JP4123909B2 - Rotating electrical machine cooling structure and manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a rotating electrical machine cooling structure and manufacturing method suitable for a rotating electrical machine (such as a motor, a generator, or a motor / generator) suitable for an electric vehicle, a hybrid vehicle, a fuel cell vehicle, and the like.
[0002]
[Prior art]
In a conventional rotating electrical machine, a resin coating layer is provided so as to close a slot opening formed on the inner peripheral surface of a cylindrical stator, and a liquid-tight cover is attached to both ends of the stator so that a refrigerant flows through the slot. Some cooling structures are used (see, for example, Patent Document 1). With such a structure, since the refrigerant directly contacts the winding, excellent cooling performance can be obtained.
[0003]
[Patent Document 1]
Japanese Patent No. 2716286 [0004]
[Problems to be solved by the invention]
However, in the conventional rotating electrical machine described above, the winding and the stator core are simply separated by interposing insulating paper therebetween, and are connected in a continuous space. Therefore, when the refrigerant flows, there is a possibility that the insulation performance is deteriorated by tracking.
[0005]
Further, since the coating covering the slot opening is formed from the inner peripheral surface side of the stator, the coating may be deformed or dropped to the rotor side by the pressure of the refrigerant.
[0006]
Furthermore, the coating covering the slot opening is formed so as to cover the tip of the teeth, and it is necessary to enlarge the air gap. For this reason, there is a risk of a decrease in electromagnetic performance.
[0007]
The present invention has been made by paying attention to such conventional problems, and has a cooling structure and manufacturing of a rotating electrical machine that has high cooling performance, high insulation, high reliability of reliability, and no risk of performance deterioration. It aims to provide a method.
[0008]
[Means for Solving the Problems]
The present invention solves the above problems by the following means. In addition, in order to make an understanding easy, although the code | symbol corresponding to embodiment of this invention is attached | subjected, it is not limited to this.
[0009]
The present invention includes a split core (11) formed by laminating a stator core material (11a) obtained by cutting a magnetic steel sheet into a predetermined shape to a predetermined thickness, and a tooth portion (11b) of the split core (11). A first resin mold member (12) injection-molded on the periphery and the back core surface of the stator core material (11a), a coil (13) wound around the first resin mold member (12), and the coil A second resin mold member (15) formed by injection molding from the outside of (13) and formed on both sides of the stator core material (11a), and in parallel with the laminated surface of the stator core material (11a), and the second resin. d the mold member (15) is an end portion of the coil is not formed (13) (13a, 13b) disposed on the stator core end surface is absent, is bonded to the first resin molded member (12) And Dokaba (17), parallel to the layer surfaces of said stator core member (11a), and the stator core in which the second end of the coil molded resin member (15) is not formed (13) (13a, 13b) are present A terminal block (16) disposed on an end surface and fixed to the first resin mold member (12), and the coil (13) is connected to the first resin mold member (12) and the second resin mold. It is enclosed by the insulating member which consists of a member (15), a terminal block (16), and an end cover (17), and makes a refrigerant | coolant flow through the clearance gap between a coil and an insulating member, It is characterized by the above-mentioned.
[0010]
[Action / Effect]
According to the present invention, since the coil is included in the insulating member and the refrigerant is allowed to flow through the gap between the coil and the insulating member, electrical insulation is maintained between the coil and the stator core and between the different-phase coils. Be drunk. For this reason, even when the refrigerant is brought into direct contact with the coil, insulation deterioration such as tracking hardly occurs, and high insulation reliability as well as high cooling performance can be obtained.
[0011]
In addition, since the insulating member that forms the refrigerant flow path is individually formed for each divided core, even if the entire stator is deformed by the torque of the rotating electrical machine, it is less susceptible to the influence and has high durability reliability.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in more detail with reference to the drawings.
(First embodiment)
1, 2 and 3 are views showing a first embodiment of a cooling structure for a rotating electrical machine according to the present invention. 1 is a view taken in the direction of arrow I in FIG. FIG. 2 is a view taken in the direction of arrow II in FIG. FIG. 3 is an exploded view of the component parts. In FIGS. 1 and 2, the terminal block 16 and the end cover 17 at the end of the core are omitted in order to make the internal structure easier to see.
[0013]
The split stator 10 according to the present embodiment includes a split core 11, a first resin mold member 12, a coil 13, a spacer 14, and a second resin mold member 15. This divided stator 10 forms an annular stator by arranging a predetermined number on the inner periphery of a motor case (not shown).
[0014]
The split core 11 is produced by laminating a predetermined number of stator core materials 11a formed by cutting electromagnetic steel sheets into a substantially T shape. The laminated stator core material 11a may be integrated by, for example, doweling or welding so as not to collapse.
[0015]
The first resin mold member 12 is an electrically insulating insulating member that prevents conduction between the split core 11 and the coil 13. The first resin mold member 12 is formed around the teeth portion 11 b of the split core 11 and on the back core surface of the laminated stator core material 11 a, and is not formed at the distal end portion 11 c of the split core 11. The first resin mold member 12 has a substantially bobbin shape as shown in FIGS. 1 to 3 and includes flange portions 12a formed in two rows in parallel in the vertical direction. A coil 13 is wound between the flanges 12a to position the coil 13. The first resin mold member 12 includes a locating pin 12b on a surface parallel to the stator core material 11a (see FIG. 3). As will be described later, the locating pin 12b is inserted into the locating hole 16g of the terminal block 16, and the terminal block 16 is positioned.
[0016]
The coil 13 is wound around the first resin mold member 12 as described above. In the present embodiment, the coil 13 is a flat wire and is formed by two-row winding of one row on the back core side of the stator and one row on the teeth tip side of the stator. A slight gap is formed between the coils 13 so that the refrigerant is in direct contact with the coils when flowing therethrough. The end 13 a of the coil 13 is disposed on a surface parallel to the stator core material 11 a and is covered with the terminal block 16.
[0017]
In the present embodiment, the coil 13 is a flat wire and is wound in two rows. However, for example, a square winding or a round wire may be used according to the required performance, and the number of turns may be adjusted appropriately. Even so, it is obvious that it is within the scope of the technical idea of the present invention.
[0018]
The spacer 14 is a member that prevents the second resin mold member 15 from coming into close contact with the coil 13, and is disposed between the coil 13 and the second resin mold member member 15. The spacers 14 are disposed on the coils 13 on both sides of the stator core material 11a. The spacer 14 has a corrugated plate shape. For this reason, the spacer 14 forms a slight gap with the coil 13. The refrigerant comes into direct contact with the coil when flowing through the gap. The spacer 14 is preferably electrically insulative, but may be electrically conductive as long as the insulating properties of the coil are not impaired.
[0019]
The second resin mold member 15 is an insulating member disposed on the spacer 14. The 2nd resin mold member 15 adheres to the 1st resin mold member 12, and uses the crevice formed in the inside as a refrigerant channel. The material of the second resin mold member 15 is preferably the same insulating member as the first resin mold member 12. This is because if the same material is used, the adhesion of the second resin mold member 15 to the first resin mold member 12 is good.
[0020]
The terminal block 16 is an insulating member disposed on the coil 13 in parallel with the laminated surface of the stator core material 11a. The material of the terminal block 16 is also preferably the same insulating member as the first resin mold member 12. This is because the same material has good adhesion to the first resin mold member 12. The terminal block 16 is bonded to the first resin mold member 12, and a gap formed therein is used as a coolant channel. The terminal block 16 has internal terminals 16b and 16e and external terminals 16c and 16f as will be described later. The terminal block 16 connects the internal terminals 16b and 16e to the ends 13a and 13b of the coil 13 (see FIG. 5).
[0021]
Although omitted in FIG. 3, an end cover 17 is arranged on the side opposite to the terminal block 16. The end cover 17 and the first resin mold member 12 form a coolant channel (see FIG. 11).
[0022]
FIG. 4 is a diagram showing a terminal block. 4A is a view taken along arrow IV in FIG. 3, FIG. 4B is a right side view with respect to FIG. 4A, and FIG. 4C is a bottom view with respect to FIG. 4A.
[0023]
The terminal block 16 is a member made of resin. The terminal block 16 has the electric wires 16a and 16d molded therein. The electric wires 16a and 16d have internal terminals 16b and 16e exposed on the left and right side surfaces, and external terminals 16c and 16f protruding to the front. As will be described later, the terminal block 16 is disposed on the coil 13 and connects the internal terminals 16b and 16e to the end portions 13a and 13b of the coil 13 (see FIG. 5). The external terminals 16c and 16f are connected to external terminals of adjacent different phase coils. The terminal block 16 has a locate hole 16g. The locate pin 12b of the first resin mold member 12 is inserted into the locate hole 16g and positioned.
[0024]
FIG. 5 is a diagram illustrating a state in which the terminal block is attached to the first resin mold member. 5A is a side view, FIG. 5B is a BB cross-sectional view of FIG. 5A, and FIG. 5C is a CC cross-sectional view of FIG. 5A.
[0025]
The terminal block 16 is positioned by inserting the locate pin 12b of the first resin mold member 12 into the locate hole 16g. The terminal block 16 connects the internal terminals 16 b and 16 e to the end portions 13 a and 13 b of the coil 13. For this reason, the coil 13 can be electrically connected to the outside.
[0026]
6-11 is a figure explaining the manufacturing process of the cooling structure of the rotary electric machine in this invention. In each figure, FIG. (A) is a front view, FIG. (B) is a left side view, FIG. (C) is a CC cross-sectional view of FIG. (A), and FIG.
[0027]
(Stator core lamination step # 101; FIG. 6)
First, the split core 11 is formed by laminating a stator core material 11a obtained by cutting an electromagnetic steel sheet into a predetermined shape to a predetermined thickness. At this time, as described above, it is preferable to integrate the cores by dowel caulking, welding, or the like.
[0028]
(First resin mold member forming step # 102; FIG. 7)
Next, a substantially bobbin-shaped first resin mold member 12 is formed by injection molding around the teeth portion 11b of the split core 11 and on the back core surface of the stator core material 11a. At this time, it is desirable that the first resin mold member 12 does not include open holes. However, the open holes may be present as long as they can be filled by varnish impregnation after coil winding. Further, the surface of the first resin mold member 12 should have moderate irregularities rather than being smooth. This is because the adhesive strength of the second resin mold member 15 to be injection-molded in a later process is increased, and a moderate gap is formed between the coil 13 and the refrigerant can flow through the gap.
[0029]
(Coil winding step # 103; FIG. 8)
Subsequently, the coil 13 is wound around the first resin mold member 12. In the present embodiment, as described above, a rectangular wire is used to form two rows of winding, one row on the back core side of the stator and one row on the teeth tip side of the stator.
[0030]
(Spacer placement step # 104; FIG. 9)
Thereafter, in this embodiment, corrugated spacers 14 are arranged outside the wound coil 13.
[0031]
(Second resin mold member forming step # 105; FIG. 10)
Then, injection molding is performed from the outside of the spacer 14, and the second resin mold member 15 is formed from both sides of the stator core material 11a.
[0032]
(End cover fixing step # 106; FIG. 11)
Next, the end cover 17 is disposed on the end surface of the stator core where the ends 13 a and 13 b of the coil 13 do not exist, and is bonded to the first resin mold member 12. A gap 17a between the end cover 17 and the first resin mold member 12 formed at this time serves as a refrigerant flow path.
[0033]
Although not shown, the terminal block 16 is disposed on the end surface of the stator core where the end portions 13 a and 13 b of the coil 13 are present, and is fixed to the first resin mold member 12. Then, as described above, the internal terminals 16b and 16e of the terminal block 16 are connected to the end portions 13a and 13b of the coil 13 (see FIG. 5).
[0034]
According to the present embodiment, the coil 13 is encapsulated by the insulating members (the first resin mold member 12, the second resin mold member 15, the terminal block 16, and the end cover 17), and the refrigerant is placed in the gaps between the coil 13 and each insulating member. I let it flow. Therefore, electrical insulation is maintained between the coil 13 and the stator core 11 and between the different phase coils. Therefore, even if the refrigerant is brought into direct contact with the coil 13, insulation deterioration such as tracking hardly occurs, and high insulation reliability as well as high cooling performance can be obtained.
[0035]
Moreover, the insulating member which forms a refrigerant | coolant flow path was formed separately for every division | segmentation core. Therefore, even if there is deformation of the entire stator due to the torque of the rotating electrical machine, it is difficult to be affected by this and has high durability reliability.
[0036]
Furthermore, the insulating material forming the refrigerant flow path is formed only on the side portion of the split core 11 and is not formed on the tip end portion 11c. Therefore, the air gap between the stator and the rotor can be reduced, and there is no deterioration in electromagnetic performance as seen in the above-described prior art.
[0037]
(Second Embodiment)
FIG. 12 is a diagram showing a second embodiment of the cooling structure for a rotating electrical machine according to the present invention, and corresponds to FIG. 5A in the first embodiment.
[0038]
In the present embodiment, differences from the above-described first embodiment will be described, and redundant description will be omitted.
[0039]
The rotating electrical machine of the present embodiment has a flow path blocking member 18 between the coils 13 in the vicinity of the terminal block 16 with respect to the rotating electrical machine of the first embodiment.
[0040]
When the flow path closing member 18 is thus provided, the refrigerant supplied from one terminal side of the terminal block 16 passes through the refrigerant flow path at the other end formed by the end cover 17 as indicated by the arrow in the figure. The terminal block 16 is discharged from the other terminal side across the flow path closing member 18. When the refrigerant flows in one direction in this way, the flow is smooth and the coil cooling performance is further improved.
[0041]
The present invention is not limited to the embodiment described above, and various modifications and changes can be made within the scope of the technical idea, and it is obvious that these are equivalent to the present invention.
[0042]
For example, in the said embodiment, although the clearance gap is provided and the refrigerant | coolant flow path is ensured by arrange | positioning the spacer 14 between the coil 13 and the 2nd resin mold member 15, the 1st resin mold member 12 and the coil 13 are provided. A spacer 14 may be disposed between the two and a gap between them may be used as a refrigerant flow path.
[0043]
In addition, the shape of the spacer 14 is corrugated so that the refrigerant can be passed between the coil 13 and the second resin mold member 15. When it is not necessary to let the refrigerant flow through the outside of the coil, a flat plate shape may be used.
[0044]
Furthermore, when the second resin mold member formed as a separate body is fixedly formed on the first resin mold member using an adhesive or the like, it is not particularly necessary to insert a spacer.
[0045]
Furthermore, in the present invention, the flow of the refrigerant is a turn flow. For example, the end cover 17 is provided with a refrigerant discharge port, the refrigerant is supplied from one end (terminal block side), and the refrigerant is supplied to the other end ( It may be discharged from the end cover side.
[Brief description of the drawings]
FIG. 1 is a view showing a first embodiment of a cooling structure for a rotating electrical machine according to the present invention, and is a view taken in the direction of arrow I in FIG.
FIG. 2 is a diagram showing a first embodiment of a cooling structure for a rotating electrical machine according to the present invention, and is a view taken along arrow II in FIG.
FIG. 3 is an exploded view of components showing a first embodiment of a cooling structure for a rotating electric machine according to the present invention.
FIG. 4 is a diagram showing a terminal block.
FIG. 5 is a view showing a state in which a terminal block is attached to a first resin mold member.
FIG. 6 is a diagram illustrating a stator core lamination process of the cooling structure for a rotating electric machine according to the present invention.
FIG. 7 is a diagram illustrating a first resin mold member forming step of the rotating electrical machine cooling structure according to the present invention.
FIG. 8 is a diagram illustrating a coil winding process of the rotating electrical machine cooling structure according to the present invention.
FIG. 9 is a diagram for explaining a spacer arrangement step of a cooling structure for a rotating electrical machine according to the present invention.
FIG. 10 is a diagram illustrating a second resin mold member forming process of the rotating electrical machine cooling structure according to the present invention.
FIG. 11 is a diagram illustrating an end cover fixing step of the rotating electrical machine cooling structure according to the present invention.
FIG. 12 is a diagram showing a second embodiment of the rotating electrical machine cooling structure according to the present invention.
[Explanation of symbols]
10 Division stator 11 Division core 11a Stator core material 11b Teeth part 12 1st resin mold member (insulation member)
12a collar 12b locate pin 13 coil 14 spacer 15 second resin mold member (insulating member)
16 Terminal block (insulating material)
16a, 16d Electric wires 16b, 16e Internal terminals 16c, 16f External terminals 16g Locate hole 17 End cover (insulating member)
18 Channel closing member

Claims (4)

A split core formed by laminating a stator core material cut out of a magnetic steel sheet into a predetermined shape to a predetermined thickness;
A first resin mold member injection molded around the teeth portion of the split core and the back core surface of the stator core material;
A coil wound around the first resin mold member;
A second resin mold member that is injection-molded from the outside of the coil and formed on both sides of the stator core material;
In parallel with the laminated surface of the stator core material, the end cover is disposed on the stator core end surface where the second resin mold member is not formed and the end of the coil does not exist, and is bonded to the first resin mold member;
A terminal block that is arranged in parallel with the laminated surface of the stator core material and is arranged on the stator core end surface where the end portion of the coil is not formed and the second resin mold member is formed , and fixed to the first resin mold member;
Have
Including the coil with an insulating member including the first resin mold member, the second resin mold member, a terminal block, and an end cover, and allowing a coolant to flow through a gap between the coil and the insulating member;
A cooling structure for a rotating electrical machine. 2. The cooling structure for a rotating electrical machine according to claim 1, wherein the insulating member includes a terminal portion that allows a coil to be included to be electrically connected to an adjacent coil. 3. The rotating electrical machine according to claim 1, wherein the insulating member includes a closing member that is provided by closing a part of the refrigerant flow path so that the refrigerant flows in one direction. Cooling structure. A stator core laminating step of forming a split core by laminating a stator core material cut out of a magnetic steel sheet into a predetermined shape to a predetermined thickness;
A first resin mold member forming step of forming a first resin mold member around the teeth portion of the split core and the back core surface of the stator core material by injection molding;
A coil winding step of winding a coil around the first resin mold member;
A second resin mold member forming step of forming the second resin mold member from both sides of the stator core material so as to perform injection molding from the outside of the coil and allow the coolant to flow through the gap with the coil ;
An end cover is arranged in parallel with the laminated surface of the stator core material, and on the stator core end surface where the second resin mold member is not molded and the end of the coil does not exist so that the refrigerant flows through the gap between the coil , An end cover fixing step for bonding to the first resin mold member;
A terminal block is arranged in parallel with the lamination surface of the stator core material and on the stator core end surface where the second resin mold member is not molded and the end of the coil exists so that the refrigerant flows through the gap between the coil and the coil. A terminal block fixing step for fixing to the first resin mold member;
A method for manufacturing a rotating electrical machine.

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