WO2022264494A1 - Machine dynamo-électrique et procédé de fabrication de machine dynamo-électrique - Google Patents

Machine dynamo-électrique et procédé de fabrication de machine dynamo-électrique Download PDF

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Publication number
WO2022264494A1
WO2022264494A1 PCT/JP2022/005152 JP2022005152W WO2022264494A1 WO 2022264494 A1 WO2022264494 A1 WO 2022264494A1 JP 2022005152 W JP2022005152 W JP 2022005152W WO 2022264494 A1 WO2022264494 A1 WO 2022264494A1
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WO
WIPO (PCT)
Prior art keywords
segment conductor
stator
segment
electric machine
coil
Prior art date
Application number
PCT/JP2022/005152
Other languages
English (en)
Japanese (ja)
Inventor
レミ 向瀬
孝 石上
慎司 山崎
Original Assignee
日立Astemo株式会社
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 日立Astemo株式会社 filed Critical 日立Astemo株式会社
Publication of WO2022264494A1 publication Critical patent/WO2022264494A1/fr

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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
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • 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

Definitions

  • the present invention relates to a rotating electric machine and a method for manufacturing a rotating electric machine.
  • Patent Document 1 Japanese Patent Application Laid-Open No. 2002-125338
  • the stator coil has conductors that are folded back around the stator core outside of the slots on the end face side of the stator core, and are divided into inner and outer layers in the slot depth direction within the slots for every predetermined number of slots.
  • a plurality of turn portions formed by winding alternately back and forth in the axial direction of the stator so as to alternately adopting the A coil end group is formed by aligning in the circumferential direction while repeating the same oblique shape.
  • the stator coil has a substantially rectangular cross-sectional shape in at least a main portion within the slot, and a substantially circular or substantially elliptical cross-sectional shape in at least a portion including the apex of the coil end.
  • the cross-sectional area differs from the substantially elliptical portion.
  • a portion (coil end) with a substantially circular or substantially elliptical cross section has a substantially rectangular cross section.
  • a configuration is disclosed in which the cross-sectional area of the portion (straight line portion) is made smaller than that of the portion of .
  • the portion (coil end) having a substantially circular or substantially elliptical cross section is press-worked with the entire periphery sandwiched between two press dies, thereby reducing the cross-sectional area and increasing the length of the stator coil.
  • an insulating coating such as an enamel coating covering the coil ends is also stretched in the longitudinal direction of the stator coil, and the thickness of the insulating coating at the coil ends is reduced.
  • the insulation coating of the entire stator coil is thickened, the insulation coating becomes thicker than necessary at the portion (straight line portion) of the substantially rectangular cross section that is inserted into the slot, resulting in a substantial space factor of the stator coil within the slot. is lowered, and there is a risk that the performance of the rotary electric machine will be lowered or the size of the rotary electric machine will be increased.
  • An object of the present invention is to suppress the reduction in the thickness of the insulation coating at the coil ends and suppress the interference between the segment conductors in the segment conductors that make up the stator coil.
  • the rotating electric machine of the present invention includes: a stator having a stator core having a plurality of slots; a plurality of segment conductors arranged in the plurality of slots and forming a stator coil; a rotor arranged on the inner peripheral side of the stator; A rotating electrical machine comprising The plurality of segment conductors includes a pair of slanted portions at coil end portions extending from the slots, a top portion formed between the pair of slanted portions and bent with respect to the axial direction, and a radial direction including the top portions.
  • the length of the lower side which is the inner side of the bending with respect to the axial direction, is smaller than the length of the upper side, which is the outer side of the bending.
  • a method for manufacturing a rotating electric machine includes: a stator having a stator core having a plurality of slots; a plurality of segment conductors arranged in the plurality of slots and forming a stator coil; a rotor arranged on the inner peripheral side of the stator; A method for manufacturing a rotating electric machine comprising The plurality of segment conductors includes a pair of slanted portions at coil end portions extending from the slots, a top portion formed between the pair of slanted portions and bent with respect to the axial direction, and a radial direction including the top portions.
  • the length of the lower side which is the inner side of the bending with respect to the axial direction, is smaller than the length of the upper side, which is the outer side of the bending.
  • the intermediate material before the step of press-forming the segment conductor is formed into a tapered shape by pressing the bent inner corner formed in the portion to be the crank with a forming jig.
  • the present invention it is possible to suppress the reduction of the insulating coating by forming the relief portion that suppresses the interference between the segment conductors while suppressing the decrease in the cross-sectional area of the segment conductors.
  • interference between the stator coils can be avoided, and the size of the stator and the length of the coil ends can be shortened.
  • FIG. 1 is an external view of a rotating electric machine according to an embodiment of the present invention
  • FIG. 1 is a cross-sectional view cut along the axial direction of a rotary electric machine according to an embodiment of the present invention
  • FIG. 1 is a perspective view showing an example of a segment conductor according to the present invention
  • FIG. 3B is a top view of the segment conductor of FIG. 3A as viewed from above
  • FIG. 4 is a diagram showing a segment conductor inserted into a stator core, relating to the stator of the present invention; It is a figure which shows the cross-sectional shape of the segment conductor which concerns on this invention.
  • 4 is a flow chart showing a manufacturing process of segment conductors according to the present invention. It is a figure explaining the manufacturing method of the segment conductor which concerns on this invention.
  • FIG. 4 is a comparison diagram of a segment conductor according to the present invention and a segment conductor of a comparative example;
  • the direction along the axis of the shaft 4 of the rotor 80 will be referred to as the axial direction.
  • FIG. 1 is an external view of a rotating electrical machine according to one embodiment of the present invention.
  • the rotary electric machine 1 is used as a drive motor for a vehicle, or an accessory motor such as an electric power steering or an air conditioner compressor.
  • a rotary electric machine 1 includes a housing 2 , a bracket 3 , and a shaft 4 that is an output shaft, and the shaft 4 protrudes from the bracket 3 .
  • a drive circuit (not shown) is arranged on the opposite side of the shaft 4 , and a plurality of coil lead wires 5 extend from the side opposite to the mounting side of the bracket 3 .
  • FIG. 2 is a cross-sectional view cut along the axial direction of the rotating electric machine according to one embodiment of the present invention.
  • a stator 6 is fixed to the inner peripheral surface of the housing 2 by shrink fitting or press fitting.
  • the stator 60 includes an annular stator core 6 having a plurality of slots (grooves) 6a (see FIG. 4) formed from the inner peripheral surface toward the outer peripheral surface, and a plurality of stator cores having an insulating coating such as an enamel coating. and a coil (stator coil) 7 composed of a segment conductor 20, and the segment conductor 20 is inserted into the slot 6a.
  • the segment conductor 20 has two straight portions 24 (see FIG. 3A) arranged in the slot 6a and a pair of terminal portions 26 (see FIG.
  • the coil 7 is formed by electrically connecting the end portions 26 of the two segment conductors 20 .
  • the terminal portions 26 of the two segment conductors 20 are joined by Tig welding, plasma welding, laser welding, or the like.
  • the stator core 6 is generally made by punching electromagnetic steel sheets with a thickness of about 0.1 mm to 0.5 mm and laminating them.
  • a rotor core (mover core) 8 is inserted inside the stator 60 .
  • the rotor core 8 and the shaft 4 are integrated to form a rotor (movable element) 80 , and the shaft 4 is supported by bearings 9 .
  • the rotor 80 in addition to the "surface magnet type” in which the permanent magnets 10 such as rare earth or ferrite are attached to the surface of the rotor 80, the "embedded magnet type” in which the permanent magnets 10 are embedded in the grooves of the mover core, An inductive type or the like incorporating a cage-shaped conductor can be used.
  • FIG. 3A is a perspective view showing an example of a segment conductor according to the present invention
  • FIG. 3B is a top view of the segment conductor of FIG. 3A viewed from above.
  • the segment conductor 20 has two straight portions 24, a bent portion 25 connecting the two straight portions 24 on the opposite side to the terminal portion 26, and a pair of terminal portions 26 provided at both ends of the segment conductor 20. , and has a substantially symmetrical shape centered on a head (apex) 21 in the upper part of the drawing.
  • Two straight portions 24 are arranged in the slot 6a.
  • the bent portion 25 is arranged outside the slot 6 a on one end face side of the stator core 6 and constitutes the coil end 13 .
  • the terminal portion 26 is arranged outside the slot of the stator 60 and electrically connected to the terminal portion 26 of another segment conductor 20 .
  • the segment conductors 20 are arranged such that a portion of the straight portions 24 on the terminal portion 26 side is located on the other end face side of the stator core 6 together with the terminal portion 26 in the slot 6a. It is arranged on the outside and constitutes the coil end 12 .
  • a portion of the linear portion 24 on the terminal portion 26 side is bent from the main body portion of the linear portion 24 (the portion inserted into the slot 6a), and the bent portion 25 is different from the main body portion of the linear portion 24. It constitutes an oblique portion that is bent to the opposite side.
  • the segment conductor 20 has one set (pair) of inclined portions 22, one set (pair) of bent portions 23, and one set (pair) of straight line portions, which are arranged on the left and right with the head portion 21 as a boundary.
  • a portion 24; Head 21 is positioned between a pair of straight sections 24 .
  • Inclined portion 22 has an angle of more than 0 degrees and less than 90 degrees with respect to the end face of stator 6 , and is located closest to head portion 21 among inclined portion 22 , bent portion 23 and straight portion 24 .
  • the straight portion 24 has a straight shape, is connected to the inclined portion 22 via the bent portion 23 , and is inserted into the slot of the stator 6 .
  • the bent portion 23 is provided between the inclined portion 22 and the straight portion 24, and the inclined portion 22 is bent along the circumferential direction with respect to the straight portion 24 along the axial direction. Therefore, the bend 23 constitutes an axial bend. It should be noted that the expressions “along the axial direction” and “along the circumferential direction” do not mean that they completely match the “axial direction” and the “circumferential direction”, but they generally match when they match. Including cases.
  • the head portion 21, the inclined portion 22, and the bent portion 23 are collectively referred to as the bent portion 25, and the portion joined to the other segment conductor 20 formed on the opposite side of the bent portion 25 is the terminal portion 26. called. That is, the bent portion 25 is formed between the pair of straight portions 24 , and a pair of terminal portions 26 are formed on the side of the straight portion 24 opposite to the bent portion 25 .
  • the head portion 21 is the top portion of the bent portion 25 that protrudes the highest from one end surface of the stator core 6 .
  • 21a and 21b are formed, and a crank portion (crank-shaped portion) is formed by the two radially bent portions 21a and 21b.
  • the head 21 constitutes an axially bent portion that bends in the axial direction, and together with the pair of inclined portions 22 constitutes a chevron-shaped portion.
  • FIG. 4 relates to the stator of the present invention and is a diagram showing segment conductors inserted into the stator core.
  • FIG. 4 shows a state in which bent portions 25 of a plurality of segment conductors 20 inserted into stator core 6 are viewed from a direction perpendicular to the end surface of stator 6 . 4 shows the vicinity of the crank portions 27-1, 27-2 and 27-3 of the three segment conductors 20.
  • FIG. 4 shows a configuration in which the direction in which the pair of inclined portions 22 are shifted in the radial direction is different from the configuration in FIG. 3B.
  • the heads 21 of the segment conductors 20 are crank-shaped cranks 27 (27-1, 27-2, 27-3 are shown in FIG. 4). ), and the head 21 has a pair of inclined portions 22 (22-2 and 22-3 are shown in FIG. 4) at bending positions P1 (21a) and bending positions P2 (21b).
  • a portion between the bending position P1 and the bending position P2 is called a crank portion 27.
  • the head portion 21 corresponds to part of the crank portion 27 .
  • FIG. 5 is a diagram showing a cross-sectional shape of a segment conductor according to the present invention.
  • FIG. 5(a) is a sectional shape perpendicular to the longitudinal direction of the segment conductor 20 in the crank portion 27, and FIG. 5(b) is a sectional shape of the segment conductor 20 in a portion other than the crank portion 27.
  • the length W1 of the lower side which is the inner side of the bend in the cross section perpendicular to the longitudinal direction of the segment conductor 20, is greater than the width W0 of the segment conductor 20 in the portion other than the crank portion 27. small.
  • the length W2 of the upper side which is the side on the outside of the bend, is greater than the length W1 of the lower side.
  • the segment conductor 20 has a constant width dimension from the upper side to the lower side in the portion other than the crank portion 27 .
  • the width W of the segment conductor 20 at the crank portion 27 is greater than the width W0 of the segment conductor 20 at portions other than the crank portion 27 .
  • FIG. 5(a) shows an example in which the upper side of the segment conductor 20 is a straight line, it may be a curved line as shown in FIG. 5(c).
  • the left side, right side, and lower side of the segment conductor 20 may be partially straight rather than curved.
  • the length W2 of the upper side is the horizontal distance between the two edges of the upper side of the segment conductor 20 in any cross section perpendicular to the longitudinal direction of the segment conductor 20 .
  • the length W1 of the lower side is the height H0 of the segment conductor 20 in the portion other than the crank portion 27 from the height Z2 of the upper side of the segment conductor 20 in an arbitrary cross section perpendicular to the longitudinal direction of the segment conductor 20. It is the distance between the left side and the right side of the segment conductor 20 at the height Z1.
  • the upper side and the lower side of the crank portion 27 can be defined based on the upper side and the lower side of the cross-sectional shape of the portion other than the crank portion 27 .
  • the width (coil width) W of the segment conductor 20 is the maximum value of the width of the segment conductor 20 in the height direction in any cross section perpendicular to the longitudinal direction.
  • the rotary electric machine 1 of the present embodiment described above has the following features.
  • a stator 60 having a stator core 6 having a plurality of slots 6a, a plurality of segment conductors 20 arranged in the plurality of slots 6a and forming the stator coil 7, and an inner peripheral side of the stator 60
  • a rotating electrical machine 1 comprising a rotor 80 arranged in The plurality of segment conductors 20 includes a pair of inclined portions 22 in the coil end portion 13 extending from the slot 6a, a top portion 21 formed between the pair of inclined portions 22 and bent with respect to the axial direction, and the top portion 21.
  • the length W1 of the lower side which is the inner side of the bending with respect to the axial direction, is longer than the length W2 of the upper side, which is the outer side of the bending. is also made smaller.
  • the segment conductor 20 is preferably formed so that the length W1 of the lower side is smaller than the coil width W0 in the portion different from the crank portion 27.
  • the segment conductor 20 is preferably formed so that the maximum value W of the coil width at the crank portion 27 is larger than the coil width W0 at the portion different from the crank portion 27 .
  • the segment conductor 20 preferably has a tapered portion 27a formed inside the bend that bends in the axial direction so that the width of the segment conductor 20 narrows from the upper side toward the lower side.
  • the segment conductor 20 has a pair of straight portions 24 inserted into the slots 6a,
  • the portion of the segment conductor 20 that is different from the crank portion 27 may be the straight portion 24, for example.
  • FIG. 6 is a flow chart showing the manufacturing process of the segment conductor according to the present invention.
  • an example using an enamel coating as the insulating coating of the segment conductor 20 will be described.
  • the enameled wire is unwound from the reel, and the enamel coating is peeled off at the terminal portion of the segment conductor 20 (S1).
  • the intermediate material 30 is formed by bending the enameled wire and cutting the end portion (S1, S2). Then, after the top of the intermediate material 30 is tapered (S4), which will be described later, it is press-molded with a mold to finish the shape of the segment conductor 20 (S5).
  • FIG. 7 is a diagram for explaining a method of manufacturing a segment conductor according to the present invention.
  • FIG. 7 shows the shape of the intermediate material 30 before and after tapering and the forming jig.
  • (a) shows an intermediate material 30 and the arrangement of jigs with respect to the intermediate material 30.
  • FIG. (b) shows the state of the AA' section of (a) before molding (before tapering), and (c) shows the state of the AA' section of (a) after molding (after tapering).
  • the leg portions 31, 32 and upper portion 33 of the intermediate material 30 are fixed by fixing jigs 34, 35 and 36. Then, at the portion of the segment conductor 20 that will become the crank portion 27, the bent inner corner portion of the intermediate material 30 is pressed by a forming jig 37 to form a tapered shape 27a.
  • the tapered shape 27a is a shape such that the width of the segment conductor 20 decreases from the upper side of the crank portion 27 toward the lower side. In other words, in the cross section perpendicular to the longitudinal direction of the crank portion 27, the corners of the lower side are tapered from the lower side toward the upper side.
  • this embodiment is intended for a segment conductor having a bent portion, and the lead wires of the input terminal 11 and the like do not necessarily have to have the tapered shape 27a described above.
  • the manufacturing method of the rotating electric machine 1 of the present embodiment described above has the following features.
  • a stator 60 having a stator core 6 having a plurality of slots 6a and a plurality of segment conductors 20 arranged in the plurality of slots 6a and forming a stator coil 7;
  • a rotating electrical machine 1 comprising a rotor 80 that The plurality of segment conductors 20 includes a pair of inclined portions 22 in the coil end portion 13 extending from the slot 6a, a top portion 21 formed between the pair of inclined portions 22 and bent with respect to the axial direction, and the top portion 21.
  • the length W1 of the lower side which is the inner side of the bending with respect to the axial direction, is longer than the length W2 of the upper side, which is the outer side of the bending. is also formed small.
  • the intermediate material 30 before the press forming process of the segment conductor 20 is pressed by a forming jig 37 to form a tapered shape by pressing the bent inner corner formed in the portion to be the crank portion 27 .
  • the length W1 of the lower side in the cross section perpendicular to the longitudinal direction of the segment conductor 20 is smaller than the coil width W0 in the portion other than the crank portion 27, so that the distance between the corners of the adjacent segment conductors is As a result, the segment conductors 20 are less likely to interfere with each other. Therefore, the angle of the inclined portion 22 can be set small, and the coil end 13 can be shortened.
  • the upper side W2 in the cross section perpendicular to the longitudinal direction of the segment conductor 20 is larger than the lower side W1 and the coil width W is larger than the coil width W0 in the portion other than the crank portion 27, so the cross-sectional area of the segment conductor 20 is can be made narrower only in the vicinity of the lower side while keeping constant, the influence on the electrical resistance can be suppressed.
  • the tapered shape 27a is formed in a part of the segment conductor 20 in the circumferential direction, so that reduction in the cross-sectional area of the segment conductor 20 can be suppressed. Furthermore, by making the segment conductor 20 have the cross-sectional shape as described above, it is possible to further suppress the reduction in the cross-sectional area of the segment conductor 20 due to the formation of the tapered shape 27a, and to keep the cross-sectional area of the segment conductor 20 constant. is also possible.
  • the relief portion (tapered shape) 27a that suppresses interference between the segment conductors 20 while suppressing a decrease in the cross-sectional area of the segment conductors 20, thereby suppressing a decrease in the insulating coating. can do.
  • interference between coils can be avoided, and the stator can be miniaturized and the coil ends can be shortened.
  • the inner corners of the bend are pressed and formed, so the area where the enamel coating is reduced is only near the corners of the lower side (tapered portion 27a). Therefore, it is possible to suppress deterioration of insulation performance in areas other than the lower corners where the distance from the adjacent segment conductors 20 is increased.
  • FIG. 8 is a comparison diagram of a segment conductor according to the present invention and a segment conductor of a comparative example.
  • FIG. 8 shows a segment conductor 20 according to a comparative example with this embodiment, and (b) shows a segment conductor in this embodiment. Both (a) and (b) show the cross-sectional shape of the segment conductor 20 at the position farthest in the axial direction from the end surface of the stator core 6, that is, the crank portions 27a-1 and 27a- corresponding to the VIII-VIII cross section in FIG. 2, 27a-3 cross section.
  • the cross section of the crank portion 27a′-1 of the segment conductor 20′-1 is rectangular, and the lower side of the crank portion 27a′-1 of the segment conductor 20′-1 and the corners on the upper sides of the inclined portions 22a'-2 and 22a'-3 of the segment conductors 20'-2 and 20'-3 adjacent to the segment conductor 20'-1. It was small, and there was a danger that the segment conductors would interfere with each other.
  • the present invention is not limited to the above-described embodiments, and includes various modifications.
  • the above-described embodiments are detailed descriptions for easy understanding of the present invention, and are not necessarily limited to those having all the configurations.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Windings For Motors And Generators (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'objectif de la présente invention est de supprimer la réduction d'épaisseur de film d'un revêtement isolant de l'extrémité de bobine dans un conducteur de segment constituant une bobine de stator, et de pouvoir supprimer l'interférence entre des conducteurs de segment. Une pluralité de conducteurs de segment 20 ont des parties inclinées 22-2, 22-3 au niveau d'une partie d'extrémité de bobine s'étendant à partir d'une fente 6a, des sommets 21-1, 21-2, 21-3 qui sont formés entre la paire de parties inclinées et qui se plient par rapport à la direction axiale, et des parties de coude 27-1, 27-2, 27-3 qui comprennent les sommets 21-1, 21-2, 21-3 et qui se plient par rapport à la direction radiale. Dans les conducteurs de segment 20, dans la section transversale des parties de coude 27-1, 27-2, 27-3 perpendiculaires à la direction longitudinale, une longueur W1 du côté inférieur équivalant au côté interne du coude qui se plie par rapport à la direction axiale est formée pour être inférieure à une longueur W2 du côté supérieur équivalant au côté externe du coude.
PCT/JP2022/005152 2021-06-18 2022-02-09 Machine dynamo-électrique et procédé de fabrication de machine dynamo-électrique WO2022264494A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2021101546A JP2023000615A (ja) 2021-06-18 2021-06-18 回転電機および回転電機の製造方法
JP2021-101546 2021-06-18

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WO2022264494A1 true WO2022264494A1 (fr) 2022-12-22

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2011259669A (ja) * 2010-06-11 2011-12-22 Toyota Motor Corp ステータおよび回転電機
JP2014100006A (ja) * 2012-11-15 2014-05-29 Denso Corp 固定子巻線、および、固定子巻線の製造方法
WO2015119105A1 (fr) * 2014-02-10 2015-08-13 三菱電機株式会社 Machine électrique tournante et procédé de fabrication de bobine de machine électrique tournante
JP2020036427A (ja) * 2018-08-29 2020-03-05 日立オートモティブシステムズ株式会社 セグメント導体、セグメント導体の製造方法

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2011259669A (ja) * 2010-06-11 2011-12-22 Toyota Motor Corp ステータおよび回転電機
JP2014100006A (ja) * 2012-11-15 2014-05-29 Denso Corp 固定子巻線、および、固定子巻線の製造方法
WO2015119105A1 (fr) * 2014-02-10 2015-08-13 三菱電機株式会社 Machine électrique tournante et procédé de fabrication de bobine de machine électrique tournante
JP2020036427A (ja) * 2018-08-29 2020-03-05 日立オートモティブシステムズ株式会社 セグメント導体、セグメント導体の製造方法

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