WO2021100457A1 - 回転電機の固定子の製造方法、回転電機の固定子、及び回転電機 - Google Patents

回転電機の固定子の製造方法、回転電機の固定子、及び回転電機 Download PDF

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Publication number
WO2021100457A1
WO2021100457A1 PCT/JP2020/041141 JP2020041141W WO2021100457A1 WO 2021100457 A1 WO2021100457 A1 WO 2021100457A1 JP 2020041141 W JP2020041141 W JP 2020041141W WO 2021100457 A1 WO2021100457 A1 WO 2021100457A1
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WO
WIPO (PCT)
Prior art keywords
segment coil
stator
segment
coil
electric machine
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2020/041141
Other languages
English (en)
French (fr)
Japanese (ja)
Inventor
中山　健一
鳥羽　明
博光 岡本
輝明 樋口
智 荊
恵 山村
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Astemo Ltd
Original Assignee
Hitachi Astemo Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hitachi Astemo Ltd filed Critical Hitachi Astemo Ltd
Priority to JP2021558268A priority Critical patent/JP7514255B2/ja
Priority to DE112020004995.7T priority patent/DE112020004995T5/de
Priority to CN202080077500.9A priority patent/CN114651387B/zh
Priority to US17/777,991 priority patent/US12301075B2/en
Publication of WO2021100457A1 publication Critical patent/WO2021100457A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/30—Manufacture of winding connections
    • H02K15/33—Connecting winding sections; Forming leads; Connecting leads to terminals
    • H02K15/35—Form-wound windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/30—Manufacture of winding connections
    • H02K15/33—Connecting winding sections; Forming leads; Connecting leads to terminals
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/16—Stator cores with slots for windings
    • H02K1/165—Shape, form or location of the slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/06—Embedding prefabricated windings in the machines
    • H02K15/062—Windings in slots; Salient pole windings
    • H02K15/064—Windings consisting of separate segments
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • 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
    • H02K3/345—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation between conductor and core, e.g. slot insulation
    • 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
    • H02K3/48—Fastening of windings on the stator or rotor structure in slots

Definitions

  • the present invention relates to a stator of a rotary electric machine and a method for manufacturing the same.
  • the rotating electric machine generates a rotating magnetic field by supplying AC power to the stator coil, and the rotor can be rotated by this rotating magnetic field. It is also possible to convert the mechanical energy applied to the rotor into electrical energy and output AC power from the coil. In this way, the rotary electric machine operates as a motor or a generator. Since the number of welding points increases due to the high turn of the flat wire of the stator in the rotary electric machine, productivity is an issue in the conventional TIG welding. Therefore, there is a demand for manufacturing a stator using laser welding.
  • Patent Document 1 Japanese Unexamined Patent Publication No. 2013-109948
  • Patent Document 1 Japanese Unexamined Patent Publication No. 2013-109948
  • the joint structure of the flat wire is described in which the end face of the flat wire is spot-irradiated with a laser beam from above and the flat wire is heated and welded in a state where the peeled coating surfaces are butted so as to face each other. Has been done.
  • the insulator for example, enamel
  • the insulator burns out, copper is exposed, the insulation of the coil deteriorates, and the rotating electric machine There was a problem that the reliability of the laser was lowered.
  • a typical example of the invention disclosed in the present application is as follows. That is, in the method for manufacturing a stator used in a rotary electric machine, a first step of arranging the first segment coil and the second segment coil facing each other and a bridge portion in contact with the second segment coil. It is characterized by including a second step of processing the first segment coil so as to generate the above, and a third step of joining the bridge portion and the second segment coil by laser welding.
  • FIG. 1 It is a schematic diagram which shows the whole structure of the rotary electric machine which concerns on embodiment of this invention. It is a perspective view which shows the stator of the rotary electric machine which concerns on embodiment of this invention. It is a perspective view of a stator core. It is a perspective view of the coil end after welding. It is a figure which shows the flat wire before processing to a segment coil. It is a figure which shows the flat line after removing an enamel film. It is a figure which shows the flat line after cutting. It is a figure which shows the segment coil after shaping. It is a perspective view of the segment coil arranged in a slot. It is a perspective view of the segment coil after forming a bridge part. It is a figure which shows the formation of the bridge part. It is a figure which shows the welding of a segment coil. It is a perspective view of the segment coil after welding. It is a perspective view of the coil end after TIG welding.
  • the rotary electric machine according to the present embodiment is a rotary electric machine suitable for use in running an automobile.
  • the so-called electric vehicles that use a rotary electric machine include a hybrid type electric vehicle (HEV) that has both an engine and a rotary electric machine, and a pure electric vehicle (EV) that runs only on the rotary electric machine without using an engine.
  • HEV hybrid type electric vehicle
  • EV pure electric vehicle
  • the rotary electric machine described below can be used for both types of automobiles.
  • FIG. 1 is a schematic view showing the overall configuration of the rotary electric machine 100 according to the embodiment of the present invention.
  • FIG. 1 shows the inside of the rotary electric machine 100 with a part of the rotary electric machine 100 as a cross section.
  • the rotary electric machine 100 is arranged inside the case 10, a housing 112, a stator 130 having a stator core 132 fixed to the housing 112, and a rotor 150 rotatably arranged in the stator 130. And have.
  • the case 10 may be integrally formed with an engine case or a transmission case.
  • This rotary electric machine 100 is a three-phase synchronous motor with a built-in permanent magnet.
  • a three-phase synchronous motor will be described as an example of the rotary electric machine 100, but the present invention can also be applied to an induction motor.
  • the rotary electric machine 100 of this embodiment operates as an electric machine for rotating the rotor 150 by supplying a three-phase AC current to the stator coil 138 wound around the stator core 132. Further, when the rotary electric machine 100 is driven by an engine, it operates as a generator and outputs three-phase alternating current generated power. That is, the rotary electric machine 100 has both a function as an electric motor that generates rotational torque based on electric energy and a function as a generator that generates electric power based on mechanical energy, and is described above depending on the traveling state of the automobile. Functions can be used selectively.
  • the stator 130 is fixed to the housing 112.
  • the stator 130 is fixed and held in the case 10 by fastening the flange 115 provided on the housing 112 to the case 10 by the bolt 12.
  • the rotor 150 fixed to the rotating shaft 118 is supported by bearings 14A and 14B of the case 10, and is rotatably held inside the stator core 132.
  • FIG. 2 is a perspective view showing the stator 130 attached to the housing 112
  • FIG. 3 is a perspective view of the stator core 132.
  • the housing 112 is formed in a cylindrical shape by drawing a steel plate (high-strength steel plate or the like) having a thickness of about 2 to 5 mm.
  • a flange 115 is provided at one end of the housing 112 in the axial direction, and is bolted to the case 10 as described above (see FIG. 1).
  • the flange 115 is integrally formed with the housing 112 by drawing.
  • the stator 130 may be directly fixed to the case 10 without providing the housing 112.
  • the stator 130 is fixed to the inner peripheral side of the housing 112 and has a cylindrical stator core 132 and a stator coil 138 mounted on the stator core 132.
  • the stator core 132 is formed by laminating a plurality of electromagnetic steel sheets 133 formed by punching or etching, for example, having a thickness of about 0.05 to 1.0 mm.
  • the laminated electromagnetic steel sheets 133 are connected and fixed by welding, and deformation of the electrical steel sheets 133 due to the tightening force when press-fitted into the housing 112 is suppressed.
  • the stator core 132 is formed with a plurality of slots 420 extending in the axial direction at equal intervals in the circumferential direction.
  • the number of slots 420 is, for example, 72 in this embodiment.
  • the stator coil 138 is housed in the slot 420 as shown in FIG.
  • the slot 420 is an open slot, and an opening is formed on the inner peripheral side of the stator core 132.
  • the width of the opening in the circumferential direction may be substantially equal to or slightly smaller than the coil mounting portion of each slot 420 in which the stator coil 138 is mounted.
  • Insulating paper (so-called slot liner) 300 is arranged in each slot 420.
  • the insulating paper 300 is, for example, an insulating sheet of heat-resistant polyamide paper, and has a thickness of about 0.1 to 0.5 mm.
  • the insulating paper 300 is arranged in the slots 420 and the coil ends 140a and 140b. By disposing the insulating paper 300 in the slot 420, the insulating paper 300 is disposed between the coils inserted in the slot 420 and between the coil and the inner surface of the slot 420, and is disposed between the coils and the inner surface of the coil and the slot 420. The insulation withstand voltage between the two is improved.
  • the stator coil 138 is formed by connecting a plurality of U-shaped segment coils 28 (see FIGS. 4 and 5D) to each other.
  • the segment coil 28 is arranged so that one end is adjacent to the other segment coil 28 so that its end is exposed from slot 420 (ie, stator 130) and the other end is yet another segment. It is arranged adjacent to the coil 28.
  • the segment coils 28 having adjacent ends form a stator coil 138 wound around the stator core 132 by connecting the adjacent ends to each other.
  • the insulating paper 300 arranged at the coil ends 140a and 140b is arranged in an annular shape between the coils for interphase insulation and interconductor insulation at the coil ends 140a and 140b.
  • the enamel coating 281 for insulating the coil may be damaged or deteriorated. Even so, the required dielectric strength can be maintained.
  • Teeth 430 are formed between the slots 420, and each tooth 430 is integrally molded with the annular core back 440.
  • the stator core 132 is an integrated core in which each tooth 430 and a core back 440 are integrally formed.
  • the teeth 430 guides the rotating magnetic field generated by the stator coil 138 to the rotor 150 and generates a rotational torque in the rotor 150.
  • the rotor 150 has a rotor core 152 and a permanent magnet 154 held in a magnet insertion hole formed in the rotor core 152.
  • rectangular parallelepiped magnet insertion holes are formed at equal intervals in the circumferential direction in the vicinity of the outer peripheral portion.
  • Permanent magnets 154 are embedded in each magnet insertion hole and fixed with an adhesive or the like.
  • the circumferential width of the magnet insertion hole is formed to be larger than the circumferential width of the permanent magnet 154, and magnetic voids 156 are formed on both sides of the permanent magnet 154.
  • the magnetic void 156 may be embedded with an adhesive, or may be integrally solidified with the permanent magnet 154 with a resin.
  • the permanent magnet 154 forms the field pole of the rotor 150.
  • one permanent magnet 154 forms one magnetic pole, but one magnetic pole may be formed by a plurality of permanent magnets.
  • the magnetic flux density of each magnetic pole generated by the permanent magnets increases, and the magnet torque can be increased.
  • the permanent magnet 154 neodymium-based or sumarium-based sintered magnets, ferrite magnets, neodymium-based bonded magnets, and the like can be used, but the residual magnetic flux density of the permanent magnet 154 is about 0.4 to 1.3 T. Desirably, neodymium magnets are more suitable.
  • Auxiliary magnetic poles may be formed between the permanent magnets 154.
  • FIG. 4 is a perspective view of the coil end 140b after welding.
  • each slot 420 eight segment coils 28 are arranged in each slot 420, and as shown in FIG. 4, the ends of two adjacent segment coils 28 are welded and connected to form a coil end 140b. It is configured. For example, by arc welding such as laser welding or TIG (Tungsten Inert Gas) welding or plasma welding, the base metal of the copper wire constituting the segment coil 28 is melted to form a welded portion 30, and the end portion of the segment coil 28 is formed. To connect.
  • arc welding such as laser welding or TIG (Tungsten Inert Gas) welding or plasma welding
  • 5A to 5D are diagrams showing the processing of the segment coil 28.
  • the segment coil 28 is processed from a long flat wire as shown in FIG. 5A.
  • the flat wire is thinly cut on the surface so as to remove the enamel coating 281 on the surface at the position at the end of the segment coil 28 (see FIG. 5B).
  • the enamel coating 281 may be removed by laser light or cutting the surface.
  • the enamel removing portion 282 is provided on another surface of the flat wire (see FIG. 5D), so that the enamel coating 281 is removed on the other surface of the flat wire (see FIG. 5C). ..
  • the flat wire is cut to a predetermined length at the position of the enamel removing portion 282.
  • the segment coil 28 after being cut to a desired length has enamel removing portions 282 at both ends, and the enamel removing portions 282 are provided on opposite surfaces (see FIG. 5C).
  • the flat wire is shaped into a U-shaped segment coil 28 and inserted into the slot 420 of the stator core 132.
  • 6A to 6E are views showing welding of the end portion of the segment coil 28.
  • the segment coil 28 inserted into the slot 420 of the stator core 132 is arranged so that the enamel removing portion 282 faces each other (first step).
  • the enamel removing portion 282 is formed on the facing surfaces where the segment coils 28 face each other, and the enamel coating 281 remains on the surfaces other than the facing surfaces.
  • the end face of the segment coil 28 is cut in a predetermined direction (from the right side to the left side in FIG. 6B), and a bridge portion 283 is formed in the gap 29 between the segment coils 28 (second step).
  • the bridge portion 283 is formed so as to extend to a position where the tip thereof contacts the opposing segment coil 28. It is preferable that an R portion having a radius of about 0.5 mm is formed on the opposite side of the bridge portion 283 of the segment coil 28 in which the bridge portion 283 is formed.
  • the upper blade is moved in the direction of the arrow to cut the end portion of the segment coil 28. ..
  • the bridge portion 283 and the R portion 284 are formed at the end of the segment coil 28 on the upper blade side.
  • the clearance between the upper blade and the lower blade is preferably 0.04 to 0.08 mm. Further, it is preferable to provide a slight chamfer (for example, about 0.5 mm) or a curved surface at the tip of the upper blade so that a bridge portion 283 having an appropriate size can be formed.
  • the bridge portion 283 and the R portion 284 may be formed by using a die (for example, a push die). In this case, the bridge portion 283 and the R portion 284 may be formed before the segment coil 28 is inserted into the slot 420. For example, the bridge portion 283 and the R portion 284 may be formed when the flat wire is cut or processed into a U shape.
  • the bridge portion 283 may be formed on one segment coil 28 or may be formed on both segment coils 28.
  • the segment coils 28 are arranged so that the bridge portions 283 face each other.
  • the bridge portion 283 is irradiated with a laser beam to melt the copper and form the welded portion 30 (third step). Since the gap 29 between the segment coils 28 is not visible from the upper part due to the bridge portion 283 and the bridge portion 283 shields the laser light emitted from above, the laser light does not enter the gap 29 between the segment coils 28 and the laser is used. The light does not hit the enamel coating 281 and damage to the enamel coating 281 during welding can be reduced.
  • the molten copper enters the gap 29 and the welded portion 30 is formed. Molten copper flows into the gap 29 between the segment coils 28 to electrically and mechanically connect the segment coils 28 to each other.
  • segment coil 28 is connected by laser welding, but as shown in FIG. 7, the segment coil 28 may be connected by TIG welding.
  • the first step of arranging the first segment coil 28 and the second segment coil 28 facing each other and the bridge in contact with the second segment coil 28 since the segment coil 28 includes a second step of processing the first segment coil 28 so as to generate the portion 283 and a third step of joining the bridge portion 283 and the second segment coil 28 by laser welding, the segment coil 28 is provided. Since the enamel coating 281 is removed from the surface of the welded portion 30 facing the other segment coil 28 and the enamel coating 281 on the other surface remains, the connection can be made while leaving the enamel coating 281 other than the connecting surface. Insulation is improved.
  • the powder coating is more easily adhered to the enamel coating 281 than copper, the insulating property is improved by the enamel coating 281 and the powder coating. Further, according to laser welding, the height of the coil end can be reduced because the welded portion 30 does not rise.
  • the damage of the enamel coating 281 can be reduced and only the copper required for joining can be melted.
  • the segment coil 28 has a covering portion covered with an insulating coating and an exposed portion not covered with the insulating coating, and the segment coils 28 face each other with a gap 29 of a portion facing the exposed portions. Since it is arranged, the distance between the segment coil 28 and the housing 112 can be reduced because the parts other than the joint surface are covered with the enamel coating 281.
  • the present invention is not limited to the above-described embodiment, and includes various modifications and equivalent configurations within the scope of the attached claims.
  • the above-described examples have been described in detail in order to explain the present invention in an easy-to-understand manner, and the present invention is not necessarily limited to those having all the described configurations.
  • a part of the configuration of one embodiment may be replaced with the configuration of another embodiment.
  • the configuration of another embodiment may be added to the configuration of one embodiment.
  • other configurations may be added / deleted / replaced with respect to a part of the configurations of each embodiment.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Windings For Motors And Generators (AREA)
PCT/JP2020/041141 2019-11-20 2020-11-04 回転電機の固定子の製造方法、回転電機の固定子、及び回転電機 Ceased WO2021100457A1 (ja)

Priority Applications (4)

Application Number Priority Date Filing Date Title
JP2021558268A JP7514255B2 (ja) 2019-11-20 2020-11-04 回転電機の固定子の製造方法、回転電機の固定子、及び回転電機
DE112020004995.7T DE112020004995T5 (de) 2019-11-20 2020-11-04 Verfahren zum herstellen des stators einer rotierenden elektrischen maschine, stator einer rotierenden elektrischen maschine und rotierende elektrische maschine
CN202080077500.9A CN114651387B (zh) 2019-11-20 2020-11-04 旋转电机的定子的制造方法、旋转电机的定子以及旋转电机
US17/777,991 US12301075B2 (en) 2019-11-20 2020-11-04 Method for manufacturing stator of rotating electrical machine, stator of rotating electrical machine, and rotating electrical machine

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2019209364 2019-11-20
JP2019-209364 2019-11-20

Publications (1)

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WO2021100457A1 true WO2021100457A1 (ja) 2021-05-27

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PCT/JP2020/041141 Ceased WO2021100457A1 (ja) 2019-11-20 2020-11-04 回転電機の固定子の製造方法、回転電機の固定子、及び回転電機

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US (1) US12301075B2 (https=)
JP (1) JP7514255B2 (https=)
CN (1) CN114651387B (https=)
DE (1) DE112020004995T5 (https=)
WO (1) WO2021100457A1 (https=)

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Publication number Priority date Publication date Assignee Title
JP2023017570A (ja) * 2021-07-26 2023-02-07 株式会社デンソー 固定子、及び固定子の製造方法
DE102022106787B3 (de) 2022-03-23 2023-03-30 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Verfahren zur Herstellung einer Wicklung für eine elektrische Maschine und Werkstoffreservoir für ein solches Verfahren
CN115383303A (zh) * 2022-09-01 2022-11-25 深圳泰德激光技术股份有限公司 铜线焊接方法、设备及计算机可读存储介质

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JPS61192644U (https=) * 1985-05-25 1986-11-29
JPH01185149A (ja) * 1988-01-14 1989-07-24 Matsushita Electric Works Ltd モータコイルの製造方法
JP2003284300A (ja) * 2002-03-20 2003-10-03 Denso Corp 回転電機の巻線の製造方法
JP2018020340A (ja) * 2016-08-02 2018-02-08 トヨタ自動車株式会社 平角線のレーザ溶接方法
WO2019111569A1 (ja) * 2017-12-07 2019-06-13 株式会社小田原エンジニアリング コイルセグメントの切断方法及びコイルセグメント切断装置

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US12301075B2 (en) 2025-05-13
DE112020004995T5 (de) 2022-06-30
CN114651387B (zh) 2025-02-11
CN114651387A (zh) 2022-06-21
JPWO2021100457A1 (https=) 2021-05-27
US20220416630A1 (en) 2022-12-29
JP7514255B2 (ja) 2024-07-10

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