JP7030961B2 - Stator and rotary machine - Google Patents

Description

The present invention relates to a stator of a rotary electric machine and a rotary electric machine provided with the stator.

The rotary electric machine includes a stator and a rotor. The stator comprises a coil composed of windings and an iron core. The rotating electric machine generates a rotating magnetic field when AC power is supplied to the coil of the stator, and the rotating magnetic field rotates the rotor. It is also possible to convert the mechanical energy applied to the rotor into electrical energy and output AC power from the coil. In this way, the rotary electric machine operates as a motor or a generator. The rotary electric machine installed in the automobile generates torque for the running of the automobile and generates electricity during braking.

The surface of the coil winding is covered with an insulating film. For example, Patent Documents 1 and 2 describe inventions for improving the insulating property by making the thickness of the insulating coating of the coil different depending on the winding portion at the coil end portion.

Japanese Unexamined Patent Publication No. 2014-161212 Japanese Unexamined Patent Publication No. 2013-094019

The stator of a rotary electric machine needs to maintain high insulation, especially between coils having different phases and different voltages. In the conventional technique such as the inventions described in Patent Documents 1 and 2, the winding of the coil has a thick insulating coating only at the portion of the coil end in contact with the coil having a different phase. Such a coil can improve the insulation between coils having different phases, but there is a problem that it is difficult to manufacture the winding because it is necessary to determine in advance which part of the winding should be thickened to manufacture the winding. be. Another problem is that it is difficult to wind the winding around the iron core so that the thick portion of the insulating coating is located at the portion in contact with the coil having a different phase.

In addition, the coil housed in the slot of the iron core is formed by twist molding that twists the winding, but in the twisted winding, the insulating coating may stretch and cracks may occur, resulting in deterioration of the insulating property. I am concerned.

In order to provide a high-power, high-efficiency, high-quality rotary electric machine, it is necessary to increase the occupied area of the coil in the slot, and for this purpose, the space between the coils in the slot (especially between the coils of different phases) is required. It is necessary to improve the insulation property. It is also necessary to prevent the insulation of the coil from being lowered when the coil is formed.

An object of the present invention is to provide a stator having improved coil insulation, particularly insulation between coils having different phases, and a rotary electric machine provided with the stator.

The stator according to the present invention includes a cylindrical stator core having a plurality of slots, and a stator coil composed of windings and housed in the slots. The winding has an insulating coating on its surface, and inside the slot, a portion of the insulating coating in a cross section perpendicular to the length direction is a portion of the winding opposite the center of the winding. Thicker than the insulating coating. Inside the slot, the winding adjacent to the stator coil of different phase has the insulating coating on the portion adjacent to the stator coil of different phase, and the opposite portion of the portion adjacent to the stator coil of different phase. Thicker than the insulating coating.

According to the present invention, it is possible to provide a stator having improved coil insulation, particularly insulation between coils having different phases, and a rotary electric machine provided with the stator.

It is sectional drawing of the rotary electric machine according to Example 1 of this invention. It is an overall perspective view of a stator. It is the whole perspective view of the stator core. It is sectional drawing which is perpendicular to the axial direction of a rotor and a stator core. It is a perspective view which shows the stator coil. It is a conceptual diagram which shows the connection state of a stator coil. It is a figure which shows the shape of the winding (the winding before being accommodated in the slot of a stator core) which constitutes a stator coil. It is a figure which shows the shape of the winding (the winding after being accommodated in the slot of a stator core) which constitutes a stator coil. It is a figure which shows the winding which was twist-formed and accommodated in the slot of a stator core. It is a perspective view of the U-phase coil which is one phase part of a stator coil. It is a perspective view which shows the U1 phase coil. It is a perspective view which shows the U2 phase coil. FIG. 1 is a cross-sectional view of a slot showing a winding house housed in the slot of the stator core in the first embodiment. FIG. 1 is a cross-sectional view of a slot showing another winding housed in the slot of the stator core in Example 1. FIG. 2 is a cross-sectional view of the slot showing the winding housed in the slot of the stator core in the second embodiment. It is a perspective view of the stator of a centralized winding. It is sectional drawing of the stator of concentrated winding which winding is a flat wire. It is sectional drawing of the stator of concentrated winding which winding is a round wire. It is a figure which shows the schematic structure of the hybrid type electric vehicle (HEV) equipped with the rotary electric machine according to the Example of this invention.

In the stator according to the invention, the winding of the stator coil wound around the slot of the stator core has an insulating coating on the surface, and a part of the insulation inside the slot in a cross section perpendicular to the length direction. The coating is thicker than the insulating coating on the opposite part of this part (the part on the opposite side of the center of the winding). Further, inside the slot, the winding adjacent to the different-phase coil has an insulating coating on the portion adjacent to the different-phase coil, which is opposite to the portion adjacent to the different-phase coil (on the opposite side of the center of the winding). Thicker than the insulating coating of the part). It is more preferable that the winding has a portion of the insulating coating in the cross section perpendicular to the length direction thicker than the insulating coating of the opposite portion of the portion in all the length directions of the winding.

Hereinafter, the stator and the rotary electric machine according to the embodiment of the present invention will be described. The rotary electric machine according to the embodiment of the present invention is a rotary electric machine suitable for use in traveling an automobile. So-called electric vehicles that use a rotary electric vehicle include a hybrid type electric vehicle (HEV) that has both an engine and a rotary electric vehicle, and a pure electric vehicle (EV) that runs only on the rotary electric vehicle without using an engine. .. The rotary electric machines described below can be used for both electric vehicles. In the following examples, a rotary electric machine used for a hybrid type automobile will be described as a representative.

In the following description, "axial direction" refers to a direction along the rotation axis of the rotary electric machine. The "circumferential direction" refers to a direction along the rotation direction of the rotary electric machine. The "diameter direction" refers to the radial direction (radial direction) when the rotation axis of the rotary electric machine is centered. "Inner circumference side" refers to the inner side in the radial direction (the inner diameter side which is a part close to the rotation axis). The "outer peripheral side" refers to the opposite direction of the inner peripheral side, that is, the outer side in the radial direction (the outer diameter side which is a portion far from the rotation axis). The axial direction, the circumferential direction, and the radial direction are the same as the axial direction, the circumferential direction, and the radial direction of the stator and the stator core, respectively.

First, a schematic configuration of an electric vehicle equipped with a rotary electric machine according to an embodiment of the present invention will be described.

FIG. 17 is a diagram showing a schematic configuration of a hybrid electric vehicle (HEV) equipped with a rotary electric machine according to an embodiment of the present invention. The HEV includes an engine ENG and a rotary electric machine 10 as main power on the front wheel side. The power generated by the engine ENG and the rotary electric machine 10 is changed by the transmission TR and transmitted to the front wheel side drive wheel FW. Regarding the drive of the rear wheels, the rotary electric machine 10 arranged on the rear wheel side and the rear wheel side drive wheel RW are mechanically connected, and the power of the rotary electric machine 10 is transmitted to the rear wheel side drive wheel RW. The rotary electric machine 10 which is a power source on the front wheel side is arranged between the engine ENG and the transmission TR.

The rotary electric machine 10 starts the engine ENG, and switches between the generation of driving force and the generation of power generation that recovers the energy at the time of deceleration of the vehicle as electric energy according to the traveling state of the vehicle. The drive operation and the power generation operation of the rotary electric machine 10 are controlled by the power conversion device INV so that the torque and the rotation speed are optimized according to the operating condition of the vehicle. The electric power required to drive the rotary electric machine 10 is supplied from the battery BAT via the power conversion device INV. Further, when the rotary electric machine 10 performs the power generation operation, the battery BAT is charged with electric energy via the power conversion device INV.

The rotary electric machine 10 is a three-phase synchronous motor with a built-in permanent magnet. The rotary electric machine 10 operates as an electric machine for rotating the rotor by supplying a three-phase alternating current to the stator coil. Further, when the rotor is rotated by the engine ENG, the rotary electric machine 10 operates as a generator and outputs the generated power of three-phase alternating current. That is, the rotary electric machine 10 has both a function as an electric motor that generates rotational torque based on electric energy and a function as a generator that generates electric power based on mechanical energy. Two functions can be selectively used.

Next, the stator and the rotary electric machine 10 according to the first embodiment of the present invention will be described.

FIG. 1 is a cross-sectional view of the rotary electric machine 10 according to the present embodiment. The rotary electric machine 10 includes a stator 20, a housing 50 for holding the stator 20, and a rotor 11 arranged on the inner peripheral side of the stator 20. In this embodiment, the rotary electric machine 10 is installed inside the liquid cooling jacket 130. The liquid-cooled jacket 130 is composed of an engine ENG case and a transmission TR case, and is fixed to the outer peripheral side of the housing 50. The inner peripheral wall of the liquid-cooled jacket 130 and the outer peripheral wall of the housing 50 form a refrigerant passage 153 for a liquid refrigerant RF such as oil. The stator 20 includes a cylindrical stator core 132 and a stator coil. The stator coil comprises coil ends 61, 62. The rotor 11 includes a rotor core 12, a shaft 13, and a permanent magnet 18, and is fixed to the shaft 13. The shaft 13 is a rotating shaft of the rotary electric machine 10, and is rotatably supported by bearings 144 and 145 provided on the liquid-cooled jacket 130. Therefore, the liquid-cooled jacket 130 is also referred to as a bearing bracket.

In the case of the direct liquid cooling method, in the refrigerant RF, the liquid accumulated in the refrigerant storage space 150 flows out to the stator 20 through the refrigerant passages 153 and further through the refrigerant passages 154 and 155, and is fixed. Cool the child 20. The refrigerant RF may be cooling oil.

A stator 20 is fixed to the inner peripheral side of the housing 50. The rotor 11 is rotatably supported on the inner peripheral side of the stator 20. The housing 50 has a cylindrical shape and constitutes the outer cover of the rotary electric machine 10, and is also referred to as a frame or a frame. The housing 50 can be manufactured by forming a steel plate having a thickness of about 2 to 5 mm (high-strength steel plate or the like) into a cylindrical shape by drawing. The housing 50 can also be manufactured by cutting an iron-based material such as carbon steel, casting a cast steel or an aluminum alloy, or by pressing.

The housing 50 is provided with a plurality of flanges (not shown) attached to the liquid-cooled jacket 130. The plurality of flanges project radially outward at the peripheral edge of one end surface of the cylindrical housing 50. The flange is formed by cutting off a portion other than the flange at the end portion formed during drawing, and is integrated with the housing 50. The stator 20 may be directly fixed to the liquid-cooled jacket 130, which is a case, without providing the housing 50.

FIG. 2 is an overall perspective view of the stator 20. FIG. 3 is an overall perspective view of the stator core 132. As shown in FIG. 2, the stator 20 includes a stator core 132 and a stator coil 60 composed of windings 28. The stator core 132 is formed by laminating thin plates of silicon steel plate. As shown in FIGS. 2 and 3, the stator core 132 includes a plurality of slots 420 in its inner peripheral portion. The stator coil 60 is wound around the slot 420 and includes coil ends 61, 62. The heat generated from the stator coil 60 is transmitted to the liquid-cooled jacket 130 via the stator core 132, and is cooled by the refrigerant RF circulating in the liquid-cooled jacket 130.

FIG. 4 is a cross-sectional view of the rotor 11 and the stator core 132 perpendicular to the axial direction. In FIG. 4, the shaft 13 is omitted. The rotor core 12 is formed by laminating thin plates of silicon steel plate. As shown in FIG. 1, the shaft 13 is fixed to the radial center of the rotor core 12. The shaft 13 is rotatably held by bearings 144 and 145 attached to the liquid-cooled jacket 130, and rotates at a predetermined position on the inner peripheral side of the stator 20 and at a position facing the stator 20. Further, the rotor 11 includes a permanent magnet 18 and an end ring (not shown).

As shown in FIGS. 2 to 4, the stator core 132 includes a plurality of slots 420 parallel to the axial direction. The slots 420 are formed in the stator core 132 so as to be evenly spaced in the circumferential direction. The number of slots 420 is, for example, 72 in this embodiment. The slot 420 accommodates the stator coil 60. The portion of the slot 420 that accommodates the stator coil 60 is called a coil mounting portion. The inner peripheral side of each slot 420 is open. The width of the slot 420 in the circumferential direction is such that the width at this opening is approximately equal to the width at the coil mounting portion or slightly smaller than the width at the coil mounting portion. As shown in FIG. 2, an insulating member (for example, insulating paper) called a slot liner 310 is installed inside the slot 420 between the slot 420 and the stator coil 60.

As shown in FIGS. 2 to 4, teeth 430 are formed between the slots 420. Each tooth 430 is integrated with an annular core back 440. The stator core 132 is an integrated core in which each tooth 430 and a core back 440 are integrally molded. The teeth 430 guides the rotating magnetic field generated by the stator coil 60 to the rotor 11 and generates a rotational torque in the rotor 11.

The stator core 132 is manufactured by forming an annular steel sheet with a thickness of about 0.05 to 1.0 mm into an annular shape by punching, and then laminating and welding a plurality of the formed annular steel sheets. can. As shown in FIGS. It is provided. It should be noted that a plurality of electrical steel sheets may be fixed by caulking or the like without providing the welded portion 200, and the stator core 132 may be directly inserted into the case for fixing.

As shown in FIG. 4, the rotor core 12 includes magnet insertion holes 810 formed at equal intervals. Inside each magnet insertion hole 810, a rectangular permanent magnet 18 is fixed with an adhesive, powder resin, a mold, or the like. The circumferential width of the magnet insertion hole 810 is larger than the circumferential width of the permanent magnet 18, and magnetic gaps 156 are provided on both sides of the permanent magnet 18 in the circumferential direction. An adhesive may be embedded in the magnetic gap 156 with the permanent magnet 18, or a molding resin in which the permanent magnet 18 is solidified and integrated may be provided. The permanent magnet 18 has an action of forming a field pole of the rotor 11. In this embodiment, a configuration in which one permanent magnet 18 forms one magnetic pole is illustrated, but the number of permanent magnets 18 constituting each magnetic pole may be plural. When the number of permanent magnets 18 is increased, the magnetic flux density of the magnetic poles formed by the permanent magnets 18 increases, and the magnet torque can be increased.

The magnetization direction of the permanent magnet 18 is radially oriented, and the direction of the magnetization direction is reversed for each field magnetic pole. That is, in the permanent magnet 18 for forming a certain magnetic pole, the surface on the stator 20 side (side surface on the outer peripheral side) is magnetized to the N pole, and the surface on the rotation axis side (side surface on the inner peripheral side) is the S pole. In the permanent magnet 18 forming the magnetic pole next to the magnetic pole by the permanent magnet 18, the surface on the stator 20 side is magnetized to the S pole, and the surface on the rotation axis side is magnetized to the N pole. Has been done. That is, these permanent magnets 18 are magnetized and arranged so that the magnetization direction changes alternately for each magnetic pole in the circumferential direction. In this embodiment, 12 permanent magnets 18 are arranged at equal intervals, and the rotor 11 forms a 12-pole magnetic pole.

As the permanent magnet 18, neodymium-based or samarium-based sintered magnets, ferrite magnets, neodymium-based bonded magnets, and the like can be used. In this embodiment, as shown in FIG. 4, an auxiliary magnetic pole 160 is formed between the permanent magnets 18 forming the magnetic poles. The auxiliary magnetic pole 160 acts so that the magnetic resistance of the magnetic flux of the q-axis generated by the stator coil 60 becomes small. With this auxiliary magnetic pole 160, the magnetic resistance of the magnetic flux on the q-axis is much smaller than the magnetic resistance of the magnetic flux on the d-axis, so that a large reluctance torque can be generated.

FIG. 5 is a perspective view showing the stator coil 60. FIG. 6 is a conceptual diagram showing a connection state of the stator coil 60. In this embodiment, the stator coil 60 is a stator coil having a two-star configuration in which the two star connections shown in FIG. 6 are connected in parallel. That is, the stator coil 60 includes a star connection of the U1 phase coil 60U1, a V1 phase coil 60V1, and a W1 phase coil 60W1 and a star connection of the U2 phase coil 60U2, the V2 phase coil 60V2, and the W2 phase coil 60W2. These two star connections have neutral points N1 and N2, respectively. The U1 phase coil 60U1 and the U2 phase coil 60U2 constitute the U phase coil 60U. The V1 phase coil 60V1 and the V2-phase coil 60V2 constitute a V-phase coil 60V. The W1 phase coil 60W1 and the W2 phase coil 60W2 constitute a W phase coil 60W.

The winding 28 constituting the stator coil 60 may have a rectangular flat cross section having a cross section perpendicular to the length direction, or may have a round cross section. However, since the space inside the slot 420 is used as effectively as possible and the efficiency tends to improve when the winding 28 occupies a large space in the slot 420, the flat wire is more efficient than the round wire. Is desirable. The length of each side of the cross section of the flat wire may be long in the radial direction of the stator core 132 or long in the circumferential direction.

In this embodiment, the winding 28 of the stator coil 60 is a rectangular wire having a rectangular cross section, the long side of the rectangular cross section is along the circumferential direction in the slot 420, and the short side is along the radial direction.

The winding 28 of the stator coil 60 includes a segment conductor which is a conductor portion and an insulating coating provided on the surface of the winding 28. The insulating coating covers the outer circumference of the segment conductor. For the segment conductor, for example, oxygen-free copper or aerobic copper can be used. For example, the aerobic copper used for the segment conductor has an oxygen content of about 10 ppm or more to about 1000 ppm. For the insulating film, for example, enamel or resin can be used.

7A and 7B are diagrams illustrating the winding 28 constituting the stator coil 60. FIG. 7A is a diagram showing the shape of the winding 28 before being accommodated in the slot 420 of the stator core 132. FIG. 7B is a diagram showing the shape of the winding 28 after being housed in the slot 420 of the stator core 132. The winding 28 is formed of a flat wire and has a substantially U-shape having a pair of leg portions 28B which are straight portions and a crown portion 28C connecting them. One end of the leg 28B is connected to the crown 28C, and the other end is the end 28E of the winding 28.

When the windings 28 are connected to each other to form the stator coil 60 of each phase, as shown in FIG. 7B, the pair of legs 28B of the windings 28 are connected to one of the stator cores 132 in the axial direction (FIG. 7B). In 7B, it is inserted into different slots 420 from above). After that, the legs 28B1 and 28B2 protruding from the slot 420 on the other side (downward in FIG. 7B) of the stator core 132 in the axial direction are bent in the direction (circumferential direction) of the winding 28 to be connected. Then, the end portion 28E of the bent leg portion 28B1 and the end portion 28E of the bent leg portion 28B2 are welded to each other. The crown 28C of the winding 28 projects from the slot 420 in one axial direction of the stator core 132. Therefore, in the stator coil 60, the plurality of end portions 28E and the plurality of crown portions 28C protrude from the stator core 132.

As shown in FIG. 5, the set of the crown 28C protruding from one of the axial directions of the stator core 132 constitutes the coil end 61 on one side of the stator coil 60 in the axial direction. The set of ends 28E protruding from the other axial direction of the stator core 132 constitutes the coil end 62 on the other axial direction of the stator coil 60. Hereinafter, the coil end 61 is also referred to as an anti-weld side coil end 61, and the coil end 62 is also referred to as a weld side coil end 62.

As shown in FIG. 6, a lead wire 41U1 is connected to one end of the U1 phase coil 60U1, and a lead wire 41U2 is connected to one end of the U2-phase coil 60U2. Similarly, for the V phase, the lead wire 41V1 is connected to one end of the V1 phase coil 60V1, and the lead wire 41V2 is connected to one end of the V2-phase coil 60V2. Similarly, for the W phase, the lead wire 41W1 is connected to one end of the W1 phase coil 60W1, and the lead wire 41W2 is connected to one end of the W2-phase coil 60W2.

As shown in FIG. 5, in the anti-weld side coil end 61, the lead wire 41U1 and the lead wire 41U2 are drawn out. The lead wire 41U1 and the lead wire 41U2 are combined into one by the AC terminal 42U. Similarly, for the V phase, in the anti-weld side coil end 61, the lead wire 41V1 and the lead wire 41V2 are combined into one by the AC terminal 42V. Similarly for the W phase, in the anti-weld side coil end 61, the lead wire 41W1 and the lead wire 41W2 are combined into one by the AC terminal 42W.

Further, as shown in FIG. 5, a neutral point connection conductor 40N1 and a neutral point connection conductor 40N2 are arranged on the anti-weld side coil end 61. The neutral point connection conductor 40N1 connects the three-phase coils at the neutral point N1 in the star connection of the U1 phase coil 60U1, the V1 phase coil 60V1, and the W1 phase coil 60W1 shown in FIG. The neutral point connection conductor 40N2 connects the three-phase coils at the neutral point N2 in the star connection of the U2-phase coil 60U2, the V2-phase coil 60V2, and the W2-phase coil 60W2 shown in FIG.

A winding 28 is wound around the stator core 132 by a distributed winding method. The distributed winding is a method in which the winding 28 is wound around the stator core 132 so as to be distributed and accommodated in a plurality of slots 420 (see FIG. 3). In this embodiment, since the winding 28 is wound in a distributed winding, the formed magnetic flux distribution is closer to a sine wave than the concentrated winding, and is characterized in that reluctance torque is likely to be generated. Therefore, the rotary electric machine 10 according to the present embodiment has improved controllability of field weakening control and control utilizing reluctance torque, and can be used over a wide rotation speed range from low rotation speed to high rotation speed. Excellent motor characteristics suitable for electric vehicles can be obtained.

FIG. 8 is a perspective view of the U-phase coil 60U, which is one phase of the stator coil 60 shown in FIG. As shown in FIG. 6, the U-phase coil 60U is composed of a U1-phase coil 60U1 and a U2-phase coil 60U2, which are two star connections connected in parallel.

FIG. 9 is a perspective view showing the U1 phase coil 60U1. One end of the winding 28 constituting the U1 phase coil 60U1 is connected to the AC terminal 42U, and the other end is connected to the neutral point connection conductor 40N1 (see also FIG. 6).

FIG. 10 is a perspective view showing the U2-phase coil 60U2. One end of the winding 28 constituting the U2-phase coil 60U2 is connected to the AC terminal 42U, and the other end is connected to the neutral point connection conductor 40N2 (see also FIG. 6).

FIG. 11 is a diagram showing a winding 28 housed in the slot 420 of the stator core 132, and is a cross-sectional view of the slot 420. In the stator core 132 shown in FIG. 11, in the slot 420, a winding 28 constituting the U1-phase coil 60U1, a winding 28 constituting the U2-phase coil 60U2, and a winding 28 constituting the W1-phase coil 60W1 are provided. , Wounds 28 constituting the W2-phase coil 60W2 are housed side by side in the radial direction.

The winding 28 includes a segment conductor 28G which is a conductor portion, and an insulating coating 28H provided on the surface of the winding 28 and covering the outer periphery of the segment conductor 28G. In the winding 28, the thickness of one insulating coating 28H in the radial direction and the thickness of the other insulating coating 28H are different from each other inside the slot 420. Further, inside the slot 420, in the winding 28 adjacent to the coil of the different phase in the radial direction, the insulating coating 28H of the portion adjacent to the coil of the different phase is opposite to the portion adjacent to the coil of the different phase (center of the winding). It is thicker than the insulating coating 28H (the opposite portion in the radial direction across the).

In the configuration shown in FIG. 11, inside the slot 420, the winding 28 (28a) constituting the U2-phase coil 60U2 is radially adjacent to the W1-phase coil 60W1 and is insulated from the portion adjacent to the W1-phase coil 60W1. The coating film 28H (28HT) is thicker than the insulating coating film 28H (28Ht) on the opposite portion of the winding 28a adjacent to the W1 phase coil 60W1. Further, inside the slot 420, the winding 28 (28b) constituting the W1 phase coil 60W1 is radially adjacent to the U2-phase coil 60U2, and the insulating coating 28H (28HT) of the portion adjacent to the U2-phase coil 60U2 is formed. , It is thicker than the insulating coating 28H (28Ht) on the opposite portion of the winding 28b adjacent to the U2 phase coil 60U2. Further, inside the slot 420, in the winding 28, the insulating coating 28H on one side in the radial direction is thinner than the insulating coating 28H on the other side in the radial direction in the portion adjacent to the coil having the same phase.

Inside the slot 420 of the stator core 132, the windings 28 (28a, 28b) adjacent to the winding 28 of the out-of-phase coil are such that the portions 28HT having a thick insulating coating 28H are adjacent to each other to insulate between the out-of-phase coils. Sex improves. Therefore, it is not necessary to arrange an insulating member (for example, insulating paper) between the coils having different phases.

It is preferable that the winding 28 has a part of the insulating coating in the cross section perpendicular to the length direction thicker than the insulating coating of the opposite portion in the length direction, not only inside the slot 420 but also in all the length directions. .. When such a winding 28 is used, inside the slot 420, the thickness of one insulating coating 28H in the radial direction of the winding 28 and the thickness of the other insulating coating 28H are different, and the coil is adjacent to the coil of a different phase in the radial direction. The winding 28 is formed so that the insulating coating 28H (28HT) of the portion of the matching winding 28 adjacent to the coil of the different phase is thicker than the insulating coating 28H (28Ht) of the portion opposite to the portion adjacent to the coil of the different phase. It is easy to wind around the stator core 132. Since such a winding 28 can be easily manufactured, the stator 20 can be easily manufactured by winding such a winding 28 around the stator core 132.

Further, since the winding 28 includes a portion 28HT in which the insulating film 28H is thick, cracks occur in the insulating film 28H of the crown 28C when the winding 28 is formed by twist molding, and the insulating property of the winding 28 is deteriorated. Can be prevented.

FIG. 7C is a diagram showing a winding 28 twist-molded and housed in the slot 420 of the stator core 132. In FIG. 7C, the portion 28HT where the insulating coating 28H of the winding 28 is thick is hatched.

The crown 28C protruding from the slot 420 of the winding 28 is twisted (ie, twisted) when the winding 28 is housed in the slot 420. The winding 28 housed in the slot 420 has a substantially U-shape with the crown 28C as the top, and the outer peripheral portion of the substantially U-shape extends during twist molding. Therefore, the crown 28C of the winding 28 may be twisted during twist molding, and the insulating coating 28H on the outer peripheral portion may be stretched to generate cracks.

In the configuration shown in FIG. 11, since the winding 28 has a thick portion 28HT of the insulating coating 28H even at the crown 28C, if the thick portion 28HT of the insulating coating 28H is located in the portion extending during twist molding, the winding 28 is formed during twist molding. Even if it is twisted, it is possible to prevent the insulating coating 28H from cracking at the crown 28C. As a result, the insulation between the stator coils 60 can be improved at the anti-weld side coil end 61.

As the slot liner 310 installed between the slot 420 and the stator coil 60, one formed into a square cylinder shape can be used. Even with such a simple shape, the slot liner 310 can surround the stator coil 60 in the slot 420 to insulate the stator core 132 and the stator coil 60.

FIG. 12 is a view showing another winding 28 housed in the slot 420 of the stator core 132, and is a cross-sectional view of the slot 420. In FIG. 12, description of the same configuration as in FIG. 11 will be omitted.

The winding 28 is a flat wire, and the insulating coating 28H on two faces adjacent to each other among the four faces constituting the winding 28 has two faces facing each other (of these two faces). , Two surfaces opposite the center of the winding 28) thicker than the insulating coating 28H.

In the winding 28 shown in FIG. 12, the thickness of one insulating coating 28H in the radial direction and the thickness of the other insulating coating 28H are different inside the slot 420, and the thickness of one insulating coating 28H in the circumferential direction is different. The thickness of the other insulating coating 28H is different from that of the other. That is, in the winding 28, one of the insulating coatings 28H (28HT) is thick and the other insulating coating 28H (28Ht) is thin in the circumferential direction and the radial direction inside the slot 420. In two windings 28 adjacent to each other in the radial direction in the slot 420, a portion 28HT in which the insulating coating 28H is thick in the circumferential direction in one winding 28 and a portion in which the insulating coating 28H is thin in the circumferential direction in the other winding 28. 28Ht are adjacent to each other in the radial direction. That is, in the winding 28 arranged in the radial direction in the slot 420, the thick portion 28H) and the thin portion 28Ht in the circumferential direction of the insulating coating 28H are alternately arranged in the radial direction.

Further, in the inside of the slot 420, the winding 28 adjacent to the coil of the different phase in the radial direction has the insulating coating 28H (28HT) of the portion adjacent to the coil of the different phase, which is the opposite portion (winding) of the portion adjacent to the coil of the different phase. It is thicker than the insulating coating 28H (28Ht) of the opposite portion across the center of the wire. Therefore, inside the slot 420, the windings 28 (28a, 28b) adjacent to the winding 28 of the different-phase coil have the portions 28HT having a thick insulating coating 28H adjacent to each other, and the insulation between the different-phase coils is improved. improves. Therefore, it is not necessary to arrange an insulating member (for example, insulating paper) between the coils having different phases.

As described with reference to FIG. 7B, the legs 28B1 and 28B2 of the winding 28 protruding from the slot 420 are bent in the direction (circumferential direction) of the winding 28 to be connected, and the ends of the bent legs 28B1. The portion 28E and the end portion 28E of the bent leg portion 28B2 are welded to each other. When the legs 28B1 and 28B2 are bent, the insulating coating 28H on the outer peripheral portion may extend and cracks may occur.

In the configuration shown in FIG. 12, since the winding 28 includes the thick portion 28HT of the insulating coating 28H even in the legs 28B1 and 28B2, the thick portion 28HT of the insulating coating 28H is provided in the portion extending when the legs 28B1 and 28B2 are bent. When positioned, even if the legs 28B1 and 28B2 are bent in the circumferential direction, it is possible to prevent the insulating coating 28H from cracking in the legs 28B1 and 28B2. As a result, the insulation between the stator coils 60 can be improved at the weld side coil end 62.

Further, in the configuration shown in FIG. 12, similarly to the configuration shown in FIG. 11, the winding 28 has a portion 28HT in which the insulating coating 28H is thick even in the crown 28C, so that when the winding 28 is formed by twist molding, the head is formed. It is possible to prevent the insulating coating 28H of the top portion 28C from being cracked and the insulating property from being deteriorated. As a result, the insulation between the stator coils 60 can be improved at the anti-weld side coil end 61.

In the winding 28, not only inside the slot 420, but also in all of the length direction, as shown in FIG. 12, a part of the insulating coating in the cross section perpendicular to the length direction is used to insulate the opposite part of this part. It is preferably thicker than the coating. If the winding 28 is a flat wire, the winding 28 has an insulating coating on two of the four surfaces constituting the winding 28, which are adjacent to each other, in all of the length directions. Is preferably thicker than the insulating coating on the two facing surfaces (the two surfaces of these two surfaces opposite each other across the center of the winding).

Even in the configuration shown in FIG. 12, the slot liner 310 installed between the slot 420 and the stator coil 60 can be formed into a square cylinder shape. Even with such a simple shape, the slot liner 310 can surround the stator coil 60 in the slot 420 to insulate the stator core 132 and the stator coil 60.

The stator 20 and the rotary electric machine 10 according to the second embodiment of the present invention will be described. Hereinafter, this embodiment will be described only with a configuration different from that of the first embodiment. In this embodiment, the winding 28 is wound around the stator core 132 by a lap winding method.

FIG. 13 is a diagram showing a winding 28 housed in the slot 420 of the stator core 132, and is a cross-sectional view of the slot 420. In the stator core 132 shown in FIG. 13, the winding 28 constituting the U-phase coil 60U and the winding 28 constituting the W-phase coil 60W are housed side by side in the slot 420 in the radial direction. In the lap winding method, the winding 28 is wound a plurality of times and accommodated in the slot 420.

The winding 28 includes a segment conductor 28G which is a conductor portion, and an insulating coating 28H provided on the surface of the winding 28 and covering the outer periphery of the segment conductor 28G. In the winding 28, the thickness of one insulating coating 28H in the radial direction and the thickness of the other insulating coating 28H are different from each other inside the slot 420. Further, in the winding 28 adjacent to the coil of the different phase in the radial direction inside the slot 420, the insulating coating 28H of the portion adjacent to the coil of the different phase is formed from the insulating coating 28H of the portion opposite to the portion adjacent to the coil of the different phase. Is also thick.

In the configuration shown in FIG. 13, inside the slot 420, the winding 28 (28a) constituting the U-phase coil 60U is provided with an insulating coating 28H (28HT) on the inner side in the radial direction and is insulated on the outer side in the radial direction. It is thicker than the coating film 28H (28Ht). Further, inside the slot 420, the winding 28 (28b) constituting the W-phase coil 60W has an insulating coating 28H (28HT) on the outer side in the radial direction and a insulating coating 28H (28Ht) on the inner side in the radial direction. Is also thick. Further, inside the slot 420, the winding 28 (28a) constituting the U-phase coil 60U is radially adjacent to the W-phase coil 60W, and the insulating coating 28H (28HT) of the portion adjacent to the W-phase coil 60W is formed. , It is thicker than the insulating coating 28H (28Ht) at the portion opposite to the portion adjacent to the W-phase coil 60W of the winding 28a. Further, inside the slot 420, the winding 28 (28b) constituting the W-phase coil 60W is radially adjacent to the U-phase coil 60U, and the insulating coating 28H (28HT) of the portion adjacent to the U-phase coil 60U is formed. , It is thicker than the insulating coating 28H (28Ht) on the opposite portion of the winding 28b adjacent to the U-phase coil 60U.

Inside the slot 420 of the stator core 132, the windings 28 (28a, 28b) adjacent to the winding 28 of the out-of-phase coil are such that the portions 28HT having a thick insulating coating 28H are adjacent to each other to insulate between the out-of-phase coils. Sex improves. Therefore, it is not necessary to arrange an insulating member (for example, insulating paper) between the coils having different phases.

As in the first embodiment, the winding 28 has a partial insulating coating in a cross section perpendicular to the length direction, not only inside the slot 420 but also in all the length directions, to insulate the opposite portion of this portion. It is preferably thicker than the coating.

Further, as in the first embodiment, since the winding 28 includes the thick portion 28HT of the insulating coating 28H even at the crown 28C, if the thick portion 28HT of the insulating coating 28H is located in the portion extending during twist molding, the winding is wound during twist molding. Even if the 28 is twisted, it is possible to prevent the insulating coating 28H from cracking at the crown 28C. As a result, the insulation between the stator coils 60 can be improved at the anti-weld side coil end 61.

As the slot liner 310 installed between the slot 420 and the stator coil 60, a slot liner 310 formed into a square cylinder shape can be used as in the first embodiment.

The stator 20 and the rotary electric machine 10 according to the third embodiment of the present invention will be described. Hereinafter, this embodiment will be described only with a configuration different from that of the first embodiment. In this embodiment, the winding 28 is wound around the stator core 132 by a centralized winding method.

FIG. 14 is a perspective view of the stator 33 of the centralized winding. The stator 33 for centralized winding includes a divided stator core 132, a stator coil 60, and a bobbin 78 provided on the stator core 132. The bobbin 78 is a member for insulating the stator core 132 and the stator coil 60, and is made of, for example, resin. A flat wire, a round wire, or the like can be used for the winding 28 constituting the stator coil 60.

FIG. 15 is a cross-sectional view of the stator 33 of the centralized winding. FIG. 15 shows two stator cores 132a and 132b adjacent to each other, a U-phase coil 60U wound around the stator core 132a, and a W-phase coil 60W wound around the stator core 132b. There is. The windings 28 constituting the stator coil 60 (60U, 60W) are accommodated in the slot 420 side by side in the radial direction and the circumferential direction. A bobbin 78 is arranged between the stator core 132 and the stator coil 60. It is assumed that the winding 28 is a flat wire.

The winding 28 includes a segment conductor 28G which is a conductor portion, and an insulating coating 28H provided on the surface of the winding 28 and covering the outer periphery of the segment conductor 28G. In the winding 28, the thickness of one insulating coating 28H in the circumferential direction and the thickness of the other insulating coating 28H are different inside the slot 420. Further, in the winding 28 adjacent to the different-phase coil in the circumferential direction inside the slot 420, the insulating coating 28H at the portion adjacent to the different-phase coil is different from the insulating coating 28H at the portion adjacent to the different-phase coil. Is also thick.

In the configuration shown in FIG. 15, inside the slot 420, the winding 28 (28a) constituting the U-phase coil 60U has an insulating coating 28H (28HT) at a portion adjacent to the W-phase coil 60W in the circumferential direction. It is thicker than the insulating coating 28H (28Ht) on the opposite side of this portion and the center of the winding. Further, inside the slot 420, the winding 28 (28b) constituting the W-phase coil 60W has an insulating coating 28H (28HT) at a portion adjacent to the U-phase coil 60U in the circumferential direction. It is thicker than the insulating coating 28H (28Ht) on the opposite side of the center. That is, inside the slot 420, the winding 28 (28a, 28b) facing the out-of-phase coil has a thick portion 28HT of the insulating coating 28H in the portion facing the out-of-phase coil.

Inside the slot 420 of the stator core 132, the windings 28 (28a, 28b) adjacent to the winding 28 of the out-of-phase coil are such that the portions 28HT having a thick insulating coating 28H are adjacent to each other to insulate between the out-of-phase coils. Sex improves. Therefore, it is not necessary to arrange an insulating member (for example, insulating paper) between the coils having different phases.

FIG. 16 is a cross-sectional view of the stator 33 of the centralized winding, as in FIG. The stator 33 shown in FIG. 16 has the same configuration as the stator 33 shown in FIG. 15, but differs from the stator 33 shown in FIG. 15 in that the winding 28 is a round wire.

In the stator 33 shown in FIG. 16, similar to the stator 33 shown in FIG. 15, the winding 28 has the thickness of one insulating coating 28H in the circumferential direction and the thickness of the other insulating coating 28H inside the slot 420. The thickness is different. Further, in the winding 28 adjacent to the different-phase coil in the circumferential direction inside the slot 420, the insulating coating 28H at the portion adjacent to the different-phase coil is different from the insulating coating 28H at the portion adjacent to the different-phase coil. Is also thick. That is, inside the slot 420, the winding 28 (28a, 28b) facing the out-of-phase coil has a thick portion 28HT of the insulating coating 28H in the portion facing the out-of-phase coil. Therefore, even in the stator 33 shown in FIG. 16, the insulating property between the coils having different phases is improved.

As described above, in the stator according to the embodiment of the present invention, the winding 28 has a part of the insulating coating 28H in the cross section perpendicular to the length direction inside the slot 420. It is thicker than the insulating coating 28H on the opposite side (the portion on the opposite side of the center of the winding 28). Further, in the winding 28 adjacent to the out-of-phase coil inside the slot 420, the insulating coating 28H in the portion adjacent to the out-of-phase coil sandwiches the opposite portion (the center of the winding 28) in the portion adjacent to the out-of-phase coil. It is thicker than the insulating coating 28H on the opposite side). In the winding 28, a part of the insulating film 28H in the cross section perpendicular to the length direction is thicker than the insulating film 28H of the opposite part of the winding 28 in all the length directions of the winding 28. More preferred.

In the stator according to the embodiment of the present invention, the insulation property of the coil between different phases can be improved inside the slot 420, and cracks occur in the insulating coating 28H at the coil ends 61 and 62 due to twisting or bending of the winding 28. Can be prevented. Since the insulation of the coils between different phases is improved, it is not necessary to arrange an insulating member (for example, insulating paper) between the coils of different phases.

The present invention is not limited to the above embodiment, and various modifications are possible. For example, the above-described embodiment has been described in detail in order to explain the present invention in an easy-to-understand manner, and the present invention is not necessarily limited to the embodiment including all the described configurations. Further, it is possible to replace a part of the configuration of one embodiment with the configuration of another embodiment. It is also possible to add the configuration of another embodiment to the configuration of one embodiment. Further, it is possible to delete a part of the configuration of each embodiment and add / replace another configuration.

10 ... rotator, 11 ... rotator, 12 ... rotator core, 13 ... shaft, 18 ... permanent magnet, 20 ... stator, 28, 28a, 28b ... winding, 28B, 28B1, 28B2 ... legs, 28C ... Top of head, 28E ... end, 28G ... segment conductor, 28H ... insulating coating, 28HT ... thick insulating coating, 28Ht ... insulating coating on the opposite side of thick insulating coating, 33 ... centralized winding stator, 40N1, 40N2 ... Neutral point connection conductor, 41U1, 41U2, 41V1, 41V2, 41W1, 41W2 ... Mouth wire, 42U, 42V, 42W ... AC terminal, 50 ... Housing, 60 ... Steader coil, 60U ... U-phase coil, 60V ... V phase coil, 60W ... W phase coil, 60U1 ... U1 phase coil, 60U2 ... U2 phase coil, 60V1 ... V1 phase coil, 60V2 ... V2 phase coil, 60W1 ... W1 phase coil, 60W2 ... W2 phase coil, 61 ... coil End (anti-welding side coil end), 62 ... coil end (welding side coil end), 78 ... bobbin, 130 ... liquid-cooled jacket, 132, 132a, 132b ... stator core, 144, 145 ... bearing, 150 ... refrigerant storage Space, 153, 154, 155 ... Refrigerator passage, 156 ... Magnetic void, 160 ... Auxiliary magnetic pole, 200 ... Welded part, 310 ... Slot liner, 420 ... Slot, 430 ... Teeth, 440 ... Core back, 810 ... Magnet insertion hole , ENG ... engine, TR ... transmission, FW ... front wheel side drive wheel, RW ... rear wheel side drive wheel, INV ... power converter, BAT ... battery, RF ... refrigerant, N1, N2 ... neutral point.

Claims (7)

Cylindrical stator core with multiple slots and
A stator coil composed of windings and housed in the slot,
Equipped with
The winding has an insulating coating on its surface, and in all of the length directions, a part of the insulating coating in a cross section perpendicular to the length direction is a portion of the opposite portion of the winding with the center of the winding sandwiched. Thicker than the insulating coating
Inside the slot, the winding adjacent to the stator coil of different phase has the insulating coating of the portion adjacent to the stator coil of different phase, and the opposite of the portion of the portion adjacent to the stator coil of different phase. Thicker than the insulating coating on the part,
Stator characterized by that. The windings are housed inside the slot side by side in the radial direction of the stator core.
Inside the slot, the winding adjacent to the stator coil of different phase in the radial direction has the insulating coating of the portion adjacent to the stator coil of different phase adjacent to the stator coil of different phase. Thicker than the insulating coating on the opposite portion of the portion in the radial direction.
The stator according to claim 1. The windings are housed inside the slot side by side in the circumferential direction of the stator core.
Inside the slot, the winding adjacent to the stator coil of different phase in the circumferential direction has the insulating coating of the portion adjacent to the stator coil of different phase adjacent to the stator coil of different phase. Thicker than the insulating coating on the opposite portion of the portion in the circumferential direction.
The stator according to claim 1. The winding is a flat wire, and the insulating coating on two surfaces adjacent to each other among the four surfaces constituting the winding is from the insulating coating on two surfaces facing each other. Also thick,
The stator according to claim 1. The winding is a flat wire,
The stator according to any one of claims 1 to 3 . The winding is a round wire,
The stator according to any one of claims 1 to 3 . The stator according to any one of claims 1 to 6 and the stator.
A rotor arranged on the inner peripheral side of the stator and rotatably supported,
To prepare
A rotating electric machine characterized by that.

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