JP6905997B2 - Stator of rotary electric machine and rotary electric machine using it - Google Patents

Description

The present invention relates to a stator of a rotary electric machine and a rotary electric machine using the stator, and more particularly to a rotary electric machine that generates a driving force of a vehicle.

The rotary electric machine includes a stator. This stator consists of a stator core with multiple slots, a stator coil placed in the slot, and a slot liner molded with an insulating sheet to ensure insulation between the stator core and the coil. have.

Here, the slot liner is formed so as to wrap the side surface of the stator coil in the slot. Further, the slot liner is formed so as to project from the slot by a predetermined length so as to cover the stator coil from the slot to the rising portion.

In recent years, in rotary electric machines used in electric vehicles and hybrid electric vehicles, high voltage for high output and high efficiency (for example, 650 Vdc by boosting) and low coil end for miniaturization (for example, 650 Vdc by boosting) The tendency of miniaturization) is increasing. Due to the sharpening of the bending angle of the coil rise with respect to the end face of the stator core due to this reduction in coil end, there is an increasing demand for prevention of tearing at the protruding portion from the slot of the slot liner. By preventing the slot liner from breaking, the insulation function of the high-voltage rotating electric machine can be improved.

As a measure for suppressing the tearing of the slot liner, for example, Japanese Patent Application Laid-Open No. 2014-10039 has a stator core provided with a plurality of slots and a stator coil provided in each of the slots. Is provided with N (where N is a positive even number) segment conductors. The stator coil is configured by connecting a plurality of the segment conductors via a welded portion provided at the conductor end of each segment conductor, and the conductor end is circumferential at one coil end in the axial direction. Slots in a stator of a rotating electric machine, which are arranged in an annular shape in the direction to form an N-row annular row, and in which an insulating member is annularly interposed between at least a pair of the annular rows at one coil end in the axial direction. When the amount of protrusion from the stator end face of the liner is H mm and the distance from the stator end face of the coil bending start portion is L mm, H and L have a relationship of H ≧ L ≧ H / 2. There is a stator of a rotating electric machine.

When the stator coils are connected via welds provided at the ends of a plurality of segment conductors arranged radially in the slot, if only the insulation between the iron core and the segment conductors is sufficient. However, it is necessary to ensure the insulating property in the adjacent portion between the segment conductors.

Therefore, the slot liner has a B-shaped or S-shaped cross-sectional shape, etc., and has a shape that wraps around the entire side surface of each segment conductor, or between segment conductors whose adjacent current and voltage waveforms are different phases (eg, UVW in the case of three-phase AC). Considering only the insulation between the phases UV, VW, and WU), the shape is such that the segment conductors (U phase, V phase, W phase in the case of three-phase AC) whose current and voltage waveforms are in phase are wrapped as a mass. Sometimes.

Japanese Unexamined Patent Publication No. 2014-100039

An object of the present invention is a shape that wraps the entire side surface of each segment conductor, such as a B-shaped or S-shaped cross-sectional shape for high voltage, or a shape that wraps in-phase segment conductors as a mass. It is to maintain the insulation property by suppressing the breakage of the slot liner due to the lowering of the coil end, while satisfying the sufficient insulation property against the increase in voltage for the stator of the rotary electric machine having the slot liner.

The stator of the rotary electric machine according to the present invention insulates a plurality of segment coils arranged in the radial direction, a stator core forming a slot for accommodating the segment coil, and the plurality of segment coils and the stator core. A single insulating sheet having a bent portion is provided, and the insulating sheet is arranged so as to cover the entire side surface of the plurality of segment coils, and a part of each of the plurality of segment coils and a part of each of the plurality of segment coils. the insulating part of the sheet projects axially vertically from said slot, said upper and lower ends of the axial direction projecting from the slots in the insulating sheet, on the side closer to the bending direction in the circumferential direction of the segment coil A recess is formed so as to leave a part of a portion protruding from the slot toward the stator core, and a convex portion formed higher than the recess is formed in the radially opposed space of the plurality of segment coils. Will be done.

According to the present invention, deterioration of the insulating function of the rotary electric machine can be suppressed.

It is sectional drawing of the rotary electric machine seen from the direction perpendicular to the plane passing through a shaft 5. The upper figure is an external perspective view of the stator of a rotary electric machine, and the lower figure is a cross-sectional view of a plane crossing the axial direction as viewed from the axial direction. The upper figure is a side enlarged view of the upper coil end which is a part of the coil 2 protruding from the stator core 3 in the upper figure of FIG. 2, and the lower figure is a side enlarged view of the lower coil end in the upper figure of FIG. be. The upper left figure is an enlarged perspective view near the coil end, the upper right figure is an enlarged cross-sectional perspective view near the coil end, the lower left figure is the slot liner 9 before bending molding, and the lower right figure is the slot liner 9 after bending molding. Is. The figure on the left is the slot liner 92 before bending and molding according to another embodiment, and the figure on the right is the slot liner 92 after bending and molding according to another embodiment. The upper left figure is an enlarged perspective view of the vicinity of the coil end according to the other embodiment, the upper right figure is an enlarged cross-sectional perspective view of the vicinity of the coil end according to the other embodiment, and the lower left figure is a bending molding according to the other embodiment. The front slot liner 93, and the lower right figure is the slot liner 93 after bending molding according to another embodiment. The upper left figure is an enlarged perspective view of the vicinity of the coil end according to the other embodiment, the upper right figure is an enlarged cross-sectional perspective view of the vicinity of the coil end according to the other embodiment, and the lower left figure is a bending molding according to the other embodiment. The front slot liner 94, and the lower right figure is the slot liner 94 after bending molding according to another embodiment. FIG. 5 is a cross-sectional view of a plane crossing the axial direction according to another embodiment as viewed from the axial direction. The upper left figure is an enlarged perspective view of the vicinity of the coil end according to the other embodiment, the upper right figure is an enlarged cross-sectional perspective view of the vicinity of the coil end according to the other embodiment, and the lower left figure is a bending molding according to the other embodiment. The front slot liner 95, and the lower right figure is the slot liner 95 after bending molding according to another embodiment. The figure on the left is the slot liner 96 before bending and molding according to another embodiment, and the figure on the right is the slot liner 96 after bending and molding according to another embodiment. The upper left figure is an enlarged perspective view of the vicinity of the coil end according to the other embodiment, the upper right figure is an enlarged cross-sectional perspective view of the vicinity of the coil end according to the other embodiment, and the lower left figure is a bending molding according to the other embodiment. The front slot liner 97, and the lower right figure is the slot liner 97 after bending molding according to another embodiment. The upper left figure is an enlarged perspective view of the vicinity of the coil end according to the other embodiment, the upper right figure is an enlarged cross-sectional perspective view of the vicinity of the coil end according to the other embodiment, and the lower left figure is a bending molding according to the other embodiment. The front slot liner 98, and the lower right figure is the slot liner 98 after bending molding according to another embodiment.

Hereinafter, embodiments will be described with reference to the drawings.

FIG. 1 is a cross-sectional view of a rotary electric machine viewed from a direction perpendicular to a plane passing through the shaft 5.

As shown in FIG. 1, inside the housing 1 of the rotary electric machine, a stator having a stator core 3 around which a coil 2 is wound and a rotor having a rotor core 4 and a shaft 5 are provided. Be done. The housing 1 of the shaft 5 is fixed via the bearing 6.

In FIG. 2, the upper figure is an external perspective view of a stator of a rotary electric machine, and the lower figure is a cross-sectional view of a plane crossing the axial direction as viewed from the axial direction.

The stator core 3 forms a plurality of slots 7 formed along the axial direction. A segment conductor 8 and a slot liner 9 are arranged in the slot 7. A plurality of segment conductors 8 are provided, and the coil 2 is formed by connecting each of the segment conductors 8. In one slot 7, eight segment conductors 8 are arranged in a radial direction.

The slot liner 9 insulates between the segment conductor 8 and the stator core 3. The slot liner 9 is formed by bending, for example, one insulating sheet. Further, the slot liner 9 has a shape that covers the entire side surface of each of the segment conductors 8 in order to improve the insulation performance between the adjacent segment conductors 8. This expands the possibility that rotary electric machines can be applied to high voltage.

In FIG. 3, the upper figure is an enlarged side view of the upper coil end, which is a portion of the coil 2 protruding from the stator core 3 in the upper figure of FIG. In FIG. 3, the lower figure is an enlarged side view of the lower coil end in the upper figure of FIG.

The protruding portion 12 is a portion where the slot liner 9 protrudes from the end surface 10 of the stator core 3. The bent portion 13 is a portion that is bent after the segment conductor 8 protrudes from the slot 7.

The angle between the end face 10 of the stator core 3 and the segment conductor 8 is defined as the rising angle 11. When the height of the coil end of the coil 2 in the axial direction is lowered, the rising angle 11 is sharpened. As a result, the protruding portion 12 of the slot liner 9 has a large interference with the bent portion 13 of the segment conductor 8.

As a result, it is necessary to take measures against tearing due to interference in the protruding portion 12 of the slot liner 9. There is a risk of tearing and extension due to external force. This measure becomes even more important because it is necessary to improve the insulation function against high voltage. Therefore, it is necessary to find a shape of a slot liner that satisfies sufficient insulation for high voltage and low coil end.

In FIG. 4, the upper left figure is an enlarged perspective view near the coil end, the upper right figure is an enlarged cross-sectional perspective view near the coil end, the lower left figure is the slot liner 9 before bending molding, and the lower right figure is after bending molding. Slot liner 9 of.

At the end of the protruding portion 12 of the slot liner 9, a convex portion 14 is formed between the segment conductors 8 adjacent in the radial direction to ensure the insulating property between the segment conductors 8. On the other hand, by suppressing the interference between the conductor segments 8 in the bending direction side of the conductor segments 8 by molding the recess 15 is lower than the convex portion 14 to suppress the tear.

Further, R is provided at a corner portion which is a boundary between the convex portion 14 and the concave portion 15 to relax stress when an external force is applied. In particular, the R of the corner portion forming the recess 15 is formed larger than the R of the other corner portion of the slot liner 9. In the present embodiment, the case where the cross-sectional shape of the slot liner 9 is B-shaped is shown, the recess 15 is formed only on the bending direction side of the segment conductor 8, and the side opposite to the bending direction and adjacent to each other of the segment conductor 8. It has an unmolded shape on the side surface that is not formed.

In FIG. 5, the left figure is the slot liner 92 before the bending molding according to the other embodiment, and the right figure is the slot liner 92 after the bending molding according to the other embodiment.

In the present embodiment, the cross-sectional shape of the slot liner 92 is S-shaped. Even when the cross-sectional shape of the slot liner 92 is S-shaped, as shown in FIG. 5, one insulating sheet can be bent and formed, and the segment conductor is formed at the protruding portion 12 of the slot liner 9. It is possible to suppress tearing while satisfying the insulation between the eight.

In FIG. 6, the upper left view is an enlarged perspective view of the vicinity of the coil end according to the other embodiment, the upper right view is an enlarged cross-sectional perspective view of the vicinity of the coil end according to the other embodiment, and the lower left figure is the enlarged perspective view of the vicinity of the coil end according to the other embodiment. The slot liner 93 before bending and molding according to the above, and the lower right figure is a slot liner 93 after bending and molding according to another embodiment.

In the present embodiment, the recess 15 is formed not only on the bending direction side of the segment conductor 8 but also on the side opposite to the bending direction. In this case as well, as shown in FIG. 6, one insulating sheet can be bent and formed, and the protruding portion 12 of the slot liner 93 can be torn while satisfying the insulating property between the segment conductors 8. It can be suppressed.

In FIG. 7, the upper left view is an enlarged perspective view of the vicinity of the coil end according to the other embodiment, the upper right view is an enlarged cross-sectional perspective view of the vicinity of the coil end according to the other embodiment, and the lower left figure is the enlarged perspective view of the vicinity of the coil end according to the other embodiment. The slot liner 94 before bending and molding according to the above, and the lower right figure is a slot liner 94 after bending and molding according to another embodiment.

In the present embodiment, in addition to the above-described embodiment, the recess 15 is also formed on the side surface side of the segment conductor 8 which is not adjacent to each other. In this case, as shown in FIG. 7, one insulating sheet can be bent and formed, and the protruding portion 12 of the slot liner 9 suppresses tearing while satisfying the insulating property between the segment conductors 8. It is possible to do.

In the above-described embodiment, the slot liner 9 has a shape that surrounds the entire side surface of each segment conductor 8. FIG. 8 is a cross-sectional view of a plane crossing the axial direction according to another embodiment as viewed from the axial direction. In FIG. 9, the upper left view is an enlarged perspective view of the vicinity of the coil end according to the other embodiment, the upper right view is an enlarged sectional perspective view of the vicinity of the coil end according to the other embodiment, and the lower left figure is the enlarged perspective view of the vicinity of the coil end according to the other embodiment. The slot liner 95 before bending and molding according to the above, and the lower right figure is a slot liner 95 after bending and molding according to another embodiment.

In the embodiment shown in FIG. 8, only the insulation between the segment conductors 8 having adjacent current-voltage waveforms between different phases (eg, in the case of three-phase AC, between UVs, VWs, and WUs of the UVW phase) is considered. A case where the current-voltage waveform has a shape that encloses the segment conductors 8 of the same phase (in the case of three-phase AC, U-phase, V-phase, and W-phase) as a mass will be described.

Similarly, in the case where the segment conductors having the same phase are wrapped as a mass, as shown in FIG. 9, one insulating sheet can be bent and formed, and at the end of the protruding portion 12 of the slot liner 95, It is possible to suppress tearing while satisfying the insulating property between the segment conductors 6.

In the present embodiment, as in the embodiment shown in FIGS. 1 to 4, a case where the cross-sectional shape of the slot liner 9 is a B shape is shown, and the recess 15 is formed only on the bending direction side of the segment conductor 8. However, an unformed shape is shown on the side opposite to the bending direction and on the side surface side of the segment conductor 8 which is not adjacent to each other.

In FIG. 10, the left figure is the slot liner 96 before bending molding according to another embodiment, and the right figure is the slot liner 96 after bending molding according to another embodiment.

In the present embodiment, similarly to the embodiment shown in FIGS. 8 and 9, the shape is such that the in-phase segment conductor 8 is wrapped as a mass. On the other hand, the slot liner 96 has an S-shaped cross section. In the protruding portion 12 of the slot liner 9, it is possible to suppress tearing while satisfying the insulating property between the segment conductors 8.

In FIG. 11, the upper left view is an enlarged perspective view of the vicinity of the coil end according to the other embodiment, the upper right view is an enlarged cross-sectional perspective view of the vicinity of the coil end according to the other embodiment, and the lower left figure is the enlarged perspective view of the vicinity of the coil end according to the other embodiment. The slot liner 97 before bending and molding according to the above, and the lower right figure is a slot liner 97 after bending and molding according to another embodiment.

In the present embodiment, the recess 15 is formed not only on the bending direction side of the segment conductor 8 but also on the side opposite to the bending direction.

Similarly, when the recess 15 is formed not only on the bending direction side of the segment conductor 8 but also on the side opposite to the bending direction, one insulating sheet can be bent and formed, and the protruding portion 12 of the slot liner 97 can be formed. In the above, it is possible to suppress tearing while satisfying the insulating property between the segment conductors 8.

In FIG. 12, the upper left view is an enlarged perspective view of the vicinity of the coil end according to the other embodiment, the upper right view is an enlarged cross-sectional perspective view of the vicinity of the coil end according to the other embodiment, and the lower left figure is the other embodiment. The slot liner 98 before bending and molding according to the above, and the lower right figure is the slot liner 98 after bending and molding according to another embodiment.

In this embodiment, in addition to the case of the embodiment shown in FIG. 11, the case where the recess 15 is formed on the side surface side of the segment conductor 8 which is not adjacent to each other will be described.

When the recess 15 is formed on the side opposite to the bending direction of the segment conductor 8 and also on the side surface side of the segment conductor 8 which is not adjacent to each other, one insulating sheet can be bent and formed. It is possible to suppress tearing in the protruding portion 12 of the slot liner 9 while satisfying the insulating property between the segment conductors 8.

1 ... Housing, 2 ... Coil, 3 ... Stator core, 4 ... Rotor core, 5 ... Shaft, 6 ... Bearing, 7 ... Slot, 8 ... Segment conductor, 9 ... Slot liner, 10 ... Stator core end face, 11 ... Rise angle, 12 ... Protruding part, 13 ... Bending part, 14 ... Convex part, 15 ... Recessed part, 92 ... Slot liner, 93 ... Slot liner, 94 ... Slot liner, 95 ... Slot liner, 96 ... Slot liner, 97 ... Slot liner, 98 ... Slot liner

Claims (4)

Multiple segment coils arranged in the radial direction and
A stator core forming a slot for accommodating the segment coil and
A single insulating sheet that insulates the plurality of segment coils and the stator core and has a bent portion is provided.
The insulating sheet is arranged so as to cover the entire side surface of the plurality of segment coils.
A part of each of the plurality of segment coils and a part of the insulating sheet protrude from the slot in the vertical direction.
At the upper and lower ends of the insulating sheet in the axial direction protruding from the slot,
A recess is formed on the side of the segment coil close to the bending direction in the circumferential direction so as to leave a part of a portion protruding from the slot toward the stator core, and a radial facing space of the plurality of segment coils. A stator of a rotary electric machine in which a convex portion formed higher than the concave portion is formed. The stator of the rotary electric machine according to claim 1.
The plurality of segment coils arranged in the radial direction are composed of a first coil group in which the same phases are arranged among a plurality of phases of alternating current, and a second coil group in which phases different from the first coil group are arranged. Being done
The insulating sheet is composed of a first insulating portion that surrounds only the outer circumference of the first coil group and a second insulating portion that surrounds only the outer circumference of the second coil group.
The first insulating portion is a stator of a rotary electric machine that forms the convex portion between the first coil group and the second coil group. The stator of the rotary electric machine according to claim 1.
The R of the corner portion forming the recess is a stator of a rotary electric machine formed to be larger than the R of the other corner portion of the insulating sheet. A rotary electric machine provided with any of the stators according to claims 1 to 3.
A rotor surrounded by the stator so that it overlaps in the radial direction,
A rotary electric machine including the stator and a housing for accommodating the rotor.

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