Stator and terminal block of rotating electrical machine and rotating electrical machine

Abstract

The present invention aims to efficiently cool the rotor coil even in a rotor provided with a terminal block. The present invention is a stator of a rotating electric machine, comprising: a stator core; a plurality of segment coils protruding from armature slots of the stator core and arranged in a radial direction; a connecting conductor connecting the segment coils; and an insulating member holding the connecting conductor; the insulating member having a through hole through which the segment coil passes and is accommodated, and an opening on the inner circumference of the insulating member through which a coolant can flow.

Description

Technical Field

[0001] The invention relates to a stator for a rotating electric machine. Background Art

[0002] The rotating electric machine is seeking for high power, and the present invention expects to increase the number of turns of the coil.

[0003] As background technology in this technical field, there are the following prior arts. In Patent Document 1 (International Publication No. 2017 / 195481), the axial length of the stator is extended and enlarged, and the connection parts are located at both ends of the stator core, so the productivity of the rotating electric machine is deteriorated. The rotating electric machine comprises: a stator core; a stator winding, which is composed of a plurality of segment coils; and a terminal block, which fixes the inter-phase connecting conductors that connect the different phases of the segment coils of the stator winding and the inter-phase connecting conductors that connect the segment coils of the same phase of the stator winding; the stator winding has a coil connection portion that connects the ends of the plurality of segment coils to each other on one side relative to the axial direction of the stator core, and the terminal block is arranged on the side where the coil connection portion is arranged relative to the stator core.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: International Publication No. 2017 / 195481 Summary of the invention

[0007] Problem that the invention aims to solve

[0008] As the number of turns of such stator coils increases, the input and output parts where the coils are densely packed have the problem of temperature rise. Therefore, it is necessary to cool the coils with the help of a coolant (such as ATF) flowing in the armature slots. However, the terminal block installed on the upper surface side of the stator sometimes prevents the coolant from flowing into the armature slots. Therefore, a shape of the terminal block that does not prevent the coolant from flowing in is required.

[0009] Technical means of solving problems

[0010] A representative example of the invention disclosed in the present application is shown below. That is, a stator of a rotating electric machine, characterized by comprising: a stator core; a plurality of segment coils protruding from armature slots of the stator core and arranged in a radial direction; a connecting conductor connecting the segment coils; and an insulating member holding the connecting conductor; the insulating member having a through hole through which the segment coils pass and are accommodated, and having an opening on the inner circumference of the insulating member for allowing a coolant to flow into the through hole.

[0011] Effects of the Invention

[0012] According to the present invention, even a rotor provided with a terminal plate can efficiently cool the rotor coil. Other problems, configurations, and effects than those described above will become clear through the following description of the embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 Schematic diagram showing the overall structure of a rotating electrical machine according to an embodiment of the present invention.

[0014] Figure 2 1 is a perspective view showing a stator installed in a housing according to this embodiment.

[0015] Figure 3 It is a three-dimensional view of the stator of this embodiment removed from the housing.

[0016] Figure 4 4 is a three-dimensional diagram of the wiring board of this embodiment.

[0017] Figure 5 It is a three-dimensional view of the input and output connection conductors built into the wiring board of this embodiment.

[0018] Figure 6 This is a cross-sectional view of the stator in a state where a terminal block is mounted according to this embodiment.

[0019] Figure 7 FIG. 4 is a top view of the stator with the terminal block installed according to the present embodiment.

[0020] Figure 8 This is a top perspective view of the stator with the terminal block installed according to this embodiment. DETAILED DESCRIPTION

[0021] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

[0022] The rotating electric machine of this embodiment is a rotating electric machine suitable for driving a car. Here, among the so-called electric vehicles using rotating electric machines, there are hybrid electric vehicles (HEV) equipped with both an engine and a rotating electric machine and pure electric vehicles (EV) that drive only by a rotating electric machine without using an engine, and the rotating electric machine described below can be used for both types.

[0023] Figure 1 1 is a schematic diagram showing the overall structure of a rotating electrical machine 100 according to an embodiment of the present invention. Figure 1 In the figure, a part of the rotating electric machine 100 is set as a cross section to show the inside of the rotating electric machine 100. The rotating electric machine 100 is arranged inside the casing 10, and has a housing 112, a stator 130 and a rotor 150. The stator 130 has a stator core 132 fixed to the housing 112, and the rotor 150 is rotatably arranged in the stator 130. The casing 10 can be composed of an engine casing or a transmission casing.

[0024] The rotating electrical machine 100 is a three-phase synchronous motor with internal permanent magnets. In this embodiment, the rotating electrical machine 100 is used as an example to describe the three-phase synchronous motor, but the present invention can also be applied to an induction motor.

[0025] The rotating electric machine 100 of this embodiment operates as a motor, that is, a three-phase AC current is supplied to the stator coil 138 wound around the stator core 132, thereby rotating the rotor 150. In addition, when the rotating electric machine 100 is driven by the engine, it operates as a generator and outputs three-phase AC power. In other words, the rotating electric machine 100 has both the function of a motor that generates torque based on electrical energy and the function of a generator that generates electricity based on mechanical energy, and the above functions can be selectively used according to the driving state of the vehicle.

[0026] The stator 130 is fixed to the housing 112. The stator 130 is fixed and held in the housing 10 by fastening the flange 115 provided on the housing 112 to the housing 10 by bolts 12. The rotor 150 fixed to the rotating shaft 118 is supported by bearings 14A and 14B of the housing 10 and is rotatably held inside the stator core 132.

[0027] Figure 2 FIG. 1 is a perspective view showing a stator 130 installed in the housing 112. Figure 3 FIG. 1 is a perspective view of the stator 130 removed from the housing 112 . Figure 3 A portion of the stator core 132 is omitted.

[0028] The housing 112 is formed into a cylindrical shape by rolling a steel plate (high-tensile steel plate, etc.) with a thickness of about 2 to 5 mm. A flange 115 is provided at one axial end of the housing 112, and is fixed to the housing 10 by bolts 12 as described above (see FIG. Figure 1 The flange 115 is formed integrally with the housing 112 by rolling. In addition, the stator 130 may be directly fixed to the housing 10 without providing the housing 112.

[0029] The stator 130 is fixed to the inner circumference of the housing 112 and includes a cylindrical stator core 132, a stator coil 138 mounted on the stator core 132, and a terminal plate 140. The stator core 132 is formed by laminating a plurality of electromagnetic steel sheets 133 having a thickness of about 0.05 to 1.0 mm, which are formed by punching or etching. The stacked electromagnetic steel sheets 133 are connected and fixed by welding to suppress deformation of the electromagnetic steel sheets 133 caused by the tightening force when pressed into the housing 112.

[0030] The stator core 132 is provided with a plurality of armature slots 122 extending in the axial direction at equal intervals in the circumferential direction. The number of the armature slots 122 is, for example, 72 in the present embodiment. Figure 2 As shown, the stator coil 138 is received in the armature slot 122. Figure 3 In the example shown, the armature slot 122 is an open armature slot, and an opening is formed on the inner circumference of the stator core 132. The circumferential width of the opening is preferably substantially the same as or slightly smaller than the coil mounting portion of each armature slot 122 where the stator coil 138 is mounted.

[0031] Furthermore, an armature slot liner 300 is arranged in each armature slot 122. The armature slot liner 300 is molded into a predetermined shape, for example, with a heat-resistant resin, and has a thickness of about 0.1 to 0.5 mm. The armature slot liner 300 is arranged in the armature slot 122 and at the end of the coil. The armature slot liner 300 is arranged between the coils inserted into the armature slot 122 and between the coil and the inner surface of the armature slot 122, and functions as an insulating member to improve the insulation withstand voltage between the coils and between the coil and the inner surface of the armature slot 122.

[0032] The stator coil 138 is formed by connecting a plurality of U-shaped segment coils to each other. The segment coils are arranged so that their ends are exposed from the armature slots 122 (i.e., the stator 130) and one end is adjacent to another segment coil, and the other end is adjacent to another segment coil. The segment coils with adjacent ends are connected to each other at the adjacent ends, thereby forming the stator coil 138 wound on the stator core 132.

[0033] A connection plate 140 for connecting the stator 130 and an electric circuit is mounted on a portion of the end of the segment coil of the stator coil 138 .

[0034] Furthermore, the armature slot liner 300 disposed at the coil end is disposed in a ring shape between the coils to achieve phase insulation and conductor insulation at the coil end. In this way, in the rotating electric machine 100 of the present embodiment, the armature slot liner 300 is disposed inside the armature slot 122 and at the coil end, so that even if the insulation coating of the coil is damaged or deteriorated, the required insulation withstand voltage can be maintained.

[0035] A pivot tooth 121 is formed between the armature slots 122, and each pivot tooth 121 is integrally formed with an annular core back 123. The stator core 132 is an integral core in which each pivot tooth 121 is integrally formed with the core back 123. The pivot tooth 121 guides the rotating magnetic field generated by the stator coil 138 to the rotor 150, so that the rotor 150 generates torque.

[0036] The rotor 150 includes a rotor core 152 and permanent magnets 154 held in magnet insertion holes formed in the rotor core 152 .

[0037] On the rotor core 152, rectangular parallelepiped magnet insertion holes are formed at equal intervals in the circumferential direction near the outer periphery. Permanent magnets 154 are embedded in each magnet insertion hole and fixed by adhesive or the like. The circumferential width of the magnet insertion hole is formed to be larger than the circumferential width of the permanent magnet 154, and magnetic gaps are formed on both sides of the permanent magnet 154. The magnetic gaps may be embedded with adhesive or solidified with the permanent magnet 154 by resin.

[0038] The permanent magnet 154 forms the field magnetic pole of the rotor 150. Furthermore, in the present embodiment, one permanent magnet 154 is used to form one magnetic pole, but one magnetic pole may be formed by a plurality of permanent magnets 154. By increasing the number of permanent magnets 154 used to form each magnetic pole, the magnetic flux density of each magnetic pole generated by the permanent magnet 154 increases, and the magnet torque can be increased. The permanent magnet 154 may be a neodymium-based or samarium-based sintered magnet or a ferrite magnet, a neodymium-based bonded magnet, etc., and the residual magnetic flux density of the permanent magnet 154 is preferably about 0.4 to 1.3 T, and neodymium-based magnets are more suitable. Auxiliary magnetic poles may also be formed between each permanent magnet 154.

[0039] When a rotating magnetic field is generated in the stator 130 by supplying a three-phase alternating current to the stator coil 138, the rotating magnetic field acts on the permanent magnet 154 of the rotor 150 to generate a magnet torque. In addition to the magnet torque, the rotor 150 also generates the above-mentioned reluctance torque, so the above-mentioned two torques of the magnet torque and the reluctance torque act on the rotor 150 as torque, thereby obtaining a large torque.

[0040] refer to Figure 4 , Figure 5 , Figure 6 , Figure 7 , the terminal block 140 is described. Figure 4 is a three-dimensional diagram of the wiring board 140, Figure 5 1 is a perspective view of the input / output connection conductor 144 disposed inside the wiring board 140. Figure 6 is a cross-sectional view of the stator 130 in a state where the terminal block 140 is installed. Figure 7 FIG. 1 is a top view of the stator 130 with the terminal block 140 installed.

[0041] The terminal block 140 has: an input-output connection conductor 144 (reference Figure 5 ), which is a lead wire connecting the outside of the rotating electrical machine 100 and the stator 130; connecting conductors 145 and 146, which are relay wires connecting the segment coils; and an insulating member 141, which holds the input / output connecting conductor 144 and the connecting conductors 145 and 146. The connecting terminal 142 is connected to the end of the input / output connecting conductor 144 (refer to Figure 2 , Figure 3 ).

[0042] The insulating member 141 is formed by integrally molding a resin material to hold the input / output connection conductor 144 and the connection conductors 145 and 146. The insulating member 141 is opened on the inner peripheral side (opening 1412) to form a comb-shaped resin terminal row. As described later, the opening 1412 is used to introduce cooling oil into the armature slot 122 of the stator core 132.

[0043] like Figure 5 As shown, the connecting conductors 145 and 146 include an in-phase connecting conductor 145 for connecting the segment coils of the same phase and an out-of-phase connecting conductor 146 for connecting the segment coils of out-of-phase. The connecting conductors 144, 145, and 146 are fixed in the insulating member 141 with a certain interval to achieve electrical insulation in the terminal block 140.

[0044] like Figure 3 , Figure 4 , Figure 7 As shown, the end of the segment coil is inserted into the through hole 1411 of the terminal plate 140 in the axial direction, thereby installing the terminal plate 140 at a position between the axial end of the segment coil and the axial end of the stator core. By installing the terminal plate 140 at this position, the length of the coil end portion of the stator coil 138 can be shortened, so that the rotating electric machine 100 can be miniaturized.

[0045] The insulating member 141 is sized such that, when mounted on the stator 130, its inner peripheral side surface is located on the outer peripheral side relative to the tip of the pivot tooth 121. Therefore, when the rotor 150 is inserted into the stator 130, interference between the terminal plate 140 and the rotor 150 can be avoided, and the rotor 150 can be inserted from either the upper side or the lower side.

[0046] In addition, the segment coils and the connection conductors 144, 145, 146 are connected in the axial direction at the upper part of the stator 130, that is, at the upper part of the terminal plate 140. By connecting in the axial direction at the upper part, when the segment coils and the connection conductors 144, 145, 146 are connected, the conductors can be clamped together easily, and the connection portion can be located close to the stator core 132, so that the rotating electric machine 100 can be miniaturized.

[0047] In this way, by installing the terminal block 140 on the stator coil 138, the end of the segment coil is adjacent to the end of the connection conductor 144, 145, 146, and the end of the segment coil and the end of the connection conductor 144, 145, 146 can be connected.

[0048] Specifically, the same-phase connection conductor 145 is disposed between two circumferentially adjacent through holes 1411, and connects the innermost (first layer) segment coil and the outermost (sixth layer) segment coil in the armature slot 122 on the upper surface of the terminal plate 140 (refer to Figure 5 ).

[0049] Furthermore, the end of the second-layer segment coil in the armature slot 122 is connected to the end of the third-layer segment coil, and the end of the fourth-layer segment coil is connected to the end of the fifth-layer segment coil.

[0050] Two input / output connection conductors 144 are provided in each phase, one input / output connection conductor 144 is connected to the innermost (first layer) segment coil, and the other input / output connection conductor 144 is connected to the outermost (sixth layer) segment coil. Thus, two systems of coils are connected to one connection terminal 142 in each phase.

[0051] The different-phase connection conductor 146 connects the ends of the segment coils of different phases, and forms a neutral point inside the insulating member 141. The neutral point may be led out to the upper surface of the insulating member 141.

[0052] In this manner, the circuit of the stator coil 138 is formed by connecting the segment coils and the connection conductors 144 , 145 , and 146 .

[0053] Regarding the method of connecting the ends of the segment coils and the ends of the connecting conductors 144, 145, and 146, and the method of connecting the ends of the U-shaped segment coils to each other, for example, TIG welding can be used, but other joining methods such as laser welding, electron beam welding, and ultrasonic welding can also be used.

[0054] In this embodiment, the connection conductors 144, 145, 146 adjacent to the innermost segment coil are arranged at positions adjacent to the ends of the segment coils in the circumferential direction, so as to prevent the ends of the conductors from hindering the cooling oil from flowing into the opening 1412. In addition, the connection conductors 144, 145, 146 adjacent to the outermost segment coils are arranged at positions adjacent to the ends of the segment coils in the radial direction, and are cooled by the cooling oil reaching the accumulation portion 1413 described later.

[0055] Next, refer to Figure 7 and Figure 8 , the cooling of the coil in this embodiment is described. Figure 7 FIG. 1 is a top view of the stator 130 with the terminal block 140 installed. Figure 8 FIG. 1 is a top perspective view of the stator 130 with the terminal block 140 installed. Figure 7 and Figure 8 In the figure, the flow of cooling oil is indicated by arrows.

[0056] Cooling oil flows inside the housing 10 of the rotary electric machine 100 of the present embodiment to cool the heat generated by the copper loss of the stator coil 138. For example, when the automatic transmission and the rotary electric machine 100 are housed in one housing, ATF (Automatic Transmission Fluid) flows into the rotary electric machine 100, and the stator coil 138 is cooled by the ATF flowing around the stator coil 138 inside the rotary electric machine 100. The ATF usually flows from the upper surface of the stator 130 (for example, the side where the stator coil 138 is welded) through the armature slot 122 and flows out from the lower surface of the stator 130 (for example, the side where the segment coil is inserted).

[0057] In the rotating electric machine 100 of the present embodiment, since the terminal block 140 is attached to the upper surface side of the stator 130, the shape of the terminal block 140 may hinder the ATF from flowing into the stator 130. Therefore, the terminal block 140 of the present embodiment is provided with an opening 1412 on the inner peripheral side of the insulating member 141, and the cooling oil is introduced from the opening 1412 to the through hole 1411. Therefore, the cooling oil can be introduced to the stator coil 138 located at the lower part of the terminal block 140, so that the stator coil 138 located at the lower part of the terminal block 140 can be cooled.

[0058] Furthermore, a collection portion 1413 wider than the opening portion 1412 is provided on the outer peripheral side of the insulating member 141 of the terminal block 140. Therefore, the cooling oil flowing into the inside of the insulating member 141 from the opening portion 1412 reaches the collection portion 1413 and stays in the collection portion 1413, thereby effectively cooling the connection conductors 144, 145, and 146. Furthermore, the cooling oil flowing into the inside of the insulating member 141 from the opening portion 1412 cools the insulating member 141, and thus the connection conductors 144, 145, and 146 provided in the insulating member 141 can be cooled.

[0059] In the above-described embodiment, an example in which the stator coil 138 is cooled by cooling oil is described. However, the stator 130 of the present invention may be cooled by using a non-oil cooling medium (liquid or gas).

[0060] As described above, according to an embodiment of the present invention, a stator 130 of a rotating electrical machine 100 includes: a stator core 132; a plurality of segment coils protruding from armature slots 122 of the stator core 132 and arranged radially; connecting conductors 145, 146 connecting the segment coils; and an insulating member 141 that holds the connecting conductors 145, 146, the insulating member 141 having a through hole 1411 through which the segment coils pass and are accommodated, and an opening 1412 on the inner circumferential side of the insulating member 141 for allowing coolant to flow into the through hole 1411, so that even if the stator 130 is provided with a terminal block 140, the stator coil 138 can be efficiently cooled.

[0061] Insulating member 141 has reservoir 1413 on the outer peripheral side of through hole 1411 for the coolant flowing in from opening 1412 to reach. Therefore, the coolant flows into reservoir 1413 , and connection conductors 144 , 145 , 146 can be effectively cooled.

[0062] In addition, the connecting conductors 145 and 146 are connected adjacent to the segment coil arranged at the outermost periphery in the radial direction and are connected adjacent to the segment coil arranged at the innermost periphery in the circumferential direction, so that the cooling oil will not be hindered from flowing into the opening portion 1412, and effective cooling can be performed with the help of the cooling oil reaching the accumulation portion 1413.

[0063] Furthermore, the above description is only an example, and the invention is not limited or constrained by the correspondence between the matters recorded in the above embodiment and the matters recorded in the claims. For example, the above embodiment is described by taking a rotating electric machine equipped with a permanent magnet in the rotor as an example, but the present invention can also be applied to the stator of a rotating electric machine such as an induction motor. In addition, it can also be applied to fields other than rotating electric machines for vehicle driving.

[0064] Furthermore, the present invention includes various variations and equivalent structures within the spirit of the attached claims, and is not limited to the embodiments described above. For example, the embodiments described above are detailed descriptions of the present invention in an easy-to-understand manner, and the present invention is not necessarily limited to all the structures described. In addition, a part of the structure of a certain embodiment can be replaced by the structure of other embodiments. In addition, the structure of other embodiments can be added to the structure of a certain embodiment. In addition, other structures can be added, deleted, or replaced to a part of the structure of each embodiment.

[0065] Explanation of symbols

[0066] 10… cover, 12… bolt, 14A, 14B… bearing, 100… rotating electrical machine, 112… housing, 115… flange, 118… rotating shaft, 121… pivot tooth, 122… armature slot, 123… core back, 130… stator, 132… stator core, 133… electromagnetic steel plate, 138… stator coil, 140… terminal block, 141… insulating member, 1411… through hole, 1412… opening, 1413… accumulation portion, 142… input / output connection terminal, 144… input / output connection conductor, 145, 146… connection conductor, 150… rotor, 152… rotor core, 154… permanent magnet, 300… armature slot liner.

Claims

1. A stator of a rotating electrical machine, characterized in that: have: stator core; a plurality of segment coils protruding from the armature slots of the stator core and arranged in a radial direction; a connecting conductor connecting the segment coils; and an insulating member which holds the connecting conductor, The insulating member has a through hole for the segment coil to pass through and accommodate. The insulating member has an opening on the inner peripheral side thereof, through which a coolant can flow into the through hole.

2. The stator of a rotating electrical machine according to claim 1, characterized in that: The insulating member has a reservoir portion on the outer peripheral side of the through hole to which the coolant flowing in from the opening reaches.

3. The stator of a rotating electrical machine according to claim 1, characterized in that: The connection conductor is connected to and adjacent to the segment coil arranged at the outermost circumference among the plurality of segment coils in the radial direction, and is connected to and adjacent to the segment coil arranged at the innermost circumference among the plurality of segment coils in the circumferential direction.

4. A terminal block mounted on a stator of a rotating electrical machine, characterized in that: have: a connecting conductor that connects a plurality of segment coils that constitute a stator winding, protrude from armature slots of a stator core, and are arranged in a radial direction; and an insulating member which holds the connecting conductor, The insulating member has a through hole for the segment coil to pass through and accommodate. The insulating member has an opening on the inner peripheral side thereof, through which a coolant can flow into the through hole.

5. The terminal block according to claim 4, characterized in that: The insulating member has a reservoir portion on the outer peripheral side of the through hole to which the coolant flowing in from the opening reaches.

6. The terminal block according to claim 4, characterized in that: The connection conductor is connected to and adjacent to the segment coil arranged at the outermost circumference among the plurality of segment coils in the radial direction, and is connected to and adjacent to the segment coil arranged at the innermost circumference among the plurality of segment coils in the circumferential direction.

7. A rotating electrical machine, characterized in that: A stator according to any one of claims 1 to 3 is provided.

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