WO2019156136A1 - 回転電機、回転電機のステータ、およびその製造方法 - Google Patents
回転電機、回転電機のステータ、およびその製造方法 Download PDFInfo
- Publication number
- WO2019156136A1 WO2019156136A1 PCT/JP2019/004321 JP2019004321W WO2019156136A1 WO 2019156136 A1 WO2019156136 A1 WO 2019156136A1 JP 2019004321 W JP2019004321 W JP 2019004321W WO 2019156136 A1 WO2019156136 A1 WO 2019156136A1
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- WIPO (PCT)
- Prior art keywords
- block
- stator
- magnetic pole
- internal
- jumper
- Prior art date
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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
- H02K1/18—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
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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
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
-
- 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
- H02K15/08—Forming windings by laying conductors into or around core parts
- H02K15/095—Forming windings by laying conductors into or around core parts by laying conductors around salient poles
-
- 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
Definitions
- the disclosure in this specification relates to a rotating electrical machine, a stator of the rotating electrical machine, and a manufacturing method thereof.
- Patent Document 1 discloses a rotating electric machine.
- Patent Document 2 discloses a plurality of unit coils arranged on a stator and a plurality of jumper wires arranged between the plurality of unit coils. The plurality of jumper wires are arranged in a stacked manner at one end of the stator coil.
- Patent Document 3 discloses an outer salient pole type stator. The stator is composed of three partial stators.
- Patent document 4 is disclosing the stator of a rotary electric machine. The rotating electrical machine has two partial cores. All of the three windings that provide the three phases are arranged to bypass the adjacent different phase poles. For this reason, the jumper wire is arranged in a crank shape.
- Patent Document 2 a portion for arranging a plurality of jumper wires in a stacked manner occupies a large volume. For this reason, a stator may enlarge.
- Patent Document 3 does not disclose the arrangement of jumper wires.
- Patent Document 4 since all jumper wires are arranged in a crank shape, a portion in which two jumper wires are arranged in a stacked manner is generated. As a result, the stator may be enlarged.
- One object disclosed is to provide a rotating electrical machine capable of reducing the size of the physique, a stator of the rotating electrical machine, and a manufacturing method thereof.
- Another object of the disclosure is to provide a rotating electrical machine that can disperse a plurality of jumper wires on the stator, a stator for the rotating electrical machine, and a method for manufacturing the same.
- the stator of the rotating electrical machine disclosed herein is disposed at one end in the axial direction, and has a distal end block (31) having a plurality of distal end block magnetic poles (31a) and a plurality of proximal end blocks disposed at the other end in the axial direction.
- a proximal block (33) having a magnetic pole (33a) and an internal block (32) disposed between the distal block and the proximal block in the axial direction and having a plurality of internal block magnetic poles (32a) are provided. .
- the stator of the rotating electrical machine has the distal block, the inner block, and the proximal block arranged along the axial direction so that the distal block magnetic pole, the proximal block magnetic pole, and the inner block magnetic pole are arranged along the circumferential direction.
- the distal end block winding (61) extends over a plurality of unit coils and has a plurality of distal jumper wires (61j) disposed at one end, and the proximal block winding (63) includes a plurality of unit coils.
- stator of a rotating electrical machine interference between a plurality of jumper wires and a plurality of blocks is suppressed. Further, a plurality of jumper wires are arranged in a distributed manner on one end and the other end of the stator. For this reason, the enlargement of the physique of a stator is suppressed.
- the rotating electrical machine disclosed herein includes the stator and a rotor (26) that provides a rotating magnetic field to the stator.
- the stator manufacturing method for a rotating electrical machine disclosed herein includes a distal block (31) having a plurality of distal block magnetic poles (31a), a proximal block (33) having a plurality of proximal block magnetic poles (33a), and A block step (195) for manufacturing a plurality of blocks including an inner block (32) having a plurality of inner block magnetic poles (32a), and a distal block magnetic pole, a proximal block magnetic pole, and an inner block magnetic pole are arranged along the circumferential direction.
- the front end block is disposed at one end in the axial direction
- the base end block is disposed at the other end in the axial direction
- the inner block is disposed between the front end block and the base end block
- the stator is assembled ( 196).
- the step of manufacturing a plurality of blocks includes a step (195c) of disposing a front end jumper wire (61j) extending over a plurality of unit coils on a front end surface of the front end block and a base end jumper wire (63j) extending over a plurality of unit coils as a base end
- FIG. 1st Embodiment It is sectional drawing of the rotary electric machine in 1st Embodiment. It is a circuit diagram of a rotating electrical machine. It is a top view of a stator. It is a side view of a stator. It is a perspective view of a stator. It is a disassembled perspective view of a stator. It is a perspective view which shows the edge part block of the end of a stator. It is a perspective view which shows the internal block of a stator. It is a perspective view which shows the edge part block of the other end of a stator. It is process drawing which shows the manufacturing method of a rotary electric machine. It is process drawing which shows the manufacturing method of a stator. It is an exploded sectional view of an end block.
- the rotating electrical machine 20 is a generator motor.
- the rotating electrical machine 20 includes a rotational position detector for functioning as a generator motor.
- the rotational position detector is not shown.
- the rotating electrical machine 20 is interlocked with the engine by being mounted on the internal combustion engine (engine).
- the engine is a vehicle engine mounted on a vehicle or a general-purpose engine.
- vehicle should be interpreted in a broad sense, and includes a moving object such as a vehicle, a ship, and an aircraft, and a fixed object such as an amusement device and a simulation device.
- a general purpose engine can be utilized as a generator and a pump, for example. In this embodiment, the engine is mounted on a saddle-ride type vehicle.
- the engine has a body 21 and a shaft 22.
- the body 21 is provided by an engine crankcase or cover.
- the shaft 22 is a crankshaft or a rotating shaft that is linked to the crankshaft.
- the rotating electrical machine 20 includes a rotor 26 and a stator 30.
- the rotating electrical machine 20 is a rotating body centered on the axis AX. In the following description, a parallel direction along the axis AX is referred to as an axial direction.
- the rotor 26 is connected to the shaft 22.
- the rotor 26 is rotationally driven by the shaft 22.
- the stator 30 is disposed inside the rotor 26.
- the stator 30 is annular around the axis AX.
- the axis AX is also the central axis of the stator 30.
- the stator 30 is fixed by being fastened to the body 21 by bolts 23.
- the stator 30 has a mounting portion on the body 21 side in the central opening.
- the central opening of the stator 30 and the attachment portion on the body 21 side have an inlay structure.
- the stator 30 can be fixed to a crankcase or a cover.
- the left end surface of the stator 30 is referred to as one end, the tip, or the first end in the axial direction.
- the right end surface of the stator 30 is called the other end, the base end, or the second end in the axial direction.
- the stator 30 is connected to an electric circuit 25 (ELC) by a wire harness 24 including a plurality of electric wires.
- the electric circuit 25 is a vehicle circuit.
- the electric circuit 25 includes, for example, an in-vehicle power supply circuit including a vehicle battery.
- the electric circuit 25 may include an inverter circuit.
- the inverter circuit provides a DC-AC conversion circuit.
- the electric circuit 25 provides a rectifier circuit that rectifies the power generation output.
- the electric circuit 25 converts direct current into alternating current and supplies it to the stator 30.
- the electric circuit 25 includes a rotational position detector for causing the rotary electric machine 20 to function as an electric motor.
- the rotational position detector detects the rotation of the rotor 26.
- the detected rotation can include the rotational direction of the rotor 26, the rotational position of the rotor 26, or the rotational speed of the rotor 26.
- the rotor 26 includes a rotor core 27, a magnet 28, and a magnet case 29.
- the rotor core 27 is provided by a cup-shaped magnetic body.
- the rotor core 27 is also called a yoke.
- the rotor core 27 also serves as an engine flywheel.
- the rotor core 27 provides a magnetic path of a permanent magnet.
- a plurality of magnets 28 are arranged on the inner surface of the rotor core 27.
- the plurality of magnets 28 include permanent magnets.
- the plurality of magnets 28 are fixed to the rotor core 27 by an adhesive and / or a magnet case 29.
- the rotor 26 forms a rotating magnetic field.
- the rotor 26 rotates around the axis AX.
- the stator 30 is an outer salient pole type stator.
- the stator 30 has a plurality of blocks 31, 32, 33 arranged in a stacked manner along the axis AX.
- the stator 30 has a tip block 31 disposed at one end in the axial direction.
- the stator 30 has a proximal block 33 disposed at the other end in the axial direction.
- the stator 30 has an internal block 32 disposed between the distal end block 31 and the proximal end block 33 in the axial direction.
- the distal end block 31 and the proximal end block 33 are also referred to as end blocks.
- the internal block 32 is also called an intermediate block.
- the stator 30 includes a stator core 40, an insulator 50, and a winding 60.
- the stator core 40 is provided by a magnetic material such as an electromagnetic steel plate or an iron plate.
- the insulator 50 is made of resin.
- the insulator 50 mainly provides a bobbin.
- the insulator 50 is also a member that electrically insulates a plurality of electrodes.
- the winding 60 provides a single-phase or multi-phase winding.
- the stator core 40 includes a plurality of teeth portions 40a and an annular ring portion 40b that connects the teeth portions 40a.
- the plurality of teeth portions 40a provide magnetic poles.
- the plurality of teeth portions 40a are disposed on the outer periphery of the ring portion 40b.
- the stator core 40 has a plurality of cores 41, 42, and 43.
- the stator core 40 includes a distal core 41, an inner core 42, and a proximal core 43.
- the tip core 41 has a notch 44 for receiving the head of the bolt 23.
- the tip core 41 provides a tip in the axial direction of the stator 30.
- the proximal core 43 provides a proximal end in the axial direction of the stator 30.
- the tip core 41 has a thickness T41 in the ring portion 40b.
- the inner core 42 has a thickness T42 at the ring portion 40b.
- the proximal end core 43 has a thickness T43 in the ring portion 40b.
- Thicknesses T41, T42, and T43 are thicknesses in the axial direction. The thicknesses T41, T42, and T43 are not equal to each other.
- the thickness T41 is thicker than the thicknesses T42 and T43.
- the thickness T42 and the thickness T43 can be made equal.
- the thickness T41 is larger than the other thicknesses T42 and T43 in order to provide the notch 44. Therefore, the thicknesses T41, T42, and T43 are unequal.
- the thicknesses of the plurality of teeth portions 40a are equal to each other.
- the thickness of one tooth portion 40a corresponds to T41 + T42 + T43.
- the plurality of tooth portions 40 a are arranged in a distributed manner on the plurality of cores 41, 42, 43.
- the plurality of teeth portions 40a are distributed to a plurality of groups corresponding to a plurality of phases.
- the plurality of teeth portions 40a are distributed to a plurality of groups that are equally spaced from each other.
- One group is arranged in one core block. Therefore, one core block has a plurality of teeth portions 40a.
- One core block has a plurality of teeth portions 40a that are equally spaced from each other. In this embodiment, in order to provide a three-phase winding, the plurality of tooth portions 40a are distributed into three groups.
- the winding 60 provided by the stator 30 provides a three-phase winding.
- the three-phase windings are star connected.
- the three-phase winding may be delta connected.
- Winding 60 includes a plurality of phase windings 61, 62, 63.
- Winding 60 has an X-phase winding 61, a Y-phase winding 62, and a Z-phase winding 63.
- the winding 60 has a neutral point electrode 64.
- Neutral point electrode 64 provides a neutral point for multiple phase windings.
- the winding 60 has a plurality of output electrodes 65, 66, 67.
- the output electrodes 65, 66 and 67 are disposed between the winding 60 and the wire harness 24.
- the output electrodes 65, 66, 67 provide an input / output end of the rotating electrical machine 20.
- One of the plurality of phase windings 61, 62, 63 is provided by one of the plurality of blocks 31, 32, 33.
- Each of the plurality of phase windings 61, 62, 63 can be arbitrarily associated with each of the plurality of blocks 31, 32, 33.
- One phase winding has a plurality of unit coils 60u having the same phase.
- One phase winding has at least a pair of end wires 60e.
- One phase winding in this embodiment has two pairs, a total of four end lines 60e.
- One phase winding has a plurality of continuous windings 60a and 60b.
- One continuous winding has a pair of end wires 60e, a plurality of unit coils 60u, and one or a plurality of jumper wires 60j.
- the plurality of phase windings 61, 62, and 63 are similar to each other.
- the X-phase winding 61 will be described as an example.
- the X-phase winding 61 has six unit coils 61u having the same phase.
- the X-phase winding 61 has two pairs, a total of four end lines 61e.
- the X-phase winding 61 has two continuous windings 61a and 61b.
- One continuous winding has a pair of end wires 60e, three unit coils 61u, and two jumper wires 61j.
- the continuous winding 61a and the continuous winding 61b are connected in parallel to each other.
- the two continuous windings 61 a and 61 b are connected to the output electrode 65.
- the winding 60 has a plurality of joints 68.
- the joint portion 68 can be provided by various connection methods such as soldering, resistance welding, fusing, TIG welding, and laser welding.
- the strands for forming the winding 60 are made of aluminum or aluminum alloy.
- the neutral point electrode 64 and the output electrodes 65, 66, and 67 are made of an iron-based alloy.
- the joint 68 can be provided by electric welding. Note that the connection method in the joint portion 68 can be appropriately changed according to the material of the winding 60.
- FIG. 3 shows the stator 30 before connection.
- the stator 30 includes a plurality of magnetic poles 30a and an annular ring portion 30b that connects the plurality of magnetic poles 30a.
- the magnetic pole 30 a is provided by the stator core 40, the insulator 50, and the winding 60.
- the stator 30 has 1st to 18th magnetic poles 30a.
- the magnetic pole 30a, the tooth part 40a, or the unit coil 60u may be specified by a number.
- the first, fourth, seventh, tenth, thirteenth, and sixteenth magnetic poles 30 a belong to the tip block 31.
- These magnetic poles 30a are also called tip block magnetic poles 31a. Therefore, the tip block 31 has a plurality of tip block magnetic poles 31a.
- the plurality of tip block magnetic poles 31a are equally spaced from each other.
- the plurality of tip block magnetic poles 31a provide the same phase winding.
- the inner block 32 has a plurality of inner block magnetic poles 32a.
- the plurality of internal block magnetic poles 32a are equally spaced from each other.
- the inner block magnetic pole 32a provides a winding of the same electrical phase.
- the second, fifth, eighth, eleventh, fourteenth, and seventeenth magnetic poles 30a belong to the proximal block 33. These magnetic poles 30a are also called proximal block magnetic poles 33a. Therefore, the base end block 33 has a plurality of base end block magnetic poles 33a. The plurality of proximal block magnetic poles 33a are equidistant from each other. The proximal block magnetic pole 33a provides a winding of the electrically same phase.
- the stator 30 includes a stator core 40, an insulator 50, and a winding 60.
- the stator 30 has a plurality of through holes 23 a for receiving a plurality of bolts 23.
- the stator 30 has a notch 44 around the through hole 23a. In the drawing, the surface of the tip block 31 is shown.
- the stator 30 has a plurality of end lines 60e. In this state, the plurality of end lines 60e are not electrically connected. The plurality of end lines 60e extend to both sides of the stator 30 in the axial direction. The plurality of end lines 60e are connected to the neutral point electrode 64 or the output electrodes 65, 66, 67. The plurality of end lines 60 e are bent toward one end of the stator 30 and further connected to the neutral point electrode 64 or the output electrodes 65, 66, 67.
- the stator 30 has a plurality of unit coils 60u.
- One unit coil 60u has a small-diameter portion and a large-diameter portion having a diameter larger than that of the small-diameter portion.
- the small diameter portion occupies the radially inner portion of the unit coil 60u.
- the large diameter portion occupies the radially outer portion of the unit coil 60u.
- the small diameter portion is provided by one or several layers of coils.
- the large diameter portion is provided by a multilayer coil having at least one more layer than the small diameter portion.
- the stator 30 has a plurality of jumper wires 60j. Most of the plurality of jumper wires 60j are arranged in an arc along the end face of the stator 30.
- the plurality of jumper lines 60j have two types of jumper lines. All jumper wires 60j extend between two unit coils 60u having the same phase. One jumper line extends between the two unit coils 60u having the same phase along the circumferential direction. The other jumper wire extends between two unit coils of the same phase that are second along the circumferential direction. Moreover, one jumper wire 60j is arranged so as to bypass the other-phase teeth located between the two unit coils 60u having the same phase.
- One tip jumper wire 61j continuously connects, for example, the 10th unit coil and the 4th unit coil.
- the tip jumper wire 61j belongs to the tip block 31.
- the front end jumper wire 61j is disposed at one end of the stator 30.
- One internal jumper line 62j for example, continuously connects the 9th unit coil and the 6th unit coil.
- the internal jumper line 62j bypasses the 7th tooth.
- the internal jumper line 62j belongs to the internal block 32.
- the internal jumper line 62j is also called a crank line.
- the internal jumper wire 62j is disposed via both one end and the other end of the stator 30.
- One base end jumper wire 63j continuously connects the 11th unit coil and the 17th unit coil.
- the proximal jumper line 63j belongs to the proximal block 33.
- the proximal jumper wire 63j is disposed at the other end of the stator 30.
- the stator 30 has fixed portions 54 and 55.
- the fixing portion 54 provides a fixing seat for fixing the neutral point electrode 64.
- the neutral point electrode 64 has a plurality of terminals connected to the six end lines 60e.
- the fixing portion 55 provides a fixing seat for fixing the output electrodes 65, 66 and 67.
- One output electrode has a plurality of terminals connected to the two end lines 60 e and terminals for connection to the electric wires of the wire harness 24.
- One output electrode is provided by, for example, an electrode that penetrates the stator 30.
- Japanese Patent Application Laid-Open No. 2017-63541 can be referred to for the description of the fixing portions 54 and 55, the contents of which are introduced by reference.
- FIG. 4 shows the side surface of the stator 30 as viewed from the arrow IV. Numbers are assigned to the plurality of tooth portions 40a.
- the insulator 50 is formed by a first cover 50a and a second cover 50b so as to cover the stator core 40 from the axial direction.
- FIG. 5 shows a perspective view of the stator 30 before connection.
- the plurality of magnetic poles 30a are arranged along the circumferential direction.
- the plurality of magnetic poles 30a are arranged so as to face each outside in the radial direction.
- the distal end block 31, the inner block 32, and the proximal end block 33 are laminated in the axial direction so as to sequentially arrange the plurality of magnetic poles 30a along the circumferential direction.
- the plurality of magnetic poles 30a are arranged in a predetermined number order.
- the plurality of magnetic poles 30a are arranged so as to be nested with each other so that the plurality of magnetic poles 30a adjacent in the circumferential direction are arranged in order.
- the teeth part 40a of the stator core 40 is exposed to the outside in the radial direction.
- the plurality of tooth portions 40a include teeth portions 41a, 42a, and 43a. These teeth parts 41a, 42a, 43a are arranged along the circumferential direction.
- the teeth portion 41 a belongs to the tip block 31.
- the teeth part 42a belongs to the internal block 32.
- the teeth portion 43 a belongs to the proximal end block 33.
- the ring portion 40 b of the stator core 40 is exposed radially inward, that is, in the central through hole of the stator 30.
- the ring portion 40b has three ring portions 41b, 42b, and 43b arranged in a stacked manner.
- FIG. 6 shows a virtual state in which the stator 30 is disassembled into a plurality of blocks 31, 32, and 33.
- the stator 30 has a plurality of blocks 31, 32 and 33.
- the plurality of blocks 31, 32, and 33 are stacked in the axial direction on the plurality of ring portions 41 b, 42 b, and 43 b.
- the plurality of blocks 31, 32, and 33 are arranged so as to mesh with each other in the plurality of teeth portions 41a, 42a, and 43a.
- the plurality of blocks 31, 32, and 33 are meshed so that the plurality of ring portions 41 b, 42 b, and 43 b are stacked in the axial direction.
- the plurality of blocks 31, 32, and 33 are meshed so that the plurality of teeth portions 41 a, 42 a, and 43 a are arranged in numerical order along the circumferential direction.
- FIG. 7 is a perspective view showing the tip block 31.
- the tip block 31 includes a core 41, an insulator 51, and an X-phase winding 61.
- the core 41 includes a plurality of teeth portions 41a and a ring portion 41b that connects the plurality of teeth portions 41a.
- the core 41 further includes a coupling portion 41c at the radially inner end of each tooth portion 41a.
- the coupling part 41c has a slightly larger circumferential width than the tooth part 41a.
- the coupling portion 41 c provides magnetic and mechanical coupling by facing the outer peripheral surfaces of the ring portions 42 b and 43 b of the other cores 42 and 43.
- the X-phase winding 61 has a plurality of continuous windings 61a and 61b.
- the first continuous winding 61a is wound in the order of the 13th magnetic pole, the jumper wire, the 7th magnetic pole, the jumper wire, and the 1st magnetic pole.
- the second continuous winding 61b is wound in the order of No. 10 magnetic pole, jumper wire, No. 4 magnetic pole, jumper wire, and No. 16 magnetic pole.
- the plurality of front end jumper wires 61j extend between two magnetic poles 30a positioned by skipping one magnetic pole 30a among the same-phase magnetic poles 30a. That is, the tip jumper wire 61j extends between the two magnetic poles 30a separated by the inter-magnetic pole angle RD.
- the magnetic pole angle RD corresponds to the interval between the three in-phase magnetic poles 30a.
- the angle RD is also called a double angle. Specifically, the magnetic pole angle RD is 120 degrees.
- the X-phase winding 61 is wound around the plurality of magnetic poles 31a at an inter-magnetic pole angle RD.
- the circumferential length of the tip jumper wire 61j is longer than that in the case where the jumper wire is disposed across two adjacent in-phase magnetic poles 30a.
- the relatively long tip jumper wire 61j contributes to suppressing a difference from the length of an internal jumper wire 62j described later.
- the relatively long tip jumper wire 61j contributes to suppressing a difference in resistance component and a difference in inductive component between the tip jumper wire 61j and the internal jumper wire 62j.
- the first continuous winding 61a is wound over the three magnetic poles 30a.
- the first continuous winding 61a is wound over a range of 2 ⁇ RD. 2 ⁇ RD occupies 2/3 of the angle range of the tip block 31.
- the second continuous winding 61b is wound over the three magnetic poles 30a.
- the second continuous winding 61b is wound over a range of 2 ⁇ RD. 2 ⁇ RD occupies 2/3 of the angle range of the tip block 31.
- the first continuous winding 61 a and the second continuous winding 61 a overlap each other in the circumferential direction of the tip block 31.
- All of the tip jumper wires 61j are disposed on one end of the tip block 31. Therefore, all of the plurality of front end jumper wires 61j are disposed on the end face of the stator 30.
- the plurality of tip jumper wires 61j are formed in an arc shape.
- the plurality of tooth portions 41a extend in the radial direction.
- the plurality of tooth portions 41a provide a virtual annular range R31 extending in the radial direction.
- the plurality of tip jumper wires 61j are arranged in the annular range R31.
- the plurality of front end jumper wires 61j are arranged so as to be in contact with the plurality of unit coils 61u. Therefore, the plurality of tip jumper wires 61j are arranged so as to suppress the height of the stator 30 in the axial direction.
- the plurality of jumper wires 61j at the front end pass through the radially inner range of the unit coil 61u. For this reason, it is arrange
- FIG. 8 is a perspective view showing the internal block 32 disposed between the two blocks 31 and 33.
- the internal block 32 includes a core 42, an insulator 52, and a Y-phase winding 62.
- the core 42 includes a plurality of teeth portions 42a and a ring portion 42b that connects the plurality of teeth portions 42a.
- the core 42 further includes a coupling portion 42c at the radially inner end of each tooth portion 42a.
- the coupling part 42c has a slightly larger circumferential width than the tooth part 42a.
- the coupling portion 42c provides a magnetic and mechanical connection by facing the outer peripheral surfaces of the ring portions 41b and 43b of the other cores 41 and 43.
- the Y-phase winding 62 has a plurality of continuous windings 62a and 62b.
- the first continuous winding 62a is wound in the order of the 12th magnetic pole, the jumper wire, the 9th magnetic pole, the jumper wire, and the 6th magnetic pole.
- the second continuous winding 62b is wound in the order of the third magnetic pole, the jumper wire, the 18th magnetic pole, the jumper wire, and the 15th magnetic pole.
- the plurality of internal jumper wires 62j extend between the two magnetic poles 30a located at the first of the in-phase magnetic poles 30a.
- the internal jumper line 62j extends between two adjacent magnetic poles 32a in the internal block 32. That is, the internal jumper line 62j extends between the two magnetic poles 30a separated by the inter-magnetic pole angle RS.
- the magnetic pole angle RS corresponds to the distance between the two in-phase magnetic poles 30a.
- the magnetic pole angle RS is also called a single angle. Specifically, the magnetic pole angle RD is 60 degrees.
- the Y-phase winding 62 is wound around the plurality of magnetic poles 32a at the magnetic pole angle RS.
- the internal jumper wire 62j has a crank shape between the two magnetic poles 30a.
- the internal jumper wire 62j has a crank shape when viewed from the side surface of the stator 30 in the radial direction.
- the portion that can be called a crank shape includes a portion that is formed in a crank shape along the coil winding direction. Thereby, the looseness of the unit coil 62u is suppressed.
- the internal jumper wire 62j is arranged so as to bypass the two magnetic poles 30a of the other phase positioned between the two magnetic poles 30a of the same phase in order. As a result, the length in the circumferential direction of the internal jumper line 62j is longer than that in the case where the jumper line is arranged across two adjacent in-phase magnetic poles 30a.
- the first continuous winding 62a is wound over the three magnetic poles 30a.
- the first continuous winding 62a is wound over a range of 2 ⁇ RS. 2 ⁇ RS occupies 1/3 of the angle range of the internal block 32.
- the second continuous winding 62b is wound over the three magnetic poles 30a.
- the second continuous winding 62b is wound over a range of 2 ⁇ RS. 2 ⁇ RS occupies 1/3 of the angle range of the internal block 32.
- the first continuous winding 62 a and the second continuous winding 62 b do not overlap each other in the circumferential direction of the internal block 32.
- All of the plurality of internal jumper wires 62j are arranged so as to pass over both ends of the internal block 32 and between the two magnetic poles 30a. Therefore, all of the plurality of internal jumper wires 62j are crank-shaped.
- the plurality of internal jumper lines 62j are formed in an arc shape.
- the plurality of teeth portions 41a provide a virtual annular range R32 at the root portion on the radially inner side.
- the plurality of internal jumper lines 62j are arranged in the annular range R32.
- the plurality of internal jumper wires 62j are arranged in contact with the plurality of unit coils 62u. Therefore, the plurality of internal jumper wires 62j are arranged so as to suppress the height of the stator 30 in the axial direction.
- the plurality of internal jumper wires 62j pass through the radially inner range of the unit coil 62u. For this reason, it is arrange
- FIG. 9 is a perspective view showing the base end block 33.
- the proximal block 33 includes a core 43, an insulator 53, and a Z-phase winding 63.
- the core 43 includes a plurality of teeth portions 43a and a ring portion 43b that connects the plurality of teeth portions 43a.
- the core 43 further includes a coupling portion 43c at the radially inner end of each tooth portion 43a.
- the coupling part 43c has a slightly larger circumferential width than the tooth part 43a.
- the coupling portion 43c provides a magnetic and mechanical connection by facing the outer peripheral surfaces of the ring portions 41b and 42b of the other cores 41 and 42.
- the Z-phase winding 63 has a plurality of continuous windings 63a and 63b.
- the first continuous winding 63a is wound in the order of the eleventh magnetic pole, the jumper wire, the seventeenth magnetic pole, the jumper wire, and the fifth magnetic pole.
- the second continuous winding 63b is wound in the order of the 14th magnetic pole, the jumper wire, the 2nd magnetic pole, the jumper wire, and the 8th magnetic pole.
- the plurality of base end jumper wires 63j extend between two magnetic poles 30a located at the second of the in-phase magnetic poles 30a, one of which is skipped. That is, the base end jumper line 63j extends between the two magnetic poles 30a separated by the inter-pole angle RD.
- the length in the circumferential direction of the base end jumper wire 63j is longer than that in the case where the jumper wire is disposed over two adjacent in-phase magnetic poles 30a.
- the relatively long base end jumper line 63j contributes to suppressing a difference from the length of the internal jumper line 62j.
- the relatively long base end jumper line 63j contributes to suppressing a difference in resistance component and a difference in inductive component between the base end jumper line 63j and the internal jumper line 62j.
- the first continuous winding 63a is wound over the three magnetic poles 30a.
- the second continuous winding 63b is wound over the three magnetic poles 30a.
- the first continuous winding 63 a and the second continuous winding 63 b overlap each other in the circumferential direction of the proximal block 33.
- All of the plurality of base end jumper wires 63j are disposed on the other end of the base end block 33. Therefore, all of the plurality of base end jumper wires 63j are arranged on the end face of the stator 30.
- the plurality of base end jumper wires 63j are formed in an arc shape.
- the plurality of teeth portions 43a provide a virtual annular range R33 extending in the radial direction.
- the plurality of base end jumper wires 63j are arranged in the annular range R33.
- the plurality of base end jumper wires 63j are arranged in contact with the plurality of unit coils 63u. Therefore, the plurality of base end jumper wires 63j are arranged so as to suppress the height of the stator 30 in the axial direction.
- the plurality of base end jumper wires 63j pass through the radially inner range of the unit coil 63u. For this reason, it is arrange
- the end block including the distal end block 31 or the proximal end block 33 has a magnetic pole angle RD.
- the inter-pole angle RD of the end block is larger than the inter-pole angle RS of the internal block 32.
- the difference between the magnetic pole angle RD and the magnetic pole angle RS contributes to suppressing a difference in resistance component and / or a difference in induction component between the phase windings.
- FIG. 10 shows a method for manufacturing the rotating electrical machine 20.
- the rotating electrical machine manufacturing method 190 includes a part process 191 for manufacturing parts, and an assembly process 194 for assembling the rotor 26 and the stator 30 on the engine.
- the component process 191 includes a rotor process 192 for manufacturing the rotor 26 and a stator process 193 for manufacturing the stator 30.
- the rotor process 192 and the stator process 193 can be performed in parallel or in sequence.
- FIG. 11 shows details of the stator process 193.
- the stator process 193 includes a block process 195 for manufacturing a plurality of blocks 31, 32, and 33.
- the stator process 193 includes an assembly process 196 and a connection process 197.
- the assembling step 196 the plurality of blocks 31, 32, and 33 manufactured in the block step 195 are assembled to the stator 30.
- the plurality of blocks 31, 32, 33 are meshed with each other in the axial direction.
- the distal end block 31 and the proximal end block 33 are meshed with both sides of the inner block 32 in the axial direction.
- the distal end block magnetic pole 31a, the proximal end block magnetic pole 33a, and the inner block magnetic pole 32a are arranged along the circumferential direction.
- the distal end block 31 is disposed at one end in the axial direction
- the proximal end block 33 is disposed at the other end in the axial direction
- the inner block 32 is disposed between the distal end block 31 and the proximal end block 33.
- the connection step 197 the plurality of end wires 60 e of the stator 30 are connected as the windings 60.
- the block step 195 includes end block steps 195a to 195d for manufacturing the distal end block 31 and the proximal end block 33.
- the block process 195 includes internal block processes 195e-195i for manufacturing the internal block 32.
- the end block steps 195a-195d and the internal block steps 195e-195i can be performed in parallel or sequentially.
- step 195a the distal end core 41 and the proximal end core 43 are manufactured.
- step 195 a the insulators 51 and 53 are attached to the distal end core 41 and the proximal end core 43.
- step 195 b a phase winding is wound around the distal end core 41 and the proximal end core 43.
- an aluminum or aluminum alloy wire is wound by concentrated winding.
- the distal end core 41 and the proximal end core 43 include a third magnetic pole 30a of the stator 30, and the distance between the magnetic poles 30a is wide. For this reason, a winding process can be performed comparatively easily.
- the wire is relatively thick and difficult to bend, a wire that is generally difficult to wind can be wound relatively easily.
- the size, space factor, and / or number of turns of the unit coil can be increased.
- step 195c the front end jumper line 61j and the base end jumper line 63j are arranged at specified positions.
- Step 195 c provides a step of disposing the tip jumper wire 61 j extending over the plurality of unit coils 61 u on the tip surface of the tip block 31.
- Step 195 c provides a step of arranging the base end jumper wire 63 j extending over the plurality of unit coils 63 u on the base end surface of the base end block 33.
- Step 195c provides a step of arranging the tip jumper wire 61j between the two tip block magnetic poles 31a positioned by skipping one magnetic pole.
- Step 195c provides a step of placing the proximal jumper line 63j between the two proximal block magnetic poles 33a located by skipping one magnetic pole.
- the front end jumper line 61j and the base end jumper line 63j are formed in an arc shape.
- Step 195c is executed in step 195b.
- step 195d the connecting portions of the insulators 51 and 53 are removed.
- the connecting portion connects a plurality of portions of the insulators 51 and 53 to each other and can be handled as an integrated object.
- the distal end block 31 and the proximal end block 33 are manufactured.
- FIGS. 12 and 14 schematically show the disassembled state of the distal end core 41 and the proximal end core 43.
- the plurality of core sheets have a plurality of core sheets 41e and 43e that provide ring portions 41b and 43b and teeth portions 41a and 43a. Further, the plurality of core sheets have core sheets 41f and 43f that provide only the teeth portions 41a and 43a.
- An adhesive 45 (ADH) is disposed between the plurality of core sheets.
- the insulators 51 and 53 are attached to the distal end core 41 and the proximal end core 43.
- the insulators 51 and 53 are provided by first covers 51 a and 53 a and second covers 51 b and 53 b that are mounted from the axial direction of the distal end core 41 and the proximal end core 43.
- One cover 51b, 53a provides a portion that covers the plurality of tooth portions 41a, 43a.
- the covers 51b and 53a include connection portions 51c and 53c that connect a plurality of portions in the manufacturing stage. The connecting portions 51c and 53c are cut off at the manufacturing stage.
- step 195e the inner core 42 is manufactured.
- step 195 e the insulator 52 is attached to the inner core 42.
- step 195f a phase winding is wound around the inner core.
- Step 195f provides a step of winding the plurality of unit coils 62u in the winding 62 of the inner block 32 in the same winding direction.
- step 195g a strand having a required length for forming the crank-shaped internal jumper wire 62j is drawn on the internal block 32. The drawn strands are also called unfinished intermediates.
- step 195h the strand drawn in step 195g is formed into a crank shape.
- Step 195h provides a forming step of forming the internal jumper wire 62j extending over the plurality of unit coils 62u into a crank shape so as to bypass the distal end block magnetic pole 31a and / or the proximal end block magnetic pole 33a.
- Step 195h provides a step of placing the internal jumper line 62j between two adjacent internal block magnetic poles 32a.
- Step 195h provides a step of forming the inner jumper wire 62j into a U-shape that opens toward one end or the other end.
- the connecting portion of the insulator 52 is removed. In the manufacturing method, the connecting portion connects a plurality of portions of the insulator 52 to each other and can be handled as an integrated object. Thus, the internal block 32 is manufactured.
- FIG. 13 schematically shows an exploded state of the inner core 42.
- the plurality of core sheets include a plurality of core sheets 42e that provide a ring portion 42b and a tooth portion 42a. Further, the plurality of core sheets have a core sheet 42f that provides only the teeth portion 42a.
- An adhesive 45 (ADH) is disposed between the plurality of core sheets.
- the insulator 52 is attached to the inner core 42.
- the insulator 52 is provided by a first cover 52 a and a second cover 52 b that are mounted from the axial direction of the inner core 42.
- the covers 52a and 52b include a connection part 52c that connects a plurality of parts in the manufacturing stage.
- the connection part 52c is cut off in the manufacturing stage.
- the plurality of core sheets may be fixed by caulking that partially deforms the core sheet.
- the plurality of core sheets may be fixed by rivet fixing using rivets that penetrate the teeth portion in the axial direction. These various fastening techniques can be used in place of or in addition to bonding.
- FIG. 15 shows a forming process for forming an intermediate body with an element wire in step 195g.
- the forming process is also a process for forming a relatively long internal jumper line 62j.
- the internal block 32 among the internal block 32, three internal block magnetic poles 32a of No. 6, No. 9, and No. 12 related to the first continuous winding 62a are shown. Furthermore, a connecting portion 52c for providing the insulator 52 is shown.
- the wire intermediate 69 is drawn out by the manufacturing apparatus 70.
- the manufacturing apparatus 70 finishes winding one unit coil 62u, the manufacturing apparatus 70 suppresses the strands by the holder 70a.
- the manufacturing apparatus 70 draws the strand from the holder 70a.
- the manufacturing apparatus 70 draws the wire so as to be hooked on the hook 70b, and winds the wire around the next magnetic pole 30a.
- the hook 70b is separated from the inner block 32 by a predetermined distance in the axial direction.
- the strand is drawn out via the hook 70b. As a result, the long strand passing through the hook 70b provides the intermediate body 69.
- FIG. 16 shows a molding process for molding the intermediate body 69 into a crank shape in step 195h.
- the manufacturing apparatus 70 includes molds 70c, 70d, 70e, 70f, and 70g.
- the manufacturing apparatus 70 uses these molds to form the intermediate body 69 into a crank shape.
- a crank-shaped internal jumper wire 62j is provided.
- the plurality of internal jumper wires 62j provided in the intermediate block 32 are all crank-shaped.
- FIG. 17 shows the shape of the internal block 32 after manufacturing.
- the connection part 52c is removed.
- the internal jumper line 62j is disposed so as to bridge between the two unit coils 62u.
- the internal jumper line 62j has a plurality of portions (1) to (9).
- the internal jumper wire 62j has a first circumferentially extending portion 71 that extends along one end of the stator 30 from the unit coil 62u1 wound earlier.
- the first circumferentially extending portion 71 has an arc shape.
- the first circumferentially extending portion 71 extends from the 12th magnetic pole.
- the first circumferentially extending portion 71 extends along one end of the proximal block magnetic pole 33a.
- the internal jumper wire 62j has a bent portion 72 that is bent from the first circumferentially extending portion 71 between the distal block magnetic pole 31a and the proximal block magnetic pole 33a.
- the internal jumper wire 62j has a first axially extending portion 73 extending in the axial direction between the distal end block magnetic pole 31a and the proximal end block magnetic pole 33a.
- the first axial extension 73 provides a part of the crank shape.
- the internal jumper line 62j passes between the distal end block magnetic pole 31a and the proximal end block magnetic pole 33a in the first axially extending portion 73.
- the internal jumper wire 62j has a bent portion 74 that bends along the other end of the stator 30 from the first axially extending portion 73.
- the bent portion 74 is bent toward the unit coil 62u2 to be wound next.
- the internal jumper wire 62j has a second circumferentially extending portion 75 extending along the other end of the stator 30.
- the second circumferentially extending portion 75 has an arc shape.
- the second circumferentially extending portion 75 extends along the other end of the tip block magnetic pole 31a.
- the internal jumper wire 62j has a bent portion 76 that is bent from the second circumferentially extending portion 75 between the tip block magnetic pole 31a and the internal block magnetic pole 32a.
- the internal jumper wire 62j has a second axially extending portion 77 extending in the axial direction between the tip block magnetic pole 31a and the internal block magnetic pole 32a.
- the second axial extension 77 provides a part of the crank shape.
- the internal jumper line 62j passes between the tip block magnetic pole 31a and the internal block magnetic pole 32a in the second axially extending portion 77.
- the internal jumper wire 62j passes between the proximal end block magnetic pole 33a and the internal block magnetic pole 32a in the second axially extending portion 77.
- the internal jumper wire 62j has a bent portion 78 that bends along the one end of the stator 30 from the second axially extending portion 77.
- the bent portion 78 is bent toward the unit coil 62u2 to be wound next.
- the internal jumper wire 62j has a third circumferentially extending portion 79 that reaches the unit coil 62u2 to be wound next from the bent portion 78.
- the third end is arcuate.
- the third circumferentially extending portion 79 reaches the ninth magnetic pole.
- the internal jumper wire 62j continuously connects the unit coil 62u1 wound first and the unit coil 62u2 wound later.
- the winding direction of the unit coil 62u1 and the winding direction of the unit coil 62u2 are the same. Even if the winding direction of the unit coil 62u1 and the winding direction of the unit coil 62u2 are opposite, the internal jumper wire 62j has at least one axially extending portion 73, 77.
- the leading end block 31 and the proximal end block 33 are combined from both ends of the internal block 32, respectively.
- the internal jumper wire 62j of the internal block 32 requires the axially extending portions 73 and 77 in order to bypass the distal end block magnetic pole 31a and the proximal end block magnetic pole 33a.
- the internal jumper wire 62j is formed in a crank shape so as to bypass the distal end block magnetic pole 31a and the proximal end block magnetic pole 33a.
- the internal jumper wires 62j of the continuous windings 62a and 62b are mainly disposed at one end of the stator 30.
- the internal jumper wire 62j has a bypass portion to bypass the tip block magnetic pole 31a located at one end of the stator 30.
- the detour part includes an axially extending part 73, a bent part 74, a second circumferentially extending part 75, a bent part 76, and a second axially extending part 77.
- the crank-shaped jumper wire 62j has a U-shaped detour portion.
- the U-shaped detour is a U-shape that opens toward one end.
- the jumper wire 62j of the continuous windings 62a and 62b can be arranged mainly at the other end of the stator 30.
- the internal jumper wire 62j may have a U-shaped detour portion arranged so as to detour the end block magnetic pole 33a from the other end.
- the internal jumper wire 62j of the continuous winding 62a and the internal jumper wire 62j of the continuous winding 62b may be arranged in a distributed manner at one end and the other end of the stator 30.
- the internal jumper wire 62j has a crank shape arranged so as to bypass the end block magnetic pole including the distal end block magnetic pole 31a and the proximal end block magnetic pole 33a. Thereby, interference between a plurality of jumper lines and a plurality of blocks is controlled. Further, a plurality of jumper wires are arranged in a distributed manner on one end and the other end of the stator. Further, the internal jumper wire 62j is formed to have a U-shaped detour portion. The U-shaped detour portion is open toward one end or the other end. As a result, the internal jumper line 62j bypasses the end block including the distal end block 31 and the proximal end block 33. This eliminates the need to change the winding direction. Therefore, an internal jumper wire 62j that bypasses the distal end block magnetic pole 31a or the proximal end block magnetic pole 33a meshed from the end is provided.
- FIG. 18 is a side view showing meshing of the plurality of blocks 31, 32, and 33.
- the 6th to 14th magnetic poles are shown.
- the internal jumper wire 62j is disposed so as to bypass the distal end block magnetic pole 31a and the proximal end block magnetic pole 33a.
- the illustrated internal jumper wire 62j is shaped to allow the eleventh magnetic pole and the tenth magnetic pole to be positioned between the twelfth magnetic pole and the ninth magnetic pole.
- FIG. 19 shows the shape of a bobbin for the winding 60 provided by the insulator 50.
- FIG. 19 shows the shape of the 10th magnetic pole.
- the insulator 50 has a coil bobbin 56 in which a unit coil 61u is disposed.
- the coil bobbin 56 occupies the radially outer side of the tooth portion 41a.
- the insulator 50 further includes a jumper bobbin 57 that holds an internal jumper line 62j.
- the jumper bobbin 57 is disposed radially inward from the coil bobbin 56.
- the insulator 50 has an outer flange 58 between the coil bobbin 56 and the jumper bobbin 57.
- the outer flange 58 partitions the coil bobbin 56 and the jumper bobbin 57.
- the outer flange 58 contributes to provide a position for accommodating the jumper wire 62j even after the unit coil 61u is wound.
- the coil bobbin 56 is formed on all the magnetic poles 30a.
- the jumper bobbin 57 is formed on all the magnetic poles 30a.
- the jumper bobbin 57 may be formed only on the magnetic pole 30 a that may contact the axially extending portions 73 and 77.
- the block step 195 includes a step of forming the coil bobbin 56 around which the unit coil 60u is wound and the jumper bobbin 57 where the internal jumper wire 62j is held into the insulator 50.
- the jumper bobbin 57 may be formed after the coil bobbin 56 is formed.
- the jumper bobbin 57 may be formed by contact with the internal jumper wire 62j.
- FIG. 20 shows a state in which a plurality of blocks 31, 32, and 33 are combined.
- the internal jumper line 62j is disposed in the jumper bobbin 57.
- the jumper bobbin 57 stably holds the internal jumper wire 62j.
- the jumper bobbin 57 does not necessarily have the internal jumper wires 62j inserted in all the magnetic poles.
- the unused jumper bobbin 62j may accommodate the winding start line of the unit coil 60u. In this case, the number of turns can be increased in the unit coil 60u. Similarly, the winding end line of the unit coil 60u may be accommodated. In this case, the height of the coil can be reduced because it is not necessary to straddle other jumper wires, especially when winding the winding end wire to the fixed portion.
- the plurality of cores 41, 42, 43 are arranged in a stack in the axial direction in the plurality of ring portions 41b, 42b, 43b.
- the plurality of cores 41, 42, and 43 are magnetically and mechanically tightly coupled at the plurality of ring portions 41b, 42b, and 43b.
- Each of the plurality of cores 41, 42, and 43 is magnetically and mechanically continuous between a plurality of tooth portions to which the cores belong, and a ring portion to which the cores belong.
- the plurality of cores 41, 42, 43 are magnetically and mechanically coupled at the respective coupling portions 41c, 42c, 43c.
- the coupling portion 41c is magnetically coupled by facing the ring portion 42b and the ring portion 43b in the radial direction.
- the coupling portion 42c is magnetically coupled by facing the ring portion 41b and the ring portion 43b in the radial direction.
- the coupling portion 43c is magnetically coupled by facing the ring portion 41b and the ring portion 42b in the radial direction.
- the plurality of coupling portions 41c, 42c, and 43c are magnetically coupled by facing each other in the circumferential direction.
- a gap 46 in the radial direction is formed between the plurality of coupling portions 41c, 42c, and 43c and the other ring portions 41b, 42b, and 43b.
- the plurality of coupling portions 41c, 42c, 43c may be in partial contact with the other ring portions 41b, 42b, 43b.
- the plurality of coupling portions 41 c, 42 c, 43 c and the other ring portions 41 b, 42 b, 43 b are separated from each other in the gap 46.
- the gap 46 provides a mechanically loose bond.
- the gap 46 may be filled with an adhesive or a resin for fixing the winding 60. The loose coupling provided by the gap 46 results in a change in the vibration frequency of the stator 30.
- the tip jumper wire 61j of the tip block 31 is disposed at one end of the stator 30.
- the proximal end jumper line 63j of the proximal end block 33 is disposed at the other end of the stator 30.
- the internal jumper wire 62j of the internal block 32 is arranged in a crank shape so as to bypass the distal end block magnetic pole 31a and / or the proximal end block magnetic pole 33a. For this reason, interference between the plurality of jumper lines 61j, 62j, 63j and the plurality of blocks 31, 32, 33 is suppressed.
- a plurality of jumper wires 61j, 62j, and 63j are distributed on one end and the other end of the stator 30 in a distributed manner. For this reason, the enlargement of the physique of the stator 30 is suppressed. Further, the small stator 30 is formed with a simple configuration in which the internal jumper wires 62j are simply arranged in a crank shape.
- the internal jumper wire 62j may have a U-shaped bypass portion arranged so as to bypass the end block magnetic pole from one end or the other end of the stator 30 in some cases. In this case, there is no need to change the winding direction of the unit coil 62u. For this reason, a winding process is performed at high speed.
- the internal jumper line 62j extends between two adjacent internal block magnetic poles 32a in the internal block 32. Since the internal jumper wire 62j has a crank shape, it is longer than the distance between two adjacent magnetic poles 30a in the same phase.
- the tip jumper wire 61j extends between two tip block magnetic poles 31a located in the tip block 31 by skipping one tip block magnetic pole 31a. For this reason, the difference between the length of the internal jumper wire 62j and the length of the tip jumper wire 61j is suppressed.
- the base end jumper line 63j extends between two base end block magnetic poles 33a located in the base end block 33 by skipping one base end block magnetic pole 33a.
- the insulator 50 provides a coil bobbin 56 and a jumper bobbin 57.
- the jumper bobbin 57 stabilizes the shape of the jumper wire 62j and the position in the stator 30.
- the jumper bobbin 57 contributes to stably hold the jumper wire 62j.
- one phase winding has two continuous windings.
- the X-phase winding 61 has two continuous windings 61a and 61b.
- One phase winding can include two or more continuous windings.
- one phase winding has three continuous windings 261a, 261b, 261c.
- the X-phase winding 61 is shown. The same applies to the other phase windings.
- the X-phase winding 61 has three continuous windings 261a, 261b, 261c.
- One continuous winding has two unit coils 61u.
- the continuous winding 261a has two unit coils 61u, two end wires 60e, and one tip jumper wire 61j.
- the continuous winding 261a is provided by a continuous line wound around the two unit coils 61u.
- the continuous winding 261b and the continuous winding 261c are connected in parallel. This parallel circuit is connected to the neutral point electrode 64.
- the continuous winding 261a is connected in series with the parallel circuit of the continuous winding 261b and the continuous winding 261c.
- the continuous winding 261a is connected to the output electrode 65.
- the continuous winding 261a is disposed between the output electrode 65 and the parallel circuit.
- an in-phase joint 261p that connects them in series is provided.
- the in-phase junction 261p can be provided by a direct connection between the strands or by an electrode.
- one phase winding has a plurality of joints 68.
- a circuit different from the preceding embodiment is obtained. Different circuits exhibit different output characteristics. Therefore, the electrical connection relationship of the plurality of unit coils 61u can be adjusted so as to match the required output characteristics.
- One continuous winding can include a plurality of unit coils. Further, the number of unit coils included in the plurality of continuous windings may be different among the plurality of continuous windings belonging to one phase winding.
- the insulator 50 has the connection parts 51c, 52c, and 53c.
- an independent bobbin may be formed for each of the plurality of magnetic poles 30a.
- the strand is hold
- the manufacturing apparatus 70 may hook a strand.
- the internal block 32 has an insulator 52 assembled in each of the plurality of magnetic poles 32a.
- the insulator 52 provides bobbins 352e, 352f, and 352f in each of the plurality of magnetic poles 32a. These bobbins 352e, 352f, and 352f are not connected to each other in the manufacturing stage. These bobbins 352e, 352f, and 352f are assembled independently of each other in each of the plurality of magnetic poles 32a. Therefore, according to this embodiment, the stator 30 can be manufactured without the step of removing the connecting portion.
- the manufacturing apparatus 70 includes a hook 370h.
- the hook 370h is used in an intermediate stage for forming the internal jumper line 62j in the winding process for forming the first continuous winding 62a.
- the hook 370h can hold a strand by hooking the strand.
- the hook 370h for example, hooks a wire after completing the winding to the 12th tooth.
- the hook 370 h is used to form the intermediate body 69.
- the intermediate body 69 can be manufactured by hooking the strands on the hooks 370h.
- the intermediate body 69 is manufactured, for example, by changing the movement range of the wire for winding the 12th tooth so as to pass through the hook 370h and the hook 70b after the winding is completed. . Therefore, the intermediate body 69 can be manufactured only by changing the movement range of the wire in the winding process.
- the above embodiment provides a motor generator that can function as a motor or a generator.
- this disclosure may provide an electric motor or generator.
- the number of magnetic poles 30a provided by the stator 30 is not limited to 18.
- the number of magnetic poles 30a can be set to 12, 24, etc. according to the required performance.
- the number of magnetic poles of the rotor 26 can be arbitrarily set. For example, in the case of three phases, it can be 3n (n is a natural number).
- the angle of the teeth of the adjacent stators 30 may be changed as appropriate in accordance with the number of magnetic poles of the rotor 26 so that they are not equally spaced from each other.
- the number of magnetic poles of the rotor 26 and the number of magnetic poles of the stator 30 may be irregularly associated, and for example, a setting such as 16P-18S is possible.
- stator 30 including the three blocks 31, 32, and 33.
- this disclosure may provide a stator 30 comprising three or more blocks, such as 3, 4, 5, etc.
- the inner block 32 may include a first block including three magnetic poles 30a and a second block including three magnetic poles 30a. The number of blocks is set according to the ease of winding work and the ease of forming jumper wire 60j.
- the distal end block 31 and the proximal end block 33 are configured symmetrically with respect to the axial direction.
- the two end blocks provided by the distal block 31 and the proximal block 33 can have different configurations.
- only the distal end block 31 may be set as the magnetic pole distance RD
- the proximal block 33 may be set as the magnetic pole distance RS.
- the jumper bobbin 57 may be disposed only at the position where the internal jumper line 62j is disposed.
- the jumper bobbin 57 may be formed on only one of the two end blocks (the front end block 31).
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Abstract
Description
図1において、回転電機20が図示されている。回転電機20は、発電電動機である。回転電機20は、発電電動機として機能するための回転位置検出器を備えている。回転位置検出器は図示されていない。回転電機20は、内燃機関(エンジン)に装着されることによって、エンジンと連動する。エンジンは、乗り物に搭載された乗り物用エンジン、または汎用エンジンである。ここで、乗り物の語は、広義に解釈されるべきであり、車両、船舶、航空機などの移動体、および、アミューズメント機器、およびシミュレーション機器などの固定物を含む。また、汎用エンジンは、例えば、発電機、およびポンプとして利用可能である。この実施形態では、エンジンは、鞍乗り型の車両に搭載されている。
この実施形態は、先行する実施形態を基礎的形態とする変形例である。上記実施形態では、ひとつの相巻線は、2つの連続巻線を有する。例えば、X相巻線61は、2つの連続巻線61a、61bを有する。ひとつの相巻線は、2つ以上複数の連続巻線を備えることができる。この実施形態では、ひとつの相巻線は、3つの連続巻線261a、261b、261cを有する。
この実施形態は、先行する実施形態を基礎的形態とする変形例である。上記実施形態では、インシュレータ50は、接続部51c、52c、53cを有する。これに代えて、複数の磁極30aごとに独立のボビンを形成してもよい。また、上記実施形態では、製造方法において、内部ジャンパ線62jの中間体69を製造するために、ホルダ70aを使って素線を押さえている。これに代えて、製造装置70は、素線を引っ掛けてもよい。
この明細書および図面等における開示は、例示された実施形態に制限されない。開示は、例示された実施形態と、それらに基づく当業者による変形態様を包含する。例えば、開示は、実施形態において示された部品および/または要素の組み合わせに限定されない。開示は、多様な組み合わせによって実施可能である。開示は、実施形態に追加可能な追加的な部分をもつことができる。開示は、実施形態の部品および/または要素が省略されたものを包含する。開示は、ひとつの実施形態と他の実施形態との間における部品および/または要素の置き換え、または組み合わせを包含する。開示される技術的範囲は、実施形態の記載に限定されない。開示されるいくつかの技術的範囲は、請求の範囲の記載によって示され、さらに請求の範囲の記載と均等の意味及び範囲内での全ての変更を含むものと解されるべきである。
Claims (17)
- 軸方向の一端に配置され、複数の先端ブロック磁極(31a)を有する先端ブロック(31)と、前記軸方向の他端に配置され、複数の基端ブロック磁極(33a)を有する基端ブロック(33)と、前記軸方向に関して前記先端ブロックと前記基端ブロックとの間に配置され、複数の内部ブロック磁極(32a)を有する内部ブロック(32)とを備えており、
前記先端ブロック、前記内部ブロック、および前記基端ブロックは、前記先端ブロック磁極、前記基端ブロック磁極、および前記内部ブロック磁極を周方向に沿って配置するように、前記軸方向に沿って配置されており、
前記先端ブロックの巻線(61)は、複数の単位コイルにわたって延び、前記一端に配置された複数の先端ジャンパ線(61j)を有し、
前記基端ブロックの巻線(63)は、複数の単位コイルにわたって延び、前記他端に配置された複数の基端ジャンパ線(63j)を有し、
前記内部ブロックの巻線(62)は、複数の単位コイルにわたって延び、前記先端ブロック磁極および前記基端ブロック磁極を含む端部ブロック磁極を迂回するように配置されたクランク形の内部ジャンパ線(62j)を有する回転電機のステータ。 - 前記内部ジャンパ線(62j)の前記クランク形は、前記先端ブロック磁極と前記基端ブロック磁極との間を経由している軸方向延在部(73)を含む請求項1に記載の回転電機のステータ。
- 前記内部ジャンパ線(62j)の前記クランク形は、前記端部ブロック磁極と前記内部ブロック磁極との間を経由している軸方向延在部(77)を含む請求項1または請求項2に記載の回転電機のステータ。
- 前記内部ジャンパ線(62j)は、前記一端または前記他端から前記端部ブロック磁極を迂回するように配置された迂回部(73、74、75、76、77)を含む請求項1から請求項3のいずれかに記載の回転電機のステータ。
- 前記迂回部は、前記一端または前記他端に向けて開いたU字形である請求項4に記載の回転電機のステータ。
- 前記内部ブロックの巻線における複数の前記単位コイルの巻方向は同じである請求項4または請求項5に記載の回転電機のステータ。
- 前記内部ジャンパ線は、前記内部ブロックにおいて、隣接する2つの内部ブロック磁極の間に延びており、
前記先端ジャンパ線は、前記先端ブロックにおいて、1つの磁極を飛ばして位置する2つの前記先端ブロック磁極の間に延びている請求項1から請求項6のいずれかに記載の回転電機のステータ。 - 前記内部ジャンパ線は、前記内部ブロックにおいて、隣接する2つの内部ブロック磁極の間に延びており、
前記基端ジャンパ線は、前記基端ブロックにおいて、1つの磁極を飛ばして位置する2つの前記基端ブロック磁極の間に延びている請求項1から請求項7のいずれかに記載の回転電機のステータ。 - 複数の磁極は、前記単位コイルが配置されたコイルボビン(56)と、
前記内部ジャンパ線が保持されたジャンパボビン(57)とを備える請求項1から請求項8のいずれかに記載の回転電機のステータ。 - 前記コイルボビンは、前記磁極の径方向外側を占め、
前記ジャンパボビンは、前記コイルボビンより径方向内側に位置する請求項9に記載の回転電機のステータ。 - 前記内部ブロックの巻線(62)は、複数の前記内部ブロック磁極において連続的に巻かれた複数の連続巻線(62a、62b)を有する請求項1から請求項10のいずれかに記載の回転電機のステータ。
- 請求項1から請求項11のいずれかに記載のステータと、
前記ステータに回転磁界を提供するロータ(26)とを備える回転電機。 - 複数の先端ブロック磁極(31a)を有する先端ブロック(31)、複数の基端ブロック磁極(33a)を有する基端ブロック(33)、および、複数の内部ブロック磁極(32a)を有する内部ブロック(32)を含む複数のブロックを製造するブロック工程(195)と、
前記先端ブロック磁極、前記基端ブロック磁極、および前記内部ブロック磁極を周方向に沿って配置するように、前記先端ブロックを軸方向の一端に配置し、前記基端ブロックを軸方向の他端に配置し、前記内部ブロックを前記先端ブロックと前記基端ブロックとの間に配置して、ステータを組み立てる工程(196)とを備え、
複数のブロックを製造する工程は、
複数の単位コイルにわたる先端ジャンパ線(61j)を前記先端ブロックの先端面に配置する工程(195c)と、
複数の単位コイルにわたる基端ジャンパ線(63j)を前記基端ブロックの基端面に配置する工程(195c)と、
複数の単位コイルにわたる内部ジャンパ線(62j)を、前記先端ブロック磁極および/または前記基端ブロック磁極を迂回するようにクランク形に成形する成形工程(195h)とを有する回転電機のステータの製造方法。 - 前記成形工程は、前記内部ジャンパ線を前記一端または前記他端に向けて開いたU字形に成形する請求項13に記載の回転電機のステータの製造方法。
- 前記ブロック工程は、前記内部ブロックの巻線における複数の前記単位コイルを同じ巻方向で巻く請求項13または請求項14に記載の回転電機のステータの製造方法。
- 前記ブロック工程は、隣接する2つの前記内部ブロック磁極の間にわたって前記内部ジャンパ線を配置する工程と、1つの磁極を飛ばして位置する2つの前記先端ブロック磁極の間にわたって前記先端ジャンパ線を配置する工程と、1つの磁極を飛ばして位置する2つの前記基端ブロック磁極の間にわたって前記基端ジャンパ線を配置する工程とを有する請求項13から請求項15のいずれかに記載の回転電機のステータの製造方法。
- 前記ブロック工程は、前記単位コイルが巻かれるコイルボビン(56)、および前記内部ジャンパ線が保持されるジャンパボビン(57)とを成形する請求項13から請求項16のいずれかに記載の回転電機のステータの製造方法。
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