WO2019039262A1

WO2019039262A1 - Insulator for rotating electrical machine, and rotating electrical machine

Info

Publication number: WO2019039262A1
Application number: PCT/JP2018/029527
Authority: WO
Inventors: 典之荒巻; 大助仙波; 建野口
Original assignee: 株式会社ミツバ
Priority date: 2017-08-23
Filing date: 2018-08-07
Publication date: 2019-02-28
Also published as: JP2019041454A

Abstract

The objective of the present invention is to reduce the axial direction length of a stator by reducing the winding height, to achieve a reduction in the size of a rotating electrical machine. An insulator 10 includes an insulator main body 22 which covers an outer peripheral surface of a tooth 7, and an inside flange 23 and an outside flange 24 which are formed at peripheral edges at both ends in the radial direction of the insulator main body 22. A coil accommodating recessed portion 25 is formed surrounded by the inside flange 23 and the outside flange 24 on the outer peripheral side of the insulator main body 22. Extending portions 21 are provided projecting toward the radially outer side in the vicinity of both end portions 24a in the axial direction of the outside flange 24. Notched portions 26 are formed in the outside flange 24, facing both ends of the extending portions 21. A final layer 27 of a coil 8 is wound from the coil accommodating recessed portion 25 side through the notched portions 26 onto the extending portions 21.

Description

Insulator for rotary electric machine and rotary electric machine

The present invention relates to an insulating insulator mounted on a stator core of a rotating electrical machine, and more particularly to an insulator effective when applied to a rotating electrical machine having a flat outer diameter larger than the axial length and a rotating electrical machine using the same. .

Generally, in an inner rotor type brushless motor (rotary electric machine), a rotor is rotatably disposed inside a stator on which a coil is wound. Further, an insulator is attached on the stator side as a component for insulating between the stator core and the coil, and as shown in FIG. 6, the coil 51 is wound around the teeth 54 of the stator core 53 via the insulator 52. . The coils 51 wound around the teeth 54 are accommodated in the slots 55 formed between the adjacent teeth 54. At this time, as shown in FIG. 6 (a), the slots 55 expand radially outward, so the space in which the coil 51 can be wound also becomes larger outward. Therefore, it is a general practice to improve the output by winding the coil 51 more as it goes radially outward.

JP 2000-83340 A

However, when the number of winding layers on the radially outer side is increased as shown in FIG. 6, the final layer 56 located in the outermost layer has a smaller number of winding turns but the number of layers is larger than that on the inner side in the radial direction (in FIG. 5 layers on the radially outer side). Then, as the number of layers increases, the winding height Hw increases, the axial length Ls of the stator increases accordingly, and the axial length Lm (hereinafter abbreviated as motor length) of the motor increases. There was a problem.

In particular, in a flat type motor in which the outer diameter of the motor is larger than the axial length, the axial length Lc of the stator core (hereinafter abbreviated as stator core length) Lc is small and the ratio of the winding height Hw to the stator core length Lc Since the coil height Hw has a large influence on the motor length. Flat type motors are often used for engine starters and generators, in which case the motor is required to be downsized (in particular, the motor length must be reduced) because it is disposed in a limited space beside the engine. However, when the number of winding layers on the outer side in the radial direction is increased, the winding height Hw is increased, and as described above, there is a problem that the motor length is affected.

If the coil wire diameter is reduced and the number of turns is increased, the coil wire diameter of the outermost layer is also reduced, so the effect of the final layer coil on the motor length can be reduced while securing the output. However, in that case, since the winding resistance increases, there arises a new problem that the output at the time of high rotation decreases.

An object of the present invention is to reduce the axial length of the stator by reducing the height of the winding, and to miniaturize the rotating electrical machine.

The insulator according to the present invention is a rotary electric machine having a stator core including a ring-shaped back core portion and teeth radially provided radially inward from the back core portion, the stator core and the coil An insulator body disposed between and electrically insulating between the coil and the stator core, the insulator body being mounted on the teeth and covering the outer peripheral surface of the teeth, and a radially inner peripheral edge of the insulator body Formed in a form surrounded by the inner flange and the outer flange on the outer peripheral side of the insulator main body, and the outer flange formed on the outer peripheral edge of the insulator main body in the radial direction. A first coil winding portion wound in a state in which a plurality of layers are overlapped, and an axis of the outer flange Countercurrent near both ends outward in the radial direction is protruded, and having a second coil winding part which last layer of the coil to be wound around the teeth is wound, the.

In the present invention, the second coil wound portion is provided so as to protrude radially outward of the insulator, and the final layer of the coil is wound around the second coil wound portion. As a result, the number of winding layers of the coil in the axial direction in the first coil winding portion decreases by one, and the height of the winding can be suppressed to be smaller by the wire diameter of the coil. Therefore, the axial length of the stator is smaller by twice the coil wire diameter, and the axial length of the rotating electrical machine is also reduced by using the insulator.

In the insulator, a notch is formed in the outer flange facing both ends of the second coil winding unit, and a final layer of the coil is formed on the first coil winding unit side through the one notch. , And after passing through the second coil wound portion, the second coil wound portion may be guided to the first coil wound portion side from the other notched portion.

The rotary electric machine according to the present invention includes a stator core including a ring-shaped back core portion and teeth radially protruding inward from the back core portion, and is disposed between the stator core and the coil. A rotary electric machine having an insulator which electrically insulates between the coil and the stator core, wherein the insulator is mounted on the teeth and covers an outer peripheral surface of the teeth; It is surrounded by the inner flange and the outer flange on the outer peripheral side of the insulator main body, an inner flange formed on the radially inner peripheral edge of the main body, an outer flange formed on the radial outer edge of the insulator main body A first coil winding portion formed in a shape, and wound in a state in which a plurality of layers of the coil are overlapped; And a second coil winding portion which is provided radially outward in the vicinity of both axial end portions of the flange and on which the final layer of the coil wound on the teeth is wound. .

In the present invention, the second coil wound portion is provided so as to protrude radially outward of the insulator, and the final layer of the coil is wound around the second coil wound portion. As a result, the number of winding layers of the coil in the axial direction in the first coil winding portion decreases by one, and the height of the winding can be suppressed to be smaller by the wire diameter of the coil. Therefore, the axial length of the stator is reduced by twice the coil wire diameter, and the axial length of the rotary electric machine is also reduced accordingly.

In the electric rotating machine, the outer flange is provided with notches facing both ends of the second coil winding part, and the final layer of the coil is formed through the one notch and the first coil winding part After being pulled out from the side and passing through the second coil wound portion, the other of the notches may be guided to the first coil wound portion side.

According to the insulator of the present invention, the second coil winding portion on which the coil can be wound is provided on the radially outer side of the outer flange, and by winding the final layer of the coil there, the number of coil winding layers in the axial direction can be increased. It can be reduced by one roll. Thus, the winding height can be reduced by the wire diameter of the coil, and the axial length of the stator can be reduced by twice the coil wire diameter. Therefore, the axial length of the rotating electrical machine can be reduced by using the insulator.

According to the rotating electrical machine of the present invention, the insulator is provided with the second coil winding portion capable of winding the coil, and the final layer of the coil is wound there, so the number of coil winding layers in the axial direction is one turn It can be reduced by a minute. As a result, the winding height can be reduced by the wire diameter of the coil, the axial length of the stator can be reduced by twice the coil wire diameter, and the axial length of the rotating electrical machine can be reduced. .

FIG. 1 is a cross-sectional view along an axial direction of a brushless motor according to an embodiment of the present invention. FIG. 2 is a cross-sectional view taken along the line AA of FIG. It is a perspective view which shows the structure of an insulator. It is explanatory drawing which shows the attachment state of the insulator in the said brushless motor. FIG. 7 is an explanatory view showing a winding state of a coil in the brushless motor, and (b) is a cross-sectional view taken along the line BB of (a). FIG. 12 is an explanatory view showing a wound state of a coil in a conventional brushless motor, and (b) is a cross-sectional view taken along a line CC of (a).

Hereinafter, embodiments of the present invention will be described in detail based on the drawings. FIG. 1 is a cross-sectional view along an axial direction of a brushless motor 1 (a rotating electric machine; hereinafter abbreviated as a motor 1) according to an embodiment of the present invention, and FIG. 2 is a line AA of FIG. FIG. The motor 1 shown in FIG. 1 is of an inner rotor type, and includes a stator 3 fixed in the

housings

2a and 2b, and a rotor 4 rotatably disposed in the stator 3. In the present embodiment, the motor 1 is an SR motor that does not use a magnet (permanent magnet) for the rotor 4 and is used, for example, as a starter generator of an engine.

The stator 3 has a stator core 5 in which a large number of thin electromagnetic steel plates are stacked. As shown in FIG. 2, the stator core 5 includes a ring-shaped back core portion 6 and teeth 7 protruding radially inward (in the center direction) from the back core portion 6. An insulator 10 made of synthetic resin is mounted on the outer periphery of the tooth 7, and an exciting coil 8 (hereinafter abbreviated as a coil 8) is wound around the tooth 7 via the insulator 10. The coil 8 is composed of a plurality of phase coils (for example, three phases of U phase, V phase and W phase), and the coils 8 of each phase form independent circuits. An electric current is supplied to the coil 8 through the bus bar 9 formed of a conductive member (for example, a metal such as copper).

The rotor 4 is inserted inside the stator 3. The rotor 4 is composed of a rotating shaft 11 and a rotor core 12 fixed to the rotating shaft 11. The rotor core 12 is also formed by laminating a large number of thin electromagnetic steel plates. A salient pole 13 is provided on the outer periphery of the rotor core 12 so as to protrude in the radial direction (see FIG. 2). In the SR motor 1, the rotation angle of the rotor 4 is detected by a resolver (not shown), and the coils 8 of each phase are sequentially excited in accordance with the angular position of the rotor 4. The teeth 7 on which the excited coil 8 is wound become a magnetic pole one after another, and a rotating magnetic field of three phases (U phase, V phase, W phase) is formed in the stator 3. The salient poles 13 of the rotor 4 are attracted to the magnetized teeth 7, whereby the rotor 4 rotates in the stator 3 and the SR motor 1 operates.

Further, the bus bar unit 14 is disposed adjacent to one axial end side (left end side in the drawing) of the stator core 5. A plurality of bus bars 9 are embedded in the bus bar unit 14 in a mutually insulated state. The bus bar unit 14 has a configuration in which a plurality of bus bars 9 formed in an annular shape are insert-molded in resin in a main body portion 15 formed of a synthetic resin. The bus bar 9 is provided with a coil connection terminal 16 connected to the coil 8 and a power supply connection terminal (not shown) connected to the power supply side. The coil connection terminals 16 are radially projected outward in the radial direction, and are welded to the ends 17 of the coils 8 of the corresponding phases, whereby the bus bars 9 and the coils 8 are electrically connected. .

Here, in the motor 1 according to the present invention, an extending portion (second coil wound portion) 21 capable of winding the coil 8 is provided on the radial direction outer side of the insulator 10. FIG. 3 is a perspective view showing the configuration of the insulator 10 in a state in which the coil 8 is wound, FIG. 4 is an explanatory view showing an attachment state of the insulator 10 in the motor 1, and FIG. 5 is a winding of the coil 8 in the motor 1 It is explanatory drawing which shows a mounting state. As described above, the insulator 10 is formed of an insulating material such as a synthetic resin, and is extrapolated from and attached to the teeth 7 from the tip (radially inner end) side of the teeth 7.

As shown in FIG. 3, the insulator 10 has an insulator main body 22 formed in a substantially square cylindrical shape so as to cover the outer peripheral surface of the teeth 7. An inner flange 23 and an outer flange 24 are formed integrally with the insulator main body 22 at respective peripheral edges of both radial direction ends (inner and outer sides) of the insulator main body 22. A coil accommodating recess (first coil wound portion) 25 is formed on the outer peripheral side of the insulator main body 22 so as to be surrounded by the outer peripheral surface 22 a of the insulator main body 22, the inner flange 23 and the outer flange 24. As shown in FIG. 5, a plurality of layers of the coil 8 are wound around the coil accommodation recess 25. The coil 8 is wound by a flyer or the like in a state where the insulator 10 is attached to the teeth 7, and the two end portions 17 of the coil 8 are respectively drawn to the bus bar unit 14 side.

In the vicinity of both axial direction end portions 24 a of the outer flange 24, a plate-like extending portion 21 is provided protruding outward in the radial direction. As shown in FIG. 5, when the insulator 10 is attached to the teeth 7, the extended portion 21 is disposed on the end face 6 a of the back core portion 6 of the stator core 5. Further, two notches 26 are formed at both axial end portions 24 a of the outer flange 24 so as to face the both end portions 21 a of the extending portion 21 (26 a, 26 b). The final layer 27 (here, three turns) of the coil 8 wound around the teeth 7 is wound around the extension portion 21. As shown in FIGS. 3 to 5, the final layer 27 is pulled out from the coil accommodating recess 25 side through one notch 26 a and passes through the extending portion 21, and then from the other notch 26 b to the coil accommodating recess 25. It is guided to the side and wound around a portion of the extending portion 21.

As can be seen from FIGS. 5 (a) and 6 (a), the coil 8 of the motor 1 has the same total number of turns as the conventional motor, and uses the space of the slot 28 which increases in the radial direction without waste The coil is wound. On the other hand, comparing FIG. 5 (b) with FIG. 6 (b), in the motor 1, since the final layer 27 of the coil 8 is wound around the extending portion 21, the number of winding layers in the axial direction is one. It has been reduced by a minute. That is, the number of winding layers on the coil accommodation recess 25 side is reduced by one for the final layer 27 disposed in the extending portion 21, and the winding height Hw is equal to the wire diameter of the coil 8 (for example, 1 It is kept small (about 2 mm). In this case, since the coils 8 are stacked at both axial ends of the insulator 10, the axial length Ls of the stator is reduced by twice the coil wire diameter, and the motor length is also reduced accordingly.

For example, when the wire diameter of the coil 8 is 1.5 mm, the axial length Ls of the stator can be shortened by 3.0 mm (twice of the wire diameter). This is large in flat motors where the motor outer diameter Dm is large relative to the motor length Lm (Dm / Lm> 1), even if two coils are involved, and a motor having a stator core length Lc of about 30 mm In the latter case, a size reduction of approximately 10% is possible. Further, when the motor length is made the same, the stator core length Lc can be increased by twice the wire diameter, and the output can be improved accordingly.

It goes without saying that the present invention is not limited to the above-described embodiment, and various changes can be made without departing from the scope of the invention.
For example, in the above-described embodiment, the final layer 27 of the coil 8 is wound around the extending portion 21. However, when the extending portion 21 has a margin, not only the final layer 27 but also the next All or part of the second layer (the second layer from the outer side: 10 in this case) may be wound on the extension 21. In addition, when there is a margin in the extended portion 21, the number of turns (for example, 5 turns) may be increased by winding over the final layer 27 to improve the output.

Furthermore, in the above-mentioned embodiment, although the winding method which winds the coil 8 in the state which attached insulator 10 to teeth 7 is adopted, coil 8 is beforehand wound around insulator 10 and insulator 10 is in that state It may be attached to the teeth 7. However, in the latter case, since the slot 28 has a narrow frontage, it is not possible to perform winding using a large space at the back, so the present invention is more useful when applied to the former winding type motor. In addition, the above-described wire diameter, dimensions of each part of the motor, and the number of driving phases are merely examples, and the present invention is not limited to the above-described values.

Although the above-mentioned embodiment showed an example which applied the present invention to SR motor which is a kind of a brushless motor, the application object is not restricted to SR motor, and a brushless motor which arranged a permanent magnet in a rotor, various The present invention is applicable to reluctance motors, generators and the like. In addition to engine starters and generators, the present invention can be widely applied to other in-vehicle electric devices, electric products such as hybrid cars, electric cars, and air conditioners.

DESCRIPTION OF SYMBOLS 1

Brushless motor

2a, 2b Housing 3 Stator 4 Rotor 5 Stator core 6 Back core part 6a End face 7 Teeth 8 Excitation coil 9 Bus bar 10 Insulator 11 Rotor shaft 12 Rotor core 13 Salient pole 14 Bus bar unit 15 Body part 16 Coil connection terminal 17 End 21 Extension part (second coil winding part)
21a both ends 22 insulator main body 22a outer peripheral surface 23 inner flange 24 outer flange 24a axial direction both ends 25 coil accommodation recess (first coil winding portion)
26 notch 26a notch 26b notch 27 final layer 28 slot 51 coil 52 insulator 53 stator core 54 tooth 55 slot 56 final layer Dm motor outer diameter Hw winding height Lc stator core axial direction length Lm motor axial direction length Ls stator axial direction Long

Claims

A rotary electric machine having a stator core including a ring-shaped back core portion and teeth radially protruding inward from the back core portion, the stator core being disposed between the stator core and the coil, An insulator electrically insulating between a coil and the stator core, wherein
An insulator main body attached to the teeth and covering an outer peripheral surface of the teeth;
An inner flange formed on the radially inner peripheral edge of the insulator body;
An outer flange formed on a radially outer peripheral edge of the insulator body;
A first coil wound portion formed on the outer peripheral side of the insulator body so as to be surrounded by the inner flange and the outer flange, and wound in a state in which a plurality of layers of the coil are overlapped;
And a second coil winding portion which is provided radially outward in the vicinity of both axial end portions of the outer flange and on which the final layer of the coil wound around the teeth is wound. Insulating insulator.
In the insulator according to claim 1,
The outer flange has a notch formed so as to face both ends of the second coil wound portion,
The final layer of the coil is pulled out from the first coil winding portion side through one of the notches, and after passing through the second coil winding portion, the first coil winding is carried out from the other notch. An insulator characterized in that it is guided to the part side.
A stator core including a ring-shaped back core portion and teeth radially protruding inward from the back core portion;
An electric rotating machine comprising: an insulator disposed between the stator core and a coil and electrically insulating the coil from the stator core.
The insulator is
An insulator main body attached to the teeth and covering an outer peripheral surface of the teeth;
An inner flange formed on the radially inner peripheral edge of the insulator body;
An outer flange formed on a radially outer peripheral edge of the insulator body;
A first coil wound portion formed on the outer peripheral side of the insulator body so as to be surrounded by the inner flange and the outer flange, and wound in a state in which a plurality of layers of the coil are overlapped;
And a second coil winding portion which is provided radially outward in the vicinity of both axial end portions of the outer flange and on which the final layer of the coil wound around the teeth is wound. Electric rotating machine.
In the electric rotating machine according to claim 3,
The outer flange has a notch formed so as to face both ends of the second coil wound portion,
The final layer of the coil is pulled out from the first coil winding portion side through one of the notches, and after passing through the second coil winding portion, the first coil winding is carried out from the other notch. A rotary electric machine characterized in that it is guided to a part side.