CN106067701A - Electric rotating machine and manufacture method, stator coil, coil resin structure - Google Patents

Abstract

A rotating electric machine, a method for manufacturing the same, a stator coil, and a coil resin structure capable of reducing the size of a coil end portion of a stator coil. The rotating electric machine (10) has a stator (30) and a rotor (20), and the stator (30) has: a stator core (32) with a plurality of slots (31) arranged in the circumferential direction of the stator; A plurality of stator coils (41) in one slot (31), each stator coil (41) has: a first coil piece part (50) accommodated in one slot (31); ) the second coil piece part (51) in other different slots (31); and the coil end parts (52, 53) extending between the first coil piece part (50) and the second coil piece part (51) The circular wires (42) are stacked at least in the radial direction of the stator, and the stacking arrangement of the circular wires (42) in the radial direction of the stator is the same for the first coil piece (50) and the second coil piece (51).

Description

Rotating electric machine, manufacturing method thereof, stator coil, coil resin structure

technical field

The disclosed embodiments relate to a rotating electrical machine, a method of manufacturing the rotating electrical machine, a stator coil, and a coil resin structure.

Background technique

Patent Document 1 describes a rotating electric machine in which the first linear portion and the second linear portion of a plurality of coils accommodated in a plurality of slots of a stator core are accommodated in slots different from each other, and the respective coils are arranged in a circumferential position Overlapping and winding in a staggered manner.

prior art literature

patent documents

Patent Document 1: International Publication No. 2013/183188

For such a rotating electric machine, it is required to reduce the size of the coil ends of the stator coils.

Contents of the invention

The present invention was made in view of such problems, and an object of the present invention is to provide a rotating electric machine capable of downsizing the coil ends of the stator coil, a method of manufacturing the rotating electric machine, a stator coil, and a coil resin structure.

In order to solve the above-mentioned problems, one aspect of the present invention employs a rotating electric machine having a stator and a rotor, the stator having: a stator core having a plurality of slots arranged in the circumferential direction; A plurality of stator coils in one slot, each of the stator coils has: a first coil piece accommodated in one slot; and a second coil piece accommodated in another slot different from the one slot. part; and a coil end extending between the first coil piece part and the second coil piece part, the stator coil is configured such that round wires are stacked at least in the radial direction of the stator, and the round wires are stacked at least in the radial direction of the stator. The lamination arrangement in the radial direction is the same for the first coil piece and the second coil piece.

Furthermore, another aspect of the present invention is applied to a method of manufacturing a rotating electric machine having a stator and a rotor, the stator having: a stator core having a plurality of slots arranged in the circumferential direction; The plurality of stator coils in the plurality of slots, the stator core is configured by arranging a plurality of split core elements in the circumferential direction, and each of the stator coils has a first coil piece accommodated in one slot ; a second coil piece accommodated in another slot different from the one slot; and a coil end extending between the first coil piece and the second coil piece, the The stator coil is configured such that circular wires are stacked at least in a radial direction of the stator, and the stacked arrangement of the circular wires in the radial direction is the same for the first coil piece and the second coil piece, This method of manufacturing a rotating electrical machine includes the steps of: arranging the plurality of stator coils in the distributed winding manner and integrally resin molding to form a coil resin structure; and assembling the formed coil resin structure. The plurality of divided core elements constitute the stator core.

In addition, another aspect of the present invention employs a stator coil in which a plurality of stator coils are housed in a plurality of slots arranged in a circumferential direction on a stator core of a rotating electrical machine in a distributed winding manner, and the stator coil has: a first coil piece in one slot; a second coil piece accommodated in another slot different from the one slot; and a connection between the first coil piece and the second coil piece Coil ends extending between the stator coils, the stator coil is configured such that round wires are stacked at least in the radial direction of the stator, and the stacked arrangement of the round wires in the radial direction is relatively large for the first coil piece and the first coil piece. The above-mentioned second coil piece part is the same.

In addition, another aspect of the present invention applies a coil resin structure, which is formed by arranging a plurality of stator coils in a distributed winding manner and integrally molded by resin, and the plurality of stator coils are accommodated in the distributed winding manner In a plurality of slots arranged in the circumferential direction on a stator core of a rotating electrical machine, each of the stator coils has: a first coil piece accommodated in one slot; the other second coil piece in the slot; and a coil end extending between the first coil piece and the second coil piece, the stator coil is configured such that the circular wire is at least in the The stator is stacked in the radial direction, and the stacking arrangement of the circular wires in the radial direction is the same for the first coil piece and the second coil piece.

According to the rotating electric machine and the like of the present invention, it is possible to reduce the size of the coil end portion of the stator coil.

Description of drawings

FIG. 1 is a longitudinal sectional view showing an example of the overall structure of a rotating electric machine according to an embodiment.

Fig. 2 is a cross-sectional view of section II-II in Fig. 1 .

FIG. 3A is a perspective view showing an example of a structure of a stator coil.

Fig. 3B is an arrow view viewed from the direction of arrow IIIB in Fig. 3A.

Fig. 4 is a plan view showing a plurality of stator coils and a plurality of split core elements.

5 is a perspective view showing an example of the appearance of the coil resin structure.

FIG. 6 is a process diagram showing an example of a method of manufacturing a rotating electric machine.

FIG. 7 is a schematic view illustrating an example of a manufacturing process of a stator coil.

FIG. 8 is a schematic diagram illustrating an example of a manufacturing process of a stator coil.

Label description

10: Rotating electric machine, 20: Rotor, 30: Stator, 33: Split core element, 31: Slot, 32: Stator core, 41: Stator coil, 45: Coil resin structure, 50: First coil piece, 51: 2nd coil piece part, 52: coil end, 53: coil end, 56: raised part, 57: inclined part, 58: inclined part, 59: raised part, 60: inclined part, 61: inclined part.

detailed description

Hereinafter, one embodiment will be described with reference to the drawings. In addition, in the following, directions such as up, down, left, and right may be appropriately used for the convenience of describing the structure of the rotating electric machine and the like, but this is not intended to limit the positional relationship of the respective structures of the rotating electric machine and the like.

＜1. Example of the overall structure of a rotating electric machine＞

First, an example of the overall configuration of the rotating electric machine according to this embodiment will be described with reference to FIGS. 1 and 2 .

As shown in FIGS. 1 and 2 , a rotating electric machine 10 functions as a motor or a generator. The rotary electric machine 10 has a stator 30 and a rotor 20 . The stator 30 is provided on the inner periphery of the frame 11 . The rotor 20 is arranged on the inner peripheral side of the stator 30 and is provided on the outer periphery of the shaft 16 .

In addition, in this specification, the axial direction (left-right direction in FIG. 1) of the stator 30 (stator core 32) is called "stator axial direction", and the circumferential direction of the stator 30 (stator core 32) is called "stator circumferential direction". ", the radial direction of the stator 30 (stator core 32) is referred to as "stator radial direction". In addition, the side on which the load is attached to the rotary electric machine 10, that is, the side where the shaft 16 protrudes in this example (the right side in FIG. 1 ) is referred to as the “load side”, and the opposite side (the left side in FIG. 1 ) Called the "opposite load side".

A load-side bracket 12 is provided on the load side of the frame 11 . A non-load side bracket 14 is provided on the non-load side of the frame 11 . A dust seal 18 is provided at the load-side end of the load-side bracket 12 . This dust seal 18 can suppress the intrusion of foreign matter into the rotary electric machine 10 .

The shaft 16 is rotatably supported by a load-side bearing 13 provided on the load-side bracket 12 and a non-load-side bearing 15 provided on the non-load side bracket 14 . A load-side side plate 8 is mounted on the shaft 16 between the load-side bearing 13 and the load-side end surface of the rotor 20 . A non-load side plate 9 is mounted on the shaft 16 between the non-load side bearing 15 and the non-load side end surface of the rotor 20 . Movement of the rotor 20 in the stator axial direction is restricted by these load-side side plates 8 and non-load-side side plates 9 . A positioning side plate 7 is attached to a portion of the shaft 16 between the load side side plate 8 and the load side bearing 13 . An encoder 17 for detecting the rotational position of the shaft 16 is provided at the end of the shaft 16 on the opposite-to-load side.

In addition, in this example, the rotary electric machine 10 is configured to include the encoder 17 , but may be configured not to include the encoder 17 .

On the opposite-to-load end surface of a stator core 32 (described in detail later) of the stator 30, a wiring portion 44 formed by wiring a plurality of stator coils 41 (described in detail later) of the stator 30 is arranged. The connecting portion 44 is connected to an external power source (not shown) via a lead wire (not shown), and the stator coils 41 are supplied with electricity from the external power source through the lead wire and the connecting portion 44 .

The rotor 20 has: a rotor core 22 disposed opposite to the inner peripheral surface of the stator 30 with a magnetic gap in the radial direction of the stator; pole) permanent magnet 23. A hole 21 is formed in the rotor core 22 , and the hole 21 of the rotor core 22 is fitted into the shaft 16 , whereby the rotor core 22 is fixed to the outer peripheral surface of the shaft 16 .

In addition, in this example, the rotor 20 is configured such that the permanent magnets 23 are embedded in the rotor core 22 in a V-shape, but may be configured such that the permanent magnets 23 are embedded in the rotor core 22 in an I-shape. In addition, in this example, the rotor 20 is configured as a so-called IPM (Internal Permanent Magnet: Internal Permanent Magnet) type structure in which the permanent magnet 23 is embedded in the rotor core 22, but it may be configured such that the permanent magnet 23 is provided in the rotor core. The surface of 22 has a so-called SPM (Surface Permanent Magnet: Surface Mount Permanent Magnet) type structure.

In addition, the structure of the rotating electric machine 10 demonstrated above is an example only, and the structure other than the above-mentioned may be employ|adopted.

＜2. Structure example of stator＞

The stator 30 has: a substantially annular stator core 32 in which a plurality of (48 in this example) slots 31 are arranged over the entire circumference; An example of the "overlapping winding method") a plurality of (48 in this example) stator coils 41 accommodated in a plurality of slots 31 . That is, the number N of slots 31 of the stator core 32 is 48 in this example.

The stator core 32 is formed by arranging a plurality of (48 in this example) split core elements 33 having a substantially fan-shaped cross-sectional shape over the entire circumference. Each split core element 33 has a tooth portion 34 having a substantially rectangular cross-sectional shape on the inner side in the stator radial direction. The grooves 31 are formed between the tooth portions 34 , 34 of the adjacent split core elements 33 , 33 . The cross-sectional shape of each slot 31 is substantially fan-shaped (substantially trapezoidal) that narrows toward the inside in the stator radial direction.

The plurality of stator coils 41 are arranged in double-layer overlapping winding, and are integrally resin molded and fixed by molding resin to form a coil resin structure 45 (details will be described later).

In addition, the structure of the stator 30 demonstrated above is only an example, and the structure other than the above-mentioned may be sufficient. In addition, the plurality of stator coils 41 may not be integrally resin molded.

(2-1. Examples of structure and arrangement of stator coils)

Hereinafter, an example of the structure and arrangement of the stator coil 41 will be described with reference to FIGS. 2 , 3A, 3B, and 4 . In addition, in FIG. 3A, the upper side corresponds to the load side, and the lower side corresponds to the opposite load side. In FIG. 3B and FIG.

As shown in FIGS. 2, 3A, 3B, and 4, in each stator coil 41, a circular wire 42 having a substantially circular cross-sectional shape covered with an appropriate insulating coating (not shown) passes through the The parts corresponding to the coil pieces 50 and 51 to be described later are wound multiple times (22 times in this example) in the radial direction and circumferential direction of the stator, and press-molded at predetermined positions, so that each stator coil 41 are formed as air-core coils each having a deformed cross-sectional shape. In each stator coil 41, the round wire 42 is stacked in multiple layers (five layers in this example) in the radial direction of the stator at portions corresponding to the coil pieces 50 and 51 (so that the intermediate portion is not twisted into a ring shape). ) is wound into a cylindrical shape, and is also wound in a multi-layer (in this example, 6 layers) manner on the outer peripheral side of the stack, and then is also wound in a multi-layer (in this example, six layers) on the outer peripheral side of the stack 5 layers), and further wound in a manner of stacking multiple layers (6 layers in this example) on the outer peripheral side of the stack. In each stator coil 41 , one end (eg, winding start end) 54 and the other end (eg, winding end end) 55 of the round wire 42 protrude toward the opposite side to the load.

In addition, the stator coil 41 may be wound multiple times so as to be stacked in the radial direction of the stator at portions corresponding to the coil pieces 50 and 51 described later (not stacked in the stator circumferential direction but in the stator radial direction).

Each stator coil 41 has a first coil piece 50 , a second coil piece 51 , and two coil ends 52 and 53 .

The first coil piece 50 is, for example, a long side portion (not shown) of a winding body 80 (see FIG. ) is formed by press molding so that the outer shape of the groove 31 matches the cross-sectional shape of the slot 31 on the inner side in the stator radial direction (corresponding to an example of "one side"). The first coil piece portion 50 extends along the stator axial direction, and is accommodated inside one slot 31 in the stator radial direction (hereinafter referred to as “inner peripheral side” as appropriate).

In the first coil piece portion 50 , four round wires 42 are stacked in the stator circumferential direction. In addition, in the first coil piece portion 50, the stacking of the circular wires 42 on the innermost peripheral side among the stator coils 41 (hereinafter referred to as “1st A stacking” as appropriate) is stacked in five layers in the radial direction of the stator. The lamination of circular wires 42 on the outer peripheral side of 1A stack a (hereinafter appropriately referred to as "1B lamination") b is stacked in six layers in the radial direction of the stator, and the lamination of circular wires 42 on the outer peripheral side of the above-mentioned 1B stack b (hereinafter It is appropriately referred to as "the 1st C stack") c is stacked in five layers in the radial direction of the stator, and the stacking of the circular wire 42 on the outer peripheral side (the outermost side of the stator coil 41) of the above-mentioned 1st C stack c (hereinafter appropriately referred to as "1D stacking") d is stacked in 6 layers in the radial direction of the stator. Among the 1A laminations a to 1D laminations d of the circular lines 42 constituting the first coil piece portion 50, the innermost circular line 42 in the stator radial direction has a smaller stator circumferential dimension and a stator radial dimension. The larger the size, the more the outer circle line 42 in the radial direction of the stator is, the flatter the cross-sectional shape is. The outermost circle line 42 in the stator radial direction has a larger circumferential dimension of the stator and a radial dimension smaller.

The second coil piece portion 51 has a cross-sectional shape such that the outer shape of the other long side portion (not shown) of the winding body 80 and the slot 31 are outside in the stator radial direction (corresponding to an example of “the other side”). Consistent patterns are formed by compression molding. That is, the second coil piece portion 51 is formed in a flatter shape than the above-mentioned first coil piece portion 50 . The second coil piece 51 extends in the axial direction of the stator at a position separated from the first coil piece 50 by a predetermined distance substantially in the circumferential direction of the stator, and is accommodated in a slot 31 different from the above-mentioned one (in this example, in the circumferential direction of the stator). The outer side in the stator radial direction of the other slots 31 apart from the four slots (hereinafter referred to as "outer peripheral side" as appropriate).

In the second coil piece portion 51 , four round wires 42 are stacked in the stator circumferential direction. In addition, in the second coil piece portion 51, the stacking of the circular wires 42 on the innermost peripheral side of the stator coil 41 (hereinafter appropriately referred to as “2nd A stacking”) e is stacked in five layers in the radial direction of the stator. The stacking of circular wires 42 on the outer peripheral side of stack e (hereinafter appropriately referred to as "2B stacking") f is stacked in six layers in the radial direction of the stator, and the stacking of circular wires 42 on the outer peripheral side of the above-mentioned 2B stacking f (hereinafter appropriately referred to as (referred to as "2C lamination") g is stacked in five layers in the radial direction of the stator, and the lamination of circular wire 42 on the outer peripheral side (the outermost peripheral side) of the above-mentioned 2C lamination g (hereinafter appropriately referred to as "2D lamination") )h stacked 6 layers in the radial direction of the stator. In each of the 2A lamination e to the 2D lamination h of the circular line 42 constituting the second coil piece portion 51, the innermost circular line 42 in the stator radial direction has a smaller dimension in the stator circumferential direction and the stator radial direction is smaller. The larger the size of the circular line 42 on the radially outer side of the stator, the flatter the cross-sectional shape is. The outermost circular line 42 in the radial direction of the stator is larger in the circumferential direction of the stator and the radial Smaller size.

That is, the first coil piece portion 50 of one stator coil 41 is accommodated on the inner peripheral side of each slot 31, and the second coil piece portion 51 of another stator coil 41 is accommodated on the outer peripheral side. The first coil piece portion 50 is accommodated on the inner peripheral side of the slot 31 separated by four slots in the stator circumferential direction. In order to realize this arrangement, the separation distance L between the coil pieces 50 and 51 of each stator coil 41 and the separation distances of the four slots 31 in the circumferential direction of the stator (considering the above-mentioned difference in position between the inner and outer peripheral sides) X is approximately equal.

Furthermore, in each stator coil 41 , the arrangement (order) and configuration of the stacking of the round wires 42 in the radial direction of the stator among the first A stack a to the first D stack d of the round wires 42 constituting the first coil piece 50 The arrangement (order) of lamination of the circular wires 42 in the stator radial direction is the same in each of the 2A stack e to the 2D stack h of the circular wires 42 of the second coil piece portion 51 .

That is, the portion of the circular line 42 positioned at the innermost in the stator radial direction in the first A stack a on the first coil piece portion 50 side is also arranged at the outermost position in the stator radial direction in the second A stack e on the second coil piece portion 51 side. inside position. In addition, the circular line 42 portion located second inside in the stator radial direction in the first A stack a on the side of the first coil piece 50 is also arranged on the second inner side in the stator radial direction in the second A stack e on the second coil piece portion 51 side. 2nd on the inner side. In addition, the circular line 42 portion located third inside in the stator radial direction in the first A stack a on the first coil piece portion 50 side is also arranged on the stator radial direction in the second A stack e on the second coil piece portion 51 side. 3rd position on the inner side. In addition, the circular line 42 portion located fourth inside in the stator radial direction in the first A stack a on the first coil piece portion 50 side is also arranged on the stator radial direction in the second A stack e on the second coil piece portion 51 side. 4th on the inner side. In addition, the portion of the circular line 42 located at the outermost in the stator radial direction in the first A stack a on the first coil piece portion 50 side is also arranged on the outermost side in the stator radial direction in the second A stack e on the second coil piece portion 51 side. at the location. In the other 1B stack b on the side of the first coil piece 50 and the 2nd B stack f on the side of the second coil piece 51 , and the 1st C stack c on the side of the first coil piece 50 and on the side of the second coil piece 51 The same applies to the 2C lamination g, the 1D lamination d on the first coil piece portion 50 side, and the 2D lamination h on the second coil piece portion 51 side.

The coil end portion 52 is formed by connecting one end portion of the two long side portions of the wound body 80 to a substantially mountain-shaped portion 81 (see FIG. 8 described later) extending between the two long side portions. The shape is formed by compression molding. The coil end portion 52 extends between the coil piece portions 50 , 51 so as to connect the respective load-side end portions of the coil piece portions 50 , 51 , and is arranged outside the slot 31 . In the coil end portion 52 , the round wires 42 are stacked (not stacked approximately along the axial direction of the stator) approximately along a surface direction perpendicular to the axial direction of the stator. The coil end portion 52 has a raised portion 56 raised outward in the stator axial direction, that is, the load side in this example, and two inclined portions 57 and 58 inclined in a plane direction perpendicular to the stator axial direction. The inclined parts 57 and 58 are located on both sides of the raised part 56 so as to connect the raised part 56 and the load-side ends of the coil piece parts 50 and 51 respectively, and are inclined in opposite directions. The protruding portion 56 is press-molded so as to sandwich the middle portion (approximately central portion in this example) of the coil end portion 52 from both sides in the extending direction of the coil end portion 52 .

The coil end portion 53 is formed by adding an outer shape of another substantially mountain-shaped portion (not shown) extending between the two long side portions so as to connect the other ends of the above two long side portions of the wound body 80 . Formed by compression molding. The coil end portion 53 extends between the coil piece portions 50 , 51 so as to connect the opposite-to-load end portions of the coil piece portions 50 , 51 , and is disposed outside the slot 31 . In the coil end portion 53 , the round wires 42 are stacked (not stacked approximately along the stator axial direction) approximately along a surface direction perpendicular to the stator axial direction. The coil end portion 53 has a protruding portion 59 protruding outward in the stator axial direction, that is, the anti-load side in this example, and two inclined portions 60 and 61 inclined in a plane direction perpendicular to the stator axial direction. The inclined parts 60 and 61 are located on both sides of the raised part 59 so as to connect the raised part 59 and the opposite-to-load end parts of the coil piece parts 50 and 51 respectively, and are inclined in opposite directions. The protruding portion 59 is press-molded so as to sandwich the middle portion (approximately central portion in this example) of the coil end portion 53 from both sides in the extending direction of the coil end portion 53 .

Each raised portion 56, 59 is formed such that the angular range θ in the circumferential direction of the stator is not more than the range (slot pitch) obtained by dividing 360° by the number N of the slots 31 (N=48 in this example), that is, θ≦ 360°/N.

That is, the plurality of stator coils 41 are densely arranged such that, on the side of the coil end 52, the positions of the protruding portions 56 in the stator circumferential direction are sequentially shifted, and the inclined portions 57 and 57 of the adjacent stator coils 41 and 41 are arranged in such a manner that 58, 58 overlap each other in the stator axial direction, and on the side of the coil end 53, the positions of the protruding portions 59 in the stator circumferential direction are sequentially shifted, and the inclined portions 60, 60 of the adjacent stator coils 41, 41 and the inclined portions 61, 61 overlap each other in the axial direction of the stator.

In addition, the structure and arrangement of the stator coil 41 demonstrated above are only an example, and the structure and arrangement other than the above-mentioned may be employ|adopted. For example, the above structure can be adopted for only one coil end to achieve miniaturization.

(2-2. Structural Example of Coil Resin Structure)

Next, an example of the structure of the coil resin structure 45 will be described with reference to FIG. 5 .

As shown in FIG. 5 , the coil resin structure 45 is formed by arranging the above-mentioned plurality of stator coils 41 in a double-layer overlapping winding manner in such a manner that θ≤360°/N is integrally resin-molded and fixed by molding resin. Thus, the whole is formed into a bobbin shape close to a cylindrical shape. The coil resin structure 45 has a short substantially cylindrical end portion 65 , a short substantially cylindrical end portion 66 , and an intermediate portion 67 located between the end portions 65 , 66 .

The coil end portion 52 of each stator coil 41 is covered and enclosed by the end portion 65 . The coil end portion 53 of each stator coil 41 is covered and enclosed by the end portion 66 . The end portions 54 , 55 of the respective stator coils 41 protrude from the end portion 66 .

The outer diameter of the intermediate portion 67 is smaller than the outer diameter of the end portions 65 , 66 . On the intermediate portion 67, a plurality of substantially rectangular plate portions 68 are arranged along the circumferential direction of the coil resin structure 45. The first coil piece portion 50 of one stator coil 41 is different from the one stator coil 41 ( In this example, the second coil pieces 51 of the other stator coils 41 separated by four slots in the circumferential direction of the coil resin structure 45 are stacked so as to be disposed on the inside and outside of the coil resin structure 45 in the radial direction. The stacked state is covered and enclosed by each plate portion 68 . The tooth portion 34 of the split core element 33 is fitted into the gap 69 between the adjacent plate portions 68 , 68 from the outside in the radial direction of the coil resin structure 45 .

That is, the stator core 32 is configured by assembling a plurality of split core elements 33 on the coil resin structure 45 , and the coil resin structure 45 and the stator core 32 are integrally assembled to form the stator 30 . The assembled stator 30 is attached to the load-side bracket 12 by fitting the end portion 65 of the coil resin structure 45 to the load-side bracket 12 . At this time, the coil ends 52 of the respective stator coils 41 are in close contact with the load-side bracket 12 by the above-mentioned molding resin.

In addition, the structure of the coil resin structure 45 demonstrated above is an example only, and the structure other than the above-mentioned may be employ|adopted.

＜3. Example of manufacturing method of rotating electric machine＞

Next, an example of a method of manufacturing the rotary electric machine 10 will be described with reference to FIGS. 6 to 8 .

As shown in FIG. 6 , in the manufacturing process of the stator coil 41 , first, the round wire 42 is wound a plurality of times in a substantially tortoise shell shape, for example. At this time, as described above, the round wire 42 is wound into a cylindrical shape so that the portions corresponding to the coil pieces 50 and 51 are stacked in multiple layers in the radial direction of the stator (so as not to be twisted in the middle). , and wound in a multi-layer manner on the outer peripheral side of the stack, and wound in a multi-layer manner on the outer peripheral side of the stack, and further wound in a multi-layer manner on the outer peripheral side of the stack winding.

Thereafter, as shown in FIG. 7 , the wound body 80 is disposed between the jigs 70 and 71 , and the jig 70 is lowered in a state of fixing the jig 71 so that the width direction of the wound body 80 (left-right direction in FIG. 7 ) One side and the other side are shifted in the thickness direction (vertical direction in FIG. 7 ) of the wound body 80 .

Then, the orientation of one side and the other side in the width direction of the wound body 80 is adjusted. Thereafter, the outer shape of one long side portion of the wound body 80 is molded by mold so that the outer shape of one long side portion of the winding body 80 matches the cross-sectional shape of the inner peripheral side of the groove 31 , thereby forming the first coil piece portion 50 . In addition, the outer shape of the other long side portion of the wound body 80 is molded with a die so that the outer peripheral cross-sectional shape of the groove 31 is matched to form the second coil piece portion 51 .

Furthermore, as shown in FIG. 8 , the winding body 80 is arranged between the molds 72, 73, 74, and the molds 72, 73 are lowered while the mold 74 is fixed, so that the substantially mountain-shaped portion 81 of the winding body 80 The coil end 52 is formed by press molding such that the outer shape is sandwiched between the dies 72 and 73 and the die 74 . Thereafter, press molding is performed so as to sandwich the substantially central portion of the coil end portion 52 between the molds 72 , 73 to form the raised portion 59 and the inclined portions 57 , 58 . In addition, the coil end portion 53 side is also formed in the same manner as above. Thus, the stator coil 41 is completed.

In addition, in the manufacturing process of the coil resin structure 45 , first, the plurality of stator coils 41 produced above are arranged by double-layer overlapping winding so that θ≦360°/N. Thereafter, the arrayed plurality of stator coils 41 are integrally resin molded and fixed by molding resin. Thus, the coil resin structure 45 is completed.

In addition, in the manufacturing process of the stator 30, the tooth portions 34 of the split core elements 33 are fitted into the respective gaps 69 of the coil resin structure 45 manufactured above from the radially outer side of the coil resin structure 45, so that the coil resin A plurality of split core elements 33 are assembled on the structure body 45 . Thus, the stator core 32 is formed, and the coil resin structure 45 is integrated with the stator core 32 . As a result, the stator 30 is completed.

Thereafter, the stator 30 manufactured above is attached to the load-side bracket 12 such that the end portion 65 of the coil resin structure 45 is fitted into the load-side bracket 12 . Furthermore, the stator 30 attached to the load-side bracket 12 is inserted and attached to the inner periphery of the frame 11 . Thereafter, the shaft 16 and the rotor 20 mounted on the outer periphery of the shaft 16 are inserted into the inner peripheral side of the stator 30 mounted on the inner periphery of the frame 11 and mounted. Furthermore, a non-load-side bracket 14 is attached to the non-load-side end portion of the frame 11 . Thus, the rotating electric machine 10 is completed.

In addition, the manufacturing method of the rotating electrical machine 10 described above is only an example, and the steps of the manufacturing method of the rotating electrical machine 10 may be performed in time series in the order described above, or may be performed in parallel or separately without being performed in time series. In addition, the order of the process performed in time series may be changed suitably according to circumstances.

<4. Effect example of this embodiment>

As described above, in the rotating electric machine 10 of the present embodiment, the plurality of stator coils 41 are housed in the plurality of slots 31 of the stator core 32 in a distributed winding manner. Each stator coil 41 is configured such that the round wires 42 are stacked at least in the stator radial direction, and the stacked arrangement of the round wires 42 in the stator radial direction is the same in the first coil piece portion 50 and the second coil piece portion 51 . As a result, the round wires 42 can be laminated (not laminated approximately along the stator axial direction) approximately along a surface direction perpendicular to the stator axial direction at the coil end portions 52 and 53 . As a result, the dimensions of the coil end portions 52 and 53 in the stator axial direction can be reduced compared to the case where the round wires 42 are stacked on the coil end portions 52 and 53 substantially along the stator axial direction. Therefore, it is possible to reduce the size of the coil end portions 52 and 53 . In addition, in this embodiment, since the round wire 42 is used as the conductor of the stator coil 41, the shape of each part of the stator coil 41 can be easily adjusted by press molding. As a result, winding can be performed with a larger conductor cross-sectional area than when a rectangular wire is used as the conductor, and it can be used for slots 31 of various shapes. In addition, when the shape of the groove 31 is substantially fan-shaped or the like as in the present embodiment, the occupation rate can be increased compared to the case where a rectangular wire is used as the conductor.

In addition, in this embodiment, the coil end 52 of each stator coil 41 has: a bulge 56 that bulges outward in the axial direction of the stator; Two inclined portions 57 and 58 inclined in the vertical surface direction. In addition, the coil end portion 53 of each stator coil 41 has: a raised portion 59 raised outward in the stator axial direction; 2 inclined parts 60, 61. Thereby, a plurality of stator coils 41 can be closely arranged in such a manner that the position of the protruding portion 56 in the stator circumferential direction is sequentially shifted on the side of the coil end portion 52, and the inclined portions 57, 57 of the adjacent stator coils 41, 41 are aligned with each other. The inclined portions 58, 58 overlap each other in the stator axial direction, and on the side of the coil end 53, the stator circumferential positions of the protruding portions 59 are sequentially staggered, and the inclined portions 60, 60 of the adjacent stator coils 41, 41 are inclined to each other. The portions 61, 61 overlap each other in the stator axial direction. As a result, a plurality of stator coils 41 housed in a distributed winding system can be realized.

In addition, in this embodiment, the protruding portions 56 , 59 of the respective stator coils 41 are formed by press-molding the intermediate portions of the coil end portions 52 , 53 . As a result, the protruding portions 56, 59 are formed by press molding in such a manner that the middle portions of the coil end portions 52, 53 are sandwiched by a plurality of molds, and the coil end portions 52, 59 provided with the protruding portions 56, 59 can be reduced in size. 53 radial dimensions. As a result, it is possible to downsize the stator 30 or increase the number of stator coils 41 (the number of slots 31 ) of the stator 30 while maintaining the size of the stator 30 . In addition, since the raised portions 56 and 59 are formed by press molding, the width of the raised portions 56 and 59 can be adjusted to a desired width, and therefore the stator coil 41 can be used in rotating electric machines 10 of various sizes.

In addition, in this embodiment, in particular, the plurality of stator coils 41 are accommodated in the plurality of slots 31 in an overlapping manner. Accordingly, in the rotary electric machine 10 in which the plurality of stator coils 41 are accommodated in a plurality of slots 31 in an overlapping manner, the size reduction of the coil end portions 52 and 53 can be achieved.

In addition, in this embodiment, in particular, the first coil piece portion 50 of each stator coil 41 is accommodated on the inner peripheral side of one slot 31 , and the second coil piece portion 51 is accommodated on the outer peripheral side of the other slot 31 . Accordingly, in the rotating electrical machine 10 in which the plurality of stator coils 41 are housed in the plurality of slots 31 by double-layer overlapping winding, the size reduction of the coil end portions 52 and 53 can be achieved.

In addition, in this embodiment, in particular, the protruding portions 56 and 59 of the respective stator coils 41 are formed so that θ≦360°/N (the angle range θ is equal to or less than the slot pitch). Thereby, since a plurality of stator coils 41 can be densely arranged, it is possible to realize a plurality of stator coils 41 accommodated by double-layer overlapping winding.

<5. Modifications, etc.>

In addition, embodiment is not limited to the said content, Various deformation|transformation is possible in the range which does not deviate from the summary and technical thought.

In the above description, when descriptions such as "perpendicular", "parallel", and "plane" appear, this description is not strictly meaningful. That is, such "perpendicular", "parallel", and "plane" allow design and manufacturing tolerances and errors, and mean "substantially perpendicular", "substantially parallel", and "substantially plane".

In addition, in the above description, when descriptions such as "same", "equal", and "different" appear in the dimensions or sizes in appearance, this description is not strictly meaningful. That is, these "same", "equal", "different" and the like allow design and manufacturing tolerances and errors, and mean "substantially the same", "substantially equal", and "substantially different".

In addition to the above, it is also possible to appropriately combine and use the methods in the above-described embodiment and each modification.

In addition, although not exemplifying one by one, the above-mentioned embodiment and each modified example can be implemented by adding various changes within a range not departing from the gist.

Claims (10)

1. an electric rotating machine, this electric rotating machine has stator and rotor, it is characterised in that

Described stator has:

It is arranged with the stator core of multiple groove in the circumferential；And

The multiple stator coils being accommodated in the plurality of groove according to distributed winding manner,

Each described stator coil has:

It is accommodated in the 1st loop piece portion in 1 groove；

It is accommodated in the 2nd loop piece portion in other grooves different from described 1 groove；And

The end turn extended between described 1st loop piece portion and described 2nd loop piece portion,

This stator coil is configured to: round wires at least in the radially stacking of described stator, described round wires described radially The configuration of stacking be identical for described 1st loop piece portion and described 2nd loop piece portion.

Electric rotating machine the most according to claim 1, it is characterised in that

The described end turn of each described stator coil has:

Protrusion to the axial outward side protuberance of described stator；And

Rake, this rake lays respectively at the both sides of described protrusion, and relative to described axially vertical face side To inclination.

Electric rotating machine the most according to claim 2, it is characterised in that

The described protrusion of each described stator coil is formed by the extrusion forming of the mid portion of described end turn.

Electric rotating machine the most according to claim 3, it is characterised in that

The plurality of stator coil is accommodated in the plurality of groove according to overlapping winding method.

Electric rotating machine the most according to claim 4, it is characterised in that

The described 1st loop piece portion of each described stator coil is accommodated in the side of the described radial direction of described 1 groove, and Described 2nd loop piece portion is accommodated in the opposite side of the described radial direction of other grooves described.

Electric rotating machine the most according to claim 5, it is characterised in that

The described protrusion of each described stator coil is formed as, set described protrusion described circumference angular range as In the case of θ, the quantity of described groove are N, θ≤360 °/N.

7. a manufacture method for electric rotating machine, this electric rotating machine has stator and rotor,

Described stator has:

It is arranged with the stator core of multiple groove in the circumferential；And

The multiple stator coils being accommodated in the plurality of groove according to distributed winding manner,

Described stator core is arranged in the circumferential direction by multiple segmentations key element unshakable in one's determination and constitutes,

Each described stator coil has:

It is accommodated in the 1st loop piece portion in 1 groove；

It is accommodated in the 2nd loop piece portion in other the described groove different from described 1 groove；And

The end turn extended between described 1st loop piece portion and described 2nd loop piece portion,

This stator coil is configured to: round wires at least in the radially stacking of described stator, described round wires described radially The configuration of stacking be identical for described 1st loop piece portion and described 2nd loop piece portion,

The manufacture method of this electric rotating machine is characterised by, including following operation:

By the plurality of stator coil according to the arrangement of described distributed winding manner and resin forming integratedly, form coil tree Fat structure；And

The described coil resin structure formed assembles the plurality of segmentation key element unshakable in one's determination, thus constitute described fixed Son is unshakable in one's determination.

The manufacture method of electric rotating machine the most according to claim 7, it is characterised in that

The plurality of stator coil is accommodated in the plurality of groove according to overlapping winding method,

The described 1st loop piece portion of each described stator coil is accommodated in the side of the described radial direction of described 1 groove, and The described 2nd loop piece portion of each described stator coil is accommodated in other the opposite side of described radial direction of groove described,

The described end turn of each described stator coil has:

Protrusion, it is formed by the extrusion forming of the mid portion of this end turn, and axial to described stator Outward side protuberance；And

Rake, it lays respectively at the both sides of described protrusion, tilts relative to described axially vertical direction, face,

The operation forming described coil resin structure includes following operation: at the angle of the described circumference setting described protrusion In the case of degree scope is θ, the quantity of described groove is N, according to described overlapping winding side in the way of θ≤360 °/N Formula arranges the plurality of stator coil.

9. a stator coil, these stator coils multiple are accommodated in the stator at electric rotating machine according to distributed winding manner In the multiple grooves circumferentially arranged in iron core, it is characterised in that this stator coil has:

It is accommodated in the 1st loop piece portion in 1 groove；

It is accommodated in the 2nd loop piece portion in other the described groove different from described 1 groove；And

The end turn extended between described 1st loop piece portion and described 2nd loop piece portion,

This stator coil is configured to: round wires at least in the radially stacking of described stator, described round wires described radially The configuration of stacking be identical for described 1st loop piece portion and described 2nd loop piece portion.

10. a coil resin structure, it and is set according to distributed winding manner arrangement integratedly by multiple stator coils Fat is molded with, and the plurality of stator coil is accommodated in the stator core at electric rotating machine according to described distributed winding manner On in multiple grooves of circumferentially arranging, it is characterised in that

Each described stator coil has:

It is accommodated in the 1st loop piece portion in 1 groove；

It is accommodated in the 2nd loop piece portion in other the described groove different from described 1 groove；And

The end turn extended between described 1st loop piece portion and described 2nd loop piece portion,

This stator coil is configured to: round wires at least in the radially stacking of described stator, described round wires described radially The configuration of stacking be identical for described 1st loop piece portion and described 2nd loop piece portion.