JP2008092654A - Rotating electric machine stator and coil winding method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce a dead space in a coil structure of a stator in a dynamo-electric machine. <P>SOLUTION: A slot region Rsl is partitioned into a first sectional slot region Rsl1 onto which a first coil 12a is wound, and a second sectional slot region Rsl2 onto which a second coil 12b is wound. Each layer above a second layer in the coils 12a, 12b is positioned in a valley between the coils on the lower layer side of own region other than a border Rbd and an end Rce. The second coil 12b belatedly wound is positioned in the valley between the first and second coil 12a, 12b in the lower layer bridged between the first and second slot regions on the border Rbd between the first and second slot regions. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a structure of a stator of a rotating electric machine (motor or generator) in which a coil is wound around a core and a coil winding method, and more particularly to a countermeasure for reducing dead space.

  In recent years, with the development of new technologies such as electric vehicles, hybrid vehicles, and robots, the performance required for rotating electric machines (motors and generators) for driving them has become more sophisticated. For example, in an electric vehicle and a hybrid vehicle, it is required to flow a large current and save space. In addition, robots are required to have higher speed, space saving, and higher output.

  Generally, when increasing the current flowing through the coil, increasing the coil wire diameter increases the difficulty of coil winding due to increased rigidity of the coil wire, and eddy loss. Therefore, a structure in which multiple thin wires are wound around the core is often adopted. Has been. For example, in Patent Document 1, a plurality of coils in a bundle in parallel are inclined at a predetermined angle with respect to a horizontal winding surface of the core, and winding of the core is performed from a coil wire close to the core among the inclined bundled coil wires. A method has been disclosed in which a coil wire is prevented from climbing up by winding it sequentially on a surface to realize a high-density coil structure. Further, in Patent Document 2, as shown in FIG. 6, a partition wall 203a that divides the slot region Rsl into two partial slot regions Rsl1 and Rsl2 is provided in an insulator 203 laid in the slot region Rsl of the core 201. A method for realizing a high-density coil structure by individually winding the coil 202 around the partial slot region is disclosed.

JP-A-7-194075 Japanese Patent Laid-Open No. 11-27886

  However, as disclosed in Patent Document 1, it is known that a so-called para-winding, in which a plurality of coil wires are wound in a bundled state, causes swelling at the coil end portion. 5 (a) and 5 (b) are diagrams for explaining the results of analysis by the inventor through experiments. FIG. 5 (a) is a side view of the motor stator as viewed from the coil end side, and FIG. 5 (b) is an end of the coil end part on the back yoke side of the motor stator, It is a perspective view explaining the state of the coil of each site | part. As shown in FIG. 5A, a region surrounded by the insulator 203 by the back yoke portion 101a of the split core 101 and the flange portion 101b is the slot region Rsl. As shown in FIG. 5 (b), it has been observed that the coil end portion bulges when climbing over the lower layer coil due to the rising of the layer. The coil end portion is a start and end region of winding of the coil, and is substantially orthogonal to the side (coil side portion) where the split cores 101 face each other. It has also been observed that the swelling occurs in both the back yoke portion 101a and the region in contact with the flange portion 101b. In other words, it is difficult to eliminate the bulge at the end, and as a result, the size (height dimension) on the end side of the motor increases due to the bulge.

  On the other hand, in the method of Patent Document 2, a gap is generated between the partition wall 203a and the coil 202 as shown in FIG. That is, a partition 203a and a gap existing between the partition 203a and the coil 202 exist as dead spaces between the two divided partial slot regions Rsl1 and Rsl2. As a result, although the bulge can be eliminated, the space factor in the slot region is reduced, and there is a limit to increasing the density of the coil structure.

  An object of the present invention is to fix a rotating electrical machine that can realize high density and high power of a coil structure by taking a means for reducing dead space in a slot region as much as possible while winding a plurality of coil wires around a core. It is to provide a method of winding a child and a coil.

  The stator of the rotating electrical machine of the present invention is obtained by individually laminating and winding coil wires from the bottom of the split core in the plurality of partial slot regions of the slot region, and each layer of the second and higher layers of each partial slot region In the portion excluding the boundary and the end of the adjacent region (adjacent partial slot region), the upper layer side coil wire is located in the valley between the lower layer side coil wires of the own region (partial slot region), In the boundary part, either the self region or the adjacent partial slot region is located in the valley between the lower layer side coil wires extending over the self region and the adjacent partial slot region.

  Thereby, useless space in the slot region is reduced, and a high-density coil structure is obtained. And it is also possible to realize a large current by flowing the current in a plurality of coils. It is also possible to prevent swelling at the coil end portion.

  However, the use of a cheaper coil winding device is possible because the upper layer side coil wire of the partial slot region that is wound later is located in the valley between the lower layer side coil wires straddling the own region and the adjacent region at the boundary portion. It is possible to achieve the further effect that the manufacturing cost can be kept low.

  In addition, since the boundary between each partial slot region and the adjacent region is inclined from the bottom of the split core toward the upper layer side toward the partial slot region to be wound first, there is almost no collapse and stable. A stator of a rotating electric machine having a coil structure is obtained.

  Furthermore, since the plurality of coils are connected in parallel, a stator of a rotating electric machine with a small eddy loss can be obtained while flowing a large current.

  The coil winding method of the present invention is a method in which coil wires are individually stacked and wound around a plurality of partial slot regions of the slot region from the bottom of the split core, and the coil wires of the second and higher layers are adjacent to each other. While the upper layer side coil wire is located in the valley between the lower layer side coil wires of the own region in the region excluding the boundary portion and the end portion with the region, the lower layer side coil wire straddling the own region and the adjacent region is located at the boundary portion. It is the method of winding so that the upper coil wire of any one of a self area | region or an adjacent area | region may be located in a valley.

  By this method, a high-density coil structure in which useless space in the slot region is reduced can be obtained. And it is also possible to realize a large current by flowing the current in a plurality of coils.

  However, after the winding of the coil wire in either one of the own region or the adjacent region is completed, the coil wire is wound on the other region, and at the boundary portion, the valley between the lower layer side coil wires extending over the own region and the adjacent region is wound. By positioning the upper coil wire of the partial slot region that is wound later, an inexpensive coil winding device can be used, and the manufacturing cost can be reduced.

  By performing the winding of the coil wire in either one of the own region or the adjacent region and the winding of the coil wire in the other region in parallel, the working time can be shortened.

  According to the stator or coil winding method of the rotating electrical machine of the present invention, it is possible to realize a high-density coil structure that is suitable for increasing current and that reduces wasted space.

  FIG. 1 is a cross-sectional view showing a schematic structure of a stator 10 of a rotating electrical machine (motor or generator) in an embodiment, and shows a cross section parallel to a coil end portion. As shown in the figure, the stator 10 is assembled by enclosing a plurality of split cores 11 in an annular shape and enclosing from the outside using a ring member (not shown). A rotor (not shown) provided with permanent magnets is disposed inside the stator 10. A side region (slot region Rsl) surrounded by the insulator 13 by the back yoke portion 11a and the flange portion 11b of the split core 11 is a region around which the coils 12a and 12b are wound. The slot region Rsl is generally trapezoidal or rectangular. The split core 11 includes a structure in which a large number of silicon steel plates are laminated with a resin insulation layer interposed therebetween, or a structure in which powder metal is sintered after compression molding, and any of them may be used. In the present embodiment, the coils 12a and 12b are configured by covering the surface of a conductive wire made of a copper alloy with a resin insulating film, but are not limited to this structure. Moreover, the cross section of the coil wire may not be circular but may be hexagonal, for example.

  7A and 7B are a perspective view showing a schematic structure of the split core 11 and a cross-sectional view taken along the line VII-VII in this order. The coils 12a and 12b are wound around the slot region rsl shown in FIG. Since the insulator 13 has not only a function of insulating the split core 11 and the coils 12a and 12b but also a function of smoothly winding the coil, the insulator 13 is formed to be thick with R provided at the corners. The coil end portion is a start and end region of coil winding, and is substantially orthogonal to the side (coil side portion) where the divided cores 11 face each other. And in this Embodiment, the groove | channel 18 for guiding a coil wire is formed in the part by the side of the coil end of the insulator 13 as shown to Fig.7 (a), (b). Further, the back yoke portion 11a (insulator 13) and the flange portion 11b (insulator 13) are formed with cuts leading to the grooves 18.

  FIG. 2 is an enlarged partial cross-sectional view showing the slot region Rsl of the split core 11 and shows a cross section parallel to the coil end portion. As shown in the figure, in the present embodiment, the slot region Rsl is divided into a first partial slot region Rsl1 around which the first coil 12a is wound and a second partial slot region Rsl2 around which the second coil 12b is wound. Has been. The first coil 12a is wound before the second coil 12b. However, the second coil 12b does not have to be wound after the first coil 12a is completely wound. That is, as will be described later, the winding can be performed in parallel while adjusting the timing of both. In the case of the structure shown in FIG. 2, the first coil 12a is introduced from a notch provided on the coil end side of the flange portion 11b, and starts winding through the groove 18 formed on the bottom surface of the insulator 13. Reach position. In general, the first coil 12a and the second coil 12b that are to be wound first are introduced from either the back yoke portion 11a or the flange portion 11b and formed on the bottom surface of the insulator 13. It is preferable to reach the winding start position through the groove 18.

  Unlike the structure shown in FIG. 2, the entire protruding portions of the back yoke portion 11 a and the flange portion 11 b may be configured by an insulator, and a cut may be formed only in the insulator 13. In place of the notches, the insulator 13 shown in FIG. 2 may have a structure in which a groove extending from the outer periphery to the groove 18 is formed, or holes may be formed in the back yoke portion 11a and the flange portion 11b. In this embodiment, the coil wire can be introduced from either the back yoke portion 11a or the flange portion 11b. However, only one of the back yoke portion 11a and the flange portion 11b may be cut. Further, the portion of the insulator 13 where the groove 18 is formed may be thin, and the groove 18 may be formed in the split core 11.

  The structural features of the present embodiment are as follows. First, in the first partial slot region Rsl1, the second and higher layers of the first coil 12a wound earlier are the valleys between the coil lines of the lower first coil 12a except for the boundary portion Rbd and the end portion Rce. Is located. Further, in the second partial slot region Rsl2, the second and higher layers of the second coil 12b wound later are the valleys between the coil lines of the lower second coil 12b except for the end portion Rce and the boundary portion Rbd. Is located. That is, the second and higher layers of the first coil 12a and the second coil 12b are the coil wires of the coil (12a or 12b) in its own region (the partial slot region) except for the boundary portion Rbd and the end portion Rce. Located in the valley. In the boundary portion Rbd, the coil wire of the second coil 12b in the region wound late (in the present embodiment, the second partial slot region Rsl2) spans the first and second partial slot regions Rsl1, Rsl2. It is located in the valley between the coil wires of the lower layer coil (that is, the second coil 12b and the first coil 12a). The end Rce is either located in the valley between the lower layer coil wires of the own region or is located at a site defined by the lower end coil wire of the own region and the wall surface of the insulator 13. It is. In the latter case, the coil wire is located in the valley between the virtual coil wires when the coil wire is virtually outside the coil wire at the lower end portion.

  FIG. 3 is a perspective view schematically showing the structure of the coil wire winding device 20 according to the present embodiment. As shown in the figure, the coil wire winding device 20 includes a first nozzle 21a and a second nozzle 21b for feeding the first winding 22a and the second winding 22b, respectively, rotation of the split core 11 and the corner portion. A detector 24 and a control device 25 are provided. The split core 11 is attached to a rotatable jig (not shown). On the other hand, the first nozzle 21a and the second nozzle 21b are attached to a jig (not shown) that can move in the coil winding direction of the split core 11 and can adjust the twist. The control device 25 includes a memory 26, a counter 27, and a timer 28. The control device 25 controls the rotation of the split core 11 and the positions and twists of the nozzles 21a and 21b. Yes. Hereinafter, the coil winding method according to the present embodiment will be described with reference to FIGS. 2 and 3.

  First, the first winding 22a is wound around the split core 11 in the partial slot region Rsl1, and the first coil 12a is sequentially formed from the lower layer to the upper layer. When the first coil 12a is wound to some extent, the second winding 22b is wound around the split core 11 to form the second coil 12b. For both the first coil 12a and the second coil 12b, winding is started from a portion where the coil end portion is located. By this method, the first coil 12a and the second coil 12b can be wound in parallel. At this time, in the first partial slot region Rsl1, the coil wire of the first coil 12a of each layer is wound around the valley position between the coil wires of the lower coil 12a, that is, the intermediate position, except for the lowermost layer and the end portion Rce. Further, in the second partial slot region Rsl2, the coil wire of the second coil 12b in each layer of the second layer and higher layers, except for the end portion Rce, is the valley position between the coil wires of the lower second coil 12b, or the lower first layer. The coil is wound around the valley position (boundary portion Rbd) between the coil wire of the two coils 12b and the coil wire of the first coil 12a.

  As a result, for example, the first layer of the first coil 12a is wound 8 times, the second layer is wound 7 times, the third layer is wound 7 times, and the fourth layer is wound 6 times, for a total of 33 times. The first layer of the second coil 12b is wound four times, the second layer is five times, the third layer is five times, the fourth layer is six times, the fifth layer is six times, and the sixth layer is wound seven times. All are wound a total of 33 times. In this way, since the first and second coils 12a and 12b are wound the same number of times and the lengths of both are substantially equal, the electrical resistance values are substantially equal, so that the circulating current generated when connected in parallel is suppressed. can do. Further, the winding of the coil ends at a portion where the coil end portion is located, and is drawn from the portion to the common flange portion (back yoke portion 11a or flange portion 11b). Thereafter, both ends of the first coil 12a and the second coil 12b are connected.

  In the present embodiment, when the coils are wound in parallel, the timing at which the winding of the second winding 22b around the core 11 is started from the first layer of the second coil 12b in the structure shown in FIG. The first layer of the first coil 12a is formed before the second layer is raised, and the first coil is raised from the third layer to the fourth layer of the second coil 12b. The third layer of 12a is formed, the fifth layer of the first coil 12a is formed from the fifth layer to the sixth layer of the second coil 12b, It is sufficient if the condition is satisfied. This timing adjustment is performed using the timer 28, the counter 27, and the memory 26. However, when the method of rotating the nozzles 21a and 21b around the split core 11 without rotating the split core 11, the above condition does not need to be satisfied.

  In addition, the second coil 12b may be formed after the first coil 12a is completely formed, which is generally a simple method. At this time, the process of winding the first coil 12a and the process of winding the second coil 12b may be performed separately, and parallel processing control is unnecessary. When this winding method is adopted, the number of nozzles for deriving the coil wire is not necessarily two as shown in FIG. 3, and only one nozzle may be used. However, working time can be shortened by performing parallel processing.

  After winding the first coil 12a and the second coil 12b, the winding start ends and the winding end ends of the coils 12a and 12b are connected. That is, the first and second coils 12a and 12b are connected in parallel. Thereby, the coil structure around the split core 11 is completed. In general, the first coil 12a and the second coil 12b have substantially the same length, but the length may be slightly different.

  FIG. 4 is a photograph showing a state in the middle of conducting the coil wire winding experiment. At the time shown in FIG. 4, the first coil 12a is already formed in the first partial slot region Rsl1, and the second coil 12b is being formed in the second partial slot region Rsl2. As shown in the figure, it can be seen that the first coil 12a and the second coil 12b are stacked without generating an extra space.

  According to the present embodiment, the slot region Rsl is divided into a first partial slot region Rsl1 around which the first coil 12a is wound and a second partial slot region Rsl2 around which the second coil 12b is wound. A coil continuously exists between Rsl1 and Rsl2. As a result, there is no dead space due to the partition wall 203a as shown in the conventional structure of FIG. 6 and the gap existing between the partition wall 203a and the coil 202. Therefore, the density of the coil structure can be increased by reducing the dead space. Further, since both the first coil 12a and the second coil 12b are single-wire wounds, there is no bulging when the layers rise in the coil end portion as shown in FIGS. 5B and 5C. (See FIG. 4). That is, there is no increase in dimension on the coil end side.

  Also, according to the coil winding method of the present embodiment, since it is a single wire winding, there is no need for correction of torsion, etc., compared to simultaneous winding of a plurality of wires, so that coil collapse hardly occurs and the coil winding itself is easy. It becomes.

(Other embodiments)
The structure of the embodiment of the present invention disclosed above is merely an example, and the scope of the present invention is not limited to the scope of these descriptions. The scope of the present invention is indicated by the description of the scope of claims, and further includes meanings equivalent to the description of the scope of claims and all modifications within the scope.

  In the above embodiment, the slot region Rsl is divided into two partial slot regions (first partial slot region Rsl1 and second partial slot region Rsl2). A single-winding coil may be wound individually for each slot region.

  In the above embodiment, the slot region Rsl has a trapezoidal cross-sectional shape, but may have a structure having a rectangular slot region.

  In the above embodiment, the coil winding device 20 has a structure that rotates the split core 11. However, the nozzles 21a and 21b that feed out the windings 22a and 22b without splitting the split core 11 are split. What has the structure rotated around the core 11 may be used. In that case, the coil structure is not limited to that shown in FIG. For example, in the boundary between the first partial slot region Rsl1 and the second partial slot region Rsl2, in the second layer, the valley between the coil wire of the first coil 12a and the coil wire of the second coil 12b in the boundary portion Rbd. The upper coil wire of the second coil 12b is located, and in the third layer, the upper coil of the first coil 12a is located in the valley between the coil wire of the first coil 12a and the coil wire of the second coil 12b in the boundary portion Rbd. It is also possible to adopt a structure in which the line is located. This is because it is not necessary to synchronize the nozzles 21a and 21b, so that if one of the nozzles 21a and 21b is rotating and the other is kept stationary, a free winding method is possible.

  However, since the coil winding device having a structure for rotating the nozzles 21a and 21b has a complicated structure, the device is also expensive. In addition, the winding process becomes complicated. As a result, the manufacturing cost may be increased. On the other hand, in the method of the above embodiment, since it can be used simply by increasing the number of nozzles of the apparatus used for commonly used single-wire winding and para-winding (multi-wire winding), the apparatus cost is hardly increased. There is an advantage.

  From the above, conceptually, the stator of the rotating electrical machine of the present invention has a plurality of partial slot regions (Rsl1, Rsl2,...) Around which coils are individually wound, and each partial slot region ( Rsl1, Rsl2,..., The coil wires of each of the second and higher layers have their own region (the partial slot in question) in the region excluding the boundary Rbd and the end Rce with the adjacent region (Rsl1 or Rsl2 in the above embodiment). The upper layer side coil wire is located in the valley between the lower layer side coil wires of the region, and the lower layer straddling the own region and the adjacent region (two partial slot regions Rsl1, Rsl2 in the above embodiment) at the boundary portion Rbd It is only necessary that the upper layer side coil wire of the partial slot region (Rsl1 or Rsl2) of either the self region or the adjacent region is located in the valley between the side coil wires.

  However, in the boundary portion Rbd with the adjacent region, the upper layer of the partial slot region (Rsl2 in the above embodiment) that is wound lately in the valley between the lower layer side coil wires extending over the self region and the adjacent region (Rsl1, Rsl2). It is more preferable that the side coil wire (12b in the above embodiment) is located. This structure can be realized by using an inexpensive coil winding device that rotates the partial core, so that the manufacturing cost can be kept low. Here, “winding with delay” means that after winding of one coil (in the above embodiment, the first coil 12a) is completed, the other coil (in the above embodiment, the second coil 12b) is wound. This includes both the case where winding is started and the case where winding of the other coil is started before winding of one coil is completed and both are wound in parallel.

  The method of winding a stator or coil of a rotating electric machine according to the present invention can be used for a motor or a generator disposed in a hybrid vehicle, an electric vehicle, a fuel cell, a robot, or the like.

It is sectional drawing which shows the schematic structure of the stator of the rotary electric machine in embodiment. It is a fragmentary sectional view which expands and shows the slot area | region of the division | segmentation core in embodiment. It is a perspective view which shows roughly the structure of the coil wire winding apparatus which concerns on embodiment. It is a photograph figure which shows the state in the middle of performing the winding experiment of a coil wire. (A), (b) is a figure for demonstrating the result which the inventor performed the analysis by experiment. 10 is a cross-sectional view showing a coil structure of a stator of a rotating electrical machine disclosed in Patent Document 2. FIG. (A), (b) is a perspective view which shows schematic structure of a division | segmentation core in order, and sectional drawing in the VII-VII line.

Explanation of symbols

Rsl slot region Rsl1 first partial slot region Rsl2 second partial slot region Rce end portion Rbd boundary portion 10 stator 11 split core 11a back yoke portion 11b flange portion 12a first coil 12b second coil 13 insulator 18 groove 20 coil winding device 21a 1st nozzle 21b 2nd nozzle 22a 1st winding 22b 2nd winding 24 Detector 25 Control device 26 Memory 27 Counter 28 Timer

Claims (7)

A split core composed mainly of a magnetic material;
A slot region formed in the split core and having a plurality of partial slot regions;
A stator of a rotating electrical machine comprising a coil wound and laminated separately from the bottom of the split core in the plurality of partial slot regions,
In each layer above the second layer of each partial slot region,
In the region excluding the boundary and the edge with the adjacent region, the upper layer coil wire is located in the valley between the lower layer coil wires of the own region,
In the boundary part, either the self region or the upper region side coil wire of the adjacent region is located in the valley between the self region and the lower layer side coil wire spanning the adjacent region,
Stator for rotating electric machine. The stator of the rotating electrical machine according to claim 1,
In the boundary portion, a rotating electrical machine in which an upper layer side coil wire of a partial slot region wound around the own region or the adjacent region is positioned in a valley between the own region and the lower layer side coil wire extending over the adjacent region. Stator. In the stator of the rotating electrical machine according to claim 1 or 2,
The boundary between each partial slot region and the adjacent region is a stator of a rotating electrical machine that is inclined from the bottom of the split core toward the upper layer side toward the partial slot region that is wound first. In the stator of the rotary electric machine according to any one of claims 1 to 3,
The plurality of coils is a stator of a rotating electrical machine connected in parallel. In the slot region having a plurality of partial slot regions, including the step of laminating and winding the coil wire individually from the bottom of the split core in each partial slot region,
In the second and higher layers of each partial slot region,
In the region excluding the boundary and the edge with the adjacent region, the upper layer coil wire is located in the valley between the lower layer coil wires of the own region,
In the boundary part, either the self region or the upper layer side coil wire of the adjacent region is located between the self region and the valley between the lower layer coils extending over the adjacent region,
A method of winding a coil. The coil winding method according to claim 5,
After the winding of the coil wire is finished in either the self region or the adjacent region, the coil wire is wound on the other side,
In the boundary portion, a coil winding method of positioning an upper layer side coil wire of a partial slot region wound later in the own region or the adjacent region in a valley between the lower region side coil wire extending over the own region and the adjacent region . The coil winding method according to claim 5,
A method for winding a coil wire, wherein the winding of the coil wire in either one of the self region or the adjacent region and the winding of the coil wire in the other region are performed in parallel.

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