JP4631340B2 - Rotating electric machine - Google Patents

Description

  The present invention relates to a rotating electrical machine, and more particularly to an insulating structure of a stator of the rotating electrical machine.

  In a rotating electrical machine including a stator (hereinafter also referred to as a stator) and a rotor (hereinafter also referred to as a rotor), the stator includes a stator core in which a plurality of slots are formed and comb teeth (hereinafter referred to as teeth) provided between the slots. And a coil wound around (also referred to as). The rotor is composed of a rotor core, a magnet having magnetic force, and a shaft serving as a rotation axis.

  In such a configuration, a magnetic field is generated when electric power is supplied to the coil. Based on the generated magnetic field, a flow of magnetic flux is formed between the rotor and the stator, whereby the rotor obtains a rotational force.

  Here, in the stator, the stator core and the coil need to be electrically insulated. A number of insulating means have been conventionally disclosed for the purpose of ensuring insulation with a simple work process (see, for example, Patent Documents 1 to 3).

  For example, according to the rotating electrical machine described in Patent Document 1, the inner surface of a slot formed between two adjacent salient poles (corresponding to teeth) of a laminated core and both end faces located in the laminating direction of each salient pole, Covered by slot insulation. At this time, in the portion covering the end face of the salient pole of the slot insulating member, the winding for restricting the winding position of the winding is formed so that the winding portion is not formed in the vicinity of the pair of extension portions of the magnetic pole portion of the salient pole. The line position restricting protrusion is integrally formed. Further, in the space formed between the two extended portions facing the circumferential direction of the two adjacent salient poles and the winding portions wound respectively on the two adjacent salient poles, the wedge insulating paper and A so-called sheet-like or plate-like insulating member is inserted.

  In such a state, a winding portion is formed by winding a winding conductor on each salient pole of the laminated iron core via a slot insulating member. When forming the winding portion, the winding conductor is wound directly by inserting the nozzle of the winding machine into each slot on both sides of the salient pole. At this time, the winding position restricting projection provided on the slot insulating member restricts the winding position of the winding so that the winding portion does not protrude toward the inlet side of the slot and the space for inserting the wedge insulating paper is not narrowed. .

  According to this, electrical insulation between the laminated iron core and the winding portion is ensured by the slot insulating member that covers the inner surface and end surface of the slot and the wedge insulating paper that is inserted into the opening on the inner peripheral side of the slot. Is done. Further, a space for inserting the wedge insulating paper is secured by the winding position restricting projection formed integrally with the slot insulating member, and the wedge insulating paper that has been difficult to work can be easily inserted.

  Moreover, according to the rotary electric machine described in Patent Document 2, an insulator is inserted into each slot of the stator core. The insulator has a shape in which one sheet is bent in accordance with the cross-sectional shape of the slot, and a folded portion in which one end portion in the axial direction is folded outward is formed. This folded portion is used for positioning when the insulator is assembled to the slot. Subsequently, a conductor segment is inserted into the insulator. Finally, the ends of the conductor segments are connected to the ends of other conductor segments inserted in different slots, thereby forming a stator winding.

  According to this, the electrical insulation between each conductor segment and the inner wall surface of the slot is performed by the insulator. By providing a folded portion at one end in the axial direction of the insulator and having a flat shape at the other end, the insulator can be easily inserted into each slot with the other end at the top, and the shaft of the insulator It is possible to prevent positional displacement in the direction.

  As described above, in the conventional rotating electric machine, the electrical insulation between the stator core and the coil can be easily ensured by the slot insulating member or the insulator mounted in advance on the inner surface of each slot into which the coil is inserted. it can.

  By the way, when the rotating electrical machine operates and a current flows through the coil, Joule heat proportional to the current density is generated in the coil. In particular, when the rotating electrical machine is operated at a high load, the amount of Joule heat generated increases with an increase in the amount of current, and there is a risk of burning the enamel insulating film covering the coil and the insulating member.

  For this reason, with respect to conventional rotating electrical machines, there has been a limit imposed on the operation within a current density range that does not cause a problem in insulation characteristics. In addition, increasing the current density is effective for reducing the physique of the rotating electrical machine, but there is a limit to the physique that can be realized due to the above-described limitations on the current density.

  Therefore, in order to realize both the operation under high load and the reduction of the physique of the rotating electrical machine and the securing of insulation, it is necessary to quickly dissipate the heat generated in the coil to the outside of the coil. Providing a heat dissipation path with good thermal conductivity is an issue.

  For example, according to the rotating electrical machine described in Patent Document 3, a slot insulator made of a cylindrical body of an epoxy insulating material is mounted in advance on the inner periphery of the slot of the stator core. In this state, two sides of the linear portion of the coil formed so that a straight rectangular wire is formed into a U shape are inserted into adjacent slots with the teeth interposed therebetween, and molded with an epoxy thermosetting resin. Furthermore, a predetermined number of coils are stacked in the slot, and one end surface on the side opposite to the U-shape of each coil protruding from the end of the slot is connected to the other end surface on the side opposite to the U-shape on the adjacent coil with a thin plate-like piece. As a result, a coil having a predetermined number of turns is formed. Finally, a predetermined number of thin plate bar pieces are stacked and molded with thermosetting resin, and when the connection ring is connected to the coil, the entire stator is molded again.

According to this configuration, since the slot insulator and the thermosetting resin filled with the mold are interposed between the coil and the stator core, sufficient electrical insulation is ensured. On the other hand, the heat generated in the coil is conducted to the thermosetting resin filled in the slot, and further conducted to the thermosetting resin covering the coil end made of the thin bar-like piece and transmitted to the frame. Can be efficiently dissipated.
JP-A-10-75544 JP 2000-50553 A JP 2001-292548 A

  Here, in the conventional rotating electrical machines described in Patent Documents 1 to 3, attention is paid to the heat radiation path of heat generated in the coils of each stator.

  First, according to the rotating electrical machine described in Patent Document 1, heat generated in the winding portion (= coil) is conducted in the order of the winding portion → slot insulating member → laminated core (= stator core).

  Here, in the structure of the stator according to Patent Document 1, since a clearance is required when the slot insulating member is assembled to the inner surface of the slot, a gap having a predetermined width exists between the laminated iron core and the slot insulating member. . A similar gap exists between the winding portion and the slot insulating member. These two air gaps increase both the thermal resistance between the winding portion and the slot insulating member and the thermal resistance between the slot insulating member and the laminated iron core (= lower thermal conductivity). As a result, the heat dissipation of the coil is hindered.

  Next, in the rotating electrical machine described in Patent Document 2, similarly, it is difficult to reduce the thermal resistance due to the gaps for assembling accuracy respectively interposed between the conductor segment and the insulator and between the insulator and the stator core. Yes.

  Finally, in the rotating electrical machine described in Patent Document 3, similarly, heat generated in the coil is conducted in the order of coil → slot insulator → stator core. At this time, in the structure of the stator according to Patent Document 3, since the two gaps are filled with thermosetting resin, the thermal resistance between the coil-slot insulator and the heat between the slot insulator-stator core. The resistance is reduced with respect to the thermal resistance when it is a gap. Therefore, the overall thermal resistance between the coil and the stator core is reduced, and heat can be radiated more efficiently.

  On the other hand, even in the structure of the stator, the thermal resistance component of the slot insulator itself arranged for ensuring insulation still exists. For this reason, the further improvement of heat dissipation cannot be expected, but a limit will arise in high load operation | movement and the physique reduction of a rotary electric machine.

  In addition, in the stator structure, a plurality of molding processes are performed for ensuring insulation and reducing thermal resistance, so that a dedicated molding die is required for each process. In addition, there is a problem that the manufacturing cost is significantly increased due to an increase in the number of manufacturing steps accompanying the mold processing.

  Therefore, the present invention has been made in order to solve such a problem, and an object of the present invention is to achieve a high-load operation and a reduction in physique in a stator by realizing both insulation ensuring and high cooling efficiency. It is to provide an electric machine.

  According to an aspect of the present invention, a rotating electrical machine includes a rotor and a stator fixed to the outer periphery of the rotor, and the stator has a plurality of slots each extending in the rotation axis direction of the rotor. A stator core arranged in a plurality of coils, a coil made of a laminated conductor wound around a plurality of teeth respectively formed between adjacent slots, and a part of a gap of a predetermined interval provided between the stator core and the coil A first electrically insulating member disposed in the region; and a heat-conductive sealing member disposed so as to close the gap.

  Preferably, the sealing member has a higher thermal conductivity than the first electrical insulating member.

  Preferably, the predetermined interval is a distance necessary for electrically insulating the stator core and the coil.

  Preferably, the partial region of the gap is a region in the vicinity of both open end portions of each of the plurality of slots in the rotation axis direction of the rotor.

  Preferably, the first electrically insulating member extends in the rotation axis direction of the rotor and has a cylindrical portion having an end surface having substantially the same shape as the opening end portion of the slot, and an outer peripheral side of one end surface of the cylindrical portion. And a support part for fixing the cylindrical part. The other end face of the cylindrical body is fitted to the both opening end portions of the slot, starting from the other end face.

  Preferably, the cylindrical portion is closed at a portion corresponding to the tip portion of the tooth on the end surface.

  Preferably, the cylindrical portion is configured such that the length of the rotor in the rotation axis direction is shorter than the length of the slot in the rotation axis direction of the rotor.

  Preferably, the length of the cylindrical portion in the rotation axis direction of the rotor is set to a necessary and sufficient length that can maintain the gap at a predetermined interval.

  Preferably, the first electrical insulating member further includes a plurality of grooves arranged on at least one of the inner surface and the outer surface of the cylindrical portion and the support portion, each extending in the rotation axis direction of the rotor.

  Preferably, the first electrically insulating member includes a cylindrical body that can be wound around an arbitrary portion of the coil. When the coil is wound around a plurality of teeth, the coil is wound around the coil so that the winding portion becomes a partial region of the gap.

  Preferably, the stator further includes a second electrically insulating member having thermal conductivity and disposed so as to close a gap between at least one end face of the rotor of the stator core in the rotation axis direction and the coil.

  Preferably, the second electrical insulating member is elastically deformed in accordance with a load applied in the rotation axis direction of the rotor, thereby forming a gap between at least one end surface of the stator core in the rotation axis direction and the coil. Block it.

  Preferably, each of the coils has an open end portion that is open so as to be wound around the teeth, and a plurality of laminated flat plate conductors arranged in the radial direction of the rotor, and one open end portion of each of the plurality of laminated flat plate conductors And a plurality of bus bars respectively connecting the other open end portions of the adjacent laminated flat plate conductors.

  Preferably, each of the plurality of laminated flat conductors has a different length in the rotation axis direction of the rotor between adjacent laminated flat conductors.

  Preferably, each of the plurality of bus bars has a different length in the rotation axis direction of the rotor between adjacent bus bars.

  Preferably, the coil is an edgewise coil that bends a flat conductor strip in the width direction of the strip.

  Preferably, the coil includes a first bent portion that is bent, and a second bent portion that is disposed adjacent to the coil stacking direction of the first bent portion, and the first bent portion and the second bent portion. The positions of the inner portions of the bent portions are arranged so as to be shifted from each other in the plane direction of the flat conductor.

  According to the present invention, the electric insulation member provided partially in the gap between the coil and the stator core can reduce the thermal resistance between the two while maintaining the electrical insulation. Load operation and downsizing can be achieved.

  Furthermore, in the conventional stator, a plurality of molding processes that have been performed for electrical insulation and heat dissipation can be performed by a single molding process, so that the manufacturing cost can be greatly reduced. .

  Furthermore, if it is set as the structure which winds an electrical insulation member around a coil, the shape of an electrical insulation member can be simplified with a substantially cylindrical shape, and the further reduction of manufacturing cost can be aimed at.

  In addition, by installing a plurality of electrical insulation members in the gap between the coil and the stator core, the heat generated in the coil can be efficiently radiated through the plurality of heat radiation paths, so that the current density of the coil can be further increased. A rotating electrical machine capable of reducing the load operation and the physique can be realized.

  Moreover, by making the coil end portion into a fin shape, the heat dissipation effect of the coil can be further enhanced, which is effective in reducing the size of the rotating electrical machine.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the drawings, the same reference numerals indicate the same or corresponding parts.

[Embodiment 1]
1 is an external view of a rotating electrical machine according to Embodiment 1 of the present invention.

  Referring to FIG. 1, the rotating electrical machine includes a rotor (not shown) that is rotatably fixed and a stator 100 a that is fixed to the outer periphery of the rotor.

  A rotor (not shown) is accommodated rotatably via a rotating shaft (not shown).

  The stator 100a is fixed so as to surround the outer periphery of the rotor in order to control the rotation of the rotor. Stator 100 a includes a stator core 102, a coil 112, a bus bar 110, a bus bar positioning block 104, and a transition member 106.

  The stator core 102 has a hollow cylindrical shape, and has an annular yoke portion and a predetermined number of comb teeth (hereinafter also referred to as teeth) arranged in an annular shape pointing radially inward on the inner peripheral side of the yoke portion. And a predetermined number of grooves (hereinafter also referred to as slots, for example, 146, 148) formed between the adjacent teeth 108 and extending in the axial direction.

  Note that the number of teeth 108 and slots 146 corresponds to the number of poles of the rotating electrical machine, and in this embodiment, the number of poles is, for example, “21”.

  The coil 112 is wound around and fixed to each of a predetermined number of teeth 108. Specifically, the coil 112 is composed of a plurality of laminated coils (not shown) each of which is formed by laminating flat conductors each formed in a U-shape in advance. The coil 112 is inserted into two slots (for example, 146, 148) where two sides of the straight line portion are adjacent so as to straddle the teeth 108.

  Further, at the open ends of the coils 112 protruding from the slots 146 and 148, one open end of the plurality of laminated coils and the other open end of the laminated coils adjacent to the plurality of laminated coils are connected to the bus bar 110. Are coupled to each other. As a result, the coil 112 having a predetermined number of turns according to the number of laminated coils is formed. At this time, both end portions of the laminated body coil protruding from the slot along the axial direction constitute a coil end portion of the coil 112.

  In assembling the bus bar 110, first, a plurality of bus bars 110 for connecting the open ends of the coils 112 are positioned and fixed to the bus bar positioning block 104. Subsequently, the bus bar positioning block 104 is disposed at a predetermined position and pressed, whereby the bus bars 110 respectively corresponding to the open ends of the plurality of laminated coils are assembled.

  At this time, as shown in FIG. 1, among the slots 146 and 148 located on both sides of the tooth 108, the coil 112 has a bus bar on the inner peripheral side of one slot 146 and the outer peripheral side of the other slot 148. A coil end not connected to 110 is formed. Since the coil end portions are located on the inner peripheral side and the outer peripheral side for each slot, the entire stator core 102 is configured to be annularly arranged along the circumferential direction.

  In this configuration, the coil end located on the inner peripheral side of the slot and the coil end located on the outer peripheral side of the other slot are coupled by the crossover member 106. Specifically, the coil end portion on the inner peripheral side of the coil 112 wound around one tooth 108 is the outer peripheral side of the coil 112 wound around the tooth 108 positioned at the third tooth in the circumferential direction from the tooth 108. Are coupled to the coil ends. That is, the coil end portion is coupled via the cross member 106 every three teeth.

  Furthermore, as shown in FIG. 1, three adjacent coil end portions 140, 142, and 144 among the plurality of coil end portions located on the inner peripheral side are coupled to each other by the cross member 106. In addition, terminals for transmitting / receiving electric power to / from the outside of the stator 100a are arranged on the coil ends 134, 136, and 138 on the outer peripheral side facing these.

  In this way, the stator 100a of the three-phase synchronous motor having the coil end portions 134, 136 and 138 as input / output terminals is formed. When the phase-controlled AC power is supplied to each of the coil end portions 134, 136, and 138, the stator 100a generates a magnetic field corresponding to the AC power. The rotor obtains a rotational force based on the generated magnetic field.

  In the stator 100a configured as described above, when AC power is supplied from the coil end portions 134, 136, and 138, a current controlled for each phase flows through the coil 112. As a result, Joule heat is generated in the coil 112 in an amount proportional to the product of the square of the magnitude of the current and the coil resistance. The heat generated in the coil 112 is conducted to the stator core 102 around which the coil 112 is wound, and further conducted to a case (not shown) in which the stator core 102 is fixed.

  Here, in order to prevent burning of the stator 100a due to heat generation of the coil 112, it is necessary to quickly dissipate the heat of the coil 112. As described above, if the heat dissipation is improved, the current density of the coil can be increased, and the high load operation and the size reduction of the rotating electrical machine can be achieved. On the other hand, in order to avoid insulation damage of the stator 100a, sufficient electrical insulation between the coil 112 and the stator core 102 must be ensured.

  In view of this, in the present embodiment, a structure of a stator that is excellent in heat dissipation while ensuring insulation between the coil and the stator core is proposed.

  FIG. 2 is a diagram showing details of the stator core 102 in the stator 100a of FIG.

  Referring to FIG. 2, stator core 102 includes a plurality of teeth 108 arranged at a predetermined interval in the circumferential direction, and a plurality of slots (for example, 146, 148) each formed between adjacent teeth.

  Stator core 102 further includes an electrical insulating member 10a fitted in both ends of the opening along the axial direction in slot 148. In addition, although illustration is abbreviate | omitted, also in slots other than the slot 148, the electric insulation member 10a is similarly fitted by both opening edge parts.

  The stator 100a according to the present embodiment is characterized in that the electrical insulating member 10a is provided only in the vicinity of both opening ends of the slot 148 in the axial direction. In this respect, it differs from the conventional stator structure in which an electrical insulating member (slot insulator, insulator, etc.) is provided over the entire length of the slot in the axial direction.

  FIG. 3 is a diagram showing an example of the configuration of the electrical insulating member 10a shown in FIG.

  Specifically, as shown in FIG. 3, the electrical insulating member 10 a is a cylindrical body in which a part of the side surface is not closed, and at one end surface thereof, the support portion is formed so that the side surface is folded outward. Have When the electrical insulating member 10a is fitted in the slot, the support portion fixes the electrical insulating member 10a in the vicinity of the opening end of the slot, thereby avoiding misalignment.

  As shown in FIG. 2, when the electrical insulating member 10 a is fitted to both open ends of all slots, the coil 112 is inserted into each adjacent slot across the teeth 108. Further, the open ends of the coil 112 are coupled to each other by the bus bar 110, whereby the coil 112 is wound. Finally, a molding process is performed on the entire stator 100a with the coil 112 wound around the teeth 108. Thereby, the area | region except the electrical insulation member 10a between the coil 112 and the stator core 102 is filled with the resin mold material. The details of this molding process will be described later.

  As described above, in the stator 100a according to the present embodiment, the resin mold material is interposed between the coil 112 and the stator core 102 except for the electrical insulating members 10a provided at both opening ends of the slot. Become. In this configuration, heat generated in the coil 112 during operation is dissipated along a heat dissipation path described below.

  FIG. 4 is a diagram illustrating a heat dissipation path between the coil 112 and the stator core 102. Specifically, FIG. 4A is a diagram illustrating a heat dissipation path for heat generated in the coil 112, and FIG. 4B is a circuit diagram schematically illustrating the heat dissipation path.

  Referring to FIG. 4A, heat (= heat generation amount Q) generated in coil 112 is conducted from coil 112 to stator core 102. At this time, in the case of a conventional stator structure in which the electrical insulating member 122 is uniformly interposed between the coil 112 and the stator core 102, the heat generation amount Q is conducted from the coil 112 to the stator core 102 through the electrical insulating member 122. .

  As shown in FIG. 4B, this heat dissipation path can be represented by thermal resistances R1 and R2 connecting the coil 112, the stator core 102, and the case 150, respectively.

  Specifically, a thermal resistance R <b> 1 exists between the coil 112 and the stator core 102. In addition, a thermal resistance R2 exists between the stator core 102 and the case 150. In particular, with respect to the thermal resistance R 1, the thermal resistance component r 1 in the gap between the coil 112 and the electrical insulation member 122, the thermal resistance component r 2 inherent to the electrical insulation member 122, and the thermal resistance component in the gap between the electrical insulation member 122 and the stator core 102. It can be considered that three thermal resistance components r1 to r3 made of r3 are connected in series.

  Here, in order to increase the cooling efficiency of the stator 100a, it is necessary to reduce the thermal resistances R1 and R2 that hinder heat conduction. The thermal resistance is mainly determined by the distance that heat is conducted and the thermal conductivity of the conduction medium. Therefore, to reduce the thermal resistance, it is effective to shorten the conduction distance and increase the thermal conductivity of the conductive medium. If this is applied to the stator 100a of FIG. 4A, among the thermal resistances R1 and R2, the thermal resistance R2 can be reduced by bringing the stator core 102 and the case 150 into contact with each other. As for the thermal resistance R1, it can be said that it is effective to use a conductive medium having high thermal conductivity in the gap between the coil 112 and the stator core 102 and to reduce the width of the gap.

  On the other hand, it is necessary to maintain a minimum distance necessary for ensuring electrical insulation between the coil 112 and the stator core 102 between the coil 112 and the stator core 102. For this reason, there is a limit in reducing the width of the gap.

  Therefore, in the present embodiment, the electrical insulation member 10a shown in FIG. 2 is used for electrical insulation between the coil 112 and the stator core 102, thereby realizing the stator 100a having high thermal conductivity while ensuring insulation. .

  FIG. 5 is a diagram illustrating a cross-sectional structure of the AA cross section in FIG. Specifically, FIG. 5A shows a sectional structure of a conventional stator, and FIG. 5B shows a sectional structure of the stator according to the present embodiment.

  Referring to FIG. 5A, in the conventional stator, one side of the straight portion of coil 112 is located at the center of a slot formed between adjacent teeth 108 of stator core 102. A cylindrical electrical insulating member 122 having substantially the same shape as the slot is disposed in a gap having a predetermined width formed between both side surfaces of the coil 112 and the teeth 108. The electrical insulation member 122 ensures electrical insulation between the stator core 102 and the coil 112. Note that the gap generated between the coil 112 and the electric insulating member 122 and the gap generated between the electric insulating member 122 and the stator core 102 are each configured by filling a gap or a resin mold.

  On the other hand, in the stator 100a according to the present embodiment, as shown in FIG. 5B, the gap formed between one side of the linear portion of the coil 112 and the teeth 108 is from both opening end portions of the slot. The fitted electrical insulating member 10a is disposed. Furthermore, the entire region of the gap except for the portion where the electrical insulating member 10 a is disposed is covered with the resin molding material 120.

  Next, in the two stators configured as described above, the heat radiation paths of the heat generated in the coil 112 are compared.

  First, in the conventional stator, heat generated in the coil 112 is conducted in the order of the coil 112 → the gap or resin mold → the electrical insulating member 122 → the gap or resin mold material → the stator core 102. In this heat dissipation path, if the gap before and after the electrical insulating member 122 is made of a resin mold material, the thermal resistance can be reduced and the thermal conductivity can be increased as compared with the case where the gap is made with a low thermal conductivity. However, in the heat dissipation path of the conventional stator, the thermal resistance component possessed by the electrical insulating member 122 still exists.

  Next, in stator 100a according to the present embodiment, most of the heat generated in coil 112 is conducted in the order of coil 112 → resin molding material 120 → stator core 102, except for both ends in the axial direction.

  Comparing the above two heat dissipation paths, it is clear that the heat dissipation path according to the present embodiment does not include the electrical insulating member 122 as a path with respect to the heat dissipation path in the conventional structure. Therefore, according to the present embodiment, the thermal resistance component of the electrical insulating member 122 can be removed from the thermal resistance between the coil 112 and the stator core 102, and the thermal resistance can be greatly reduced.

  It is desirable that the resin mold material 120 interposed between the coil 112 and the stator core 102 is a high thermal conductive resin mold material having a higher thermal conductivity than the resin mold material used in the conventional stator. At this time, the thermal conductivity of the high thermal conductive resin mold material is selected so as to be at least higher than the thermal conductivity of the electrical insulating member 10a.

  On the other hand, regarding the electrical insulation, also in the present embodiment, the coil 112 is accurately positioned at the central portion of the slot by the electrical insulating member 10a disposed at both opening ends of the slot. Furthermore, since the coil 112 is composed of the laminate coil 114, the accuracy of the shape of the linear portion of the coil 112 that fits in the slot is good, so that a gap with a predetermined width necessary for electrical insulation between the coil 112 and the stator core 102 is obtained. Can be maintained, and insulation can be easily secured.

  From the above, according to the present embodiment, since the thermal resistance between the coils 112 and the stator core 102 can be reduced while maintaining the electrical insulation, the cooling efficiency of the rotating electrical machine can be increased and the high load operation and Miniaturization can be achieved.

  Furthermore, in the conventional stator, a plurality of molding processes, which have been performed for electrical insulation and heat dissipation, can be performed by a single molding process, so that the manufacturing cost can be greatly reduced. it can.

  Hereinafter, a specific structure of the stator 100a according to the present embodiment will be described with reference to its manufacturing process.

  FIG. 6 is a diagram showing a process of assembling the coil 112 inserted into the stator core 102.

  Referring to FIG. 6, when electrically insulating member 10 a is fitted to both open ends of the slot, the open ends of coil 112 are inserted into two slots 146 and 148 adjacent to each other with teeth 108 interposed therebetween. .

  As described above, the coil 112 is composed of a plurality of laminated coils 114, and is inserted into the adjacent slots 146 and 148 on the two sides of the straight portion. That is, in one slot 146, one side of the straight line portion of one coil 112 and the other side of the straight line portion of another coil 112 adjacent thereto are arranged adjacent to each other in the circumferential direction.

  FIG. 7 is a view showing the appearance of the coil 112 shown in FIG.

  Referring to FIG. 7, the coil 112 includes a plurality of laminated coils 114 each formed by laminating a U-shaped flat conductor. As the flat conductor, for example, a metal flat plate made of a copper rolled material is used. In addition, the surface treatment of the copper oxide insulating film is performed in advance on the surface of the metal flat plate of the copper rolled material.

  In detail, the metal flat plate of a copper rolling raw material is press-molded into a U-shape in a pressing process. A predetermined number of the U-shaped metal flat plates are laminated. At this time, each metal flat plate is provided with a plurality of protruding portions, and is fixed to each other by a so-called laminated caulking, in which the protruding portion of the protruding portion of the other metal flat plate is press-fitted into the concave portion of the protruding portion of one metal flat plate. Is done. In this way, the laminated coil 114 is formed by fixing a predetermined number of metal flat plates to each other.

  Further, the laminated coil 114 is subjected to an insulation process for the adjacent laminated coil 114. This insulation treatment is performed, for example, by interposing an inorganic material such as glass or enamelling each laminated body. As shown in FIG. 7, a predetermined number of the laminated coils 114 subjected to the insulation treatment are bonded to each other to form the coil 112.

  Here, if a plurality of laminated coils forming the coil 112 are configured by laminating metal flat plates having different dimensions, the cross-sectional shape of the coil 112 can be freely set. As shown in FIG. 7, according to the shape of the slot, if the width of the metal flat plate increases from the radially inner periphery side to the outer periphery side (from the upper surface to the lower surface in FIG. 7), the slot The space factor of the coil 112 can be increased. Thereby, the thermal resistance between the coil 112 and the stator core 102 is reduced, and heat dissipation is improved.

  FIG. 8 is a diagram showing an assembling process of the coil 112 inserted into the stator core 102.

  As shown in FIG. 8, the coil 112 formed of the plurality of laminated coils 114 shown in FIG. 7 is inserted into the slots 146 and 148 located on both sides so as to straddle the teeth 108. Further, after inserting the coil 112 into the slot, wedge insulating paper is assembled along the axial direction in order to ensure electrical insulation between the coil 112 and the tip of the tooth 108.

  In addition, as shown in FIG. 8, in the open end part of the coil 112, the several laminated body coil 114 has a fitting part from which a shape mutually differs, respectively. In this fitting portion, the laminated body coil 114 and the bus bar 110 are assembled. In addition, by providing the fitting part of a different shape between adjacent laminated body coils, the assembly mistake at the time of the assembly | attachment of the bus-bar 110 can be prevented.

  FIG. 9 is a view showing the appearance of the coil 112 with the bus bar 110 assembled thereto.

  Referring to FIG. 9, the fitting portion at the open end of multilayer coil 114 is joined to the joint of bus bar 110 that is a linear conductor. At this time, one end of the bus bar 110 is joined to one open end of the multilayer coil 114. On the other hand, the other end of the bus bar 110 is joined to the other open end of the multilayer coil 114 adjacent to the multilayer coil 114.

  Similarly, one of the open ends of a plurality (10 in FIG. 9) of laminated coils 114 is joined to the other of the open ends of the adjacent laminated coils 114 via the bus bar 110, respectively. Then, the coil is wound around the tooth 108 ten times. In this way, a 10-turn coil 112 is formed.

  When the bus bar 110 is assembled to the laminated body coil 112, a joining process such as laser welding or TIG (Tungsten Inert Gas arc) is applied to the fitting portion between the bus bar 110 and the open end of each laminated body coil 112 at each point. Applied.

  As shown in FIG. 10, the bus bar 110 can be assembled at a time by a fixed bus bar positioning block 104 in which a plurality of bus bars 110 are positioned.

  In this case, the bus bar positioning block 104 is installed at a predetermined position and pressed, whereby the plurality of bus bars 110 are respectively assembled to the open ends of the corresponding multilayer coils 114. The bus bar 110 and the fitting portion at the open end of the laminate coil 114 are joined by laser welding or TIG welding, respectively.

  FIG. 11 is a diagram illustrating a process of assembling the cross member 106 to the coil end.

  When the bus bar 110 and the fitting portion of each laminated body coil 114 are joined, as shown in FIG. 11, the coils 112 wound for each tooth 108 are connected to each other using the transition member 106. Since the rotating electrical machine according to the present embodiment is a three-phase AC synchronous motor, the coil end on the outer peripheral side of the coil 112 and the coil end on the inner peripheral side of the coil 112 are connected every three teeth. The connection between the coil end and the crossover member 106 is performed, for example, by laser welding or TIG welding.

  As described above, when the stator 100a shown in FIG. 1 is formed, the entire stator 100a is molded. Thereby, the stator 100a having the appearance shown in FIG. 12 is completed.

  Here, in the molding process in this embodiment, the coil end portion shown in FIG. 11 is electrically insulated, and as described above, the electrical insulation between the coil 112 and the stator core 102 and the heat dissipation path between them are performed. Form.

  FIG. 13 is a diagram for explaining a molding process performed on the stator 100a according to the present embodiment.

  Referring to FIG. 13, stator 100 a is sealed with a mold die 210. A molding material gate 212 for injecting a resin molding material from the molding material tank 200 to the molding die 210 is provided on the lower bottom surface in the axial direction of the molding die 210. Further, on the upper bottom surface in the axial direction of the mold die 210, a vacuuming gate 214 for making the inside of the mold die 210 in a vacuum state is provided. With such a configuration, when the resin molding material flows in from the molding material gate 212, the resin molding material flows through the inside of the molding die 210 in the direction opposite to the direction of gravity and flows out from the vacuuming gate 214. It will be.

  The stator 100a is disposed inside the mold 210 so that the axial direction matches the flow path of the resin mold material. As described above, the stator 100a has a configuration in which the coil 112 is wound around each tooth 108 of the stator core 102, and the coil 112 and the stator core 102 are insulated from each other at both opening ends in the axial direction of the slot. An electrical insulating member 10a is provided for each.

  In the above configuration, in the molding process, first, the vacuum gate 214 is opened with the molding material gate 212 closed, and the interior of the mold 210 is evacuated.

  Next, when the mold material gate 212 is opened, a resin mold material is injected into the mold 210 in a vacuum state. The resin mold material flows toward the vacuum gate 214 against the direction of gravity. At this time, as shown in FIG. 13, the resin mold material rises while filling the space inside the stator core 102 other than the coil 112 with resin. Even in the gap between the coil 112 and the stator core 102, the entire region except the electrical insulating member 10a is filled with the resin mold material.

  Finally, when it is confirmed that the resin molding material has reached the bus bar 110 positioned at the upper end of the coil 112, the molding material gate 212 is closed. Furthermore, the mold processing step is completed by heating the entire mold 210 to cure the resin mold material.

  In FIG. 13, the molding process using an injection mold has been described as an example. However, when the flow resistance of the resin mold material is high, such as when the viscosity of the resin mold material is high or the flow path is narrow, the resin mold material is used. It is good also as a structure performed by what is called pressure injection which pressurizes and inject | pours into a metal mold | die.

  Further, the molding process is not limited to the injection molding described above, and can be similarly performed by injection molding in which a resin molding material is injected into the stator 100a.

  FIG. 14 is a flowchart for explaining a manufacturing process of stator 100a in the rotating electrical machine according to the first embodiment.

  Referring to FIG. 14, first, electrical insulating member 10a is fitted to both opening ends of the slot of stator core 102 (step S01). As shown in FIG. 2, the electrical insulating member 10a is installed only in the vicinity of the opening end of the slot.

  Next, a coil 112 is wound around each tooth 108 of the stator core 102. Specifically, after the open ends of the plurality of laminated coils constituting the coil 112 are inserted into the slots 146 and 148 on both sides of each tooth 108, the electrical connection between the coil 112 and the tip of the tooth 108 is performed. In order to ensure the mechanical insulation, wedge insulating paper is assembled along the axial direction (step S02).

  Next, one open end of the laminate coil 114 and the other open end of the adjacent laminate coil 114 are coupled by the bus bar 110 (step S03).

  Furthermore, the fitting part of the open end part of the laminated body coil 114 and the bus-bar 110 is joined by welding, respectively. Finally, the stator 100a in the three-phase AC rotating electric machine is formed by connecting the coil end portions every three teeth using the cross member 106 (step S04).

  When the stator 100a is formed by the above steps S01 to S04, the entire stator 100a is molded.

  Specifically, as shown in FIG. 13, the stator 100 a is sealed with the mold die 210 (step S 05), the vacuum drawing gate 214 provided on the upper surface of the mold die 210 is opened, and the interior of the mold die 210 is opened. Is brought into a vacuum state (step S06).

  Next, the molding material gate 212 provided on the lower surface of the molding die 210 is opened, and a resin molding material is injected against the direction of gravity (step S07). Thereby, the resin molding material rises while filling the space other than the coil 112 of the stator 100a with the resin. By performing heat curing in a state where the entire stator 100a is filled with resin, the molding process is completed (step S08).

  In the present embodiment, the coil 112 of the stator 100a is constituted by the U-shaped laminated coil 114, but the same effect can be obtained even when it is constituted by the U-shaped laminated coil. it can.

  Furthermore, as shown in FIG. 15, the coil 112 may be constituted by a so-called edgewise coil that is bent not in the thickness direction that is easily bent with respect to the strip of the flat conductor but in the width direction that is difficult to bend. In this case, the coil 112 is inserted into the teeth of the stator core from the inside in the radial direction after the electrical insulating member 10a is attached to the opening end of the slot.

  Here, the electrical insulating member 10a according to the present embodiment can be configured by the structures listed below in addition to the structure shown in FIG. According to these structures, in addition to the above effects, further effects are exhibited in terms of productivity and reliability. Below, the example of a change is demonstrated about the structure of the electrical insulation member which concerns on this Embodiment.

[Modification 1]
FIG. 16 is a diagram showing a first modification of the electrical insulating member according to Embodiment 1 of the present invention.

  Referring to FIG. 16, the electrical insulating member 10 b is a cylindrical body whose side surface is closed over the entire circumference, and for fixing the electrical insulating member 10 b near the open end of the slot at one end. Includes support.

  The electrical insulating member 10b according to this modification is different from the electrical insulating member 10a according to the first embodiment (see FIG. 3) in which a part of the side surface is not closed in that the side surface is closed. In response to this difference, this modified example has the following characteristics in the insulating structure.

  FIG. 17 is a diagram showing an insulating structure using an electrical insulating member according to Embodiment 1 of the present invention. FIG. 17A shows an insulating structure using the electric insulating member 10a shown in FIG. 3, and FIG. 17B shows an insulating structure using the electric insulating member 10b shown in FIG.

  As shown in FIG. 17A, since the electrical insulating member 10a is not closed at the tip of the tooth 108 of the stator core 102, the coil 112 and the tip of the tooth 108 are inserted after the coil 112 is inserted into the slot. In order to ensure electrical insulation, wedge insulating paper 124 is assembled along the axial direction. According to this configuration, high assembly accuracy is required in order to avoid a short circuit due to poor assembly of the wedge insulating paper 124.

  On the other hand, as shown in FIG. 17B, the electrical insulating member 10b according to this modified example has a closed structure at the tip end portion of the tooth 108. Therefore, when the coil 112 is inserted into the slot, the coil 112 and the tooth The tip of 108 is already insulated by the electrical insulating member 10b. Therefore, according to this modified example, the process of assembling the wedge insulating paper 124 to the tip of the tooth can be omitted, so that the insulation can be ensured by a simpler process. Furthermore, since the number of parts and the number of processes are reduced with the abolition of the wedge insulating paper 124, the cost can be reduced and the productivity can be improved.

[Modification 2]
FIG. 18 is a diagram showing a second modification of the electrical insulating member according to Embodiment 1 of the present invention.

  Referring to FIG. 18, the electrical insulating member 10c according to the present modification is a cylindrical body whose side surface is closed over the entire circumference, similarly to the electrical insulating member 10b shown in FIG. And a support portion for fixing the electrical insulating member 10c in the vicinity of the opening end of the slot.

  The electrical insulating member 10c according to the present modification example further includes a plurality of groove portions 12 extending from the side surface to the support portion along the axial direction.

  Specifically, the grooves 12 are arranged in parallel at predetermined intervals on the inner peripheral side surface of the electrical insulating member 10c. These groove portions 12 are provided in the molding step shown in FIG. 13 to facilitate the flow of the resin mold material into the gap between the stator core 102 and the coil 112 when the resin mold material is injected. According to this, the flow resistance of the resin molding material is reduced with respect to the electrical insulating members 10a and 10b shown in FIGS.

  Therefore, according to this modified example, since the molding pressure during the molding process can be lowered by reducing the flow resistance of the resin molding material, the molding apparatus can be configured with a lower cost and the manufacturing cost can be reduced. be able to.

  Further, since the load applied to the coil 112 is reduced as the molding pressure is reduced, the deformation at the coil end portion is reduced, and the quality can be improved.

  Furthermore, in the evacuation performed at the beginning of the molding process, air inside the mold 210 is easily removed, so that air pools intervening in the coil 112 and the stator core 102 are avoided. This makes it difficult for voids during resin molding material injection between the coil 112 and the stator core 102 to improve thermal conductivity and insulation.

  In this modification, the groove portion 12 is arranged on the inner peripheral side surface of the electrical insulating member. However, as shown in FIGS. 19A and 19B, the outer peripheral side surface of the electrical insulating member 10c is used. The same effect can be obtained with the arrangement arranged in the above.

  As described above, according to the first embodiment of the present invention, the thermal resistance between the two can be reduced while maintaining the electrical insulation between the coil and the stator core. Further, it is possible to reduce the size of the rotating electrical machine.

  Furthermore, in the conventional stator, a plurality of molding processes, which have been performed for electrical insulation and heat dissipation, can be performed by a single molding process, so that the manufacturing cost can be greatly reduced. it can.

  Moreover, since the resin mold material fills the space between the stator core and the coil without gaps by the groove provided on the side surface of the electrical insulating member, the heat dissipation is further improved.

[Embodiment 2]
FIG. 20 shows a structure of the stator as viewed from the center of the rotating shaft of the rotating electrical machine according to the second embodiment of the present invention in the outer peripheral direction (FIG. 20A), and its AA sectional view (FIG. 20B )).

  Referring to FIG. 20A, stator 100b includes a stator core 102 and coils 112 wound around a plurality of teeth 108 of stator core 102, respectively.

  The coil 112 includes a plurality of U-shaped laminated coils 114 as in the first embodiment. As shown in FIG. 9, the laminated coil 114 is bonded to the adjacent laminated coil 114, and at one end of the laminated coil 114, the other end of the laminated coil 114 adjacent to the one end is the bus bar 110. Joined by.

  Furthermore, the coil 112 includes an electrical insulating member 20 assembled to a part of the two sides of the straight portion and the bottom side connecting the two sides.

  For example, as shown in FIG. 20A, the electrical insulating member 20 is assembled at two locations on each of the two sides of the linear portion of the coil 112, and at one location on the bottom portion and the bus bar 110. A total of six are provided for each.

  Specifically, the electrical insulation member 20 is assembled on each side of the coil 112 by assembling a resin part formed in advance by injection molding or by directly molding a resin on the coil 112. Alternatively, it can be performed by winding an insulating tape around a desired portion of the coil 112. In any of the assembling means, the electrical insulating member 20 is simplified to a substantially cylindrical shape, so that the manufacturing process is further simplified with respect to the electrical insulating members 10a to 10c according to the first embodiment. can do.

  FIG. 20B is a diagram showing an AA cross section of the stator 100b shown in FIG. As shown in FIG. 20B, electrical insulation is ensured between the teeth 108 of the stator core 102 and the coil 112 by the electrical insulation member 20. Similarly, electrical insulation between the stator core 102 and the two linear portions of the coil 112 and the bus bar 110 is ensured by the electrical insulation member 20.

  As described above, according to the present embodiment, the electrical insulating members 20a to 10c are fitted in the slots of the stator core 102 in that the electrical insulating member 20 is assembled to the coil 112 and the bus bar 110.

  On the other hand, in the present embodiment, the electrical insulating member 20 is assembled so that when the linear portion is inserted into the slot, the location is aligned with the vicinity of the opening end of the slot at the location where the coil 112 is attached to the two sides of the linear portion. In common with the first embodiment.

  Further, the space between the coil 112 and the stator core 102 is also filled with the high thermal conductive resin molding material 120 (not shown) in the entire region except for the winding portion of the electrical insulating member 20, as in the first embodiment. Common.

  Therefore, in the stator 100b according to the present embodiment, the heat generated in the coil 112 is radiated in the order of the coil 112 → the high thermal conductive resin molding material 120 → the stator core 102, as in the first embodiment. -The thermal resistance between the stator cores 102 is reduced.

  Further, in the electrical insulation between the coil 112 and the stator core 102, the coil 112 is accurately positioned with respect to the slot of the stator core 102 by the electrical insulation member 20 assembled to the coil 112, so that good insulation characteristics are ensured. can do.

  In the present embodiment, six electrical insulating members 20 are assembled to one coil 112. However, as long as insulation between the coil 112 and the stator core 102 is ensured, the total number of assembled parts is not limited.

  As for the molding process of the stator 100b, as in the first embodiment, after the coil 112 is wound around the stator core 102, the entire stator 100b can be covered with the high thermal conductive resin mold 120. In addition to this configuration, the coil 112 around which the electrical insulating member 20 is wound may be molded in advance and then wound around the stator core 102.

  FIG. 21 is a flowchart showing a stator manufacturing process in the rotary electric machine according to Embodiment 2 of the present invention.

  Referring to FIG. 21, first, electrical insulating member 20 is assembled at a desired location of coil 112 (step S11). At this time, assembling of the coil 112 with respect to the straight portion is performed such that the position of the electrical insulating member 20 is in the vicinity of both open end portions of the slot, as shown in FIG.

  Next, the coil 112 assembled with the electrical insulating member 20 is wound around each tooth 108 of the stator core 102. Specifically, after the open ends of the U-shaped coil 112 are inserted into the slots on both sides of each tooth 108, respectively, in order to ensure electrical insulation between the coil 112 and the tip of the tooth 108, The wedge insulating paper 124 is assembled along the axial direction (step S12).

  Next, one open end of the laminate coil 114 and the other open end of the adjacent laminate coil 114 are coupled by the bus bar 110 (step S13).

  Furthermore, the fitting part of the open end part of the coil 112 and the bus bar 110 is joined by welding, respectively. Finally, the stator 100b in the three-phase AC rotating electric machine is formed by connecting the coil end portions every three teeth using the cross member 106 (step S14).

  When the stator 100b is formed by the above steps S11 to S14, the entire stator 100b is subjected to a molding process. More specifically, as in the first embodiment, the stator 100 is sealed with the mold die 210 shown in FIG. 13 (step S15), the vacuum drawing gate 214 provided on the upper surface of the mold die 210 is opened, and the mold die is opened. The inside of the mold 210 is evacuated (step S16).

  Next, the molding material gate 212 provided on the lower surface of the molding die 210 is opened, and a resin molding material is injected against the direction of gravity (step S17). Thereby, the resin mold material rises while filling the space other than the coil 112 of the stator 100b with the resin. By performing heat curing in a state where the entire stator 100b is filled with resin, the molding process is completed (step S18).

  As described above, according to the second embodiment of the present invention, the thermal resistance between the two can be reduced while maintaining the electrical insulation between the coil and the stator core. And size reduction can be achieved.

  Furthermore, by adopting a configuration in which the electrical insulating member is wound around the coil, the shape can be simplified to a substantially cylindrical shape, and the manufacturing cost can be further reduced.

[Embodiment 3]
FIG. 22 is a diagram showing the stator as viewed from the center of the rotating shaft of the rotating electrical machine according to the third embodiment of the present invention in the outer peripheral direction.

  Referring to FIG. 22, stator 100 c includes a stator core 102 and coils 112 wound around a plurality of teeth 108 of stator core 102.

  The coil 112 includes a plurality of U-shaped laminated coils 114 as in the first embodiment. As shown in FIG. 9, the laminated coil 114 is bonded to the adjacent laminated coil 114, and at one end of the laminated coil 114, the other end of the laminated coil 114 adjacent to the one end is the bus bar 110. Joined by.

  Stator 100c further includes an electrical insulating member 10a disposed in the vicinity of both opening ends of each slot of stator core 102, and a high thermal conductive insulating member 30 disposed between teeth 108 and bus bar 110. A space between the stator core 102 and these insulating members is filled with a high thermal conductive resin molding material 120 (not shown) by a molding process shown in FIG.

  The electrical insulating member 10a has the structure shown in FIG. 3, and is fitted from above and below along the axial direction to the opening end of the slot. In addition to the electrical insulation member 10a shown in FIG. 2, electrical insulation members 10b and 10c shown in FIGS. 16, 18 and 19 may be employed as the electrical insulation member. Further, as shown in the second embodiment, the electrical insulating member 20 may be assembled to the coil 112 itself.

  High thermal conductivity insulating member 30 is provided between one end surface of teeth 108 in the axial direction and bus bar 110. Regarding the installation of the high heat conductive insulating member 30, first, after inserting the coil 112 into the slot, the high heat conductive insulating member 30 is disposed on one end surface of the tooth 108 on the open end side of the coil 112. Subsequently, when the bus bar 110 is joined to the open end of the coil 112, a load is applied to the bus bar 110 in the axial direction as shown by an arrow in FIG.

  Thereby, the high thermal conductive insulating member 30 is elastically deformed by receiving a load from the axial direction and fills the gap between the bus bar 110 and the stator core 102. When the bus bar 110 and the high thermal conductivity insulating member 30, and the high thermal conductivity insulating member 30 and the stator core 102 are in close contact with each other, the thermal resistance is reduced, and the heat generated in the coil 112 can be quickly conducted.

  According to the present embodiment, the heat generated in the coil 112 is generated from the coil 112 → the high thermal conductive resin mold 120 → the first heat radiation path along the circumferential direction including the stator core 102, and the coil 112 → the high thermal conductive insulating member 30 → The coil 112 can be cooled more efficiently because it is conducted by the second heat radiation path along the axial direction of the stator core 102. Therefore, the current density of the coil 112 can be further increased, and the physique of the rotating electrical machine can be further reduced.

  As described above, the high thermal conductive insulating member 30 according to the present embodiment is effective in reducing the thermal resistance between the coil 112 and the stator core 102, and in particular, a varnish treatment for applying a transparent surface film material called a varnish. The effect is remarkably exhibited in the rotating electric machine to which is applied.

  Specifically, in the rotating electric machine that has been subjected to the varnish treatment, unlike the rotating electric machine that has been subjected to the molding process, the gap between the stator core 102 and the coil 112 is not filled with the resin molding material, and a gap is formed. . The gap prevents heat generated in the coil 112 from being transmitted to the stator core 102. However, according to the present embodiment, even in such a case, since the high thermal conductive insulating member 30 connects the coil 112 and the stator core 102 with low thermal resistance, the heat of the coil 112 is efficiently transferred to the stator core 102. It can dissipate heat.

[Example of change]
FIG. 23 shows the stator as viewed from the center of the rotating shaft of the rotating electrical machine according to the modification of the third embodiment of the present invention in the outer peripheral direction.

  Referring to FIG. 23, stator 100d according to this modification is different from stator 100c shown in FIG. 22 only in that high heat conductive insulating members 30 are provided on both end surfaces of teeth 108 in the axial direction. Therefore, detailed description of overlapping parts will not be repeated.

  Specifically, the high thermal conductive insulating member 30 is provided between the bottom of the coil 112 and the teeth 108 and between the bus bar 110 and the teeth 108. The high heat conductive insulating member 30 located between the bus bar 110 and the tooth 108 is elastically deformed and installed by applying a load when the bus bar 110 is joined to the coil 112 as in FIG.

  Similarly, when the high heat conductive insulating member 30 between the bottom side of the coil 112 and the tooth 108 is inserted into the slot in a state of being attached to the bottom side of the coil 112 in advance, the load at the time of joining the bus bar 110 is reduced. And is elastically deformed and installed from the bottom.

  With this configuration, the heat generated in the coil 112 is conducted in the circumferential direction in the order of the coil 112 → the high thermal conductive resin molding material 120 → the stator core 100d, and the coil 112 → the high thermal conductive insulating member 30 → the stator core 102. In this order, conduction is performed from two directions opposite to each other in the axial direction. Therefore, heat dissipation can be further improved with respect to the structure of the stator 100c of FIG.

  Similar to FIG. 22, this effect can be obtained even in a varnished stator, and the cooling efficiency can be further improved.

  As described above, according to the third embodiment of the present invention, the heat generated in the coil is conducted through the plurality of heat radiation paths, so that the coil can be cooled more efficiently. Therefore, it is possible to further increase the current density of the coil, and it is possible to realize a rotating electrical machine capable of high load operation and physique reduction.

[Embodiment 4]
FIG. 24 shows an external appearance of the stator in the rotating electric machine according to the fourth embodiment of the present invention.

  Referring to FIG. 24, stator 100e includes a stator core 102 and coils 112 wound around a plurality of teeth 108 of stator core 102, respectively.

  In the slots (for example, 146 and 148) formed on both sides of the teeth 108, the electrical insulating member 10a is fitted to both opening ends as in the first embodiment. In this state, the straight portion of the coil 112 is inserted into each slot.

  The coil 112 includes a plurality of U-shaped laminated coils 114. As shown in FIG. 9, the laminated coil 114 is bonded to the adjacent laminated coil 114, and at one end of the laminated coil 114, the other end of the laminated coil 114 adjacent to the one end is the bus bar 110. Joined by.

  Stator 100e according to the present embodiment differs from stator 100a according to Embodiment 1 in the shape of coil 112. Specifically, as shown in FIG. 24, the coil 112 is configured such that its coil end portion has a fin shape. As shown below, this fin shape is formed by adjoining laminated coils 114 having different lengths in the axial direction.

  FIG. 25A is a diagram showing the stator 100e viewed from the center of the rotating shaft of the rotating electrical machine according to the fourth embodiment in the outer peripheral direction, and FIG. 25B is a cross-sectional view taken along the line AA in FIG. FIG.

  Referring to FIG. 25A, electrical insulation member 10a shown in FIG. 3 is fitted into stator core 102 at both open ends of each slot, and coil 112 is inserted into each slot on both sides of teeth 108. The In addition to the electrical insulation member 10a shown in FIG. 3, electrical insulation members 10b and 10c shown in FIGS. 16, 18, and 19 may be employed as the electrical insulation member. Further, as shown in the second embodiment, the electrical insulating member 20 may be assembled to the coil 112 itself.

  The coil 112 includes a plurality of U-shaped laminated coils 114 as in the first embodiment. At the open end of laminated coil 114, one end and the other end of laminated coil 114 adjacent to each other are joined by bus bar 110, respectively. A high thermal conductive resin mold is filled between the coil 112 and the stator core 102 by the molding process shown in FIG.

  As described above, the coil 112 is characterized by the shape of the coil end CE portion. Specifically, as shown in FIG. 25B, the length of the multilayer coil 114 is different from that of the adjacent multilayer coil 114 in the axial direction. By laminating a plurality of the laminate coils 114, a fin shape as shown in FIG. 25B is formed.

  Thus, according to this Embodiment, the effect mentioned below can be acquired by making coil end part CE into fin shape.

  1stly, when the thermal radiation area in the coil end part CE increases, the heat which generate | occur | produced in the coil 112 can be efficiently escaped from the coil end part CE. When the stator 100e is covered with the resin mold material, the heat generated in the coil 112 is conducted from the coil end portion CE to the mold material. On the other hand, when the stator 100e is directly air-cooled or oil-cooled without using a molding material, the heat generated in the coil 112 is conducted from the coil end portion CE to air or oil.

  Here, when comparing the rotating electrical machine according to the present embodiment and a conventional rotating electrical machine in which a metal conductor is wound around a stator core to form a coil, the conventional rotating electrical machine has a coil end portion densely packed with metal conducting wires. Since it has a shape, it is disadvantageous in terms of heat dissipation, because individual metal conductors are hard to touch air or the like, and heat is easily trapped. On the other hand, in the rotating electrical machine according to the present embodiment, the coil end portion CE can be easily formed into a fin shape by changing the lengths of the individual axial directions of the laminated body coil 114. It is advantageous in terms of ease.

  Second, the amount of heat generated by the coil 112 can be suppressed by making the coil end portion CE into a fin shape. Specifically, the fin shape increases the conductor cross-sectional area of the bottom portion of the multilayer coil 114 forming the coil end portion CE, and decreases the electrical resistance of the bottom portion of the multilayer coil 114. Thereby, the electrical resistance of the coil 112 as a whole is also reduced. In general, the amount of heat generated by the coil 112 is represented by the product of the square of the current amount, the electrical resistance, and the energization time. Therefore, the amount of heat generated by the coil 112 is suppressed by reducing the electrical resistance of the coil 112.

  Third, the physique of the rotating electrical machine can be reduced by the synergistic action of the first and second effects. That is, by increasing the heat radiation amount from the coil 112 and suppressing the heat generation amount of the coil 112 itself, the allowable value of the current density that can be passed through the coil 112 can be increased.

  In general, if the current density of the coil 112 is increased, the magnetomotive force generated in the stator 100e increases, so that the radial thickness of the stator core 102 required to generate the same amount of torque can be reduced, and the physique of the rotating electrical machine can be reduced. Can be small. On the other hand, since the amount of heat generated by the coil 112 increases as the current density increases, the temperature of the components of the rotating electrical machine exceeds the heat resistance temperature, and there is a risk of burning.

  However, according to the present embodiment, since the heat radiation amount of the coil 112 is increased and the heat generation amount itself can be suppressed, the current density of the coil 112 can be increased. As a result, the size of the rotating electrical machine can be reduced.

  FIG. 26 is a diagram showing a comparison of current densities in the rotating electrical machine according to the present embodiment, the conventional rotating electrical machine, and the rotating electrical machine according to the first embodiment.

  In FIG. 26, as the conventional rotary electric machine, the coil is composed of a round metal conductor coated with enamel insulation coating and varnished, and the coil is a round metal conductor coated with enamel insulation coating. As a representative example, a material that has been configured and processed by molding is given. Further, the rotating electrical machine according to the first embodiment and the rotating electrical machine according to the present embodiment both use the laminated body coil 114, and are different only in the shape of the coil end portion CE.

  As is clear from FIG. 26, the rotating electrical machine according to the present invention shows a significant improvement in the current density increase rate compared to the conventional rotating electrical machine. Specifically, the rotating electrical machine according to the first embodiment is approximately 1.4 times the conventional ratio, and the rotating electrical machine according to the fourth embodiment is further improved, resulting in an increase of approximately 1.5 times the conventional ratio. It is done.

  As described above, since the current density is significantly increased, the rotating electrical machine according to the present invention can significantly reduce the size of the conventional rotating electrical machine. This is because the use of the laminated coil 114 for the coil 112 improves the space factor of the coil 112 in the slot, and in addition, the heat insulation between the coil 112 and the stator core 102 is achieved by an insulating structure unique to the present invention. This is because the resistance is reduced.

  Furthermore, according to the present embodiment, since the coil end portion CE has a fin shape, the heat dissipation of the coil 112 is improved and the amount of generated heat is suppressed, so that a further compact rotating electrical machine is realized.

  Even when the edgewise type coil shown in FIG. 15 is applied to the coil 112, the coil end portion is formed into a fin shape by arranging adjacent bent portions so as to be shifted from each other between adjacent windings. be able to.

  Furthermore, the above effect can be obtained not only by the configuration according to the present embodiment in which the coil end portion CE of the coil 112 is fin-shaped, but also by configuring the bus bar 110 to be fin-shaped.

  FIG. 27A shows a structure of bus bar 110 in the rotating electrical machine according to the modification of the fourth embodiment. FIG. 27B shows a cross section taken along the line AA in FIG.

  Referring to FIG. 27A, a plurality of bus bars 110 are arranged in parallel so that open ends of a plurality of laminated coils (not shown) are coupled to each other. At this time, as shown in FIG. 27 (B), the bus bar 110 is characterized in that it is configured so that the adjacent bus bars 110 have different axial lengths. Thereby, the fin-shaped bus bar 110 is formed.

  As described above, according to the fourth embodiment of the present invention, the coil end portion is formed into a fin shape, whereby the current density of the coil can be increased and the physique of the rotating electrical machine can be further reduced. .

[Embodiment 5]
FIG. 28 is a cross sectional view showing the structure of the rotating electrical machine according to the fifth embodiment of the present invention.

  Referring to FIG. 28, the rotating electric machine includes a rotor 101, a stator 100a, and a case 150 in which the rotor 101 and the stator 100 are accommodated in an integrated manner.

  The rotor 101 is accommodated in the case 150 so as to be rotatable via a rotation shaft (not shown).

  The stator 100 a is fixedly accommodated inside the case 150 so as to surround the outer periphery of the rotor 101 in order to control the rotation of the rotor 101. Stator 100a has the structure shown in FIG. 1 of the first embodiment, and includes a coil 112 and a stator core 102.

  The stator core 102 has the same structure as the stator core 102 according to the first embodiment, and a coil 112 is wound around each of the teeth 108 and fixed thereto.

  The coil 112 has the same structure as that of the coil 112 according to the first embodiment, and is configured by a U-shaped laminated body coil 114. Note that the detailed structure of the stator core 102 and the coil 112 is the same as that in FIGS. 6 to 12, and thus the description thereof is omitted in the present embodiment.

  Case 150 has a cylindrical side surface for accommodating annular stator 100, and a stepped portion is formed on the side close to the bottom of the side surface. In the case 150, the stator core 102 is fastened by a bolt 152 having one end face in the axial direction supported by a stepped portion and the other end face passed through a screw hole disposed on the outer periphery of the stator core 102. Thus, the stator core 102 is fixed to the case 150 by bolting in the axial direction.

  The rotating electrical machine further includes a high thermal conductive insulating member 40 disposed between one axial end surface of the coil 112 wound around the stator core 102 and the bottom surface on the inner peripheral side of the case 150.

  As shown in FIG. 28, when the high heat conductive insulating member 40 is disposed between the bottom surface of the case 150 and the end surface of the coil 112, the high heat conductive insulating member 40 is elastically deformed by receiving a fastening load generated in the axial direction at the time of bolt fastening. Thereby, the coil, the high thermal conductivity insulating member, and the high thermal conductivity insulating member and the case 150 are in close contact with each other on the contact surfaces.

  With this configuration, the heat generated in the coil 112 is conducted to the stator core 102 via the high thermal conductive resin mold 120 (not shown) and also conducted to the case 150 via the high thermal conductive insulating member 40. Will be. At this time, since the coil 112 and the high thermal conductive insulating member 40 and the high thermal conductive insulating member 40 and the case 150 are in close contact with each other, both can be configured with low thermal resistance, and good thermal conductivity is obtained. can get.

  According to the present embodiment, as a heat dissipation path for heat generated in the coil 112, a path for heat conduction from the coil 112 to the case 150 is provided in addition to a path for heat conduction from the coil 112 to the stator core 102. Therefore, higher heat dissipation can be obtained. As a result, the current density of the coil 112 can be further increased, so that the physique of the rotating electrical machine can be further reduced.

  In addition, about the structure which provides a thermal radiation path | route between the coil 112 and the case 150 of the stator 100a in a rotary electric machine, it can implement | achieve also by the structure which concerns on the following modified examples.

[Modification 1]
FIG. 29 is a cross sectional view showing the structure of the rotating electric machine according to the first modification of the fifth embodiment of the present invention.

  Referring to FIG. 29, the rotating electrical machine includes a rotor 101, a stator 100a, a case 150 in which the rotor 101 and the stator 100a are integrated and accommodated, a high thermal conductive insulating member 40, an elastic member 156, and an elastic member holder. 154.

  The rotating electrical machine according to this modified example has basically the same structure as the rotating electrical machine shown in FIG. 28, and is different in that an elastic member 156 and an elastic member holder 154 are added. Therefore, in this modified example, only this difference will be described, and detailed description of common parts will not be repeated. Note that the high thermal conductive insulating member 40 is disposed between the coil 112 and the case 150 as in FIG.

  The elastic member holder 154 is disposed on one end surface of the stator core 102 in the axial direction, and is fixed to the case integrally with the stator core by a bolt 152.

  The elastic member 156 is configured by a disc spring, for example, and is disposed between the elastic member holder 154 and the coil 112. The elastic member 156 generates an axial elastic force according to the stress from the elastic member holder 154, as will be described later.

  In the above configuration, when the stator core 102 is fixed to the case 150 by bolt fastening, a fastening load is applied to the stator core 102. At this time, the stator member 102 is joined to the elastic member holder 154 in the axial direction by the elastic member holder 154 being joined in the axial direction. This fastening load acts on the elastic member 156 via the elastic member holder 154.

  When the elastic member 156 receives a fastening load through the elastic member holder 154, its shape is deformed in the axial direction. Further, according to this deformation, an elastic force is generated in the elastic member 156 to return to the original shape in the axial direction and in the direction opposite to the fastening load. This elastic force acts on the coil 112 in contact with the elastic member 156 in the axial direction.

  When the coil 112 receives an elastic force in the axial direction from the elastic member 156, the coil 112 is in a state of being pressed against the case 150. At this time, the high thermal conductive insulating member 40 interposed between the coil 112 and the case 150 is elastically deformed in accordance with the surface pressure in the axial direction. Thereby, the coil 112 and the high heat conductive insulating member 40, and the high heat conductive insulating member 40 and the case 150 are in close contact with each other.

  In the above configuration, the heat generated in the coil 112 is conducted to the stator core 102 through the high thermal conductive resin mold 120 (not shown) filled between the coil 112 and the stator core 102 as in the case of FIG. Then, it is also conducted to the case 150 through the high thermal conductive insulating member 40. At this time, since the coil 112 and the high thermal conductive insulating member 40 and the high thermal conductive insulating member 40 and the case 150 are in close contact with each other, both can be configured with low thermal resistance, and good thermal conductivity is obtained. can get.

[Modification 2]
FIG. 30 is a cross sectional view showing the structure of the rotating electrical machine according to the second modification of the fifth embodiment of the present invention.

  Referring to FIG. 30, the rotating electrical machine includes a rotor 101, a stator 100 a (including a stator core 102 and a coil 112), a case 150 in which the rotor 101 and the stator 100 a are integrally accommodated, and a high thermal conductivity insulating member 40. And a water jacket 158.

  The rotating electrical machine according to this modified example has basically the same structure as the rotating electrical machine shown in FIG. 28, and a high thermal conductive insulating member 40 is disposed between the coil 112 and the case 150, as in FIG. The Therefore, also in this modified example, a heat dissipation path is formed between the coil 112 and the case 150 by elastically deforming the high thermal conductive elastic member 40 by the fastening load when the stator core 102 is bolted to the case 150.

  Further, in the rotating electrical machine according to this modification, a water jacket 158 is installed on the surface of the case 150 as a cooling means. Specifically, the water jacket 158 has a structure in which the water jacket 158 enters the inside from the surface of the case 150, and forms a refrigerant passage for circulating the refrigerant (cooling water) inside the case 150. The case 150 is cooled by circulating the refrigerant in the refrigerant passage with an electric pump (not shown) via a radiator (not shown) or the like.

  In this modified example, when the case 150 is cooled by this cooling structure, a large temperature difference is generated between the coil 112 and the case 150. Thereby, the heat generated in the coil 112 is easily radiated to the case 150 via the high thermal conductive insulating member 40, and the cooling efficiency can be further increased with respect to the rotating electrical machine of FIG.

  As described above, according to the fifth embodiment of the present invention, the heat generated in the coil is radiated to the stator core through the high thermal conductive resin mold filled between the coil and the stator core, and the high thermal conductive insulating member is used. Since heat is also radiated through the case, higher heat dissipation can be obtained. Thereby, the current density of the coil can be further increased, and the physique of the rotating electrical machine can be further reduced.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  The present invention can be applied to a rotating electrical machine and a vehicle equipped with the rotating electrical machine as a power source.

It is a figure which shows the external appearance of the rotary electric machine according to Embodiment 1 of this invention. It is a figure which shows the detail of the stator core in the stator of FIG. It is a figure which shows an example of a structure of the electrical insulation member shown in FIG. It is a figure explaining the heat dissipation path between a coil and a stator core. It is a figure which shows the cross-section of the AA cross section in FIG. 4 (A). It is a figure which shows the assembly | attachment progress of the coil inserted in a stator core. It is a figure which shows the external appearance of the coil shown in FIG. It is a figure which shows the assembly | attachment progress of the coil inserted in a stator core. It is a figure which shows the external appearance of the coil by which the bus bar was assembled | attached. It is a figure which shows the external appearance of the coil by which the bus-bar positioning block to which a some bus bar is fixed is assembled | attached. It is a figure which shows progress of assembling a bridge member to a coil edge part. It is a figure which shows the external appearance of the stator which performed the mold process. It is a figure for demonstrating the molding process given to the stator which concerns on Embodiment 1 of this invention. It is a flowchart for demonstrating the manufacturing process of the stator in the rotary electric machine by Embodiment 1 of this invention. It is a figure which shows the other structural example of the coil in the stator which concerns on Embodiment 1 of this invention. It is a figure which shows the 1st modification of the electrical insulation member which concerns on Embodiment 1 of this invention. It is a figure which shows the insulation structure by the electrical insulation member which concerns on Embodiment 1 of this invention. It is a figure which shows the 2nd modification of the electrical insulation member which concerns on Embodiment 1 of this invention. It is a figure which shows the other structural example of the 2nd modification of the electrical insulation member which concerns on Embodiment 1 of this invention. FIG. 20A shows the structure of the stator viewed from the center of the rotating shaft of the rotating electrical machine according to the second embodiment of the present invention in the outer circumferential direction (FIG. 20A), and FIG. is there. It is a flowchart which shows the manufacturing process of the stator in the rotary electric machine which concerns on Embodiment 2 of this invention. It is a figure which shows the stator seen from the center of the rotating shaft of the rotary electric machine according to Embodiment 3 of this invention to the outer peripheral direction. It is a figure which shows the stator seen from the center of the rotating shaft of the rotary electric machine according to the modification of Embodiment 3 of this invention to the outer peripheral direction. It is a figure which shows the external appearance of the stator in the rotary electric machine according to Embodiment 4 of this invention. The figure (FIG. 25 (A)) which shows the stator seen from the center of the rotating shaft of the rotary electric machine which concerns on Embodiment 4 of this invention to the outer peripheral direction, and the figure which shows the AA cross section of FIG. 25 (A) (FIG. 25) (B)). It is a figure which shows and compares the current density in the rotary electric machine which concerns on this Embodiment, the conventional rotary electric machine, and the rotary electric machine which concerns on Embodiment 1. FIG. The figure (FIG. 27 (A)) which shows the structure of the bus bar in the rotary electric machine according to the modification of Embodiment 4 of this invention, The figure (FIG. 27 (B)) which shows the AA cross section of FIG. 27 (A), It is. It is sectional drawing which shows the structure of the rotary electric machine according to Embodiment 5 of this invention. It is sectional drawing which shows the structure of the rotary electric machine according to the 1st modification of Embodiment 5 of this invention. It is sectional drawing which shows the structure of the rotary electric machine according to the 2nd modification of Embodiment 5 of this invention.

Explanation of symbols

  10a to 10c Electrical insulating member, 12 Groove, 20 Electrical insulating member, 30 High thermal conductive insulating member, 40 High thermal conductive elastic member, 100a to 100e Stator, 101 Rotor, 102 Stator core, 104 Bus bar positioning block, 106 Cross member, 108 teeth, 110 Busbar, 112 Coil, 114 Laminated Coil, 120 High Thermal Conductive Resin Mold Material, 122 Electrical Insulating Member, 124 Wedge Insulating Paper, 134, 136, 138, 140, 142, 144 Coil End, 146, 148 Slot, 150 Case , 152 bolt, 154 elastic member holder, 156 elastic member, 158 water jacket, 200 mold material tank, 210 mold metal mold, 212 mold material gate, 214 vacuuming gate, CE coil en Department.

Claims (16)

A rotor,
A stator fixed to the outer periphery of the rotor,
The stator is
A stator core in which a plurality of slots each extending in the direction of the rotation axis of the rotor are annularly arranged;
A coil made of a laminated conductor wound around a plurality of teeth respectively formed between adjacent slots;
A first electrical insulating member disposed in a partial region of a gap having a predetermined interval provided between the stator core and the coil;
Arranged so as to close the gap, seen including a sealing member having thermal conductivity,
A part of the gap is a rotating electric machine that is only a region in the vicinity of both opening ends of each of the plurality of slots in the rotation axis direction of the rotor .   The rotating electrical machine according to claim 1, wherein the sealing member has a higher thermal conductivity than the first electrical insulating member.   The rotating electrical machine according to claim 1 or 2, wherein the predetermined interval is a distance necessary for electrically insulating the stator core and the coil. The first electrical insulating member is
A cylindrical portion extending in the rotational axis direction of the rotor and having an end surface having substantially the same shape as the opening end portion of the slot;
A support portion disposed on the outer peripheral side of the one end surface of the cylindrical portion, and for fixing the cylindrical portion;
2. The rotating electrical machine according to claim 1 , wherein the rotating electrical machine is fitted into each of the opening end portions of the slot with the other end surface of the cylindrical portion as a head. The rotating electrical machine according to claim 4 , wherein the cylindrical portion is closed at a portion corresponding to a tip portion of the tooth on the end surface. The cylindrical portion, the rotation axis direction of the length of the rotor is shorter than the length of the rotational axis of the rotor of the slot, the rotating electrical machine according to claim 4 or 5. The rotating electrical machine according to claim 6 , wherein the cylindrical portion has a length in a rotation axis direction of the rotor that is necessary and sufficient to hold the gap at the predetermined interval. The first electrical insulating member is
Arranged on at least one surface of the inner and outer surfaces of the tubular portion and the support portion, each further comprises a plurality of grooves extending in the direction of the rotation axis of the rotor, to any one of claims 4 to 7 of the The rotating electrical machine described. The first electrical insulating member includes a cylindrical body that can be wound around an arbitrary portion of the coil, and when the coil is wound around the plurality of teeth, the winding portion is a part of the gap. The rotating electrical machine according to claim 1 , wherein the rotating electrical machine is wound around the coil so as to be a region. The stator is
The rotation axis direction of the at least one end face of the rotor of the stator core and are arranged so as to close the gap between the coils, further comprising a second electrically insulating member having a thermal conductivity, claims 1-9 The rotating electrical machine according to any one of the above. The second electrical insulating member is elastically deformed according to a load applied in the rotation axis direction of the rotor, so that at least one end surface of the stator core in the rotation axis direction of the stator core is between the coil and the coil. closing the gap rotary electric machine according to claim 1 0. The coil is
A plurality of laminated flat conductors each having an open end that can be wound around the teeth and arranged in the radial direction of the rotor;
And one of said open ends of each of said plurality of laminated flat conductor, for coupling the other of said open end of the adjacent laminated flat conductor each include a plurality of bus bars, to any one of claims 1 to 1 1 of 1 The rotating electrical machine according to the item . Each of said plurality of laminated flat conductor, the rotation axis direction of the length of the rotor is different from each other between the adjacent laminated flat conductor, the electric rotating machine according to claim 1 2. Each of said plurality of bus bars, the rotational direction of the length of the rotor is different from each other between the adjacent bus, rotating electrical machine according to claim 1 3. The rotating electrical machine according to any one of claims 1 to 11, wherein the coil is an edgewise coil that bends a strip of a flat conductor in a width direction of the strip. The coil is
A first bent portion subjected to the bending;
A second bending portion arranged next to the coil bending direction of the first bending portion,
The first bent portion and the position of the inner portion of the second bending portion are arranged to be shifted from each other in the planar direction of the flat conductor, the electric rotating machine according to claim 1 5.

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