WO2017056949A1 - 回転電機および回転電機の製造方法 - Google Patents
回転電機および回転電機の製造方法 Download PDFInfo
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- WO2017056949A1 WO2017056949A1 PCT/JP2016/076838 JP2016076838W WO2017056949A1 WO 2017056949 A1 WO2017056949 A1 WO 2017056949A1 JP 2016076838 W JP2016076838 W JP 2016076838W WO 2017056949 A1 WO2017056949 A1 WO 2017056949A1
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- core
- electrical machine
- rotating electrical
- coil
- stator
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/18—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/16—Stator cores with slots for windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/16—Stator cores with slots for windings
- H02K1/165—Shape, form or location of the slots
-
- 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
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/024—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with slots
-
- 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
- H02K15/06—Embedding prefabricated windings in machines
- H02K15/062—Windings in slots; salient pole windings
- H02K15/064—Windings consisting of separate segments, e.g. hairpin windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
- H02K3/14—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots with transposed conductors, e.g. twisted conductors
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/28—Layout of windings or of connections between windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
- H02K3/345—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation between conductor and core, e.g. slot insulation
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
- H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
- H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
Definitions
- the present invention relates to a rotating electric machine that can be manufactured with high output, high quality, and low cost, and a method of manufacturing the rotating electric machine.
- Patent Document 1 As a conventional rotating electric machine, there is known a structure of a rotating electric machine in which the stator core is divided in the radial direction to increase the space factor of the coil to achieve high output (for example, see Patent Document 1).
- a stator of a rotating electrical machine that includes an annular structure (outer core) that presses a split core inward in the radial direction of the stator has been proposed.
- the stator core shown in Patent Document 1 includes an annular outer core and a plurality of inner cores divided in the circumferential direction, and by providing connection portions extending from the respective tooth portions to both sides in the circumferential direction.
- the area of the contact surface between the outer core and the inner core is enlarged. This has the effect of reducing the magnetic resistance between the outer core and the inner core and increasing the output of the rotating electrical machine.
- connection portion extending in the circumferential direction from the tooth portion abuts on the other connection portion extending from the adjacent tooth portion, thereby generating a compressive stress between the adjacent inner cores so that each inner core is Since it can be fixed to the outer core without increasing the number of parts, the rotating electrical machine can be manufactured at low cost.
- connection portions extending on both sides in the circumferential direction of the respective inner cores are fitted with the connection portions of other inner cores adjacent in the circumferential direction,
- a compressive stress acts between the adjacent inner cores to increase iron loss.
- the precision of the mold is required, the life of the mold is shortened, and the manufacturing cost of the rotating electrical machine is increased.
- connection portion of the inner core adjacent in the circumferential direction is not fitted in the circumferential direction, the inner core cannot be fixed, so that the outer core and the inner core are separately welded, bonded, filled with resin, etc.
- the fixing means it is necessary to fix by the fixing means, and the material cost and manufacturing cost of the rotating electrical machine increase.
- the present invention has been made to solve the above-described problems, and an object of the present invention is to provide a rotating electrical machine that can be manufactured with high output, high quality, and low cost, and a method for manufacturing the rotating electrical machine.
- the rotating electrical machine according to this invention is A cylindrical outer core, and a plurality of inner cores that are circumferentially arranged along the inner peripheral surface of the outer core and that have a tooth portion and a protrusion extending in the circumferential direction from a radially outer end of the tooth portion.
- a stator comprising a circumferential side surface of the adjacent inner core facing the teeth portion and a coil housed in a slot surrounded by an inner peripheral surface of the protrusion of the adjacent inner core;
- a rotating electrical machine comprising a rotor rotatably supported inside the stator, There is a gap between the circumferential side surfaces of at least two adjacent inner cores,
- the coil includes a first slot storage unit and a second slot storage unit stored in different slots, and A turn portion connecting the first slot storage portion and the second slot storage portion on one end surface in the axial direction of a stator core composed of the outer core and the inner core;
- the turn part is elastically biased in a direction in which the first slot storage part and the second slot storage part are about to leave in the circumferential direction.
- the manufacturing method of the rotating electrical machine according to the present invention is as follows: A cylindrical outer core, and a plurality of inner cores that are circumferentially arranged along the inner peripheral surface of the outer core and that have a tooth portion and a protrusion extending in the circumferential direction from a radially outer end of the tooth portion.
- a stator comprising a circumferential side surface of the adjacent inner core facing the teeth portion and a coil housed in a slot surrounded by an inner peripheral surface of the protrusion of the adjacent inner core;
- a rotor supported rotatably inside the stator, There is a gap between the circumferential side surfaces of at least two adjacent inner cores,
- the coil includes a first slot storage unit and a second slot storage unit stored in different slots, and
- the rotating electrical machine according to the present invention since the adjacent inner cores are not fitted in the circumferential direction, the stress acting on the adjacent inner cores is reduced, and the hysteresis loss due to the alternating magnetic field is reduced. High efficiency of electric machines can be realized.
- the management cost of the inner core mold can be reduced. Furthermore, since it is not necessary to use fixing means such as adhesion, the number of parts and the number of processes can be reduced and the productivity of the rotating electrical machine can be improved.
- the stator winding is brought into a state close to a predetermined dimension in advance by inserting the inner core from the outer peripheral side to the stator winding assembled with a plurality of coils. Since the wire can be formed in advance, an unnecessarily large force does not act between the stator core and the stator winding. Thereby, the reliability with respect to the insulation between a coil and a stator core can be improved.
- FIG. 4 is an enlarged view of a portion surrounded by a circle in FIG. 3.
- FIG. 4 is an enlarged view of a portion surrounded by a circle in FIG. 3.
- FIG. 4 is an enlarged view of the coil which concerns on Embodiment 1 of this invention.
- It is the top view which looked at the coil which concerns on Embodiment 1 of this invention from the axial direction upper direction.
- FIG. 12 is a schematic cross-sectional view taken along line AA in FIG. 11.
- FIG. 13 is an enlarged view of a portion surrounded by a circle in FIG. 12. It is a perspective view of the stator coil
- FIG. 27 is an enlarged view of a portion surrounded by a circle in FIG. 26. It is an example which shows the state of the slot bottom part vicinity which concerns on Embodiment 1 of this invention. It is a figure which shows the state of the slot bottom part vicinity which concerns on Embodiment 6 of this invention.
- FIG. 1 is a perspective view of the rotating electrical machine 100.
- FIG. 2 is a cross-sectional view of the rotating electrical machine 100.
- the rotating electrical machine 100 includes a bottomed cylindrical frame 1a and a housing 1 having a bracket 1b that closes an opening of the frame 1a, a stator 3 fastened to the bracket 1b by bolts 9, a center of the bottom of the frame 1a, and At the center of the bracket 1b, a rotor 2 supported rotatably on the inner peripheral side of the stator 3 via a bearing 4 is provided.
- the rotor 2 is embedded at a predetermined pitch in the circumferential direction in the vicinity of the rotor core 21, the rotating shaft 22 inserted and fixed in the axial center position of the rotor core 21, and the outer peripheral surface of the rotor core 21. And a plurality of permanent magnets 23 which are arranged and constitute magnetic poles.
- the rotor 2 is not limited to a permanent magnet rotor, and a squirrel-cage rotor in which a non-insulated rotor conductor is housed in a slot of a rotor core and both sides are short-circuited by a short-circuit ring, or an insulated conductor. You may use the winding-type rotor which attached the wire to the slot of the rotor core.
- the stator 3 electrically connects a stator core 31, a stator winding 32 (coil rod) attached to the stator core 31, and the stator winding 32 and the stator core 31.
- Insulating paper 14 (insulating member) is provided.
- the stator winding 32 is configured by connecting a plurality of coils 5. That is, the assembly of the coils 5 is the stator winding 32.
- FIG. 3 is a plan view of the rotating electrical machine 100 as viewed from the axial direction. Note that a portion surrounded by a circle includes a cross-sectional view perpendicular to the axial direction.
- FIG. 4 is an enlarged view of a portion surrounded by a circle in FIG.
- the stator 3 has eight poles, the stator core 31 has 48 slots, and the stator winding 32 is described using a three-phase winding. Therefore, the slots 6 of the stator core 31 are formed at a rate of two per phase per pole.
- the stator core 31 includes a cylindrical outer core 31a and a plurality of inner cores 31b arranged in the circumferential direction along the inner peripheral surface of the outer core 31a.
- the inner core 31b includes a tooth portion 31b1 extending radially inward and two protrusions 31b2 extending from the radially outer end of the tooth portion 31b1 toward both sides in the circumferential direction.
- a slot 6 for accommodating the coil 5 is formed surrounded by the opposing circumferential side surface of the teeth 31b1 of the adjacent inner core 31b and the inner peripheral surface of the protrusion 31b2 of the adjacent inner core 31b.
- the insulating paper 14 that electrically insulates the coil 5 and the stator core 31 is accommodated along the wall surface.
- the outer core 31a and the inner core 31b of the stator core 31 are configured by laminating and integrating a predetermined number of electromagnetic steel plates.
- a stator iron core you may employ
- the outer core 31 a is provided with a mounting hole 12 for fixing the stator core 31 in the housing 1.
- a fixing means such as shrink fitting or press fitting, so that productivity can be improved.
- the compressive stress by the fitting mentioned later does not act on the outer core 31a, the hysteresis loss due to the AC magnetic field can be reduced and the efficiency of the rotating electrical machine can be increased.
- the rigidity of the stator core tends to be lower than that of the integral core, but the mounting portion 12A having the mounting hole 12 in which the radial width of the outer core is increased. By providing this, there is an effect of improving the rigidity of the stator core 31.
- the fixing is not limited to the mounting hole 12, and may be fixed by fitting with the frame 1a.
- FIG. 5 is a perspective view of the minimum unit coil 5 constituting the stator winding 32.
- FIG. 6 is a plan view of the coil 5 as viewed from above in the axial direction.
- FIG. 7 is a front view of the coil 5 as viewed from the inside in the radial direction.
- FIG. 8 is a conceptual diagram schematically showing the arrangement of the slot 5 in the slot accommodating portions S1 to S6 of the coil 5 in the slot 6. As shown in FIG.
- the coil 5 has, for example, a shape in which a conductor wire made of continuous copper, aluminum, or the like that is insulation-coated with an enamel resin is wound in an 8-shape when viewed from the inside in the radial direction.
- a conductor wire made of continuous copper, aluminum, or the like that is insulation-coated with an enamel resin is wound in an 8-shape when viewed from the inside in the radial direction.
- oxygen-free copper By using oxygen-free copper, blowholes that occur during welding can be suppressed, which has the effect of improving the reliability of the weld.
- a copper alloy having excellent thermal conductivity such as Cu—Zr may be used. By using a material excellent in thermal conductivity, there is an effect of improving the heat dissipation of the coil 5.
- the coil 5 includes slot accommodating portions S1 to S6 accommodated in the slot 6, turn portions T1 to T5 extending from one slot 6 until accommodated in the other slots 6, and terminal portions H1 at both ends. , E1.
- the first slot storage portion and the second slot storage portion referred to in the claims are in a relationship such that, for example, if the slot storage portion S6 is the first slot storage portion, the slot storage portion S5 becomes the second slot storage portion. .
- slot accommodating portions S1 to S6 of the coil 5 are accommodated in an orderly manner in the radial direction.
- the numbers attached to the upper portions of the slots 6 are serial numbers assigned to the slots 6 for convenience of explanation.
- the third to fifth slots 6 and the ninth to eleventh slots 6 are omitted.
- the positions where the second slots 6 are numbered S1 to S6 indicate the radial positions where the slot accommodating portions S1 to S6 are accommodated, respectively.
- only one coil 5 will be illustrated and described in order to explain the storage positions of the slot storage portions S1 to S6 of the coil 5.
- the slot accommodating portion S1 of a certain coil 5 is accommodated in the position of S1 of the seventh slot 6.
- a conductor wire that protrudes from the seventh slot 6 to the back side of the paper surface of FIG. 8 becomes a turn portion T1 (shown by a broken line) on one end surface of the stator core 31 and is located at the position S2 of the first slot 6. It is continuously connected to the slot storage portion S2 to be stored.
- the conductor wire coming out from the first slot 6 to the front side in FIG. 8 becomes a turn portion T2 (shown by a solid line) and is accommodated at the position of S7 of the seventh slot 6. Continuously connected to S3.
- the conductor wire that protrudes from the seventh slot 6 to the back side in FIG. 8 becomes a turn portion T3 (shown by a broken line) and is accommodated at the position S4 of the thirteenth slot 6. S4 is connected continuously.
- the conductor wire extending from the thirteenth slot 6 to the front side in FIG. 8 becomes a turn portion T4 (shown by a solid line) and is accommodated at the position S5 of the seventh slot 6. Connect to S5 continuously.
- the conductor wire that protrudes from the seventh slot 6 to the back side in FIG. 8 becomes a turn portion T5 (shown by a broken line) and is accommodated at the position of S6 of the first slot 6.
- S6 is connected continuously.
- the slot accommodating portions S1 to S6 of the coil 5 are separated from each other in the circumferential direction by one magnetic pole pitch (spanning six slots in this embodiment) via the turn portions T1 to T5. 6 are sequentially stored in different positions in the radial direction by one conductor wire.
- the terminal part H1 connected to the slot storage part S1 and the terminal part E1 connected to the slot storage part S6 are connected to the terminal parts H1, E1 or neutral points of the other coils 5 and the power feeding part by means of joining such as welding. Is done.
- 48 stator coils 32 are configured by arranging 48 coils 5 thus configured in the circumferential direction and performing predetermined connections.
- At least one location between the protrusions 31b2 of the adjacent inner cores 31b is provided with a gap G without contacting each other in the circumferential direction.
- a gap G By preventing the protrusions 31b2 from contacting each other in the circumferential direction, no compressive stress is applied in the circumferential direction between any adjacent inner cores 31b.
- the stress acting on the stator core 31 can be reduced, the hysteresis loss due to the AC magnetic field can be reduced, and the rotating electrical machine 100 can be made highly efficient.
- the manufacturing cost can be reduced.
- the inner cores are not electrically short-circuited in the laminating direction. Increase efficiency.
- the inner core 31b is arranged in the circumferential direction inside the outer core 31a so that the gap G between the adjacent inner cores 31b is larger than zero.
- the number of divisions in the circumferential direction of the inner core 31b is N
- the position of the two-dot chain line 21g shown in FIG. 4 is the position of the outer peripheral surface of the rotor 2 arranged inside the stator 3.
- the size relationship between the gap G and the air gap L between the outer peripheral surface of the rotor core 21 and the inner tip 31b1s of the teeth 31b1 of the inner core 31b is preferably L> G.
- the gaps G may be distributed over the entire circumference.
- the magnetic resistance in the circumferential direction between the tooth portions 31b1 becomes uniform as compared with the case where the gaps G are concentrated at only one place, thereby reducing cogging torque and torque ripple. be able to.
- the outer core 31a and the inner core 31b are not fitted as described above. Therefore, in the state as it is, the inner core 31b cannot be fixed to the inner peripheral surface of the outer core 31a. Therefore, the inner core 31b is fixed to the inner peripheral surface of the outer core 31a by the coil 5 by utilizing the repulsive force of the coil 5 and the shape of the slot 6.
- FIG. 9 is a schematic view of one turn portion T5 of the coil 5 and two slot accommodating portions S6 and S5 connected to the turn portion T5 as viewed from the inside in the radial direction.
- FIG. 10 is a schematic view in which the state before and after the part of the coil 5 shown in FIG. 9 is inserted into the slot is viewed from the axial direction.
- H indicates a circumferential pitch (width) when the coil 5 is inserted into the slot, and corresponds to one magnetic pole pitch.
- H2 indicates the pitch in the circumferential direction in FIGS. 9 and 10 when the coil 5 is formed in advance.
- the circumferential pitch H2 at the time of forming the coil 5 is set so that H ⁇ H2.
- 11 is a schematic front view of the three coils 5 in which only the slot accommodating portions S5 and S6 and the turn portion T5 are extracted and viewed from the radially inner side of the stator 3.
- 12 is a schematic cross-sectional view taken along line AA in FIG.
- FIG. 13 is an enlarged view of a portion surrounded by a circle in FIG. 12 and 13, only the slot accommodating portion S6 of the fourth coil 5 is shown for convenience of explanation.
- 11 to 13 the outer core 31a actually formed in a cylindrical shape, the inner core 31b formed in an arc shape, and the coil 5 are illustrated in a planar shape for convenience of explanation.
- the turn portions T1 to T5 of the coil 5 are manufactured in advance so that the circumferential width of the turn portions T1 to T5 is larger than that when the coil 5 is stored in the slot 6. And a force (spring repulsive force) to open outward in the circumferential direction is generated.
- the slot accommodating portions S5 and S6 are Spread outward in the direction.
- the slot accommodating portions S5 and S6 are respectively indicated by arrows in FIG. Try to move away from each other.
- the slot accommodating portion S6 moves radially outward along the side wall of the slot 6, hits the protrusion 31b2 via the insulating paper 14, and presses it radially outward.
- the slot accommodating portion S5 of the other coil 5 presses the previous slot accommodating portion S6 on the radially outer side outwardly in the radial direction.
- the other slot accommodating portions S1 to S4 are also moved radially outward along the inner wall of the slot 6, and the protrusion 31b2 is formed as a whole in the slot accommodating portions S6 to S1.
- the outer peripheral surface of the inner core 31b that presses outward in the direction and receives this force is further pressed against the inner peripheral surface of the outer core 31a on the outer side.
- the direction in which the slot accommodating portion S6 presses the inner core 31b diagonally outward in the circumferential direction and the direction in which the slot accommodating portion S5 presses the inner core 31b diagonally outward in the circumferential direction are opposite in the circumferential direction.
- the inner core 31b is firmly fixed to the radially outer side by the resultant force, and vibration noise of the rotating electrical machine 100 can be reduced.
- a cushioning material including, for example, an epoxy resin may be provided between the contact surfaces of the inner core 31b and the outer core 31a.
- the buffer material is preferably an insulating material such as an epoxy material or an acrylic material.
- an insulating material By using an insulating material, there is no electrical short circuit between the inner core 31b and the outer core 31a in the axial direction, so that eddy current loss generated in the stator core 31 can be suppressed.
- the axial length of the inner core 31b is equal to or less than the axial length of the outer core 31a.
- the coil 5 of the present embodiment has been described using a coil having six slot accommodating portions S1 to S6, the coil to be used is an elastic that connects at least two slot accommodating portions and these slot accommodating portions. It is good also considering the coil comprised by one turn part which has as a minimum unit.
- FIG. 14 is a perspective view of the stator winding 32 in which 48 coils 5 are assembled.
- FIG. 15 is a perspective view showing a state in which 48 inner cores 31 b are arranged in the circumferential direction around the stator winding 32.
- FIG. 16 is a perspective view showing a state after the inner core 31 b is inserted into the stator winding 32.
- FIG. 17 is a perspective view showing a state after the outer core 31a is mounted on the outer side of the inner core 31b.
- stator winding 32 is assembled by combining 48 coils 5 in the circumferential direction (stator winding manufacturing process).
- the insulating paper 14 that electrically insulates the coil 5 and the stator core 31 is attached to the stator winding 32 (insulating paper insertion step).
- the inner core 31 b is arranged on the outer peripheral side of the stator winding 32 evenly and radially so as to surround the stator winding 32 (inner core arrangement step).
- all inner cores 31b are gripped by a gripping tool (not shown), and these are moved radially inward so that all the inner cores 31b are uniformly reduced in diameter as shown in FIG.
- the inner core 31b is inserted between the windings 32 (inner core insertion step). At this time, the widths of the turn portions T1 to T5 connecting the two slot storage portions of each coil 5 are contracted and elastically biased.
- the outer core 31a is inserted into the outer side of the inner core 31b from the axial direction (outer core insertion step). Thereafter, when the gripping of the inner core 31b by the above-described gripping tool is released, the widths of all the turn portions T1 to T5 are expanded, and each coil 5 presses the inner core 31b outward in the radial direction as described above.
- the core 31b can be fixed to the inner peripheral surface of the outer core 31a (inner core fixing step).
- the adjacent inner cores 31b are not fitted in the circumferential direction by the gap G, and thus act on the inner core 31b.
- the efficiency of the rotating electrical machine 100 can be increased by reducing the stress to be generated and reducing the hysteresis loss due to the AC magnetic field.
- the management cost of the mold of the inner core 31b can be reduced. Furthermore, since it is not necessary to use fixing means such as adhesion, the number of parts and the number of processes can be reduced and the productivity of the rotating electrical machine 100 can be improved.
- the stator winding 32 can be formed in a state close to a predetermined dimension in advance. Therefore, an unnecessarily large force does not act between the stator core 31 and the stator winding 32. Thereby, the reliability with respect to the insulation between the coil 5 and the stator core 31 can be improved.
- FIG. 18 is a plan view of the stator 203 viewed from the axial direction. Note that a portion surrounded by a circle includes a cross-sectional view perpendicular to the axial direction.
- FIG. 19 is an enlarged view of a portion surrounded by a circle in FIG.
- the inner peripheral surface of the outer core 231a is engaged with a recess 231b3 provided in the axial direction on the outer peripheral surface of the inner core 231b, and protrudes radially inward to position the inner core 231b in the circumferential direction. It has the convex part 231a3 (positioning part) extended in an axial direction. At this time, a gap G is provided between the surfaces facing each other in the circumferential direction of the projection 231b2 (positioning portion) protruding in the circumferential direction from the adjacent inner core 231b. A gap is also provided between the concave portion 231b3 and the convex portion 231a3 so that they do not fit each other.
- the pitch accuracy in the circumferential direction of the teeth portion 231b1 is provided by providing the recessed portion 231b3 and the protruding portion 231a3 for positioning the inner core 231b in the circumferential direction. Therefore, cogging torque and torque ripple can be reduced. In addition, the above-mentioned uneven
- FIG. 20 is a plan view of the stator 303 as seen from the axial direction. Note that a portion surrounded by a circle includes a cross-sectional view perpendicular to the axial direction.
- FIG. 21 is an enlarged view of a portion surrounded by a circle in FIG.
- the inner core 331b according to the present embodiment has a shape having two teeth portions 331b1 by integrating the adjacent inner cores 31b in the first embodiment. By setting it as such a structure, the number of parts can be suppressed and productivity of a rotary electric machine can be improved.
- FIG. 22 is a plan view of the stator 403 as seen from the axial direction.
- 23 is a cross-sectional view perpendicular to the axial direction.
- FIG. 23 is an enlarged view of the portion surrounded by the circle in FIG. Note that a portion surrounded by a circle includes a cross-sectional view perpendicular to the axial direction.
- the inner core 431b has a shape having two teeth portions 431b1 as in the third embodiment.
- a V-shaped concave portion 431a3 (groove) whose cross section perpendicular to the axial direction gradually narrows toward the outer peripheral side is formed in the axial direction.
- a convex portion 431b3 having a V-shaped cross section perpendicular to the axial direction, which is in contact with the concave portion 431a3 of the outer core 431a, is formed in the axial direction.
- the inner peripheral surface of the outer core 431a and the inner peripheral surface of the inner core 431b are configured as described above, so that the inner side By pressing the core 431b radially outward by the coil 5, the inner core 431b is accurately positioned in the circumferential direction, so that the positional accuracy of the tooth portion 431b1 in the circumferential direction can be improved. Thereby, the cogging torque and torque ripple of the rotating electrical machine can be reduced.
- the description has been given using the inner core 431b having the two teeth portions 431b1 as in the third embodiment, but it may be combined with the one having the one teeth portion 31b1 as in the first embodiment. Is possible.
- FIG. 24 is a perspective view of the stator 503.
- the stator 503 has an end plate 515 that presses at least one end surface of the stator core 31 in the axial direction.
- the rigidity of the stator core 531 is improved and the vibration and noise of the rotating electrical machine are suppressed. Can do.
- FIG. 25 is a perspective view of the stator 603.
- FIG. 26 is a plan view of the stator 603 viewed from the axial direction. Note that a portion surrounded by a circle includes a cross-sectional view perpendicular to the axial direction.
- FIG. 27 is an enlarged view of a portion surrounded by a circle in FIG.
- the inner core 631b has a protrusion 631b2 extending in the circumferential direction only on one side in the circumferential direction.
- FIG. 28 is an example showing a state in the vicinity of the slot bottom 31c of the stator 3 according to the first embodiment.
- the slot bottom 31c has a dividing surface 31d in the circumferential direction of the inner core 31b. Therefore, the slot bottom 31c is divided into two in the axial direction at the center. If the insulating paper 14 is made of a thin and soft material, if wrinkles or the like occur in the insulating paper 14, there is a possibility that the insulating paper 14 is caught between the split surfaces 31d of the inner core 31b.
- FIG. 29 is a diagram showing a state in the vicinity of the slot bottom portion 631c of the stator 603 according to the present embodiment.
- the insulating paper 14 since there is no circumferential dividing surface of the inner core 631b at the slot bottom 631c, even if the insulating paper 14 is pressed radially outward by the coil 5, the insulating paper 14 is between the adjacent inner cores 631b. It will not be bitten by. Therefore, the insulating paper 14 is not torn and there is an effect of improving the reliability of the rotating electrical machine. Moreover, since the defect in which the insulating paper 14 is bitten is eliminated, there is an effect of improving the operating rate of equipment and improving the productivity of the rotating electrical machine.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
- Manufacture Of Motors, Generators (AREA)
- Windings For Motors And Generators (AREA)
Abstract
Description
円筒状の外側コアと、前記外側コアの内周面に沿って周方向に配置され、ティース部と前記ティース部の径方向外側端部から周方向に延出する突起を有する複数の内側コアと、
隣り合う前記内側コアの前記ティース部の対向する周方向側面と、隣り合う前記内側コアの前記突起の内周面に囲まれたスロットに収納されるコイルとからなる固定子と、
前記固定子の内側に回転可能に支持された回転子とを備えた回転電機において、
隣り合う少なくとも二つの前記内側コアの周方向側面の間には隙間を有し、
前記コイルは、異なる前記スロットに収納される第一スロット収納部、及び第二スロット収納部と、
前記第一スロット収納部と前記第二スロット収納部とを、前記外側コアと前記内側コアとからなる固定子鉄心の軸方向の一端面上において繋ぐターン部とを有し、
前記ターン部は、前記第一スロット収納部と前記第二スロット収納部とが、周方向に離れようとする方向に弾性付勢されているものである。
円筒状の外側コアと、前記外側コアの内周面に沿って周方向に配置され、ティース部と前記ティース部の径方向外側端部から周方向に延出する突起を有する複数の内側コアと、
隣り合う前記内側コアの前記ティース部の対向する周方向側面と、隣り合う前記内側コアの前記突起の内周面に囲まれたスロットに収納されるコイルとからなる固定子と、
前記固定子の内側に回転可能に支持された回転子とを備え、
隣り合う少なくとも二つの前記内側コアの周方向側面の間には隙間を有し、
前記コイルは、異なる前記スロットに収納される第一スロット収納部、及び第二スロット収納部と、
前記第一スロット収納部と前記第二スロット収納部とを、前記外側コアと前記内側コアとからなる固定子鉄心の軸方向の一端面上において繋ぐターン部とを有する回転電機の製造方法において、
前記コイルを、前記ターン部の周方向の幅が、前記スロットに装着された際の幅より大きくなるように予め成形するコイル製造工程と、
複数の前記コイルを組み立ててコイル籠を構成する固定子巻線製造工程と、
前記内側コアを前記コイル籠の外側に配置する内側コア配置工程と、
前記内側コアを把持して前記内側コアを、径方向内側に移動させて、
各前記コイルの前記ターン部の幅を収縮させながら前記コイル籠に全ての前記内側コアを挿入する内側コア挿入工程と、
前記内側コアを挿入した前記コイル籠の外周側に前記外側コアを軸方向から挿入する外側コア挿入工程とを有するものである。
以下、本発明の実施の形態1に係る回転電機および回転電機の製造方法を図を用いて説明する。
図1は、回転電機100の斜視図である。
図2は、回転電機100の断面図である。
本明細書で、特に断り無く「軸方向」、「周方向」、「径方向」、「内周側」、「外周側」、「内周面」、「外周面」、というときは、それぞれ、固定子の「軸方向」、「周方向」、「径方向」、「内周側」、「外周側」、「内周面」、「外周面」をいうものとする。また、この明細書で、特に断り無く「上」、「下」と言うときは、基準となる場所において、軸方向に垂直な面を想定し、その面を境界として固定子の中心点が含まれる側を「下」、その反対を「上」とする。また、高さの高低を比較する場合は、固定子の中心からの距離が長い方を「高い」とする。
図4は、図3の丸印で囲んだ部分の拡大図である。
説明の便宜上、固定子3は、極数を8極とし、固定子鉄心31のスロット数を48個とし、固定子巻線32は、3相巻線のものを用いて説明する。したがって、固定子鉄心31のスロット6は、毎極毎相当たり2個の割合で形成されている。
なお、取付穴12による固定に限定せず、フレーム1aと嵌合して固定してもよい。
図5は、固定子巻線32を構成する最小単位のコイル5の斜視図である。
図6は、コイル5を軸方向上方から見た平面図である。
図7は、コイル5を径方向内側から見た正面図である。
図8は、コイル5のスロット収納部S1~S6のスロット6内における配置を模式的に示す概念図である。
図4に示すように、隣接する内側コア31bの突起31b2同士の間の少なくとも1箇所は、周方向に互いに当接させずに、隙間Gを設けている。突起31b2同士を周方向に当接させないことにより、隣り合ういずれの内側コア31b間にも周方向に圧縮応力が加わることはない。これにより固定子鉄心31に作用する応力を低減して、交流磁界によるヒステリシス損を低減でき、回転電機100を高効率化できる。
本発明では、外側コア31aと内側コア31bは、上述のように嵌合されていない。したがって、そのままの状態では、内側コア31bを外側コア31aの内周面に固定することはできない。そこで、コイル5の反発力と、スロット6の形状を利用して、コイル5によって各内側コア31bを外側コア31aの内周面に固定する構成としている。
図10は、図9に示したコイル5の一部分が、スロットに挿入される前後の状態を軸方向から見た模式図である。
図9、10において、Hは、コイル5がスロットに挿入されたときの周方向ピッチ(幅)を示し、1磁極ピッチ分に相当する。同様に、H2は、コイル5を予め成形した際の図9、10における周方向のピッチを示す。コイル5の成形時の周方向ピッチH2は、H<H2となるように設定する。
図11は、3つのコイル5のスロット収納部S5、S6とターン部T5だけを抽出し、固定子3の径方向内側から見た正面模式図である。
図12は、図11のA-A線における断面模式図である。
図13は、図12の丸印で囲んだ部分の拡大図である。
なお、図12、13については、4つ目のコイル5のスロット収納部S6だけについても説明の便宜上記載している。
また、図11から図13において、実際は円筒状に形成された外側コア31a、円弧状に形成された内側コア31bおよびコイル5を説明の便宜上、平面状に引き延ばして図示している。
図14は、48個のコイル5を組み立てた固定子巻線32の斜視図である。
図15は、固定子巻線32の周囲に内側コア31bを48個、周方向に配置した状態を示す斜視図である。
図16は、固定子巻線32に内側コア31bを挿入した後の状態を示す斜視図である。
図17は、外側コア31aを内側コア31bの外側に装着した後の状態を示す斜視図である。
以下、本発明の実施の形態2に係る回転電機および回転電機の製造方法を、実施の形態1と異なる部分を中心に説明する。
図18は、固定子203を軸方向から見た平面図である。なお、丸印で囲んだ部分は軸方向に垂直な断面図を含む。
図19は、図18の丸印で囲んだ部分の拡大図である。
以下、本発明の実施の形態3に係る回転電機と回転電機の製造方法を、実施の形態1、2と異なる部分を中心に説明する。
図20は、固定子303を軸方向からみた平面図である。なお、丸印で囲んだ部分は軸方向に垂直な断面図を含む。
図21は、図20の丸印で囲んだ部分の拡大図である。
以下、本発明の実施の形態4に係る回転電機と回転電機の製造方法を、実施の形態1~3と異なる部分を中心に説明する。
図22は、固定子403を軸方向からみた平面図である。なお、丸印で囲んだ部分は軸方向に垂直な断面図である
図23は、図22の丸印で囲んだ部分の拡大図である。なお、丸印で囲んだ部分は軸方向に垂直な断面図を含む。
内側コア431bは、実施の形態3と同様にティース部431b1を2つ有する形状となっている。外側コア431aの内周面には、軸方向に垂直な断面が外周側に次第に狭くなるV字形の凹部431a3(溝)が軸方向に形成されている。そして、内側コアの431bの外周面には、外側コア431aの凹部431a3に沿うように当接する、軸方向に垂直な断面がV字形の凸部431b3が軸方向に形成されている。
以下、本発明の実施の形態5に係る回転電機と回転電機の製造方法を、実施の形態1~4と異なる部分を中心に説明する。
図24は、固定子503の斜視図である。固定子503は、固定子鉄心31の少なくとも一端面を軸方向に押圧する端板515を有する。
以下、本発明の実施の形態6に係る回転電機および回転電機の製造方法を、実施の形態1、5と異なる部分のみを説明する。
図25は、固定子603の斜視図である。
図26は、固定子603を軸方向から見た平面図である。なお、丸印で囲んだ部分は軸方向に垂直な断面図を含む。
図27は、図26の丸印で囲んだ部分の拡大図である。
図27に示すように、内側コア631bは、周方向に延出する突起631b2を周方向一方側のみに有する。内側コア631bをこのような構成とすることで、スロット底部631cに、内側コア631bの周方向分割面がなくなる。
実施の形態1では、図28に示すようにスロット底部31cに、内側コア31bの周方向の分割面31dがある。したがって、スロット底部31cは、中央部で軸方向に2分割されている。絶縁紙14が、薄くて柔らかい材質の材料で作られているような場合、万が一、絶縁紙14に皺などが発生すると、内側コア31bの分割面31dの間にこれが噛み込まれる恐れがある。
Claims (13)
- 円筒状の外側コアと、前記外側コアの内周面に沿って周方向に配置され、ティース部と前記ティース部の径方向外側端部から周方向に延出する突起を有する複数の内側コアと、
隣り合う前記内側コアの前記ティース部の対向する周方向側面と、隣り合う前記内側コアの前記突起の内周面に囲まれたスロットに収納されるコイルとからなる固定子と、
前記固定子の内側に回転可能に支持された回転子とを備えた回転電機において、
隣り合う少なくとも二つの前記内側コアの周方向側面の間には隙間を有し、
前記コイルは、異なる前記スロットに収納される第一スロット収納部、及び第二スロット収納部と、
前記第一スロット収納部と前記第二スロット収納部とを、前記外側コアと前記内側コアとからなる固定子鉄心の軸方向の一端面上において繋ぐターン部とを有し、
前記ターン部は、前記第一スロット収納部と前記第二スロット収納部とが、周方向に離れようとする方向に弾性付勢されている回転電機。 - 前記第一スロット収納部と前記第二スロット収納部は、前記第一スロット収納部と前記第二スロット収納部が収納されるそれぞれの前記スロット内において、前記コイルの導体線一本分だけ径方向に異なる位置に収納されている請求項1に記載の回転電機。
- 前記内側コアの周方向分割数をNとし、N個のそれぞれの内側コアの外周長をJ1、J2、・・・、JN、とし、前記外側コアの内径をKinとするとき、ΣJN<π・Kinである請求項1または請求項2に記載の回転電機。
- 前記回転子の回転子鉄心の外周面と、前記内側コアの前記ティース部の内側先端部との間のエアギャップより、前記隙間の方が小さい請求項1から請求項3のいずれか1項に記載の回転電機。
- 前記内側コアと、前記外側コアは、前記外側コアの内周面上における前記内側コアの周方向の位置決めをする位置決め部を有する請求項1から請求項4のいずれか1項に記載の回転電機。
- 前記位置決め部は、軸方向に延在し、軸方向に垂直な断面がV字状の溝と、前記溝に当接する軸方向に垂直な断面がV字状の凸部である請求項5に記載の回転電機。
- 前記内側コアは、二つ以上の前記ティース部を有する請求項1から請求項6のいずれか1項に記載の回転電機。
- 前記内側コアと外側コアとの間には緩衝材が設けられている請求項1から請求項7のいずれか1項に記載の回転電機。
- 前記固定子鉄心と前記コイルとは、絶縁部材により絶縁されている請求項1から請求項8のいずれか1項に記載の回転電機。
- 前記外側コアには前記固定子をハウジングに取り付けるための、軸方向に延在する取付穴が設けられている請求項1から請求項9のいずれか1項に記載の回転電機。
- 前記固定子鉄心の少なくとも軸方向の一端面には端板が設けられている請求項1から請求項10のいずれか1項に記載の回転電機。
- 前記突起は、前記ティース部の径方向外側端部から周方向一方側にのみ設けられている請求項1から請求項11のいずれか1項に記載の回転電機。
- 円筒状の外側コアと、前記外側コアの内周面に沿って周方向に配置され、ティース部と前記ティース部の径方向外側端部から周方向に延出する突起を有する複数の内側コアと、
隣り合う前記内側コアの前記ティース部の対向する周方向側面と、隣り合う前記内側コアの前記突起の内周面に囲まれたスロットに収納されるコイルとからなる固定子と、
前記固定子の内側に回転可能に支持された回転子とを備え、
隣り合う少なくとも二つの前記内側コアの周方向側面の間には隙間を有し、
前記コイルは、異なる前記スロットに収納される第一スロット収納部、及び第二スロット収納部と、
前記第一スロット収納部と前記第二スロット収納部とを、前記外側コアと前記内側コアとからなる固定子鉄心の軸方向の一端面上において繋ぐターン部とを有する回転電機の製造方法において、
前記コイルを、前記ターン部の周方向の幅が、前記スロットに装着された際の幅より大きくなるように予め成形するコイル製造工程と、
複数の前記コイルを組み立ててコイル籠を構成する固定子巻線製造工程と、
前記内側コアを前記コイル籠の外側に配置する内側コア配置工程と、
前記内側コアを把持して前記内側コアを、径方向内側に移動させて、
各前記コイルの前記ターン部の幅を収縮させながら前記コイル籠に全ての前記内側コアを挿入する内側コア挿入工程と、
前記内側コアを挿入した前記コイル籠の外周側に前記外側コアを軸方向から挿入する外側コア挿入工程とを有する回転電機の製造方法。
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JP6794590B1 (ja) * | 2020-03-05 | 2020-12-02 | 株式会社東芝 | 回転電機の固定子および回転電機 |
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2016
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- 2016-09-12 JP JP2017543088A patent/JP6381820B2/ja not_active Expired - Fee Related
- 2016-09-12 CN CN201680037495.2A patent/CN108028558B/zh active Active
- 2016-09-12 WO PCT/JP2016/076838 patent/WO2017056949A1/ja active Application Filing
- 2016-09-12 DE DE112016004389.9T patent/DE112016004389T5/de not_active Withdrawn
Patent Citations (3)
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JP2001309619A (ja) * | 2000-04-25 | 2001-11-02 | Mitsuba Corp | 回転電機におけるステータコイルの巻装方法 |
JP2011205835A (ja) * | 2010-03-26 | 2011-10-13 | Aisin Aw Co Ltd | ステータの製造方法及びステータ製造用の変形ガイド治具 |
JP2014193038A (ja) * | 2013-03-27 | 2014-10-06 | Aisin Aw Co Ltd | 回転電機用電機子及び回転電機用電機子の製造方法 |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN111226376A (zh) * | 2017-10-26 | 2020-06-02 | 三菱电机株式会社 | 定子、定子组件以及定子的制造方法 |
US11411477B2 (en) | 2020-06-22 | 2022-08-09 | Yoshio Kato | Coil insertion method and coil insertion device |
Also Published As
Publication number | Publication date |
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JP6381820B2 (ja) | 2018-08-29 |
JPWO2017056949A1 (ja) | 2018-02-15 |
CN108028558A (zh) | 2018-05-11 |
CN108028558B (zh) | 2020-03-06 |
US20180145549A1 (en) | 2018-05-24 |
DE112016004389T5 (de) | 2018-06-14 |
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