WO2021130996A1 - Stator coil end structure and manufacturing method - Google Patents

Stator coil end structure and manufacturing method Download PDF

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Publication number
WO2021130996A1
WO2021130996A1 PCT/JP2019/051273 JP2019051273W WO2021130996A1 WO 2021130996 A1 WO2021130996 A1 WO 2021130996A1 JP 2019051273 W JP2019051273 W JP 2019051273W WO 2021130996 A1 WO2021130996 A1 WO 2021130996A1
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WIPO (PCT)
Prior art keywords
coil
stator
diameter side
slot
outer diameter
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PCT/JP2019/051273
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French (fr)
Japanese (ja)
Inventor
和裕 長谷川
洋三 廣瀬
アウレル フナル
Original Assignee
日産自動車株式会社
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Application filed by 日産自動車株式会社 filed Critical 日産自動車株式会社
Priority to PCT/JP2019/051273 priority Critical patent/WO2021130996A1/en
Publication of WO2021130996A1 publication Critical patent/WO2021130996A1/en

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    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

Definitions

  • the present invention relates to a coil end structure of a stator and a manufacturing method.
  • An object of the present invention is to provide a coil end structure that can be easily manufactured and that can suppress an increase in the size of the coil end.
  • the coil end structure of the stator is a coil end structure of a stator including a stator core having a plurality of slots penetrating in the axial direction and a plurality of phases of coils wound around the stator core.
  • the coils wound around the stator are arranged radially in the slot from a plurality of conductor segments whose ends project from one axial end face of the stator core and from different slots among the plurality of ends protruding from the slot. It is composed of a connecting coil that is interposed between two predetermined protruding ends and electrically connects the two ends.
  • FIG. 1 is a perspective view of a main part of a stator to which the coil end structure according to the first embodiment is applied.
  • FIG. 2 is a diagram illustrating the shape of the connection coil of the first embodiment.
  • FIG. 3 is a partially enlarged view of a part of the coil end portion shown in FIG.
  • FIG. 4 is a diagram illustrating a method of manufacturing the coil end portion of the first embodiment.
  • FIG. 5 is a schematic cross-sectional view of the space between the first slots formed by the slot coil of the first embodiment as viewed from a cross section parallel to the radial direction.
  • FIG. 6 is a diagram illustrating a modified example of the shape of the connecting coil of the first embodiment.
  • FIG. 1 is a perspective view of a main part of a stator to which the coil end structure according to the first embodiment is applied.
  • FIG. 2 is a diagram illustrating the shape of the connection coil of the first embodiment.
  • FIG. 3 is a partially enlarged view of a part of the coil end portion
  • FIG. 7 is a schematic cross-sectional view seen from a cross section parallel to the radial direction between the first slot coil formed by the slot coil of the first embodiment and the connection coil according to the modified example.
  • FIG. 8 is a perspective view of a main part of the coil end portion of the second embodiment.
  • FIG. 9 is a schematic cross-sectional view of the space between the first slots formed by the slot coils of the second embodiment as viewed from a cross section parallel to the radial direction.
  • FIG. 1 is a perspective view of a main part of a stator 10 to which the coil end structure according to the first embodiment of the present invention is applied.
  • the stator 10 is one of the main components of a rotary electric machine, and is applied to, for example, a generator or an electric motor included in an electric vehicle.
  • FIG. 1 the upper end surface 11 of the stator core 1, the slot coil 2, and the connecting coil 3 are mainly shown. However, in FIG. 1, parts other than the upper end surface 11 of the stator core 1 (inner peripheral surface, most of the outer peripheral surface, and the lower end) are omitted. In addition, the part where the slot coil 2 and the connection coil 3 are shown in FIG. 1 is generically referred to as a coil end part below.
  • the stator core 1 is formed into a cylindrical shape by laminating steel plates press-formed into a predetermined disk shape.
  • the specific shape of the stator core 1 may be the same as the known shape.
  • the stator core 1 of the present embodiment includes 48 teeth and 48 slots formed between adjacent teeth on the inner diameter side thereof.
  • the slot penetrates in the axial direction of the stator core 1 and is formed in a substantially oval shape that is long in the radial direction of the stator core 1 when viewed from the axial direction, and opens at both end surfaces and the inner peripheral surface of the stator core 1 in the axial direction.
  • a stator coil including a slot coil 2 and a connecting coil 3 is wound around a slot formed in the stator core 1.
  • the terms used in the following description to indicate the axial direction, the radial direction, the circumferential direction, the inner diameter side, the outer diameter side, and the like shall indicate the direction with reference to the stator core 1.
  • the upper end surface or the upper surface is the upper end surface in the axial direction and indicates the surface (upper end surface 11) shown in FIG. 1
  • the lower end surface or the bottom surface is also the lower end surface in the axial direction. It shall indicate the surface opposite to the surface represented by 1.
  • the terms “upper and lower” and “bottom” used here are used only for the sake of ease of explanation when referring to the figure, and are not intended to match the upper and lower terms in the actual direction of gravity.
  • the slot coil 2 of this embodiment is a U-shaped conductor segment. Further, the slot coil 2 is a so-called flat wire, and the wider side surface of the four side surfaces is orthogonal to the radial direction, and the narrow side surface is arranged in the slot so as to be orthogonal to the circumferential direction. Consists of one member. Further, the slot coil 2 is inserted from the bottom surface of the stator core 1 so that the two ends are arranged in different slots. What is shown in FIG. 1 is a portion where the end portion of the slot coil 2 inserted from the bottom surface penetrates the slot and protrudes from the upper end surface 11. FIG. 1 shows a state in which eight slot coils 2 are arranged side by side with a predetermined interval in the radial direction in each slot. The slot coil 2 realizes a wound shape as a stator coil wound around the stator core 1 by being electrically connected to a connection coil 3 described later. Details will be described later with reference to FIG. 2 and the like.
  • the connection coil 3 is a thin plate-shaped conductive member.
  • the connection coil 3 has a function of interposing between two predetermined slot coils 2 in the radial direction at the coil end portion and conducting the two predetermined slot coils 2.
  • the predetermined two are two slot coils 2 that form a stator coil corresponding to any one phase in realizing a stator coil that is wound around the stator core 1 for each phase.
  • the stator coil of the present embodiment is configured by alternately joining the slot coil 2 and the connecting coil 3.
  • FIG. 2 is a diagram illustrating the shape of the connection coil 3 of the present embodiment.
  • FIG. 2A is a front view of the connection coil 3 before being provided in the stator core 1 as viewed from the front.
  • FIG. 2B is a perspective view of the connection coil 3 provided on the stator core 1 as viewed from above on the inner diameter side.
  • connection coil 3 of the present embodiment is a flat thin plate as shown in FIG. 2A, and has a square protruding portion on the upper end side at the peripheral end portion thereof.
  • the connecting coil 3 is a conductive member as described above, but its surface is covered with an insulating film except for the conductive surfaces 3a and 3b shown in the drawing.
  • the insulating film may be made of ceramic, resin, or the like, and is not particularly limited as long as it has insulating properties.
  • the conductive surfaces 3a and 3b may be formed by masking a predetermined portion when covering the connecting coil 3 with an insulating film.
  • the conduction surface 3a of the present embodiment is formed on the outer diameter side surface of the protruding portion formed at the upper end of one circumferential end portion (one end) of the connection coil 3.
  • the conductive surface 3b is formed on the inner diameter side surface of the protruding portion formed at the upper end of the other circumferential end (other end) of the connecting coil 3.
  • FIG. 2B when the connecting coil 3 is provided in the stator core 1, it is bent and straightened so as to have an arc shape that is convex toward the outer diameter side when viewed from the upper end and the lower end.
  • connection coil 3 has an aspect ratio that can be easily straightened in an annular shape using a straightening jig, and has a circumferential length (connection length) from the conductive surface 3a to the conductive surface 3b. It is formed so that the plate thickness (diameter thickness) with respect to the aspect ratio is sufficiently thin.
  • the surface area of the connecting coil 3 can be increased by forming the connecting coil 3 on a thin plate.
  • the heat conduction (heat receiving or heat radiating) area of the connecting coil 3 with the refrigerant can be increased, so that the cooling efficiency of the stator 10 can be improved.
  • stator coil configured in this way.
  • FIG. 3 is an enlarged partially enlarged view of a part of the coil end portion shown in FIG. The figure shows a state in which the slot coil 2 and the connecting coil 3 form an electric path for each phase at the coil end portion.
  • slot coils 2 in the present embodiment are arranged in the radial direction for each slot as shown in the figure. Then, between the slot coils 2 arranged in the row on the outermost diameter side and the slot coils 2 arranged in the second row counting from the outer diameter side (between the first slot coils), counting from the outer diameter side. Between the slot coil 2 arranged in the third row and the slot coil 2 arranged in the fourth row counting from the outer diameter side (between the second slot coils), and arranged in the fifth row counting from the outer diameter side. Between the slot coil 2 and the slot coil 2 arranged in the 6th row counting from the outer diameter side (between the 3rd slot coil), and the slot arranged in the 7th row counting from the outer diameter side.
  • the connecting coil 3 is displaced in the circumferential direction by one slot from each other in the radial direction. It is laminated and intervenes. Although it cannot be read from the figure, seven connecting coils 3 are laminated between one slot coil.
  • connection coil 3 indicated by the arrow A in the figure is arranged between the first slot coils, and the conduction surface 3a formed on the outer diameter side at the upper end of one of the circumferential ends is on the outermost diameter side.
  • the conductive surface 3b formed on the inner diameter side at the upper end of the other circumferential end while being joined to the inner diameter side of the slot coil 2 arranged in the second row is indicated by the arrow C arranged in the second row. It is arranged so as to be joined to the outer diameter side of the slot coil 2.
  • the slot coil 2 located on the outermost diameter side at least the portion of the inner diameter side surface of the slot coil 2 that is joined to the conduction surface 3a is a conduction surface that can be electrically connected to the connection coil 3. It is configured to be.
  • the slot coil 2 (see arrow C) located in the second row from the outer diameter side at least a portion of the outer diameter side surface of the slot coil 2 that is joined to the conductive surface 3b can be electrically connected to the connecting coil 3. It is configured to be a conductive surface.
  • the stator coil constituting any one phase the slot coil 2 in the first row and the stator coil 2 in the second row are electrically connected via the connection coil 3 arranged between the first slot coils.
  • connection coil 3 arranged between the other end of the slot coil 2 in the second row from the outer diameter side (see arrow C) and the second slot coil, and the slot coil 2 in the third row from the outer diameter side. are connected in the same way.
  • the slot coil 2 and the connecting coil 3 are alternately connected to each other by joining the conductive surfaces between the first slot coil and the fourth slot coil, so that the slot coil 2 and the connecting coil 3 are wound around the stator core 1 in a so-called distributed winding.
  • a rotating stator coil can be formed to form an electrical path for each phase. A method of manufacturing a stator coil constituting such an electric path will be described with reference to FIG.
  • FIG. 4 is a diagram illustrating a method of manufacturing a coil end portion of the stator 10 of the present embodiment in particular.
  • FIG. 4A shows a state in which a plurality of connection coils 3 in a state of being bent and straightened by a straightening jig (not shown) are subassembled in an annular shape so as to correspond between the first to fourth slot coils. It is a figure which shows.
  • FIG. 4B is a diagram showing a state in which the slot coil 2 inserted into the stator core 1 from the bottom surface side protrudes from the upper end surface and before the connecting coil 3 is fitted.
  • a sub-assembly composed of a plurality of connecting coils 3 formed in an annular shape along the annular shape between one of the first to fourth slot coils is also referred to as a connecting coil group below.
  • connecting coil group corresponding to one slot coil 48 connecting coils 3 are overlapped with respect to the adjacent connecting coil 3 by one slot in the circumferential direction of either clockwise or counterclockwise. In this state, it is formed by bending and straightening in an annular shape with a straightening jig (not shown). What is shown in FIG. 4A is a group of annular connection coils corresponding to each of the first to fourth slot coils.
  • connection coil group corresponding to the inner diameter side of the slot coil is formed with respect to the diameter of the ring formed by the connection coil group corresponding to the first slot coil located on the outermost outer diameter side.
  • the diameter of the annulus is smaller. Therefore, the circumferential length (connection length) of the connection coil 3 needs to be appropriately adjusted according to the radial position between the slot coils to be fitted. Therefore, the circumferential length of the connection coil 3 of the present embodiment is set to the circumferential length of seven slots of the stator core 1 at the radial position between the slot coils to be fitted.
  • the connection coil group configured in this way is inserted between the first to fourth slot coils of the coil end portion shown in FIG. 4B at the same time from above in the axial direction or for each slot coil.
  • the coil end portion of the present embodiment is formed by joining the opposing conductive surfaces of the slot coil 2 and the connecting coil 3 to each other.
  • the coil end portion can be assembled by first forming the annular shape with only the connecting coil 3 and inserting the annular shape between the corresponding first to fourth slot coils from the axial direction. Therefore, the stator 10 can be assembled easily and at high speed without requiring a complicated molding process such as wire forming and press bending as in the conventional case.
  • FIG. 5 is a schematic cross-sectional view of the coil end portion of the present embodiment as viewed from a cross section parallel to the radial direction between the first slots formed by the slot coil 2 indicated by the arrow B in FIG.
  • the right side of the figure is the outer diameter side.
  • the space between the first slot coils is a space formed by facing a portion (notch portion) formed thinner in the radial direction than the other portion at the end portion of the slot coil 2. More specifically, between the first slot coils, the slot coils 2 having notches on the inner diameter side of one end and the outer diameter side of the other end have the notches facing each other in the same slot. It is a space formed by being adjacent to each other. However, the space between the first slot coils does not necessarily have to be formed by the slot coils 2 having a notch.
  • the first slot coils may be formed by bending the slot coils 2 having the same radial thickness in a crank shape (see the crank portion 23 shown in FIG. 9).
  • seven connecting coils 3 are configured to overlap in the radial direction between the first slots of the present embodiment.
  • the connecting coil 3 is inserted between the first slots in a state of being bent and straightened in an annular shape by a straightening jig as described above with reference to FIG.
  • the restoring force of the connecting coil 3 generates a force in the direction toward the outer diameter side (see the white arrow in the figure), and the force on the outer diameter side of the connecting coil 3 is generated.
  • the surface abuts against the inner diameter side surface of the slot coil 2.
  • the connecting coil 3 is held at a predetermined position between the first slots.
  • the conductive surface 3a of the connecting coil 3 By joining the conductive surface 3b and the conductive surface 2b formed at least on the outer diameter side of the other end of the slot coil 2 in contact with the conductive surface 3b, a phase-by-phase electric path as a stator coil can be created. It is composed.
  • the bonding between the conductive surfaces may be realized by, for example, welding.
  • the restoring force of the connecting coil 3 is strong, the contact resistance between the conductive surface 3a of the connecting coil 3 and the conductive surface 3a of the slot coil 2, and the conductive surface 3b of the connecting coil 3 and the conductive surface 3b of the slot coil 2. If the contact resistance satisfies a predetermined criterion for the stator coil, the slot coil 2 and the connecting coil 3 may be joined by the conductive surfaces being strongly contacted with each other by the restoring force of the connecting coil 3.
  • the predetermined standard may be appropriately set according to the characteristics required for the electric motor to which the stator is applied. Thereby, the stator coil including the slot coil 2 and the connection coil 3 can be formed.
  • the two slot coils 2 can be electrically connected by the connecting coil 3 made of a plate-shaped member, which has the following merits as compared with the conventional case. That is, in the past, in order to connect the slot coils, complicated bending molding was required to avoid interference with other slot coils, whereas in this embodiment, complicated bending molding is not required. Therefore, the manufacturing cost can be reduced.
  • the slot coil and / or the connecting member connecting the slot coils is complicatedly bent or made into multiple phases. While there is a problem that the coil end portion becomes larger in the axial direction due to overlapping, in the present embodiment, it is sufficient to stack the plate-shaped connecting coil 3 between the slot coils 2, so that the coil end is sufficient. The axial height of the part can be reduced.
  • the two slot coils can be connected by the connecting coil 3 at the shortest straight line distance. , Copper loss generated in the stator coil can be reduced.
  • the connecting coil 3 does not necessarily have to have a protruding portion as shown in FIG. 3, and may be a rectangular connecting coil 30 as shown in FIG.
  • the connection coil 30 includes a conductive surface 30a formed on the outer diameter side of one circumferential end portion and a conductive surface 30b formed on the inner diameter side of the other circumferential end portion.
  • the connection coil 30 having such a shape is also bent and straightened in an annular shape like the connection coil 3, and is arranged between the two predetermined slot coils 2.
  • a specific configuration example of the connection coil 30 arranged between the two predetermined slot coils 2 will be described with reference to FIG. 7.
  • FIG. 7 is a coil end portion of this modified example, and is a schematic cross-sectional view seen from a cross section parallel to the radial direction between the first slot coils formed by the two slot coils 2 as in FIG.
  • the right side of the figure is the outer diameter side.
  • connection coil 30 is held at a predetermined position between the first slots by the restoring force of the connecting coil 30 as described with reference to FIG.
  • the conduction surface 30a of the connection coil 30 and the conduction surface 3a of the slot coil 2 and the conduction surface 30b of the connection coil 30 and the conduction surface 3b of the slot coil 2 are conducted by the restoring force of the connection coil 30.
  • the surfaces may be joined by contacting each other, or may be joined by welding.
  • the conductive surfaces may be joined by the following method. That is, in this modification, the conduction surface 30a of the connection coil 30 and the slot coil 2 are conductive by applying forces from both sides (inner diameter side and outer diameter side) of the two slot coils 2 sandwiching the plurality of stacked connection coils 30. The surface 3a and the conductive surface 30b of the connecting coil 30 and the conductive surface 3b of the slot coil 2 may be pressed and plastically deformed to join them.
  • the straightening jig 6 shown in FIG. 7 may be used.
  • the straightening jig 6 presses against the upper ends of the two slot coils 2 forming between the first slot coils from above in the axial direction the straightening jig 6 comes into contact with the outer diameter side of the upper ends of the slot coils 2 located on the outer diameter side.
  • the slot coil 2 is provided with an inclination 6a for moving the slot coil 2 to the inner diameter side, and an inclination 6b for abutting the inner diameter side of the upper end of the slot coil 2 located on the inner diameter side and moving the slot coil 2 to the outer diameter side.
  • the stator core 1 having a plurality of slots penetrating in the axial direction and the multi-phase coil (stator coil) wound around the stator core 1 are provided. It is a coil end structure of the stator 10.
  • the coils wound around the stator 10 are arranged in a slot in a radial direction, and a plurality of conductor segments (slot coils 2) whose ends project from one axial end surface (upper end surface 11) of the stator core 1 and a slot. It is composed of a connection coil 3 that is interposed between two predetermined ends protruding from different slots among a plurality of ends protruding from the two ends and electrically connects the two ends.
  • the two ends have a first conductive surface (conducting surface 2a) on the inner diameter side of the stator at one end, and also have a first conductive surface (conducting surface 2a).
  • a second conductive surface (conducting surface 2b) is provided on the outer diameter side of the stator at the other end, and the connecting coil 3 is a plate-shaped member and has a third conductive surface on the outer diameter side of the stator at one end in the circumferential direction of the stator.
  • the two slot coils 2 can be electrically connected by the connecting coil 3 made of a plate-shaped member, so that the two slot coils 2 can be connected by the connecting coil 3 at the shortest straight distance. Copper loss generated in the stator coil can be reduced.
  • the conductor segment (slot coil 2) has a U-shape, and the first conductive surface (conducting surface 2a) is attached to one end of one conductor segment. ), And a second conductive surface (conducting surface 2b) at the other end of the other conductor segment.
  • a distributed winding stator coil can be realized by forming a coil end portion provided with the connecting coil 3 only on one axial end surface, so that it is possible to suppress an increase in the axial length. it can.
  • one end portion has a first notch (notch portion) on the inner diameter side of the stator, and the other end portion is on the outer diameter side of the stator. It has a second notch (notch portion), and the connecting coil 3 is held between the first notch and the second notch.
  • the stator 10 including the stator coil including the slot coil 2 and the connecting coil 3 can be realized without increasing the size in the radial direction.
  • the connecting coil 3 is a flat plate-shaped member whose longitudinal direction coincides with the circumferential direction of the stator, and is bent in an annular shape along the annular shape of the stator core. It is held between the two ends in a straightened state. As a result, the connecting coil 3 can be easily held at a predetermined position between the two slot coils 2 by the restoring force to the flat plate shape.
  • the coil manufacturing method of the first embodiment is a method of manufacturing a coil (stator coil) wound around a stator core 1 having a plurality of slots penetrating in the axial direction, and is a method of manufacturing a plurality of conductor segments (slot coil 2). ) Are arranged side by side at predetermined intervals in the radial direction of the slots, the ends of the conductor segments are projected from the axial end faces of the stator core 1, and two of the ends of the plurality of conductor segments are adjacent to each other in the radial direction.
  • a plurality of connecting coils 3 as plate-like members are inserted between one end portion in the axial direction, and the inner diameter side surface of the end portion arranged on the outer diameter side of the two adjacent end portions and the connecting coil 3
  • the surfaces on the inner diameter side of the are joined together.
  • the coil end portion can be assembled by inserting the connecting coil 3 between the slot coils 2 from the axial direction, so that a complicated molding process such as wire forming or press bending as in the conventional case is not required.
  • the stator 10 can be assembled easily and at high speed.
  • the complicated molding process that has been conventionally required becomes unnecessary, the manufacturing cost can be reduced.
  • FIG. 8 is a schematic configuration diagram illustrating the coil structure of the stator 20 of the second embodiment. In the figure, only the coil end portion is shown.
  • the slot coil 22 of the present embodiment has a crank portion 23 formed by bending toward the outer diameter side at the coil end portion and further bending upward (outward in the axial direction). Details between the first slot coils formed by such slot coils 22 will be described with reference to FIG.
  • FIG. 9 is a schematic configuration diagram of the coil end portion of the present embodiment as viewed from a cross section parallel to the radial direction between the first slot coils formed by the two slot coils 22.
  • the right side of the figure is the outer diameter side, and the slot coil 22 located on the outer diameter side is formed with a crank portion 23.
  • crank portion 23 By forming such a crank portion 23 on the slot coil 22, the surface on the outer diameter side of the slot coil 22 located on the inner diameter side and the surface on the inner diameter side of the slot coil 22 located on the outer diameter side are formed.
  • the formed space can be expanded in the radial direction.
  • the radial thickness of the connecting coil 3 arranged in the space can be further increased. Therefore, for example, even when the cross-sectional area optimized from the viewpoint of reducing copper loss is taken into consideration, the axial length having a larger radial thickness than that of the connection coil 3 of the first embodiment can be obtained. Since it can be shortened, the axial height of the coil end portion can be made smaller even if the crank portion 23 is added.
  • crank portion 23 does not necessarily have to be bent toward the outer diameter side as shown in the figure, and may be bent toward the inner diameter side. Further, the crank portion 23 does not necessarily have to be bent at a right angle to the outer diameter side as shown in the drawing, and may be formed so as to be inclined upward on the outer diameter side or the inner diameter side and bent outward in the axial direction. In that case, the name of the crank portion 23 is the inclined portion 23.
  • the conductor segment (slot coil 22) is bent toward the outer diameter side or the inner diameter side in the stator radial direction and is bent outward in the axial direction. It has an inclined portion 23 that is inclined toward the outer diameter side or the inner diameter side in the stator radial direction and is bent outward in the axial direction.
  • the space formed by the outer diameter side surface of the slot coil 22 located on the radial side and the inner diameter side surface of the slot coil 22 located on the outer diameter side can be expanded in the radial direction.
  • the slot coil 2 has a U-shape in the above embodiment
  • the U-shape here does not necessarily have to be a U-shape having a curved line. It suffices if both ends face in one direction and each end can be inserted into a different slot of the stator core, including a substantially U-shape composed of a straight line.
  • the slot coil 2 does not necessarily have to be U-shaped, and may have a rod shape in which both ends face in opposite directions.
  • the coil end portions described in the above-described embodiment are formed on both end faces in the axial direction of the stator core 1.
  • connection coil 3 described above 7 slots
  • number of connection coils 3 constituting the connection coil group 48 sheets
  • the number between the slot coils (1st to 4th total 4).
  • Etc. are examples, and may be appropriately changed according to the number of slots of the applicable stator core and the number of windings of the stator coil to be wound.

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

Abstract

This stator coil end structure is provided with: a stator core which has a plurality of slots formed to run through in the axial direction; and a plurality of phases of coils wound on the stator core. The coils wound on the stator comprise: a plurality of conductor segments that are arranged side by side in the slots in the radial direction and that have ends projected from one axial-direction-end surface of the stator core; and a connection coil that is provided between prescribed two ends projected from different slots, among the plurality of ends projected from the slots, so as to electrically connect the two ends.

Description

ステータのコイルエンド構造、及び製造方法Coil end structure of stator and manufacturing method
　本発明は、ステータのコイルエンド構造、及び製造方法に関する。 The present invention relates to a coil end structure of a stator and a manufacturing method.
　従来、ステータに巻き回されるコイルにおいて、ステータのスロットに略Ｕ字形状の導体セグメントを複数挿入し、挿入した複数の導体セグメントの端部を所定形状に屈曲させ、屈曲させた端部同士を溶接により接合することでコイルエンドを形成する技術が開示されている（ＪＰ２０１４－１０７８７６Ａ及びＪＰ２０１３－２７１７５Ａを参照）。 Conventionally, in a coil wound around a stator, a plurality of substantially U-shaped conductor segments are inserted into the slots of the stator, the ends of the inserted plurality of conductor segments are bent into a predetermined shape, and the bent ends are combined with each other. Techniques for forming coil ends by joining by welding are disclosed (see JP2014-107876A and JP2013-27175A).
　しかしながら、ＪＰ２０１４－１０７８７６Ａ及びＪＰ２０１３－２７１７５Ａに開示された上記のコイルは、複数の導体セグメントの端部を屈曲させてから相互に接続させるという方法で形成されるため、導体セグメントを複雑な形状に屈曲させる必要がある。このため、コイルエンドのサイズが大きくなり、ステータを載置するスペースが拡大してしまうという課題がある。また、このようなコイルエンドを形成する必要があるために製造工程が複雑化し、製造コストが大きくなるという課題もある。 However, since the above coils disclosed in JP2014-107876A and JP2013-27175A are formed by bending the ends of a plurality of conductor segments and then connecting them to each other, the conductor segments are bent into a complicated shape. I need to let you. Therefore, there is a problem that the size of the coil end becomes large and the space for mounting the stator increases. Further, since it is necessary to form such a coil end, there is also a problem that the manufacturing process is complicated and the manufacturing cost is increased.
　本発明は、容易に製造でき、且つ、コイルエンドのサイズが大きくなることを抑制することができるコイルエンド構造を提供することを目的とする。 An object of the present invention is to provide a coil end structure that can be easily manufactured and that can suppress an increase in the size of the coil end.
　本発明の一態様におけるステータのコイルエンド構造は、軸方向に貫通する複数のスロットを有するステータコアと、ステータコアに巻き回される複数相のコイルと、を備えるステータのコイルエンド構造である。ステータに巻き回されるコイルは、スロットに径方向に並んで配置されステータコアの一方の軸方向端面から端部が突出する複数の導体セグメントと、スロットから突出する複数の端部のうち異なるスロットから突出する所定の二つの端部間に介在し当該二つの端部を電気的に接続する接続コイルと、から構成される。 The coil end structure of the stator according to one aspect of the present invention is a coil end structure of a stator including a stator core having a plurality of slots penetrating in the axial direction and a plurality of phases of coils wound around the stator core. The coils wound around the stator are arranged radially in the slot from a plurality of conductor segments whose ends project from one axial end face of the stator core and from different slots among the plurality of ends protruding from the slot. It is composed of a connecting coil that is interposed between two predetermined protruding ends and electrically connects the two ends.
　本発明の実施形態については、添付された図面とともに以下に詳細に説明する。 The embodiments of the present invention will be described in detail below together with the attached drawings.
図１は、第１実施形態に係るコイルエンド構造が適用されたステータの要部斜視図である。FIG. 1 is a perspective view of a main part of a stator to which the coil end structure according to the first embodiment is applied. 図２は、第１実施形態の接続コイルの形状を説明する図である。FIG. 2 is a diagram illustrating the shape of the connection coil of the first embodiment. 図３は、図１で示すコイルエンド部の一部を拡大した部分拡大図である。FIG. 3 is a partially enlarged view of a part of the coil end portion shown in FIG. 図４は、第１実施形態のコイルエンド部を製造する方法を説明する図である。FIG. 4 is a diagram illustrating a method of manufacturing the coil end portion of the first embodiment. 図５は、第１実施形態のスロットコイルが形成する第１スロット間を径方向に平行な断面から見た概略断面図である。FIG. 5 is a schematic cross-sectional view of the space between the first slots formed by the slot coil of the first embodiment as viewed from a cross section parallel to the radial direction. 図６は、第１実施形態の接続コイルの形状の変形例を説明する図である。FIG. 6 is a diagram illustrating a modified example of the shape of the connecting coil of the first embodiment. 図７は、第１実施形態のスロットコイルと変形例に係る接続コイルとが形成する第１スロットコイル間を径方向に平行な断面から見た概略断面図である。FIG. 7 is a schematic cross-sectional view seen from a cross section parallel to the radial direction between the first slot coil formed by the slot coil of the first embodiment and the connection coil according to the modified example. 図８は、第２実施形態のコイルエンド部の要部斜視図である。FIG. 8 is a perspective view of a main part of the coil end portion of the second embodiment. 図９は、第２実施形態のスロットコイルが形成する第１スロット間を径方向に平行な断面から見た概略断面図である。FIG. 9 is a schematic cross-sectional view of the space between the first slots formed by the slot coils of the second embodiment as viewed from a cross section parallel to the radial direction.
　＜第１実施形態＞
　図１は、本発明の第１実施形態に係るコイルエンド構造が適用されたステータ１０の要部斜視図である。ステータ１０は、回転電機の主要構成部品の一つであって、例えば、ジェネレータや、電動車両が備える電動モータに適用される。 <First Embodiment>
FIG. 1 is a perspective view of a main part of a stator 10 to which the coil end structure according to the first embodiment of the present invention is applied. The stator 10 is one of the main components of a rotary electric machine, and is applied to, for example, a generator or an electric motor included in an electric vehicle.
　図１では、ステータコア１の上端面１１と、スロットコイル２と、接続コイル３とが主に示されている。ただし、図１では、ステータコア１の上端面１１以外の部分（内周面、外周面の大部分、および下端）は省略されている。なお、図１においてスロットコイル２と接続コイル３とが示された部分を総称して、以下ではコイルエンド部と称する。 In FIG. 1, the upper end surface 11 of the stator core 1, the slot coil 2, and the connecting coil 3 are mainly shown. However, in FIG. 1, parts other than the upper end surface 11 of the stator core 1 (inner peripheral surface, most of the outer peripheral surface, and the lower end) are omitted. In addition, the part where the slot coil 2 and the connection coil 3 are shown in FIG. 1 is generically referred to as a coil end part below.
　ステータコア１は、所定の円板形状にプレス形成された鋼板が積層されて、円筒形状に形成される。ステータコア１の具体的な形状は、公知の形状と同様であってよい。具体的な一例として、本実施形態のステータコア１は、その内径側に、４８個のティースと、隣接するティース間に形成される４８個のスロットとを備えている。スロットは、ステータコア１の軸方向に貫通し、軸方向から見てステータコア１の径方向に長い略長円形状に形成されており、ステータコア１の軸方向の両端面と内周面とに開口している。このステータコア１に形成されたスロットに、スロットコイル２と接続コイル３とからなるステータコイルが巻き回される。 The stator core 1 is formed into a cylindrical shape by laminating steel plates press-formed into a predetermined disk shape. The specific shape of the stator core 1 may be the same as the known shape. As a specific example, the stator core 1 of the present embodiment includes 48 teeth and 48 slots formed between adjacent teeth on the inner diameter side thereof. The slot penetrates in the axial direction of the stator core 1 and is formed in a substantially oval shape that is long in the radial direction of the stator core 1 when viewed from the axial direction, and opens at both end surfaces and the inner peripheral surface of the stator core 1 in the axial direction. ing. A stator coil including a slot coil 2 and a connecting coil 3 is wound around a slot formed in the stator core 1.
　なお、以下の説明において用いられる軸方向、径方向、周方向、内径側、及び外径側等の方向を示す用語は、特に指定しない限り、ステータコア１を基準とする方向を示すものとする。また、上端面あるいは上面は、軸方向の上端面であって、図１で表されている面（上端面１１）を示し、下端面あるいは底面は、同じく軸方向の下端面であって、図１で表されている面の逆側の面を示すものとする。ただし、ここで用いられる上下、底の用語は、図を参照した際の説明のし易さのために用いたにすぎず、現実の重力方向における上下等と一致させる意図ではない。 Unless otherwise specified, the terms used in the following description to indicate the axial direction, the radial direction, the circumferential direction, the inner diameter side, the outer diameter side, and the like shall indicate the direction with reference to the stator core 1. Further, the upper end surface or the upper surface is the upper end surface in the axial direction and indicates the surface (upper end surface 11) shown in FIG. 1, and the lower end surface or the bottom surface is also the lower end surface in the axial direction. It shall indicate the surface opposite to the surface represented by 1. However, the terms "upper and lower" and "bottom" used here are used only for the sake of ease of explanation when referring to the figure, and are not intended to match the upper and lower terms in the actual direction of gravity.
　本実施形態のスロットコイル２は、Ｕ字型の導体セグメントである。またスロットコイル２は、いわゆる平角線であって、４つの側面のうち広い方の側面が径方向に直行し、細い方の側面が周方向に直交するようにしてスロット内に配置され、ステータ１０の一部材を構成する。また、スロットコイル２は、ステータコア１の底面から、二つの端部がそれぞれ異なるスロットに配置されるように挿入される。図１に示されているのは、底面から挿入されたスロットコイル２の端部がスロットを貫通して上端面１１から突出した部分である。図１では、８本のスロットコイル２が、各スロットにおいて径方向に所定の間隔を有して並んで配置されている状態が示されている。スロットコイル２は、後述する接続コイル３と電気的に接続されることによって、ステータコア１に巻き回されるステータコイルとしての巻回形状を実現する。詳細は、図２等を用いて後述する。 The slot coil 2 of this embodiment is a U-shaped conductor segment. Further, the slot coil 2 is a so-called flat wire, and the wider side surface of the four side surfaces is orthogonal to the radial direction, and the narrow side surface is arranged in the slot so as to be orthogonal to the circumferential direction. Consists of one member. Further, the slot coil 2 is inserted from the bottom surface of the stator core 1 so that the two ends are arranged in different slots. What is shown in FIG. 1 is a portion where the end portion of the slot coil 2 inserted from the bottom surface penetrates the slot and protrudes from the upper end surface 11. FIG. 1 shows a state in which eight slot coils 2 are arranged side by side with a predetermined interval in the radial direction in each slot. The slot coil 2 realizes a wound shape as a stator coil wound around the stator core 1 by being electrically connected to a connection coil 3 described later. Details will be described later with reference to FIG. 2 and the like.
　接続コイル３は、薄板状の導電部材である。接続コイル３は、コイルエンド部において、径方向における所定の二つのスロットコイル２の間に介在し、当該所定の二つのスロットコイル２を導通させる機能を有する。ここでの所定の二つとは、ステータコア１に相毎に巻き回されるステータコイルを実現するにあたって、任意の一つの相に対応するステータコイルを構成する二つのスロットコイル２である。本実施形態のステータコイルは、スロットコイル２と接続コイル３とが交互に接合されて構成される。ステータコイルの詳細の説明に先立って、本実施形態の接続コイル３の形状の詳細について、図２を参照して説明する。 The connection coil 3 is a thin plate-shaped conductive member. The connection coil 3 has a function of interposing between two predetermined slot coils 2 in the radial direction at the coil end portion and conducting the two predetermined slot coils 2. The predetermined two here are two slot coils 2 that form a stator coil corresponding to any one phase in realizing a stator coil that is wound around the stator core 1 for each phase. The stator coil of the present embodiment is configured by alternately joining the slot coil 2 and the connecting coil 3. Prior to the detailed description of the stator coil, the details of the shape of the connection coil 3 of the present embodiment will be described with reference to FIG.
　図２は、本実施形態の接続コイル３の形状を説明する図である。図２（ａ）は、ステータコア１に備えられる前の接続コイル３を正面から見た正面図である。図２（ｂ）は、ステータコア１に備えられた状態における接続コイル３を内径側の上方から見た斜視図である。 FIG. 2 is a diagram illustrating the shape of the connection coil 3 of the present embodiment. FIG. 2A is a front view of the connection coil 3 before being provided in the stator core 1 as viewed from the front. FIG. 2B is a perspective view of the connection coil 3 provided on the stator core 1 as viewed from above on the inner diameter side.
　本実施形態の接続コイル３は、図２（ａ）で示すような平らな薄板であって、その周方向端部における上端側に角形状の突出部を有する。接続コイル３は、上記の通り導電部材であるが、その表面は、図示する導通面３ａ、３ｂ以外は絶縁膜で覆われている。絶縁膜は、セラミックや樹脂等で構成されてよく、絶縁性を有している限り特に制限されない。導通面３ａ、３ｂは、接続コイル３を絶縁膜で覆う際に所定部分をマスキングすること等により形成されてよい。 The connection coil 3 of the present embodiment is a flat thin plate as shown in FIG. 2A, and has a square protruding portion on the upper end side at the peripheral end portion thereof. The connecting coil 3 is a conductive member as described above, but its surface is covered with an insulating film except for the conductive surfaces 3a and 3b shown in the drawing. The insulating film may be made of ceramic, resin, or the like, and is not particularly limited as long as it has insulating properties. The conductive surfaces 3a and 3b may be formed by masking a predetermined portion when covering the connecting coil 3 with an insulating film.
　図示するように、本実施形態の導通面３ａは、接続コイル３の一方の周方向端部（一方端）における上端に構成された突出部の外径側の面に形成される。また、導通面３ｂは、接続コイル３の他方の周方向端部（他方端）における上端に構成された突出部の内径側の面に形成される。図２（ｂ）で示すように、接続コイル３がステータコア１に備わる際には、上端及び下端から見て外径側に凸な円弧状となるように曲げ矯正される。 As shown in the figure, the conduction surface 3a of the present embodiment is formed on the outer diameter side surface of the protruding portion formed at the upper end of one circumferential end portion (one end) of the connection coil 3. Further, the conductive surface 3b is formed on the inner diameter side surface of the protruding portion formed at the upper end of the other circumferential end (other end) of the connecting coil 3. As shown in FIG. 2B, when the connecting coil 3 is provided in the stator core 1, it is bent and straightened so as to have an arc shape that is convex toward the outer diameter side when viewed from the upper end and the lower end.
　なお、接続コイル３は、矯正治具を用いて容易に円環状に矯正することが可能なようなアスペクト比が設定されるとともに、導通面３ａから導通面３ｂまでの周方向長さ（接続長さ）に対する板厚（径方向厚）が十分薄くなるように形成される。 The connection coil 3 has an aspect ratio that can be easily straightened in an annular shape using a straightening jig, and has a circumferential length (connection length) from the conductive surface 3a to the conductive surface 3b. It is formed so that the plate thickness (diameter thickness) with respect to the aspect ratio is sufficiently thin.
　そして、導通面３ａ、３ｂが形成された接続コイル３が曲げ矯正された状態で二つのスロットコイル２の間に嵌め込まれると、接続コイル３の平板状態（直線状態）へ復元しようとする力（復元力）が発生する。この復元力は外径側に向かう方向（図中の白抜き矢印参照）に作用し、接続コイル３の外径側の面の少なくとも一部が外径側に位置するスロットコイル２の内径側に押し当たるとともに、接続コイル３の内径側の面の少なくとも一部が内径側に位置するスロットコイル２の外径側に押し当たる。その結果、接続コイル３は、二つのスロットコイル２間に保持される。この状態で、スロットコイル２に押し当てられた接続コイル３の導通面３ａ、３ｂとスロットコイル２の所定位置とが接合されることによって、任意の相の電気経路を構成するステータコイルを形成することができる。 Then, when the connecting coil 3 on which the conductive surfaces 3a and 3b are formed is fitted between the two slot coils 2 in a bent and corrected state, a force that tries to restore the connecting coil 3 to the flat plate state (straight line state) ( Restoring force) is generated. This restoring force acts in the direction toward the outer diameter side (see the white arrow in the figure), and at least a part of the outer diameter side surface of the connecting coil 3 is on the inner diameter side of the slot coil 2 located on the outer diameter side. At the same time, at least a part of the inner diameter side surface of the connecting coil 3 is pressed against the outer diameter side of the slot coil 2 located on the inner diameter side. As a result, the connecting coil 3 is held between the two slot coils 2. In this state, the conductive surfaces 3a and 3b of the connection coil 3 pressed against the slot coil 2 and the predetermined positions of the slot coil 2 are joined to form a stator coil that constitutes an electric path of an arbitrary phase. be able to.
　なお、接続コイル３の断面積とスロットコイル２の断面積とを同じ面積とする場合には、接続コイル３を薄板上に形成したことによって接続コイル３の表面積を大きくすることができる。その結果、接続コイル３の冷媒との熱伝導（受熱又は放熱）面積を大きくとることができるので、ステータ１０の冷却効率を向上させることができる。 When the cross-sectional area of the connecting coil 3 and the cross-sectional area of the slot coil 2 have the same area, the surface area of the connecting coil 3 can be increased by forming the connecting coil 3 on a thin plate. As a result, the heat conduction (heat receiving or heat radiating) area of the connecting coil 3 with the refrigerant can be increased, so that the cooling efficiency of the stator 10 can be improved.
　このように構成されるステータコイルの詳細について、図３を参照して以下に説明する。 The details of the stator coil configured in this way will be described below with reference to FIG.
　図３は、図１で示すコイルエンド部の一部を拡大した部分拡大図である。図では、コイルエンド部において、スロットコイル２と接続コイル３とが相毎の電気経路を構成している状態が示されている。 FIG. 3 is an enlarged partially enlarged view of a part of the coil end portion shown in FIG. The figure shows a state in which the slot coil 2 and the connecting coil 3 form an electric path for each phase at the coil end portion.
　具体的には、本実施形態におけるスロットコイル２は、図示するようにスロット毎に径方向に８個（８列）並べられている。そして、最も外径側の列に配置されたスロットコイル２と、外径側から数えて２列目に配置されたスロットコイル２との間（第１スロットコイル間）、外径側から数えて３列目に配置されたスロットコイル２と、外径側から数えて４列目に配置されたスロットコイル２との間（第２スロットコイル間）、外径側から数えて５列目に配置されたスロットコイル２と、外径側から数えて６列目に配置されたスロットコイル２との間（第３スロットコイル間）、及び、外径側から数えて７列目に配置されたスロットコイル２と、外径側から数えて８列目に配置されたスロットコイル２との間（第４スロットコイル間）に、接続コイル３が互いにスロット一つ分周方向にずれながら、径方向に積層して介在している。なお、図からは読み取れないが、一つのスロットコイル間には、７枚の接続コイル３が積層している。 Specifically, eight slot coils 2 in the present embodiment are arranged in the radial direction for each slot as shown in the figure. Then, between the slot coils 2 arranged in the row on the outermost diameter side and the slot coils 2 arranged in the second row counting from the outer diameter side (between the first slot coils), counting from the outer diameter side. Between the slot coil 2 arranged in the third row and the slot coil 2 arranged in the fourth row counting from the outer diameter side (between the second slot coils), and arranged in the fifth row counting from the outer diameter side. Between the slot coil 2 and the slot coil 2 arranged in the 6th row counting from the outer diameter side (between the 3rd slot coil), and the slot arranged in the 7th row counting from the outer diameter side. Between the coil 2 and the slot coil 2 arranged in the 8th row counting from the outer diameter side (between the 4th slot coil), the connecting coil 3 is displaced in the circumferential direction by one slot from each other in the radial direction. It is laminated and intervenes. Although it cannot be read from the figure, seven connecting coils 3 are laminated between one slot coil.
　スロットコイル２と接続コイル３とで形成される電気経路の詳細について、代表して図中の矢印Ａで示された接続コイル３を用いて説明する。図中の矢印Ａで示された接続コイル３は、第１スロットコイル間に配置されており、一方の周方向端部の上端における外径側に形成された導通面３ａが、最も外径側に配置された矢印Ｂで示すスロットコイル２の内径側に接合するとともに、他方の周方向端部の上端における内径側に形成された導通面３ｂが、２列目に配置された矢印Ｃで示すスロットコイル２の外径側に接合するように配置される。 The details of the electric path formed by the slot coil 2 and the connecting coil 3 will be described with reference to the connecting coil 3 indicated by the arrow A in the figure. The connection coil 3 indicated by the arrow A in the figure is arranged between the first slot coils, and the conduction surface 3a formed on the outer diameter side at the upper end of one of the circumferential ends is on the outermost diameter side. The conductive surface 3b formed on the inner diameter side at the upper end of the other circumferential end while being joined to the inner diameter side of the slot coil 2 arranged in the second row is indicated by the arrow C arranged in the second row. It is arranged so as to be joined to the outer diameter side of the slot coil 2.
　一方で、最も外径側に位置するスロットコイル２（矢印Ｂ参照）は、スロットコイル２の内径側の面における少なくとも導通面３ａと接合する部分が接続コイル３と電気的に接続可能な導通面となるように構成されている。また、外径側から２列目に位置するスロットコイル２（矢印Ｃ参照）は、スロットコイル２の外径側の面における少なくとも導通面３ｂと接合する部分が接続コイル３と電気的に接続可能な導通面となるように構成されている。これにより、任意の一相を構成するステータコイルにおいて、一列目のスロットコイル２と２列目のステータコイル２とが第１スロットコイル間に配置された接続コイル３を介して電気的に接続される。 On the other hand, in the slot coil 2 located on the outermost diameter side (see arrow B), at least the portion of the inner diameter side surface of the slot coil 2 that is joined to the conduction surface 3a is a conduction surface that can be electrically connected to the connection coil 3. It is configured to be. Further, in the slot coil 2 (see arrow C) located in the second row from the outer diameter side, at least a portion of the outer diameter side surface of the slot coil 2 that is joined to the conductive surface 3b can be electrically connected to the connecting coil 3. It is configured to be a conductive surface. As a result, in the stator coil constituting any one phase, the slot coil 2 in the first row and the stator coil 2 in the second row are electrically connected via the connection coil 3 arranged between the first slot coils. To.
　そして、外径側から２列目のスロットコイル２（矢印Ｃ参照）の他方の端部と第２スロットコイル間に配置された接続コイル３と、外径側から３列目のスロットコイル２とが同様に接続される。このようにして、第１スロットコイル間から第４スロットコイル間においてスロットコイル２と接続コイル３とが互いの導通面を接合させて交互につながることにより、ステータコア１に対していわゆる分布巻きで巻き回されるステータコイルを形成し、相毎の電気経路を構成することができる。このような電気経路を構成するステータコイルの製造方法について、図４を参照して説明する。 Then, the connection coil 3 arranged between the other end of the slot coil 2 in the second row from the outer diameter side (see arrow C) and the second slot coil, and the slot coil 2 in the third row from the outer diameter side. Are connected in the same way. In this way, the slot coil 2 and the connecting coil 3 are alternately connected to each other by joining the conductive surfaces between the first slot coil and the fourth slot coil, so that the slot coil 2 and the connecting coil 3 are wound around the stator core 1 in a so-called distributed winding. A rotating stator coil can be formed to form an electrical path for each phase. A method of manufacturing a stator coil constituting such an electric path will be described with reference to FIG.
　図４は、本実施形態のステータ１０の特にコイルエンド部を製造する方法を説明する図である。図４（ａ）は、不図示の矯正治具によって曲げ矯正された状態の複数の接続コイル３が、第１から第４スロットコイル間にそれぞれ対応するように円環状にサブ組立された状態を示す図である。図４（ｂ）は、ステータコア１に底面側から挿入されたスロットコイル２が上端面から突出している状態であって、接続コイル３が嵌め込まれる前の状態を示す図である。なお、第１から第４スロットコイル間のうちの一つのスロットコイル間の円環形状に沿う円環状に形成された複数の接続コイル３からなるサブ組立を、以下では接続コイル群とも称する。 FIG. 4 is a diagram illustrating a method of manufacturing a coil end portion of the stator 10 of the present embodiment in particular. FIG. 4A shows a state in which a plurality of connection coils 3 in a state of being bent and straightened by a straightening jig (not shown) are subassembled in an annular shape so as to correspond between the first to fourth slot coils. It is a figure which shows. FIG. 4B is a diagram showing a state in which the slot coil 2 inserted into the stator core 1 from the bottom surface side protrudes from the upper end surface and before the connecting coil 3 is fitted. A sub-assembly composed of a plurality of connecting coils 3 formed in an annular shape along the annular shape between one of the first to fourth slot coils is also referred to as a connecting coil group below.
　一つのスロットコイル間に対応する接続コイル群は、４８枚の接続コイル３が隣接する接続コイル３に対して時計回りまたは反時計回りのいずれか一方の周方向に一スロット分ずれて重ねあわされた状態で、不図示の矯正治具によって円環状に曲げ矯正されることで形成される。図４（ａ）で示されているのは、第１から第４スロットコイル間にそれぞれ対応する円環状の接続コイル群である。 In the connecting coil group corresponding to one slot coil, 48 connecting coils 3 are overlapped with respect to the adjacent connecting coil 3 by one slot in the circumferential direction of either clockwise or counterclockwise. In this state, it is formed by bending and straightening in an annular shape with a straightening jig (not shown). What is shown in FIG. 4A is a group of annular connection coils corresponding to each of the first to fourth slot coils.
　なお、図示するとおり、最外形側に位置する第１スロットコイル間に対応する接続コイル群が形成する円環の径に対して、より内径側のスロットコイル間に対応する接続コイル群が形成する円環の径がより小さくなっている。従って、接続コイル３の周方向長さ（接続長さ）は、嵌め込まれるスロットコイル間の径方向位置に応じて適宜調整される必要がある。よって、本実施形態の接続コイル３の周方向長さは、嵌め込まれるスロットコイル間の径方向位置におけるステータコア１のスロット７つ分の周方向長さに設定される。そして、このようにして構成された接続コイル群が、図４（ｂ）に示すコイルエンド部の第１から第４スロットコイル間に軸方向上方から同時に、またはスロットコイル間毎に挿入される。そして、スロットコイル２と接続コイル３との対向する導通面同士を接合することによって、本実施形態のコイルエンド部が形成される。 As shown in the figure, the connection coil group corresponding to the inner diameter side of the slot coil is formed with respect to the diameter of the ring formed by the connection coil group corresponding to the first slot coil located on the outermost outer diameter side. The diameter of the annulus is smaller. Therefore, the circumferential length (connection length) of the connection coil 3 needs to be appropriately adjusted according to the radial position between the slot coils to be fitted. Therefore, the circumferential length of the connection coil 3 of the present embodiment is set to the circumferential length of seven slots of the stator core 1 at the radial position between the slot coils to be fitted. Then, the connection coil group configured in this way is inserted between the first to fourth slot coils of the coil end portion shown in FIG. 4B at the same time from above in the axial direction or for each slot coil. Then, the coil end portion of the present embodiment is formed by joining the opposing conductive surfaces of the slot coil 2 and the connecting coil 3 to each other.
　このように、接続コイル３のみで先に円環形状を構成し、これを、対応する第１から第４スロットコイル間に軸方向から挿入することでコイルエンド部の組立を実現することができるので、従来のようにワイヤーフォーミングやプレス曲げといった複雑な成形工程を要さずに、ステータ１０を容易に且つ高速に組み立てることができる。 In this way, the coil end portion can be assembled by first forming the annular shape with only the connecting coil 3 and inserting the annular shape between the corresponding first to fourth slot coils from the axial direction. Therefore, the stator 10 can be assembled easily and at high speed without requiring a complicated molding process such as wire forming and press bending as in the conventional case.
　図５は、本実施形態のコイルエンド部であって、図３の矢印Ｂで示すスロットコイル２が形成する第１スロット間を径方向に平行な断面から見た概略断面図である。図の右側が外径側である。なお、以下では代表して第１スロットコイル間についてのみ説明するが、第２～第４スロットコイル間についても同様である。 FIG. 5 is a schematic cross-sectional view of the coil end portion of the present embodiment as viewed from a cross section parallel to the radial direction between the first slots formed by the slot coil 2 indicated by the arrow B in FIG. The right side of the figure is the outer diameter side. In the following, only the space between the first slot coils will be described as a representative, but the same applies to the space between the second to fourth slot coils.
　図示するように、第１スロットコイル間は、スロットコイル２の端部において他の部分より径方向に薄く形成される部分（切欠き部）が対向することにより形成される空間である。より詳細には、第１スロットコイル間は、一方の端部の内径側と他方の端部の外径側とに切欠き部を有するスロットコイル２が、同一スロット内において切欠き部を対向させて隣接することにより形成される空間である。ただし、第１スロットコイル間は、必ずしも切欠き部を有するスロットコイル２で形成される必要はない。第１スロットコイル間は、径方向厚が同一のスロットコイル２をクランク状に折り曲げることによって形成されてもよい（図９で示すクランク部２３を参照）。 As shown in the figure, the space between the first slot coils is a space formed by facing a portion (notch portion) formed thinner in the radial direction than the other portion at the end portion of the slot coil 2. More specifically, between the first slot coils, the slot coils 2 having notches on the inner diameter side of one end and the outer diameter side of the other end have the notches facing each other in the same slot. It is a space formed by being adjacent to each other. However, the space between the first slot coils does not necessarily have to be formed by the slot coils 2 having a notch. The first slot coils may be formed by bending the slot coils 2 having the same radial thickness in a crank shape (see the crank portion 23 shown in FIG. 9).
　図５が示すように、本実施形態の第１スロット間には径方向に７枚の接続コイル３が重なるように構成されている。ここで、接続コイル３は、図４を参照して上述したように、矯正治具によって円環状に曲げ矯正された状態で第１スロット間に挿入される。挿入された後に矯正治具が取り外されると、接続コイル３の復元力により、外径側に向かう方向（図中の白抜き矢印参照）への力が発生し、接続コイル３の外径側の面がスロットコイル２の内径側の面に押し当たる。これにより接続コイル３は、第１スロット間の所定位置に保持される。 As shown in FIG. 5, seven connecting coils 3 are configured to overlap in the radial direction between the first slots of the present embodiment. Here, the connecting coil 3 is inserted between the first slots in a state of being bent and straightened in an annular shape by a straightening jig as described above with reference to FIG. When the straightening jig is removed after being inserted, the restoring force of the connecting coil 3 generates a force in the direction toward the outer diameter side (see the white arrow in the figure), and the force on the outer diameter side of the connecting coil 3 is generated. The surface abuts against the inner diameter side surface of the slot coil 2. As a result, the connecting coil 3 is held at a predetermined position between the first slots.
　そして、コイルエンド部において、接続コイル３の導通面３ａと、スロットコイル２の一方の端部の内径側において少なくとも導通面３ａと接触する部分に形成された導通面２ａ、及び、接続コイル３の導通面３ｂと、スロットコイル２の他方の端部の外径側において少なくとも導通面３ｂと接触する部分に形成された導通面２ｂとを接合することによって、ステータコイルとしての相毎の電気経路が構成される。なお、導通面同士の接合は、例えば溶接により実現されてよい。あるいは、接続コイル３の復元力が強く、接続コイル３の導通面３ａとスロットコイル２の導通面３ａとの接触抵抗、及び、接続コイル３の導通面３ｂとスロットコイル２の導通面３ｂとの接触抵抗がステータコイルとしての所定の基準を満たすのであれば、スロットコイル２と接続コイル３とは、接続コイル３の復元力によって導通面同士が強く接触することで接合されてよい。なお、所定の基準は、ステータが適用される電動モータに求める特性等に応じて適宜設定されてよい。これにより、スロットコイル２と接続コイル３とからなるステータコイルを構成することができる。 Then, at the coil end portion, the conductive surface 3a of the connecting coil 3, the conductive surface 2a formed at least on the inner diameter side of one end of the slot coil 2 in contact with the conductive surface 3a, and the connecting coil 3 By joining the conductive surface 3b and the conductive surface 2b formed at least on the outer diameter side of the other end of the slot coil 2 in contact with the conductive surface 3b, a phase-by-phase electric path as a stator coil can be created. It is composed. The bonding between the conductive surfaces may be realized by, for example, welding. Alternatively, the restoring force of the connecting coil 3 is strong, the contact resistance between the conductive surface 3a of the connecting coil 3 and the conductive surface 3a of the slot coil 2, and the conductive surface 3b of the connecting coil 3 and the conductive surface 3b of the slot coil 2. If the contact resistance satisfies a predetermined criterion for the stator coil, the slot coil 2 and the connecting coil 3 may be joined by the conductive surfaces being strongly contacted with each other by the restoring force of the connecting coil 3. The predetermined standard may be appropriately set according to the characteristics required for the electric motor to which the stator is applied. Thereby, the stator coil including the slot coil 2 and the connection coil 3 can be formed.
　このように、コイルエンド部において、板状部材からなる接続コイル３によって二つのスロットコイル２間を電気的に接続することができることで、従来に比べて以下のようなメリットがある。すなわち、従来では、スロットコイル間を接続するために、他のスロットコイルとの干渉を避けるために複雑な曲げ成形が必要であったのに対して、本実施形態では複雑な曲げ成形が不要になるので製造コストを低減することができる。 In this way, at the coil end portion, the two slot coils 2 can be electrically connected by the connecting coil 3 made of a plate-shaped member, which has the following merits as compared with the conventional case. That is, in the past, in order to connect the slot coils, complicated bending molding was required to avoid interference with other slot coils, whereas in this embodiment, complicated bending molding is not required. Therefore, the manufacturing cost can be reduced.
　また、従来では、コイルエンド部において他のスロットコイルとの干渉を避けながらスロットコイル間を接続するために用いる接続部材の軸方向位置を決めるためにベースプレートやカフサプレートによる位置決め工程が必要であったのに対して、本実施形態では、軸方向の位置決めに要するこれらの部材や工程が不要になるので製造コストをより低減することができる。 Further, conventionally, a positioning process using a base plate or a cuffer plate has been required to determine the axial position of a connecting member used for connecting between slot coils while avoiding interference with other slot coils at the coil end portion. On the other hand, in the present embodiment, these members and processes required for axial positioning are not required, so that the manufacturing cost can be further reduced.
　また、従来では、コイルエンド部においてスロットコイル間を接続する際に他のスロットコイルとの干渉を避けるために、スロットコイル及び／又はスロットコイルを繋ぐ接続部材を複雑に曲げたり、多相にして重ねたりすることで、コイルエンド部が軸方向に大きくなる課題があったのに対して、本実施形態では、スロットコイル２間に板状の接続コイル３を積層することで足りるので、コイルエンド部の軸方向高さを小さくすることができる。 Further, conventionally, in order to avoid interference with other slot coils when connecting between slot coils at the coil end portion, the slot coil and / or the connecting member connecting the slot coils is complicatedly bent or made into multiple phases. While there is a problem that the coil end portion becomes larger in the axial direction due to overlapping, in the present embodiment, it is sufficient to stack the plate-shaped connecting coil 3 between the slot coils 2, so that the coil end is sufficient. The axial height of the part can be reduced.
　また、従来では、上述したような複雑な電気経路を構成する必要があったのに対して、本実施形態では、二つのスロットコイル間を接続コイル３によって直線の最短距離で繋ぐことができるので、ステータコイルに生じる銅損を低減することができる。 Further, in the past, it was necessary to construct a complicated electric path as described above, but in the present embodiment, the two slot coils can be connected by the connecting coil 3 at the shortest straight line distance. , Copper loss generated in the stator coil can be reduced.
　ここで、接続コイル３の変形例について説明する。接続コイル３は、図３で示したように必ずしも突出部を有している必要はなく、図６で示すような矩形形状の接続コイル３０であってもよい。そして、接続コイル３０は、一方の周方向端部の外径側に形成された導通面３０ａと、他方の周方向端部の内径側に形成された導通面３０ｂとを備える。このような形状の接続コイル３０も、接続コイル３と同様に円環状に曲げ矯正されて、所定の二つのスロットコイル２の間に配置される。所定の二つのスロットコイル２の間に配置された接続コイル３０の具体的な構成例について、図７を参照して説明する。 Here, a modified example of the connecting coil 3 will be described. The connecting coil 3 does not necessarily have to have a protruding portion as shown in FIG. 3, and may be a rectangular connecting coil 30 as shown in FIG. The connection coil 30 includes a conductive surface 30a formed on the outer diameter side of one circumferential end portion and a conductive surface 30b formed on the inner diameter side of the other circumferential end portion. The connection coil 30 having such a shape is also bent and straightened in an annular shape like the connection coil 3, and is arranged between the two predetermined slot coils 2. A specific configuration example of the connection coil 30 arranged between the two predetermined slot coils 2 will be described with reference to FIG. 7.
　図７は、本変形例のコイルエンド部であって、図５と同様、二つのスロットコイル２が形成する第１スロットコイル間を径方向に平行な断面から見た概略断面図である。図の右側が外径側である。以下でも代表して第１スロットコイル間についてのみ説明するが、第２～第４スロットコイル間についても同様である。 FIG. 7 is a coil end portion of this modified example, and is a schematic cross-sectional view seen from a cross section parallel to the radial direction between the first slot coils formed by the two slot coils 2 as in FIG. The right side of the figure is the outer diameter side. Hereinafter, only the space between the first slot coils will be described as a representative, but the same applies to the space between the second to fourth slot coils.
　本変形例においても、図５を用いて説明したのと同様に接続コイル３０の復元力によって、第１スロット間の所定位置に保持される。さらに、本変形例でも、接続コイル３０の導通面３０ａとスロットコイル２の導通面３ａ、及び、接続コイル３０の導通面３０ｂとスロットコイル２の導通面３ｂを、接続コイル３０の復元力によって導通面同士が接触することより接合させてもよいし、溶接により接合してもよい。 Also in this modified example, it is held at a predetermined position between the first slots by the restoring force of the connecting coil 30 as described with reference to FIG. Further, also in this modification, the conduction surface 30a of the connection coil 30 and the conduction surface 3a of the slot coil 2 and the conduction surface 30b of the connection coil 30 and the conduction surface 3b of the slot coil 2 are conducted by the restoring force of the connection coil 30. The surfaces may be joined by contacting each other, or may be joined by welding.
　ただし、本変形例は、図示するように接続コイル３０の軸方向高さが同じであるため、導通面同士を以下の方法により接合させてもよい。すなわち、本変形例では、複数積層された接続コイル３０を挟む二つのスロットコイル２の両側（内径側および外径側）から力を与えることによって接続コイル３０の導通面３０ａとスロットコイル２の導通面３ａ、及び、接続コイル３０の導通面３０ｂとスロットコイル２の導通面３ｂを押圧し、塑性変形させることによって接合してもよい。 However, in this modified example, since the heights of the connecting coils 30 in the axial direction are the same as shown in the figure, the conductive surfaces may be joined by the following method. That is, in this modification, the conduction surface 30a of the connection coil 30 and the slot coil 2 are conductive by applying forces from both sides (inner diameter side and outer diameter side) of the two slot coils 2 sandwiching the plurality of stacked connection coils 30. The surface 3a and the conductive surface 30b of the connecting coil 30 and the conductive surface 3b of the slot coil 2 may be pressed and plastically deformed to join them.
　なお、塑性変形させる際には、図７で示す矯正治具６を用いてもよい。矯正治具６は、第１のスロットコイル間を形成する二つのスロットコイル２の上端に軸方向上方から押圧する際に、外径側に位置するスロットコイル２の上端の外径側に当接して当該スロットコイル２を内径側に移動させる傾斜６ａと、内径側に位置するスロットコイル２の上端の内径側に当接して当該スロットコイル２を外径側に移動させる傾斜６ｂとを備える。このような矯正治具６を用いることによっても、スロットコイル２と接続コイル３０との導通面同士を容易に接合させることができる。 When plastically deforming, the straightening jig 6 shown in FIG. 7 may be used. When the straightening jig 6 presses against the upper ends of the two slot coils 2 forming between the first slot coils from above in the axial direction, the straightening jig 6 comes into contact with the outer diameter side of the upper ends of the slot coils 2 located on the outer diameter side. The slot coil 2 is provided with an inclination 6a for moving the slot coil 2 to the inner diameter side, and an inclination 6b for abutting the inner diameter side of the upper end of the slot coil 2 located on the inner diameter side and moving the slot coil 2 to the outer diameter side. By using such a straightening jig 6, the conductive surfaces of the slot coil 2 and the connecting coil 30 can be easily joined to each other.
　以上、第１実施形態のステータ１０のコイルエンド構造によれば、軸方向に貫通する複数のスロットを有するステータコア１と、ステータコア１に巻き回される複数相のコイル（ステータコイル）と、を備えるステータ１０のコイルエンド構造である。ステータ１０に巻き回されるコイルは、スロットに径方向に並んで配置されステータコア１の一方の軸方向端面（上端面１１）から端部が突出する複数の導体セグメント（スロットコイル２）と、スロットから突出する複数の端部のうち異なるスロットから突出する所定の二つの端部間に介在し当該二つの端部を電気的に接続する接続コイル３と、から構成される。これにより、コイルエンド部において、他のステータコイルとの干渉を回避するためにステータコイルを複雑に曲げ成形する必要がなくなるので、容易に製造でき、且つ、コイルエンドのサイズが大きくなることを抑制することができるコイルエンド構造を実現することができる。 As described above, according to the coil end structure of the stator 10 of the first embodiment, the stator core 1 having a plurality of slots penetrating in the axial direction and the multi-phase coil (stator coil) wound around the stator core 1 are provided. It is a coil end structure of the stator 10. The coils wound around the stator 10 are arranged in a slot in a radial direction, and a plurality of conductor segments (slot coils 2) whose ends project from one axial end surface (upper end surface 11) of the stator core 1 and a slot. It is composed of a connection coil 3 that is interposed between two predetermined ends protruding from different slots among a plurality of ends protruding from the two ends and electrically connects the two ends. This eliminates the need for complicated bending and molding of the stator coil in order to avoid interference with other stator coils at the coil end portion, so that the coil end can be easily manufactured and the size of the coil end is suppressed from becoming large. It is possible to realize a coil end structure that can be used.
　また、第１実施形態のステータ１０のコイルエンド構造によれば、二つの端部（スロットコイル２）は、一方の端部のステータ内径側に第１導通面（導通面２ａ）を有するとともに、他方の端部のステータ外径側に第２導通面（導通面２ｂ）を有し、接続コイル３は、板状部材であって、ステータ周方向における一方端のステータ外径側に第３導通面（導通面３ａ）を有するとともに、他方端のステータ内径側に第４導通面（導通面３ｂ）を有し、二つの端部と接続コイルとは、第１導通面（導通面２ａ）と第３導通面（導通面３ａ）、及び、第２導通面（導通面２ｂ）と第４導通面（導通面３ｂ）がそれぞれ接合される。これにより、板状部材からなる接続コイル３によって二つのスロットコイル２間を電気的に接続することができるので、二つのスロットコイル２間を接続コイル３によって直線の最短距離で繋ぐことができ、ステータコイルに生じる銅損を低減することができる。 Further, according to the coil end structure of the stator 10 of the first embodiment, the two ends (slot coil 2) have a first conductive surface (conducting surface 2a) on the inner diameter side of the stator at one end, and also have a first conductive surface (conducting surface 2a). A second conductive surface (conducting surface 2b) is provided on the outer diameter side of the stator at the other end, and the connecting coil 3 is a plate-shaped member and has a third conductive surface on the outer diameter side of the stator at one end in the circumferential direction of the stator. It has a surface (conduction surface 3a) and a fourth conduction surface (conduction surface 3b) on the inner diameter side of the stator at the other end, and the two ends and the connecting coil are the first conduction surface (conduction surface 2a). The third conductive surface (conducting surface 3a), the second conductive surface (conducting surface 2b), and the fourth conductive surface (conducting surface 3b) are joined to each other. As a result, the two slot coils 2 can be electrically connected by the connecting coil 3 made of a plate-shaped member, so that the two slot coils 2 can be connected by the connecting coil 3 at the shortest straight distance. Copper loss generated in the stator coil can be reduced.
　また、第１実施形態のステータ１０のコイルエンド構造によれば、導体セグメント（スロットコイル２）はＵ字形状を有し、一の導体セグメントの一方の端部に第１導通面（導通面２ａ）を有し、他の導体セグメントの他方の端部に第２導通面（導通面２ｂ）を有する。これにより、一方の軸方向端面にのみ、接続コイル３を備えるコイルエンド部を形成することで分布巻きのステータコイルを実現することができるので、軸方向長さが大きくなることを抑制することができる。 Further, according to the coil end structure of the stator 10 of the first embodiment, the conductor segment (slot coil 2) has a U-shape, and the first conductive surface (conducting surface 2a) is attached to one end of one conductor segment. ), And a second conductive surface (conducting surface 2b) at the other end of the other conductor segment. As a result, a distributed winding stator coil can be realized by forming a coil end portion provided with the connecting coil 3 only on one axial end surface, so that it is possible to suppress an increase in the axial length. it can.
　また、第１実施形態のステータ１０のコイルエンド構造によれば、一方の端部はステータ内径側に第１切欠き（切欠き部）を有し、他方の端部は、ステータ外径側に第２切欠き（切欠き部）を有し、接続コイル３は、第１切欠きと第２切欠きとの間に保持される。これにより、スロットコイル２と接続コイル３とからなるステータコイルを備えるステータ１０を、径方向のサイズを大きくすることなく実現することができる。 Further, according to the coil end structure of the stator 10 of the first embodiment, one end portion has a first notch (notch portion) on the inner diameter side of the stator, and the other end portion is on the outer diameter side of the stator. It has a second notch (notch portion), and the connecting coil 3 is held between the first notch and the second notch. Thereby, the stator 10 including the stator coil including the slot coil 2 and the connecting coil 3 can be realized without increasing the size in the radial direction.
　また、第１実施形態のステータ１０のコイルエンド構造によれば、接続コイル３は、長手方向がステータ周方向と一致する平板形状の部材であって、ステータコアの円環形状に沿う円環状に曲げ矯正された状態で二つの端部間に保持される。これにより、平板形状への復元力によって、接続コイル３を二つのスロットコイル２間の所定位置に容易に保持することができる。 Further, according to the coil end structure of the stator 10 of the first embodiment, the connecting coil 3 is a flat plate-shaped member whose longitudinal direction coincides with the circumferential direction of the stator, and is bent in an annular shape along the annular shape of the stator core. It is held between the two ends in a straightened state. As a result, the connecting coil 3 can be easily held at a predetermined position between the two slot coils 2 by the restoring force to the flat plate shape.
　また、第１実施形態のコイルの製造方法は、軸方向に貫通する複数のスロットを有するステータコア１に巻き回されるコイル（ステータコイル）の製造方法であって、複数の導体セグメント（スロットコイル２）をスロットの径方向に所定の間隔を有して並べて配置し、当該導体セグメントの端部をステータコア１の軸方向端面から突出させ、複数の導体セグメントの端部のうち径方向に隣り合う二つの端部の間に複数の板状部材としての接続コイル３を軸方向から挿入し、隣り合う二つの端部のうち外径側に配置された端部の内径側の面と、接続コイル３の一方の周方向端部の外径側の面、及び、隣り合う二つの端部のうち内径側に配置された端部の外径側の面と、接続コイル３の他方の周方向端部の内径側の面を、それぞれ接合する。これにより、スロットコイル２間に接続コイル３を軸方向から挿入することでコイルエンド部の組立を実現することができるので、従来のようにワイヤーフォーミングやプレス曲げといった複雑な成形工程を要さずに、ステータ１０を容易に且つ高速に組み立てることができる。また、従来必要であった複雑な成形工程が不要となるので、製造コストを低減することができる。 The coil manufacturing method of the first embodiment is a method of manufacturing a coil (stator coil) wound around a stator core 1 having a plurality of slots penetrating in the axial direction, and is a method of manufacturing a plurality of conductor segments (slot coil 2). ) Are arranged side by side at predetermined intervals in the radial direction of the slots, the ends of the conductor segments are projected from the axial end faces of the stator core 1, and two of the ends of the plurality of conductor segments are adjacent to each other in the radial direction. A plurality of connecting coils 3 as plate-like members are inserted between one end portion in the axial direction, and the inner diameter side surface of the end portion arranged on the outer diameter side of the two adjacent end portions and the connecting coil 3 The outer diameter side surface of one circumferential end, the outer diameter side surface of the end arranged on the inner diameter side of the two adjacent ends, and the other circumferential end of the connecting coil 3. The surfaces on the inner diameter side of the are joined together. As a result, the coil end portion can be assembled by inserting the connecting coil 3 between the slot coils 2 from the axial direction, so that a complicated molding process such as wire forming or press bending as in the conventional case is not required. In addition, the stator 10 can be assembled easily and at high speed. In addition, since the complicated molding process that has been conventionally required becomes unnecessary, the manufacturing cost can be reduced.
　＜第２実施形態＞
　以下では、第２実施形態に係るステータ２０のコイル構造について説明する。本実施形態のコイル構造は、スロットコイル２２の形状が、第１実施形態のスロットコイル２と相違する。 <Second Embodiment>
Hereinafter, the coil structure of the stator 20 according to the second embodiment will be described. In the coil structure of the present embodiment, the shape of the slot coil 22 is different from that of the slot coil 2 of the first embodiment.
　図８は、第２実施形態のステータ２０のコイル構造を説明する概略構成図である。図では、コイルエンド部のみが示されている。 FIG. 8 is a schematic configuration diagram illustrating the coil structure of the stator 20 of the second embodiment. In the figure, only the coil end portion is shown.
　図示するように、本実施形態のスロットコイル２２は、コイルエンド部において外径側に折れ曲がり、さらに上方（軸方向外側）に折れ曲がることで形成されるクランク部２３を有する。このようなスロットコイル２２によって形成される第１スロットコイル間の詳細について図９を参照して説明する。 As shown in the figure, the slot coil 22 of the present embodiment has a crank portion 23 formed by bending toward the outer diameter side at the coil end portion and further bending upward (outward in the axial direction). Details between the first slot coils formed by such slot coils 22 will be described with reference to FIG.
　図９は、本実施形態のコイルエンド部であって、二つのスロットコイル２２が形成する第１スロットコイル間を径方向に平行な断面から見た概略構成図である。図の右側が外径側であり、外径側に位置するスロットコイル２２には、クランク部２３が形成されている。 FIG. 9 is a schematic configuration diagram of the coil end portion of the present embodiment as viewed from a cross section parallel to the radial direction between the first slot coils formed by the two slot coils 22. The right side of the figure is the outer diameter side, and the slot coil 22 located on the outer diameter side is formed with a crank portion 23.
　スロットコイル２２にこのようなクランク部２３が形成されていることにより、内径側に位置するスロットコイル２２の外径側の面と、外径側に位置するスロットコイル２２の内径側の面とで形成される空間を径方向に拡張することができる。これにより、当該空間に配置される接続コイル３の径方向厚みをより大きくすることができる。このため、例えば銅損を低減する観点から最適化された断面積を考慮した場合であっても、第１実施形態の接続コイル３に比べて、径方向厚みを大きくした分軸方向長さを短くすることができるので、クランク部２３を加味したとしてもコイルエンド部の軸方向高さをより小さくすることができる。 By forming such a crank portion 23 on the slot coil 22, the surface on the outer diameter side of the slot coil 22 located on the inner diameter side and the surface on the inner diameter side of the slot coil 22 located on the outer diameter side are formed. The formed space can be expanded in the radial direction. As a result, the radial thickness of the connecting coil 3 arranged in the space can be further increased. Therefore, for example, even when the cross-sectional area optimized from the viewpoint of reducing copper loss is taken into consideration, the axial length having a larger radial thickness than that of the connection coil 3 of the first embodiment can be obtained. Since it can be shortened, the axial height of the coil end portion can be made smaller even if the crank portion 23 is added.
　なお、クランク部２３は、図示するように必ずしも外径側に折り曲げる必要は無く、内径側に折り曲げてもよい。また、クランク部２３は、図示するように必ずしも外径側に直角に折り曲げる必要は無く、外径側又は内径側の上方に向かって傾斜させるとともに軸方向外側に折れ曲がるように形成されてもよい。なおその場合には、クランク部２３の名称は傾斜部２３とする。 The crank portion 23 does not necessarily have to be bent toward the outer diameter side as shown in the figure, and may be bent toward the inner diameter side. Further, the crank portion 23 does not necessarily have to be bent at a right angle to the outer diameter side as shown in the drawing, and may be formed so as to be inclined upward on the outer diameter side or the inner diameter side and bent outward in the axial direction. In that case, the name of the crank portion 23 is the inclined portion 23.
　以上、第２実施形態のステータ２０のコイルエンド構造によれば、導体セグメント（スロットコイル２２）は、ステータ径方向における外径側又は内径側に折れ曲がるとともに軸方向外側に折れ曲がるクランク部２３、または、ステータ径方向における外径側又は内径側に傾斜するとともに軸方向外側に折れ曲がる傾斜部２３を有する。これにより、径側に位置するスロットコイル２２の外径側の面と、外径側に位置するスロットコイル２２の内径側の面とで形成される空間を径方向に拡張することができる。 As described above, according to the coil end structure of the stator 20 of the second embodiment, the conductor segment (slot coil 22) is bent toward the outer diameter side or the inner diameter side in the stator radial direction and is bent outward in the axial direction. It has an inclined portion 23 that is inclined toward the outer diameter side or the inner diameter side in the stator radial direction and is bent outward in the axial direction. As a result, the space formed by the outer diameter side surface of the slot coil 22 located on the radial side and the inner diameter side surface of the slot coil 22 located on the outer diameter side can be expanded in the radial direction.
　本発明は、上述した実施形態に限定されることはなく、様々な変形や応用が可能である。また、上記実施形態および変形例は、矛盾が生じない範囲で適宜組み合わせてもよい。 The present invention is not limited to the above-described embodiment, and various modifications and applications are possible. Further, the above-described embodiments and modifications may be appropriately combined as long as there is no contradiction.
　例えば、上記実施形態においてスロットコイル２はＵ字形状である旨を説明したが、ここでのＵ字形状は、必ずしも曲線を有するＵ字形状である必要はない。両端部が一方向を向き、それぞれの端部をステータコアの異なるスロットに挿入することが出来ればよく、直線で構成されるような略Ｕ字形状も含む。 For example, although it has been explained that the slot coil 2 has a U-shape in the above embodiment, the U-shape here does not necessarily have to be a U-shape having a curved line. It suffices if both ends face in one direction and each end can be inserted into a different slot of the stator core, including a substantially U-shape composed of a straight line.
　また、スロットコイル２は、必ずしもＵ字形状である必要は無く、両端部が互いに逆方向を向いた棒形状であってもよい。この場合には、上述した実施形態で説明したコイルエンド部が、ステータコア１の軸方向両端面に形成される。 Further, the slot coil 2 does not necessarily have to be U-shaped, and may have a rod shape in which both ends face in opposite directions. In this case, the coil end portions described in the above-described embodiment are formed on both end faces in the axial direction of the stator core 1.
　また、上述した接続コイル３の周方向長さ（スロット７つ分）、接続コイル群を構成する接続コイル３の枚数（４８枚）、スロットコイル間の数（第１から第４の計４つ）等の数量は例示であって、適用されるステータコアが有するスロット数や、巻回されるステータコイルの巻線数に応じて適宜変更されてよい。 Further, the circumferential length of the connection coil 3 described above (7 slots), the number of connection coils 3 constituting the connection coil group (48 sheets), and the number between the slot coils (1st to 4th total 4). ) Etc. are examples, and may be appropriately changed according to the number of slots of the applicable stator core and the number of windings of the stator coil to be wound.

Claims (7)

  1. 　軸方向に貫通する複数のスロットを有するステータコアと、
    　前記ステータコアに巻き回される複数相のコイルと、を備えるステータのコイルエンド構造であって、
    　前記コイルは、
    　　前記スロットに径方向に並んで配置され、前記ステータコアの一方の軸方向端面から端部が突出する複数の導体セグメントと、
    　　前記スロットから突出する複数の前記端部のうち、異なる前記スロットから突出する所定の二つの前記端部間に介在し、当該二つの前記端部を電気的に接続する接続コイルと、から構成される、
    ステータのコイルエンド構造。     A stator core with multiple slots that penetrate in the axial direction,
    A coil end structure of a stator including a multi-phase coil wound around the stator core.
    The coil
    A plurality of conductor segments arranged in the slot in the radial direction and having an end projecting from one axial end surface of the stator core.
    It is composed of a connection coil that is interposed between two predetermined ends protruding from different slots among the plurality of ends protruding from the slot and electrically connects the two ends. ,
    Coil end structure of the stator.
  2. 　請求項１に記載のステータのコイルエンド構造であって、
    　前記二つの端部は、一方の前記端部のステータ内径側に第１導通面を有するとともに、他方の前記端部のステータ外径側に第２導通面を有し、
    　前記接続コイルは、板状部材であって、ステータ周方向における一方端のステータ外径側に第３導通面を有するとともに、他方端のステータ内径側に第４導通面を有し、
    　前記二つの端部と前記接続コイルとは、前記第１導通面と前記第３導通面、及び、前記第２導通面と前記第４導通面がそれぞれ接合される、
    ステータのコイルエンド構造。     The coil end structure of the stator according to claim 1.
    The two ends have a first conductive surface on the inner diameter side of the stator of one of the ends and a second conductive surface on the outer diameter side of the stator of the other end.
    The connection coil is a plate-shaped member, and has a third conductive surface on the outer diameter side of the stator at one end in the circumferential direction of the stator and a fourth conductive surface on the inner diameter side of the stator at the other end.
    The two ends and the connecting coil are joined to the first conductive surface and the third conductive surface, and the second conductive surface and the fourth conductive surface, respectively.
    Coil end structure of the stator.
  3. 　請求項２に記載のステータのコイルエンド構造であって、
    　前記導体セグメントはＵ字形状を有し、一の前記導体セグメントの一方の前記端部に前記第１導通面を有し、他の前記導体セグメントの他方の前記端部に前記第２導通面を有する、
    ステータのコイルエンド構造。     The coil end structure of the stator according to claim 2.
    The conductor segment has a U-shape, one end of the conductor segment has the first conductive surface, and the other end of the other conductor segment has the second conductive surface. Have, have
    Coil end structure of the stator.
  4. 　請求項１から３のいずれか一項に記載のステータのコイルエンド構造であって、
    　一方の前記端部はステータ内径側に第１切欠きを有し、
    　他方の前記端部は、ステータ外径側に第２切欠きを有し、
    　前記接続コイルは、前記第１切欠きと前記第２切欠きとの間に保持される、
    ステータのコイルエンド構造。     The coil end structure of the stator according to any one of claims 1 to 3.
    One of the ends has a first notch on the inner diameter side of the stator.
    The other end has a second notch on the outer diameter side of the stator.
    The connecting coil is held between the first notch and the second notch.
    Coil end structure of the stator.
  5. 　請求項１から４のいずれか一項に記載のステータのコイルエンド構造であって、
    　前記接続コイルは、
    　　長手方向がステータ周方向と一致する平板形状の部材であって、前記ステータコアの円環形状に沿う円環状に曲げ矯正された状態で前記二つの前記端部間に保持される、
    ステータのコイルエンド構造。     The coil end structure of the stator according to any one of claims 1 to 4.
    The connecting coil
    It is a flat plate-shaped member whose longitudinal direction coincides with the circumferential direction of the stator, and is held between the two ends in a state of being bent and straightened in an annular shape along the annular shape of the stator core.
    Coil end structure of the stator.
  6. 　請求項１から５のいずれか一項に記載のステータのコイルエンド構造であって、
    　前記導体セグメントは、
    　　ステータ径方向における外径側又は内径側に折れ曲がるとともに軸方向外側に折れ曲がるクランク部、または、ステータ径方向における外径側又は内径側に傾斜するとともに軸方向外側に折れ曲がる傾斜部を有する、
    ステータのコイルエンド構造。     The coil end structure of the stator according to any one of claims 1 to 5.
    The conductor segment
    It has a crank portion that bends to the outer diameter side or inner diameter side in the stator radial direction and bends outward in the axial direction, or an inclined portion that inclines to the outer diameter side or inner diameter side in the stator radial direction and bends outward in the axial direction.
    Coil end structure of the stator.
  7. 　軸方向に貫通する複数のスロットを有するステータコアに巻き回されるコイルの製造方法であって、
    　複数の導体セグメントを前記スロットの径方向に所定の間隔を有して並べて配置し、当該導体セグメントの端部を前記ステータコアの軸方向端面から突出させ、
    　複数の前記導体セグメントの端部のうち径方向に隣り合う二つの前記端部の間に複数の板状部材としての接続コイルを軸方向から挿入し、
    　前記隣り合う二つの前記端部のうち外径側に配置された前記端部の内径側の面と、前記接続コイルの一方端の外径側の面、及び、前記隣り合う二つの前記端部のうち内径側に配置された前記端部の外径側の面と、前記接続コイルの他方端の内径側の面を、それぞれ接合する、
    コイルの製造方法。     A method of manufacturing a coil wound around a stator core having a plurality of slots penetrating in the axial direction.
    A plurality of conductor segments are arranged side by side with a predetermined interval in the radial direction of the slot, and the end portion of the conductor segment is projected from the axial end surface of the stator core.
    A plurality of connecting coils as plate-like members are inserted in the axial direction between two radially adjacent ends of the plurality of conductor segments.
    The inner diameter side surface of the end portion arranged on the outer diameter side of the two adjacent ends, the outer diameter side surface of one end of the connection coil, and the two adjacent end portions. Of these, the outer diameter side surface of the end portion arranged on the inner diameter side and the inner diameter side surface of the other end of the connection coil are joined to each other.
    Coil manufacturing method.
PCT/JP2019/051273 2019-12-26 2019-12-26 Stator coil end structure and manufacturing method WO2021130996A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001292548A (en) * 2000-01-31 2001-10-19 Hitachi Ltd Stator of rotating electric machine
JP2002262497A (en) * 2001-02-28 2002-09-13 Hitachi Ltd Rotary electric machine and its manufacturing method
JP2006050853A (en) * 2004-08-06 2006-02-16 Yaskawa Electric Corp Motor

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001292548A (en) * 2000-01-31 2001-10-19 Hitachi Ltd Stator of rotating electric machine
JP2002262497A (en) * 2001-02-28 2002-09-13 Hitachi Ltd Rotary electric machine and its manufacturing method
JP2006050853A (en) * 2004-08-06 2006-02-16 Yaskawa Electric Corp Motor

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