WO2022244185A1 - 回転電機 - Google Patents
回転電機 Download PDFInfo
- Publication number
- WO2022244185A1 WO2022244185A1 PCT/JP2021/019161 JP2021019161W WO2022244185A1 WO 2022244185 A1 WO2022244185 A1 WO 2022244185A1 JP 2021019161 W JP2021019161 W JP 2021019161W WO 2022244185 A1 WO2022244185 A1 WO 2022244185A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- terminal
- winding
- electric machine
- stator
- phase
- Prior art date
Links
- 238000004804 winding Methods 0.000 claims abstract description 92
- 229920005989 resin Polymers 0.000 claims abstract description 48
- 239000011347 resin Substances 0.000 claims abstract description 48
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 42
- 239000000463 material Substances 0.000 claims description 14
- 238000000465 moulding Methods 0.000 claims description 11
- 230000001737 promoting effect Effects 0.000 claims description 2
- 230000035882 stress Effects 0.000 description 20
- 230000008646 thermal stress Effects 0.000 description 10
- 230000000694 effects Effects 0.000 description 5
- 239000007769 metal material Substances 0.000 description 4
- 230000017525 heat dissipation Effects 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- 239000012141 concentrate Substances 0.000 description 2
- 238000010292 electrical insulation Methods 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- PMVSDNDAUGGCCE-TYYBGVCCSA-L Ferrous fumarate Chemical group [Fe+2].[O-]C(=O)\C=C\C([O-])=O PMVSDNDAUGGCCE-TYYBGVCCSA-L 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/28—Layout of windings or of connections between windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/52—Fastening salient pole windings or connections thereto
- H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
- H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
-
- 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
- H02K1/14—Stator cores with salient poles
- H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
- H02K1/148—Sectional cores
-
- 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
- H02K15/0025—Shaping or compacting conductors or winding heads after the installation of the winding in the core or machine ; Applying fastening means on winding heads
- H02K15/0037—Shaping or compacting winding heads
- H02K15/0043—Applying fastening means on winding headS
-
- 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
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/08—Insulating casings
-
- 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
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/02—Windings characterised by the conductor material
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K9/00—Arrangements for cooling or ventilating
- H02K9/22—Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
- H02K9/227—Heat sinks
Definitions
- the present disclosure relates to rotating electric machines.
- a rotary electric machine used for an electric power steering device for a vehicle is known. From the viewpoint of heat dissipation and quietness, such a rotating electric machine has a molded resin portion in which connection terminals of a stator and windings are molded with resin or the like (see Patent Documents 1 and 2, for example).
- the electric power steering device is installed inside the vehicle in a place where temperature changes are relatively large.
- an electric power steering system may be placed in the engine room of a vehicle. In this case, the rotating electric machine forming part of the electric power steering apparatus is exposed to even greater temperature changes.
- thermal stress is repeatedly generated due to the difference in the coefficient of linear expansion of the constituent materials of the molded resin portion of the rotating electrical machine, the windings, and the connection terminals of the windings.
- thermal stress is repeatedly generated due to the difference in the coefficient of linear expansion of the constituent materials of the molded resin portion of the rotating electrical machine, the windings, and the connection terminals of the windings.
- the service life of the rotary electric machine is limited due to the fatigue phenomenon caused by repeated occurrence of thermal stress.
- the present disclosure has been made to solve the above problems, and aims to provide a rotating electric machine that can increase the service life.
- a rotating electric machine includes a stator and a rotor.
- the stator includes a plurality of iron cores arranged in an annular shape, windings wound around each of the plurality of iron cores, connection terminals to which the windings are connected, the plurality of iron cores and the windings. and a mold member partially covering the .
- the rotor rotates around a center coinciding with the ring center of the plurality of iron cores.
- the molding member has a resin portion covering the plurality of cores and the windings, and a plurality of terminal exposure portions exposing the connection terminals.
- the service life of the rotating electrical machine can be increased.
- FIG. 1 is a schematic cross-sectional view showing the structure of a rotating electric machine according to Embodiment 1;
- FIG. 2 is a perspective view showing the structure of a stator that constitutes the rotating electric machine according to Embodiment 1.
- FIG. FIG. 2 is a cross-sectional view showing the structure of a stator that configures the rotating electric machine according to Embodiment 1;
- FIG. 2 is a cross-sectional view showing the structure of a stator that configures the rotating electric machine according to Embodiment 1;
- FIG. 8 is a partial cross-sectional view showing the structure of a terminal wire that constitutes the rotating electric machine according to Embodiment 2;
- FIG. 11 is a partial cross-sectional view showing the structure of a terminal wire that constitutes a rotating electric machine according to a modification of Embodiment 2;
- FIG. 11 is a partial cross-sectional view showing the structure of a terminal wire that constitutes a rotating electric machine according to Embodiment 3;
- FIG. 1 to 7 identical or similar components are denoted by the same reference numerals.
- the terms “circumferential direction”, “radial direction” and “axial direction” used in the following description respectively correspond to the “circumferential direction”, “radial direction” and “axial direction” in the stator of the rotary electric machine.
- the phrase “radially outward” means a direction radially outward from the center of the stator.
- the phrase “radially inward” means radially from the outside toward the center of the stator.
- FIG. 1 is a schematic cross-sectional view showing the structure of a rotating electrical machine 100 according to Embodiment 1.
- the rotary electric machine 100 is applied, for example, to an electric power steering device mounted on a vehicle.
- the electric power steering device drives the rotary electric machine 100 by a drive control device or the like.
- the drive control device controls driving of the rotating electrical machine 100 based on output signals such as torque signals output from the rotating electrical machine 100 .
- the rotating electrical machine 100 includes a frame 11 , a stator 1 , a rotor 12 , a shaft 13 (rotating shaft), and bearings 14 and 15 .
- the rotating electrical machine 100 is, for example, a three-phase brushless motor.
- the frame 11 is made of, for example, a metal member such as aluminum that has excellent heat radiation properties from the rotating electric machine 100 .
- the shape of frame 11 corresponds to the outer shape of rotating electric machine 100 . When viewed from the axial direction, the shape of the frame 11 is, for example, cylindrical.
- Frame 11 is a case that surrounds members arranged inside rotary electric machine 100 .
- a stator 1 , a rotor 12 , and a portion of a shaft 13 are arranged inside the frame 11 .
- the stator 1 is arranged on the inner surface of the frame 11 . That is, the frame 11 mechanically holds the stator 1 inside the frame 11 . Thus, the frame 11 is configured to resist torque when the rotating electric machine 100 generates torque on the shaft 13 .
- the rotor 12 is arranged inside the frame 11 and fixed around the shaft 13 .
- the rotor 12 is composed of permanent magnets.
- the shaft 13 is a rod-shaped member. A known metal material is used as the material of the shaft 13 . When viewed from the axial direction, the center of the shaft 13 and the center of the rotor 12 match.
- the shaft 13 axially extends from the inside of the frame 11 toward the outside.
- the first bearing 14 and the second bearing 15 are located at both ends of the frame 11.
- a first bearing 14 and a second bearing 15 rotatably support the shaft 13 .
- the first bearing 14 rotatably supports the shaft 13 inside the frame 11 .
- the shaft 13 passes through the second bearing 15 .
- a shaft 13 extending from the second bearing 15 toward the outside of the frame 11 is an output shaft of the rotary electric machine 100 .
- FIG. 2 is a perspective view showing the structure of stator 1 that configures rotary electric machine 100 according to the first embodiment.
- FIG. 3 is a cross-sectional view showing the structure of stator 1 constituting rotating electric machine 100 according to Embodiment 1, viewed from the axial direction.
- FIG. 4 is a cross-sectional view showing the structure of a stator that configures rotating electrical machine 100 according to Embodiment 1, and is a view showing a cross section including center line CL of rotating electrical machine 100 along the axial direction.
- Frame 11, rotor 12, shaft 13, first bearing 14, and second bearing 15 are omitted in FIGS.
- the stator 1 includes a plurality of iron cores 2 arranged in an annular shape, windings 3 wound around each of the plurality of iron cores 2, winding holders 22, and terminals.
- a hook 23 and a mold member 30 are provided.
- the center of the ring made up of the plurality of iron cores 2 arranged in an annular shape corresponds to the position of the center line CL shown in FIG. Therefore, in the following description, the center of the ring in which the multiple iron cores 2 are arranged may be referred to as the "ring center CL".
- Each of the multiple cores 2 has a back yoke 4 and teeth 5 .
- a known metal material is used as the material of the iron core 2 .
- the back yoke 4 forms the outer peripheral portion of the core 2 on the radially outer side.
- the teeth 5 extend radially inward from the inner peripheral surface of the back yoke 4 . That is, the teeth 5 form the inner portion of the iron core 2 .
- the width (arc width) of the teeth 5 is smaller than the width (arc width) of the back yoke 4 .
- slots 6 are formed between two teeth 5 adjacent to each other in a plurality of iron cores 2 arranged in an annular shape. The windings 3 wound around the teeth 5 are arranged in the slots 6 as will be described later.
- the plurality of iron cores 2 are arranged, for example, in an annular shape along the circumferential direction of the stator 1 .
- a connecting portion (not shown) is provided between two adjacent iron cores 2 .
- the connecting portion connects two cores 2 adjacent to each other and determines the positions of the plurality of cores 2 in the entire stator 1 .
- An annular center CL of the plurality of iron cores 2 coincides with the center of the shaft 13 and the rotor 12 . Therefore, the magnetic force generated between the iron core 2 and the rotor 12 causes the shaft 13 and the rotor 12 to rotate around the center that coincides with the ring center CL.
- the connecting portion for example, there is a welded structure in which two cores 2 adjacent to each other are joined by welding.
- a welded structure in which a plurality of iron cores 2 are arranged in an annular shape, two back yokes 4 facing each other along the circumferential direction are connected by welding. It is not limited to such a welded structure, and a fitting structure in which a concave portion and a convex portion are fitted together may be employed.
- fitting structure An example of the fitting structure will be described. Of the two end faces of the back yoke 4 of the iron core 2 in the circumferential direction, one end face is provided with a concave portion, and the other end face is provided with a convex portion. In the fitting structure, two iron cores 2 adjacent to each other are connected so that the concave portion and the convex portion are fitted to each other. As the structure of the connecting portion, a structure in which the above-described welding structure and fitting structure are combined may be adopted.
- the number of iron cores 2 arranged in an annular shape is twelve. Note that, if the rotating electric machine 100 constitutes a three-phase brushless motor, the number of cores 2 is not limited to 12, and may be 13 or more or 11 or less.
- the multiple cores 2 are composed of a U-phase core 2U, a V-phase core 2V, and a W-phase core 2W for each of the U-phase, V-phase, and W-phase of the three-phase AC.
- the U-phase core 2U, the V-phase core 2V, and the W-phase core 2W may be simply referred to as the core 2 in some cases.
- Winding 3 As a material for the winding 3, a known wiring material is used. Winding 3 is wound around teeth 5 of each of a plurality of iron cores 2 . The winding 3 is wiring connected to the winding end portion 7 and the terminal wire 8 . The winding end portion 7 and the terminal wire 8 correspond to lead wiring that is a part of the winding 3 . The winding end portion 7 extends axially from the winding 3 wound around the teeth 5 . The winding ends 7 are exposed outside the core 2 from the core 2 . In other words, the exposed portion of the winding 3 exposed from the iron core 2 is the winding end portion 7 . The terminal wire 8 is a portion that is drawn from the stator 1 to the outside of the stator 1 . The terminal wire 8 is exposed from a mold member 30 which will be described later.
- the windings 3 are composed of U-phase windings 3U, V-phase windings 3V, and W-phase windings 3W for each of U-phase, V-phase, and W-phase of three-phase alternating current.
- the U-phase winding 3U, the V-phase winding 3V, and the W-phase winding 3W are wound around the teeth 5 of the U-phase core 2U, the teeth 5 of the V-phase core 2V, and the teeth 5 of the W-phase core 2W, respectively.
- the U-phase winding 3U, the V-phase winding 3V, and the W-phase winding 3W may be simply referred to as windings 3 in some cases.
- the U-phase winding 3U, the V-phase winding 3V, and the W-phase winding 3W are connected by ⁇ connection (delta connection) or Y connection (star connection).
- a known circuit configuration is adopted as a circuit including the U-phase winding 3U, the V-phase winding 3V, the W-phase winding 3W, and the neutral point.
- the U-phase winding 3U, the V-phase winding 3V, and the W-phase winding 3W are connected at the connection terminal 21 .
- Windings 3 wound around teeth 5 of iron core 2 are electrically and mechanically connected to connection terminals 21 .
- the winding holder 22 is, for example, a member attached to the back yoke 4 of each of the cores 2 .
- the winding holder 22 holds the wiring that is not wound around the teeth 5 in the stator 1 .
- the winding holder 22 is a holder that holds lead wiring drawn out from the winding 3 wound around the teeth 5 toward the outside of the teeth 5 .
- a material of the winding holder 22 for example, a known insulating material having electrical insulation is adopted.
- the winding holder 22 has, for example, U-phase grooves 22U, V-phase grooves 22V, and W-phase grooves 22W for each of U-phase, V-phase, and W-phase of three-phase AC.
- Lead wires corresponding to the U-phase winding 3U, the V-phase winding 3V, and the W-phase winding 3W are arranged in the U-phase groove 22U, the V-phase groove 22V, and the W-phase groove 22W, respectively.
- One winding holder 22 is attached to one iron core 2 .
- Each of the U-phase groove 22U, the V-phase groove 22V, and the W-phase groove 22W provided in the winding holder 22 is an arcuate groove extending along the circumferential direction.
- mutually adjacent winding holders 22 are joined, that is, mutually adjacent circular arc grooves are joined. Therefore, in the entire stator 1, the U-phase grooves 22U, the V-phase grooves 22V, and the W-phase grooves 22W extend in the circumferential direction.
- the lead wires in the U-phase groove 22U, the V-phase groove 22V, and the W-phase groove 22W the winding holder 22 holds the lead wires.
- the terminal hook 23 is a member attached to the back yoke 4 of the iron core 2, for example.
- a material of the terminal hook 23 for example, a known insulating material having electrical insulation is adopted.
- the terminal hook 23 may be formed integrally with the winding holder 22 or may be separate from the winding holder 22 .
- the terminal hook 23 is arranged at a position corresponding to the terminal wire 8 and the connection terminal 21 .
- the terminal hook 23 functions as a positioning member that determines the positions of the terminal wire 8 and the connection terminal 21 .
- Examples of the terminal hook 23 include a clip that retains the terminal wire 8 and the connection terminal 21 by using elastic force. Note that the structure of the terminal hook 23 is not limited to a clip.
- the molding member 30 has a resin portion 31 and a plurality of exposed terminal portions 32 .
- Mold member 30 is provided on stator 1 so as to surround substantially the entire stator 1 by a known molding method using a mold.
- the molded member 30 is not configured to completely cover the stator 1, but has a configuration in which members such as the terminal wires 8 and the connection terminals 21 are exposed by the terminal exposed portions 32.
- the resin portion 31 covers the windings 3 wound around the teeth 5 , the winding ends 7 , and the winding holders 22 .
- the resin portion 31 enters the gap between the back yokes 4 of the iron cores 2 adjacent to each other.
- the resin portion 31 also functions as a fixing portion that fixes the plurality of iron cores 2 arranged in an annular shape.
- nylon resin such as PA66 may be used as the resin material forming the resin portion 31 .
- resin material such as PA66
- PA66 nylon resin
- the terminal exposure portion 32 exposes the terminal wire 8 , the connection terminal 21 and the terminal hook 23 to the outside of the molded member 30 .
- the position where each of the plurality of exposed terminal portions 32 is formed corresponds to the position of the terminal wire 8 and the position of the connection terminal 21 .
- the terminal exposed portion 32 is a portion where resin is not formed. Therefore, the terminal exposed portion 32 can be referred to as a "non-molded portion".
- the terminal exposed portion 32 can also be called a “recessed portion” or a “stepped portion” formed in the resin portion 31 .
- a plurality of terminal exposed portions 32 are formed on the molded member 30 at equal intervals along the circumferential direction of the stator 1 .
- the mold member 30 is formed along the circumferential direction of the stator 1 so as to partially cover the outer circumference of the stator 1 .
- the resin portion 31 and the exposed terminal portion 32 are formed in a state in which the wire 3 is wound around the tooth 5 and the connection terminal 21 is held by the terminal hook 23. .
- the stator is designed to suppress vibrations in the stator, improve the overall mechanical rigidity of the stator, suppress noise generated from the rotating electric machine, and improve the heat dissipation of the rotating electric machine.
- the entire structure is molded with resin.
- a conventional rotating electrical machine not only the entire stator is molded with resin, but also a structure in which the connection terminals to which three-phase windings are connected are molded with resin.
- the metal material forming the windings and connection terminals is different from the resin material used for the mold, so there is a difference in coefficient of linear expansion between the metal material and the resin material. exists.
- thermal stress is repeatedly generated between the windings and the resin, or between the connection terminals and the resin, due to the difference in coefficient of linear expansion.
- a fatigue phenomenon occurs at a location where such thermal stress occurs, and there is a problem that the service life of the rotating electric machine is limited.
- the rotating electrical machine 100 includes a mold member 30 having terminal exposed portions 32 .
- the terminal wire 8 and the connection terminal 21 are exposed at the terminal exposure portion 32 .
- the terminal wire 8 and the connection terminal 21 are not covered with the resin portion 31 and are not in contact with the resin portion 31 .
- the service life of rotating electric machine 100 can be increased.
- the rotary electric machine 100 according to Embodiment 1 includes terminal hooks 23 that determine the positions of the terminal wires 8 and the connection terminals 21 . Therefore, the positional accuracy with which the terminal wires 8 and the connection terminals 21 are arranged can be maintained. In other words, since the terminal hooks 23 position the terminal wires 8 and the connection terminals 21 with high accuracy, even if the molded member 30 is deformed due to heat shrinkage when the molded member 30 is molded, the terminal wires 8 and the connection terminals are positioned. It is possible to suppress the displacement of the terminal 21 . Therefore, it is not necessary to adjust the positions of the terminal wire 8 and the connection terminal 21, and the productivity of the rotating electric machine 100 can be improved.
- the rotary electric machine 100 according to Embodiment 1 includes a winding holder 22 having U-phase grooves 22U, V-phase grooves 22V, and W-phase grooves 22W.
- the U-phase grooves 22U, the V-phase grooves 22V, and the W-phase grooves 22W extend in the circumferential direction. Therefore, the positional accuracy of the windings 3 and the connection terminals 21 can be improved by arranging the lead wires of the windings 3 in the U-phase grooves 22U, the V-phase grooves 22V, and the W-phase grooves 22W.
- the molding member 30 can be easily formed by molding. It can be carried out.
- mold molding for example, mold closing is used.
- the terminal exposed portions 32 are formed on the molded member 30 at regular intervals along the circumferential direction of the stator 1 . Therefore, even if the mold member 30 is deformed due to heat shrinkage when molding the mold member 30 , the intervals between the plurality of exposed terminal portions 32 are kept uniform in the circumferential direction of the mold member 30 . That is, the moldability of the mold member 30 can be improved, and the productivity of the stator 1 can be improved.
- the plurality of terminal exposed portions 32 are provided at equal intervals along the circumferential direction of the molded member 30, the thermal stress generated between the member covered with the resin portion 31 and the resin portion 31 can be uniformly distributed. can do. As a result, the service life of rotating electric machine 100 can be increased. Furthermore, by providing a plurality of terminal exposed portions 32 at equal intervals along the circumferential direction of the molded member 30, the position of the center of gravity of the stator 1 and the position of the circle formed by the plurality of iron cores 2 arranged in an annular shape The position of the ring center CL can be matched. As a result, when the shaft 13 is rotated by driving the rotating electrical machine 100, the effect of suppressing the vibration of the rotating electrical machine 100 (vibration resistance) is obtained.
- the molding member 30 has both the resin portion 31 and the terminal exposed portion 32, the thickness of the resin portion 31 in the radial direction can be partially reduced. As a result, the stress generated between the winding 3 and the resin portion 31 can be relaxed. Moreover, since the terminal exposed portion 32 is a concave portion or a stepped portion formed in the resin portion 31 , the amount of the resin material used for forming the mold member 30 is reduced, contributing to weight reduction of the stator 1 . Furthermore, heat generated from the stator 1 is dissipated by the resin portion 31, so the heat dissipation of the stator 1 can be ensured.
- the position where the terminal exposed portion 32 is formed in the mold member 30 corresponds to a portion where stress is concentrated in a conventional structure in which the entire stator is molded with resin.
- the resin portion 31 is not formed in the portion where the stress concentrates, and the terminal exposed portion is formed in the portion where the stress concentrates. 32 is located. Therefore, the stress concentration that occurs in the conventional rotating electrical machine is less likely to occur in rotating electrical machine 100 . Therefore, in the terminal exposed portion 32, the thermal stress generated in the winding 3 and the connection terminal 21 can be relaxed.
- Embodiment 2 A rotating electric machine according to Embodiment 2 will be described with reference to FIG.
- FIG. 5 is a partial cross-sectional view showing the structure of the terminal wire 8 that constitutes the rotating electric machine according to the second embodiment. Descriptions of the same configurations in the first embodiment and the second embodiment are omitted.
- Embodiment 2 differs from Embodiment 1 in the structure of the terminal wire 8 . Differences between the first embodiment and the second embodiment will be mainly described below.
- the terminal wire 8 arranged in the terminal exposed portion 32 has a bent portion 9a.
- the bent portion 9a is formed in the middle of the terminal wire 8 extending in the axial direction.
- the bent portion 9a has a crank shape.
- the bent portion 9a can be called a “stress absorbing portion” that absorbs the stress generated in the terminal wire 8.
- the same or similar effects as those of Embodiment 1 described above can be obtained. Furthermore, even if stress is generated in the terminal wire 8, the bent portion 9a absorbs the stress in the terminal wire 8, so the stress in the terminal wire 8 is alleviated, and the service life of the rotating electric machine can be further improved.
- FIG. 6 is a partial cross-sectional view showing the structure of a terminal wire 8 forming a rotating electric machine according to a modification of the second embodiment.
- the shape of the bent portion described in Embodiment 2 is not limited to the crank shape shown in FIG.
- the terminal wire 8 may have a substantially S-shaped bent portion 9b instead of the bent portion 9a shown in FIG.
- the bent portion 9b can be called a “stress absorbing portion” that absorbs the stress generated in the terminal wire 8.
- FIG. also in this case, the same or similar effects as in the above-described second embodiment can be obtained.
- Embodiment 3 A rotating electric machine according to Embodiment 3 will be described with reference to FIG.
- FIG. 7 is a partial cross-sectional view showing the structure of the terminal wire 8 that constitutes the rotating electric machine according to the third embodiment. Descriptions of the same configurations in the first embodiment and the third embodiment are omitted.
- Embodiment 3 differs from Embodiment 1 in the structure of the terminal wire 8 . Differences between the first embodiment and the third embodiment will be mainly described below.
- the terminal wire 8 arranged in the terminal exposed portion 32 has a thin wire portion 10 having a diameter smaller than that of the terminal wire 8 .
- the thin wire portion 10 is formed in the middle of the terminal wire 8 extending in the axial direction.
- the thin wire portion 10 can be called a “deformation promoting portion” that promotes deformation of the thin wire portion 10 .
- the terminal wire 8 has the thin wire portion 10 , the thin wire portion 10 is positively deformed in accordance with the stress generated in the terminal wire 8 . Therefore, the deformation of the thin wire portion 10 relieves the stress generated in the portion having a diameter larger than that of the thin wire portion 10 .
- the same or similar effects as those of Embodiment 1 described above can be obtained. Furthermore, even if stress occurs in the terminal wire 8, the thin wire portion 10 is deformed, so the stress in the terminal wire 8 is relieved, and the service life of the rotating electric machine can be further improved.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Insulation, Fastening Of Motor, Generator Windings (AREA)
- Motor Or Generator Frames (AREA)
Abstract
Description
このような回転電機は、放熱性、静穏性の観点から、固定子および巻線の結線端子を樹脂等によってモールドしたモールド樹脂部を有する(例えば、特許文献1、2参照)。
図1~図7において、互いに同一又は同様の構成部分には同じ符号が付されている。
以下の説明において用いられる文言「周方向」、「径方向」、及び「軸方向」は、回転電機の固定子における「周方向」、「径方向」、及び「軸方向」の各々に対応している。さらに、文言「径方向外側」は、径方向において固定子の中心から外側に向かう方向を意味する。文言「径方向内側」は、径方向において固定子の外側から中心に向かう方向を意味する。
図1は、実施の形態1に係る回転電機100の構造を示す模式断面図である。
回転電機100は、例えば、車両に搭載される電動パワーステアリング装置に適用される。電動パワーステアリング装置は、駆動制御装置等によって回転電機100を駆動する。駆動制御装置は、回転電機100から出力されるトルク信号等の出力信号に基づき、回転電機100の駆動を制御する。
回転電機100は、フレーム11と、固定子1と、回転子12と、シャフト13(回転軸)と、ベアリング14、15とを備える。
回転電機100は、例えば、3相ブラシレスモータである。
フレーム11は、例えば、回転電機100から生じる熱の放熱性に優れたアルミニウム等の金属製部材で構成されている。フレーム11の形状は、回転電機100の外形に相当する。軸方向から見て、フレーム11の形状は、例えば、円筒形状である。フレーム11は、回転電機100の内部に配置される部材を囲むケースである。フレーム11の内部には、固定子1、回転子12、及びシャフト13の一部が配置されている。
回転子12は、フレーム11の内部に配置され、シャフト13の周囲に固定されている。回転子12は、永久磁石で構成されている。
シャフト13は、棒状の部材である。シャフト13の材料としては、公知の金属材料が用いられる。軸方向から見て、シャフト13の中心と、回転子12の中心とは一致している。シャフト13は、フレーム11の内部から外部に向けて延在するように軸方向に延在している。
図2は、実施の形態1に係る回転電機100を構成する固定子1の構造を示す斜視図である。図3は、実施の形態1に係る回転電機100を構成する固定子1の構造を示す断面図であって、軸方向から見た図である。図4は、実施の形態1に係る回転電機100を構成する固定子の構造を示す断面図であって、軸方向に沿う回転電機100の中心線CLを含む断面を示す図である。
図2及び図4においては、フレーム11、回転子12、シャフト13、第1ベアリング14、及び第2ベアリング15は省略されている。
円環状に配置された複数の鉄心2で構成された円環の中心は、図4に示す中心線CLの位置に対応している。このため、以下の説明では、複数の鉄心2が配置されている円環の中心を、「円環中心CL」と称する場合がある。
複数の鉄心2の各々は、バックヨーク4とティース5とを有する。鉄心2の材料としては、公知の金属材料が用いられる。
バックヨーク4は、径方向外側における鉄心2の外周部を形成する。
ティース5は、バックヨーク4の内周面から径方向内側に向けて延在する。つまり、ティース5は、鉄心2の内側部分を形成する。周方向において、ティース5の幅(円弧幅)は、バックヨーク4の幅(円弧幅)より小さい。このため、円環状に配置された複数の鉄心2において、互いに隣り合う2つのティース5の間には、スロット6が形成されている。スロット6には、後述すように、ティース5に巻回された巻線3が配置される。
複数の鉄心2の円環中心CLは、シャフト13及び回転子12の中心と一致している。このため、鉄心2と回転子12との間に発生する磁力の作用により、シャフト13及び回転子12は、円環中心CLに一致する中心回りに回転する。
なお、連結部の構造としては、上述した溶接構造と、嵌合構造とが組み合わされた構造が採用されてもよい。
巻線3の材料としては、公知の配線材料が用いられる。
巻線3は、複数の鉄心2の各々のティース5に巻回されている。巻線3は、巻線端部7及び端末線8に繋がる配線である。巻線端部7及び端末線8は、巻線3の一部である引き出し配線に相当する。
巻線端部7は、ティース5に巻回されている巻線3から軸方向に向けて延在している。巻線端部7は、鉄心2から鉄心2の外側に露出している。換言すると、鉄心2から露出した巻線3の露出部分は、巻線端部7である。
端末線8は、固定子1から、固定子1の外部に引き出される部位である。端末線8は、後述するモールド部材30から露出している。
以下の説明では、U相巻線3U、V相巻線3V、及びW相巻線3Wを、単に巻線3と称する場合がある。
図4に示すように、U相巻線3U、V相巻線3V、及びW相巻線3Wは、結線端子21において、結線されている。鉄心2のティース5に巻回された巻線3は、結線端子21に電気的かつ機械的に接続されている。
巻線ホルダ22は、例えば、複数の鉄心2の各々のバックヨーク4に取り付けられた部材である。巻線ホルダ22は、固定子1において、ティース5に巻回されていない配線を保持する。換言すると、巻線ホルダ22は、ティース5に巻回された巻線3からティース5の外側に向けて引き出された引き出し配線を保持するホルダである。
巻線ホルダ22の材料としては、例えば、電気絶縁性を有する公知の絶縁材料が採用される。
U相溝22U、V相溝22V、及びW相溝22Wに引き出し配線が配置されることで、巻線ホルダ22は、引き出し配線を保持する。
端子フック23は、例えば、鉄心2のバックヨーク4に取り付けられた部材である。端子フック23の材料としては、例えば、電気絶縁性を有する公知の絶縁材料が採用される。端子フック23は、巻線ホルダ22と一体に形成されてもよいし、巻線ホルダ22とは別体であってもよい。
端子フック23は、端末線8及び結線端子21に対応する位置に配置されている。端子フック23は、端末線8及び結線端子21の位置を決定する位置決め部材として機能する。端子フック23としては、例えば、弾性力を利用して端末線8及び結線端子21を保持するクリップが挙げられる。なお、端子フック23の構造は、クリップに限定されない。
図4に示すように、モールド部材30は、樹脂部31と、複数の端子露出部32を有する。モールド部材30は、金型を用いた公知の成形方法により、固定子1の略全体を囲むように固定子1に設けられている。ただし、後述するように、モールド部材30は、固定子1を完全に覆うように構成されておらず、端子露出部32によって端末線8、結線端子21等の部材を露出させる構成を有する。
樹脂部31は、ティース5に巻回された巻線3と、巻線端部7と、巻線ホルダ22とを被覆している。樹脂部31は、互いに隣り合う鉄心2のバックヨーク4の間の隙間に入り込んでいる。つまり、樹脂部31は、円環状に配置された複数の鉄心2を固定する固定部としても機能する。
端子露出部32は、端末線8、結線端子21と、端子フック23を、モールド部材30の外部に露出させている。
複数の端子露出部32の各々が形成される位置は、端末線8の位置、及び結線端子21の位置に対応している。端子露出部32は、樹脂部31とは異なり、樹脂が形成されていない部位である。このため、端子露出部32と「非モールド部」と称することができる。端子露出部32は、樹脂部31に形成された「凹部」或いは「段差部」と称することもできる。複数の端子露出部32は、固定子1の周方向に沿って、均等な間隔で、モールド部材30に形成されている。
従来の回転電機においては、固定子における振動発生の抑制、固定子の全体の機械的剛性の向上、回転電機から発生する騒音発生の抑制、及び回転電機の放熱性の向上のため、固定子の全体が樹脂でモールドされた構造が採用されている。さらに、従来の回転電機においては、固定子の全体が樹脂でモールドされているだけでなく、3相の巻線が結線される結線端子が樹脂でモールドされた構造も採用されている。
さらに、複数の端子露出部32がモールド部材30の周方向に沿って均等な間隔で設けることで、固定子1の重心の位置と、円環状に配置された複数の鉄心2で構成された円環中心CLの位置とを合わせることができる。この結果、回転電機100の駆動によってシャフト13が回転した状態では、回転電機100の振動の発生を抑制する効果(耐振動性)が得られる。
実施の形態2に係る回転電機について、図5を参照して説明する。
図5は、実施の形態2に係る回転電機を構成する端末線8の構造を示す部分断面図である。
実施の形態1と実施の形態2とが同じ構成については説明を省略する。実施の形態2は、端末線8の構造の点で、実施の形態1とは異なる。以下、実施の形態1と実施の形態2との相違点を主に説明する。
同様に、径方向又は周方向に向けて端末線8を変形させるような応力が端末線8に発生しても、この応力は、屈曲部9aによって吸収される。このため、端末線8が径方向又は周方向に変形することが抑制される。
図6は、実施の形態2の変形例に係る回転電機を構成する端末線8の構造を示す部分断面図である。
実施の形態2において説明した屈曲部の形状は、図5に示すクランク形状に限定されない。図6に示すように、端末線8は、図5に示す屈曲部9aに代えて、略S字形状の屈曲部9bを有してもよい。屈曲部9bは、端末線8に生じる応力を吸収する「応力吸収部」と称することができる。
この場合においても、上述した実施の形態2と同様又は類似の効果が得られる。
実施の形態3に係る回転電機について、図7を参照して説明する。
図7は、実施の形態3に係る回転電機を構成する端末線8の構造を示す部分断面図である。
実施の形態1と実施の形態3とが同じ構成については説明を省略する。実施の形態3は、端末線8の構造の点で、実施の形態1とは異なる。以下、実施の形態1と実施の形態3との相違点を主に説明する。
Claims (6)
- 円環状に配置された複数の鉄心と、前記複数の鉄心の各々に巻回された巻線と、前記巻線が結線される結線端子と、前記複数の鉄心及び前記巻線を部分的に被覆するモールド部材と、を有する固定子と、
前記複数の鉄心の円環中心に一致する中心回りに回転する回転子と、
を備え、
前記モールド部材は、前記複数の鉄心及び前記巻線を被覆する樹脂部と、前記結線端子を露出させる複数の端子露出部とを有する、
回転電機。 - 前記複数の鉄心の各々に取り付けられた巻線ホルダを備え、
前記巻線ホルダは、前記固定子の周方向に沿って延在する円弧溝を有し、
前記円弧溝には、前記巻線の一部が配置される、
請求項1に記載の回転電機。 - 前記複数の端子露出部は、前記固定子の周方向に沿って、均等な間隔で、前記モールド部材に形成されている、
請求項1又は請求項2に記載の回転電機。 - 前記巻線は、前記巻線に繋がる端末線を有し、
前記端末線は、前記複数の端子露出部の各々に位置し、
前記端末線は、前記端末線に生じる応力を吸収する応力吸収部を有する、
請求項1から請求項3のいずれか一項に記載の回転電機。 - 前記巻線は、前記巻線に繋がる端末線を有し、
前記端末線は、前記複数の端子露出部の各々に位置し、
前記端末線は、前記端末線に生じる応力によって変形する変形促進部を有する、
請求項1から請求項3のいずれか一項に記載の回転電機。 - 前記樹脂部の材料として、PA66が用いられている、
請求項1から請求項5のいずれか一項に記載の回転電機。
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