WO2015092833A1 - 回転電機 - Google Patents
回転電機 Download PDFInfo
- Publication number
- WO2015092833A1 WO2015092833A1 PCT/JP2013/007460 JP2013007460W WO2015092833A1 WO 2015092833 A1 WO2015092833 A1 WO 2015092833A1 JP 2013007460 W JP2013007460 W JP 2013007460W WO 2015092833 A1 WO2015092833 A1 WO 2015092833A1
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- WIPO (PCT)
- Prior art keywords
- phase
- winding
- stator core
- coil
- stator
- Prior art date
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Classifications
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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
- H02K3/28—Layout of windings or of connections between windings
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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
- H02K3/18—Windings for salient poles
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- 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
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/0094—Structural association with other electrical or electronic devices
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/52—Fastening salient pole windings or connections thereto
- H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
- H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
Definitions
- the present invention relates to a winding wound around a stator of a rotating electric machine.
- the stator of the three-phase brushless motor has a stator core that is an iron core, a winding wound around the outer periphery of the teeth of the stator core, a bus bar that is electrically connected to the end of the coil, and an insulation between the bus bar. It is comprised from the insulation holder hold
- a rotating electrical machine provided with such a stator, for example, a rotating electrical machine described in Patent Document 1 has been proposed.
- U-phase connection bus ring U-phase connection bus ring
- W-phase connection bus ring W-phase connection bus ring
- neutral point connection bus ring of which, each phase connection bus ring Is disposed on one end side of both axial end portions of the stator core, and the neutral point connecting bus ring is disposed on the other end side of the axial end portions of the stator core.
- This rotating electrical machine distributes each phase connection bus ring and neutral point connection bus ring to one end side and the other end side of the axial ends of the stator core. As a result, it is avoided that the space for arranging the bus rings is required only on one end side in the axial direction of the stator core, thereby reducing the outer diameter of the stator. It can be done.
- the outer diameter of the stator is obtained by distributing each phase connection bus bar and the neutral point connection bus bar to one end side and the other end side in the axial direction of the stator core.
- the bus bars are covered by the bus bar, especially the coil end portions, which are wound around the periphery of the stator core by disposing the bus bar at both axial ends of the stator core. For this reason, there is a problem that the cooling performance with respect to the coil end portion is lowered.
- each phase connection bus bar and the neutral point connection bus bar are arranged only on one end side in the axial direction of the stator core, the coil end portion on the other end side in the axial direction of the stator core Since the coil end portion is exposed to a coolant (eg, cooling air or cooling oil) and the coil end portion is cooled, there is a problem that the outer diameter of the stator is increased.
- a coolant eg, cooling air or cooling oil
- the present invention has been made to solve the above problems, and an object of the present invention is to provide a rotating electrical machine in which the cooling performance of a winding wound around a stator core is improved while reducing the outer diameter of the stator. To do.
- a rotating electrical machine includes a stator core having an annular core back and a plurality of teeth, and is wound around the teeth, and one end and the other end of each of the axial end portions of the stator core.
- a plurality of windings for U-phase, V-phase, and W-phase extending from the part side and the other end side, a bobbin that insulates the stator core and the winding, and both axial ends of the stator core
- U-phase, V-phase, and W-phase power supply bus bars arranged on one end side of the coil, and a coil group is formed by windings of the U-phase, V-phase, and W-phase.
- each coil group One end of the winding forming each coil group is connected to the power bus bar of each phase, and the other end of the winding of each phase is a phase located at both ends of the winding. The other end of the winding faces the other end of the remaining phase winding.
- FIG. 4 is a perspective view around the other end (23U2, 23V2, 23W2) of each phase winding forming the coil group 23G of FIG. 3; It is a modification of the bobbin 22 shown in FIG. It is another modification of the bobbin 22 shown in FIG. It is a modification of the other end (23U2, 23V2, 23W2) of the coil
- FIG. 1 is a cross-sectional view of rotating electric machine 100 according to Embodiment 1 of the present invention.
- 2 and 3 are plan views schematically showing the configuration of the stator 20 of the rotating electrical machine 100 shown in FIG. 1, wherein FIG. 2 is a front side plan view, FIG. 3 is a back side plan view, and FIG. FIG. 3 is a cross-sectional view taken along line AA in FIG.
- FIG. 5 is a perspective view around the other end (23U2, 23V2, 23W2) of each phase winding forming one coil group 23G of FIG.
- a rotating electrical machine 100 shown in FIG. 1 includes a rotor 10 and a stator 20, and the outer peripheral surface of the rotor 10 faces the inner peripheral surface of the stator 20 with a predetermined gap therebetween.
- the rotor 10 is fixed to the rotor shaft 60.
- the stator 20 is fitted into a cylindrical frame 70.
- the stator 20 holds an annular stator core 21, a bobbin 22 attached to the stator core 21, a stator coil 23 that is a winding wound around the stator core 21 via the bobbin 22, and the stator core 21. It has a core holder 24, a plurality of power bus bars 25 electrically connected to one end of the stator coil 23, and a bus bar holder 27 that holds each power bus bar 25.
- the stator core 21 has a plurality of teeth portions 21b (12 in the example of FIG. 2) protruding at equal intervals from the inner peripheral side of the annular core back portion 21a, and is divided by the core back portion 21a for each tooth portion 21b.
- the plurality of divided cores are combined in a ring shape and press-fitted into the core holder 24.
- a three-phase coil constituting a stator coil 23 described later is wound around the tooth portion 21b.
- the bobbin 22 is an insulating member that electrically insulates between the stator coil 23 and the tooth portion 21b of the stator core 21, and is disposed at both axial ends of the tooth portion 21b.
- the bobbin 22 may be configured integrally with a bus bar holder 27 described later.
- extending portions 22 a and 22 b extending outward in the axial direction are provided on the inner peripheral side and the outer peripheral side of the bobbin 22, and the cross-sectional shape viewed from the circumferential direction is provided. It has an almost U shape.
- a slit 22 c is formed near the center in the circumferential direction of the extending portion 22 b provided on the outer peripheral side of the bobbin 22.
- the slit 22c is formed in the extending portion 22b of the bobbin 22, so that the stator coil 23 wound through the bobbin 22 can be seen from the outside in the radial direction.
- the refrigerant 30 passes through the slit 22c and flows inward in the radial direction, and is configured to hit the coil end portion 23a of the stator coil 23.
- the present invention is not limited to this, and the refrigerant hits the coil end portion through the slit. Any configuration may be used. For example, a configuration in which a spiral slit is formed or a configuration in which a gap or a hole is formed in the radial direction may be employed.
- ATF Auto Transmission Fluid
- AT Automatic Transmission
- a groove 22e for supporting the other end (23U2 to 23W2) of the stator coil 23 is formed on the outer peripheral side of the bobbin 22 and on the axial end face 22d thereof.
- the groove 22e is formed in the radial direction to the outer peripheral side of the bobbin 22 so that the circumferential position of the other end of the stator coil 23 is regulated, and the other end of the stator coil 23 is supported by the groove 22e.
- the circumferential position of the other end of the stator coil 23 is regulated.
- the stator coil 23 is a winding wound around the tooth portion 21 b of the stator core 21 via the bobbin 22. More specifically, the U-phase winding 23U, the V-phase winding 23V, and the W-phase winding 23W are each a three-phase coil including a plurality of windings, and the rotation for rotating the rotor 10 is performed. Generate a magnetic field.
- One end of the stator coil 23 extends outward in the axial direction from one end side (the right side in FIG. 4) of both end portions in the axial direction of the stator core 21, and the power bus bar 25 (see FIG. 4) corresponding to each phase. In the example of FIG.
- a coil group 23G is formed by the windings 23U to 23W of the respective phases constituting the three-phase coil (stator coil 23).
- a coil group 23G is formed by three windings each including one winding 23U to 23W of each phase, and four (plural) coil groups 23G are formed.
- the present invention is not limited to this, and the coil group only needs to include one or more windings of each phase.
- the coil group is configured to include a plurality of windings of each phase. It may be.
- the coil group includes a plurality of windings for each phase, for example, when the coil group is formed by six windings each including two windings for each phase, the U-phase winding includes two windings. When these windings are connected in parallel, as in the case shown in FIGS.
- one end of each of the two U-phase windings and The other end is one end and the other end of the U-phase winding.
- one end of the winding U1 becomes one end of the U-phase winding
- the winding U2 Is the other end of the U-phase winding.
- one end (23U1 to 23W1) of each phase winding forming each coil group 23G is connected to the power supply bus bar 25 (U phase bus bar 25U to W phase bus bar 25W) corresponding to each phase. Is done.
- both (23W2) are bent in the circumferential direction and extended in the circumferential direction toward the other end (23V2) of the V-phase winding 23V, and the V-phase winding 23V Are connected to each other by, for example, TIG welding in the vicinity of the other end (23V2). That is, in each coil group 23G, the other ends (23U2, 23W2) of the phase windings located at both ends in the circumferential direction extend toward the other end (23V2) of the remaining phase windings. The other ends (23U2 to 23W2) of the windings of each phase forming the coil group 23G are connected to each other.
- the core holder 24 is a ring-shaped holder that holds the stator core 21 from the outer peripheral side or one axial side of the rotating electrical machine 100.
- the power bus bar 25 is a conductive member made of copper or copper alloy or the like formed in a ring shape (annular shape), and is disposed on one end side of the stator core 21 as shown in FIG. Yes.
- the power bus bar 25 includes a U-phase bus bar 25U, a V-phase bus bar 25V, and a W-phase bus bar 25W corresponding to each phase (U-phase, V-phase, and W-phase) of the stator coil 23, and the U-phase bus bar 25U is located on the inner side.
- the V-phase bus bar 25V and the W-phase bus bar 25W are stacked in the radial direction in this order.
- the bus bar holder 27 is made of, for example, an electrically insulating resin member, and holds the power supply bus bar 25 (more specifically, the U-phase bus bar 25U, the V-phase bus bar 25V, and the W-phase bus bar 25W).
- the bus bar holder 27 is mounted on one side in the axial direction of the stator core 21 and on the outer peripheral side of the bobbin 22.
- the bus bar holder 27 may be configured integrally with the bobbin 22.
- the bus bar holder 27 has, for example, a concave holding groove 27b for holding the power bus bar 25.
- the bus bar holder 27 is held in the holding groove 27b so as to be inserted from the axial direction of the rotating electrical machine 100 in a state where the U-phase bus bar 25U to the W-phase bus bar 25W are stacked in the radial direction.
- an adhesive such as silicon is bonded between the bus bar holder 27 and the U-phase bus bar 25U to W-phase bus bar 25W.
- both are bonded.
- the stator 20 according to Embodiment 1 of the present invention is wound around the stator core 21 having the annular core back 21a and the plurality of teeth 21b, and the teeth 21, and one end and the other end thereof are wound.
- a plurality of windings 23 (23U, 23V, 23W) for U-phase, V-phase, and W-phase respectively extending from one end side and the other end side of both end portions of the stator core 21 in the axial direction. )
- the bobbin 22 that insulates the stator core 21 and the winding 23, and the U-phase, V-phase, and W-phase respectively disposed on one end side of the axial end portions of the stator core 21.
- a power bus bar 25 25U, 25V, 25W
- a coil group 23G composed of windings 23 (23U, 23V, 23W) of U phase, V phase and W phase is formed, and each coil group 23G is formed phase
- One end of the winding (23U1, 23V1, 23W1) is connected to the power bus bar 25 (25U, 25V, 25W) of each phase, and in addition to the winding of the phase located at both ends in the circumferential direction in the coil group 23G
- the ends (23U2, 23W2) extend toward the other ends (23V2) of the remaining phase windings, so that the other ends (23U2, 23V2, 23W2) of the respective phase windings are connected to each other.
- the U-phase winding 23U of one coil group 23G and the W-phase winding 23W of the other coil group 23G are adjacent to each other in the circumferential direction.
- the other ends of both windings extend in the circumferential direction from the other end side of the stator core 21, but extend in opposite directions from each other. Since the refrigerant passes through the gap formed on the other end side and hits the coil end portion 23a of the stator coil 23, the coil end portion 23a is cooled, and thus the cooling performance of the winding 23 wound around the stator core 21 is improved. Can be made.
- a coil group 23G is formed by windings (23U, 23V, 23W) of U phase, V phase, and W phase, and one end (23U1, 23V1, 23W1) of winding 23 is connected to power bus bar 25 (25U) of each phase. , 25V, 25W), and the other ends (23U2, 23V2, 23W2) of the winding 23 are connected to each other, and the connecting portion 23b becomes a neutral point.
- the connecting portion 23b becomes a neutral point.
- the extending portion 22b extending in the axial direction is provided on the outer peripheral side of the bobbin 22, and the slit 22c is formed in the extending portion 22b. Therefore, the refrigerant 30 on the outer peripheral side of the stator 20 passes through the slit 22c and directly hits the coil end portion 23a of the winding 23, thereby cooling the coil end portion 23a. The cooling performance of the wound winding wire 23 can be further improved.
- the other ends (23U2, 23V2, 23W2) of the windings of the respective phases forming the coil group 23G have an outer diameter from the other end side in the axial direction of the stator core 21. Since the groove 22e that further restricts the circumferential position of the other end (23U2, 23V2, 23W2) of the winding of each phase is further provided on the outer peripheral side of the bobbin 22, The other end (23U2, 23V2, 23W2) of the winding of each phase is supported in the groove 22e, and the circumferential position thereof is regulated.
- the winding adjacent to the circumferential direction by the spring back of the winding Since the other ends of the windings of each phase toward the circumferential direction can be prevented from spreading in the circumferential direction, and therefore, the other ends of the windings of adjacent coil groups can be prevented from contacting each other. Winding each adjacent phase Insulation between can be reliably ensured. Moreover, since the circumferential position of the other end (23U2, 23V2, 23W2) of the winding of each phase in the stator 20 is regulated, the other end (23U2, 23V2, 23W2) of each phase and the coil The refrigerant flows stably to the end portion 23a, and the cooling performance is further improved.
- the restricting means for restricting the circumferential position of the other end (23U2, 23V2, 23W2) of each phase winding is formed on the axial end face 22d of the bobbin 22, and the other end (23U2, 23V2, 23W2), the other end (23U2, 23V2, 23W2) of the winding of each phase can be reliably fixed. As a result, it is possible to reliably fix the connection point at which the other ends (23U2, 23V2, 23W2) of the windings of each phase are connected to each other.
- the other ends (23U2, 23V2, 23W2) of the windings of each phase are connected to each other by welding, and the other ends (23U2, 23V2, 23W2) of the windings of each phase are connected.
- an adhesive 26 is used to support the other ends (23U2, 23V2, 23W2) of the windings of each phase, but in order to improve the vibration resistance of the windings, for example.
- the other ends (23U2, 23V2, 23W2) of the windings of each phase may be bonded to the bobbin 22.
- a slit 22c is formed on the right side (right side in FIG.
- the slit 22c1 is formed over the entire coil end portion 23a, and the other end (23U2, 23V2, 23W2) of the winding of each phase may be supported in the slit 22c1.
- each phase winding 23U2, 23V2, 23W2 in the example of FIG. 7
- the bobbin 22 located between the groove 22e and the slit 22c2 extends. Since the portion 22b serves as a stopper that suppresses the radially inward movement of the other ends of the phase windings (23U2 and 23W2 in the example of FIG. 7) located at both ends in the circumferential direction, The other end of the winding can be more reliably fixed, and hence the connection point can be more reliably fixed.
- the windings of the phases positioned at both ends are extended from the other end side of the stator core in the outer diameter direction.
- the other end of the stator core is bent in the circumferential direction and connected to each other by being bent outward in the axial direction after welding.
- the present invention is not limited to this, and as shown in FIG. After extending from the end side in the outer diameter direction, it is bent outward in the axial direction, and the other ends of the phase windings located at both ends are bent in the circumferential direction and connected to each other by welding. Good.
- connection method it is possible to suppress the coil from extending radially outward after the coil (winding) is hooked in the groove during winding. Furthermore, in the first embodiment, the case where both the slit 22c and the groove 22e are formed on the bobbin 22 has been described. However, as shown in FIG. 9, only the groove 22e may be formed. Needless to say. 9 is a perspective view of the periphery of the connecting portion 23b1, where (a) shows a perspective view before welding and (b) shows a perspective view after welding, as shown in FIG. 9 (a). Before welding, the other end of each phase winding may be bent outward in the axial direction and welded.
- the restricting means for restricting the circumferential position of the other end (23U2, 23V2, 23W2) of the winding of each phase is formed on the axial end face 22d of the bobbin 22,
- the groove 22e supporting the other end (23U2, 23V2, 23W2) of the winding is shown, instead of the groove 22e, as shown in FIG. 10, the other end (23U2, 23V2) of each phase winding is shown.
- 23W2) may be formed through the through hole 22f.
- the circumferential position of the other end of each phase winding is regulated, and the axial position of the other end of each phase winding is also regulated. Fixing can be ensured, and therefore the connection point can be fixed more reliably.
- FIG. 11 is a perspective view around the neutral point holder 41 constituting the stator 40 of the rotating electrical machine 200 according to Embodiment 2 of the present invention.
- the rotating electric machine 200 including the stator 40 according to the second embodiment includes a neutral point holder 41 that holds a connection point to which the other end of each phase winding is connected.
- subjected to FIG. 11 shows the same part.
- the neutral point holder 41 is made of, for example, a resin member having electrical insulation, and holds a connection portion 23b to which the other ends (23U2, 23V2, 23W2) of the windings of each phase are connected. To do.
- the neutral point holder 41 is disposed on the outer peripheral side of the bobbin 22 on the axial end surface 21 e of the core back portion 21 a on the other end side in the axial direction of the stator core 21.
- the neutral point holder 41 is bonded, for example, by filling the adhesive 26 between the bottom surface and the axial end surface 21e of the core back portion 21a, and is fixed to the axial end surface 21e of the core back portion 21a.
- the present invention is not limited to this.
- a protrusion protruding inward in the axial direction is provided on the bottom surface of the neutral point holder, and a dovetail groove is provided in the axial end surface of the core back portion of the stator core.
- the provided protrusion may be fixed by a dovetail groove of the stator core.
- the axial length (h1) of the neutral holder 41 is lower than the axial length (h2) of the bobbin 22 from the axial end surface 21e of the core back portion 21a where the neutral point holder 41 is disposed. (See FIG. 11).
- the neutral point holder 41 may be configured integrally with the bobbin 22. Further, the linear expansion coefficient of the neutral point holder 41 is larger than the linear expansion coefficient of the stator coil 23.
- the neutral point holder 41 Since the linear expansion coefficient of the neutral point holder 41 is larger than the linear expansion coefficient of the stator coil 23, the connecting portion 23b of the stator coil 23 is neutral even if the temperature of the stator 20 changes due to the operation of the rotating electrical machine or the like. It can be held in the point holder 41.
- the neutral point holder 41 has, for example, a concave holding groove 41a for holding the connection portion 23b.
- the neutral point holder 41 is held in the holding groove 41 a so that the connection portion 23 b is inserted from the axial direction of the rotating electrical machine 200.
- the adhesive point 26 is filled between the neutral point holder 41 and the connection portion 23b, for example, so that both are bonded.
- the neutral point holder 41 that holds the connection portion 23b to which the other end (23U2, 23V2, 23W2) of the winding of each phase is connected is provided. Since it has, the connection part 23b can be more reliably fixed in the neutral point holder 41. In addition, since the circumferential position of the connecting portion 23b in the stator 40 is also fixed, it is possible to reliably ensure insulation between adjacent windings and the other end of each phase winding (23U2, 23V2). 23W2) is also regulated in the circumferential direction, so that the refrigerant flows stably to the other end (23U2, 23V2, 23W2) of each phase winding and the coil end portion 23a, and the cooling performance is further improved.
- the neutral point holder for holding the winding is disposed on the outer periphery of the stator core
- the neutral point holder 41 is disposed on the axial end surface 21e of the core back portion 21a on the other end side in the axial direction of the stator core 21. Since the refrigerant also flows on the outer periphery of the heat, the heat generated in the stator coil 23 and transmitted to the stator core 21 can be effectively cooled. Furthermore, compared to the stator in which the neutral point holder is disposed on the outer peripheral side of the stator core, the radial length of the portion of the core back portion where the neutral point holder is disposed is shortened with respect to the radial direction. The stator can be downsized in the radial direction.
- the axial length (h1) of the neutral point holder 41 is greater than the axial length (h2) of the bobbin 22 from the axial end surface 21e of the core back portion 21. Therefore, even if the neutral point holder 41 is provided, the axial height of the stator 40 does not change, so that the neutral point holder 41 does not increase in size in the axial direction of the stator. Can be provided.
- the rotary electric machines 100 and 200 shown in the first and second embodiments of the present invention are general rotary electric machines including the rotor 10 and the stator 20, or the rotor 10 and the stator 40, and have a configuration according to the present invention.
- the present invention can be applied to a drive motor (electric motor) having a stator, and can also be applied to, for example, a generator such as an alternator or a motor generator having functions of an electric motor and a generator.
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- Insulation, Fastening Of Motor, Generator Windings (AREA)
- Windings For Motors And Generators (AREA)
Abstract
Description
また、各相結線用バスバーと中性点結線用バスバーとをステータコアの軸方向の一方の端部側にのみ配設した場合、ステータコアの軸方向の他方の端部側のコイルエンド部は、バスバーに覆われていないことから、コイルエンド部に冷媒(例.冷却風、冷却油)があたり、コイルエンド部が冷却されるが、ステータの外径寸法が大きくなるという問題がある。
以下、本発明の実施の形態1について図1~図10に基づいて説明するが、各図において、同一、または相当部材、部位については同一符号を付して説明する。
図1は、本発明の実施の形態1に係る回転電機100の断面図である。図2、3はともに、図1に示す回転電機100のステータ20の構成を模式的に示した平面図であって、図2は正面側平面図、図3は裏面側平面図、図4は、図2のA-A線に沿う断面図である。また、図5は図3の一つのコイル群23Gを形成する各相の巻線の他端(23U2、23V2、23W2)周辺の斜視図である。
図1に示す回転電機100は、ロータ10とステータ20を備え、ロータ10の外周面はステータ20の内周面と所定の間隙を介して対向している。ロータ10はロータ軸60に固定されている。ステータ20は、筒状のフレーム70に嵌合されている。以下では、図2~図5を参照しながら、本発明の実施の形態1に係るステータ20の構成要素について詳述する。
ボビン22の内周側及び外周側には、図2、図3に示すように、軸方向外方に延出する延出部22a、22bが設けられており、周方向から見た断面形状が略コの字状となっている。そして、図5に示すように、ボビン22の外周側に設けられた延出部22bの周方向中央付近には、スリット22cが形成されている。なお、図5に示した例では、ボビン22の延出部22bにスリット22cが形成されることで、このボビン22を介して巻装されたステータコイル23が、径方向外側から見えるようになり、冷媒30はこのスリット22cを通り、径方向内方に流れ、ステータコイル23のコイルエンド部23aにあたるように構成されているが、この場合に限らず、冷媒がスリットを介してコイルエンド部にあたる構成であれば良く、例えば、らせん状のスリットが形成される構成や径方向に向かって隙間や孔が生じる構成としてもよい。
なお、冷媒30としては、空気のほか、例えば、回転電機100の近傍に配置された、AT(Automatic Transmission:自動変速機)内の潤滑・作動油であるATF(Automatic Transmission Fluid:オートマチックトランスミッションフルード)等があり、このATFをステータ20の外周側から滴下もしくは噴射することで、ステータ20が冷却される。
また、3相コイル(ステータコイル23)を構成する各相の巻線23U~23Wでコイル群23Gを形成している。図2、図3には、各相の巻線23U~23Wをそれぞれ1つ含む3つの巻線によりコイル群23Gが形成され、このコイル群23Gが4つ(複数)形成される例が示されているが、この場合に限らず、コイル群が、各相の巻線を1つ以上含むものであれば良く、例えば、各相の巻線をそれぞれ複数含むようにコイル群が構成されるようにしてもよい。なお、コイル群が各相の巻線を複数含む場合として、例えば、各相の巻線をそれぞれ2つ含む6つの巻線によりコイル群が形成される場合、U相の巻線は2つの巻線(それぞれ巻線U1、巻線U2とする)からなり、これらの巻線が並列接続されるときは、図2、図3に示した場合と同様、2つのU相巻線それぞれの一端及び他端が、U相の巻線の一端及び他端となる。また、これらの巻線が直列接続(巻線U1の他端と巻線U2の一端とを接続)されるときは、巻線U1の一端が、U相の巻線の一端となり、巻線U2の他端が、U相の巻線の他端となる。V相の巻線、W相の巻線についても同様である。
それぞれのコイル群23Gを形成する各相の巻線の一端(23U1~23W1)は、前述したように、各相に対応する電源用バスバー25(U相バスバー25U~W相バスバー25W)にそれぞれ接続される。また、それぞれのコイル群23Gを形成する各相の巻線の他端(23U2~23W2)のうち、U相用の巻線23Uの他端(23U2)及びW相用の巻線23Wの他端(23W2)は、図5に示すように、ともに周方向に折り曲げられ、V相用の巻線23Vの他端(23V2)に向かって周方向に延出しており、V相用の巻線23Vの他端(23V2)近傍にて、例えばTIG溶接されることで、互いに接続されている。すなわち、それぞれのコイル群23G内において、周方向両端に位置する相の巻線の他端(23U2、23W2)が残りの相の巻線の他端(23V2)に向かってそれぞれ延出することで、コイル群23Gを形成する各相の巻線の他端(23U2~23W2)は互いに接続されている。
電源用バスバー25は、リング状(円環状)に形成された、銅又は銅合金等からなる導電性部材であり、図4に示すように、ステータコア21の一方の端部側に配設されている。電源用バスバー25は、ステータコイル23の各相(U相、V相及びW相)に対応したU相バスバー25U、V相バスバー25V及びW相バスバー25Wからなり、U相バスバー25Uが内側に位置し、V相バスバー25V、W相バスバー25Wの順に径方向に積層される。
また、U相、V相及びW相の巻線(23U、23V,23W)でコイル群23Gが形成され、巻線23の一端(23U1、23V1,23W1)は、各相の電源バスバー25(25U,25V,25W)にそれぞれ接続されるとともに、巻線23の他端(23U2、23V2,23W2)は、互いに接続されており、その接続部23bが中性点となることから、従来のように中性点結線用バスバーを別途設ける必要がなく、部品点数が削減されるとともに、ステータの外径寸法を小さくすることができる。
したがって、ステータ10の外径寸法を小さくしつつ、ステータコア21に巻回される巻線23の冷却性が向上した回転電機100を提供することができる。
また、各相の巻線の他端(23U2、23V2、23W2)の周方向位置を規制する規制手段は、ボビン22の軸方向端面22dに形成され、各相の巻線の他端(23U2、23V2、23W2)を支持する溝22eであることから、各相の巻線の他端(23U2、23V2、23W2)を確実に固定することができる。その結果、各相の巻線の他端(23U2、23V2、23W2)が互いに接続される接続点の固定も確実に行うことができる。
なお、本実施の形態1においては、各相の巻線の他端(23U2、23V2、23W2)が溶接により互いに接続されることに加え、各相の巻線の他端(23U2、23V2、23W2)を支持する溝22eを備えることにより、各相の巻線の他端(23U2、23V2、23W2)は確実に固定されるが、巻線の耐振性向上のために、例えば接着剤26を使って各相の巻線の他端(23U2、23V2、23W2)がボビン22に接着されるようにしてもよい。
なお、スリット22c及び溝22eの構成として、図5には、ボビン22の外周側に設けられた延出部22bにおいて、径方向外側から見て右側(図5の右側)にスリット22cが形成され、径方向外側から見て左側(図5の左側)に溝22eが形成されており、スリット22c及び溝22eがそれぞれ別々に形成されている場合について示したが、この場合に限らず、図6に示すように、コイルエンド部23a全体にわたってスリット22c1が形成されており、このスリット22c1内にて各相の巻線の他端(23U2、23V2、23W2)が支持される構成としてもよい。また、図7に示すように、溝22eと同程度の周方向幅を有するスリット22c2が形成される構成としてもよい。この場合、各相の巻線の他端(図7の例では、23U2、23V2、23W2)の周方向位置が規制されるとともに、溝22eとスリット22c2との間に位置するボビン22の延出部22bが、周方向両端に位置する相の巻線の他端(図7の例では、23U2、23W2)の径方向内方への移動を抑制するストッパの役割を果たすことから、各相の巻線の他端をより確実に固定することができ、それゆえ、接続点の固定もより確実に行うことができる。
さらにまた、本実施の形態1においては、ボビン22にスリット22cと溝22eとがともに形成される場合について示したが、図9に示すように、溝22eのみが形成される構成としても良いことは言うまでもない。なお、図9は、接続部23b1周辺の斜視図であって、(a)は溶接前、(b)は溶接後の斜視図を示したものであるが、図9(a)に示すように、溶接する前に各相の巻線の他端を軸方向外方に折り曲げ、溶接するようにしてもよい。
以下、実施の形態2に係るステータ40を備えた回転電機200について図11に基づいて説明する。図11は、本発明の実施の形態2に係る回転電機200のステータ40を構成する中性点ホルダ41周辺の斜視図である。図11に示すように、実施の形態2に係るステータ40を備えた回転電機200は、各相の巻線の他端が接続される接続点を保持する中性点ホルダ41を備えている点で、実施の形態1で示した回転電機100とは異なる。他の構成は上記実施の形態1の回転電機100と同様であるので、詳細説明は省略する。なお、図11に付した符号のうち、前出のものと同一の符号は同一の部分を示す。
また、中性ホルダ41の軸方向長さ(h1)は、この中性点ホルダ41が配置されるコアバック部21aの軸方向端面21eからのボビン22の軸方向長さ(h2)よりも低い(図11参照)。なお、中性点ホルダ41は、ボビン22と一体に構成されてもよい。また、中性点ホルダ41の線膨張係数は、ステータコイル23の線膨張係数よりも大きい。中性点ホルダ41の線膨張係数が、ステータコイル23の線膨張係数よりも大きいことから、回転電機の動作等によりステータ20の温度変化が生じても、ステータコイル23の接続部23bを中性点ホルダ41内に保持することができる。
中性点ホルダ41は、接続部23bを保持するための、例えば凹状の保持溝41aを有する。中性点ホルダ41は、保持溝41aにて、接続部23bが回転電機200の軸方向から差し込まれるようにして保持される。接続部23bが中性点ホルダ41に回転電機200の軸方向から差し込まれると、中性点ホルダ41と接続部23bとの間に、例えば、接着剤26を充填することで、両者は接着される。
これに対し、本発明の実施の形態2において、中性点ホルダ41は、ステータコア21の軸方向の他方の端部側のコアバック部21aの軸方向端面21eに配置されているので、ステータコア21の外周にも冷媒が流れることから、ステータコイル23で発生し、ステータコア21に伝わった熱を効果的に冷却することができる。
さらに、ステータコアよりも外周側に中性点ホルダを配置したステータに比べて、コアバック部の、中性点ホルダが配置された部分の径方向長さの分、径方向に対して短くなるので、ステータの径方向に対する小型化が可能となる。
Claims (8)
- 環状のコアバック及び複数のティースを有するステータコアと、
前記ティースに巻装されるとともに、一端及び他端がそれぞれ前記ステータコアの軸方向の両端部のうちの一方の端部側及び他方の端部側より延出されたU相、V相及びW相用のそれぞれ複数の巻線と、
前記ステータコアと前記巻線とを絶縁するボビンと、
前記ステータコアの軸方向の両端部のうちの一方の端部側に配設されたU相、V相及びW相用のそれぞれの電源バスバーと、を備え、
前記U相、V相及びW相の巻線からなるコイル群が複数形成され、前記コイル群を形成する各相の巻線の一端は、各相の電源バスバーにそれぞれ接続されるとともに、前記コイル群内において周方向両端に位置する相の巻線の他端が残りの相の巻線の他端に向かってそれぞれ延出することで、前記各相の巻線の他端は互いに接続されることを特徴とする回転電機。 - ボビンの外周側には、軸方向に延出する延出部が設けられているとともに、前記延出部には、スリットが形成されていることを特徴とする請求項1に記載の回転電機。
- コイル群を形成する各相の巻線の他端は、ステータコアの軸方向の他方の端部側より外径方向にそれぞれ延出しているとともに、
ボビンの外周側に、前記各相の巻線の他端の周方向位置を規制する規制手段をさらに備えていることを特徴とする請求項1または請求項2のうちいずれか1項に記載の回転電機。 - 規制手段は、ボビンの軸方向端面に形成され、各相の巻線の他端を支持する溝であることを特徴とする請求項3に記載の回転電機。
- 規制手段は、各相の巻線の他端が貫通する貫通孔であることを特徴とする請求項3に記載の回転電機。
- 各相の巻線の他端が接続されている接続部を保持するホルダをさらに備えていることを特徴とする請求項1から請求項5のいずれか1項に記載の回転電機。
- ホルダは、ステータコアの軸方向の他方の端部側のコアバックの軸方向端面に配置されていることを特徴とする請求項6に記載の回転電機。
- ホルダの軸方向長さが、コアバックの軸方向端面からのボビンの軸方向長さよりも低いことを特徴とする請求項7に記載の回転電機。
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