WO2024185370A1 - 回転電機、回転電機用ステータ、回転電機用ステータの中性点ターミナル、及び回転電機用ステータの製造方法 - Google Patents

回転電機、回転電機用ステータ、回転電機用ステータの中性点ターミナル、及び回転電機用ステータの製造方法 Download PDF

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Publication number
WO2024185370A1
WO2024185370A1 PCT/JP2024/003856 JP2024003856W WO2024185370A1 WO 2024185370 A1 WO2024185370 A1 WO 2024185370A1 JP 2024003856 W JP2024003856 W JP 2024003856W WO 2024185370 A1 WO2024185370 A1 WO 2024185370A1
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WO
WIPO (PCT)
Prior art keywords
axial direction
conductors
space
electric machine
conductor
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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/JP2024/003856
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English (en)
French (fr)
Japanese (ja)
Inventor
央流 辻
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DensoTrim Corp
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DensoTrim Corp
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Filing date
Publication date
Application filed by DensoTrim Corp filed Critical DensoTrim Corp
Priority to JP2025505138A priority Critical patent/JPWO2024185370A1/ja
Priority to CN202480011696.XA priority patent/CN120677620A/zh
Publication of WO2024185370A1 publication Critical patent/WO2024185370A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • 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
    • H02K15/04—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
    • 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
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto

Definitions

  • the present specification relates to a rotating electric machine, a stator for a rotating electric machine, a neutral terminal for a stator for a rotating electric machine, and a manufacturing method for a stator for a rotating electric machine, and the rotating electric machine is useful, for example, as a generator or starter for a motorcycle.
  • Patent document 1 shows a neutral terminal for a three-phase rotating electric machine.
  • the neutral terminal is located on the base of the stator for the rotating electric machine.
  • Bolts for attaching the stator to the engine are located on this base.
  • Terminals that are electrically connected to the coil conductors are also located on the base.
  • a sensor case that detects the rotation state of the rotating electric machine is also located there. Therefore, increasing the length in the direction in which the grooves are lined up (the second axial direction) would impair the assembly of the rotating electric machine.
  • This disclosure is based on the premise that the coils are star-connected into three phases, and each of the three phases is also connected in parallel in three. In that case, the objective is to house the three conductors for each phase in a compact space between the first and second axial directions.
  • One aspect of the present disclosure relates to a rotating electric machine that includes a rotor with multiple permanent magnets arranged in the circumferential direction and rotating with a shaft, a stator core having an annular base portion and multiple times three teeth portions extending radially outward from the base portion, an insulator made of an insulating material that is arranged on at least a portion of the base portion and the teeth portions of the stator core, and a stator having coils wound around the outer periphery of the insulator at positions corresponding to the teeth portions of the stator core.
  • the rotating electric machine of the first disclosure has coils star-connected for three phases, with three conductors for each phase electrically connected to a neutral terminal.
  • the neutral terminal is fixed to a fixing portion formed in a groove shape in the base portion of the insulator, and is a plate extending in a first axial direction and a second axial direction perpendicular to the first axial direction.
  • the neutral terminal has a fixing portion that engages with the insulator at one end in the first axial direction, and a conductor coupling portion that engages three conductors for each phase at the other end in the first axial direction, with a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction.
  • the rotating electric machine of the first disclosure has three conductor connection parts arranged along the second axial direction, each of which holds three conductors for each of the three phases.
  • Each connection part has a central column part that forms a first space for arranging two conductors along one side of the second axial direction and a second space for arranging one conductor on the other side of the second axial direction and extends in the first axial direction, a first claw part that is arranged on the first space side of the central column part and inclined toward the central column part to hold two conductors in the first space, and a second claw part that is arranged on the second space side of the central column part and inclined toward the central column part to hold one conductor in the second space.
  • the height of the central column part in the first axial direction, the height of the inclined first claw part in the first axial direction, and the height of the inclined second claw part in the first axial direction are set to be approximately equal.
  • each joint portion forms a first space in which two conductors are arranged along either one of the second axial directions, so that the length in the first axial direction required to arrange the two conductors can be reduced. Furthermore, because the two conductors are arranged within the first space, the length in the second axial direction can also be reduced.
  • the height of the central column in the first axial direction, the height of the inclined first claw portion in the first axial direction, and the height of the inclined second claw portion in the first axial direction are set to be approximately equal, so that the inclination of the first claw portion and the second claw portion can also reduce the length of the joint in the first axial direction.
  • the second disclosure is a stator for a rotating electric machine that includes a stator core having an annular base portion and a number of teeth extending radially outward from the base portion, an insulator made of an insulating material that is disposed on at least a portion of the base portion and the teeth portion of the stator core, and a coil wound around the outer periphery of the insulator at a position corresponding to the teeth portion of the stator core, the coil being star-connected for three phases, and three conductors for each phase being electrically connected to a neutral terminal.
  • the neutral terminal is fixed to a fixing portion formed in a groove shape in the base portion of the insulator.
  • the neutral terminal is a plate extending in a first axial direction and a second axial direction perpendicular to the first axial direction.
  • the neutral terminal has a fixing portion that engages with the insulator at one end in the first axial direction, and a conductor coupling portion that engages three conductors for each phase at the other end in the first axial direction, with a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction.
  • the conductor connecting portion has three connecting portions arranged along the second axial direction, each of which holds three conductors for each of the three phases.
  • Each connecting portion has a central column portion that forms a first space in which two conductors are arranged along one of the directions in the second axial direction, and a second space in which one conductor is arranged on the other side in the second axial direction, and extends in the first axial direction, a first claw portion that is arranged on the first space side of the central column portion and inclined toward the central column portion to hold two conductors in the first space, and a second claw portion that is arranged on the second space side of the central column portion and inclined toward the central column portion to hold one conductor in the second space.
  • the height of the central column portion in the first axial direction, the height of the inclined first claw portion in the first axial direction, and the height of the inclined second claw portion in the first axial direction are set to be approximately equal.
  • each joint portion forms a first space in which two conductors are arranged along either one of the second axial directions, so that the length in the first axial direction required to arrange the two conductors can be reduced. Furthermore, because the two conductors are arranged within the first space, the length in the second axial direction can also be reduced.
  • the height of the central column in the first axial direction, the height of the inclined first claw portion in the first axial direction, and the height of the inclined second claw portion in the first axial direction are set to be approximately equal, so that the inclination of the first claw portion and the second claw portion can also reduce the length of the joint in the first axial direction.
  • the third disclosure is a neutral terminal of a stator for a rotating electric machine, which includes a stator core having an annular base portion and a number of teeth extending radially outward from the base portion, an insulator made of an insulating material arranged on at least a portion of the base portion and the teeth portion of the stator core, and a coil wound around the outer periphery of the insulator at a position corresponding to the teeth portion of the stator core, the coil being star-connected for three phases, and three conductors for each phase being electrically connected to the neutral terminal.
  • the neutral terminal of the stator for a rotating electric machine of the third disclosure is fixed to a fixing portion formed in a groove shape in the base portion of the insulator.
  • the neutral terminal is a plate material extending in a first axial direction and a second axial direction perpendicular to the first axial direction.
  • the neutral terminal is configured such that a fixing portion that engages with the insulator is disposed at one end in the first axial direction, and a conductor coupling portion that engages three conductors for each phase is disposed at the other end in the first axial direction, with a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction.
  • the conductor connecting portion has three connecting portions arranged along the second axial direction, each of which holds three conductors for each of the three phases.
  • Each connecting portion has a central column portion that forms a first space in which two conductors are arranged along one side of the second axial direction, and a second space in which one conductor is arranged on the other side of the second axial direction, and extends in the first axial direction, a first claw portion that is arranged on the first space side of the central column portion and inclined toward the central column portion to hold two conductors in the first space, and a second claw portion that is arranged on the second space side of the central column portion and inclined toward the central column portion to hold one conductor in the second space.
  • the height of the central column portion in the first axial direction, the height of the inclined first claw portion in the first axial direction, and the height of the inclined second claw portion in the first axial direction are set to be approximately equal.
  • each joint portion forms a first space in which two conductors are arranged along either one of the second axial directions, so that the length in the first axial direction required to arrange the two conductors can be reduced. Furthermore, because the two conductors are arranged within the first space, the length in the second axial direction can also be reduced.
  • the height of the central column in the first axial direction, the height of the inclined first claw portion in the first axial direction, and the height of the inclined second claw portion in the first axial direction are set to be approximately equal, so that the inclination of the first claw portion and the second claw portion can also reduce the length of the joint in the first axial direction.
  • the side of the central column facing the first space is recessed in the second axial direction to form part of the first space.
  • the length of the assembly in the second axial direction is set shorter than the length of the conductor joint, and longer than the length in the second axial direction connecting the first and second claws of the joints arranged on both sides in the second axial direction, which are located on the inside in the second axial direction.
  • either the first or second claw is set to be longer than the length in the second axial direction connecting the claws arranged on the inside in the second axial direction, so even if the length of the assembly part in the second axial direction is shortened, it is possible to maintain a width that ensures the current density. In other words, it is possible to prevent the current from concentrating in a specific narrow area and generating heat in that area.
  • the length of the fixed portion in the second axial direction is shorter than the length of the assembly portion in the second axial direction.
  • the fixed portion is located on the opposite side of the conductor connection portion in the first axial direction, and is therefore located at the innermost part of the insulator in the first axial direction. If the length of the fixed portion in the second axial direction at this innermost part is shortened, it is possible to shorten the length of the insulator in the second axial direction as well. As a result, the area of the insulator that occupies the base portion of the stator core can be reduced in the area corresponding to the fixed portion.
  • a first wedge portion and a second wedge portion for engagement are arranged in the first axial direction on both sides of the fixed portion in the second axial direction.
  • the length in the second axial direction of the first wedge portion arranged on the outside in the first axial direction is shorter than the length in the second axial direction of the second wedge portion arranged on the inside in the first axial direction. Because the first wedge portion with a shorter length in the second axial direction is arranged on the outside in the first axial direction, it is possible for the first wedge portion to function as a guide. This makes it easier to assemble the neutral terminal to the insulator.
  • the eighth disclosure is a method for manufacturing a stator for a rotating electric machine.
  • This manufacturing method first employs a joint forming process in which the central column, first claw, and second claw of the joint are all formed parallel to the first axial direction, and the height of the first claw and second claw in the first axial direction is greater than the height of the central column in the first axial direction.
  • a conductor arrangement process is performed in which two conductors are arranged side by side in the second axial direction in the first space, and one conductor is arranged on the second space side.
  • a crimping process is performed in which the first claw and second claw are simultaneously tilted toward the central column until they abut against the central column, and the height of the central column in the first axial direction, the height of the tilted first claw, and the height of the tilted second claw in the first axial direction are made approximately equal.
  • the first claw portion and the second claw portion are simultaneously crimped toward the central column portion, making the crimping process of the two claw portions easier.
  • the crimping process is also made easier by crimping the first claw portion and the second claw portion until they abut against the central column portion.
  • the first claw portion and the second claw portion are inclined in the crimping process, the height in the first axial direction of the central column portion, the height in the first axial direction of the inclined first claw portion, and the height in the first axial direction of the inclined second claw portion can be made approximately equal.
  • the ninth disclosure is also a manufacturing method for a stator for a rotating electric machine.
  • the manufacturing method of the ninth disclosure includes a press-fitting process in which the fixed portion and the assembly portion of the neutral terminal are press-fitted in the first axial direction into the fixed portion of the insulator. This press-fitting process is performed until the joint portion abuts against the insulator outside the fixed portion of the base portion. Since the press-fitting in the first axial direction is performed until the joint portion abuts against the insulator outside the fixed portion of the base portion, it is easy to determine the press-fitting distance. Furthermore, since the portion that contacts the insulator is exposed, it is easy to visually check the fit when pressed in.
  • FIG. 1 is a cross-sectional view of a rotating electrical machine assembled with a crankshaft and a cylinder block.
  • FIG. 2 is a front view showing a rotor, a stator, a power cable, and a sensor case of the rotating electric machine.
  • FIG. 3 is a perspective view showing a stator and a sensor case of a rotating electrical machine.
  • FIG. 4 is a front view showing the steel plates that form the stator core.
  • FIG. 5 is a perspective view showing the first insulator. 6 is a perspective view of the first insulator shown in FIG. 5 as viewed from another direction.
  • FIG. 7 is a diagram of a three-phase star-connected electrical circuit in which each phase is wired in three parallel connections.
  • FIG. 1 is a cross-sectional view of a rotating electrical machine assembled with a crankshaft and a cylinder block.
  • FIG. 2 is a front view showing a rotor, a stator, a power cable, and a sensor
  • FIG. 8 is a front view of the neutral terminal with the conductor wires installed.
  • FIG. 9 is a side view of the neutral terminal.
  • FIG. 10 is a front view of the insulator shown in FIG.
  • FIG. 11 is a cross-sectional view showing a fixing portion of the insulator.
  • FIG. 12 is a cross-sectional view showing a state in which an insulator is attached to the neutral terminal.
  • FIG. 13 is an explanatory diagram showing the process of crimping the neutral terminal.
  • FIG. 14 is a front view showing a comparative example of a neutral terminal.
  • FIG. 1 is a cross-sectional view of a rotating electric machine 1 combined with a crankshaft 100.
  • 101 is a cylinder block, and pistons (not shown) reciprocate within cylinders (not shown) in the cylinder block 101. The movement of the pistons rotates the crankshaft 100 via connecting rods (not shown).
  • the crankshaft 100 is made of iron with a diameter of about 20 millimeters, and is rotationally supported by bearings 102 in the cylinder block 101.
  • the rotor 300 of the rotating electric machine 1 is fixed to the crankshaft 100 at the base 301. Therefore, the rotor 300 rotates integrally with the crankshaft 100.
  • the rotor 300 is made of iron material and has a disk portion 302 that extends radially outward from the base portion 301 that engages with the crankshaft 100, and a cylindrical portion 303 formed on the radially outer portion of the disk portion 302.
  • twelve permanent magnets 304 are arranged inside the cylindrical portion 303 in a circumferential direction.
  • the thickness of the permanent magnets 304 is about 4 to 5 millimeters.
  • the number of permanent magnets 304 is not limited to 12, and can be set appropriately to provide the number of poles and magnetic flux according to the required performance, such as 10 or 24.
  • a stator 400 is disposed inside the rotor 300.
  • Fig. 2 is a front view of the stator 400 as seen from the cylinder block 101 side.
  • the stator 400 is made by laminating a number of magnetic steel plates 440 as shown in Fig. 4, and is integrally formed with a base portion 401 attached to the cylinder block 101 and a number of teeth portions 402 extending radially outward from the base portion 401.
  • the outer diameter of the stator 400 is about 110 to 130 mm, and therefore the inner diameter of the rotor 300 is sized to form a minute gap of about 1 mm between the outer diameter of the stator 400 and the permanent magnet 304. Providing a minute gap makes it possible to absorb deformation caused by assembly of the rotor 300 and vibration caused by the operation of the internal combustion engine.
  • the base portion 401 has three stator bolt holes 4030 for fixing the stator 400 to the cylinder block 101.
  • the base portion 401 also has a sensor case bolt hole 4031 for fixing the sensor case 500 to the stator 400.
  • the base portion 401 also has three terminal holes 4032 through which the electrical terminal fixing portion 4170 of the insulator 410 described below passes.
  • the base portion 401 also has a clip press-fit fixing hole 4033 for fixing the clip 610.
  • the base portion 401 also has a terminal fixing hole 4034 to which the fixing portion 481 of the neutral terminal 480 described below is fixed.
  • FIG. 3 is a perspective view showing the stator 400 and sensor case 500 with the rotor 300 removed from Figure 2.
  • a gap 405 is formed between adjacent coils 404, and the gap 405 widens radially outward.
  • the sensor case 500 is disposed in the gap 405.
  • the sensor case 500 is molded from a resin such as polyamide, similar to the insulator 410 described above.
  • the first magnetic detection sensor 541, the second magnetic detection sensor 542, the third magnetic detection sensor 543, and the fourth magnetic detection sensor 544 are disposed within the sensor case 500.
  • the first to fourth magnetic sensors 541 to 544 each have a power line, a ground line, and a signal line, and as shown in FIG. 2, these lines are grouped together as sensor wiring 545.
  • the sensor wiring 545 is held together with the power cable 600 by a clip 610.
  • the clip 610 is fixed to a clip bolt hole in the base part 401 by a clip bolt 611.
  • the clip 610 only needs to be fixed to the base part 401 of the stator 400, and is not limited to being fixed by a bolt using the clip bolt 611.
  • the clip 610 is press-fitted into the clip press-fit fixing hole 4033.
  • the insulator 410 is arranged to cover the stator 400 from both axial sides.
  • Figures 5 and 6 show a first insulator 411 arranged on one side of the stator 400, and Figures 15 and 16 show a second insulator 412 arranged on the other side.
  • the insulator 410 has a bobbin portion 4120 formed in correspondence with the teeth portion 402.
  • the first insulator 411 shown in Figures 5 and 6 has a fixing portion 4100 that holds the neutral terminal 480 at a portion corresponding to the base portion 401. More specifically, the fixing portion 4100 has a terminal holding portion 4105, into which the fixing portion 481 of the neutral terminal 480 is inserted. The terminal holding portion 4105 is then inserted into a terminal fixing hole 4034 formed in the base portion 401.
  • the first insulator 411 has three electrical terminal fixing portions 4170 formed in positions corresponding to the base portion 401.
  • the electrical terminal fixing portions 4170 hold electrical terminals therein that electrically connect to the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 (shown in FIG. 7).
  • the electrical terminal fixing portions 4170 pass through the terminal holes 4032 in the base portion 401. These electrical terminals route the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 wound on one side of the stator 400 to the other side.
  • the second insulator 412 shown in Figures 15 and 16 has an electrical terminal positioning portion 4171 formed at a position corresponding to the base portion 401.
  • the electrical terminal positioning portion 4171 has three electrical terminal holding holes 4172 formed at positions corresponding to the electrical terminal fixing portion 4170. Therefore, the first insulator 411 and the second insulator 412 are fitted together by inserting the tip of the electrical terminal fixing portion 4170 of the first insulator 411 into the electrical terminal holding hole 4172.
  • the second insulator 412 also has a terminal receiving portion 4106 formed at a position corresponding to the terminal holding portion 4105 of the first insulator 411 that passes through the terminal fixing hole 4034 of the base portion 401. Therefore, the terminal fixing hole 4034 and the terminal holding portion 4105 are covered by the terminal receiving portion 4106.
  • the base portion 401 has stator bolt through holes 4030 formed at 120 degrees apart.
  • the sensor case 500 is disposed between these stator bolt through holes 4030, and the clip 610 is also disposed therebetween.
  • three electrical terminal fixing portions 4170 are formed at positions corresponding to the base portion 401 of the insulator 410. Therefore, the space available for arranging the fixing portion 4100 of the insulator 410 is limited.
  • FIG. 7 shows an electrical circuit diagram of each coil 404.
  • the rotating electric machine 1 has three-phase AC, that is, U-phase, V-phase, and W-phase.
  • each phase is connected in parallel with three conductors.
  • U-phase conductors 60, U1 conductor 61, U2 conductor 62, and U3 conductor 63 are connected in parallel.
  • Two coils 404 are wound around each of the conductors 61 to 63.
  • U1-1 to U3-2 there are a total of six U-phase coils 404, as indicated by symbols U1-1 to U3-2.
  • the V and W phases The V-phase conductor 50 of the V phase is indicated by symbols 51, 52, and 53, and the W-phase conductor 70 of the W phase is indicated by symbols 71, 72, and 73.
  • the six V-phase coils 404 are indicated by symbols V1-1 to V3-2, and the six W-phase coils 404 are indicated by symbols W1-1 to W3-2. Therefore, the number of layers of the coils 404 is 18, which is the same as the number of teeth 402.
  • the rotating electric machine 1 is also star-connected. Therefore, the three U-phase conductors 60 each have a winding end point indicated by 64 to 66. Similarly, the three V-phase conductors 50 and the three W-phase conductors 70 each have a winding end point.
  • the winding end points of the V-phase conductor 50 are indicated by reference numerals 54 to 56, and the winding end points of the W-phase conductor 70 are indicated by reference numerals 74 to 76.
  • These winding end points are common to each other at the location indicated by C in FIG. 7. That is, as shown in FIG. 8, each winding end point is electrically connected to one neutral terminal 480.
  • the winding end point is a name for convenience, and does not necessarily have to be the end of the winding of the coil 404. It may be the start of the winding of the coil 404. Therefore, the winding end point means the end of the lead wire of the coil 404.
  • the neutral point terminal 480 is a plate extending in a first axial direction, which is the up-down direction in FIG. 8, and in a second axial direction (left-right direction in FIG. 8) perpendicular to the first axial direction. Iron or brass is used as the material for the neutral point terminal 480.
  • the plate material of the neutral point terminal 480 has a thickness of about 1 millimeter.
  • a fixing portion 481 is formed at one end of the neutral point terminal 480 in the first axial direction (the lower end in FIG. 8) so as to extend in the first axial direction. This fixing portion 481 is press-fitted and fixed into the fixing portion 4100 of the insulator 410.
  • a protruding engagement protrusion 4811 is formed near the center of the fixed portion 481.
  • the engagement protrusion 4811 is press-formed, and protrudes in the thickness direction of the neutral terminal 480. In FIG. 9, it protrudes to the left of the page, perpendicular to both the first axial direction and the second axial direction.
  • the amount of protrusion is approximately 1 millimeter. Therefore, both sides of the engagement protrusion 4811 in the first axial direction form engagement inclined surfaces 4813.
  • the middle portion of the engagement protrusion 4811 forms an engagement flat surface 4814.
  • a first wedge portion 4815 and a second wedge portion 4816 for locking are arranged on both sides of the fixing portion 481 in the second axial direction.
  • the first wedge portion 4815 is arranged closer to one end in the first axial direction than the second wedge portion 4816 (lower side in Figs. 8 and 9).
  • Both the first wedge portion 4815 and the second wedge portion 4816 for locking have a tapered shape in which the length in the second axial direction becomes shorter as they move closer to the one end in the first axial direction.
  • both the first wedge portion 4815 and the second wedge portion 4816 protrude by about 0.5 millimeters.
  • the length in the second axial direction of the first wedge portion 4815 arranged on the outside in the first axial direction is shorter than the length in the second axial direction of the second wedge portion 4816 arranged on the inside in the first axial direction.
  • the other end of the neutral terminal 480 in the first axial direction (the upper end in Figs. 8 and 9) is formed with conductor couplings 482 that engage the winding end points 64-66, 54-56, 74-76 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 (three for each phase).
  • the conductor couplings 482 are arranged in three locations: U-phase coupling 4821, V-phase coupling 4822, and W-phase coupling 4823.
  • the couplings 4821-4823 are arranged side by side in the second axial direction and have the same shape as each other.
  • Each of the joints 4821 to 4823 is composed of a central pillar 484, and a first claw portion 485 and a second claw portion 486 arranged on either side of the central pillar 484 in the second axial direction. Therefore, the central pillar 484, the first claw portion 485, and the second claw portion 486 are each formed in three places.
  • the height H1 of the central pillar 484 is slightly lower than the height H2 of the first claw portion 485 and the second claw portion 486.
  • the height H2 of the first claw portion 485 and the second claw portion 486 is about 4 millimeters
  • the height H1 of the central pillar 484 is about 3.7 millimeters.
  • a first space 487 is formed between the central pillar 484 and the first claw portion 485, and the winding end points 64, 65, 54, 55, 74, 75 of two of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 are arranged in this first space 487.
  • a second space 488 is formed between the central pillar portion 484 and the second claw portion 486. In this second space 488, the remaining winding end points 66, 56, 76 of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 are arranged.
  • the first space 487 side of the central pillar 484 is recessed by about 1 millimeter in the second axial direction. Therefore, the central pillar 484 also constitutes a part of the first space 487. This allows the first space 487 to be expanded in the second axial direction. As described above, the first space 487 has two winding end points 64, 65, 54, 55, 74, and 75 arranged therein, so expanding in the second axial direction is important because it allows the two winding end points 64, 65, 54, 55, 74, and 75 to be aligned in the second axial direction. Furthermore, it also makes it possible to align the winding end points 66, 56, and 76 arranged in the second space 488 in the second axial direction. This allows the nine winding end points 64 to 66, 54 to 56, and 74 to 76 to be arranged in a row along the second axial direction. This is a preferable arrangement when winding the coil 404.
  • the conductor will also vibrate due to vibrations associated with the operation of the internal combustion engine and/or the driving of the rotating electric machine 1, but this vibration of the conductor can be suppressed.
  • the first space 487 has a wide portion 4871 that widens in the second axial direction and a narrow portion 4872 that does not widen in the second axial direction.
  • the length of the wide portion 4871 in the second axial direction is longer than the combined diameter of the two conductors (U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70).
  • the length of the narrow portion 4872 in the second axial direction is longer than the diameter of one conductor (U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70) but shorter than the combined diameter of the two conductors. Therefore, the narrow portion 4872 is used as a passageway that leads the conductor to the wide portion 4871, and the wide portion 4871 is used as a space that holds the conductor in place.
  • FIG. 14 shows an example in which the width in the second axial direction is the same in the first space 487 and the second space 488.
  • the neutral terminal 480 must be arranged between the stator bolt through holes 4030 in the narrow space of the base portion 401, and it is not desirable to increase the height H2 in the first axial direction.
  • the height H2 in the first axial direction must be increased to avoid interference with the cylinder block 101. To achieve this, the distance between the stator 400 and the cylinder block 101 must be increased.
  • the central pillar portion 484, the first claw portion 485, and the second claw portion 486 of the neutral terminal 480 are arranged on the rotor 300 side of the stator 400, interference with the rotor 300 becomes an issue if the height H2 in the first axial direction is increased. To avoid interference with the rotor 300, the distance between the stator 400 and the rotor 300 must be increased. In any case, it is not desirable to increase the height H2 in the first axial direction.
  • the width of the central column portion 484 is wider in the embodiment shown in FIG. 8.
  • the width of the central column portion 484 can be increased by narrowing the width of the first width space 4824 between the U-phase coupling portion 4821 and the V-phase coupling portion 4822, and the second width space 4825 between the V-phase coupling portion 4822 and the W-phase coupling portion 4823.
  • the length of the U-phase coupling portion 4821, the V-phase coupling portion 4822, and the W-phase coupling portion 4823 in the second axial direction is about 6 millimeters.
  • the length of the first width space 4824 and the second width space 4825 in the second axial direction is about 3 millimeters.
  • the first width space 4824 and the second width space 4825 are spaces used to receive a crimping tool when crimping the first claw portion 485 and the second claw portion 486.
  • the crimping process is a process that changes the first claw portion 485 and the second claw portion 486 from their initial acceptable shape to the tightening shape after processing. Therefore, the length in the second axial direction cannot be zero, but a distance of about 3 millimeters is sufficient.
  • the winding end points 64-66, 54-56, 74-76 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 are housed in a first space 487 and a second space 488.
  • the first claw portion 485 and the second claw portion 486 are crimped toward the central pillar portion 484 to fix them in a fastened shape.
  • the height H2 in the first axial direction of the first claw portion 485 and the second claw portion 486 is sufficient to be a height that allows crimping compared to the diameter of one of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70.
  • the height H2 in the first direction can be lowered compared to the comparative example shown in FIG. 14.
  • the first space 487 is arranged on one side (right side) of the central column 484 in the second axial direction
  • the second space 488 is arranged on the other side (left side) of the central column 484 in the second axial direction, but the left-right direction is not limited.
  • the first space 487 and the second space 488 may be formed on either side of the central column 484 in the second axial direction.
  • FIG. 8 In the example of FIG. 8, the first space 487 is arranged on one side (right side) of the central column 484 in the second axial direction, and the second space 488 is arranged on the other side (left side) of the central column 484 in the second axial direction, but the left-right direction is not limited.
  • the first space 487 and the second space 488 may be formed on either side of the central column 484 in the second axial direction.
  • the U-phase coupling portion 4821, the V-phase coupling portion 4822, and the W-phase coupling portion 4823 are arranged in order from one side (right side) in the second axial direction, but the position in the second axial direction can be changed depending on the wiring of each coil 404 of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70. This is because at the neutral point (C in FIG. 7), the electrical connections are united and the same potential is obtained. Therefore, it is also possible to arrange the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 at the portion designated as the coupling portion (e.g., the U-phase coupling portion 4821) in the above example. Therefore, in this example, the names U-phase coupling portion 4821, V-phase coupling portion 4822, and W-phase coupling portion 4823 are names given for convenience, and it is not necessary that the conductors of the named phases are arranged there.
  • the neutral terminal 480 is configured with a collection portion 483 interposed between the conductor coupling portion 482 and the fixed portion 481 in the first axial direction.
  • the length L2 of the collection portion 483 in the second axial direction is shorter than the length L1 of the conductor coupling portion 482 in the second axial direction.
  • the length L1 of the conductor coupling portion 482 is approximately 25 millimeters
  • the length L2 of the collection portion 483 is approximately 3 millimeters shorter than that.
  • the length L2 of the assembly portion 483 is shortened to facilitate assembly of the neutral terminal 480.
  • This assembly will be described in detail later.
  • a minimum value L2Min is set for the length L2 of the assembly portion 483.
  • This minimum value L2Min is set as the distance between the claws located on the inside in the second axial direction among the first claw portion 485 and the second claw portion 486 of the coupling portions located on both sides in the second axial direction among the U-phase coupling portion 4821, the V-phase coupling portion 4822, and the W-phase coupling portion 4823.
  • the length L2 of the assembly portion 483 is set longer than the minimum value L2Min thus determined.
  • the rotating electric machine 1 is composed of the above elements.
  • the rotating electric machine 1 When the rotating electric machine 1 is used as a generator, the rotor 300 rotates in synchronization with the rotation of the crankshaft 100 of the internal combustion engine. As the rotor 300 rotates, it receives the magnetic flux of the permanent magnet 304 and generates an electromotive force in the coil 404 of the stator 400. This electromotive force is converted into three-phase AC, which is rectified to DC and charged to a battery (not shown). Conversely, when the rotating electric machine 1 is used as a starter for an internal combustion engine, the voltage from a battery (DC power source) (not shown) is converted into three-phase AC to generate a magnetic force in the coil 404.
  • DC power source DC power source
  • the magnetic force generated in the coil 404 at this time is attracted and repelled by the magnetic force of the permanent magnet 304, causing the rotor 300 to rotate.
  • the rotation of the rotor 300 also rotates the crankshaft 100, starting the internal combustion engine.
  • the second to fourth magnetic detection sensors 542, 543, 544 are used for rotation control during power generation and start-up.
  • the first magnetic detection sensor 541 is used to detect the reference position of the internal combustion engine.
  • a magnetic steel plate 440 having a base portion 401 and teeth portion 402 as shown in FIG. 4 is punched out.
  • a plurality of magnetic steel plates 440 as shown in FIG. 4 are stacked to manufacture a stator core 450.
  • the base portion 401 of the magnetic steel plate 440 has a protruding engagement portion 432 with which adjacent magnetic steel plates 440 fit when stacked. That is, the engagement portion 432 protrudes on one side and is recessed on the other side. This allows the protruding engagement portion 432 to fit into the recessed engagement portion 432 of the adjacent magnetic steel plate 440.
  • a teeth engagement portion 433 is also formed on the teeth portion 402 of the magnetic steel plate 440.
  • the teeth engaging portion 433 also protrudes on one side and is recessed on the other side. This also mechanically fixes the teeth engaging portion 433 formed on the teeth portion 402 of the adjacent magnetic steel plate 440.
  • the magnetic steel plate 440 and the teeth magnetic steel plate may also be fixed with an adhesive.
  • the insulator 410 is assembled to the stator core 450 to perform the insulator assembly process.
  • the first insulator 411 is shown arranged on one side of the stator core 450.
  • the second insulator 412 is arranged on the other side of the insulator 410.
  • the first insulator 411 is arranged so that the electrical terminal fixing portion 4170 fits into the terminal hole 4032 formed in the base portion 401 of the stator 400.
  • the first insulator 411 is arranged so that the terminal holding portion 4105 is inserted into the terminal fixing hole 4034 of the base portion 401.
  • the electrical terminal fixing portion 4170 of the first insulator 411 is inserted into the electrical terminal holding hole 4172 of the second insulator 412.
  • the neutral terminal 480 is press-fitted into the fixing portion 4100 of the first insulator 411.
  • the fixing portion 4100 is roughly the same size as the neutral terminal 480 and has an arc shape.
  • a fixing portion groove 4101 is formed corresponding to the fixing portion 481 at one end side (lower side in FIG. 10) in the first axial direction.
  • the groove width of the fixing portion groove 4101 is set to be slightly larger than the plate thickness of the neutral terminal 480, as shown in FIG. 5 and FIG. 10.
  • the collecting portion groove 4102 corresponding to the collecting portion 483 of the fixing portion 481 is about 1 mm, which is the same as the plate thickness of the neutral terminal 480.
  • the groove width of the fixing portion groove 4101 is about 0.2 mm larger than the groove width of the collecting portion groove 4102.
  • the first width space 4824 and the second width space 4825 are also used when pressing in the neutral terminal 480.
  • a downward load in the first axial direction is applied to at least one of the first width space 4824 and the second width space 4825.
  • the fixing portion 481 has an engagement protrusion 4811 protruding from around the center. Therefore, when the neutral point terminal 480 is pressed into the fixing portion groove 4101, it is guided by the engagement inclined surface 4813. When pressed into the fixing portion groove 4101, the engagement protrusion 4811 is elastically deformed, and the elastic force associated with this deformation presses the engagement flat surface 4814 in the middle part of the engagement protrusion 4811 against the fixing portion groove 4101.
  • the first wedge portion 4815 and the second wedge portion 4816 for engagement are arranged on both sides of the fixing portion 481 in the second axial direction.
  • the length in the second axial direction of the first wedge portion 4815 arranged on the outside in the first axial direction is shorter than the length in the second axial direction of the second wedge portion 4816 arranged on the inside in the first axial direction. Therefore, when the fixing portion 481 is pressed into the fixing portion groove 4101, the first wedge portion 4815 acts as a guide, making the press-in easier.
  • both the first wedge portion 4815 and the second wedge portion 4816 have a tapered shape in which the length in the second axis direction decreases as the first axis direction advances toward one end, and this tapered shape also allows for smooth press-fitting.
  • the second wedge portion 4816 in particular fits into both sides of the fixing portion groove 4101 in the second axis direction, preventing the neutral terminal 480 from coming loose.
  • the length of the assembly portion 483 in the second axial direction is shorter than the length of the conductor coupling portion 482 in the second axial direction. Therefore, as shown in FIG. 12, the conductor coupling portion 482 comes into direct contact with the insulator 410. As a result, the press-in allowance in the first axial direction of the neutral terminal 480 is easily managed. That is, the length of the assembly portion 483 in the second axial direction only needs to be shorter than the length of the fixed portion 4100 in the second axial direction, and there is no need to strictly manage the tolerance of the length of the assembly portion 483 in the second axial direction.
  • the press-in in the first axial direction of the neutral terminal 480 can be performed until the conductor coupling portion 482 comes into contact with the insulator 410.
  • the positional relationship in the first axial direction of the conductor coupling portion 482 can be stabilized.
  • This also makes it possible to stabilize the fixed positions of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70. Because the fixed position is stable, it is easy to ensure the vibration resistance strength of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70.
  • the area where the conductor joint 482 contacts the insulator 410 is exposed, it is easy to visually check the fit of the attachment.
  • the rotating electric machine 1 has three phases, U, V, and W, each of which is connected in parallel with three conductors.
  • the U-phase conductor 60 has two coils 404, U1-1 and U1-2, wound around it by the U1 conductor 61.
  • two coils 404, U2-1 and U2-2 are wound around it by the U2 conductor 62.
  • two coils 404, U3-1 and U3-2 are wound around it by the remaining U3 conductor 63.
  • the two coils 404 are connected together by a crossover wire, and the three wires 61, 62, 63 of the U-phase conductor 60 form a single continuous line up to the winding end points 64, 75, 66, respectively.
  • the coils 404 are wound in the same way for the V and W phases.
  • the V-phase conductor 50 has six V-phase coils 404 wound thereon, V1-1 to V3-2, using a V1 conductor 51, a V2 conductor 52, and a V3 conductor 53.
  • the V-phase conductor 50 also has six W-phase coils 404 wound thereon, W1-1 to W3-2, using a W1 conductor 71, a W2 conductor 72, and a W3 conductor 73.
  • the number of turns on the radially outer side is greater than the number of turns on the radially inner side. Therefore, when aligned multi-layer winding is used, the end of the winding of coil 404 is on the inner radial outer side of coil 404.
  • the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 are routed from the coil 404 whose insulation performance has been confirmed, and any excess conductors are cut and removed. Next, the insulating coating of the conductors at the ends of the coil 404 is peeled off. After that, the winding end points 64-66, 54-56, and 74-76 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 are stored in the first space 487 and the second space 488. As described above, two winding end points 64, 65, 54, 55, 74, and 75 are placed in the first space 487, and the remaining winding end point 66, 56, and 76 are placed in the second space 488.
  • the first claw portion 485 and the second claw portion 486 are crimped toward the central pillar portion 484 to fix the processed shape.
  • the first claw portion 485 and the second claw portion 486 are crimped at the same time.
  • the crimping process of the two claw portions becomes easier.
  • the first claw portion 485 and the second claw portion 486 are crimped until they abut against the central pillar portion 484. Because they are crimped until they abut, delicate adjustments to the amount of crimping are not necessary. This also makes the crimping process easier.
  • both the first claw portion 485 and the second claw portion 486 become inclined.
  • the height H2 in the first axial direction of the first claw portion 485 and the second claw portion 486 is slightly higher than the height H1 in the first axial direction of the central pillar portion 484.
  • the height in the first axial direction of the inclined first claw portion and the height in the first axial direction of the inclined second claw portion can be made approximately equal to the height H1 in the first axial direction of the central pillar portion 484.
  • the first space 487 side of the central pillar 484 is recessed in the second axial direction so that the central pillar 484 forms part of the first space 487.
  • This is a desirable shape because it allows one of the two winding end points 64, 65, 54, 55, 74, 75 to be held by a part of the central pillar 484.
  • it is sufficient that the length of the first space 487 in the second axial direction is sufficient to accommodate the two winding end points 64, 65, 54, 55, 74, 75. Therefore, it is not essential to form a recess in the central pillar 484.
  • the length of the collection portion 483 in the second axial direction is shorter than the length of the conductor coupling portion 482 in the second axial direction.
  • This is a desirable shape, as it makes it easier to press the neutral terminal 480 into the fixed portion 4100 of the insulator 410.
  • the neutral terminal 480 does not necessarily have to be press-fitted into the insulator 410. It is also possible to insert-mold the neutral terminal 480 when molding the resin insulator 410 (first insulator 411).
  • the present disclosure can be modified in various ways.
  • the number of coils 404 is 18, which is one example, and the number of coils 404 can be changed.
  • the present disclosure requires only a three-phase star connection, and does not necessarily require a three-parallel connection with three conductors.
  • the size described in the above example is one example, and the material and size can be set appropriately according to the performance required for the rotating electric machine 1.
  • the disclosure in this specification and drawings, etc. is not limited to the exemplified embodiments.
  • the disclosure includes the exemplified embodiments and modifications by those skilled in the art based thereon.
  • the disclosure is not limited to the combination of parts and/or elements shown in the embodiments.
  • the disclosure can be implemented by various combinations.
  • the disclosure can have additional parts that can be added to the embodiments.
  • the disclosure includes the omission of parts and/or elements of the embodiments.
  • the disclosure includes the substitution or combination of parts and/or elements between one embodiment and another embodiment.
  • the disclosed technical scope is not limited to the description of the embodiments. Some disclosed technical scopes are indicated by the description of the claims, and should be interpreted as including all modifications within the meaning and scope equivalent to the description of the claims.
  • a rotating electric machine including a stator having a stator core having an annular base portion and a number of teeth extending radially outward from the base portion, an insulator made of an insulating material disposed on at least a portion of the base portion and the teeth portion of the stator core, and a coil wound around an outer periphery of the insulator at a position corresponding to the teeth portion of the stator core, The coil is star-connected for three phases, and three conductors for each phase are electrically connected to a neutral terminal.
  • the neutral terminal is fixed to a fixing portion of the insulator that is formed in a groove shape in the base portion, the neutral point terminal is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction, the neutral terminal has a fixing portion at one end in the first axial direction that engages with the insulator, and a conductor coupling portion at the other end in the first axial direction that engages with the three conductors for each phase, and a collection portion is interposed between the conductor coupling portion and the fixing portion in the first axial direction,
  • the conductor coupling portion includes three coupling portions arranged along the second axial direction, the coupling portions holding three conductors for each of three phases, Each coupling portion has a central pillar portion that forms a first space in which two of the conductors are disposed along one of the directions in the second axial direction and a second space in which one of the conductors is disposed on the other side in the second axial direction and that extends in
  • a stator core having an annular base portion and a number of teeth extending radially outward from the base portion; an insulator made of an insulating material that is disposed on at least a portion of the base portion and on the teeth portion of the stator core; a coil wound around an outer periphery of the insulator at a position corresponding to the teeth of the stator core; The coil is star-connected in three phases, and three conductors for each phase are electrically connected to a neutral terminal.
  • the neutral terminal is fixed to a fixing portion of the insulator that is formed in a groove shape in the base portion, the neutral point terminal is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction, the neutral terminal has a fixing portion disposed at one end in the first axial direction for engaging with the insulator, and a conductor coupling portion disposed at the other end in the first axial direction for engaging the conductors (three for each phase), and a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction;
  • the conductor coupling portion includes three coupling portions arranged along the second axial direction, the coupling portions holding three conductors for each of three phases, Each coupling portion has a central pillar portion that forms a first space in which two of the conductors are disposed along one of the directions in the second axial direction and a second space in which one of the conductors is disposed on the other side in the second axial direction and that extends
  • a stator core having an annular base portion and a number of teeth extending radially outward from the base portion, the number of teeth being three or more; an insulator made of an insulating material that is disposed on at least a portion of the base portion and on the teeth portion of the stator core; a coil wound around an outer periphery of the insulator at a position corresponding to the teeth portion of the stator core, The coil is star-connected into three phases, and three conductors for each phase are electrically connected to a neutral terminal, The neutral terminal is fixed to a fixing portion of the insulator that is formed in a groove shape in the base portion, the neutral point terminal is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction, the neutral terminal has a fixing portion disposed at one end in the first axial direction for engaging with the insulator, and a conductor coupling portion disposed at the other end in the first axial direction for engaging the conduct
  • the first space side of the central pillar is recessed in the second axial direction to form part of the first space.
  • a rotating electric machine as described in Technical idea 1 a stator for a rotating electric machine as described in Technical idea 2, or a neutral terminal of a stator for a rotating electric machine as described in Technical idea 3.
  • the length of the assembly in the second axial direction is shorter than the length of the conductor connection part, and is longer than the length of the connection between the first claw portion and the second claw portion that is located on the inside in the second axial direction, among the connection portions located on both sides in the second axial direction.
  • a rotating electric machine according to Technical Idea 1 or Technical Idea 4 dependent on Technical Idea 1 a stator for a rotating electric machine according to Technical Idea 2 or Technical Idea 4 dependent on Technical Idea 2, or a neutral point terminal of a stator for a rotating electric machine according to Technical Idea 3 or Technical Idea 4 dependent on Technical Idea 3.
  • the length of the fixed portion in the second axial direction is shorter than the length of the assembly portion in the second axial direction.
  • a rotating electric machine as described in Technical idea 1 or Technical idea 4 or Technical idea 5 which is dependent on Technical idea 1 a stator for a rotating electric machine as described in Technical idea 2 or Technical idea 4 or Technical idea 5 which is dependent on Technical idea 2, or a neutral point terminal of a stator for a rotating electric machine as described in Technical idea 3 or Technical idea 4 or Technical idea 5 which is dependent on Technical idea 3.
  • a first wedge portion and a second wedge portion for engagement are arranged in the first axial direction on both sides of the fixed portion in the second axial direction, and the length in the second axial direction of the first wedge portion arranged on the outside of the first axial direction is shorter than the length in the second axial direction of the second wedge portion arranged on the inside of the first axial direction.
  • a rotating electric machine according to Technical Idea 1 or any of Technical Ideas 4 to 6 that are dependent on Technical Idea 1 a stator for a rotating electric machine according to Technical Idea 2 or any of Technical Ideas 4 to 6 that are dependent on Technical Idea 2, or a neutral point terminal of a stator for a rotating electric machine according to Technical Idea 3 or any of Technical Ideas 4 to 6 that are dependent on Technical Idea 3.
  • a manufacturing method for a stator for a rotating electric machine which includes a crimping process in which the first claw portion and the second claw portion are simultaneously inclined toward the central column portion until they abut against the central column portion, thereby making the height of the central column portion in the first axial direction, the height of the inclined first claw portion, and the height of the inclined second claw portion in the first axial direction

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
PCT/JP2024/003856 2023-03-03 2024-02-06 回転電機、回転電機用ステータ、回転電機用ステータの中性点ターミナル、及び回転電機用ステータの製造方法 Ceased WO2024185370A1 (ja)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013165590A (ja) * 2012-02-10 2013-08-22 Denso Trim Kk 磁石式発電機
WO2016171205A1 (ja) * 2015-04-21 2016-10-27 株式会社ミツバ アウターローター型回転電機
JP2017099223A (ja) * 2015-11-27 2017-06-01 デンソートリム株式会社 内燃機関用回転電機およびその電極

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013165590A (ja) * 2012-02-10 2013-08-22 Denso Trim Kk 磁石式発電機
WO2016171205A1 (ja) * 2015-04-21 2016-10-27 株式会社ミツバ アウターローター型回転電機
JP2017099223A (ja) * 2015-11-27 2017-06-01 デンソートリム株式会社 内燃機関用回転電機およびその電極

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