WO2019146499A1 - Stator of dynamo-electric machine and method for manufacturing stator of dynamo-electric machine - Google Patents

Abstract

The stator of a dynamo-electric machine according to the present invention comprises an annular stator core 20 in which a plurality of slots 223 are arranged in a circumferential direction, and stator coils 25 inserted into each of the plurality of slots 223. The stator core 20 has three or more split cores 22. The split cores 22 include a first split core group 21a and a second split core group 21b. The circumferential positions of the slots 223 of the second split core group 21b are displaced by a given amount in a circumferential first direction relative to the circumferential positions of the slots 223 of the first split core group 21a. The stator coils 25 inserted into each of the slots 223 are in contact with all of the inner walls 223a in the circumferential first direction of the first split core group 21a, and with all of the inner walls 223b in a circumferential second direction of the second split core group 21b.

Description

Stator of rotating electrical machine and method of manufacturing stator of rotating electrical machine

The present invention relates to a stator of a rotating electrical machine and a method of manufacturing the stator of the rotating electrical machine.

In the distributed winding method, which is one of the winding methods of the stator coil of the rotating electrical machine, the plurality of coil end portions do not interfere with each other. For this reason, the coil end portion has to be long in the axial direction of the rotating electrical machine. Therefore, in the coil end portion, a method in which the stator coil is configured by a plurality of divided coils is used as a method for achieving both the prevention of interference and the shortening of the axial length.

In a stator employing a split coil, a gap is required between the inner wall of the slot and the split coil in order to assemble the split coil by inserting the split coil into the slot of the stator core. However, in a stator adopting a split coil, there is such a gap, and there is a problem that the thermal conductivity between the split coil and the stator core becomes low.

As a prior art example which employ | adopted the split coil, there exists a rotary electric machine described in patent document 1. FIG. In the rotating electrical machine described in Patent Document 1, the stator coil is configured of a plurality of U-shaped divided coils. The split coil inserted into the slot is pressed against the inner wall of the slot by the elastic force of the split coil to increase the thermal conductivity.

Japanese Patent Application Publication No. 2007-110899

However, in the rotating electrical machine described in Patent Document 1, the split coil is inserted while being pressed against the inner wall of the slot. For this reason, in order to insert a division | segmentation coil, the rotary electric machine described in patent document 1 needs comparatively big insertion load. However, when inserting a split coil with such a large insertion load, it was not easy to insert so that bending of a split coil and damage to an insulation coating did not occur. That is, the rotary electric machine described in Patent Document 1 has a problem that the assembly can not be easily performed.

The present invention has been made to solve the above-mentioned problems, and is a stator of a rotating electrical machine which can be easily assembled and can ensure good thermal conductivity between a stator coil and a stator core, and An object of the present invention is to provide a method of manufacturing a stator of a rotating electrical machine.

The stator of the rotating electrical machine according to the present invention is accommodated in an annular stator core, in which a plurality of slots extending in the central axis direction are arranged in the circumferential direction, and in the plurality of slots, from the circumferential dimensions of the plurality of slots , A stator coil having a small circumferential dimension, the stator core having three or more core segments coaxially arranged in contact with each other, and three or more core segments having a circumferential direction of the slot A first divided core group constituted by two or more divided iron cores whose positions coincide with each other, and a second divided iron core group constituted by one or more divided iron cores whose circumferential positions of the slots coincide with each other; , And at least one of the divided cores constituting the second divided core group is disposed between the divided cores constituting the first divided core group, and divided into the second divided core group. Around the slot of iron core The position is displaced by a fixed amount in a first direction in the circumferential direction with respect to the circumferential direction position of the slots of the split iron cores constituting the first split core group, and the stator coil is provided in each of the plurality of slots It is in contact with the inner wall in the first direction of the circumferential direction of the slots of the split core forming the first split core group and the inner wall in the second direction of the circumferential direction of the slots of the split core forming the second split core group. .

In the stator coil of the rotary electric machine according to the present invention, at least one core segment of the core segments constituting the second core segment group is arranged between core segments constituting the first core segment group. In addition, the circumferential position of the slots of the split iron cores constituting the second split core group is constant in a first direction in the circumferential direction with respect to the circumferential position of the slots of the split iron cores constituting the first split core group It is displaced. With the above configuration, in each of the plurality of slots, the stator coil is divided into an inner wall in a first direction in the circumferential direction of the slots of the divided iron cores constituting the first divided iron core group and a second divided iron core group It is in contact with the inner wall in the second direction in the circumferential direction of the slot of the iron core. Therefore, the stator coil of the rotary electric machine according to the present invention can be easily assembled, and can ensure good thermal conductivity between the stator coil and the stator core.

BRIEF DESCRIPTION OF THE DRAWINGS It is sectional drawing which shows the rotary electric machine by Embodiment 1 of this invention. It is a top view which shows the axial direction end surface of a stator core. It is a principal part top view which shows a part of axial direction end surface of a stator core. It is a perspective view which shows a part of stator core. It is an enlarged view of the connection part of a stator core. It is a side view of a U-shaped coil. It is a principal part top view of a stator core in the state where an insulating material was inserted. It is a top view of a stator in the state where a coil and insulating material are inserted in a slot. It is sectional drawing of the split iron core which is a 1st position. It is sectional drawing which shows the state before inserting a connection member in a to-be-connected part. It is sectional drawing which shows the state after inserting a connection member in a to-be-connected part. It is a top view of the stator core in the second position. It is sectional drawing of the stator core in a 2nd position. It is a perspective view which shows the stator core in a 2nd position. It is a top view which shows the stator core in a 2nd position. It is sectional drawing of the stator core in a 2nd position. It is sectional drawing in case two division iron cores are arranged in the direction of an axis. It is a principal part top view which shows the stator core by Embodiment 5 of this invention.

Embodiment 1
FIG. 1 is a cross-sectional view of a rotating electrical machine according to a first embodiment of the present invention.

The rotating electric machine comprises a frame 1, a stator 2 and a rotor 3. In the present specification, the axial direction of the central axis of the stator 2 is referred to as “axial direction”. Moreover, the circumferential direction and radial direction regarding the central axis of the stator 2 are described as "circumferential direction" and "radial direction", respectively.

The frame 1 has a frame main body 11 having a cylindrical portion and a bottom portion closing the opening of one of the cylindrical portions, and an end plate 12 closing the opening of the frame main body 11. At the bottom of the frame body 11 and the end plate 12, bearings 13 for rotatably holding the rotor 3 are provided. The frame body 11 is hollow inside and is formed of metal. Specifically, the material is iron or aluminum. The frame body 11 accommodates the stator 2 and the rotor 3 therein. The frame 1 plays a role as a transfer path of heat generated in the stator 2 in addition to the role of holding the components housed inside.

The rotor 3 has a rotation shaft 31 located at the center of the rotor 3, a rotor core 32 fitted and fixed to the outer diameter portion of the rotation shaft 31, and a rotation fixed to the outer peripheral surface of the rotor core 32 A child magnet 33 is provided. The rotating shaft 31 is a rod-like member having a circular cross section in which a plurality of diameter portions are formed. The rotor 3 is rotatably supported by two bearings 13. The rotating shaft 31 is formed in a stepped shape in which the diameter of the portion in which the rotor core 32 is fitted and the portion in which the bearing 13 is fitted is different. The portion fitted to the bearing 13 is smaller in diameter than the portion fitted to the rotor core 32. The rotating shaft 31 is formed of metal.

The rotor core 32 is cylindrical, and a hollow portion in which the rotation shaft 31 is fitted is provided at the center. A plurality of rotor magnets 33 are arranged at equal angular pitches in the circumferential direction on the outer peripheral surface of the cylindrical rotor core 32. The rotor magnet 33 is a permanent magnet.

The rotor 3 in which the rotor magnet 33, the rotor core 32, and the rotating shaft 31 are integrally formed is rotated by the action of magnetic force when a current flows through the stator coil 25. Further, the rotor 3 may be a form, cage or claw pole type rotor in which permanent magnets are embedded in the rotor core 32.

The stator 2 has an annular stator core 20 and a stator coil 25. The stator 2 is inserted into and fixed to the inside of the cylindrical portion of the frame main body 11 by press fitting, shrink fitting, or the like. FIG. 2 is a top view showing an axial end face of the stator core, and FIG. 4 is a perspective view showing a part of the stator core 20 before the stator coil is inserted. The stator core 20 is composed of three divided cores 22. The divided core 22 includes a first divided core 22 a and a second divided core 22 b which are different in the shape of the ridge portion 222 at the tip of the tooth 221. Specifically, as shown in FIG. 4, the stator core 20 includes two first split iron cores 22 a and one second split iron core 22 b in the axial direction of the first split iron cores 22 a and the second split iron cores. 22b, the first split iron cores 22a are arranged in contact with each other and coaxially arranged in this order. The first split iron core 22a and the second split iron core 22b are distinguished by subscripts a and b. When collectively referring to components, only reference numerals are used.

The first divided core 22a is a laminated core configured by laminating only a plurality of first core pieces 23a. The second split iron core 22b is a laminated iron core configured by laminating only a plurality of second iron core pieces 23b. The first split iron core 22a and the second split iron core 22b respectively have an annular back yoke 220, and a plurality of annular back yokes 220 each extending from the back yoke 220 toward the center of the back yoke 220 and arranged at an equal pitch in the circumferential direction. And a tooth 221.

The back yoke 220 is in contact with the inner wall of the cylindrical portion of the frame body 11 over the entire outer peripheral surface. Each tooth 221 is formed such that the width in the circumferential direction is narrowed toward the inner circumferential side, and a ridge portion 222 protruding to both sides in the circumferential direction is formed at the tip end portion. The ridges 222 of the adjacent teeth 221 have a gap and are not in contact with each other.

Slots 223 extending in a direction parallel to the central axis of stator core 20 are formed by teeth 221 adjacent to each other in the circumferential direction. The stator coil 25 is inserted into the slot 223. Here, the first divided iron core group 21a is configured by the two first divided iron cores 22a. Moreover, the 2nd divided core group 21b is comprised by one 2nd divided core 22b. In the stator core 20 before the stator coil 25 is inserted into the slot 223, as shown in FIG. 4, the circumferential positions of the slots 223 of the first divided core 22a and the second divided core 22b coincide. . The circumferential position of the flange portion 222 of the second core segment 22b is displaced in the second direction with respect to the circumferential position of the flange portion 222 of the first core segment 22a. The left side in FIG. 4 is the first circumferential direction, and the right side is the second circumferential direction.

As described later, after the stator coil 25 is inserted into the slot 223, the second divided core 22b is rotated with respect to the first divided core 22a. As shown in FIG. 2, a holding mechanism 28 is provided to the first split iron core 22 a and the second split iron core 22 b. Thereby, the second divided core 22b can be easily rotated to the second position with respect to the first divided core 22a. Furthermore, the first split iron core 22a and the second split iron core 22b can be fixed in the second position.

The holding mechanism 28 includes a connecting portion 224 provided on the back yoke 220 and a connected portion 225 formed on the connecting portion 224. The holding mechanism 28 further includes a connecting member 226, which is not shown. The connecting member 226 is inserted into the connected portion 225 as described later. The connecting portion 224 is a portion formed by extending the back yoke 220 outward in the radial direction on the outer peripheral portion of the back yoke 220. FIG. 2 shows split iron cores 22 in which connected portions 225 are provided at three locations in the circumferential direction. The coupled portion 225 is a coupling hole into which the coupling member 226 is inserted.

The first split iron core 22 a and the second split iron core 22 b are slightly different in the shape of the collar portion 222, and are also different in the shapes of the connecting portion 224 and the connected portion 225. That is, the first core piece 23a and the second core piece 23b are different in the shape of the buttocks equivalent portion, the connection portion equivalent portion, and the connected portion equivalent portion. The first core piece 23a and the second core piece 23b are configured in the same manner except that the shapes of the buttocks equivalent portion, the connection portion equivalent portion, and the connected portion equivalent portion are different.

FIG. 3 is a top view of an essential part showing a part of the axial end face of the stator core 20 before the stator coil 25 is inserted. In the figure, the first split iron core 22a is shown by a solid line. In addition, the second split iron core 22b is shown by a broken line. When the first split iron core 22a and the second split iron core 22b are overlapped with each other with the circumferential positions of the slots 223 aligned, the shape of the ridge portion 222 of the teeth 221 is the first split iron core 22a and the second split iron core 22b It is different. In FIG. 3, the flange portion 222 of the first divided core 22 a is located on the left side with respect to the circumferential center of the teeth 221 as viewed from the axial direction, that is, in a first direction. On the other hand, the ridge portion 222 of the second split iron core 22b is located on the right side with respect to the circumferential center of the teeth 221 as viewed in the axial direction, that is, in the second direction. As shown in FIG. 3, in the first split iron core 22 a, the amount of protrusion in the first direction of the circumferential direction of the ridge portion 222 is larger than the amount of protrusion in the second direction of the circumferential direction of the ridge portion 222 . On the other hand, in the second split iron core 22b, the amount of protrusion in the second direction in the circumferential direction of the ridge portion 222 is larger than the amount of protrusion in the first direction in the circumferential direction of the ridge portion 222.

The first core piece 23a and the second core piece 23b are respectively punched out of a magnetic steel sheet which is a magnetic thin plate. Although not shown in the drawings, the first core piece 23a and the second core piece 23b are provided with a plurality of uneven fitting portions in which the core pieces are fitted to each other. In the portions corresponding to the back yokes of the first core piece 23a and the second core piece 23b, a convex portion is provided on the surface facing in the first axial direction, and a concave portion is provided on the surface facing the second axial direction It is done. The convex portion and the concave portion are provided at the same circumferential position and the same radial position. When the first core pieces 23a are stacked, the concavo-convex portions are configured to be fitted to each other, and the first core pieces 23a are fitted and fixed to each other. Similarly, when the second core pieces 23b are stacked, the concavo-convex portions are configured to fit with each other, and the second core pieces 23b are fitted and fixed to each other.

The recess and the protrusion provided on the first core piece 23a and the second core piece 23b are simultaneously provided when punching out the first core piece 23a and the second core piece 23b from the magnetic steel sheet. A plurality of recesses and projections are provided in each of the first core piece 23a and the second core piece 23b, and the first core pieces 23a and the second core pieces 23b are firmly fixed to each other. The fixation between the first core pieces 23a and between the second core pieces 23b may be welding or bonding.

The first core piece 23a constituting the first split core 22a has a concave portion and a convex portion except for the first core piece 23a disposed at the end in the first direction of the axial direction of the first split core 22a. It is provided. Although the first core piece 23a arranged at the end of the first divided core 22a in the first direction of the axial direction has a recess in the surface in contact with the first core piece 23a stacked adjacently, The convex part is not provided in the field which is an end face of the 1st division core 22a. Similarly, the second core piece 23b constituting the second split core 22b has a recess and a convex except for the second core piece 23b disposed at the end in the second direction of the axial direction of the second split core 22b. A department and is provided. The second core piece 23b arranged at the end in the second direction of the axial direction of the second split core 22b is provided with a recess on the surface in contact with the second core piece 23b stacked adjacently The convex part is not provided in the field which is an end face of the 2nd division iron core 22b. Thereby, the opposing end faces of the adjacent split iron cores 22 can be in surface contact without interference by the convex portions. Therefore, division | segmentation iron cores 22 comrades can be arrange | positioned adjacently, without a clearance gap.

FIG. 5 is an enlarged view of a connecting portion of the stator core 20. As shown in FIG. In FIG. 5, for convenience of explanation, the connecting portion of the first split iron core 22a is set to 224a, and the connected portion is set to 225a. Similarly, the connecting portion of the second split iron core 22b is set to 224b, and the connected portion is set to 225b. When the first split iron core 22a and the second split iron core 22b are stacked so that the circumferential direction positions of the slots 223 coincide with each other, the connecting portion 224a and the connected portion 225a provided on the first split iron core 22a The connection part 224b and the to-be-connected part 225b which were provided in the split iron core 22b are displaced to the 2nd direction of the circumferential direction. That is, when the first split iron core 22a and the second split iron core 22b are stacked so that the slots 223 coincide with each other, the connecting portion 224a and the connecting portion 225a of the first split iron core 22a are displaced in the left direction in FIG. And is shown by a solid line. The connecting portion 224 b and the connected portion 225 b of the second core segment 22 b are displaced to the right in FIG. 5 and are indicated by broken lines.

The stator coil 25 is composed of a plurality of U-shaped coils 26. The stator coil 25 generates a magnetic field that causes the rotor 3 to rotate when current flows. FIG. 6 is a side view of the U-shaped coil 26. As shown in FIG. The coil 26 has two straight portions 261 and a connecting portion 262 connecting the two straight portions 261. The coil 26 is formed of, for example, a linear conductor such as a copper wire, an aluminum wire or the like, which is covered with enamel and coated. The connection portion 262 is located on the axially outer side of the stator core 20 to form a coil end portion.

The coil 26 is inserted into each slot 223 of the stator core 20. The two straight portions 261 of the U-shaped coil 26 are inserted into a pair of slots 223 arranged across one or more slots 223. Here, four straight portions 261 are inserted in each slot 223. The circumferential dimension of the slot 223 is larger than the circumferential dimension of the linear portion 261 of the coil 26. Therefore, a gap is secured between the coil 26 and the inner wall in the circumferential direction of the slot 223. Therefore, it is possible to easily insert the coil 26 into the slot 223. After the coil 26 is inserted into each slot 223, the coil 26 to be connected is connected with the end of the coil 26 to form a coil for each phase.

The stator 2 has an insulating material 27 in addition to the stator core 20 and the stator coil 25. FIG. 7 is a top view of relevant parts of the stator core 20 with the insulating material 27 inserted therein. The insulating material 27 is fitted in each slot 223. The material of the insulating material 27 includes polyimide (PI), polyethylene terephthalate (PET), polyphenylene sulfide (PPS), and the like. The insulating material 27 is preferably formed of a material having excellent electrical insulation and thermal conductivity. The insulating material 27 electrically insulates between the stator core 20 and the stator coil 25.

The overlapping portion 27 a when the insulating material 27 is inserted into the slot 223 is disposed on the bottom side of the slot 223. The overlapping portion 27 a may be disposed on the opening side of the slot 223.

In the present specification, the circumferential dimension of the straight portion 261 includes the thickness of the insulating material 27. For example, when the circumferential dimension of the slot 223 is larger than the circumferential dimension of the linear portion 261, the circumferential dimension of the slot 223 is the circumferential dimension of the linear portion 261 plus twice the thickness of the insulating material 27 Means greater.

Below, the assembly method of the stator 2 is demonstrated. A plurality of first iron core pieces 23a and second iron core pieces 23b are respectively stacked to produce a first divided iron core 22a and a second divided iron core 22b. Next, the first split iron cores 22a and the second split iron cores 22b are arranged alternately in contact with each other with the central axes of the first split iron cores 22a and the second split iron cores 22b aligned. The two first split iron cores 22a constitute a first split iron core group 21a. Also, one second divided core 22 b constitutes a second divided core group 21 b.

Next, the first split iron core 22a and the second split iron core 22b are disposed so as to be at the first position. The first position is a circumferential position of each of the first divided core 22 a and the second divided core 22 b when the stator coil 25 is inserted into each slot 223. Specifically, the first position is the position of the first split iron core 22a and the second split iron core 22b at which the circumferential positions of the slots 223 in all the split iron cores 22 coincide.

FIG. 8 is a top view of the stator 2 in a state in which the coil 26 and the insulating material 27 are inserted into the slot 223. In the figure, the coil 26 is shown in cross section.

At the first position, the ridges 222 of the teeth 221 of the first split iron core 22a are different from the ridges of the teeth 221 of the second split iron core 22b because the shapes of the first iron core pieces 23a and the second iron core pieces 23b are slightly different. The part 222 is displaced in the circumferential direction. The insulating material 27 is inserted into each slot 223 with the split core 22 in the first position. Subsequently, the linear portion 261 of the coil 26 is inserted into the slot 223 to a prescribed position. FIG. 9 is a cross-sectional view of the stator 2 located at the first position. Since the circumferential positions of the slots 223 coincide with each other, and the circumferential dimension of the slots is larger than the circumferential dimension of the linear portions 261, the linear portions 261 of the coil 26 should interfere with the slots 223. Can be inserted easily.

After all the coils 26 are inserted into the slots 223, the ends of the coils 26 to be connected are connected. In this way, all coils 26 of one phase are connected. In the case of a three-phase coil, coils 26 for the remaining two phases are respectively connected.

Next, in the core segment displacing step, core segments 22 are rotated. The first divided core group 21a constituting the divided core 22 is fixed, and the second divided core group 21b is rotated about the central axis of the divided core 22 by a fixed amount, so that the rotational angular position of the divided core 22 is Two positions. The second position is a position where the split core 22 is in the assembled state. Specifically, from the first position where the circumferential positions of all the slots 223 of the first divided core group 21a and the second divided core group 21b coincide with each other, only the second divided core group 21b is used. Is a position displaced by a fixed amount in the first direction in the circumferential direction. In the second position, the inner wall in the first direction in the circumferential direction of all the slots 223 of the first divided core group 21a is in contact with the side surface facing the first direction in the circumferential direction of the linear portion 261 of the coil 26 . Further, the inner wall in the second direction in the circumferential direction of all the slots 223 of the second core segment group 21b is in contact with the side surface facing the second direction in the circumferential direction of the linear portion 261 of the coil 26.

In a state in which the first divided core group 21a is fixed while the first divided core group 21a and the second divided core group 21b are alternately arranged adjacent to each other with their central axes aligned, the second divided core group 21a is fixed. The core groups 21b are rotated by a fixed amount in the circumferential direction. At the time of the rotation operation, the ridge portions 222 displaced by a fixed amount in the circumferential direction are displaced due to the difference in the shapes of the ridge portions 222 of the first core piece 23a and the second core piece 23b. It is rotated in the circumferential direction so as to reduce the amount, that is, the amount of deviation. The shape of the collar portion 22 is designed so as to be magnetically ideal in a state where the amount of displacement of the collar portion 222 is reduced by rotation. In addition, the shift | offset | difference between the ridge parts 222 is lose | eliminated, and the state which the circumferential direction position of all the ridge parts 222 corresponded is a magnetic most ideal state. When the circumferential positions of all the ridges 222 coincide with each other, the circumferential positions of the circumferential ends of the ridges 222 of the first divided core group 21a and the circumferential ends of the second divided core group 21b ridges 222 It is in the state where the circumferential direction positions of are aligned.

The coils 26 inserted in the slots 223 are alternately pressed from both sides in the circumferential direction by the inner walls of the slots 223 of the first divided core 22 a and the second divided core 22 b by the rotation of the divided cores 22.

In order to turn the second split iron core 22b to the second position with respect to the first split iron core 22a, the connecting member 226 is inserted into each of the connected portions 225. The connecting member 226 is inserted into all the connected portions 225 of the three core segments 22 arranged axially continuously. When the connecting member 226 is inserted, the second divided core 22b rotates to the second position with respect to the first divided core 22a. 10 and 11 are cross-sectional views showing the state before and after inserting the connecting member 226 into the connected portion 225, respectively. The connecting member 226 is a pin having a circular cross section having an outer diameter that fits with the inner diameter of the connected portion 225 without play. The connecting member 226 has a length equal to or greater than the axial length of the stator core 20 composed of three divided iron cores 22 arranged continuously in the axial direction. The connecting member 226 is tapered so that the connecting member 226 can be easily inserted into the connected portion 225.

FIG. 12 is a top view of the stator core 20 in the second position. In FIG. 12, the first split iron core 22a is shown by a solid line. In addition, the second split iron core 22b is shown by a broken line. When the second divided core 22b is at the second position with respect to the first divided core 22a, the positions of all the connected parts 225 are aligned. On the other hand, the circumferential position of the slot 223 of the second core segment 22b is displaced with respect to the slot 223 of the first core segment 22a. Therefore, the inner wall in the first direction of the circumferential direction of the slot 223 of the stator core 20 and the inner wall in the second direction are in an uneven state in the axial direction.

At the same time as the connecting member 226 is inserted into the connected portion 225, each of the first divided core 22a or the second divided core 22b rotates. Before the connecting member 226 is inserted into the connected portion 225, the circumferential positions of all the slots 223 coincide. When the connecting member 226 is inserted into the connected portion 225, the circumferential position of the slot 223 of the second divided core 22b relative to the first divided core 22a is displaced by a fixed amount.

FIG. 13 is a cross-sectional view of the stator core 20 in the second position. The inner wall 223a in the first direction in the circumferential direction of the slots 223 of the stator core 20 and the inner wall 223b in the second direction are in an uneven state in the axial direction. Therefore, the inner wall 223a in the first direction in the circumferential direction of the slot 223 of the first split core 22a contacts the side surface 261a facing the first direction in the circumferential direction of the linear portion 261 of the coil 26 through the insulating material 27. ing. Further, the inner wall 223b in the second direction in the circumferential direction of the slot 223 of the second core segment 22b contacts the side surface 261b facing the second direction in the circumferential direction of the linear portion 261 of the coil 26 via the insulating material 27. ing.

FIG. 14 is a perspective view showing the stator core 20 in the second position. In the second position, circumferential positions of the ridge portions 222 of the teeth of the first split iron core 22a and the teeth of the second split iron core 22b all coincide with each other. FIG. 15 is a top view of the stator core 20 in the second position. FIG. 16 is a cross-sectional view of the stator core 20 at the second position. The dimension between the inner wall 223a in the first direction in the circumferential direction of the slot 223 of the first split core 22a and the inner wall 223b in the second direction in the circumferential direction of the slot 223 of the second split core 22b is shown in the figure. It is indicated by X. The dimension X is narrower than the slot dimension formed in each split core 22.

The number of core segments 22 arranged in the axial direction is preferably three or more. For example, there are three, a first split iron core 22a, a second split iron core 22b, and a first split iron core 22a. Alternatively, the second divided iron core 22b, the first divided iron core 22a, and the second divided iron core 22b may be used. The number of each of the first split iron core 22a and the second split iron core 22b may be selected to be three or more in total, but in any case, one or more of the first split iron cores 22a The divided core groups 21a are configured, and one or more second divided cores 22b configure a second divided core group 21b.

Although the number of divided iron cores 22 arranged in the axial direction has been described as three or more, the reason why two are not preferable will be described below. FIG. 17 is a cross-sectional view of a comparative example in which two split iron cores 22 are arranged in the axial direction. The two arranged case is a case where one first divided core 22a and one second divided core 22b are arranged in the axial direction. In the comparative example shown in FIG. 17, when the stator core 20B is positioned at the second position, the coils 26 inserted in the slots 223 become oblique. As a result, the side surfaces of the coil 26 do not come in surface contact with the inner wall of the slot 223, resulting in point contact, and good thermal conductivity can not be obtained. In addition, when the coil 26 is inclined, the position of the end of the coil 26 is displaced, which causes a problem in connection between the coils 26.

According to the first embodiment, stator core 20 includes two first split iron cores 22a and one second split iron core 22b as first split iron core 22a, second split iron core 22b, and first split iron core 22a. In order, it mutually contacts and is coaxially arranged and comprised. The circumferential positions of the slots 223 of the two first core segments 22a coincide with each other. In the second position, the circumferential position of the slot 223 of the second core segment 22b is displaced by a fixed amount in the first circumferential direction with respect to the circumferential position of the slot 223 of the first core segment 22a. . The linear portions 261 of the coils 26 housed in the respective slots 223 are the first circumferential wall of the slots 223 of the first core segment 22a, and the second circumferential core of the slots 223 of the second core segment 22b. It is in contact with the inner wall 223 b in two directions via the insulating material 27 housed in the slot 223. Thereby, good thermal conductivity between the stator coil 25 and the stator core 20 is ensured. Further, since the coil 26 and the stator core 20 are in contact with each other through the insulating material 27 at a plurality of locations in the slot 223, the natural frequency of the coil 26 and the stator core 20 is increased. This makes it difficult to amplify the magnetic vibration generated at the time of driving, and the magnetic noise of the rotating electrical machine is reduced.

When the first split iron core 22a and the second split iron core 22b are positioned at the second position on the first split iron core 22a and the second split iron core 22b, the positions of the holes coincide with each other when viewed from the axial direction The connection part 225 is formed. Therefore, by inserting the connecting member 226 into the connected portion 225, the first split iron core 22a and the second split iron core 22b coaxially arranged can be positioned and fixed at the second position. At this time, since the tip of the connecting member 226 is formed in a tapered shape, the connecting member 226 is inserted into the connected portion 225 of the first divided core 22a and the second divided core 22b located at the first position. Only by doing this, the first split iron core 22a and the second split iron core 22b can be displaced from the first position to the second position. The first core piece 23a and the second core piece 23b have burrs due to being punched out of the magnetic thin plate. Since the insulating material 27 is accommodated in the slot 223, the occurrence of damage to the insulating coating of the coil 26 due to the burrs of the first core piece 23a and the second core piece 23b is suppressed.

In the method of manufacturing the stator 2 according to the first embodiment, first, the two first split iron cores 22 a and one second split iron core 22 b are brought into contact with each other with the circumferential positions of the slots 223 aligned. The split iron cores 22a, the second split iron cores 22b, and the first split iron cores 22a are coaxially arranged in this order. Next, after the insulating material 27 is accommodated in each of the slots 223, the coil 26 is inserted into each of the slots 223. Next, the second split iron core 22b is displaced in the first circumferential direction with respect to the first split iron core 22a. Thereby, the inner wall 223a in the first direction of the circumferential direction of the slot 223 of the first split core 22a and the inner wall 223b in the second direction of the circumferential direction of the slot 223 of the second split core 22b are interposed via the insulating material 27. The linear portion 261 of the coil 26 is pressed.

Thereby, the coil 26 can be easily accommodated in the slot 223 without causing the bending of the coil 26 and damage to the insulating coating. Therefore, the stator 2 in which good thermal conductivity between the stator coil 25 and the stator core 20 is secured can be easily assembled.

In the first embodiment, although the three connecting members 226 inserted into the three connected portions 225 are separated into one by one, the three connecting members 226 are integrally connected by the annular member. May be Thereby, the three connection members 226 can be simultaneously inserted into the three connected portions 225, and the assembly time of the stator 2 can be shortened.

Moreover, in the said Embodiment 1, although the connection member 226 is comprised with the pin, you may comprise the connection member 226 with a volt | bolt. Thereby, the three split iron cores 22 can be integrally fixed by fastening the nut to the screw portion of the connection member 226 protruding from the connected portion 225.

Second Embodiment
The second embodiment is configured in the same manner as the first embodiment except that a linear coil is used instead of the U-shaped coil 26.

In the first embodiment, since the U-shaped coil 26 is used, the number of linear portions 261 of the coil 26 accommodated in the slot 223 is an even number. That is, in the first embodiment, the odd number of straight portions 261 can not be accommodated. In the second embodiment, since a linear coil is used, the number of coils accommodated in the slot 223 can be arbitrarily set regardless of odd number and even number.

Therefore, according to the second embodiment, the number of turns of the phase coil of the stator coil can be set arbitrarily.

Although only a linear coil is used in the second embodiment, both a U-shaped coil and a linear coil may be used.

Third Embodiment
In the first embodiment, the first core pieces 23a are stacked to produce the first split core 22a, and the second core pieces 23b are stacked to produce the second split core 22b. In the third embodiment, the first divided core 22a and the second divided core 22b are manufactured using only the first core piece 23a. That is, the first core pieces 23a are stacked with the first surface of the first core piece 23a facing up to produce the first divided core 22a. Next, the first core piece 23a is stacked with the second surface opposite to the first surface of the first core piece 23a up, and the second divided core 22b is manufactured. Then, the stator core 20 is manufactured by stacking the first split iron core 22a, the second split iron core 22b, and the first split iron core 22a in this order.

Also in the third embodiment, on the contact surface between the first split iron core 22a and the second split iron core 22b, the convex portion for fitting and fixing the first core pieces 23a to each other is not formed. Further, a U-shaped coil 26 is accommodated in the stator core 20. Thus, in the third embodiment, the first split iron core 22a and the second split iron core 22b are configured using only the first core piece 23a, as in the first embodiment except that the first split core 22a and the second split iron core 22b are configured. It is configured.

Therefore, also in the third embodiment, the same effect as that of the first embodiment can be obtained. According to the third embodiment, since the iron core pieces 23 are only one type of the first iron core pieces 23a, only one type of die can be used to punch out the iron core pieces 23, thereby achieving cost reduction.

In the third embodiment, the first split iron core 22a and the second split iron core 22b are manufactured using only the first core piece 23a, but the first split iron core is only using the second core piece 23b. 22a and the second split iron core 22b may be produced. Further, although only the U-shaped coil 26 is used in the third embodiment, only a linear coil may be used, or both of the U-shaped coil and the linear coil may be used. Good.

Fourth Embodiment
In the fourth embodiment, although not shown, a stator core is configured using a first divided core and a second divided core that are formed of massive iron cores formed from a mass of magnetic material. The first divided core and the second divided core formed of the massive iron core are formed in the same shape as the first divided core 22a and the second divided core 22b formed of the laminated core in the first embodiment. Also in the fourth embodiment, the stator core is configured by overlapping the first divided core and the second divided core in the order of the first divided core, the second divided core, and the first divided core. In addition, a U-shaped coil is accommodated in the stator core.

The fourth embodiment is configured in the same manner as the first embodiment except that the first divided iron core which is a massive iron core and the second divided iron core are stacked to constitute a stator core. Therefore, also in the fourth embodiment, the same effect as that of the first embodiment can be obtained.

Although only the U-shaped coil 26 is used in the fourth embodiment, only a linear coil may be used, or both a U-shaped coil and a linear coil may be used. .

Embodiment 5
FIG. 18 is a top view of relevant parts showing a stator core in a stator of a rotary electric machine according to Embodiment 5 of the present invention. In FIG. 18, the holding mechanism 28A includes a coupled portion 225A provided on the outer peripheral portion of the back yoke 220 of the stator core 20A, and a coupling member 226A fitted to the coupled portion 225A. The to-be-connected portion 225A is formed in a concave shape with a triangular cross-section in which the circumferential width gradually narrows toward the inner diameter side. Three coupled portions 225A are distributed in the circumferential direction. The connecting member 226A has a triangular cross section that can be fitted to the connected portion 225A, and is manufactured in a columnar body having a length equal to or longer than the axial length of the stator core 20A. The fifth embodiment is configured in the same manner as the first embodiment except that the holding mechanism 28A is used instead of the holding mechanism 28.

Also in the fifth embodiment, stator core 20A includes two first split iron cores 22A and one second split iron core 22B in the order of first split iron core 22A, second split iron core 22B, and first split iron core 22A. , Arranged in contact with each other and arranged coaxially. In the connected portion 225A formed on the first divided core 22A and the connected portion 225A formed on the second divided core 22B, the first divided core 22A and the second divided core 22B are located at the first position. When it is displaced by a fixed amount in the circumferential direction. Further, in the connected portion 225A formed on the first divided core 22A and the connected portion 225A formed on the second divided core 22B, the first divided core 22A and the second divided core 22B are in the second position. When positioned, the concave shapes match as viewed from the axial direction.

In the fifth embodiment, after the coil 26 is housed in each of the slots 223 with the two first split iron cores 22A and one second split iron core 22B coaxially arranged being positioned at the first position, the connecting member 226A Is inserted into each of the connected portions 225A from the radially outer side. Thereby, the first split iron core 22A and the second split iron core 22B can be displaced from the first position to the second position. Then, the connecting member 226A fitted to the connected portion 225A is fixed to the stator core 20A by adhesion, welding or the like. Thereby, the first split iron core 22A and the second split iron core 22B are positioned and fixed at the second position.

Therefore, also in the fifth embodiment, the same effect as that of the first embodiment can be obtained.

In the fifth embodiment, the holding mechanism 28A is used in place of the holding mechanism 28 in the stator 2 in the first embodiment. However, in the stator in the second embodiment to the fourth embodiment, holding is performed. Similar effects can be obtained by using the holding mechanism 28A instead of the mechanism 28.

Further, in the fifth embodiment, the connecting member 226A fitted to the connected portion 225A is fixed to the stator core 20A by adhesion, welding or the like. Therefore, when the fixing portion is protruded from both ends of the connecting member 226A and the connecting member 226A is fitted to the to-be-connected portion 225A, the stator core 20A is pinched by the fixing portion from both sides in the axial direction. The connecting member 226A may be held by the stator core 20A. At this time, a convex portion is provided in the fixed portion, a concave portion is provided in the end face of the stator core 20A, and the convex portion of the fixed portion and the concave portion of the stator core 20A are fitted to prevent the connection member 226A from coming off. You may

Although only the U-shaped coil 26 is used in the fifth embodiment, only a linear coil may be used, or both of the U-shaped coil and the linear coil may be used. Good.

Moreover, although the insulating material 27 is each accommodated in the slot 223 in said each embodiment, the insulating material 27 may be abbreviate | omitted. In this case, the stator coil 25 is in direct contact with the inner wall of each of the slots 223 of the stator core 20. The insulation between the stator coil 25 and the stator core 20 is ensured by the insulating film coated on the stator coil 25.

Moreover, in the above-described embodiments, although the ridge portions 222 of the adjacent teeth 221 are separated, the ridge portions 222 of the adjacent teeth 221 may be connected to each other.

Moreover, in each said embodiment, although the stator coil 25 is comprised by U-shaped or linear coil, a stator coil may be comprised by the turtle-shaped coil. In this case, since the turtle-shaped coil is inserted into the slot 223 of the stator core 20A from the inner diameter side, the teeth 221 are manufactured with the collar portion 222 omitted.

In each of the above-described embodiments, the stator core 20 is configured by coaxially arranging the three divided cores 22. However, the number of the divided cores 22 constituting the stator core 20 is limited to three. There may be four or more. For example, if the five split cores are a first split core group consisting of three first split cores and a second split core group consisting of two second split cores, the first split core, the second split core The first split iron core, the second split iron core, and the first split iron core are arranged coaxially in this order to form a stator core. Alternatively, the stator core may be configured by coaxially arranging the first split core, the first split core, the second split core, the first split core, and the second split core in this order. That is, at least one second split iron core in two second split iron cores constituting the second split iron core group, and two first split irons in three first split iron cores constituting the first split iron core group It should just be located between iron cores.

Moreover, in each said embodiment, although the 1st division | segmentation iron core group is comprised from two 1st division | segmentation iron cores, 1st division | segmentation iron core group is comprised by two types of division | segmentation iron cores from which the lamination | stacking number of 1st iron core pieces differs. You may That is, as long as the shape seen from the axial direction is the same, the axial direction thickness may differ between the several 1st divided core which comprises a 1st divided core group. Similarly, the axial direction thickness may differ, as long as the shape seen from the axial direction of the some 2nd divided core which comprises a 2nd divided core group is the same.

Further, in each of the above-described embodiments, the first split iron core 22a is configured by laminating a plurality of first core pieces 23a, but the first split iron core 22a is a single ferrous iron core having a thick plate thickness. You may be comprised by the piece 23a. In addition, although the second split core 22b is configured by laminating a plurality of second core pieces 23b, the second split core 22b is configured by one second core strip 23b having a large thickness. It is also good.

In each of the above embodiments, the holding mechanisms 28 and 28A for positioning and fixing the first split iron core 22a and the second split iron core 22b at the second position are provided. However, the first split iron core 22a and the second split iron core 22 b may be further positioned and fixed at the first position. That is, the said holding mechanism has the to-be-connected part which a hole shape or concave shape corresponds seeing from an axial direction, when the 1st division | segmentation iron core 22a and the 2nd division | segmentation iron core 22b are located in a 1st position. This facilitates assembly of the stator core.

In the present invention, within the scope of the invention, the embodiments can be freely combined, or the embodiments can be appropriately modified or omitted.

2 stator, 20, 20A stator core, 21a first split core group, 21b second split core group, 22 split core, 22a, 22A first split core, 22b, 22B second split core, 223 slots, 223a Inner wall on the side, 223b Inner wall on the other side, 225, 225A Connected part, 226, 226A Connecting member, 23 Core piece, 23a First core piece, 23b Second core piece, 25 Stator coil, 26 coil, 27 Insulating material , 28, 28A Holding mechanism.

Claims (13)

An annular stator core having a plurality of circumferentially arranged slots extending in the central axial direction;
A stator coil accommodated in each of the plurality of slots and having a circumferential dimension smaller than the circumferential dimension of the plurality of slots;
The stator core has three or more core segments coaxially arranged in contact with each other,
The three or more split iron cores have a first split core group including two or more split iron cores whose circumferential positions of the slots coincide with each other, and one or more of which the circumferential positions of the slots coincide with each other And a second divided core group consisting of divided core cores, and
At least one split core of the split cores constituting the second split core group is disposed between the split cores constituting the first split core group,
The circumferential direction position of the slots of the divided core forming the second divided core group is constant in a first direction in the circumferential direction with respect to the circumferential position of the slots of the divided core forming the first divided core group Is displaced,
The stator coil includes, in each of the plurality of slots, an inner wall in a first direction in a circumferential direction of slots of divided iron cores constituting the first divided iron core group and a divided iron core constituting the second divided iron core group A stator of a rotating electrical machine in contact with an inner wall in a second direction in a circumferential direction of the slot. Each of the three or more divided irons has a ridge that protrudes in the first direction and the second direction in the circumferential direction from the tip of the teeth that constitute the slot,
The rotation according to claim 1, wherein the circumferential position of the ridge portion of the split iron core constituting the first split iron core group and the circumferential direction position of the ridge portion of the split iron core constituting the second split iron core group are aligned. Electrical stator. In each of the plurality of slots, an insulating material is accommodated, and in each of the plurality of slots, the stator coil has a first direction in the circumferential direction of the slots of the divided iron cores constituting the first divided core group. The rotation according to claim 1 or 2, wherein the insulating material is in contact with the inner wall of the second divided iron core group and the inner wall in the second direction in the circumferential direction of the slot of the divided core forming the second divided core group. Electrical stator. The electric rotating machine according to any one of claims 1 to 3, wherein the stator coil comprises a U-shaped coil housed between a pair of slots arranged sandwiching one or more slots. Stator. The stator of the rotating electrical machine according to any one of claims 1 to 4, wherein the stator coil comprises a plurality of linear coils accommodated in each of the plurality of slots. The stator for a rotating electrical machine according to any one of claims 1 to 5, wherein each of the three or more divided cores is a laminated core configured by laminating magnetic thin plates. The magnetic thin plate includes two types of magnetic thin plates having different shapes,
The three or more divided iron cores are formed by laminating a divided iron core configured by laminating one magnetic thin plate of the two types of magnetic thin plates, and another magnetic thin plate of the two types of magnetic thin plates The stator of a rotating electrical machine according to claim 6, wherein the stator comprises a divided core configured. The stator of a rotating electrical machine according to claim 6, wherein the magnetic thin plate is a single type of magnetic thin plate. The stator for a rotating electrical machine according to any one of claims 1 to 5, wherein each of the three or more divided iron cores is a massive iron core. The circumferential position of the slot of the second divided core group is displaced by a fixed amount in the first direction of the circumferential direction with respect to the circumferential position of the slot of the first divided core group in the three or more divided cores. The stator of the rotary electric machine according to any one of claims 1 to 9, further comprising: a holding mechanism that positions and holds the state. The stator of a rotary electric machine according to claim 10, wherein the holding mechanism includes connected parts provided on the three or more divided iron cores, and a connecting member fitted to the connected parts. A method of manufacturing a stator of a rotating electrical machine according to any one of claims 1 to 11,
Producing the three or more split cores;
Coaxially arranging the three or more divided cores in such a manner that circumferential positions of the plurality of slots coincide with each other, and are in contact with each other;
Housing the stator coil in each of the plurality of slots;
The divided iron cores constituting the second divided iron core group are displaced by a fixed amount in the first circumferential direction with respect to the divided iron cores constituting the first divided iron core group,
In each of the plurality of slots, an inner wall in a first direction of a circumferential direction of slots of divided iron cores constituting the first divided core group and a circumferential direction of circumferential slots of divided iron cores constituting the second divided iron core group A split core displacement step of bringing the stator coil into contact with an inner wall in two directions, and a method of manufacturing a stator of a rotary electric machine. Each of the three or more divided iron cores has a ridge that protrudes in a first direction and a second direction in the circumferential direction from the tip of the teeth constituting the slot,
In the divided core displacement step,
There is less deviation in the circumferential direction between the circumferential position of the ridge portion of the split core forming the first split core group and the circumferential position of the ridge portion of the split core forming the second split core group. 13. The manufacturing of the stator of the rotary electric machine according to claim 12, wherein the divided cores constituting the second divided core group are circumferentially displaced with respect to the divided cores constituting the first divided core group. Method.

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