connected to the UBDS 7 arranged in the next U1-phase slot by the circumferential conductor part UBE6 hidden underneath.
- FIG. 17 shows a cross-sectional view of the vicinity of the circumferential conductor portion.
- the U1 phase and the U2 phase are arranged so as to overlap each other in the diameter direction, and then the V1 phase and the V2 phase are arranged so as to overlap each other in the diameter direction. Since the W2 phases are arranged so as to overlap in the diameter direction, the number of places where the interphase insulating paper 21 is attached can be reduced.
- the shape of the V1 phase, V2 phase, W1 phase, and W2 phase conductors a detailed description is omitted, but the twisted portions of the V1, V2, W1, and W2 phases do not interfere with other phases. In addition, it is adjusted at the twisted part so that it can be easily inserted.
- the three-phase coil G is completed by winding up to the third turn.
- the in-slot conductor UACS14 is disposed on the outer periphery of the first in-slot conductor UACS6 of the U1 phase, and the in-slot conductor UACS22 is further disposed on the outer periphery thereof.
- an in-slot conductor UACS15 is arranged on the outer circumference of the first in-slot conductor UACS7 of the U1 phase
- an in-slot conductor UACS23 is arranged on the outer circumference thereof.
- the in-slot conductor portion UBDS14 is disposed on the outer periphery of the first in-slot conductor portion UBDS6 of the U2 phase, and the in-slot conductor portion UBDS22 is disposed on the outer periphery thereof. Further, an in-slot conductor portion UBDS15 is disposed on the outer periphery of the first in-slot conductor portion UBDS7 of the U2 phase, and an in-slot conductor portion UBDS23 is disposed on the outer periphery thereof.
- the three-phase coil G is completed by completely winding the one shown in FIG.
- segmented core member H is mounted
- the plurality of in-slot conductors S can be overlapped in the circumferential direction so that the long side of the cross section is in the radial direction of the stator 10, so that the in-slot conductors are located at positions that do not interfere with other phases. Since the portion S can be arranged, the slots can be connected by a minimum path, and a plurality of circumferential conducting wire portions E are overlapped in the circumferential direction of the stator 10 at the coil end. Since the space occupied at the coil end can be minimized, the coil end can be made smaller. Further, since it is not necessary to braid the coil at the coil end, the production efficiency can be increased.
- the bending connection portions EL and ER are provided with two bending portions EL1, EL1, EL2, and ER2, thereby making the lane portion at the coil end one stage.
- the lane portion can be made one stage by increasing the bend R without providing two bend portions in the bend connection portion.
- the coil end height z and the distance d are increased.
- the second bent portions EL2 and ER2 are formed by the tilting process performed after the twisting process, whereby the lane part at the coil end is made one stage.
- the lane portion can be made one stage by pulling the circumferential conducting wire portion E left and right.
- the enamel coating of the conductive wire may be damaged, and the insulation performance may be significantly reduced.
- the second bent portions EL2 and ER2 on the lead side are formed by a tilting process performed after twisting, but the second bent portions EL2 and ER2 are twisted similarly to the anti-lead side.
- the first bent portions EL1 and ER1 and the second bent portions EL2 and ER2 may be formed by bending performed before processing, that is, by two-stage edgewise bending.
- the conductor material portion in the slot is twisted in a state where two conductor materials are overlapped.
- twisting may be performed for each conductor material. it can.
- UASX, UASY, UCSX, UCSY four rectangular conductors (UASX, UASY, UCSX, UCSY) are overlapped as the in-slot conductor S, but two conductors UA and UC are shifted by one pitch. (UASX, UCSX) may be overlapped. Moreover, you may comprise 6 conductors (UASX, UASY, UAZZ, UCSX, UCSY, UCSZ) by superposing
- the twisted portions HM and HN are formed with curved surfaces, but may be formed with a flat surface having steps. Furthermore, although the circumferential conducting wire portion E is kept in the shape of the original conducting wire, it may be made thinner than the original shape by pressing. By further thinning the circumferential conductor E by press working, the size in the stator radial direction can be reduced.
- stator assembly shown in FIG. 18 may be molded with resin to form a stator.
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Abstract
Description
また、順次編み込む工程を採用しない場合には、スロット間のコイルエンド結線において、他相をまたぐので、長いコイル線を3次元的に配置しなければならず、コイルエンド結線が長くなり、コイルエンドが大きくなるという問題が生じる。
ところが、上記した提案技術では、図21に示すように、コイル籠を形成するために導線同士を重ね合わせた際に、コイルエンドにおいて導線の曲げ部分が干渉し合う。そのため、レーン部が2段となってコイルエンドに無駄なスペースが生じ、ステータ径方向(バックヨーク側)へコイルが膨らんでしまい、ステータ径方向に大型化するという問題があった。
また、コイルエンドにおいて、コイルを編み込む必要がないため、生産効率を上げることもできる。
図1に、導線の材料を示す。図1に示すのは、U相の第1導線である導線材料UAXXである。導線材料UAXXは、所定位置で45°のエッジワイズ曲げが行われ、略「十」形状に形成されるとともに、紙面前後方向にクランク成形されている。導線材料UAXXの長さは、ほぼステータ1周分である。本実施の形態における導線UAXXの断面は、短辺が1mm、長辺が6mmの矩形状である。図1に見えているのは、長辺であり、短辺は厚みとしてある。材質は、銅であり、絶縁のためのエナメル被覆がされている。エナメル被覆の厚みは、図1のように変形されても、十分な絶縁性を保つことができるように、設定している。なお、図1は、直線状であった導線材料UAXXに対して曲げ加工及びクランク成形を行った状態を示している。
曲げ接続部EL,ERのうち、リード側に配置される円周導線部E2,E4,・・・の左右に形成されている箇所(E2L,E2R,・・・)では、一段階で45°のエッジワイズ曲げが行われている。また、曲げ接続部EL,ERのうち、反リード側に配置される円周導線部E1,E3,・・・の左右に形成されている箇所(E1L,E1R,・・・)では、二段階に45°のエッジワイズ曲げ行われている。
曲げ角度を決定するためのパラメータには、材料パラメータと、設計パラメータと、性能設計パラメータと、性能パラメータとがある。そして、材料パラメータには、図3に示す導線幅a、及び導線厚bが含まれる。設計パラメータには、図3に示すスロット挿入部長さLs、捻り部長さLn、リード側捻り部干渉回避長さL1、反リード側捻り部干渉回避長さL2、反リード側曲げ接続部直線長さL3、リード側第1曲げ角度θ1x、及び反リード側第1曲げ角度θ1yが含まれる。性能設計パラメータには、図3に示す曲げRの大きさR、及び捻り幅cが含まれる。性能パラメータには、図3に示すコイルエンド高さz、及び距離dが含まれる。なお、距離dは、隣接するスロットに配置されたスロット内導線部の端部に形成された捻り部同士が干渉するか否かを判断するための指標となるものであり、距離dが隣接するスロット間の距離より小さければ捻り部同士の干渉が起こらないことを意味する。
スロット挿入部長さLsは、ステータ積厚に依存するものであり、本実施の形態では、Ls=50(mm)である。捻り部長さLnは、式(1)により決定される。
なお、エナメル被覆の厚みは、図5のように捻り加工されても、十分な絶縁性を保つことができるように、設定している。
6個の組導線UAC、UBD、VAC、VBD、WAC、WBDの各々が、1周目に8箇所のスロット内導線部Sを備えるので、1周目に48箇所のスロット内導線部Sが形成される。48箇所のスロット内導線部Sは、1スロット分ずつずれて位置している。
これに対して、本実施の形態に係る三相コイルGでは、コイルエンドにおいて導線の曲げ部分が干渉しないため、コイルエンドに無駄なスペースがなくなるのでステータ径方向へのコイルの膨らみが低減されている。このようにして、三相コイルGでは、ステータ径方向への小型化が図られている。
なお、三相コイルGの基本的な構成は、提案技術におけるコイル籠と同じあり、その詳細は特願2009-016549号に記載しているので、ここでは三相コイルGの詳細な説明は省略する。
スロット内導線部は、U相の第1組導線UAC(導線UA+導線UC)からなるU1相、U相の第2組導線UBD(導線UB+導線UD)からなるU2相、V相の第1組導線VAC(導線VA+導線VC)からなるV1相、V相の第2組導線VBD(導線VB+導線VD)からなるV2相、W相の第1組導線WAC(導線WA+導線WC)からなるW1相、W相の第2組導線WBD(導線WB+導線WD)からなるW2相が順次並んで配置されている。
また、スロット内導線部UAS6(UAS6X+UAS6Y)は、下側に隠れている円周導線部UAE6により、次のU1相スロットに配置されたUACS7に接続している。
U2相の1周目に配置されているスロット内導線部UDS5(UDS5X+UDS5Y)は、図16に示すように上側に表れた円周導線部UDE5により、次のU1相スロットに配置されたUBDS7に接続している。
また、スロット内導線部UBS6(UBS6X+UBS6Y)は、下側に隠れている円周導線部UBE6により、次のU1相スロットに配置されたUBDS7に接続している。
V1相、V2相、W1相、W2相の導線の形状については、詳細な説明を割愛するが、V1相、V2相、W1相、W2相の捻り部は、他相と干渉しないように、また挿入しやすいように、捻り部で調整している。
U2相の1周目のスロット内導線部UBDS6の外周にスロット内導線部UBDS14が配置され、さらにその外周にスロット内導線部UBDS22が配置される。また、U2相の1周目のスロット内導線部UBDS7の外周にスロット内導線部UBDS15が配置され、さらにその外周にスロット内導線部UBDS23が配置される。
図14に示すものを完全に巻き取ることにより、三相コイルGが完成する。さらに、三相コイルGに対して、分割された分割コア部材Hを、各スロット内導線部の間の空間に、外周から装着し固定する。そして、外部接続端子を固着する。これにより、図18に示すステータ10が完成する。
また、コイルエンドにおいて、コイルを編み込む必要がないため、生産効率を上げることもできる。
さらに、円周導線部Eを、元の導線の形状のままとしているが、プレス加工により、元の形状よりさらに薄くしても良い。円周導線部Eをプレス加工により、さらに薄くすることにより、ステータ径方向の大きさを小型化することができる。
E 円周導線部
EL,ER 曲げ接続部
EL1,ER1 第1曲げ部
EL2,ER2 第2曲げ部
G 三相コイル
HM,HN 捻り部
S スロット内導線部
UA,UB,UC,UD U相導線
UAC U相第1組導線
UBD U相第2組導線
VA,VB,VC,VD V相導線
VAC V相第1組導線
VBD V相第2組導線
WA,WB,WC,WD W相導線
WAC W相第1組導線
WBD W相第2組導線
Claims (7)
- 断面が矩形状の導線を用いたコイルを有するステータにおいて、
前記導線が、つづら折り状に連続して形成されており、
前記ステータのスロット内に、前記導線を、前記矩形の長辺が前記ステータの径方向となるように、前記ステータの円周方向に複数重ねて配置したスロット内導線部と、
コイルエンドに、前記導線を、前記矩形の短辺が前記ステータの径方向となるように、前記ステータの径方向に複数重ねて配置した円周導線部と、
前記スロット内導線部と前記円周導線部とを接続する曲げ接続部と、
前記曲げ接続部内に形成された捻り部と、
を有し、
前記曲げ接続部には、前記円周導線部側に形成された第1曲げ部と、前記スロット導線部側に形成された第2曲げ部とが設けられている
ことを特徴とするステータ。 - 請求項1に記載するステータにおいて、
前記第1曲げ部における曲げ角度θ1がθ1<90°であり、
前記曲げ角度θ1と前記第2曲げ部における曲げ角度θ2とが、θ1+θ2=90°の関係を満たす
ことを特徴とするステータ。 - 請求項1又は請求項2に記載するステータにおいて、
一方のコイルエンド側における第2曲げ部は、前記捻り部が形成された後に前記曲げ接続部をステータ側に倒し込むことにより形成される
ことを特徴とするステータ。 - 請求項1から請求項3に記載するいずれか1つのステータにおいて、
他方のコイルエンド側における第2曲げ部は、前記捻り部が形成される前に前記導線をエッジワイズ曲げすることにより形成される
ことを特徴とするステータ。 - 断面が矩形状の導線を用いたコイルを有するステータの製造方法において、
前記導線に対して90°より小さい角度でエッジワイズ曲げを行う曲げ工程と、
前記曲げ工程が実施された前記導線のうちステータのスロットに内に配置される部分を捻る捻り工程と、
を含み、
前記曲げ工程にて、前記導線のうち少なくとも一方のコイルエンド側に位置する箇所に対して2段階にエッジワイズ曲げを行う
ことを特徴とするステータの製造方法。 - 請求項5に記載するステータの製造方法において、
前記曲げ工程にて、前記導線のうち一方のコイルエンド側に位置する箇所に対しては1段階のエッジワイズ曲げを行い、
前記捻り工程が実施された前記導線の捻り部のうち前記一方のコイルエンド側に位置するものの端部を、倒し込む倒し込み工程をさらに含む
ことを特徴とするステータの製造方法。 - 請求項5又は請求項6に記載するステータの製造方法において、
前記捻り工程にて、前記曲げ工程が実施された複数の前記導線同士を、捻り位置を合わせて重ねた状態で同時に捻る
ことを特徴とするステータの製造方法。
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US13/131,838 US8987969B2 (en) | 2009-09-30 | 2009-09-30 | Stator and manufacturing method thereof |
CN2009801547450A CN102282745B (zh) | 2009-09-30 | 2009-09-30 | 定子及其制造方法 |
PCT/JP2009/066995 WO2011039850A1 (ja) | 2009-09-30 | 2009-09-30 | ステータ及びその製造方法 |
JP2010540985A JP5278440B2 (ja) | 2009-09-30 | 2009-09-30 | ステータ及びその製造方法 |
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DE102017104932A1 (de) * | 2016-03-08 | 2017-09-14 | Grob-Werke Gmbh & Co. Kg | Herstellungsverfahren für einen Stator |
US10305335B2 (en) * | 2016-07-14 | 2019-05-28 | Hitachi Automotive Systems, Ltd. | Stator for rotating electrical machine and rotating electrical machine |
DE102016222385A1 (de) * | 2016-11-15 | 2018-05-17 | Robert Bosch Gmbh | Laserschweißverfahren für Stator |
EP3893362A1 (de) * | 2020-04-07 | 2021-10-13 | Wobben Properties GmbH | Formspule für ein windenergieanlagengenerator sowie deren herstellung und windenergieanlage damit |
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CN102282745A (zh) | 2011-12-14 |
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