JP2015201966A - Stator of rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make it possible to reduce cost and reduce a length in an axial direction of a crossover part by reducing a used amount of an insulating resin for insulating a connection part of a conductor segment where an insulating coat is peeled off.SOLUTION: An end part 25 of a conductor segment 23 includes: a coating part 26 covered with an insulating coat 30; and a peeling part 27 where the insulating coat 30 is peeled off. A boundary line BL between the coating part 26 and the peeling part 27 is inclined to a virtual surface P orthogonal to an axis line L of the conductor segment 23 before bending the conductor segment 23, and, when the conductor segment 23 is bent, is inclined in a direction parallel to an end face 11b of a stator core 11.

Description

  The present invention relates to a stator for a rotating electrical machine.

  2. Description of the Related Art Conventionally, electric vehicles and hybrid vehicles equipped with a rotating electrical machine as a power source have been developed. In particular, in a hybrid vehicle, there is a strong demand for space saving for the rotating electrical machine in order to coexist with the engine and to ensure comfort. On the other hand, high power is required for a rotating electrical machine for driving, and measures such as increasing the number of turns of a stator coil and dealing with high voltage by improving insulation performance are being studied.

  In order to meet such a demand, a plurality of U-shaped conductor segments having a pair of leg portions and a connecting portion connecting both leg portions are inserted into the slots of the stator core, and the conductor segments project from different slots. 2. Description of the Related Art A segment conductor type rotating electrical machine stator is known in which a stator coil is configured by connecting ends of each other.

  In the segment conductor type stator coil, the end portions of the conductor segments with insulating coatings protruding from the slots are bent, the end portions from which the insulating coatings have been peeled are joined together by welding or the like, and then the insulating resin is applied to the joint portions. In the vicinity of the joint, peeling or cracking is likely to occur in the insulating coating due to a load due to bending or thermal stress during welding, and there is a possibility that the insulating performance will deteriorate. For this reason, the insulating resin is applied over a wide area in the vicinity of the joint where the insulation performance of the insulating film may be degraded, not only at the peeled portion of the insulating film, thereby preventing deterioration of the insulating film at or near the joint. There has been proposed a rotating electric machine configured to do so (for example, see Patent Documents 1, 2, and 3).

Japanese Patent No. 4042386 Japanese Patent No. 4910572 JP 2012-139075 A

  As shown in FIGS. 8A and 8B, the film peeling portion 101 of the conductor segment 100 described in Patent Document 1 has an insulating film 104 from the straight portion 102 to the skew portion 103 at the end of the conductor segment 100. Is peeled off and formed from the joint tip to the portion that first intersects with the adjacent conductor segment 100 at a predetermined interval. However, since the boundary line BL between the film peeling portion 101 and the insulating film 104 is perpendicular to the axis L of the conductor segment 100, the boundary line BL is inclined with respect to the end surface 105 a of the stator core 105. The film peeling portion 101 is generally insulated by an insulating resin 106 applied in parallel to the end surface 105a of the stator core 105 after joining. For this reason, in the configuration shown in FIG. 8A, even if the application amount of the insulating resin 106 is reduced, as shown in FIG. 8B, at least the end face 105a of the stator core 105 on the inclined boundary line BL. It is necessary to apply the insulating resin 106 over a wide area outside the line segment X parallel to the end face 105a, passing through the point A closest to the end surface 105a, and the amount of the insulating resin 106 applied increases, resulting in an increase in weight, cost, and refrigerant. There is a problem such as a decrease in the route that passes through.

  Further, as shown in FIGS. 9A and 9B, the film peeling portion 201 of the conductor segment 200 described in Patent Document 2 is formed only on the straight portion 202 close to the joint portion, and the skew portion 203. Is not reached. However, the insulating coating 204 may be deteriorated due to heat deterioration due to heat at the time of joining by welding or the like, or peeling due to processing stress acting at the time of bending. For this reason, in the configuration shown in FIG. 9A, even if it is attempted to reduce the coating amount of the insulating resin 206, as shown in FIG. 9B, the end face 205a of the stator core 205 and the end surface 205a of the stator core 205 are covered. The insulating resin 206 outside the parallel line segment X must be applied over a wide range, and the amount of the insulating resin 206 applied increases.

  Further, as shown in FIGS. 10A and 10B, the film peeling portion 301 of the conductor segment 100 described in Patent Document 3 is formed on a part or all of the bending R portion 307 following the straight portion 302. Yes. In this conductor segment 300, since the outer R side of the bending R portion 307 is extended during bending, the insulating coating 304 may float due to bending stress. For this reason, in the configuration shown in FIG. 10A, even if it is attempted to reduce the coating amount of the insulating resin, as shown in FIG. 10B, the coating film edge moves to the stator core 305 side from the initial peeling position B. As a result, there is a problem that the coating amount of the insulating resin outside the line segment X parallel to the end face 305a of the stator core 305 increases.

  The objective of this invention is providing the stator of the rotary electric machine which can reduce the usage-amount of the insulating resin which insulates the junction part of the conductor segment from which the insulating film was peeled, and can reduce cost.

In order to achieve the above object, the invention described in claim 1
An annular stator core (for example, a stator core 11 in an embodiment described later) formed with a plurality of slots (for example, a slot 12 in the embodiment described later);
It has a conductor segment (for example, a conductor segment 23 in an embodiment to be described later) with a plurality of insulating films (for example, an insulating film 30 in an embodiment to be described later) inserted into the slot, and one end of the stator core (for example, End portions (for example, end portions 25 in the embodiments described later) of the conductor segments projecting in the axial direction from end surfaces 11b) in the embodiments described later are bent in the circumferential direction and joined to join portions (for example, A segment conductor type rotating electrical machine stator (for example, a stator in an embodiment to be described later), and a coil (for example, a stator coil 15 in an embodiment to be described later) forming a joining portion 28 in an embodiment to be described later. 10)
The end portion of the conductor segment includes a covering portion (for example, a covering portion 26 in an embodiment described later) covered with the insulating film and a peeling portion (for example, in an embodiment described later) from which the insulating film is peeled off. And a peeling portion 27) of
A boundary line between the covering portion and the peeling portion (for example, a boundary line BL in an embodiment described later) is an axis of the conductor segment before the conductor segment is bent (for example, an axis L in an embodiment described later). Formed with an inclination relative to a virtual plane orthogonal to
The boundary line is inclined in a direction parallel to the end face of the stator core when the end of the conductor segment is bent.

The invention according to claim 2 is the invention according to claim 1,
The inclination angle of the boundary line with respect to a virtual plane orthogonal to the axis of the conductor segment (for example, the inclination angle θ1 in the embodiment described later) is the bending angle of the end portion of the conductor segment (for example, an embodiment described later). And the same angle as the bending angle θ2).

  According to the first aspect of the present invention, when the end portion of the conductor segment is bent, the boundary line between the covering portion and the peeling portion is displaced in a direction parallel to the end surface of the stator core. Therefore, it is possible to reduce the amount of insulating resin applied for the purpose, and the cost is suppressed.

  According to the second aspect of the present invention, when the end portion of the conductor segment is bent, the boundary line between the covering portion and the peeling portion is parallel to the end surface of the stator core, so that the application range of the insulating resin is minimized. Thereby, the joint portion of the conductor segment can be insulated with the minimum amount of insulating resin.

It is a front side perspective view of the stator which concerns on this invention. It is a back surface side perspective view of the stator shown in FIG. It is a perspective view of a conductor segment. It is an enlarged view of the edge part of the conductor segment before bending formation. It is an enlarged view of the edge part of the conductor segment bent and formed. FIG. 5 is an enlarged perspective view partially showing a state in which ends of conductor segments that are inserted into the slots of the stator core and bent are joined together. It is the VII-VII sectional view taken on the line of FIG. 6, and is a schematic diagram of the junction part insulated by insulating resin. (A) is a figure which shows the state of the coating film of the junction part vicinity of the conventional conductor segment described in patent document 1, (b) is a principal part enlarged view explaining the application | coating range of the insulating resin in (a). (A) is a figure which shows the state of the film of the junction part vicinity of the conventional conductor segment of patent document 2, (b) is a principal part enlarged view explaining the application | coating range of the insulating resin in (a). (A) is a figure which shows the state of the film of the junction part vicinity of the conventional conductor segment of patent document 3, (b) is a principal part enlarged view explaining the application | coating range of the insulating resin in (a).

  Hereinafter, a stator of a segment conductor type rotating electrical machine according to an embodiment of the present invention will be described with reference to the drawings.

  FIG. 1 is a front perspective view of a stator according to the present invention, and FIG. 2 is a rear perspective view. As shown in FIGS. 1 and 2, the stator 10 according to the present embodiment includes a stator core 11 in which a plurality of slots 12 penetrating in the axial direction are arranged at predetermined intervals in the circumferential direction, and a plurality of phases accommodated in the slots 12. (For example, U-phase, V-phase, W-phase) stator coil 15. A rotor (not shown) is rotatably disposed inside the stator 10 and is housed in a casing (not shown) to constitute a rotating electric machine.

  As shown in FIG. 3, the stator coil 15 has a pair of leg portions 21 a and 21 b extending in parallel with each other, and a connecting portion 22 that connects the leg portions 21 a and 21 b at one end, A substantially U-shaped conductor segment 23 made of a rectangular flat wire is formed of a plurality of coil segment groups 20 arranged in a bundle for each predetermined number (four in this embodiment).

  One leg 21a of each conductor segment 23 is inserted into a radially inner portion of one slot 12a, and the other leg 21b is the other slot located at a predetermined number of slots away from one slot 12a. 12b is inserted into the radially outer portion.

  As shown in FIGS. 2 and 6, the protruding portions 21 c of the pair of leg portions 21 a and 21 b that pass through the slot 12 and protrude from the stator core 11 in the axial direction are the leg portions adjacent in the slot 12 in the radial direction. 21a and 21b are bent in the circumferential direction of the stator core 11 so that the bending directions are opposite to each other, and are joined to the corresponding end portions 25 of the conductor segments 23 by welding or the like.

  More specifically, both the leg portions 21a and 21b of the conductor segment 23 are formed in a state in which the tips of the end portions 25 protruding in the axial direction from the stator core 11 through the slots 12 are held by a jig (not shown). 11 and the jig are made to rotate relative to both sides by a predetermined angle while being close to each other, part of both legs 21a and 21b of the conductor segment 23 is bent in one circumferential direction, and the rest of both legs 21a and 21b of the conductor segment 23 is It is bent in the other circumferential direction. Further, the end 25 of the conductor segment 23 has a straight portion 41 at the tip, a portion from the straight portion 41 to the slot 12 of the stator core 11 becomes a skewed portion 42, and a connecting portion between the straight portion 41 and the skewed portion 42 is provided. A bent R portion 43 is formed.

  Thereby, as for the stator coil 15, in the front side, the connection part 22 of the some coil segment group 20 continues in the circumferential direction, and the connection parts 22 adjacent in the circumferential direction overlap partially seeing from an axial direction. The coil ends are formed on one end face 11a in the axial direction of the stator core 11 (see FIG. 1). Further, on the back surface side, the end portions 25 of the plurality of conductor segments 23 are arranged in the radial direction and the circumferential direction, and the end portions 25 of the corresponding conductor segments 23 are welded, whereby the other axial end of the stator core 11 is welded. A coil end is formed on the end face 11b.

  As shown in FIG. 4, the conductor segment 23 is insulated by an insulating coating 30, and a peeling portion 27 from which the insulating coating 30 has been peeled is formed at the ends 25 of both leg portions 21 a and 21 b joined by welding or the like. Is formed. That is, the end portion 25 of the conductor segment 23 has a covering portion 26 covered with the insulating coating 30 and a peeling portion 27 from which the insulating coating 30 has been peeled off. The covering portion 26 and the peeling portion 27 have a boundary line. It is partitioned by BL.

  The peeling portion 27 is formed when the conductor segment 23 has a single rod shape, or when at least the substantially U-shaped conductor segment 23 is in a single state before being inserted into the slot 12, that is, before the conductor segment 23 is bent. In addition, the insulating coating 30 at the end 25 is peeled off.

  A boundary line BL between the covering portion 26 and the peeling portion 27 is formed to be inclined with respect to a virtual plane P orthogonal to the axis L of the conductor segment 23 before bending. The boundary line BL with respect to the virtual plane P orthogonal to the axis L at this time is a boundary when the protruding portions 21c of the legs 21a and 21b protruding from the slot 12 are bent in the circumferential direction of the stator core 11 as shown in FIG. The line BL is inclined in a direction parallel to the other end surface 11 b of the stator core 11.

  Further, as shown in FIG. 5, the inclination angle θ1 of the boundary line BL with respect to the virtual plane P orthogonal to the axis L may be set to substantially the same angle (θ1 = θ2) as the bending angle θ2 with respect to the axis L. preferable. According to this, when the protruding portion 21c is bent in the circumferential direction, the boundary line BL and the other end surface 11b of the stator core 11 become parallel.

  In the conductor segment 23 before the bending, the side of the boundary line BL on the stator core 11 side is the inside of the bending R portion 43 (hereinafter referred to as “inside bending R”), and the side of the boundary line BL opposite to the stator core 11 is the side of the bending R portion 43. It is the outside (hereinafter referred to as “bending outside R”).

  The peeling position of the peeling portion 27 is set in consideration of the influence on the insulating coating 30 due to heat by bending and bending. Specifically, the distance at which the insulating coating 30 deteriorates due to the bonding heat and the position where the processing load is applied by bending are set, and the peel length of the in-bending R-side IR is set. Next, the position of the peeled surface of the in-bending R side IR after processing, that is, the distance from the stator core 11 where the peeled surface is desired to be aligned is calculated from the peeled length of the in-bending R side IR, and the bending outside after processing is calculated to this distance. The separation length of the outer R-side OR is set so that the separation surface of the R-side OR is also positioned.

  As shown in FIGS. 6 and 7, the protruding portions 21c of the leg portions 21a and 21b protruding from the slot 12 are bent in the circumferential direction of the stator core 11, and the end portions 25 of the corresponding conductor segments 23 are joined together by welding or the like. Thus, the joint portion 28 is formed. Then, the peeling portion 27 and the covering portion 26 in the vicinity of the peeling portion 27 are insulated by applying the insulating resin 31 together with the joint portion 28.

  At this time, since the boundary line BL between the covering portion 26 and the peeling portion 27 is parallel to the other end surface 11b of the stator core 11, the insulating resin 31 is greatly exceeded from the boundary line BL in the direction of the stator core 11. Without applying, it is possible to insulate the necessary portion by simply applying the covering portion 26 in the vicinity of the boundary line BL, and the amount of the insulating resin 31 used can be suppressed.

  In addition, the insulating resin 31 is generally applied to the peeling portion 27 by powder stored in a container (not shown) with the other end surface 11b of the stator core 11 from which the leg portions 21a and 21b protrude facing downward. The insulating resin 31 is applied by inserting the joint portion 28 into the insulating resin 31. Therefore, according to the stator 10 of the present embodiment, it is possible to easily apply the insulating resin 31 to the minimum required range only by managing the amount of vertical movement of the stator core 11 holding the end surface 11b downward. .

  As described above, according to the stator 10 according to the present embodiment, the end portion 25 of the conductor segment 23 includes the covering portion 26 covered with the insulating coating 30 and the peeling portion 27 from which the insulating coating 30 has been peeled off. And the boundary line BL between the covering portion 26 and the peeling portion 27 is formed to be inclined with respect to a virtual plane P orthogonal to the axis L before bending of the conductor segment 23 and inserted into the slot 12 of the stator core 11. When the end portion 25 of the conductor segment 23 is bent, the conductor segment 23 is inclined in a direction parallel to the end surface 11b of the stator core 11, so that the amount of insulating resin 31 applied for insulating the peeling portion 27 is reduced. And the cost is reduced. Further, the axial length of the transition portion can be shortened, and the rotating electrical machine can be reduced in size.

  In addition, the inclination angle θ1 of the boundary line BL between the covering portion 26 and the peeling portion 27 with respect to the axis L of the conductor segment 23 is set to the same angle as the bending angle θ2 of the end portion 25 of the conductor segment 23, whereby the conductor segment 23 is When inserted into the slot 12 and bent, the boundary line BL is parallel to the end surface 11b of the stator core 11, and the application range of the insulating resin 31 can be minimized, whereby the minimum amount of insulating resin is used. The joint portion 28 of the conductor segment 23 can be insulated at 31.

In addition, this invention is not limited to embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably.
For example, the inclination angle θ1 of the boundary line BL between the covering portion 26 and the peeling portion 27 with respect to the axis L of the conductor segment 23 is not limited to the same angle as the bending angle θ2 of the end portion 25 of the conductor segment 23. 26 and the separation portion 27 are formed so as to be inclined with respect to a virtual plane P orthogonal to the axis L of the conductor segment 23 before the conductor segment 23 is bent, and the boundary line BL is an end of the conductor segment 23. When the portion is bent, it may be inclined in a direction parallel to the end surface 11 b of the stator core 11.

10 Stator 11 Stator core 11b End face (one end)
12, 12a, 12b Slot 15 Stator coil (coil)
23 Conductor segment 25 End portion 26 Covering portion 27 Separating portion 28 Joining portion 30 Insulating coating 31 Insulating resin BL Boundary line L Axis line P Virtual plane θ1 orthogonal to the axis L Inclination angle (inclination angle)
θ2 Bending angle

Claims (2)

An annular stator core formed with a plurality of slots;
A plurality of conductor segments with insulating coatings inserted into the slots, and ends of the conductor segments protruding in an axial direction from one end of the stator core are bent in the circumferential direction and joined to form a joint. A stator of a segment conductor type rotating electrical machine comprising a coil,
The end of the conductor segment has a covering portion covered with the insulating coating, and a peeling portion where the insulating coating is peeled off,
The boundary line between the covering portion and the peeling portion is formed to be inclined with respect to a virtual plane orthogonal to the axis of the conductor segment before the conductor segment is bent,
The boundary line is a stator of a rotating electrical machine that is inclined in a direction parallel to an end surface of the stator core when the end portion of the conductor segment is bent. A stator for a rotating electrical machine according to claim 1,
The stator of a rotating electrical machine, wherein an inclination angle of the boundary line with respect to a virtual plane orthogonal to the axis of the conductor segment has the same angle as a bending angle of the end portion of the conductor segment.

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