JP2018125924A - Slot coil, stator for rotating electrical machine, and method for manufacturing stator for rotating electrical machine - Google Patents

Abstract

The present invention provides a slot coil, a stator for a rotating electrical machine, and a method for manufacturing a stator for a rotating electrical machine that can reduce the amount of varnish used when the slot coil is fixed to a stator core by a varnish.
A slot coil 25 is inserted into a slot 23 provided in a stator core 21, and the periphery of the slot coil 25 is covered with an insulating material 28. Less than laps. The insulating material 28 is in contact with the end surface 21b of the stator core 21 on one end side, and the flange portion 29 suppresses leakage of the varnish 60 filled in the gap between the outer peripheral surface 28a of the insulating material 28 and the inner peripheral surface 23a of the slot 23. Have
[Selection] Figure 5A

Description

  The present invention relates to a slot coil, a stator for a rotating electrical machine, and a method for manufacturing a stator for a rotating electrical machine.

  In recent years, rotating electric machines using segment coils have been proposed as stators for rotating electric machines. For example, in Patent Document 1, a coil loop is formed by combining a slot coil disposed in a slot of a stator core and a connection coil serving as a transition portion disposed outside the stator core. Moreover, in the rotary electric machine described in Patent Document 1, it is described that a slot coil covered with an insulating material is press-fitted into a slot of a stator core.

  In general, when a slot coil is press-fitted into a slot of a stator core, an insulating material is caught by a convex portion formed on the inner peripheral surface of the slot due to a dimensional error of laminated steel plates, and the insertion of the slot coil is obstructed. It was necessary to increase the load, and a large-scale manufacturing apparatus was required.

  On the other hand, conventionally, in a stator of a rotating electrical machine, a method of fixing a coil to a stator core with a varnish is known (for example, Patent Document 2).

JP 2013-027174 A JP 2014-39345 A

  However, in the method of fixing the coil to the stator core with varnish, the varnish dripped from the nozzle penetrates the coil and penetrates into the stator core, but the amount remaining in the stator core is small, and a large amount of varnish leaks from the stator core.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a slot coil, a stator for a rotating electrical machine, and a rotating electrical machine that can reduce the amount of varnish used when the slot coil is fixed to a stator core by a varnish. A stator manufacturing method is provided.

In order to achieve the above object, the invention described in claim 1
A slot coil (for example, a slot coil 25 in an embodiment described later) inserted into a slot (for example, a slot 23 in an embodiment described later) provided in a stator core (for example, a stator core 21 in an embodiment described later),
The slot coil is covered with an insulating material (for example, an insulating material 28 in an embodiment described later),
The outer periphery of the insulating material is smaller than the inner periphery of the slot,
The insulating material abuts one end surface of the stator core (for example, an end surface 21b in an embodiment described later) on one end side, and an outer peripheral surface of the insulating material (for example, an outer peripheral surface 28a in an embodiment described later) and the slot. A varnish leakage suppressing portion (for example, described later) that suppresses leakage of a varnish (for example, varnish 60 in an embodiment to be described later) filled in a gap with the inner peripheral surface (for example, an inner peripheral surface 23a of the embodiment to be described later). It has a collar part 29) of the embodiment.

The invention according to claim 2 is the invention according to claim 1,
The varnish leakage suppressing portion includes a first flange portion (for example, a first flange portion 29A in an embodiment described later) that projects from the outer peripheral surface of the insulating material to one side in the circumferential direction, and a circumferential direction from the outer peripheral surface of the insulating material. And a second collar portion projecting to the other side (for example, a second collar portion 29B in an embodiment described later).

The invention according to claim 3 is the invention according to claim 1,
The varnish leakage suppressing portion is configured separately from the insulating material.

The invention according to claim 4 is the invention according to any one of claims 1 to 3,
The varnish leakage suppressing portion includes a sealing member (for example, a rubber wire 66 and a rubber sheet 67 in the embodiment described later) on a contact surface (for example, a back surface 29d in the embodiment described later) that contacts the one end surface of the stator core. ) Is provided.

The invention described in claim 5
A stator core (for example, a stator core 21 according to an embodiment described later) having a plurality of slots (for example, a slot 23 according to an embodiment described later);
In a stator of a rotating electrical machine (e.g., a stator 10 in an embodiment described later) provided with a coil (e.g., a coil 50 in an embodiment described later) attached to the stator core,
The coil includes a plurality of slot coils (for example, a slot coil 25 according to an embodiment described later) inserted into the slot and a plurality of slots that connect the slot coils on the axially outer side from the axial end surface of the stator core. A connection coil (for example, a connection coil 40 in an embodiment described later), and the slot coil and the connection coil are coupled to each other at a contact portion (for example, contact surfaces P2, P3 in an embodiment described later). And
The slot coil is covered with an insulating material (for example, an insulating material 28 in an embodiment described later),
The outer periphery of the insulating material is smaller than the inner periphery of the slot,
In the gap between the outer peripheral surface of the insulating material (for example, the outer peripheral surface 28a of the embodiment described later) and the inner peripheral surface of the slot (for example, the inner peripheral surface 23a of the later-described embodiment), a varnish (for example, described later) Varnish 60) of the embodiment is filled,
The said insulating material has a varnish leak suppression part (for example, the collar part 29 of below-mentioned embodiment) which suppresses the leakage of the said varnish (for example, varnish 60 of below-mentioned embodiment) at one end side.

The invention according to claim 6 is the invention according to claim 5,
The varnish leakage suppressing portion includes a first flange portion (for example, a first flange portion 29A in an embodiment described later) that projects from the outer peripheral surface of the insulating material to one side in the circumferential direction, and a circumferential direction from the outer peripheral surface of the insulating material. And a second collar portion projecting to the other side (for example, a second collar portion 29B in an embodiment described later).

The invention according to claim 7 is the invention according to claim 5,
The varnish leakage suppressing portion is configured separately from the insulating material.

The invention according to claim 8 is the invention according to any one of claims 5 to 7,
The varnish leakage suppressing portion includes a sealing member (for example, a rubber wire 66 and a rubber sheet 67 in the embodiment described later) on a contact surface (for example, a back surface 29d in the embodiment described later) that contacts the one end surface of the stator core. ) Is provided.

The invention according to claim 9 is the invention according to any one of claims 5 to 8,
The varnish leakage suppressing portion includes a first engaging portion (for example, a first engaging portion in an embodiment described later) on an abutting surface (for example, a back surface 29d in an embodiment described later) that contacts the one end surface of the stator core. 75)
The one end surface of the stator core is provided with a second engagement portion (for example, a second engagement portion 76 in an embodiment described later) that engages with the first engagement portion,
The first engaging portion and the second engaging portion are provided so as to surround the slot.

The invention according to claim 10 is the invention according to any one of claims 5 to 9,
A slot coil arrangement step of inserting the slot coil into the slot of the stator core, and abutting the varnish leakage suppressing portion of the insulating material with the one end surface of the stator core;
A varnish filling step in which the one end surface side of the stator core is disposed downward, and a varnish is filled from the other end surface side of the stator core into a gap between the outer peripheral surface of the insulating material and the inner peripheral surface of the slot. .

The invention according to claim 11 is the invention according to claim 10,
In the varnish filling step, the varnish is filled while pressing the varnish leakage suppressing portion of the insulating material toward the one end face of the stator core.

  According to the first and fifth aspects of the invention, since the insulating material covering the slot coil has the varnish leakage suppressing portion that contacts the one end surface of the stator core on one end side, the outer peripheral surface of the insulating material and the inner peripheral surface of the slot Leakage of the varnish filled in the gap can be suppressed, and the amount of varnish used can be reduced.

  According to invention of Claim 2 and 6, a varnish leak suppression part is the 1st collar part projected on the circumferential direction one side from the outer peripheral surface of an insulating material, and the 2nd projected on the circumferential direction other side from the outer peripheral surface of an insulating material. Since it has a collar part, leakage of varnish can be effectively suppressed for a slot that is generally long in the radial direction.

  According to invention of Claim 3 and 7, the slot coil coat | covered with the insulating material can be easily manufactured by comprising a varnish leak suppression part separately from an insulating material.

  According to invention of Claim 4 and 8, since the sealing member is provided in the contact surface contact | abutted with the one end surface of a stator core in the varnish leak suppression part, the leak of a varnish can be suppressed more effectively.

  According to the ninth aspect of the present invention, the varnish leakage suppression portion is provided with the first engagement portion on the contact surface that contacts the one end surface of the stator core, and the one end surface of the stator core is engaged with the first engagement portion. Since the second engagement portion is provided, and the first engagement portion and the second engagement portion are provided so as to surround the slot, it is possible to more effectively suppress varnish leakage.

  According to the invention of claim 10, the slot coil is inserted into the slot of the stator core, and the varnish leakage suppressing portion of the insulating material is brought into contact with one end surface of the stator core, and the one end surface side of the stator core is directed downward. And a varnish filling step of filling the varnish from the other end surface side of the stator core into the gap between the outer peripheral surface of the insulating material and the inner peripheral surface of the slot, so that the outer peripheral surface of the insulating material and the inner peripheral surface of the slot The leakage of the varnish filled in the gap can be suppressed, and the amount of varnish used can be reduced.

  According to the invention of claim 11, since the varnish is filled while pressing the varnish leakage suppressing portion of the insulating material toward the one end face of the stator core in the varnish filling step, the slot coil is prevented from jumping out of the slot during the varnish filling. it can.

It is a perspective view of the stator of the rotary electric machine of one Embodiment of this invention. It is a disassembled perspective view of a stator. It is a disassembled perspective view of one base plate assembly. It is a disassembled perspective view of the other baseplate assembly. It is a perspective view of a slot coil. It is a disassembled perspective view of a slot coil. It is a longitudinal cross-sectional view which shows a part of stator. It is a front view which shows a part of base plate assembly. It is a perspective view of a multi-phase coil. It is a perspective view which extracts and shows the coil for one phase from the coil of multiple phases shown in FIG. It is an expanded view which shows the connection aspect of the coil of a U phase. It is a schematic diagram which shows the connection aspect of the coil of U phase, V phase, and W phase. It is a perspective view for demonstrating joining with an outer side connection coil extension part and an inner side connection coil extension part. It is a perspective view for demonstrating joining of the inner diameter side edge part of an outer side connection coil, and the level | step-difference part of an outer diameter side slot coil, and joining of the inner diameter side edge part of an inner side connection coil, and the level difference part of inner diameter side slot coil. FIG. 4 is an enlarged perspective view showing a state where a slot coil covered with an insulating material is inserted into one slot of a stator core. It is AA sectional view taken on the line of FIG. It is a front view of the stator core in which the slot coil coat | covered with the insulating material was inserted. It is explanatory drawing of a slot coil arrangement | positioning process. It is explanatory drawing of a varnish filling process. It is a fragmentary perspective view of the slot coil which shows the collar part of the insulating material provided with the rubber wire. It is a fragmentary perspective view of the slot coil of the collar part of the insulating material provided with the rubber sheet. It is a fragmentary perspective view of the slot coil which shows the collar part comprised separately from the insulating material which coat | covers a slot coil. It is a fragmentary perspective view of the slot coil which shows the collar part of a 1st modification. It is a fragmentary perspective view of the slot coil which shows the collar part of a 2nd modification. It is the elements on larger scale of the end surface of a stator core which shows the groove part which the collar part of a 2nd modification engages.

  Hereinafter, an embodiment of a stator for a rotating electrical machine according to the present invention will be described with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.

[Stator]
As shown in FIGS. 1 and 2, the stator 10 of the rotating electrical machine of the present embodiment includes a stator core assembly 20 and a pair of base plate assemblies 30L and 30R, and the base plate assemblies 30L and 30R include the stator core assembly. The solid 20 is arranged and assembled on both sides. Between the stator core assembly 20 and the base plate assemblies 30L, 30R, for example, an insulating sheet 65 such as a silicon sheet is disposed to insulate the stator core assembly 20 from the base plate assemblies 30L, 30R.

[1 Stator core assembly]
The stator core assembly 20 includes a stator core 21 and a plurality of slot coils 25.

[1-1 Stator core]
The stator core 21 is configured by, for example, laminating a plurality of pressed silicon steel plates, and includes a plurality of teeth 22 and a plurality of slots 23 formed between adjacent teeth 22 on the radially inner side. . The slot 23 is formed so as to penetrate in the axial direction of the stator core 21, is formed in a substantially oval shape that is long in the radial direction of the stator core 21 when viewed from the axial direction, and the opening 24 opens to the inner peripheral surface of the stator core 21. Yes. A plurality of fastening portions 15 that fasten the stator core 21 to a housing (not shown) are provided on the outer peripheral portion of the stator core 21.

[1-2 Slot coil]
The slot coil 25 inserted into each slot 23 has an outer-diameter side slot coil 26 and an inner-diameter side slot coil 27 which are plate-like conductors having a rectangular cross section with reference to FIG. 5A, FIG. 5B and FIG. The outer peripheral side slot coil 26 and the inner peripheral side slot coil 27 except for both ends in the axial direction are integrally formed by being coated with an insulating material 28 having a rectangular cross section such as injection molded resin. Specifically, the outer diameter side slot coil 26 has a length (L1 + 4 × L2) substantially equal to the sum of the axial width L1 of the stator core 21 and the axial width (4 × L2) of four connecting coils 40 described later. And both end portions in the axial direction are exposed from the insulating material 28 by a length (2 × L2) substantially equal to the axial width of the two connecting coils 40 in the axial direction. Further, one end of the outer diameter side slot coil 26 in the axial direction is notched in a stepped manner in a surface facing one side in the circumferential direction by a length (L2) equal to the axial width of one connection coil 40. The stepped portion 26a is formed by reducing the thickness, and the other axial end of the outer diameter side slot coil 26 is the other in the circumferential direction by a length (L2) equal to the axial width of one connecting coil 40. A stepped portion 26a is formed by cutting the surface facing the step into a step and reducing the plate thickness.

  The inner diameter side slot coil 27 is set to a length (L1 + 2 × L2) substantially equal to the sum of the axial width (L1) of the stator core 21 and the axial width (2 × L2) of two connecting coils 40 described later. Both end portions in the axial direction are exposed from the insulating material 28 by a length (L2) substantially equal to the axial width of one connection coil 40. Further, one end of the inner diameter side slot coil 27 in the axial direction is cut into a stepped shape with a surface facing the other in the circumferential direction by a length (L2) equal to the axial width of one connection coil 40. As a result, the step portion 27a is formed, and the other axial end portion of the inner diameter side slot coil 27 faces one side in the circumferential direction by a length (L2) equal to the axial width of one connection coil 40. The stepped portion 27a is formed by cutting the surface into a stepped shape and reducing the plate thickness.

  In other words, the slot coil 25 is exposed from the insulating material 28 on both sides in the axial direction by the length (2 × L2) of the outer diameter side slot coil 26 substantially equal to the axial width of the two connecting coils 40. The inner diameter side slot coil 27 is exposed from the insulating material 28 on both sides in the axial direction by a length (L2) equal to the axial width of one connection coil 40, and the outer diameter side slot coil 26 and the inner diameter side slot coil. Step portions 26a and 27a are formed at both tip portions of 27 so as to face the opposite side in the circumferential direction by a length (L2) equal to the axial width of one connection coil 40, respectively. Further, at one end in the axial direction and the other end in the axial direction, the stepped portions 26a of the outer diameter side slot coil 26 and the stepped portions 27a of the inner diameter side slot coil 27 are formed so as to face each other in the circumferential direction. Yes.

  As shown in FIGS. 5A and 5B, the insulating material 28 has a flange 29 only on the outer peripheral surface 28 a on one end side in the longitudinal direction (axial direction). The flange portion 29 abuts on the end surface 21 b of the stator core 21, thereby sealing a gap between the outer peripheral surface 28 a of the insulating material 28 that covers the slot coil 25 and the inner peripheral surface 23 a of the slot 23. The flange portion 29 includes a substantially rectangular first flange portion 29 </ b> A that projects from the outer peripheral surface 28 a of the slot coil 25 to one side in the circumferential direction, and a substantially rectangular second flange portion that projects to the other circumferential side of the slot coil 25. 29B.

  The plurality of slot coils 25 including the outer diameter side slot coil 26 and the inner diameter side slot coil 27 are arranged so that the outer diameter side slot coil 26 is radially outward and the inner diameter side slot coil 27 is radially inner in each slot 23. The stator core 21 is arranged in the radial direction. Each slot coil 25 is inserted into a plurality of slots 23 of the stator core 21 and arranged in the circumferential direction of the stator core 21 to constitute the stator core assembly 20. In the stator core assembly 20, as shown in FIGS. 14 and 15, the back surfaces 29 d of the first flange portion 29 </ b> A and the second flange portion 29 </ b> B of each slot coil 25 are in contact with the end surface 21 b of the stator core 21.

  The outer-diameter side slot coil 26 has tip portions protruding from both end faces 21a and 21b of the stator core 21 by a length (2 × L2) substantially equal to the axial width of approximately two connecting coils 40, respectively. The inner end side slot coil 27 inserted into the slot 23 protrudes from both end faces 21a and 21b of the stator core 21 by a length (L2) equal to the axial width of approximately one connection coil 40. As shown in FIG.

  Further, an insulating material 28 that covers both the slot coils 26 and 27 is interposed between the outer diameter side slot coil 26 and the inner diameter side slot coil 27 and the slot 23 of the stator core 21 to ensure insulation from the stator core 21. Has been.

  The insulating material 28 covering the outer diameter side slot coil 26 and the inner diameter side slot coil 27 has an outer periphery other than the flange portion 29 smaller than the outer periphery of the slot 23 and substantially the same shape as the slot 23. Therefore, a gap filled with a varnish 60 described later is formed between the outer peripheral surface 28 a of the insulating material 28 covering the slot coil 25 and the inner peripheral surface 23 a of the slot 23. Since the flange portion 29 is not formed on the outer peripheral surface 28 a on the other end side in the longitudinal direction (axial direction) of the insulating material 28, the insulating material 28 that covers the slot coil 25 is formed from the end surface 21 a side of the stator core 21. A gap between the outer peripheral surface 28 a and the inner peripheral surface 23 a of the slot 23 can be accessed. As the insulating material 28, an epoxy resin, an enamel resin, or the like can be used.

[1-3 Assembly of stator core assembly]
In assembling the stator core assembly 20 configured as described above, first, the slot coil 25 is inserted into each slot 23 of the stator core 21 (slot coil arranging step). At this time, as shown in FIG. 17A, the slot coil 25 is inserted into the slot 23 of the stator core 21, and the first flange portion 29 </ b> A and the second flange portion 29 </ b> B of the insulating material 28 are brought into contact with the end surface 21 b of the stator core 21. In order to maintain the contact state between the first flange portion 29A and the second flange portion 29B of the insulating material 28 and the end surface 21b of the stator core 21, an insulating material is formed by a jig 71 in which a coil penetration portion 70 through which the slot coil 25 passes is formed. The 28 first flange portion 29 </ b> A and the second flange portion 29 </ b> B are pressed against the end surface 21 b of the stator core 21.

  Subsequently, as shown in FIG. 17B, the end surface 21 b of the stator core 21 is directed downward, the stator core 21 is held in a state inclined at a predetermined angle, and the first flange portion 29 </ b> A and the second flange portion of the insulating material 28 are held by the jig 71. The varnish 60 is filled while pressing 29B against the end surface 21b of the stator core 21 from below (varnish filling step). The filling of the varnish 60 is performed by dropping the molten varnish 60 from above from a varnish injection nozzle 73 disposed on the end surface 21a side of the stator core 21 while rotating the stator core 21. As a result, the varnish 60 is filled between the outer peripheral surface 28a of the insulating material 28 covering the slot coil 25 and the inner peripheral surface 23a of the slot 23, but the first and second flange portions 29A and 29A of the insulating material 28 are filled. Since 29B is in contact with the end surface 21b of the stator core 21, the gap between the outer peripheral surface 28a of the insulating material 28 covering the slot coil 25 and the inner peripheral surface 23a of the slot 23 is sealed, and the varnish 60 is the end surface of the stator core 21. Leakage from the 21b side can be suppressed. Thereafter, by cooling the varnish 60, the varnish 60 filled between the outer peripheral surface 28a of the insulating material 28 covering the slot coil 25 and the inner peripheral surface 23a of the slot 23 as shown in FIGS. Is hardened, and the slot coil 25 is fixed to the stator core 21.

  In order to further prevent the varnish 60 from leaking from the end surface 21b side of the stator core 21, the back surface 29d of the first flange portion 29A and the second flange portion 29B contacting the end surface 21b of the stator core 21 are shown in FIG. 18A. Thus, a rubber wire 66 extending in the radial direction may be provided outside the gap between the outer peripheral surface 28a of the insulating material and the inner peripheral surface 23a of the slot 23, and covers the entire back surface 29d as shown in FIG. 18B. A rubber sheet 67 may be provided.

[2 Base plate assembly]
The base plate assemblies 30L and 30R respectively disposed on both sides of the stator core assembly 20 include base plates 31L and 31R and a plurality of connection coils 40 as shown in FIGS.

[2-1 Base plate]
The base plates 31 </ b> L and 31 </ b> R are substantially annular members that are formed of an insulating resin (nonmagnetic material) or the like and have inner and outer diameters substantially equal to the stator core 21.

  As shown in FIGS. 3 and 4, the inner diameter side of the base plates 31 </ b> L and 31 </ b> R correspond to the outer diameter side slot coil 26 and the inner diameter side slot coil 27 of each slot coil 25 inserted into the slot 23 of the stator core 21. Thus, a plurality of outer diameter side through holes 32 and a plurality of inner diameter side through holes 33 are formed so as to penetrate the base plate 31R at equal intervals and to communicate the outer surface 35 and the inner surface 36 with each other. By assembling the base plate assemblies 30L and 30R to the stator core assembly 20, the outer diameters of the base plates 31L and 31R are inserted into the slots 23 of the stator core 21 into the outer diameter side through holes 32 and project from the end faces 21a and 21b of the stator core 21. The distal end portion of the side slot coil 26 is disposed, and the distal end portion of the inner diameter side slot coil 27 that is inserted into the slot 23 of the stator core 21 and protrudes from the end faces 21a and 21b of the stator core 21 in the inner diameter side through holes 33 of the base plates 31L and 31R. Is placed.

  On the outer diameter side of the base plates 31L and 31R, a plurality of connecting coil joint holes 34 are formed so as to penetrate the base plates 31L and 31R at equal intervals so as to communicate the outer surface 35 and the inner surface 36. As shown in FIG. 7, the outer side surface 35 and the inner side surface 36 of the base plates 31L and 31R have a plurality of outer side surface grooves 37 and inner side surface grooves having substantially U-shaped cross-sections that open to the outer side surface 35 and the inner side surface 36, respectively. 38 is formed in the vicinity of the circumferential direction along the involute curve.

  The base plate 31L is provided with a fan-shaped portion 31a extending in a fan shape outward in the radial direction at the upper portion in the figure on the outer diameter side of the base plate 31L. In the fan-shaped portion 31a, input terminal cutout portions 34c in which the input terminal portions 43 are arranged are formed at equal intervals one by one, and bus bars 61U, 61V, 61W for connecting the coils in the same phase are connected to each other. A bus bar notch (not shown) in which a portion is arranged, and a mid-point bus bar notch (not shown) in which a mid-point bus bar 62 for connecting the U, V, and W phase coils to each other is provided. .

  In the connection coil joining holes 34 of the base plates 31L and 31R, an outer diameter side end portion 112 of the outer connection coil 41 and an outer diameter side end portion 123 of the inner connection coil 42 described later are arranged. The outer diameter side through hole 32, the inner diameter side through hole 33, and the connection coil joint hole 34 have a rectangular shape when viewed from the axial direction, and have a larger space than the coil member disposed inside them.

  In these base plates 31L and 31R, as shown in FIG. 6, the space between the outer surface grooves 37 and 37 adjacent to each other and the space between the inner surface grooves 38 and 38 are separated by a partition wall 31b standing from the base plate 31L. Further, the outer surface groove 37 and the inner surface groove 38 that face each other in the axial direction are separated by the intermediate wall 31c.

  The base plates 31L and 31R have the innermost diameter portion 39 in which the inner diameter side through-hole 33 is formed set to a length (L2) equal to the axial width of one connection coil 40, and the outer diameter side. The region other than the innermost diameter portion 39 in which the through hole 32 and the connection coil joining hole 34 are formed is the axial width (2 × L2) of the two connection coils 40 and the thickness (L3) of the intermediate wall 31c. The axial width (2 × L2 + L3) is set approximately equal to the total.

  In the base plate assemblies 30L and 30R, as shown in FIG. 7, each outer surface groove 37 of the base plates 31L and 31R has a connection coil joint hole 34 and a predetermined counterclockwise direction from the connection coil joint hole 34 in a front view. Are curved along an involute curve so as to be connected to the outer diameter side through holes 32 that are spaced apart from each other. In FIG. 7, a state in which an outer connection coil 41 and an inner connection coil 42 described later are accommodated in the outer surface groove 37 and the inner surface groove 38 is shown.

  Each of the inner side surface grooves 38 of the base plates 31L and 31R has a predetermined angle in the front view when viewed from the front side in the connection coil joint hole 34 and the connection coil joint hole 34 (clockwise as viewed from the side in FIG. 7). The inner diameter side through hole 33 that is separated is formed so as to be bent while avoiding the outer diameter side through hole 32.

  That is, the outer diameter side through hole 32 and the inner diameter side through hole 33 are connected via the connection coil joining hole 34 in which the outer surface groove 37 and the inner surface groove 38 are continuously connected in common.

[2-2 Connection coil]
The connection coil 40 is formed in a plate shape by a conductive material such as copper, and is divided into an outer connection coil 41 inserted into the outer surface groove 37 and an inner connection coil 42 inserted into the inner surface groove 38, respectively. be able to. The outer connection coil 41 referred to here is the connection coil 40 that is on the outer side in the axial direction of the stator 10 when the stator core assembly 20 and the base plate assemblies 30L and 30R are assembled. Is the connecting coil 40 which is the axially inner side of the stator 10.

  The outer connecting coil 41 is a plate-shaped conductor having a uniform thickness and a rectangular cross section, and the inner diameter side end portion 111 extends from the outer connecting coil main body 110 formed along the involute curve having the same shape as the outer surface groove 37. While being bent in the radial direction, the outer diameter side end portion 112 is also bent in the radial direction from the outer connecting coil body 110. An outer connecting coil extending portion 113 is formed at the outer diameter side end portion 112 of the outer connecting coil 41 so as to extend inward in the axial direction. The axial width (L2) of the outer connecting coil body 110 and the inner diameter side end portion 111 is equal to the groove depth of the outer surface groove 37, and the axial width (L4) of the outer connecting coil extending portion 113 is outer. The axial width (2 × L2 + L3) is set equal to the sum of the groove depths of the side groove 37 and the inner side groove 38 and the thickness (L3) of the intermediate wall 31c.

  The inner connecting coil 42 is a plate-like conductor having a uniform thickness and a rectangular cross section, and the inner connecting coil body 120 formed along the involute curve having the same shape as the inner side surface groove 38 has an outer diameter side through hole 32. The inner diameter side end portion 122 is bent in the radial direction via the bypass portion 121 formed so as to bypass the inner diameter, and the outer diameter side end portion 123 is also bent in the radial direction from the inner connection coil body 120. An inner connection coil extension portion 124 is formed at the outer diameter side end portion 123 of the inner connection coil 42 so as to extend outward in the axial direction. The axial width (L2) of the inner connecting coil main body 120 and the inner diameter side end portion 122 is equal to the groove depth of the inner side surface groove 38, and the axial width (L4) of the inner connecting coil extending portion 124 is the outer width. The axial width (2 × L2 + L3) is set equal to the sum of the groove depths of the side groove 37 and the inner side groove 38 and the thickness of the intermediate wall 31c.

  The outer connection coil 41 and the inner connection coil 42 have the same plate thickness, and the outer connection coil 41 and the inner connection coil 42 have the same plate thickness as the outer diameter side slot coil 26 and the inner diameter side slot. The same plate thickness as that of the coil 27 is set. The plate thickness of the outer connection coil 41 and the inner connection coil 42 is smaller than the axial width (L2) of the outer connection coil 41 and the inner connection coil 42 (the outer connection coil body 110 and the inner connection coil body 120). Note that “the axial width of x (x = 1, 2, 4) of the connection coils 40” described above means the axial width of the outer connection coil body 110 and the inner connection coil body 120. Further, “substantially equal” is an expression including an error corresponding to the intermediate wall 31c. The thickness of the insulating sheet 65 was not considered.

  The outer connection coil 41, the inner connection coil 42, and the slot coil 25 are processed by press punching or the like from a metal plate (for example, a copper plate) having a predetermined plate thickness, so that a desired axial width and a desired planar shape are obtained. Can be formed. Further, for the outer connection coil 41, an outer connection coil body 110 formed along an involute curve having the same shape as the outer surface groove 37 by bending a punched plate-shaped conductor, and the outer connection coil body 110 The inner diameter side end portion 111 and the outer diameter side end portion 112 which are connected so as to be bent can be formed. Similarly, for the inner connection coil 42, the inner connection coil body 120 formed along the involute curve having the same shape as the inner surface groove 38 by bending a punched plate-shaped conductor, and the inner connection coil body An inner diameter side end portion 122 and an outer diameter side end portion 123 connected so as to be bent from 120 can be formed.

  The outer connection coil 41 is inserted into the outer surface groove 37 of the base plates 31L and 31R. The inner diameter side end portion 111 of the outer connection coil 41 is disposed in the outer diameter side through hole 32. As shown in FIG. 13, when the stator core assembly 20 and the base plate assemblies 30L and 30R are assembled, the slots of the stator core 21 are similarly formed. 23 is in contact with the stepped portion 26a of the outer diameter side slot coil 26 inserted into the outer diameter side through hole 32.

  The inner connection coil 42 is inserted into the inner side surface groove 38 of the base plates 31L and 31R. The inner diameter side end portion 122 of the inner connection coil 42 is disposed in the inner diameter side through hole 33. As shown in FIG. 13, when the stator core assembly 20 and the base plate assemblies 30L and 30R are assembled, the slots 23 of the stator core 21 are also formed. Is inserted into the inner diameter side through-hole 33 and contacts the stepped portion 27 a of the inner diameter side slot coil 27.

  As shown in FIG. 12, the outer diameter side end portion 112 of the outer connection coil 41 and the outer diameter side end portion 123 of the inner connection coil 42 are both disposed in the connection coil joint hole 34, and the outer connection coil extension portion. The side surface 113a facing one circumferential direction of the 113 and the side surface 124a facing the other circumferential direction of the inner connecting coil extending portion 124 are in contact with each other over the entire radial and axial directions.

[3 Joining]
The inner diameter side end 111 of the outer connection coil 41 and the stepped portion 26a of the outer diameter side slot coil 26, the inner diameter side end 122 of the inner connection coil 42 and the stepped portion 27a of the inner diameter side slot coil 27, which are in contact with each other, and the outer side The outer connecting coil extending portion 113 of the connecting coil 41 and the inner connecting coil extending portion 124 of the inner connecting coil 42 are both welded, preferably laser welded, with planar plate surfaces intersecting the plate thickness direction. Are joined together. In the following description, the case of joining by laser welding will be described as an example.

  As shown in FIG. 12, the outer connection coil extension portion 113 and the inner connection coil extension portion 124 are both planar plate surfaces that intersect the axial direction and extend along the axial direction. The side surfaces 113a facing the circumferential direction of the extending portion 113 and the side surfaces 124a facing the other circumferential direction of the inner connecting coil extending portion 124 are brought into contact with each other so that the respective plate surfaces are in the entire radial and axial directions. Surface contact is made. In a state where both side surfaces 113a and 124a are in surface contact, laser welding is performed along the contact surface P1 extending in the radial direction from the outer side in the axial direction of the connection coil joint hole 34 to be bonded at the contact surface P1. Thereby, the outer diameter side end 112 of the outer connection coil 41 and the outer diameter side end 123 of the inner connection coil 42 located in the same connection coil joint hole 34 are electrically connected, and the base plate assemblies 30L and 30R are connected. Composed. In FIG. 12, the base plates 31L and 31R are omitted. The same applies to FIG.

  As shown in FIG. 13, in the assembly of the stator core assembly 20 and the base plate assemblies 30L and 30R, the outer connection is achieved by assembling the insulation sheet 65 in the axial direction with the relative positions in the circumferential direction being interposed. The inner diameter side end portion 111 of the coil 41 and the stepped portion 26a of the outer diameter side slot coil 26 come into contact with each other, and the inner diameter side end portion 122 of the inner connection coil 42 and the stepped portion 27a of the inner diameter side slot coil 27 come into contact with each other. Both are positioned.

  The inner diameter side end portion 111 of the outer connection coil 41 that contacts the stepped portion 26a of the outer diameter side slot coil 26 has a side surface 111a facing the other circumferential direction which is a flat plate surface over the entire side surface 26b of the stepped portion 26a. At the same time, the bottom surface 111b contacts the entire bottom surface 26c of the stepped portion 26a. Along the contact surface P2 that extends in the radial direction from the outer side in the axial direction of the outer diameter side through-hole 32 in a state where the planar side surfaces 111a and 26b that intersect the axial direction and cross the plate thickness direction are in surface contact. It joins in contact surface P2 by laser welding.

  The inner diameter side end 122 of the inner connection coil 42 that abuts the stepped portion 27a of the inner diameter side slot coil 27 has a side surface 122a facing one side in the circumferential direction, which is a flat plate surface, over the entire side surface 27b of the stepped portion 27a. The bottom surface 122b contacts the entire bottom surface 27c of the stepped portion 27a. The laser is along the contact surface P3 extending in the radial direction from the outer side in the axial direction of the inner diameter side through hole 33 in a state where the planar both side surfaces 122a, 27b intersecting the plate thickness direction and in the axial direction are in surface contact. It joins in contact surface P3 by welding.

  By joining in this way, the outer diameter side slot coil 26 and the inner diameter side slot coil 27 inserted into the slot 23 of the stator core 21 are electrically connected via the outer connection coil 41 and the inner connection coil 42. In this state, the base plate assemblies 30L and 30R are assembled to the stator core assembly 20. The outer connection coil 41 and the inner connection coil 42 connect the slot coils 25 of the same phase (for example, U phase) to form a transition portion of the coil 50.

  Therefore, for example, as shown in FIG. 9, the outer diameter side slot coil 26 and the inner diameter side slot coil 27 arranged in the same slot 23 are connected to one end side (the front side in the figure) of the outer diameter side slot coil 26. The outer connection coil 41 is connected to the inner connection coil 42 that extends radially outward and in the clockwise direction, and is connected to the other end side (the rear side in the drawing) of the outer diameter side slot coil 26. The coil 41 extends radially outward and counterclockwise and is connected to the in-phase inner connection coil 42. Further, the inner connection coil 42 connected on one end side (the front side in the drawing) of the inner diameter side slot coil 27 extends radially outward and counterclockwise and is connected to the outer connection coil 41 of the same phase. The inner connection coil 42 connected on the other end side (the rear side in the figure) of the slot coil 27 extends radially outward and clockwise and is connected to the outer connection coil 41 having the same phase.

  Thus, the stator 10 is configured by assembling a pair of base plate assemblies 30L and 30R on both sides of the stator core assembly 20, and the segmented coils 50 have six coil loops each having the same structure. (U-phase coil 50U, V-phase coil 50V, and W-phase coil 50W) are formed. Each of the six coil loops (U-phase coil 50U, V-phase coil 50V, and W-phase coil 50W) has three sets of U-phase coils 50U, three sets of V-phase coils 50V, And three sets of W-phase coils 50W are wound in this order in the counterclockwise direction (see FIG. 10). 8 is a perspective view of a multi-phase coil extracted from the stator 10 for easy understanding, and FIG. 9 is a perspective view of a single-phase coil (for example, a U-phase). FIG. 10 is a developed view showing the connection mode of the U-phase coil, and FIG. 11 is a schematic diagram showing the connection mode of the U-phase, V-phase, and W-phase coils.

Referring to FIG. 10, the U-phase coil as an example will be described in more detail with reference to FIG. 10. The six coil loops constituting the U-phase coil have three coil loops (U loops) continuously in the clockwise direction. The three coil loops ( U loop) are continuously wound in the counterclockwise direction, and the U loop and the U loop are connected in series by the bus bar 61U. The outer-diameter side slot coil 26 and the inner-diameter side slot coil 27 which are disposed in one slot 23 and are covered with an insulating material 28 are composed of a coil constituting a U loop and a coil constituting a U loop. The current flow direction is the same direction.

  For example, focusing on one U loop, the outer connection coil 41 and the inner connection coil 42 are connected in this order from one end in the axial direction (right hand side in the figure) of the outer diameter side slot coil 26 disposed in the U phase slot 23. Then, it is connected to the inner diameter side slot coil 27 in the next U-phase slot 23. Thereafter, the inner connection coil 42 and the outer connection coil 41 are connected in this order from the other axial end of the inner diameter side slot coil 27 (the left hand side in the figure), and the outer diameter side slot coil in the next U-phase slot 23 is further connected. 26. Thereafter, the U loop is formed by repeating this connection configuration.

Similarly, the other two phases, i.e., also six coil loops that constitute the V-phase coil (W-phase coil), three V loops are wave winding in the opposite direction (W loops) and three V loops (W Loop ) Are connected in series by a bus bar 61U (bus bar 61W), and an outer diameter side slot coil 26 and an inner diameter side slot coil 27 arranged in one slot 23 constitute a V loop (W loop) and a V loop. ( W loop) and the current flow direction is the same direction. These U-phase coil 50U, V-phase coil 50V, and W-phase coil 50W are star-connected by a midpoint bus bar 62 as shown in FIG.

[4 Summary]
As described above, according to the stator 10 of the rotating electrical machine of the present embodiment, the insulating material 28 that covers the slot coil 25 has the flange portion 29 that contacts the end surface 21b of the stator core 21 on one end side. The leakage of the varnish 60 filled in the gap between the outer peripheral surface 28a of the 28 and the inner peripheral surface 23a of the slot 23 can be suppressed, and the usage amount of the varnish 60 can be reduced.

  In addition, the flange portion 29 includes a first flange portion 29A that protrudes from the outer peripheral surface 28a of the insulating material 28 to one side in the circumferential direction and a second flange portion 29B that protrudes from the outer peripheral surface 28a of the insulating material 28 to the other circumferential direction. Therefore, leakage of the varnish 60 can be effectively suppressed with respect to the slot 23 that is long in the radial direction.

  Further, by providing the flange portion 29 with the rubber wire 66 or the rubber sheet 67 on the back surface 29d that contacts the end surface 21b of the stator core 21, the leakage of the varnish 60 can be more effectively suppressed.

In addition, this invention is not limited to embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably.
For example, in the above embodiment, the flange portion 29 is integrally formed with the insulating material 28 that covers the slot coil 25, but as shown in FIG. 19, what is the insulating material 28 that covers the slot coil 25? You may comprise by another body (for example, cap type). Thus, by forming the flange portion 29 separately from the insulating material 28, the slot coil 25 covered with the insulating material 28 can be easily manufactured.

  Moreover, the shape of the collar part 29 is not restricted to this, Arbitrary shapes can be selected. For example, as shown in FIG. 20, in addition to the first flange portion 29A and the second flange portion 29B protruding in the circumferential direction from the outer peripheral surface 28a of the slot coil 25, a third flange portion 29C protruding outward in the radial direction is formed. May be. FIG. 21A is an example in which a first engagement portion 75 extending downward is provided on the outer edge portion of the back surface 29d of the first flange portion 29A, the second flange portion 29B, and the third flange portion 29C. Further, on the end surface 21 b of the stator core 21, as shown in FIG. 21B, a second engagement portion 76 formed of a U-shaped groove portion that engages with the first engagement portion 75 of the flange portion 29 surrounds the slot 23. Is provided.

  As described above, the first engagement portion 75 and the second engagement portion 76 are provided so as to surround the slot 23, and the slot coil 25 is inserted into the slot 23 of the stator core 21, and the first flange portion of the insulating material 28. 29A, the second flange portion 29B, and the third flange portion 29C are brought into contact with the end surface 21b of the stator core 21 and the first engagement portion 75 and the second engagement portion 76 are engaged, so that the varnish 60 is more effectively applied. Leakage can be suppressed.

10 Stator 21 of rotating electrical machine Stator core 21b End face (one end face)
23 slot 23a inner peripheral surface 25 slot coil 28 insulating material 28a outer peripheral surface 29 flange 29A first flange 29B second flange 29d back surface (contact surface)
40 Coil 50 Coil 60 Varnish 66 Rubber wire (sealing member)
67 Rubber sheet (sealing member)
75 1st engaging part 76 2nd engaging part P2 Contact surface (contact part)
P3 Contact surface (contact part)

Claims (11)

A slot coil inserted into a slot provided in the stator core,
The slot coil is coated with an insulating material on the periphery,
The outer periphery of the insulating material is smaller than the inner periphery of the slot,
The insulating material has a varnish leakage suppression portion that abuts one end surface of the stator core on one end side and suppresses leakage of varnish filled in a gap between the outer peripheral surface of the insulating material and the inner peripheral surface of the slot. , Slot coil. The slot coil according to claim 1,
The varnish leakage suppressing portion includes a first flange portion that protrudes from the outer peripheral surface of the insulating material to one side in the circumferential direction, and a second flange portion that protrudes from the outer peripheral surface of the insulating material to the other circumferential direction. Slot coil. The slot coil according to claim 1,
The varnish leakage suppressing portion is a slot coil configured separately from the insulating material. The slot coil according to any one of claims 1 to 3,
The slot coil, wherein the varnish leakage suppressing portion is provided with a sealing member on a contact surface that contacts the one end surface of the stator core. A stator core having a plurality of slots;
In a stator of a rotating electrical machine comprising a coil attached to the stator core,
The coil includes a plurality of slot coils inserted into the slots, and a plurality of connection coils that connect the slot coils on the axially outer side than the axial end surface of the stator core, and the slot coils; The connecting coil is coupled at the contact portion,
The slot coil is coated with an insulating material on the periphery,
The outer periphery of the insulating material is smaller than the inner periphery of the slot,
The gap between the outer peripheral surface of the insulating material and the inner peripheral surface of the slot is filled with varnish,
The said insulating material is a stator of a rotary electric machine which has a varnish leak suppression part which contact | abuts the one end surface of the said stator core on one end side, and suppresses the leak of the said varnish. A stator for a rotating electrical machine according to claim 5,
The varnish leakage suppressing portion includes a first flange portion that protrudes from the outer peripheral surface of the insulating material to one side in the circumferential direction, and a second flange portion that protrudes from the outer peripheral surface of the insulating material to the other circumferential direction. A stator for rotating electrical machines. A stator for a rotating electrical machine according to claim 5,
The varnish leakage suppression unit is a stator of a rotating electrical machine configured separately from the insulating material. A stator for a rotating electrical machine according to any one of claims 5 to 7,
A stator of a rotating electrical machine, wherein the varnish leakage suppressing portion is provided with a sealing member on a contact surface that contacts the one end surface of the stator core. A stator for a rotating electrical machine according to any one of claims 5 to 8,
The varnish leakage suppression portion is provided with a first engagement portion on a contact surface that contacts the one end surface of the stator core,
The one end surface of the stator core is provided with a second engagement portion that engages with the first engagement portion,
The stator of a rotating electrical machine, wherein the first engaging portion and the second engaging portion are provided so as to surround the slot. A method of manufacturing a stator for a rotating electrical machine according to any one of claims 5 to 9,
A slot coil arrangement step of inserting the slot coil into the slot of the stator core, and abutting the varnish leakage suppressing portion of the insulating material with the one end surface of the stator core;
A varnish filling step in which the one end surface side of the stator core is disposed downward, and a varnish is filled from the other end surface side of the stator core into a gap between the outer peripheral surface of the insulating material and the inner peripheral surface of the slot. The manufacturing method of the stator of a rotary electric machine. A method of manufacturing a stator for a rotating electrical machine according to claim 10,
In the varnish filling step, the varnish is filled while pressing the varnish leakage suppressing portion of the insulating material toward the one end face of the stator core.

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