Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/04—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
  • H02K15/0414—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines the windings consisting of separate elements, e.g. bars, segments or half coils
• • 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

Definitions

• This disclosure relates to armatures, rotating electric machines, linear motors, and methods for manufacturing armatures.
• a thin rotating electric machine is an axial gap type rotating electric machine in which a circular rotor and an armature are arranged facing each other.
• an armature for an axial gap type rotating electric machine has been disclosed in which multiple coils manufactured by punching copper plate are stacked with an insulating layer sandwiched between them (see, for example, Patent Document 1).
• the present disclosure has been made to solve the above-mentioned problems, and aims to provide an armature with high insulation between adjacent coils on the same layer.
• the armature disclosed herein is an armature arranged opposite the mover across a gap, and has a coil whose width changes from the first direction toward the third direction when viewed from the first direction, where the direction facing the mover is defined as a first direction, the direction perpendicular to the first direction and in which the mover moves relative to the armature is defined as a second direction, and the direction perpendicular to the first and second directions is defined as a third direction.
• the coils are stacked in two or more layers in the first direction with an insulator interposed between them, and at least two coils are arranged in the second direction.
• Chamfered portions are formed at the corners of the coils in a cross section perpendicular to the third direction.
• the armature disclosed herein has chamfered corners of the coils in a cross section perpendicular to the third direction, thereby improving insulation between adjacent coils on the same layer.
• FIG. 1 is a cross-sectional view of a rotating electric machine according to a first embodiment.
• FIG. 2 is a plan view of a rotor according to the first embodiment.
• FIG. 2 is a plan view of the armature according to the first embodiment.
• FIG. 2 is a side view of the armature according to the first embodiment.
• FIG. 2 is a plan view of the armature according to the first embodiment.
• FIG. 2 is a circuit diagram of an armature according to the first embodiment.
• FIG. 4 is a plan view of an armature of a reference example according to the first embodiment.
• FIG. 2 is an enlarged cross-sectional view of a coil of the armature according to the first embodiment.
• FIG. 10 is an enlarged cross-sectional view of a coil of an armature of a comparative example according to the first embodiment.
• FIG. 2 is an enlarged view of a coil of the armature according to the first embodiment.
• FIG. 10 is an enlarged view of a coil of an armature of a comparative example according to the first embodiment.
• 4 is a flowchart showing a method for manufacturing the armature according to the first embodiment.
• 1A and 1B are diagrams showing a coil in the process of being manufactured according to the first embodiment;
• 5A to 5C are diagrams for explaining a method for manufacturing an armature according to the first embodiment.
• 5A to 5C are diagrams for explaining a method for manufacturing an armature according to the first embodiment.
• FIG. 10A to 10C are diagrams for explaining deformation of the coil when pressed by a die in the armature according to the first embodiment.
• 10A to 10C are diagrams for explaining deformation of the coil when pressed by a die in the armature according to the first embodiment.
• 10A to 10C are diagrams for explaining deformation of the coil when pressed by a die in the armature according to the first embodiment.
• FIG. 2 is a plan view of the armature according to the first embodiment.
• FIG. 10 is an enlarged cross-sectional view of a coil of an armature according to a second embodiment.
• FIG. 10 is an enlarged view of a coil of an armature according to a second embodiment.
• FIG. 11 is an enlarged cross-sectional view of a coil of an armature according to a third embodiment.
• FIG. 11 is an enlarged cross-sectional view of a coil of an armature of a comparative example according to the third embodiment.
• FIG. 11 is an enlarged view of a coil of an armature according to a third embodiment.
• FIG. 11 is an enlarged view of a coil of an armature of a comparative example according to the third embodiment.
• FIG. 11 is an enlarged cross-sectional view of a coil of an armature of a comparative example according to the third embodiment.
• FIG. 10 is an enlarged cross-sectional view of a coil of an armature according to a fourth embodiment.
• FIG. 10 is an enlarged cross-sectional view of a coil of an armature according to a fourth embodiment.
• FIG. 10 is an enlarged cross-sectional view of a coil of an armature according to a fourth embodiment.
• FIG. 10 is an enlarged view of a coil of an armature according to a fourth embodiment.
• FIG. 10 is an enlarged view of a coil of an armature according to a fourth embodiment.
• FIG. 10 is an enlarged cross-sectional view of a coil of an armature according to a fifth embodiment.
• FIG. 11 is an enlarged view of a coil of an armature according to a fifth embodiment.
• Fig. 1 is a cross-sectional view of a rotating electric machine according to embodiment 1.
• Fig. 1 is a cross-sectional view showing the structure of the right half from the center of rotation, which will be described later, in order to explain the structure of the rotating electric machine according to this embodiment.
• the rotating electric machine 1 of this embodiment is an axial gap type rotating electric machine in which an annular rotor and an armature are arranged axially opposite each other.
• the rotating electric machine 1 of this embodiment is composed of a stator 2 and a rotor 3.
• the stator 2 has a circular armature 21, a housing 22 that holds the armature 21, a bearing 23, and a bracket 24.
• the rotor 3 has a rotating shaft 31 that is rotatably supported relative to the stator 2 via the bearing 23, a circular rotor core 32 that is fastened to the rotating shaft 31, and magnets 33 that are arranged circumferentially around the rotor core 32.
• the rotating shaft 31 rotates around the center of rotation C.
• the direction parallel to the center of rotation C will be referred to as the axial direction
• the direction perpendicular to the axial direction will be referred to as the radial direction
• the circumferential direction of the annular armature 21 will be referred to as the circumferential direction.
• the inner diameter side is the direction approaching the center of rotation C in the radial direction
• the outer diameter side is the direction moving away from the center of rotation C in the radial direction.
• the rotor core 32 is arranged on both sides of the armature 21 in the axial direction, and the magnets 33 are arranged facing the armature 21 across a gap in the axial direction.
• a coil is formed in the armature 21, and a current is applied to this coil from the power supply terminal 4.
• the armature 21 generates a rotating magnetic field due to the applied current.
• the rotor 3 rotates due to this rotating magnetic field. Therefore, the rotor 3 is arranged coaxially with the armature 21 across a gap, and can also be described as a mover that moves relative to the armature 21.
• Figure 2 is a plan view of the rotor 3 of this embodiment, viewed from the armature 21 side.
• the magnets 33 are arranged in a line in the circumferential direction of the annular rotor core 32.
• the magnets 33 are magnetized in a direction perpendicular to the plane of the paper in Figure 2, with south poles and north poles arranged alternately in the circumferential direction.
• FIG. 3 is a plan view of the armature 21 of this embodiment
• FIG. 4 is a side view of the armature 21 of this embodiment.
• the armature 21 of this embodiment is composed of two layers of coils stacked in the axial direction. Therefore, FIG. 3 shows the coils of the first layer.
• FIG. 5 is a plan view of the coils of the second layer of the armature 21 of this embodiment.
• the coils of each layer are made of a conductive metal such as copper, and an insulating coating is formed on their surfaces.
• the armature 21 of this embodiment has 72 coils 26 divided circumferentially by slits 25.
• Each coil 26 is composed of a slot portion 26a in the radial center, an outer diameter turn portion 26b on the outer diameter side of the slot portion 26a, and an inner diameter turn portion 26c on the inner diameter side of the slot portion 26a.
• the first layer coil 26 is joined to the second layer coil 26 at an outer diameter joint portion 27.
• the second layer coil 26 joined at the outer diameter joint portion 27 is joined to the first layer coil 26 at an inner diameter joint portion 28.
• the coils 26 joined in this manner are joined to coils 26 positioned six pitches apart circumferentially by bus bars 29.
• bus bars 29 may be used for purposes other than electrically joining coils in the stacking direction. For example, they may be used as a neutral point connection portion in a Y-connection. Furthermore, the bus bar 29 is not limited to joining coils spaced six slot pitches apart, but may also join coils spaced five slot pitches or seven slot pitches apart.
• the first and second layer coils which are six pitches apart, are joined in sequence to form a wave-wound armature coil.
• the armature of this embodiment has a distributed winding with full pitch winding of 2 per pole per phase, and as shown in Figure 3, the coils U1, U2, W1, W2, V1, and V2 are arranged in order. Also, as shown in Figure 4, power supply terminals 4 are connected to both ends of the coils U1, U2, W1, W2, V1, and V2.
• FIG. 6 is a circuit diagram of an armature according to this embodiment.
• a U-phase coil, in which U1 and U2 coils are connected in series, a W-phase coil, in which W1 and W2 coils are connected in series, and a V-phase coil, in which V1 and V2 coils are connected in series, are connected in a Y-connection, and a three-phase AC power supply 30 such as an inverter is connected to the ends of the coils of each phase.
• a rotating magnetic field is generated in the armature by applying three-phase AC current from the three-phase AC power supply 30 to the coils of each phase.
• the armature is fully-pitch wound with two coils per pole per phase, but the armature may be fractionally wound, distributed with one coil per pole per phase, salient pole concentrated winding, or other types of winding, as long as the winding method generates a rotating magnetic field and coils set to different potentials are arranged adjacent to each other.
• the armature of this embodiment is not limited to three phases, and can also be applied to dual three-phase structures, or structures that generate a rotating magnetic field with five-phase or seven-phase current.
• Figure 7 is a plan view of an armature wound with magnet wire of the same cross-sectional shape as a reference example. Note that the busbars and power supply terminals are omitted from Figure 7.
• the width of the coil 26 must be determined by physical constraints such as space interference on the inner diameter and ensuring insulation distance. In this case, the space other than the coil on the outer diameter side becomes large. As a result, the coil space factor cannot be increased, resulting in reduced efficiency and output.
• the coil width when viewed from the axial direction is varied, allowing the coils to be arranged densely even on the outer diameter side, resulting in higher efficiency and higher output.
• the coils in order to obtain coil shapes with different cross-sectional areas, the coils must be formed by stamping, laser processing, etching, etc. For example, if the coils are formed by stamping, the corners of the coil will be nearly right-angled.
• Figure 8 is an enlarged cross-sectional view of the coils of the armature according to this embodiment.
• Figure 8 is a cross-sectional view of the portion indicated by A-A in Figure 3, i.e., a cross-sectional view perpendicular to the radial direction, with the vertical direction of the page being the axial direction and the horizontal direction being the circumferential direction.
• Figure 8 shows an enlarged view of a slot portion where coils of different phases are adjacent in the circumferential direction.
• coils 41 and 42 which are stacked in two layers in the axial direction, are U-phase coils
• coils 43 and 44 which are stacked in two layers in the axial direction, are W-phase coils.
• These coils 41 to 44 are covered with an insulating coating 45.
• the potential difference between coils 41 and 43 of different phases is greater than the potential difference between coils 41 and 42 of the same phase.
• the corners of the coils are chamfered in a radial cross section.
• chamfering refers to removing sharp corners after machining to form a flat, curved surface, etc.
• a chamfered shape refers to a shape that can reduce electric field concentration by removing sharp corners.
• the corners of the coils are rounded.
• the chamfered shape will be referred to as chamfered portion 40.
• the shape of the chamfered portion defined in this embodiment is achieved, it is not limited to processing methods that remove sharp corners after machining, but can also be processing methods that directly form chamfered portions using near-net shaping with a 3D printer, die casting, etc.
• Figure 9 is an enlarged cross-sectional view of a coil in an armature of a comparative example to this embodiment.
• Figure 9 is a cross-sectional view in a direction perpendicular to the radial direction, with the vertical direction on the page being the axial direction and the horizontal direction being the circumferential direction.
• Figure 9 shows an enlarged view of a slot portion in which coils of different phases are adjacent in the circumferential direction.
• coils 41 and 42 which are stacked in two layers in the axial direction, are U-phase coils
• coils 43 and 44 which are stacked in two layers in the axial direction, are W-phase coils.
• These coils 41 to 44 are covered with an insulating coating 45.
• the potential difference between coils 41 and 43 of different phases is greater than the potential difference between coils 41 and 42 of the same phase.
• the corners of the coils are not chamfered, so the corners of the coils are nearly right-angled in radial cross section. In this embodiment, if the corners of the coils are not chamfered in radial cross section, the corners of the coils will be nearly right-angled.
• FIG. 10 is an enlarged view of the portion indicated by the dashed circle in FIG. 8
• FIG. 11 is an enlarged view of the portion indicated by the dashed circle in FIG. 9.
• three locations are assumed to be potential locations where short-circuiting with other coils may occur, relative to coil 41: between the corner of coil 41 indicated by double-headed arrow a and the corner of coil 42; between the corner of coil 41 indicated by double-headed arrow b and the corner of coil 43; and between the corner of coil 41 indicated by double-headed arrow c and the corner of coil 44.
• the lengths of double-headed arrow a and double-headed arrow b are the same between the armature of this embodiment and the armature of the comparative example.
• the corners are shaped like chamfered portions 40, which alleviates electric field concentration compared to the armature of the comparative example shown in FIG. 11.
• the length of double-ended arrow c is longer in the armature of this embodiment shown in Figure 10 than in the armature of the comparative example shown in Figure 11.
• the insulation between the corners of coil 41 and coil 44 is higher in the armature of this embodiment than in the armature of the comparative example.
• the corners of the armature of this embodiment are chamfered, electric field concentration is alleviated compared to the armature of the comparative example shown in Figure 11.
• the corners of the coils in the radial cross section are chamfered 40, which improves the insulation between adjacent coils in the same layer. Furthermore, in the armature of this embodiment, the insulation between adjacent coils in the same layer is improved compared to the armature of the comparative example, so the thickness of the insulating coating 45 can also be reduced. Reducing the thickness of the insulating coating 45 can also improve the coil space factor. As a result, it is possible to achieve a smaller armature, higher output, and higher efficiency.
• the chamfered portion has a rounded shape, but the chamfered portion may also have a shape known as C-chamfering, in which sharp corners left after machining are cut at a 45-degree angle, a shape known as light chamfering, in which only the tip of a sharp corner is cut, or a shape in which a sharp corner is cut into a polygonal shape.
• the method for manufacturing an armature according to this embodiment includes a coil forming step S1, a chamfered portion forming step S2, an insulating coating forming step S3, a coil joining step S4, and a coil cutting step S5.
• FIG. 13 is a diagram showing the coil after slits have been punched in the coil formation process S1.
• the metal plate 34 is processed into a circular ring shape, and a slit 25 is formed through the metal plate 34.
• a coil 26 is formed in the metal plate 34, consisting of a slot portion 26a, an outer diameter turn portion 26b, and an inner diameter turn portion 26c.
• the outer diameter joint portion 27 and the inner diameter joint portion 28 are formed at the same time as the coil 26 is formed. At this time, the outer diameter joint portion 27 is connected to the outer diameter connecting portion 36 via the outer diameter cutting portion 35. Furthermore, the inner diameter joint portion 28 is connected to the inner diameter connecting portion 38 via the inner diameter cutting portion 37. Furthermore, in the coil forming process S1, a positioning hole 39 is formed in the outer diameter connecting portion 36.
• connecting the coil 26 to the outer diameter connecting portion 36 and the inner diameter connecting portion 38 makes it easier to transport the coil, and forming the positioning holes 39 makes it easier to position it in subsequent processes.
• FIG 14 is a diagram for explaining the chamfer forming process S2.
• the coil 26 formed in the coil forming process S1 has corners that are approximately right angles. As shown in Figure 14, this coil 26 is placed on a lower mold 51. An upper mold 52 is pressed from above onto the coil 26 placed on the lower mold 51. Through this process, chamfers 40 are formed at the corners of the coil 26. Note that, as shown in Figure 15, multiple coils 26 lined up in the circumferential direction may be pressed simultaneously using the lower mold 51 and upper mold 52. Alternatively, the entire coil 26 may be pressed simultaneously.
• Figure 16 is a diagram illustrating the deformation of a coil when a limited number of coils are pressed with a mold.
• the arrows indicate the force applied from the coil 26 to the upper mold 52.
• a similar force is also applied to the lower mold 51, but this is not shown.
• a force is applied at right angles to the coil at the end of the upper mold 52, which may cause the mold to deform.
• a smaller circumferential spacing is desirable to improve the coil's space factor, so the thickness of the mold at the circumferential end is smaller. If the circumferential gap of the coil is increased to suppress mold deformation, the output of the rotating electric machine will decrease.
• Figure 17 is a diagram illustrating the deformation of coils when a limited number of coils are pressed with a mold. As shown in Figure 17, it is also possible to form a chamfer on only one side of the coil adjacent to the end of the mold. In this case, the imbalance of force on the mold is smaller than with the method shown in Figure 16, but the coil adjacent to the end of the mold will move. If the coil shifts circumferentially, in the worst case scenario, it will short-circuit with the adjacent coil. Even if there is no short-circuit, the required insulation distance cannot be secured, and insulation reliability cannot be ensured.
• Figure 18 is a diagram illustrating the deformation of the coil when the entire coil is pressed simultaneously with a mold.
• the circumferential ends of the mold are eliminated, which has the effect of suppressing deformation of the coil 26.
• Suppressing deformation of the coil 26 and reducing variation in the circumferential gap of the coil has the effect of improving insulation reliability.
• the force acting on the mold is reduced because there are no ends, which has the effect of extending the life of the mold.
• pressing the entire coil 26 simultaneously can also prevent warping of the coil.
• an insulating coating is formed on the surface of the coil.
• Methods that can be used to form the insulating coating include electrocoating and powder coating.
• the first and second layer coils are manufactured by performing the coil forming process S1, the chamfer forming process S2, and the insulating coating forming process S3 on two metal plates, respectively.
• the insulating coating formed on the surfaces of the outer diameter joint portion 27 and the inner diameter joint portion 28 is first peeled off.
• the first and second layer coils are then overlapped and joined at the outer diameter joint portion 27 and the inner diameter joint portion 28.
• Methods that can be used to join the coils include welding, crimping, and soldering.
• the power supply terminal 4 and the bus bar 29 are joined to the coil 26, respectively.
• the chamfer may also be formed by cutting the corners of the coil using an abrasive.
• Methods using an abrasive include sandblasting, shot blasting, and barrel polishing. Methods using an abrasive can form the chamfer without using a mold, which has the effect of reducing costs.
• the abrasive increases the surface roughness of the coil, improving adhesion between the coil and the insulating coating and preventing pinholes and peeling in the insulating coating. As a result, the reliability of the coil's insulation is improved.
• the insulating coating is formed after chamfering the corners of the coil, allowing for a more uniform thickness of the insulating coating at the corners of the coil compared to coils without chamfering. If the insulating coating were formed without chamfering, the electric field concentration at the corners would cause the insulating coating to have an uneven thickness. Therefore, to ensure the insulating properties of the insulating coating, it is necessary to increase the average thickness of the entire insulating coating. As a result, the coil space factor is reduced in armatures without chamfering. In the armature manufacturing method of this embodiment, the insulating coating is formed after chamfering the corners of the coil, eliminating the need to increase the average thickness of the insulating coating more than necessary, which also has the effect of improving the coil space factor.
• the coil 26 is processed while connected to the outer diameter connecting portion 36 and the inner diameter connecting portion 38, but the coil 26 may also be processed while separated. Even in this case, the thickness of the insulating coating at the corners of the coil can be made uniform by providing the chamfered portion forming process S2 before the insulating coating forming process S3.
• the armature has been described as being for an axial gap type rotating electric machine, but the same effect as this embodiment can be achieved by forming chamfered portions at the corners of the coils in the armature of a linear motor in which disk-shaped coils 26 are arranged in a straight line, as shown in Figure 19. Furthermore, in a radial gap type rotating electric machine in which the armature is made by processing linearly arranged coils into a cylindrical shape, the same effect as this embodiment can be achieved by forming chamfered portions at the corners of the coils.
• an armature composed of two layers of coils has been described as an example, but the same effect as this embodiment can be achieved in an armature composed of three or more layers of coils by forming chamfered portions at the corners of the coils.
• the axial thickness of the coils can be reduced, thereby reducing the skin effect, eddy current loss, etc.
• the armature in this embodiment has been described as being composed of Y-connected coils as an example, it may also be composed of coils connected in parallel, delta, etc.
• Embodiment 2 In the armature according to the second embodiment, two layers of coils are arranged circumferentially shifted from each other in the armature of the first embodiment. Note that a rotating electric machine having the armature of this embodiment is similar to the rotating electric machine of the first embodiment shown in FIG.
• Figure 20 is an enlarged cross-sectional view of the coils of the armature according to this embodiment.
• Figure 20 is a cross-sectional view in a direction perpendicular to the radial direction, with the vertical direction on the page being the axial direction and the horizontal direction being the circumferential direction.
• Figure 20 shows an enlarged view of a slot portion where coils of different phases are adjacent in the circumferential direction.
• coils 41 and 42 which are stacked in two layers in the axial direction, are U-phase coils
• coils 43 and 44 which are stacked in two layers in the axial direction, are W-phase coils.
• These coils 41 to 44 are covered with insulating coating 45.
• chamfered portions 40 are formed at the corners of the coils in a radial cross section. Furthermore, in the armature of this embodiment, the second layer coils are arranged circumferentially offset from the first layer coils.
• Figure 21 is an enlarged view of the portion indicated by the dashed circle in Figure 20. As shown in Figure 21, in the armature of this embodiment, the corners of axially adjacent coils do not face each other, and the corner of one coil faces the flat portion of the axially adjacent coil. Therefore, in the armature of this embodiment, the insulation is improved compared to the armature of embodiment 1, in which the corners of axially adjacent coils face each other.
• the amount of circumferential deviation between axially adjacent coils is X
• the distance between circumferentially adjacent coils is Y
• the distance from the circumferential end of the coil to the start position of the chamfered portion 40 is R.
• X it is preferable that X>R.
• X ⁇ Y+2R it is preferable that X ⁇ Y+2R. If X ⁇ Y+2R, the distance between coils 42 and 43 of different phases will be small, which could result in a decrease in insulation. By satisfying X ⁇ Y+2R, the distance between coils of different phases can be increased, preventing a decrease in insulation.
• Embodiment 3 In the armature of the first embodiment, two layers of coils are stacked in the axial direction, and insulation between the coils is ensured by an insulating coating formed on the surface of the coils. In the armature of the third embodiment, an insulating sheet is placed between the two layers of coils stacked in the axial direction to ensure insulation between the coils. Note that a rotating electric machine having an armature of this embodiment is similar to the rotating electric machine of the first embodiment shown in FIG. 1.
• Figure 22 is an enlarged cross-sectional view of the coils of the armature according to this embodiment.
• Figure 22 is a cross-sectional view perpendicular to the radial direction, with the vertical direction of the page being the axial direction and the horizontal direction being the circumferential direction.
• Figure 22 shows an enlarged view of a slot where coils of different phases are adjacent in the circumferential direction.
• coils 41 and 42 which are stacked in two layers in the axial direction, are U-phase coils
• coils 43 and 44 which are stacked in two layers in the axial direction
• Chamfered portions 40 are formed at the corners of these coils 41 to 44.
• no insulating coating is formed on the surfaces of these coils 41 to 44, and insulating sheets 46 are placed between axially adjacent coils.
• the armature of this embodiment is manufactured by the armature manufacturing method shown in Figure 12 of embodiment 1, excluding the insulating coating formation process S3, and by placing an insulating sheet in areas other than the outer diameter joint and inner diameter joint when overlapping the first and second layer coils in the coil joining process S4.
• Figure 23 is an enlarged cross-sectional view of a coil in an armature of a comparative example to this embodiment.
• Figure 23 is a cross-sectional view in a direction perpendicular to the radial direction, with the vertical direction of the page being the axial direction and the horizontal direction being the circumferential direction.
• Figure 23 shows an enlarged view of a slot portion where coils of different phases are adjacent in the circumferential direction.
• coils 41 and 42 which are stacked in two layers in the axial direction, are U-phase coils
• coils 43 and 44 which are stacked in two layers in the axial direction
• No chamfers are formed at the corners of these coils 41 to 44.
• no insulating coating is formed on the surfaces of these coils 41 to 44, and an insulating sheet 46 is placed between axially adjacent coils.
• FIG. 24 is an enlarged view of the portion indicated by the dashed circle in FIG. 22, and FIG. 25 is an enlarged view of the portion indicated by the dashed circle in FIG. 23.
• the creepage distance between circumferentially adjacent coils is indicated by a double-ended arrow d.
• the length of double-ended arrow d is longer in the armature of this embodiment shown in FIG. 24 than in the armature of the comparative example shown in FIG. 25. Therefore, the insulation between circumferentially adjacent coils is higher in the armature of this embodiment, in which chamfered portions 40 are formed, than in the armature of the comparative example.
• Figure 26 is an enlarged cross-sectional view of a coil in an armature of another comparative example related to this embodiment.
• the armature of another comparative example shown in Figure 26 uses a punching process in the coil formation process and does not have a chamfered portion.
• protrusions 47 called burrs are formed at the corners of the coil.
• these protrusions 47 can damage the insulating sheet 46, potentially reducing the insulating properties of the insulating sheet 46.
• gaps 48 can still form between the insulating sheet 46 and the protrusions 47. These gaps 48 reduce the coil's space factor and increase the thermal resistance from the coil to the insulating sheet. As a result, a rotating electrical machine equipped with the armature of this comparative example will experience a decrease in output.
• the coil and insulating sheet are in close contact with each other as shown in Figure 24, which improves the coil space factor and reduces the thermal resistance from the coil to the insulating sheet.
• a rotating electric machine equipped with the armature of this embodiment can achieve high output.
• Embodiment 4 In the armature of embodiment 3, an insulating sheet is disposed between two layers of coils stacked in the axial direction. In the armature of embodiment 4, the circumferentially adjacent coils in the armature of embodiment 3 are fixed with fixing members. Note that a rotating electric machine having an armature of this embodiment is similar to the rotating electric machine of embodiment 1 shown in FIG. 1.
• Figure 27 is an enlarged cross-sectional view of a coil of an armature according to this embodiment.
• Figure 27 is a cross-sectional view perpendicular to the radial direction, with the vertical direction of the page being the axial direction and the horizontal direction being the circumferential direction.
• Figure 27 shows an enlarged view of a slot portion where coils of different phases are adjacent in the circumferential direction.
• coils 41 and 42 which are stacked in two layers in the axial direction, are U-phase coils
• coils 43 and 44 which are stacked in two layers in the axial direction, are W-phase coils.
• Chamfered portions 40 are formed at the corners of these coils 41 to 44.
• fixing members 49 are disposed between circumferentially adjacent coils 41 and 43, and between circumferentially adjacent coils 42 and 44.
• the fixing members 49 secure the circumferentially adjacent coils to each other.
• a thermosetting resin or a room-temperature curing adhesive can be used as the fixing member 49.
• Figure 28 is an enlarged cross-sectional view of the coil of another armature according to this embodiment.
• Figure 28 is a cross-sectional view in a direction perpendicular to the radial direction, with the vertical direction on the page being the axial direction and the horizontal direction being the circumferential direction.
• the surface of the fixing member 49 is curved.
• Figure 29 is an enlarged view of the portion indicated by the dashed circle in Figure 27, and Figure 30 is an enlarged view of the portion indicated by the dashed circle in Figure 28.
• the creepage distance between circumferentially adjacent coils is indicated by double-ended arrows d.
• the length of double-ended arrow d is longer in the armature shown in Figure 30 than in the armature shown in Figure 29. Therefore, the insulation between circumferentially adjacent coils is higher in the armature shown in Figure 30 than in the armature shown in Figure 29.
• the surface of fixing member 49 is curved.
• Embodiment 5 The armature of the fifth embodiment is the armature of the first embodiment, in which a magnetic member is disposed between circumferentially adjacent coils. Note that a rotating electric machine having the armature of the present embodiment is similar to the rotating electric machine of the first embodiment shown in FIG.
• Figure 31 is an enlarged cross-sectional view of a coil of an armature according to this embodiment.
• Figure 31 is a cross-sectional view in a direction perpendicular to the radial direction, with the vertical direction of the page being the axial direction and the horizontal direction being the circumferential direction.
• Figure 31 shows an enlarged view of a slot portion where coils of different phases are adjacent in the circumferential direction.
• coils 41 and 42 which are stacked in two layers in the axial direction, are U-phase coils
• coils 43 and 44 which are stacked in two layers in the axial direction, are W-phase coils.
• Chamfered portions 40 are formed at the corners of these coils 41 to 44.
• FIG. 41 is an enlarged view of the portion indicated by the dashed circle in Figure 31.
• magnetic metal particles such as iron-based or iron-silicon-based particles solidified with resin can be used as the magnetic member 50.
• the magnetic member 50 is inserted into at least a portion of the circumferentially adjacent coils.
• the magnetic member may be inserted only between the slot portions 26a of the coils 26 in Figure 5 of embodiment 1. Because magnetic members are typically conductive, it is necessary to ensure insulation between the coil and the magnetic member. Even in this case, however, providing a chamfered portion on the coil has the effect of improving insulation. Furthermore, in areas where no magnetic material is inserted, the coils are adjacent to each other circumferentially without any magnetic material in between, so the same effect as in embodiment 1 can be expected.
• appendices an armature disposed opposite to the mover across a gap, a direction facing the mover is defined as a first direction, a direction perpendicular to the first direction in which the mover moves relative to the armature is defined as a second direction, and a direction perpendicular to the first direction and the second direction is defined as a third direction, the coil has a width that changes from the first direction toward the third direction, the coils are stacked in two or more layers in the first direction with an insulator interposed therebetween, at least two of the coils are arranged in the second direction, and chamfered portions are formed at the corners of the coils in a cross section perpendicular to the third direction.
• a rotating electric machine comprising: the armature according to any one of claims 1 to 8; and a mover arranged coaxially opposite the armature with a gap therebetween.
• (Appendix 10) 9.
• a linear motor comprising: an armature according to any one of claims 1 to 8; and a mover arranged linearly opposite the armature with a gap interposed therebetween.

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• 2024
  • 2024-10-21 WO PCT/JP2024/037388 patent/WO2025197166A1/ja active Pending
  • 2024-10-21 JP JP2025544662A patent/JPWO2025197166A1/ja active Pending
• 2025
  • 2025-03-18 TW TW114110033A patent/TW202539133A/zh unknown

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