JP7061194B2 - Stator of rotary electric machine and its manufacturing method - Google Patents

Stator of rotary electric machine and its manufacturing method Download PDF

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JP7061194B2
JP7061194B2 JP2020536403A JP2020536403A JP7061194B2 JP 7061194 B2 JP7061194 B2 JP 7061194B2 JP 2020536403 A JP2020536403 A JP 2020536403A JP 2020536403 A JP2020536403 A JP 2020536403A JP 7061194 B2 JP7061194 B2 JP 7061194B2
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stator
welded portion
electric machine
rotary electric
coil
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JPWO2020031612A1 (en
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健一 中山
俊夫 堀
博光 岡本
雄貴 荒井
雄志 金野
俊一郎 佐藤
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Hitachi Astemo Ltd
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/10—Applying solid insulation to windings, stators or rotors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
    • 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

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

Description

本発明は、回転電機の固定子及びその製造方法に関する。 The present invention relates to a stator of a rotary electric machine and a method for manufacturing the same.

回転電機は、固定子コイルに交流電力を供給することで回転磁界を発生させ、この回転磁界により回転子を回転させることができる。また、回転子に加わる機械エネルギーを電気エネルギーに変換してコイルから交流電力を出力することもできる。このように、回転電機は、電動機または発電機として作動する。 The rotary electric machine generates a rotating magnetic field by supplying AC power to the stator coil, and the rotor can be rotated by this rotating magnetic field. It is also possible to convert the mechanical energy applied to the rotor into electrical energy and output AC power from the coil. In this way, the rotary electric machine operates as a motor or a generator.

本技術分野の背景技術として、以下の先行技術がある。特許文献１（特開２０１１－５４２６３号）には、一対の導体セグメントの端部の先端部を溶融してなる溶融部を周方向一方側に付勢しつつ固化することにより、溶融痕すなわち接合端部を周方向一方側に偏って膨設された形状に形成された回転電機が記載されている。 The following prior arts are the background technologies in this technical field. In Patent Document 1 (Japanese Unexamined Patent Publication No. 2011-54263), a melted portion formed by melting the tip ends of a pair of conductor segments is solidified while being urged to one side in the circumferential direction, whereby a melt mark, that is, a bond is formed. Described is a rotary electric machine formed in a shape in which an end portion is swelled in a biased manner toward one side in the circumferential direction.

また、特許文献２（国際公開２０１３／９９００１号）には、回転電機の小型化と溶接性の改善を実現する回転電機を提供するため、平角導体を曲げ加工して形成したセグメントコイルとセグメントコイルが挿入されるスロットを有する固定子コアとを固定子に有する回転電機において、固定子コアの端面より突出し捻られたセグメントコイルのリード部分の先端に形成された溶接部は、固定子の径方向に並ぶ溶接玉の少なくとも１つが固定子コアの径方向に長い長楕円体であり、長楕円体の長手方向と固定子コアの軸方向とが形成する角度は、固定子コアの中心軸を含むコア切断面状で９０度より小さくする火IT年電機が記載されている。 Further, in Patent Document 2 (International Publication No. 2013/99001), in order to provide a rotary electric machine that realizes miniaturization of the rotary electric machine and improvement of weldability, a segment coil and a segment coil formed by bending a flat conductor are provided. In a rotary electric machine having a stator core having a slot into which the stator is inserted, the welded portion formed at the tip of the lead portion of the segment coil protruding from the end face of the stator core and twisted is in the radial direction of the stator. At least one of the weld balls lined up in is an oblong body that is long in the radial direction of the stator core, and the angle formed between the longitudinal direction of the oblong body and the axial direction of the stator core includes the central axis of the stator core. A fire IT year electric machine that has a core cut surface shape and is smaller than 90 degrees is described.

また、特許文献３（特開２０１６－９３０２７号）には、ステータコイルと絶縁材料により形成される複数のキャップとを含む回転電機ステータにおいて、ステータコイルは、コイルエンドにおいて周方向複数位置で径方向に並んで配置されそれぞれが導体の接合部である複数の接合部を有する。各キャップは、周方向に離れて径方向に伸びる２つの側壁部と、それらの径方向一端を連結する連結部とを有し上下方向両端及び径方向他端が開口する。複数のキャップは、コイルエンドの周方向複数位置において複数の接合部の径方向一端の接合部から径方向他端の接合部の少なくとも一部までを収容し、各キャップ内において接合部に絶縁性樹脂が接着されている回転電機ステータが記載されている。 Further, in Patent Document 3 (Japanese Patent Laid-Open No. 2016-93027), in a rotary electric machine stator including a stator coil and a plurality of caps formed of an insulating material, the stator coil is radially located at a plurality of circumferential positions at the coil end. It has a plurality of joints arranged side by side, each of which is a joint of conductors. Each cap has two side wall portions extending radially apart from each other in the circumferential direction and a connecting portion connecting their radial one ends, and both the vertical end and the radial end are opened. The plurality of caps accommodates from the joint at one end in the radial direction to at least a part of the joint at the other end in the radial direction at multiple positions in the circumferential direction of the coil end, and the joint is insulated in each cap. A rotary electric stator to which a resin is adhered is described.

また、特許文献４（特開２０１４－５０２０７号）には、周方向に並んだ複数のスロットが形成された固定子鉄心、および当該固定子鉄心の前記スロット内に挿入された固定子コイルを有する固定子と、前記固定子鉄心に対して隙間を介して回転可能に配置された回転子１５０と、を備える回転電機において、前記固定子コイルは、略Ｕ字形状に成形された矩形断面の導体からなる複数のセグメントコイルが複数接続されることにより構成され、前記セグメントコイルは端部に他のセグメントコイルと接続された接続部を有し、前記接続部は角部を有する回転電機が記載されている。 Further, Patent Document 4 (Japanese Unexamined Patent Publication No. 2014-50207) has a stator core in which a plurality of slots arranged in the circumferential direction are formed, and a stator coil inserted into the slots of the stator core. In a rotary electric machine including a stator and a rotor 150 rotatably arranged with respect to the stator core through a gap, the stator coil is a conductor having a rectangular cross section formed into a substantially U shape. A rotary electric machine is described in which a plurality of segment coils comprising a plurality of segments are connected, the segment coil has a connection portion connected to another segment coil at an end portion, and the connection portion has a corner portion. ing.

特開２０１１－５４２６３号公報Japanese Unexamined Patent Publication No. 2011-54263 国際公開２０１３／９９００１号International release 2013/99001 特開２０１６－９３０２７号公報Japanese Unexamined Patent Publication No. 2016-93027 特開２０１４－５０２０７号公報Japanese Unexamined Patent Publication No. 2014-50207

この種の回転電機は、成形されたセグメントコイルをコイルエンドで溶接して固定子コイルを形成するが、セグメントコイルの溶接部は熱によって膨張し、温度変化による応力が発生する。このため、セグメントコイルの溶接部が破断し、コイルが断線し、回転電機の動作が不完全になるという課題があった。 In this type of rotary electric machine, a molded segment coil is welded at the coil end to form a stator coil, but the welded portion of the segment coil expands due to heat, and stress due to temperature change is generated. Therefore, there is a problem that the welded portion of the segment coil is broken, the coil is broken, and the operation of the rotary electric machine becomes incomplete.

上記課題を解決するために、例えば特許請求の範囲に記載の構成を採用する。本願は上記課題を解決する手段を複数含んでいるが、その一例を挙げるならば、回転電機用の固定子であって、径方向に開口したスロットが周方向に並んで複数形成された固定子鉄心と、前記スロット内に前記固定子の径方向に配置される複数のセグメントコイルとを備え、前記複数のセグメントコイルには、前記スロットの外部に露出した前記複数のセグメントコイルのそれぞれの端部に形成され、隣接するセグメントコイルを接続する複数の溶接部と、前記複数の溶接部を覆うとともに、前記固定子の径方向に前記溶接部を接続する絶縁被覆部とを有し、軸方向から見た場合、前記複数の溶接部の各々は、隣接して配置される第１セグメントコイルと第２セグメントコイルとを接続するものであって、前記第１セグメントコイルの端部に形成される第１溶接部と、前記第２セグメントコイルの端部に形成される第２溶接部とを含み、前記第１溶接部及び前記第２溶接部の少なくとも一方より、前記固定子の周方向の幅が狭い凹部が形成される第３溶接部が前記第１溶接部と前記第２溶接部との間に設けられ、前記複数の溶接部の少なくとも一つには、前記セグメントコイルの側面より前記径方向の内周側又は外周側に突出する突出部が形成される。 In order to solve the above problems, for example, the configuration described in the claims is adopted. The present application includes a plurality of means for solving the above-mentioned problems. For example, a stator for a rotary electric machine, in which a plurality of slots opened in the radial direction are arranged side by side in the circumferential direction. The iron core is provided with a plurality of segment coils arranged in the slot in the radial direction of the stator, and the plurality of segment coils are each end portion of the plurality of segment coils exposed to the outside of the slot. It has a plurality of welded portions forming the above and connecting adjacent segment coils, and an insulating coating portion that covers the plurality of welded portions and connects the welded portions in the radial direction of the stator. When viewed, each of the plurality of welded portions connects the first segment coil and the second segment coil arranged adjacent to each other, and is formed at the end of the first segment coil. The width of the stator in the circumferential direction is larger than at least one of the first welded portion and the second welded portion, including one welded portion and a second welded portion formed at the end of the second segment coil. A third welded portion in which a narrow recess is formed is provided between the first welded portion and the second welded portion, and at least one of the plurality of welded portions has the radial direction from the side surface of the segment coil. A protruding portion is formed so as to project to the inner peripheral side or the outer peripheral side of the.

本発明によれば、溶接部の剛性を向上できる。前述した以外の課題、構成及び効果は、以下の実施例の説明によって明らかにされる。 According to the present invention, the rigidity of the welded portion can be improved. Issues, configurations and effects other than those mentioned above will be clarified by the description of the following examples.

本発明の実施形態に係る回転電機の全体構成を示す模式図である。It is a schematic diagram which shows the whole structure of the rotary electric machine which concerns on embodiment of this invention. 本発明の実施形態に係る回転電機の固定子を示す斜視図である。It is a perspective view which shows the stator of the rotary electric machine which concerns on embodiment of this invention. 固定子鉄心の斜視図である。It is a perspective view of a stator core. 溶接後のコイルエンドの斜視図である。It is a perspective view of the coil end after welding. 溶接後のコイルエンドの側面図である。It is a side view of the coil end after welding. 溶接後のコイルエンドの平面図である。It is a top view of the coil end after welding. 架橋部の形成後のコイルエンドの斜視図である。It is a perspective view of the coil end after the formation of the cross-linking part. 架橋部の形成後のコイルエンドの断面図である。It is sectional drawing of the coil end after formation of a cross-linking part. セグメントコイルの溶接方向を示す図である。It is a figure which shows the welding direction of a segment coil. セグメントコイルの溶接方向を示す図である。It is a figure which shows the welding direction of a segment coil. 溶接後のコイルエンドの側面図である。It is a side view of the coil end after welding. 治具を用いる溶接方法を示す図である。It is a figure which shows the welding method using a jig. 別の溶接方法を示す図である。It is a figure which shows another welding method.

以下、図面を参照して本発明の実施例を説明する。 Hereinafter, embodiments of the present invention will be described with reference to the drawings.

（回転電機の全体構成）
本実施形態に係る回転電機は、自動車の走行への使用が好適な回転電機である。ここで、回転電機を使用するいわゆる電気自動車には、エンジンと回転電機の両方を備えるハイブリッドタイプの電気自動車（ＨＥＶ）と、エンジンを用いないで回転電機のみで走行する純粋な電気自動車（ＥＶ）とがあるが、以下に説明する回転電機は両方のタイプに利用できる。(Overall configuration of rotary electric machine)
The rotary electric machine according to the present embodiment is a rotary electric machine suitable for use in traveling an automobile. Here, the so-called electric vehicles that use a rotary electric machine include a hybrid type electric vehicle (HEV) that has both an engine and a rotary electric machine, and a pure electric vehicle (EV) that runs only on the rotary electric machine without using an engine. However, the rotary electric machines described below can be used for both types.

図１は、本発明の実施例に係る回転電機１００の全体構成を示す模式図である。図１では、回転電機１００の一部分を断面として、回転電機１００の内部を示している。回転電機１００は、ケース１０の内部に配設され、ハウジング１１２と、ハウジング１１２に固定される固定子鉄心１３２を有する固定子１３０と、固定子１３０内に回転自在に配設される回転子１５０とを有する。ケース１０は、エンジンのケースや変速機のケースによって構成されてもよい。 FIG. 1 is a schematic view showing an overall configuration of a rotary electric machine 100 according to an embodiment of the present invention. FIG. 1 shows the inside of the rotary electric machine 100 with a part of the rotary electric machine 100 as a cross section. The rotary electric machine 100 is arranged inside the case 10, a stator 130 having a stator core 132 fixed to the housing 112, and a rotor 150 rotatably arranged in the stator 130. And have. The case 10 may be composed of an engine case or a transmission case.

この回転電機１００は、永久磁石内蔵型の三相同期モータである。本実施例では、回転電機１００の例として三相同期モータについて説明するが、本発明は誘導モータにも適用できる。 The rotary electric machine 100 is a three-phase synchronous motor with a built-in permanent magnet. In this embodiment, a three-phase synchronous motor will be described as an example of the rotary electric machine 100, but the present invention can also be applied to an induction motor.

本実施例の回転電機１００は、固定子鉄心１３２に巻回される固定子コイル１３８に三相交流電流が供給されることで、回転子１５０を回転させる電動機として作動する。また、回転電機１００は、エンジンによって駆動されると、発電機として作動して三相交流の発電電力を出力する。つまり、回転電機１００は、電気エネルギーに基づいて回転トルクを発生する電動機としての機能と、機械エネルギーに基づいて発電する発電機としての機能の両方を有しており、自動車の走行状態によって前述した機能を選択的に利用できる。 The rotary electric machine 100 of this embodiment operates as an electric motor for rotating the rotor 150 by supplying a three-phase alternating current to the stator coil 138 wound around the stator core 132. Further, when the rotary electric machine 100 is driven by an engine, it operates as a generator and outputs three-phase alternating current generated power. That is, the rotary electric machine 100 has both a function as an electric motor that generates rotational torque based on electric energy and a function as a generator that generates electric power based on mechanical energy, and is described above depending on the running state of the automobile. Functions can be used selectively.

固定子１３０はハウジング１１２に固定されている。固定子１３０は、ハウジング１１２に設けられたフランジ１１５がボルト１２によりケース１０に締結されることによって、ケース１０内に固定され、保持されている。回転軸１１８に固定された回転子１５０は、ケース１０の軸受け１４Ａ、１４Ｂにより支承され、固定子鉄心１３２の内側において回転可能に保持される。 The stator 130 is fixed to the housing 112. The stator 130 is fixed and held in the case 10 by fastening the flange 115 provided on the housing 112 to the case 10 by bolts 12. The rotor 150 fixed to the rotary shaft 118 is supported by the bearings 14A and 14B of the case 10 and is rotatably held inside the stator core 132.

図２は、ハウジング１１２に取り付けられた固定子１３０を示す斜視図であり、図３は固定子鉄心１３２の斜視図である。ハウジング１１２は、厚さ２～５ｍｍ程度の鋼板（高張力鋼板など）を絞り加工によって円筒形状に形成されている。ハウジング１１２の軸方向一端にはフランジ１１５が設けられており、前述したようにケース１０にボルトで固定される（図１参照）。フランジ１１５は、絞り加工によってハウジング１１２と一体に形成される。なお、ハウジング１１２を設けずに、固定子１３０をケース１０に直接固定してもよい。 FIG. 2 is a perspective view showing the stator 130 attached to the housing 112, and FIG. 3 is a perspective view of the stator core 132. The housing 112 is formed by drawing a steel plate (high-strength steel plate or the like) having a thickness of about 2 to 5 mm into a cylindrical shape. A flange 115 is provided at one end of the housing 112 in the axial direction, and is bolted to the case 10 as described above (see FIG. 1). The flange 115 is integrally formed with the housing 112 by drawing. The stator 130 may be directly fixed to the case 10 without providing the housing 112.

固定子１３０は、ハウジング１１２の内周側に固定され、円筒状の固定子鉄心１３２と、固定子鉄心１３２に装着される固定子コイル１３８とを有している。固定子鉄心１３２は、例えば、厚さが０．０５～１．０ｍｍ程度の打ち抜き加工又はエッチング加工によって成形された複数の電磁鋼板１３３を積層して形成される。積層された電磁鋼板１３３は溶接によって接続されて、固定され、ハウジング１１２に圧入した際の締め付け力に起因する電磁鋼板１３３の変形が抑制される。 The stator 130 is fixed to the inner peripheral side of the housing 112 and has a cylindrical stator core 132 and a stator coil 138 mounted on the stator core 132. The stator core 132 is formed by laminating a plurality of electromagnetic steel sheets 133 formed by punching or etching, for example, having a thickness of about 0.05 to 1.0 mm. The laminated electrical steel sheet 133 is connected and fixed by welding, and deformation of the electrical steel sheet 133 due to the tightening force when press-fitted into the housing 112 is suppressed.

固定子鉄心１３２には、軸方向に延在する複数のスロット４２０が周方向に等間隔となるように形成されている。スロット４２０の数は、例えば本実施の形態では７２個である。スロット４２０には、図２に示すように固定子コイル１３８が収容される。図３に示す例では、スロット４２０は開スロットであり、固定子鉄心１３２の内周側には開口が形成されている。この開口の周方向の幅は、固定子コイル１３８が装着される各スロット４２０のコイル装着部とほぼ同等又はコイル装着部よりも若干小さいとよい。 A plurality of slots 420 extending in the axial direction are formed in the stator core 132 so as to be equidistant in the circumferential direction. The number of slots 420 is, for example, 72 in this embodiment. As shown in FIG. 2, the stator coil 138 is housed in the slot 420. In the example shown in FIG. 3, the slot 420 is an open slot, and an opening is formed on the inner peripheral side of the stator core 132. The width of the opening in the circumferential direction may be substantially equal to or slightly smaller than the coil mounting portion of each slot 420 in which the stator coil 138 is mounted.

なお、各スロット４２０内には、絶縁紙（いわゆるスロットライナー）３００が配置されている。絶縁紙３００は、例えば耐熱ポリアミド紙の絶縁シートであり、厚さは０．１～０．５ｍｍ程である。絶縁紙３００は、スロット４２０やコイルエンド１４０ａ、１４０ｂに配設される。絶縁紙３００をスロット４２０に配設することによって、スロット４２０に挿通されるコイルの相互間、及びコイルとスロット４２０の内面との間に配設されて、コイル間やコイルとスロット４２０の内面との間の絶縁耐圧を向上している。 Insulating paper (so-called slot liner) 300 is arranged in each slot 420. The insulating paper 300 is, for example, an insulating sheet of heat-resistant polyamide paper, and has a thickness of about 0.1 to 0.5 mm. The insulating paper 300 is arranged in the slot 420 and the coil ends 140a and 140b. By disposing the insulating paper 300 in the slot 420, the insulating paper 300 is disposed between the coils inserted in the slot 420 and between the coil and the inner surface of the slot 420, and is arranged between the coils and the inner surface of the coil and the slot 420. The insulation withstand voltage between the two is improved.

固定子コイル１３８は、Ｕ字形状の複数のセグメントコイル２８（図４、図７参照）が互いに接続されて形成される。セグメントコイル２８は、その端部がスロット４２０（すなわち固定子１３０）から露出するように、一つの端部が他のセグメントコイル２８と隣接するように配置され、他方の端部がさらに他のセグメントコイル２８と隣接して配置されている。端部が隣接するセグメントコイル２８は、その隣接する端部において互いに接続されることによって、固定子鉄心１３２に巻回される固定子コイル１３８を形成している。 The stator coil 138 is formed by connecting a plurality of U-shaped segment coils 28 (see FIGS. 4 and 7) to each other. The segment coil 28 is arranged so that one end is adjacent to the other segment coil 28 so that its end is exposed from the slot 420 (ie, stator 130) and the other end is the other segment. It is arranged adjacent to the coil 28. The segment coils 28 having adjacent ends form a stator coil 138 wound around the stator core 132 by being connected to each other at the adjacent ends.

また、コイルエンド１４０ａ、１４０ｂに配設される絶縁紙３００は、コイルエンド１４０ａ、１４０ｂにおける相間絶縁や導体間絶縁のためにコイル間に環状に配設される。このように、本実施例の回転電機１００では、スロット４２０の内側やコイルエンド１４０ａ、１４０ｂに絶縁紙３００が配設されているため、コイルの絶縁被膜６００が傷ついたり劣化したりしても、必要な絶縁耐圧を保持できる。 Further, the insulating paper 300 arranged at the coil ends 140a and 140b is arranged in an annular shape between the coils for interphase insulation and interconductor insulation at the coil ends 140a and 140b. As described above, in the rotary electric machine 100 of the present embodiment, since the insulating paper 300 is arranged inside the slot 420 and at the coil ends 140a and 140b, even if the insulating coating 600 of the coil is damaged or deteriorated, The required withstand voltage can be maintained.

スロット４２０間にはティース４３０が形成されており、各ティース４３０は環状のコアバック４４０と一体に成形されている。固定子鉄心１３２は、各ティース４３０とコアバック４４０とが一体に成形された一体型コアとされている。ティース４３０は、固定子コイル１３８によって発生した回転磁界を回転子１５０に導き、回転子１５０に回転トルクを発生させる。 Teeth 430 are formed between the slots 420, and each tooth 430 is integrally molded with the annular core back 440. The stator core 132 is an integrated core in which each tooth 430 and a core back 440 are integrally formed. The teeth 430 guides the rotating magnetic field generated by the stator coil 138 to the rotor 150, and generates a rotational torque in the rotor 150.

回転子１５０は、回転子鉄心１５２と、回転子鉄心１５２に形成された磁石挿入孔に保持されている永久磁石１５４とを有している。 The rotor 150 has a rotor core 152 and a permanent magnet 154 held in a magnet insertion hole formed in the rotor core 152.

回転子鉄心１５２には、直方体形状の磁石挿入孔が外周部近傍において周方向に等間隔で形成されている。各磁石挿入孔には永久磁石１５４が埋め込まれ、接着剤などで固定されている。磁石挿入孔の円周方向の幅は、永久磁石１５４の円周方向の幅よりも大きく形成されており、永久磁石１５４の両側には磁気的空隙１５６が形成されている。この磁気的空隙１５６は接着剤を埋め込んでもよいし，樹脂で永久磁石１５４と一体に固めてもよい。 In the rotor core 152, rectangular parallelepiped magnet insertion holes are formed at equal intervals in the circumferential direction in the vicinity of the outer peripheral portion. Permanent magnets 154 are embedded in each magnet insertion hole and fixed with an adhesive or the like. The circumferential width of the magnet insertion hole is formed to be larger than the circumferential width of the permanent magnet 154, and magnetic voids 156 are formed on both sides of the permanent magnet 154. The magnetic void 156 may be embedded with an adhesive, or may be integrally solidified with the permanent magnet 154 with a resin.

永久磁石１５４は、回転子１５０の界磁極を形成するものである。なお、本実施形態では、一つの永久磁石１５４で一つの磁極を形成する構成としているが、一つの磁極を複数の永久磁石によって構成してもよい。各磁極を形成するための永久磁石を複数に増やすことで、永久磁石が発する各磁極の磁束密度が大きくなり、磁石トルクを増大することができる。永久磁石１５４には、ネオジウム系、サマリウム系の焼結磁石やフェライト磁石、ネオジウム系のボンド磁石などを用いることができるが、永久磁石１５４の残留磁束密度は、０．４～１．３Ｔ程度が望ましく、ネオジウム系の磁石がより適している。各永久磁石１５４間に補助磁極が形成されてもよい。 The permanent magnet 154 forms the field pole of the rotor 150. In the present embodiment, one permanent magnet 154 forms one magnetic pole, but one magnetic pole may be formed by a plurality of permanent magnets. By increasing the number of permanent magnets for forming each magnetic pole to a plurality, the magnetic flux density of each magnetic pole generated by the permanent magnet becomes large, and the magnet torque can be increased. A neodymium-based or sumarium-based sintered magnet, a ferrite magnet, a neodymium-based bonded magnet, or the like can be used as the permanent magnet 154, but the residual magnetic flux density of the permanent magnet 154 is about 0.4 to 1.3 T. Desirably, neodymium magnets are more suitable. Auxiliary magnetic poles may be formed between the permanent magnets 154.

三相交流電流が固定子コイル１３８に供給されることにより固定子１３０に回転磁界が発生すると、この回転磁界が回転子１５０の永久磁石１５４に作用して磁石トルクが発生する。回転子１５０には、この磁石トルクに加えて、上述のリラクタンストルクが発生するので、回転子１５０には上述の磁石トルクとリラクタンストルクとの両方のトルクが回転トルクとして作用し、大きな回転トルクを得ることができる。 When a rotating magnetic field is generated in the stator 130 by supplying a three-phase alternating current to the stator coil 138, this rotating magnetic field acts on the permanent magnet 154 of the rotor 150 to generate magnet torque. In addition to this magnet torque, the above-mentioned relaxation torque is generated in the rotor 150. Therefore, both the above-mentioned magnet torque and the above-mentioned relaxation torque act as the rotation torque in the rotor 150, and a large rotation torque is applied. Obtainable.

図４、図５、図６、図７及び図８は、コイルエンド１４０ｂを示す図であり、図４がコイルエンド１４０ｂの溶接後の斜視図、図５が溶接後の側面図、図６がコイルエンド１４０ｂを端面方向から見た平面図、図７が架橋部４０の形成後の斜視図、図８が架橋部４０の形成後の側面図である。 4, FIG. 5, FIG. 6, FIG. 7, and FIG. 8 are views showing the coil end 140b, FIG. 4 is a perspective view of the coil end 140b after welding, FIG. 5 is a side view after welding, and FIG. A plan view of the coil end 140b as viewed from the end face direction, FIG. 7 is a perspective view after the bridge portion 40 is formed, and FIG. 8 is a side view after the bridge portion 40 is formed.

本実施例では、各スロット４２０に８個のセグメントコイル２８が配置されており、図４に示すように、隣接する二つのセグメントコイル２８の端部が溶接されて接続されて、コイルエンド１４０ｂが構成されている。例えば、ＴＩＧ（Tungsten Inert Gas）溶接などのアーク溶接やプラズマ溶接やレーザ溶接などによって、セグメントコイル２８を構成する銅線の母材を溶融して溶接部３０を形成し、セグメントコイル２８の端部を接続する。 In this embodiment, eight segment coils 28 are arranged in each slot 420, and as shown in FIG. 4, the ends of two adjacent segment coils 28 are welded and connected to form a coil end 140b. It is configured. For example, by arc welding such as TIG (Tungsten Inert Gas) welding, plasma welding, laser welding, etc., the base metal of the copper wire constituting the segment coil 28 is melted to form a welded portion 30, and the end portion of the segment coil 28 is formed. To connect.

溶接部３０には、回転軸１１８に垂直な面において、セグメントコイル２８の径方向の側面に凹部３２が設けられている。隣接するセグメントコイル２８の端部は、被覆や絶縁紙３００の厚さの分だけ隙間２９が設けられるように配置されており、この隙間２９の位置に凹部３２を設けている。換言すると、図６に示すように、溶接部３０は、第１セグメントコイル２８の端部に形成される第１溶接部３４Ａと、第１セグメントコイル２８と隣接して配置される第２セグメントコイル２８の端部に形成される第２溶接部３４Ｂとを含み、さらに、第１溶接部３４Ａ及び第２溶接部３４Ｂの少なくとも一方より、固定子１３０の径方向において幅が狭い凹部３２が形成されている第３溶接部３４Ｃが第１溶接部３４Ａと第２溶接部３４Ｂとの間に設けられている。このように溶接部３０に凹部３２を設けることによって、溶接部３０の表面積が増加し、コイルが冷却油と接触する面積が増加し、冷却油による冷却効果を向上できる。 The welded portion 30 is provided with a recess 32 on the radial side surface of the segment coil 28 on the surface perpendicular to the rotating shaft 118. The ends of the adjacent segment coils 28 are arranged so that a gap 29 is provided by the thickness of the coating or the insulating paper 300, and a recess 32 is provided at the position of the gap 29. In other words, as shown in FIG. 6, the welded portion 30 has a first welded portion 34A formed at the end of the first segment coil 28 and a second segment coil arranged adjacent to the first segment coil 28. A recess 32 having a width narrower in the radial direction of the stator 130 is formed than at least one of the first weld 34A and the second weld 34B, including the second weld 34B formed at the end of the 28. The third welded portion 34C is provided between the first welded portion 34A and the second welded portion 34B. By providing the recess 32 in the welded portion 30 in this way, the surface area of the welded portion 30 is increased, the area where the coil is in contact with the cooling oil is increased, and the cooling effect of the cooling oil can be improved.

さらに、溶接部３０において溶融後に固体化した銅の表面は、溶接用電極５０の移動に伴って加熱状態が変わることから、図６に示すように、溶接部３０の表面の色は、均一ではなく、グラデーションになっている。このように、溶接部３０の表面がグラデーションになることによって、金属光沢を有する単一色より光の反射が抑制でき、画像認識で突出部３１を容易に検出できる。なお、後述する皺３３が形成される側が暗い色になり、皺３３が形成されない側が明るい色になる。 Further, since the heated state of the copper surface solidified after melting in the welded portion 30 changes with the movement of the welding electrode 50, the color of the surface of the welded portion 30 is not uniform as shown in FIG. There is no gradation. As described above, the surface of the welded portion 30 has a gradation, so that the reflection of light can be suppressed as compared with a single color having a metallic luster, and the protruding portion 31 can be easily detected by image recognition. The side where the wrinkles 33 are formed, which will be described later, has a dark color, and the side where the wrinkles 33 are not formed has a bright color.

また、溶接部３０は、図５に示すように、セグメントコイル２８の側面より固定子１３０の径方向の一方（外周方向又は内周方向）に突出する突出部３１を有している。すなわち、突出部３１は、接続すべき複数のセグメントコイル２８の溶接前の重心位置と、当該突出部３１の重心位置とが異なるように、溶接部３０に設けられる。 Further, as shown in FIG. 5, the welded portion 30 has a protruding portion 31 projecting from the side surface of the segment coil 28 in one radial direction (outer peripheral direction or inner peripheral direction) of the stator 130. That is, the protruding portion 31 is provided in the welded portion 30 so that the position of the center of gravity of the plurality of segment coils 28 to be connected before welding is different from the position of the center of gravity of the protruding portion 31.

径方向に突出する突出部３１を溶接部３０に設けることによって、隣接するセグメントコイル２８間の距離を一定に保つことができ、溶接部３０の形状や大きさのバラツキによるコイルの絶縁性能の低下を抑制できる。 By providing the welded portion 30 with a protruding portion 31 projecting in the radial direction, the distance between adjacent segment coils 28 can be kept constant, and the insulation performance of the coil deteriorates due to variations in the shape and size of the welded portion 30. Can be suppressed.

また、突出部３１の一定の形状や大きさに形成することによって、隣接する溶接部３０間の距離が一定になり、後述する架橋部４０を形成するための合成樹脂材料の供給量を溶接部３０間の距離によって制御する必要がなく、架橋部４０を容易かつ確実に形成できる Further, by forming the protruding portion 31 into a constant shape and size, the distance between the adjacent welded portions 30 becomes constant, and the supply amount of the synthetic resin material for forming the crosslinked portion 40, which will be described later, is adjusted to the welded portion. It is not necessary to control by the distance between 30s, and the crosslinked portion 40 can be easily and surely formed.

コイルの溶接は、図９に示すように、電圧を印加した溶接用電極５０を内周側から外周側に移動して、コイルエンド１４０ｂの銅を溶融し、溶融した銅が移動する溶接用電極５０に引っ張られた状態で固体化することによって、突出部３１を形成する。形成される突出部３１の形状や大きさは、溶接用電極５０の移動速度や電流（温度）を制御することによって制御できる。 In coil welding, as shown in FIG. 9, the welding electrode 50 to which a voltage is applied is moved from the inner peripheral side to the outer peripheral side to melt the copper of the coil end 140b, and the molten copper moves to the welding electrode. The protrusion 31 is formed by solidifying in a state of being pulled by 50. The shape and size of the formed protrusion 31 can be controlled by controlling the moving speed and the current (temperature) of the welding electrode 50.

溶接用電極５０の移動は、例えば、内周側から外周側へ１方向のみとして、内周側から外周側へ順次、セグメントコイル２８の端部を溶接してもよい。このようにすると、全ての突出部３１が外周方向に突出するように形成され、固定子１３０に回転子１５０を挿入する際のクリアランスを確保できる。 For example, the welding electrode 50 may be moved in only one direction from the inner peripheral side to the outer peripheral side, and the end portion of the segment coil 28 may be welded sequentially from the inner peripheral side to the outer peripheral side. In this way, all the projecting portions 31 are formed so as to project in the outer peripheral direction, and a clearance for inserting the rotor 150 into the stator 130 can be secured.

また、溶接時の溶接用電極５０の移動は、図１０に示すように、列毎に交互に移動方向を変えてもよい。このようにすると、溶接部３０には、その重心位置が内周側に寄って形成される第１溶接列（列１、列３）と、外周側に寄って形成される第２溶接列（列２）とが形成される。このように溶接用電極５０の移動の方向を列毎に異ならせることによって、溶接用電極５０を外周側から内周側の初期位置に又は内周側から外周側の初期位置に移動する必要がなくなり、効率的に溶接ができ、溶接に要する時間を短縮できる。 Further, as shown in FIG. 10, the moving direction of the welding electrode 50 at the time of welding may be alternately changed for each row. In this way, the welded portion 30 has a first welded row (rows 1 and 3) whose center of gravity is formed closer to the inner peripheral side and a second welded row (rows 1 and 3) formed closer to the outer peripheral side. Column 2) and are formed. By making the direction of movement of the welding electrode 50 different for each row in this way, it is necessary to move the welding electrode 50 from the outer peripheral side to the initial position on the inner peripheral side or from the inner peripheral side to the initial position on the outer peripheral side. Welding can be done efficiently, and the time required for welding can be shortened.

また、図１０に示すように、溶接部３０には溶接の際の溶接用電極５０の移動方向側に、固定子１３０の周方向に延伸する皺３３が形成される。皺３３は、固定子１３０の径方向に並んで複数形成されるとよい。皺３３によって溶接部３０の表面積、すなわちセグメントコイル２８の端部が冷却油と接触する面積が増加し、冷却油による冷却効果を向上できる。 Further, as shown in FIG. 10, a wrinkle 33 extending in the circumferential direction of the stator 130 is formed in the welded portion 30 on the moving direction side of the welding electrode 50 at the time of welding. A plurality of wrinkles 33 may be formed side by side in the radial direction of the stator 130. The wrinkles 33 increase the surface area of the welded portion 30, that is, the area where the end portion of the segment coil 28 comes into contact with the cooling oil, and the cooling effect of the cooling oil can be improved.

本実施例では、隣接するセグメントコイル２８の線材は並行に配置されており、被覆や絶縁紙３００の厚さの分だけ、コイルエンドにおいて母材の銅の間には隙間２９が設けられるが、本実施例の溶接部３０は溶接用電極５０が溶融した銅と共に隙間２９を超えるように移動し、隙間２９の上にも溶融した銅が固体化した溶接部３０が形成される。従来採用されていた溶接用電極５０を移動しないで溶接する方法では、端部が接触するようセグメントコイル２８を曲げていたところ（例えば、特許文献４、特開２０１４－５０２０７号の図１３参照）、本実施例では、図９に示すように、溶接用電極５０を固定子の１３０の径方向に移動させる溶接方法の採用によって、セグメントコイル２８の端部を接触させなくても、セグメントコイル２８を溶接によって確実に接続できる。さらに、セグメントコイル２８を曲げなくてよいので、隣接するコイル間が近接せず、適切な絶縁性を保持できる。 In this embodiment, the wires of the adjacent segment coils 28 are arranged in parallel, and a gap 29 is provided between the copper base materials at the coil end by the thickness of the coating and the insulating paper 300. In the welded portion 30 of this embodiment, the welding electrode 50 moves together with the molten copper so as to exceed the gap 29, and the welded portion 30 in which the molten copper is solidified is also formed on the gap 29. In the conventionally adopted method of welding without moving the welding electrode 50, the segment coil 28 is bent so that the ends are in contact with each other (see, for example, Patent Document 4, FIG. 13 of JP-A-2014-50207). In this embodiment, as shown in FIG. 9, by adopting a welding method in which the welding electrode 50 is moved in the radial direction of the stator 130, the segment coil 28 does not have to touch the ends of the segment coil 28. Can be securely connected by welding. Further, since the segment coil 28 does not have to be bent, the adjacent coils do not come close to each other, and appropriate insulation can be maintained.

コイルエンド１４０ｂは、セグメントコイル２８を溶接によって接続した後、図７、図８に示すように、複数の溶接部３０を接続するようにコーティングを行い架橋部４０を形成する。この架橋部４０は、なお、図８では、架橋部４０の構造が分かり易いように、架橋部４０の内部を示している。架橋部４０は、同じスロット４２０のコイルのコイルエンド１４０ｂが一体となるように固定子１３０の径方向に合成樹脂の被覆を形成する。例えば、架橋部４０は、粉体コーティングによって形成するとよい。また、絶縁ワニスの塗布によって、架橋部４０を形成してもよい。また、絶縁チューブや絶縁キャップで、架橋部４０を構成してもよい。隣接する溶接部３０を径方向に繋ぐように、溶接部３０を覆う絶縁被覆部として機能する架橋部４０を形成することによって、溶接部３０に生じる応力を分散でき、溶接部３０の温度変化による変形や破損（例えば、コイルの破断）を抑制できる。 After the segment coil 28 is connected by welding, the coil end 140b is coated so as to connect a plurality of welded portions 30 as shown in FIGS. 7 and 8 to form a crosslinked portion 40. In FIG. 8, the cross-linked portion 40 shows the inside of the cross-linked portion 40 so that the structure of the cross-linked portion 40 can be easily understood. The cross-linking portion 40 forms a synthetic resin coating in the radial direction of the stator 130 so that the coil ends 140b of the coils of the same slot 420 are integrated. For example, the crosslinked portion 40 may be formed by powder coating. Further, the crosslinked portion 40 may be formed by applying an insulating varnish. Further, the crosslinked portion 40 may be formed by an insulating tube or an insulating cap. By forming the crosslinked portion 40 that functions as an insulating coating portion that covers the welded portion 30 so as to connect the adjacent welded portions 30 in the radial direction, the stress generated in the welded portion 30 can be dispersed, and the temperature of the welded portion 30 changes. Deformation and breakage (for example, breakage of the coil) can be suppressed.

なお、前述したように溶接部３０に突出部３１を設けると、溶接部３０の間隔を一定にでき、架橋部４０を形成するための合成樹脂材料の供給量が一定となり、架橋部４０の形成に便利であるが、溶接部３０に突出部３１を設けずに、架橋部４０を形成してもよい。 If the protruding portion 31 is provided in the welded portion 30 as described above, the interval between the welded portions 30 can be made constant, the supply amount of the synthetic resin material for forming the crosslinked portion 40 becomes constant, and the crosslinked portion 40 is formed. However, the crosslinked portion 40 may be formed without providing the protruding portion 31 in the welded portion 30.

なお、内周側では隣接するスロット４２０に配置されたセグメントコイル２８が近接しているので、固定子１３０の内周側において、架橋部４０が周方向に繋がることがある。このため、全ての溶接部３０がスポーク状に一体に繋がり、溶接部３０の強度をさらに向上でき、クラック等の発生を防止できる。 Since the segment coils 28 arranged in the adjacent slots 420 are close to each other on the inner peripheral side, the cross-linking portion 40 may be connected in the circumferential direction on the inner peripheral side of the stator 130. Therefore, all the welded portions 30 are integrally connected in a spoke shape, the strength of the welded portions 30 can be further improved, and the occurrence of cracks and the like can be prevented.

また、溶接部３０の周囲には冷却油が流れており、架橋部４０に沿って外周側から内周側（又は内周側から外周側）へ冷却油が流れ、冷却油が溶接部３０の切れ目で逃げることがなく、冷却効果を向上できる。特に、架橋部４０が固定子鉄心１３２と結合するように形成された場合、架橋部４０に沿って流れる冷却油が固定子鉄心１３２の内部に流出することなく、溶接部３０を確実に冷却できる。 Further, cooling oil flows around the welded portion 30, cooling oil flows from the outer peripheral side to the inner peripheral side (or from the inner peripheral side to the outer peripheral side) along the crosslinked portion 40, and the cooling oil flows from the welded portion 30. The cooling effect can be improved without escaping at the break. In particular, when the crosslinked portion 40 is formed so as to be bonded to the stator core 132, the cooling oil flowing along the crosslinked portion 40 does not flow out to the inside of the stator core 132, and the welded portion 30 can be reliably cooled. ..

突出部３１は、図５に示すように、同じスロット４２０に配置される（すなわち、コイルエンドが固定子１３０の径方向に並ぶ）コイルの全ての溶接部３０に設けられても、一部の溶接部３０のみに設けられてもよい。例えば、両端を除く溶接部３０に突出部３１が設けられてもよい。すなわち、図１１に示すように、固定子の最内周に設けられる内溶接部３０Ａと、最外周に設けられる外溶接部３０Ｄには突出部３１が設けられず、内溶接部３０Ａと外溶接部３０Ｄとの間の中溶接部３０Ｂ及び３０Ｃに突出部３１が設けられてもよい。なお、固定子の最内周に設けられる内溶接部３０Ａと、最外周に設けられる外溶接部３０Ｄには突出量が小さい突出部３１が設けられ、内溶接部３０Ａと外溶接部３０Ｄとの間の中溶接部３０Ｂ及び３０Ｃに突出量が大きい突出部３１が設けられてもよい。 As shown in FIG. 5, the protrusion 31 is provided in all the welds 30 of the coil arranged in the same slot 420 (that is, the coil ends are arranged in the radial direction of the stator 130), but a part thereof. It may be provided only in the welded portion 30. For example, the protruding portion 31 may be provided in the welded portion 30 excluding both ends. That is, as shown in FIG. 11, the inner welded portion 30A provided on the innermost circumference of the stator and the outer welded portion 30D provided on the outermost circumference are not provided with the protruding portion 31, and the inner welded portion 30A and the outer welded portion 30A and the outer welded portion 30D are not provided. Protruding portions 31 may be provided in the intermediate welded portions 30B and 30C between the portions 30D. The inner welded portion 30A provided on the innermost circumference of the stator and the outer welded portion 30D provided on the outermost periphery are provided with a protruding portion 31 having a small protrusion amount, and the inner welded portion 30A and the outer welded portion 30D are provided with each other. A protruding portion 31 having a large protruding amount may be provided in the middle welded portions 30B and 30C between them.

溶接用電極５０が固定子１３０の径方向に移動する際に、内周側及び外周側の両端の溶接部３０の位置では溶接用電極５０の移動速度や熱条件が変わることがあり、突出部３１の形状や大きさがばらつくことがある。このような場合には、図１１に示すように、固定子１３０の径方向に並ぶ、両端を除くコイルの溶接部３０に突出部３１が設けられるとよい。最内周の溶接部３０に内周側に突出する突出部３１を設けないことによって、固定子１３０に回転子１５０を挿入する際のクリアランスを確保できる。 When the welding electrode 50 moves in the radial direction of the stator 130, the moving speed and thermal conditions of the welding electrode 50 may change at the positions of the welded portions 30 at both ends on the inner peripheral side and the outer peripheral side, and the protruding portion. The shape and size of 31 may vary. In such a case, as shown in FIG. 11, it is preferable that the protrusions 31 are provided in the welded portions 30 of the coils arranged in the radial direction of the stator 130 except for both ends. By not providing the protruding portion 31 projecting to the inner peripheral side in the welded portion 30 on the innermost circumference, it is possible to secure a clearance when inserting the rotor 150 into the stator 130.

また、図１２に示すように、溶接用電極５０が固定子１３０の径方向に移動する際に、コイルの内周側及び外周側に治具６０Ａ、６０Ｂを設けることによって、内周側及び外周側の両端の溶接部３０においても溶接用電極５０の移動速度や熱条件を、両端以外の溶接部３０と同じにできる。この治具６０Ａ、６０Ｂは、セグメントコイル２８の端部と同じ材質のものを用いて、コイルセグメント２８の端部と同様に溶融するとよく、望ましくは同等の熱容量に構成するとよい。このため、内周側及び外周側の両端の溶接部３０の位置では溶接用電極５０の速度や熱条件が変わらずに、全ての溶接部３０において同じ形状の突出部３１を形成できる。 Further, as shown in FIG. 12, when the welding electrode 50 moves in the radial direction of the stator 130, the jigs 60A and 60B are provided on the inner peripheral side and the outer peripheral side of the coil to provide the inner peripheral side and the outer peripheral side. In the welded portions 30 at both ends on the side, the moving speed and thermal conditions of the welding electrode 50 can be made the same as those of the welded portions 30 other than the both ends. The jigs 60A and 60B may be made of the same material as the end portion of the segment coil 28 and may be melted in the same manner as the end portion of the coil segment 28, preferably having the same heat capacity. Therefore, the protrusions 31 having the same shape can be formed in all the welded portions 30 without changing the speed and thermal conditions of the welding electrodes 50 at the positions of the welded portions 30 at both ends on the inner peripheral side and the outer peripheral side.

なお、治具６０Ａ、６０Ｂは内周側及び外周側の両方に配置しても、一方に配置してもよい、特に、外周側はセグメントコイル２８が固定子鉄心１３２に近接していることから、最外周の溶接部３０の突出部３１の突出量を抑制して（又は、突出部３１を形成しないで）、コイルと固定子鉄心１３２の接触を抑制するとよい。 The jigs 60A and 60B may be arranged on both the inner peripheral side and the outer peripheral side, or may be arranged on one of them. In particular, since the segment coil 28 is close to the stator core 132 on the outer peripheral side. It is preferable to suppress the protrusion amount of the protrusion 31 of the welded portion 30 on the outermost periphery (or without forming the protrusion 31) to suppress the contact between the coil and the stator core 132.

また、図１３に示すように、３本以上のセグメントコイル２８を溶接によって接続することも可能である。図では、コイル１からコイル４の４本のコイルエンド１４０ｂが溶接によって接続されており、コイル５からコイル８の４本のコイルエンド１４０ｂが溶接によって接続されている。セグメントコイル２８の端部の近傍で、溶接用電極５０を固定子１３０の径方向に移動させる本実施例の溶接方法では、溶接によって接続すべきコイルが配置される間隔を調整することによって、３以上のセグメントコイル２８を接続できる。 Further, as shown in FIG. 13, it is also possible to connect three or more segment coils 28 by welding. In the figure, the four coil ends 140b of the coil 1 to the coil 4 are connected by welding, and the four coil ends 140b of the coil 5 to the coil 8 are connected by welding. In the welding method of this embodiment in which the welding electrode 50 is moved in the radial direction of the stator 130 in the vicinity of the end of the segment coil 28, the interval in which the coils to be connected by welding are arranged is adjusted to 3. The above segment coil 28 can be connected.

例えば、突出部３１の径方向に突出する長さの２分の１の間隔で配置されたセグメントコイル２８は、突出部３１によって隣接するセグメントコイル２８との間が接続される。一方、突出部３１の径方向に突出する長さの２倍の間隔で配置されたセグメントコイル２８は、隣接するセグメントコイル２８との間が接続されずに、その距離によって定まる絶縁が保たれる。 For example, the segment coils 28 arranged at intervals of half the length of the projecting portions 31 projecting in the radial direction are connected to the adjacent segment coils 28 by the projecting portions 31. On the other hand, the segment coils 28 arranged at intervals of twice the length of the projecting portions 31 projecting in the radial direction are not connected to the adjacent segment coils 28, and the insulation determined by the distance is maintained. ..

次に、本実施例の固定子の製造方法を説明する。溶接工程の前に、セグメントコイル２８をスロット４２０配置する（第１工程）。 Next, a method for manufacturing the stator of this embodiment will be described. Before the welding step, the segment coil 28 is arranged in the slot 420 (first step).

コイルの溶接は、図９に示すように、電圧を印加した溶接用電極５０を内周側から外周側に移動して、セグメントコイル２８の端部の銅を溶融し、溶融した銅が移動する溶接用電極５０に引っ張られた状態で固体化することによって、突出部３１を形成する（第２工程）。溶接用電極５０の移動速度や電流（温度）を制御することによって、形成される突出部３１の形状や大きさを制御できる。シールドガスにはアルゴンやヘリウム、又はアルゴンとヘリウムの混合ガスなどを用いるとよい。 In the welding of the coil, as shown in FIG. 9, the welding electrode 50 to which a voltage is applied is moved from the inner peripheral side to the outer peripheral side to melt the copper at the end of the segment coil 28, and the molten copper moves. The protruding portion 31 is formed by solidifying in a state of being pulled by the welding electrode 50 (second step). By controlling the moving speed and the current (temperature) of the welding electrode 50, the shape and size of the formed protrusion 31 can be controlled. Argon, helium, or a mixed gas of argon and helium may be used as the shield gas.

溶接用電極５０の移動は、例えば、内周側から外周側へ１方向のみとしてもよいし。また、溶接用電極５０の移動は、図１０に示すように、列毎に交互に移動方向を変えてもよい。具体的には、列１では外周側から内周側に溶接用電極５０を移動して溶接する第１列溶接工程を行う。次に、列１と隣接する列２では逆方向である内周側から外周側に溶接用電極５０を移動して溶接する第２列溶接工程を行う。次に、列２と隣接する列３では逆方向である外周側から内周側に溶接用電極５０を移動して溶接する第１列溶接工程を行う。このため、第１列溶接工程で溶接部３０に形成される突出部３１と、第２列溶接工程で溶接部３０に形成される突出部３１とは、固定子１３０の径方向において逆向きに突出するように形成される。このように溶接用電極５０の移動の方向を列毎に異ならせることによって、溶接用電極５０を外周側から内周側の初期位置に又は内周側から外周側の初期位置に移動する必要がなくなり、効率的に溶接ができ、溶接に要する時間を短縮できる。 The welding electrode 50 may be moved in only one direction from the inner peripheral side to the outer peripheral side, for example. Further, as shown in FIG. 10, the welding electrode 50 may be moved in different directions alternately for each row. Specifically, in row 1, a first row welding step is performed in which the welding electrode 50 is moved from the outer peripheral side to the inner peripheral side and welded. Next, in the row 2 adjacent to the row 1, a second row welding step is performed in which the welding electrode 50 is moved from the inner peripheral side to the outer peripheral side in the opposite direction and welded. Next, in the row 3 adjacent to the row 2, the first row welding step is performed in which the welding electrode 50 is moved from the outer peripheral side to the inner peripheral side in the opposite direction and welded. Therefore, the protruding portion 31 formed in the welded portion 30 in the first row welding step and the protruding portion 31 formed in the welded portion 30 in the second row welding step are opposite in the radial direction of the stator 130. It is formed to protrude. By making the direction of movement of the welding electrode 50 different for each row in this way, it is necessary to move the welding electrode 50 from the outer peripheral side to the initial position on the inner peripheral side or from the inner peripheral side to the initial position on the outer peripheral side. Welding can be done efficiently, and the time required for welding can be shortened.

セグメントコイル２８を溶接によって接続した後、図７、図８に示すように、複数の溶接部３０を接続するようにコーティングを行い架橋部４０を形成する（第３工程）。具体的には、同じスロット４２０のコイルのコイルエンド１４０ｂが一体となるように固定子１３０の径方向に合成樹脂の被覆を形成して、架橋部４０を形成する。例えば、架橋部４０は、粉体コーティングによって形成するとよい。また、絶縁ワニスの塗布によって、架橋部４０を形成してもよい。また、絶縁チューブや絶縁キャップで、架橋部４０を構成してもよい。 After connecting the segment coils 28 by welding, as shown in FIGS. 7 and 8, coating is performed so as to connect the plurality of welded portions 30 to form the crosslinked portions 40 (third step). Specifically, a synthetic resin coating is formed in the radial direction of the stator 130 so that the coil ends 140b of the coils of the same slot 420 are integrated to form the crosslinked portion 40. For example, the crosslinked portion 40 may be formed by powder coating. Further, the crosslinked portion 40 may be formed by applying an insulating varnish. Further, the crosslinked portion 40 may be formed by an insulating tube or an insulating cap.

また、図１２に示すように、治具６０Ａ、６０Ｂを用いた溶接時には、溶接用電極５０は、コイル内周側又は外周側の治具６０Ａの位置である開始位置からコイルの反対側の治具６０Ｂの位置である終了位置に移動する。治具６０Ａ、６０Ｂを設けることによって、内周側及び外周側の両端の溶接部３０においても溶接用電極５０の移動速度や熱条件を、両端以外の溶接部３０と同じにできる。この治具６０Ａ、６０Ｂは、セグメントコイル２８の端部と同じ材質のものを用いるよく、望ましくは同等の熱容量に構成するとよい。 Further, as shown in FIG. 12, during welding using the jigs 60A and 60B, the welding electrode 50 cures the opposite side of the coil from the start position which is the position of the jig 60A on the inner peripheral side or the outer peripheral side of the coil. It moves to the end position which is the position of the tool 60B. By providing the jigs 60A and 60B, the moving speed and thermal conditions of the welding electrode 50 can be made the same as those of the welded portions 30 at both ends on the inner peripheral side and the outer peripheral side. The jigs 60A and 60B may be made of the same material as the end of the segment coil 28, and preferably have the same heat capacity.

治具６０Ａ、６０Ｂを設けることによって、内周側及び外周側の両端の溶接部３０の位置では溶接用電極５０の速度や熱条件が変わらずに、全ての溶接部３０において同じ形状の突出部３１を形成できる。 By providing the jigs 60A and 60B, the speed and thermal conditions of the welding electrode 50 do not change at the positions of the welded portions 30 at both ends on the inner peripheral side and the outer peripheral side, and the protruding portions having the same shape in all the welded portions 30. 31 can be formed.

なお、以上の説明はあくまでも一例であり、発明を解釈する際、上記実施の形態の記載事項と特許請求の範囲の記載事項の対応関係に何ら限定も拘束もされない。例えば、上述した実施の形態では回転子に永久磁石を備えた回転電機を例に説明したが、本発明は、誘導モータ等の回転電機の固定子にも同様に適用することができる。また、車両駆動用回転電機以外にも適用できる。また、ある実施の形態の構成の一部を他の実施の形態の構成に置き換えることが可能であり、また、ある実施の形態の構成に他の実施の形態の構成を加えることも可能である。 It should be noted that the above description is merely an example, and when interpreting the invention, there is no limitation or limitation on the correspondence between the description items of the above-described embodiment and the description items of the claims. For example, in the above-described embodiment, a rotary electric machine having a permanent magnet in the rotor has been described as an example, but the present invention can be similarly applied to a stator of a rotary electric machine such as an induction motor. Further, it can be applied to other than the rotary electric machine for driving a vehicle. Further, it is possible to replace a part of the configuration of one embodiment with the configuration of another embodiment, and it is also possible to add the configuration of another embodiment to the configuration of one embodiment. ..

なお、本発明は前述した実施例に限定されるものではなく、添付した特許請求の範囲の趣旨内における様々な変形例及び同等の構成が含まれる。例えば、前述した実施例は本発明を分かりやすく説明するために詳細に説明したものであり、必ずしも説明した全ての構成を備えるものに本発明は限定されない。また、ある実施例の構成の一部を他の実施例の構成に置き換えてもよい。また、ある実施例の構成に他の実施例の構成を加えてもよい。また、各実施例の構成の一部について、他の構成の追加・削除・置換をしてもよい。 It should be noted that the present invention is not limited to the above-mentioned examples, but includes various modifications and equivalent configurations within the scope of the attached claims. For example, the above-mentioned examples have been described in detail in order to explain the present invention in an easy-to-understand manner, and the present invention is not necessarily limited to those having all the described configurations. Further, a part of the configuration of one embodiment may be replaced with the configuration of another embodiment. Further, the configuration of another embodiment may be added to the configuration of one embodiment. In addition, other configurations may be added / deleted / replaced with respect to a part of the configurations of each embodiment.

２８：セグメントコイル
２９：隙間
３０、３０Ａ、３０Ｂ、３０Ｃ、３０Ｄ：溶接部
３１：突出部
３２：凹部
３３：皺
３４Ａ：第１溶接部
３４Ｂ：第２溶接部
３４Ｃ：第３溶接部
４０：架橋部
１００：回転電機
１３０：固定子
１３２：固定子鉄心
１４０ａ、１４０ｂ：コイルエンド
１５０：回転子
４２０：スロット28: Segment coil 29: Gap 30, 30A, 30B, 30C, 30D: Welded portion 31: Protruding portion 32: Recessed portion 33: Wrinkle 34A: First welded portion 34B: Second welded portion 34C: Third welded portion 40: Bridge Part 100: Rotor 130: Stator 132: Stator core 140a, 140b: Coil end 150: Rotor 420: Slot

Claims (5)

回転電機の固定子であって、
径方向に開口したスロットが周方向に並んで複数形成された固定子鉄心と、
前記スロット内に前記固定子の径方向に複数配置されるセグメントコイルとを備え、
前記複数のセグメントコイルには、
前記スロットの外部に露出した前記複数のセグメントコイルのそれぞれの端部に形成され、隣接するセグメントコイルを接続する複数の溶接部と、
前記複数の溶接部を覆うとともに、前記固定子の径方向に前記溶接部を接続する絶縁被覆部とを有し、
軸方向から見た場合、前記複数の溶接部の各々は、隣接して配置される第１セグメントコイルと第２セグメントコイルとを接続するものであって、前記第１セグメントコイルの端部に形成される第１溶接部と、前記第２セグメントコイルの端部に形成される第２溶接部とを含み、
前記第１溶接部及び前記第２溶接部の少なくとも一方より、前記固定子の周方向の幅が狭い凹部が形成される第３溶接部が前記第１溶接部と前記第２溶接部との間に設けられ、
前記複数の溶接部の少なくとも一つには、前記セグメントコイルの側面より前記径方向の内周側又は外周側に突出する突出部が形成される回転電機の固定子。 It is a stator of a rotary electric machine,
A stator core in which a plurality of slots opened in the radial direction are arranged side by side in the circumferential direction, and
A plurality of segment coils arranged in the slot in the radial direction of the stator are provided.
The plurality of segment coils are included in the plurality of segment coils.
A plurality of welded portions formed at the respective ends of the plurality of segment coils exposed to the outside of the slot and connecting adjacent segment coils, and a plurality of welded portions.
It has an insulating coating portion that covers the plurality of welded portions and connects the welded portions in the radial direction of the stator.
When viewed from the axial direction, each of the plurality of welds connects the first segment coil and the second segment coil arranged adjacent to each other, and is formed at the end of the first segment coil. The first welded portion to be formed and the second welded portion formed at the end of the second segment coil are included.
A third welded portion in which a recess having a narrower circumferential width of the stator is formed between at least one of the first welded portion and the second welded portion is between the first welded portion and the second welded portion. Provided in
A stator of a rotary electric machine having a protrusion formed on at least one of the plurality of welds so as to project from the side surface of the segment coil to the inner peripheral side or the outer peripheral side in the radial direction. 請求項１に記載の回転電機の固定子であって、 The stator of the rotary electric machine according to claim 1.
前記溶接部が形成される前は、前記第１セグメントコイルの端部と前記第２セグメントコイルの端部との間には隙間が設けられるように、前記第１セグメントコイル及び前記第２セグメントコイルが前記スロット内に配置される回転電機の固定子。 Before the welded portion is formed, the first segment coil and the second segment coil are provided so that a gap is provided between the end portion of the first segment coil and the end portion of the second segment coil. Is a stator of a rotary electric machine arranged in the slot. 請求項１に記載の回転電機の固定子であって、 The stator of the rotary electric machine according to claim 1.
前記複数の溶接部の各々には、前記固定子の周方向に延伸する皺が複数形成される回転電機の固定子。 A stator of a rotary electric machine in which a plurality of wrinkles extending in the circumferential direction of the stator are formed in each of the plurality of welded portions. 請求項１に記載の回転電機の固定子であって、 The stator of the rotary electric machine according to claim 1.
前記複数の溶接部は、 The plurality of welds are
前記溶接部の重心位置が内周側に寄って形成される第１溶接列と、 The first welding row formed so that the position of the center of gravity of the welded portion is closer to the inner peripheral side, and
前記溶接部の重心位置が外周側に寄って形成される第２溶接列とを含む回転電機の固定子。 A stator of a rotary electric machine including a second welding row formed so that the position of the center of gravity of the welded portion is closer to the outer peripheral side. 請求項１に記載の回転電機の固定子であって、 The stator of the rotary electric machine according to claim 1.
前記複数の溶接部は、前記固定子の最外周に設けられる外溶接部と、前記固定子の最内周に設けられる内溶接部と、前記外溶接部と前記内溶接部との間に設けられる中溶接部とを含み、 The plurality of welded portions are provided between the outer welded portion provided on the outermost periphery of the stator, the inner welded portion provided on the innermost circumference of the stator, and the outer welded portion and the inner welded portion. Including the welded part
前記中溶接部の突出部は前記外溶接部の突出部又は前記内溶接部の突出部より大きい、又は、前記中溶接部には突出部が設けられ、前記外溶接部及び前記内溶接部には突出部が設けられない回転電機の固定子。 The protrusion of the middle weld is larger than the protrusion of the outer weld or the protrusion of the inner weld, or the middle weld is provided with a protrusion, and the outer weld and the inner weld are provided with a protrusion. Is a stator of a rotary electric machine that is not provided with a protrusion.
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