JP2000041365A - Method of manufacturing electric motor and stator for electric motor - Google Patents

Abstract

(57) [Problem] To improve the space factor of a coil incorporated in each slot of a stator core and to shorten the length of the coil to reduce the resistance, to achieve high efficiency and to reduce the loss and to reduce the size. Provided are a method for manufacturing an electric motor and a stator for the electric motor, which achieve weight reduction. The present invention provides a stator core (1) formed by laminating electromagnetic steel sheets, and a group of magnetic pole teeth (5) formed integrally with or connected to the stator core at predetermined intervals on the inner periphery of the stator core. A group of magnetic pole teeth is sequentially and regularly incorporated, and a coil formed by being wound around the bobbin made of an insulating material is plastically deformed by applying pressure to the formed coil, and has different cross-sectional shapes, and An electric motor comprising a stator having a plurality of types of high-density formed coils 20a and 20b formed so that a combination of adjacent cross sections conforms to a slot shape between the magnetic pole teeth.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a motor used for various industrial equipment, and more particularly to a motor used for an electric vehicle, a hybrid vehicle and the like, and a method for manufacturing a stator for the motor.

[0002]

2. Description of the Related Art In a stator of an electric motor, windings are arranged in a plurality of slots provided in a stator core according to a predetermined rule. The winding types are roughly classified into a distributed winding that forms a coil across a plurality of slots and a concentrated winding in which the coil is wound only on one magnetic pole tooth. Also, as a method of distributed winding, after enameled wire is wound around the outside of the stator core, from the slot opening, both sides of the coil are simultaneously directed in the outer diameter direction, forcibly slipped into the slot, An inserter method of inserting a line is common. On the other hand, as a method of the concentrated winding, there is a straight winding method in which an enamel wire is passed through a nozzle driven at the inner diameter of a stator core, and winding is performed directly on a slot by rotating the nozzle and vertically moving the nozzle in an axial direction.

In order to increase the efficiency and reduce the size and weight of the motor, it is important to increase the space factor (the winding density in the slot). The intersection of the lines inside the line may cause the space factor to be limited. In these systems, the space factor is generally limited to 50 to 70%. Also, as the output of the motor increases, it is necessary to flow a large current,
Although it is necessary to increase the area of the conductor, that is, the diameter of the enameled wire, a wire having a high rigidity deteriorates the workability of the winding and cannot be wound. Therefore, in the above method, generally, the wire diameter of φ1.2 or less is the limit. Therefore,
When winding the stator of a high-output motor, a method of winding a thin wire into a plurality of bundles is adopted. Therefore, the intersection of the wires increases even within the bundle of wires that are wound at the same time,
In addition, the space factor is declining.

To improve the space factor, for example, Japanese Unexamined Patent Publication No. Hei 6-105487 (prior art 1) discloses that an insulating material is provided on a core 80 divided for each magnetic pole tooth as shown in FIG. A concentrated winding method is shown in which the core 83 is assembled, and the core 83 is assembled in an annular shape after being directly wound around the magnetic pole teeth with insulating material. In addition, Japanese Unexamined Patent Publication
As shown in FIG. 14, a coil 91 wound on a bobbin is incorporated into a divided magnetic pole tooth portion 92, and the magnetic pole tooth portion 92 is slid into a core body 93 in the axial direction, as shown in FIG. And how to assemble them. Also, JP-A-3-3625 (Prior Art 3), JP-A-9-84287 (Prior Art 4) and JP-A-9-308142 (Prior Art 5) disclose laminating thin steel plates. A ring-shaped armature core formed, teeth protruding at equal intervals in the circumferential direction inside the armature core, an armature coil wound around the teeth by concentrated winding, and between adjacent teeth. A bobbin mounted in a slot formed on the bobbin and containing an armature coil, wherein the bobbin has a trapezoidal cross section and a rectangular cross section having a rectangular cross section alternately arranged in a circumferential direction. The arrangement is described. Furthermore, Prior Art 4 also describes that a plate-like retaining member made of an insulating material such as resin is attached between cuts formed near the tips of adjacent pole teeth.
Furthermore, in the prior art 5, it is described that the bottom surface of the slot is composed of two planes perpendicular to the center line of the teeth on both sides from the base of the adjacent teeth.

[0005]

By the way, a high-output electric motor typified by an electric vehicle and a hybrid vehicle effectively uses limited energy, so that high efficiency and small and light weight of each part including the electric motor are required. Is required. However, in the prior art 1, the core is divided, and when assembling the divided core, welding is performed for each magnetic pole tooth, so that the insulation provided on the surface of the thin electromagnetic steel sheet is short-circuited to thereby reduce the eddy current. As a result, there is a problem that the output of the electric motor is deteriorated due to the occurrence of an air gap at the dividing surface. Further, in the prior art 2, since the core is assembled from the axial direction, there is a problem that the electromagnetic steel plate is rubbed at the joint portion of the core and the insulating layer is short-circuited.

Also, in order to improve the space factor, in the method using the split core described in the prior art 1, when winding the wire in the slot, a tension sufficient to make the wire go straight is applied to the insulating film. The wire is wound in a bulging trajectory in the center of the core, resulting in a gap between the wires and a gap between the coils, There has been a problem that the space factor has a limit, and the larger the conductor cross-sectional area of the coil, the greater the effect. Further, the prior arts 3, 4, and 5 only describe that in a concentrated winding stator, two types of cross-sectional shapes of coils having only windings are used to improve the winding density, and the space factor is limited. There is no sufficient consideration for achieving high efficiency, small loss, and small size and light weight.

SUMMARY OF THE INVENTION An object of the present invention is to improve the space factor of a coil incorporated in each slot of a stator core and shorten the length of the coil to reduce the resistance, thereby achieving high efficiency and high efficiency. Another object of the present invention is to provide an electric motor which realizes a small size and light weight with a small loss. Another object of the present invention is to provide a high-efficiency, small-sized and lightweight high-output motor for driving an electric vehicle, a hybrid vehicle, and the like, which require a stator using a coil having a large conductor cross-sectional area. It is in. Another object of the present invention is to
An object of the present invention is to provide a method of manufacturing a stator for an electric motor, which is capable of easily manufacturing a stator coil that constitutes an electric motor with high efficiency, reduced loss, and reduced size and weight.

[0008]

In order to achieve the above object, the present invention provides a stator core (stator back core) formed by laminating electromagnetic steel sheets, and the stator core having a predetermined interval on an inner periphery of the stator core. A group of magnetic pole teeth formed integrally with the group of magnetic pole teeth, and a pressure is applied to the coil formed by being regularly wound around the group of magnetic pole teeth and wound around the bobbin made of insulating material. A stator having a plurality of types of high-density formed coils formed so as to be applied and plastically deformed so that the cross-sectional shapes are different from each other, and a combination of adjacent cross-sections is adapted to the slot shape between the magnetic pole teeth. An electric motor characterized in that: Further, the present invention provides a stator core (stator back core) formed by laminating electromagnetic steel sheets, and the stator core is joined to the inner periphery of the stator core at a predetermined interval,
A group of magnetic pole teeth formed by laminating magnetic steel sheets, and a coil formed by being regularly wound around the group of magnetic pole teeth and wound around the bobbin made of insulating material. A stator having a plurality of types of high-density molded coils molded so that the cross-sectional shapes are different from each other by applying pressure and plastically deformed, and a combination of adjacent cross-sections is adapted to the slot shape between the magnetic pole teeth. An electric motor characterized by comprising:

Further, the present invention is characterized in that, in the electric motor, the plurality of types of high-density formed coils are constituted by two types, one having a substantially rectangular cross-sectional shape and one having a substantially trapezoidal cross-sectional shape. . Further, the present invention is characterized in that, in the electric motor, a semi-closed slot or a closed slot is formed by attaching a member of a magnetic material to a tip of each magnetic pole tooth in the group of magnetic pole teeth. Further, in the present invention, in the electric motor, in the stator core, a desired portion of the outer diameter is notched symmetrically about the axis, and the inner diameter of the core back is substantially constant in accordance with the notch. Forming a modified slot between the magnetic pole teeth, and incorporating a plurality of types of high-density molded coils having a cross-sectional shape conforming to the shape of the modified slot into each of the magnetic pole teeth forming the modified slot. I do.

[0010] Also, the present invention provides the electric motor, conductors sectional area of each wire of the plurality of types of high-density molded coil, characterized in that it is a 1.3mm ² ~8.0mm ^2.

[0011] The present invention also provides a motor, in which a plurality of types of high-density formed coils can generate a uniform magnetic field, so that various high-density formed coils have a sectional area, a number of turns, a conductor type, and the like. It is characterized in that the conductor wire thickness and the insulation type are made substantially constant.

[0012] Further, the present invention provides a winding step of winding a wire around an outer periphery of a bobbin made of an insulating material so as to form a plurality of types of coils, so as to conform to the above-mentioned type, and winding the bobbin in the winding step. A tooth-shaped member is inserted into the inner diameter of the bobbin for each of the plurality of types of coils wound and arranged, and a predetermined pressure is applied to both sides, and a tip has a molding surface adapted to a plurality of types of molding cross-sectional shapes. A forming step of forming a high-density forming coil having a plurality of types of forming cross-sectional shapes by plastically deforming each wire by pressing the forming punch member at a desired pressure from the outer peripheral direction and fixing the same; Each type of high-density molded coil having a plurality of types of molded cross-sections fixed is formed integrally with the stator core at predetermined intervals on the inner periphery of a stator core formed by laminating electromagnetic steel sheets. Is a manufacturing method of the motor stator, characterized in that it comprises a built-in step of incorporating successively regularly from the inner diameter side with respect to the group of pole teeth which. The present invention also provides a winding step of aligning and winding a wire around an outer periphery of a bobbin made of an insulating material so as to form a plurality of types of coils, and winding the wire around the bobbin in the winding step. A tooth-shaped member is inserted into the inner diameter of the bobbin for each of the plurality of types of coils formed, and a predetermined pressure is applied to both sides, and a forming punch member having a forming surface adapted to a plurality of types of forming cross-sectional shapes at its tip end Is pressed at a desired pressure from the outer peripheral direction to plastically deform each wire to form and fix a high-density molded coil having the plurality of types of molded cross-sectional shapes. A stator core formed by laminating magnetic steel sheets with magnetic pole teeth formed by laminating magnetic steel sheets by sequentially incorporating each type of high-density formed coil having a plurality of types of formed cross-sectional shapes The inner circumference is a manufacturing method of the motor stator, characterized in that it comprises a built-in step of binding at a predetermined interval.

As described above, according to the above configuration,
Without lowering the insulation reliability, improve the space factor of the coil incorporated in each slot of the stator core and shorten the length of the coil to reduce the resistance, achieve high efficiency and reduce loss. The motor can be reduced in size and weight. Further, according to the configuration, an electric vehicle conductor sectional area stators are required with large coils is 1.3mm ² ~8.0mm ^2, the high-output electric motor for driving a hybrid vehicle such as a high efficiency In addition, the size and weight can be reduced. Further, according to the above configuration, a stator coil constituting a high-efficiency, small-size, and light-weight motor with reduced loss can be easily manufactured without lowering insulation reliability. In particular, in the forming step, by setting the forming pressure at the time of forming the high-density formed coil to about 35 kg / mm ² or less, it is possible to manufacture a high-density formed coil having an arbitrary cross-sectional shape without deteriorating the insulation characteristics. it can.

[0014]

Embodiments of the present invention will be described with reference to the drawings. First, the first stator in a high output motor for driving an electric vehicle stator conductor cross-sectional area according to the present invention is using a large coil is 1.3mm ² ~8.0mm ² is required, the hybrid vehicle or the like
The embodiment will be described with reference to FIGS. FIG. 1 is a plan sectional view showing a first embodiment of a stator in a high-output motor according to the present invention, and FIG. 2 is a schematic partial sectional perspective view showing a high-output motor according to the present invention. As shown in FIG. 2, a plurality of types of high-density formed coils 2 are provided in a plurality of slots 10 provided in stator core 1.
0a and 20b are arranged in accordance with a predetermined rule, and a rotor 9 is rotatably arranged in the stator.
It is composed of

As shown in the slot cross section shown in FIG. 1, the stator 8 has a plurality of types of high sections whose cross sections are formed so that the space factor, which is the ratio of the cross section of the coil to the cross section of the slot, is high. The density forming coils 20a and 20b are
They are arranged in the slot 10 in combination. Next, the space factor will be described. FIG. 3 shows four types of coil cross sections as explanatory diagrams of the space factor. FIG.
3 (a) and 3 (b) show a case where a round wire is used as a coil wire material and aligned winding is performed, and FIGS. 3 (c) and 3 (d) show
This shows a case where the cross section of the aligned coil is formed into an arbitrary shape, for example, the cross section of the coil is formed into a rectangular shape. In this figure, a rectangular range including all the coils is defined as a slot 30. At this time, the diameter of the wire 31 is d, the width of the slot 30 is w, the height is h, the number of lines in the width direction is m, the number of lines in the depth direction is n, and the number of lines in the slot 30 is N.

In the case of FIG. 3A, w = m × d, h = n ×
d, and the space factor sf is sf = π / 4 × 100 = 7
Geometrically, it is impossible to obtain a space factor higher than 8%. In the case of FIG. 3B, w = d + √
3d / 2 × (m−1), h = d × n, and the space factor sf is sf = (N × πd2 / 4) / (w ×
h) × 100. For example, when m = 3 and n = 3, sf = 76%. In this case, with the same winding specification,
To increase the space factor,
It is necessary to increase m and n, that is, what has been wound by one wire must be wound in a bundle composed of a plurality of thin wires in an aligned manner. As shown in FIG. For these reasons, in general,
For aligned windings, the limit was 50-70%.

By the way, as shown in FIGS. 3C and 3D, in the aligned coils 32a and 32b,
High-density formed coil 33 formed by forming a cross section
By obtaining a and 33b, it is possible to obtain a space factor higher than the above limit, that is, 70 to 80% or more. The improvement of the space factor will be specifically described. For example, for a stator having the same core shape, a space factor improvement of 20% corresponds to an increase in the cross-sectional area of the coil by 20%, and a resistance reduction of 20%, that is, Copper loss can be reduced, and motor efficiency improves. Also,
By improving the space factor, there is almost no void in the slot, so that the performance of cooling the heat generated by the coil is improved, and the performance of the motor is further improved. In particular, the conductor area is 1.3 mm
^The above-described effect is remarkable in a high-output electric motor for driving an electric vehicle, a hybrid vehicle, or the like that requires a stator using a large coil of ^{2 to} 8.0 mm ² .

Next, an embodiment of a method for manufacturing a stator for a high-output motor according to the present invention will be described with reference to FIGS. First, as shown in FIG. 4, a winding frame 40 includes a base member 41 forming one flange (side surface), a center member 42 forming a core of rectangular cross section, and a punch member forming another flange (side surface). 43 and is assembled. Before winding, the bobbin-shaped insulating material 15 that matches the winding frame is inserted into the winding frame 40 in advance. It is necessary to select the insulating material 15 in consideration of the cross-sectional formation and coil fixation in a later process. For example, using an aramid paper, an engineering plastic material, a film material such as a liquid crystal polymer, etc. It is advisable to manufacture and use a bobbin shape. Further, it is more preferable to select an insulating material having a tensile strength of 7 kg / mm ² in order to increase the design margin of the insulating properties of the insulating material 15 in the cross-section forming step in the subsequent step. In addition, in order to reduce copper loss (Joule heat loss caused by coil resistance and current) which causes a reduction in efficiency of a high-output motor, a high-density coil 20
Should be wound with a minimum circumference, and in order to achieve this, the Lm dimension of the winding frame 40 is taken into consideration by considering the minimum bending radius of the winding in the stator stacking thickness L (shown in FIG. 2). Then, it is good to set it to the minimum value including the clearance of assembly.

Next, a method of aligning winding on the winding frame 40 will be described with reference to FIG. As shown in FIG. 5 (a), a winding machine is provided with a main shaft 50 for winding a wire and an oscillating shaft 51 for changing the angle of a winding frame. Configure so that it can be drawn. In particular, in order to obtain a coil cross-section having an arbitrary shape, it is necessary to form an oblique crossover wire 59 as shown in FIG. 5 (b). The bobbin 40 is tilted by swinging. Further, the winding machine supports a holding member for holding the coil wound on the bobbin, and controls the holding member so as to follow a change in the diameter of the coil with the rotation of the main shaft 50. A winding frame side guide shaft 52 for controlling the position of the coil may be provided. And the reel 40
A winding guide 53 that can be driven in three axes is arranged as a guide for controlling the trajectory of the line. By fixing the end of the wire 55 to the winding frame 40, the wire 55 is supplied from the wire bobbin 60 via the tensioner mechanism 54 that controls the tension at the time of winding. In this way, by controlling each axis 50, 51 of the winding frame and each axis of the winding guide 53, and controlling the tension on the rotating shaft 50 by the tension mechanism 54, the wire 55 is It is possible to obtain a coil having an arbitrary shape along the shape of the bobbin by being aligned and wound. At this time, if the shape of the coil is such that the winding is easy, the winding machine may use equipment in which the number of axes to be controlled is reduced or the number of axes is reduced in order to reduce equipment costs. According to this method, it is possible to form an array winding 32 of a plurality of types of coils corresponding to a plurality of types of high-density formed coils.

Next, a method of forming each of a plurality of types of aligned and wound coils in order to improve the space factor with respect to the slots of the stator will be described with reference to FIG.
FIG. 6 shows an embodiment of the molding apparatus. In this way, in order to form the cross section of the coil that has been wound, the tip for pressing the winding frame 40 taken out of the winding machine from the lateral direction in the drawing corresponds to the cross-sectional shape of the high-density formed coil. A side punch 41 having a forming surface is set on the coil portion of the winding frame 40 to form a forming apparatus. Here, a side punch 51 having a molding surface corresponding to the cross-sectional shape of the high-density molding coil at the tip while applying a pressing force of P2 from two axial directions.
, The cross section of the coil 32 that has been aligned and wound can be formed into a cross section along the forming die. In this case, the bobbin base member 41 forming the flange (side surface)
By applying a desired pressure P1 to the punch member 43 and the punch member 43, the interval between the bobbin base member 41 and the punch member 43 can be kept constant. Furthermore, the forming die is
Since it is also used as 0, the aligned winding state in the previous process is maintained, the wires are hardly crossed, and the wire can be formed with almost no deterioration in insulation. In addition, a plurality of types of high-density formed coils 20a,
In order to form Ob, it is necessary to replace the side punches 51 having different molding surfaces.

Further, at this time, the coil contact surface (forming surface)
By using a side punch 51 having a different inclination angle and the like, a winding frame base member 41 having a different inclination angle and the like of the coil contact surface, and a punch member 43, the cross-section of the aligned coil 32 can be formed into an arbitrary shape. Can be molded into In particular, in order to obtain a high-density molded coil 20a having a substantially rectangular cross-section and a high-density molded coil 20b having a substantially trapezoidal cross-section, a side punch whose tip molding surface does not tilt and a trapezoidal inclined shape are used. All you have to do is prepare a side punch. As a molding device, FIG.
As shown in (b), by applying the pressing force P3 to the cam mechanism 52 in the same direction, the side punch 51 may be pushed in while applying the pressing force of P2. Further, the sectional shape may be changed by changing the pressing force using the same mold. Further, for example, in the above-described high-output motor, the conductor 31 is made of copper, the insulation film 24 is made of polyamide-imide, and a wire 31 having a conductor diameter of 1.3 to 3.2 mm is used. In this case, the working pressure P2
Is preferably set to about 35 kg / mm ² or less.

By this molding, the coil is fixed while maintaining the state where the cross section of the coil is formed. At this time,
The insulating material 15 may be fixed together. As this fixing method, the wire rod is a self-bonding wire having a fusion layer on the outermost layer,
A method of applying heat or fusing by heating with a heater or the like, or a method of bonding with an adhesive, varnish impregnation, or the like may be used. Here, as shown in FIG. 7, in the cross section of the formed high-density formed coil 33, the insulating material 15
In the above, the contact portion of the wire on the coil contact surface side is compressed, and the opposite side is substantially flat. In addition, the high-density formed coil 33
Is in a state in which there is almost no void in the coil due to the cross-sectional molding. At this time, the insulation thickness t after molding is set to a size capable of exhibiting a dielectric strength greater than or equal to the motor specification, and the insulation reliability is improved when the performance after molding of the insulating material is taken into consideration. Therefore, a high-density formed coil having a high space factor and no waste in circumference can be formed. By incorporating this high-density formed coil into the core, a high space factor stator can be obtained, and a high-efficiency small and lightweight motor can be obtained. Can be realized.

Next, an embodiment of a stator incorporating a high-density formed coil according to the present invention will be described. First,
A first embodiment of a stator in which two types of high-density formed coils are incorporated in a stator core will be described with reference to FIG. Stator core 1 is a laminated iron core using an electromagnetic steel sheet such as a silicon steel sheet. High-density formed coils 20a, 20 arranged on each magnetic pole tooth 5 of stator core 1, respectively.
b, in the cross-sectional shape in a direction orthogonal to the axial direction of the stator core 1, the inside is substantially parallel to the teeth, and when the respective coils are combined, the shape becomes substantially the same as the slot cross-section, so that the space factor can be improved. . That is, as shown in FIG. 1, the high-density formed coil 20a is formed into, for example, a substantially parallelogram cross section, and the high-density formed coil 20b is formed into, for example, a substantially fan-shaped cross section. , 20b are respectively inserted into the magnetic pole teeth 5 of the stator core 1, so that the high-density formed coil 20a having a substantially parallelogram cross-sectional shape and the high-density formed coil 20b having a substantially fan-shaped cross-section are formed in one slot. As a result, the gap between the coils is almost eliminated, and the space factor in the slot can be increased. Further, since the stator core 1 has no divided portion, deterioration of magnetic characteristics such as an increase in an air gap and an increase in an eddy current due to the division does not occur.

Next, in the first embodiment of the stator, the magnetic pole teeth portion or the slot opening is
FIG. 9 shows a second embodiment in which different parts are combined.
This will be described with reference to FIG. As shown in FIG. 9, the combination of a plate-shaped component 62 in the slot opening or a substantially fan-shaped component 61 inside the core of the magnetic pole teeth prevents coil detachment after assembling the high-density molded coil. It is also possible to reduce cogging torque which causes noise and the like. The material of these separate parts may be a part in which electromagnetic steel sheets are laminated as in the case of the core, or a part manufactured by fixing powder of a magnetic material so as to reduce the eddy current. This stator can be manufactured by incorporating the coil 20b radially in each magnetic pole teeth portion and then incorporating the coil 20a. The method of connecting these components depends on the environmental conditions of the motor, but it is preferable to press-fit or bond with a thermosetting resin.

Next, a description will be given of a third embodiment of a stator in which two types of high-density formed coils are incorporated in a stator core obtained by dividing magnetic pole teeth components, with reference to FIG. As shown in FIG. 10, the stator core 2 includes an annular core-back iron core 3 and teeth cores 5a to 5l divided for each magnetic pole tooth. Each of the two types of high-density formed coils 20a and 20b is inserted into each of the teeth cores 5a to 5l. Here, the core back iron core 3 and each of the teeth cores 5a to 5l are laminated iron cores using electromagnetic steel sheets. By combining these iron cores, the stator core 2 can form a semi-closed slot having an opening in the slot 10 on the inner peripheral side of the core. Each tooth part iron core 5a ~
5l are arranged radially with respect to the axis of the core and substantially evenly in the circumferential direction, and include a portion parallel to the radial direction and a portion formed in a substantially sector shape toward the inner periphery. ,
It is substantially T-shaped. Each divided iron iron core 5
The coupling portion between a to 51 and the core back iron core 3 has one coupling surface 4 formed in a concave shape and the other coupling surface 6 formed in a convex shape so as to fit each other. In this stator, after arranging each of the coils 20a and 20b on the core back iron core 3, the teeth cores 5a to 5l may be incorporated in the radial direction, or the teeth cores 5a to 5l may be attached to the teeth cores 5a to 5l. Coil 20
After each of a and 20b is assembled, each of the incorporated tooth cores 5a to 5l may be assembled into the core back iron core 3 to produce the core. The method of connecting these components depends on the environmental conditions of the motor, but it is preferable to perform bonding using a thermosetting resin, mechanical bonding by caulking from the stator axis direction, spot welding from the stator axis direction, or the like. .

On the other hand, each magnetic pole tooth 5 of the stator core 2
High-density formed coils 20a, 20b respectively arranged in
In the same manner as in the above-described embodiment, the cross-section is formed in an arbitrary shape so that a shape having a high density and a high space factor can be obtained in a state where the coils 20a and 20b are combined.
In this way, a stator having a high space factor can be similarly obtained for the divided cores. In all of the embodiments described above, two types of high-density formed coils 20a,
Although the description has been made with the combination of 0b, the type of the coil cross section may be increased, or conversely, may be reduced, in order to improve the space factor and the motor performance, and to improve the assemblability.
Since an increase in the number of coils leads to an increase in the types of the winding frame and the forming die (forming device), three or less types are desirable.

Next, a fourth embodiment of the stator in which the outer diameter and the status lot shape are changed will be described with reference to FIG. In the fourth embodiment, the stator core 70 is formed so that a part 71 of a round core shape is cut out so that a space for the outer diameter can be obtained.
In a certain area, slots 11a and 11b having different shapes from the area having a round outer diameter are formed so that the dimension c of the core back becomes substantially constant from the relation of the magnetic flux density. When the outer diameter of the other outer diameter portion of the stator core 70 is similarly made rectangular by notching, the slots are formed in different shapes 11a and 11b so that the dimension c of the core back becomes substantially constant. For the core having such irregularly shaped slots, the above-described high-density molded coil, that is, a coil having a cross section of an arbitrary shape is manufactured, and these are combined and incorporated into the core, thereby increasing the stator occupancy. The moment can be increased. In this case, by designing a combination of the cross-sectional shapes of the coils according to the shapes of the deformed slots 11a and 11b, and using a winding frame and a molding die that match the designed combination of the cross-sectional shapes of the coils, the deformed slots 11a and 11b It is possible to manufacture a high-density formed coil conforming to the shape of the above. As described above, by configuring the stator with the high space factor having the odd-shaped slots 11a and 11b, the vibration generated in the core can be reduced, and the outer shape can be cut out, so that the space for mounting the electric motor can be reduced. Can be expanded.

Next, an embodiment of the above-described motor connection will be described with reference to FIGS. FIG. 12 is a connection diagram in the case of 12 coils and 4 coils connected in series in a three-phase motor. That is, 12 coils,
The three-phase motor in the case of the four-coil series connection includes four U coils in which high-density formed coils 20b and high-density formed coils 20a are alternately connected in series, and a high-density formed coil 20a and a high-density formed coil 20b. Three V-coils alternately connected in series and four W-coils alternately connected in high-density formed coil 20b and high-density formed coil 20a
It is composed of phases. Then, 1 if the corresponding Ri of the number of turns was 4n (integer), n ₁ = n (n ₁ is the number of turns / coil) to. FIG. 13 is a connection diagram in the case of 12 coils, 2 series and 2 parallel connections in a three-phase motor. That is, 1
The three-phase motor in the case of two coils, two series, and two parallel connections is composed of four U coils in which high-density molded coils 20b and high-density molded coils 20a are alternately connected in two series and two parallel, and a high-density molded coil 20a. The four V coils in which the high-density molded coils 20b are alternately connected in two series and two parallels, and the four W coils in which the high-density molded coils 20b and the high-density molded coils 20a are alternately connected in two series and two parallels It is composed of three phases. And the number of turns equivalent to 1 is 4n (integer)
In this case, n ₂ = 2n (n ₂ is the number of turns / coil).

FIG. 14 is a connection diagram in the case of 12 coils and 4 parallel connections in a three-phase motor. That is, the three-phase motor in the case of 12 coils and 4 parallel connections has four U coils in which the high density formed coil 20b and the high density formed coil 20a are alternately connected in 4 parallel, and the high density formed coil 20a and the high density formed coil 20a. 4 in which the forming coil 20b and the forming coil 20b are alternately connected in parallel.
It is constituted by three phases of four V coils and four W coils in which the high-density formed coil 20b and the high-density formed coil 20a are alternately connected in four parallels. Then, 1 if the corresponding Ri of the number of turns was 4n _{(integer), n 3 = 4n (n} 3 is the number of turns / coil) to. Thus, the stator core
By incorporating two or three types of high-density molded coils formed in an arbitrary shape from the radial direction, the space factor of the status lot can be improved, and the coil length can be shortened to reduce coil resistance. As a result, the loss of the motor is reduced, the cooling performance of the coil is improved,
High output, high efficiency, small size and light weight of the motor can be realized.

[0030]

According to the present invention, the space factor of the coil incorporated in each slot of the stator core is improved and the length of the coil is shortened to reduce the resistance without lowering the insulation reliability. Moreover, by improving the cooling performance of the coil, there is an effect that the motor can be reduced in size and weight with high efficiency and small loss. Further, according to the present invention, the conductor sectional area is 1.3 mm.
The high output motor for driving an electric vehicle, a hybrid vehicle, or the like that requires a stator using a large coil of ^{2 to} 8.0 mm ² has the effect of achieving high efficiency, small size, and light weight. . According to the present invention,
It is possible to easily manufacture a stator coil that constitutes an electric motor with high efficiency, small loss, and small loss without reducing the insulation reliability. In particular,
In the forming step, by setting the forming pressure at the time of forming the high-density formed coil to about 35 kg / mm ² or less, a high-density formed coil having an arbitrary cross-sectional shape can be manufactured without deteriorating the insulation characteristics.

[Brief description of the drawings]

FIG. 1 is a plan sectional view showing a first embodiment of a stator of a high-output motor according to the present invention.

FIG. 2 is a schematic partial cross-sectional perspective view showing a high-output motor according to the present invention.

FIG. 3 is a sectional view of a coil for explaining a space factor;

FIG. 4 is a view showing one embodiment of a bobbin according to the present invention.

FIG. 5 is an explanatory diagram of an alignment winding method according to the present invention.

FIG. 6 is an explanatory view of a molding device according to the present invention.

FIG. 7 is a perspective view showing a high-density formed coil according to the present invention and an enlarged cross-sectional view taken along the line AA.

FIG. 8 is a diagram showing a first embodiment in which a high-density formed coil is incorporated into an undivided core according to the present invention.

FIG. 9 is a view showing a second embodiment in which a coil detachment preventing component is incorporated in a non-split core according to the present invention.

FIG. 10 is a view showing a third embodiment in which a high-density molded coil is incorporated in a split core according to the present invention.

FIG. 11 is a view showing a fourth embodiment in which a high-density formed coil is incorporated in a core having a modified slot shape according to the present invention.

FIG. 12 is a connection diagram of a three-phase motor according to the present invention in the case of 12 coils and 4 coils connected in series.

FIG. 13 is a connection diagram in the case of 12 coils, 2 series and 2 parallel connections in the three-phase motor according to the present invention.

FIG. 14 is a connection diagram in the case of 12 coils and 4 parallel connections in the three-phase motor according to the present invention.

FIG. 15 is a view showing a conventional stator structure.

FIG. 16 is a diagram showing another conventional stator structure.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Stator core, 2 ... Electric motor, 3 ... Core back iron core,
4, 6: coupling surface, 5, 5a to 5l: magnetic pole teeth iron core,
8 ... stator, 9 ... rotor, 10 ... slot, 11a,
11b: odd-shaped slot, 15: insulating material, 20: combined high-density molded coil, 20a, 20b, 33, 33
a, 33b: high-density formed coil, 24: insulating coating, 3
2, 32a, 32b ... aligned winding coil, 40 ... winding frame, 4
DESCRIPTION OF SYMBOLS 1 ... Base member, 42 ... Center member, 43 ... Punch member, 50 ... Main shaft, 51 ... Swing shaft, 52 ... Reel-side guide shaft, 53 ... Winding guide, 54 ... Tension mechanism, 55 ...
Wire rod, 60 ... wire rod bobbin, 70 ... stator core, 71 ...
Notch.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Yuji Enomoto 292 Yoshidacho, Totsuka-ku, Yokohama-shi, Yokohama, Japan Inside of Manufacturing Research Laboratory, Hitachi, Ltd. (72) Inventor Suetaro Shibukawa 2520, Daiba Takaba, Hitachinaka-shi, Ibaraki, Japan (72) Inventor Shoji Senoo 7-1-1 Higashi Narashino, Narashino-shi, Chiba F-term (in reference) 5H604 AA08 BB01 BB14 CC01 CC05 CC13 CC15 DA22 DB02 DB18 DB26 PB03 5H615 AA01 BB01 BB14 PP01 PP06 PP07 PP10 PP13 QQ02 QQ12 QQ19 QQ25 QQ26 RR02 SS03 SS05 SS10 SS15 SS16 SS18 SS19 TT04 TT27 TT31 TT39

Claims (8)

[Claims] A stator core formed by laminating magnetic steel sheets; a group of magnetic pole teeth formed integrally with the stator core at predetermined intervals on an inner periphery of the stator core; and a group of magnetic pole teeth. Built in sequentially,
Pressure is applied to the coil formed by being wound around the bobbin made of an insulating material in an aligned manner and plastically deformed, so that the cross-sectional shapes are different from each other, and a combination of adjacent cross-sections is a slot shape between the magnetic pole teeth. An electric motor comprising: a stator having a plurality of types of high-density formed coils formed so as to conform to the above. 2. A stator core formed by laminating electromagnetic steel sheets, a group of magnetic pole teeth joined to the stator core at predetermined intervals on an inner periphery of the stator core, and formed by laminating electromagnetic steel sheets; Incorporated into groups of teeth in order,
Pressure is applied to the coil formed by being wound around the bobbin made of an insulating material in an aligned manner and plastically deformed, so that the cross-sectional shapes are different from each other, and a combination of adjacent cross-sections is a slot shape between the magnetic pole teeth. An electric motor comprising: a stator having a plurality of types of high-density formed coils formed so as to conform to the above. 3. The electric motor according to claim 1, wherein the plurality of types of high-density formed coils are constituted by two types of a coil having a substantially rectangular cross section and a trapezoid having a substantially trapezoidal cross section. . 4. The electric motor according to claim 1, wherein in the group of magnetic pole teeth, a semi-closed slot or a closed slot is formed by attaching a member made of a magnetic material at the tip of each magnetic pole tooth. 5. A magnetic pole, wherein a desired portion of an outer diameter is notched symmetrically about an axis, and an inner diameter is formed in accordance with the notch so that a dimension of a core back is substantially constant. 2. A modified slot formed between the teeth, and a plurality of types of high-density formed coils having a cross-sectional shape adapted to the shape of the modified slot are incorporated in each magnetic pole tooth forming the modified slot.
Or the electric motor according to 2. Wherein said plurality of types of the cross-sectional area of the conductor of each wire of a high density molded coils, according to claim 1 or 2 or 3 or 4 or 5, characterized in that it is 1.3 mm ² ～8.0Mm ² An electric motor as described. 7. A winding step of aligning and winding a wire around an outer periphery of a bobbin made of an insulating material so as to form a plurality of types of coils, and winding the wire around the bobbin in the winding step. A tooth-shaped member is inserted into the inner diameter of the bobbin for each of the plurality of types of coils, and a predetermined pressure is applied to both sides, and a forming punch member having a forming surface adapted to the plurality of types of forming cross-sectional shapes at the tip is provided. A forming step of forming a high-density formed coil having a plurality of types of formed cross-sectional shapes by pressing each wire in a desired pressure from an outer peripheral direction and plastically deforming each wire; The magnetic pole tees formed integrally with the stator core at predetermined intervals on the inner periphery of a stator core formed by laminating electromagnetic steel sheets are formed by placing each type of high-density formed coil having different shaped cross-sectional shapes. Method of manufacturing a motor stator, characterized in that it comprises a built-in step of incorporating successively regularly from the inner diameter side with respect to the group of the scan. 8. A winding step of aligning and winding a wire around the outer periphery of a bobbin made of an insulating material to form a plurality of types of coils, and winding the wire around the bobbin in the winding step. A tooth-shaped member is inserted into the inner diameter of the bobbin for each of the plurality of types of coils, and a predetermined pressure is applied to both sides, and a forming punch member having a forming surface adapted to the plurality of types of forming cross-sectional shapes at the tip is provided. A forming step of forming a high-density formed coil having a plurality of types of formed cross-sectional shapes by pressing each wire in a desired pressure from an outer peripheral direction and plastically deforming each wire; Each type of high-density molded coil having different molded cross-sectional shapes is regularly and sequentially incorporated, and a magnetic pole tooth formed by laminating electromagnetic steel sheets is used to form a stator core formed by laminating electromagnetic steel sheets. Method of manufacturing a motor stator, characterized in that it comprises a built-in step of bonding at predetermined intervals in the circumference.