Stator for a rotating electric machine and method for assembling a rotating electric machine

Abstract

The purpose of this invention is to provide a stator for a rotary electric motor with excellent insulation reliability. This invention is a rotary electric motor comprising a rotor and a stator disposed around the outer periphery of the rotor. The stator has a stator core (5) formed by stacking multiple electromagnetic steel plates (5a) and stator coils (7) wound around the stator core (5) with insulators (61, 62, 1) in between. The insulators (61, 62, 1) are composed of a first winding frame portion (61), a second winding frame portion (62), and an insulating sheet (1). The first winding frame portion (61) and the second winding frame portion (62) are disposed at both ends in the direction of the rotation axis of the rotary electric motor and are made of resin. The insulating sheet (1) covers the side surface of the stator core (5) between the first winding frame portion (61) and the second winding frame portion (62). The contact surface between the electromagnetic steel plates (5a) and the adjacent electromagnetic steel plates (5a) in the stacking direction is composed of a smooth plane.

Description

Technical Field

[0001] This invention relates to the stator of a rotary electric machine. Background Technology

[0002] Stator coils in rotating electric machines can be wound in two ways: concentrated winding and distributed winding. Concentrated winding involves winding strands of wire around each pole tooth to form a coil, while distributed winding involves winding strands across multiple armature slots, resulting in coils of different or the same phase overlapping at the ends. Compared to distributed winding, concentrated winding reduces the size of the coil ends, which is more effective for miniaturization and increasing the efficiency of rotating electric machines. Furthermore, distributed winding allows the rotating magnetic field distribution within the stator to approximate a sine wave, resulting in higher power output and reduced noise compared to concentrated winding.

[0003] For insulation between the stator core and the stator coil, resin-molded winding frames are typically used in concentrated winding, while insulating paper is typically used in distributed winding.

[0004] Japanese Patent Application Publication No. 2009-148093 (Patent Document 1) discloses a technique for insulation using a resin-molded winding frame. In the winding frame of Patent Document 1, a generally rectangular parallelepiped-shaped winding frame body is integrally molded from resin, and a flange portion is provided on the outer diameter side of the winding frame body (see paragraphs 0044, 0046, 0047).

[0005] Furthermore, Japanese Patent Application Publication No. 2015-50428 (Patent Document 2) discloses a technique for reducing the thickness of the insulation portion and increasing the duty cycle of the stator coil by using insulating paper in a part of the winding frame. Regarding the winding frame of Patent Document 2, a winding frame with resin molded bodies formed before and after the core material is formed by placing the core material and insulating sheet in an injection mold cavity and injecting resin. The core material has a rectangular groove with a roughly H-shaped cross-section, and the insulating sheet is installed within the groove in a U-shape (see abstract).

[0006] Existing technical documents

[0007] Patent documents

[0008] Patent Document 1: Japanese Patent Application Publication No. 2009-148093

[0009] Patent Document 2: Japanese Patent Application Publication No. 2015-50428 Summary of the Invention

[0010] The problem the invention aims to solve

[0011] Patent Document 1 describes a winding frame integrally molded with a generally rectangular winding frame body and a flange portion for achieving insulation with the stator core and fixing the stator coils. To wind more stator coils, the insulation portion between the stator core and the stator coils needs to be thin within the range required to achieve the desired insulation performance. On the other hand, the fixing portion of the stator coils needs to be strong enough to withstand the load during coil winding. To increase the strength of the resin material, materials containing glass fibers or the like need to be used. However, materials containing glass fibers or the like have poor flowability during molding. When using a resin material with low flowability, the minimum thickness of the insulation portion must be increased, resulting in a decrease in the duty cycle of the stator coils.

[0012] In the winding frame of Patent Document 2, insulating paper is placed in the insulation section to prevent a decrease in the duty cycle of the stator coil, and the fixing part of the stator coil is molded from injection-molded resin. During injection molding, the molten resin molded body impregnates the surface of the insulating paper containing short fibers, thereby making the resin molded body and the insulating paper integrally formed. Here, the stator core is composed of laminated steel plates, and the resin molded body is formed on the surface of the laminated steel plates. The laminated steel plates constituting the stator core are usually made using a technique called convergence, that is, the surface of the steel plates is provided with concave and convex parts, so that the concave and convex parts of adjacent steel plates in the lamination direction interlock and are pressed in the lamination direction, thereby causing the concave and convex parts to plastically deform and join together.

[0013] By fixing the laminated steel plates together using convergence to make them a single unit, the workability of handling laminated steel plates can be improved.

[0014] On the other hand, when the layers of steel plates are fixed by convergence, the converged areas are less prone to deformation during coil winding, while the non-convex areas are more prone to deformation, which can lead to warping of the stator core. In stators where the resin molding body and insulating paper are integrally molded, increased warping of the stator core can lead to reduced insulation reliability, such as damage at the joint between the insulating paper and the winding frame.

[0015] The purpose of this invention is to provide a stator for a rotating electric motor with excellent insulation reliability.

[0016] Technical means to solve the problem

[0017] To achieve the above objectives, the rotating electric mechanism of the present invention forms a smooth plane on the surface of the multiple electromagnetic steel plates constituting the stator core.

[0018] The effects of the invention

[0019] According to the present invention, a stator for a rotating electric machine with excellent insulation reliability can be provided. Other issues, configurations, and effects beyond those described above will be clarified through the following description of embodiments. Attached Figure Description

[0020] Figure 1 A cross-sectional view showing the overall structure of a rotary electric motor RM according to an embodiment of the present invention.

[0021] Figure 2 This is a perspective view of an assembly of a stator core 5, a winding frame 6, and insulating paper 1 according to an embodiment of the present invention.

[0022] Figure 3 This is a perspective view of a stator 100 using a centrally wound stator core 8, according to an embodiment of the present invention.

[0023] Figure 4 This is a perspective view of a centralized winding digitized iron core 8 according to an embodiment of the present invention.

[0024] Figure 5 An exploded view showing the structure of an assembly of stator core 5, winding frame 6, and insulating paper 1 according to an embodiment of the present invention.

[0025] Figure 6 This is a partial cross-sectional view showing a portion of a section of the stator core 5, perpendicular to the axial direction of the rotating shaft 12, according to an embodiment of the present invention. Detailed Implementation

[0026] The following describes an embodiment of the present invention using a rotary motor used in an electric vehicle. The rotary motor of this embodiment functions as both a motor that drives the wheels of a vehicle and a generator that generates electricity using regenerative braking; these functions can be switched depending on the vehicle's driving conditions.

[0027] First, use Figure 1 The overall configuration of a rotary electric motor according to an embodiment of the present invention will be described. Figure 1 A cross-sectional view showing the overall structure of a rotary electric motor RM according to an embodiment of the present invention.

[0028] The rotary motor RM described in this embodiment is for use in hybrid electric vehicles. The rotary motor RM is mounted between the engine and the transmission or within the transmission.

[0029] The rotary motor RM is surrounded by a housing 130. Here, when the rotary motor RM is positioned between the engine and the transmission, the housing 130 can be either the engine housing or the transmission housing. Furthermore, when the rotary motor RM is mounted in the transmission, the housing 130 can be the transmission housing.

[0030] The rotary motor RM is a three-phase synchronous motor with a built-in permanent magnet. It operates as a motor by supplying a large three-phase AC current (e.g., 400A) to the stator coils. Furthermore, when the rotary motor RM is driven by an engine, it operates as a generator, outputting three-phase AC power. When operating as a generator, the current output from the stator coils is smaller than when operating as a motor, for example, 100A. Additionally, the rotary motor RM used in this example is a flat type rotary motor where the thickness in the direction of the rotation axis (the axial direction of the shaft) is smaller than its outer diameter.

[0031] The rotary electric machine RM includes a rotor 200, a stator 100, and a housing 9. The rotor 200 is disposed on the inner circumference of the stator 100 with a gap. The rotor 200 is fixed on a rotating shaft 12. The two ends of the rotating shaft 12 are rotatably supported by bearings 14A and 14B. The outer circumference of the stator 100 is fixed to the inner circumference of the housing 9.

[0032] The outer periphery of the outer shell 9 is fixed to the inner periphery of the cover 130.

[0033] A pump 140 is disposed at the bottom of the housing 130. Furthermore, a refrigerant RF storage section 150 is formed at the bottom of the housing 130. For example, insulating oil is used as the refrigerant RF. A portion of the lower side of the stator 100 is immersed in the refrigerant RF stored in the storage section 150. The pump 140 draws the refrigerant RF stored in the storage section 150 and discharges it through the refrigerant passages 152 from the refrigerant outlets 154A and 154B formed on the upper part of the housing 130.

[0034] Refrigerant outlets 154A and 154B are formed at the upper parts of both ends (coil end portions) of the stator coil wound on the pivot teeth of the stator 100. Furthermore, there are 13 refrigerant outlets 154A and 13 refrigerant outlets 154B.

[0035] The refrigerant discharged from refrigerant outlets 154A and 154B is directly sprayed onto the ends of the stator coils, cooling the ends of the stator coils. The refrigerant RF that has carried away the heat from the stator 100 accumulates in the lower part of the casing 130, where it is forcibly circulated through the refrigerant channel 152 by means of pump 140, and is discharged again from refrigerant outlets 154A and 154B to cool the stator 100.

[0036] Next, use Figures 2 to 6 The stator core 5, stator coil 7, the assembly of the stator core and stator coil 7, and stator 100 are described.

[0037] In this embodiment, the stator coil 7 of the rotary electric machine is a concentrated winding coil, in which strands of wire are wound together to form a coil for each magnetic pole tooth. The stator core 5 (an assembly of the stator coil 7 and the stator core 5) with the concentrated winding coil wound on it is referred to as the concentrated winding stator core 8. The stator 100 is constructed by assembling multiple concentrated winding stator cores 8 into one unit.

[0038] Figure 2 This is a perspective view of an assembly of a stator core 5, a winding frame 6, and insulating paper 1 according to an embodiment of the present invention.

[0039] The winding frame 6 constituting the centralized winding voltammetric core 8 is composed of a resin winding frame 61 on the terminal block side (first winding frame part) and a resin winding frame 62 on the opposite side of the terminal block (second winding frame part). The resin winding frame 61 on the terminal block side is a member constituting one end of the winding frame 6 in the direction of rotation axis (one-end member). The resin winding frame 62 on the opposite side of the terminal block is a member constituting the other end of the winding frame 6 in the direction of rotation axis (other-end member). The insulating paper 1 is a connecting member that connects the resin winding frame 61 on the terminal block side and the resin winding frame 62 on the opposite side of the terminal block.

[0040] The specific composition of the resin winding frame 61 on the side of the terminal block, the resin winding frame 62 on the opposite side of the terminal block, and the insulating paper 1 will be described in detail below.

[0041] Figure 3 This is a perspective view of a stator 100 using a centrally wound stator core 8, according to an embodiment of the present invention.

[0042] The rotary electric motor RM is coaxially arranged and has a stator 100 and a rotor 200 (reference). Figure 1 The rotor 200 is rotatably held on the inner circumference of the stator 100, transmitting the driving force generated between the stator 100 and the rotor 200 to the outside. The stator 100 is formed by arranging multiple concentrated winding stator cores 8 in a ring around the periphery within a cylindrical housing 9. Through holes 91 provided on the protrusions 91A on the outer circumference of the housing 9 are used to insert fastening components such as bolts to fix the stator 100 to the vehicle-side gearbox.

[0043] Figure 4 This is a perspective view of a centralized winding digitized iron core 8 according to an embodiment of the present invention.

[0044] The concentrated winding method of the electronic core 8 is formed by assembling multiple concentrated winding method coils 7 into a ring. Figure 4 The image shows a coil 7 wound in a concentrated manner on a winding frame 6.

[0045] The centralized winding stator core 8 includes a stator core 5, a winding frame 6, insulating paper 1, and a stator coil 7. The stator core 5 is formed by stacking electromagnetic steel plates 5a. The winding frame 6 is configured to cover the two ends of the stator core 5 in the direction of rotation axis and is made of resin. The insulating paper 1 is configured to cover the side of the stator core 5 and is fused together with the resin winding frame 6. The stator coil 7 is formed by winding an insulating film-coated wire 7a.

[0046] The winding frame 6 is disposed on both ends of the stator core 5 in the direction of rotation axis, providing electrical insulation between the stator coil 7 and the stator core 5. It also has locking portions (convex and concave portions) 6b and 6c that define the winding of the stator coil 7 and the positions of the starting and ending coil ends 701 and 702. The starting and ending coil ends 701 and 702 extend along the direction of rotation axis of the rotary electric machine RM. Insulating paper 1 is disposed on the side of the stator core 5, providing electrical insulation between the stator coil 7 and the stator core 5. The yoke portion 51 of the stator core 5 is used to connect adjacent concentrated winding stator cores 8 to each other to form a cylindrical stator 100.

[0047] Return to Figure 3 Please provide an explanation.

[0048] A circular terminal block 2 is arranged on the end face of the stator 100 of the rotary electric motor RM in the direction of rotation to form the coil end. Multiple through holes are provided on the terminal block 2, and the coil ends 70 are inserted into each through hole. In this embodiment, the number of concentrated winding coils 7 is 24, with the three coils of phase U, phase V, and phase W arranged repeatedly 8 times. Therefore, the total number of coil ends 70 is 48. The 24 coil ends 701 that begin winding are arranged on the inner circumference of the terminal block 2 and interconnected to form a neutral point. On the other hand, the 24 coil ends 702 that end winding are divided into three phases (phase U, phase V, and phase W), with 8 coils per phase. Each phase (phase U, phase V, and phase W) is arranged at different radial positions on the outer circumference of the terminal block 2. The coil ends 702 of the same phase that end winding are led out at the same radius. The 8 U-phase coils, 8 V-phase coils, and 8 W-phase coils are connected as described above to form a three-phase concentrated winding voltammetric core 8.

[0049] Coil ends 701 and 702 are inserted through holes in terminal block 2 and electrically connected to any one of the four conductors 3 (U phase, V phase, W phase, and neutral point). For this purpose, connection holes are made in the conductors 3 disposed on the surface of terminal block 2, and the end of coil end 70 is inserted through the connection holes in a manner protruding from the upper surface of the conductor 3. Subsequently, coil end 70 and the periphery of the connection holes are melted by TIG welding to join coil end 70 to conductor 3.

[0050] For example, conductor 3d connects to the coil ends 701 of 24 commutated coils 7 to form a neutral point. Conductor 3a connects to the coil ends 702 of 8 commutated coils 7 constituting the U phase, and conductor 3a is electrically connected to terminal TA1. Conductor 3b connects to the coil ends 702 of 8 commutated coils 7 constituting the V phase, and conductor 3b is electrically connected to terminal TB1. Conductor 3c connects to the coil ends 702 of 8 commutated coils 7 constituting the W phase, and conductor 3c is electrically connected to terminal TC1.

[0051] Figure 5 An exploded view showing the structure of an assembly of stator core 5, winding frame 6, and insulating paper 1 according to an embodiment of the present invention.

[0052] The stator core 5, winding frame 6, and insulating paper 1 are assembled by placing a resin winding frame 61 with a terminal block side on one end face 52a of the stator core 5, placing a resin winding frame 62 with the opposite side of the terminal block on the other end face 52b, and placing insulating paper 1 on both sides of the stator core 5 in the direction of rotation.

[0053] The resin winding frame 6 and the insulating paper 1 are made of insulating materials to maintain electrical insulation between the stator coil (not shown) and the stator core 5. With the stator core 5, winding frame 6, and insulating paper 1 assembled, the length L1 of the insulating paper 1 in the direction of rotation is larger than the length L5 of the stator core (layered electromagnet plates: laminated steel plates) 5 in the direction of rotation. The two ends of the insulating paper 1 in the direction of rotation are respectively joined to the joint 63 of the resin winding frame 61 on the terminal block side and the joint 64 of the resin winding frame 62 on the opposite side of the terminal block. The insulating paper 1 is a sheet-like insulator (sheet-like insulating member) containing short fibers. During the injection molding of the resin winding frame 6, the molten resin is incorporated between the short fibers of the insulating paper 1, thereby achieving an adhesive state on the winding frames 61 and 62.

[0054] Furthermore, the insulating paper 1 has a central portion 1a that covers the side of the stator core 5 opposite to it, and bent portions 1b and 1c that are provided on both sides of the central portion 1a in the radial direction of the stator 100. In the state before the concentrated winding coil 7 is wound, the length dimensions L1b and L1c of the circumferential bent portions 1b and 1c of the stator 100 are larger than the length dimension L51 of the yoke portion 51 that protrudes from the side of the stator core 5.

[0055] Stator core 5 is in the rotating motor RM (reference) Figure 1The stator core 5 is formed by stacking electromagnetic steel plates 5a in the direction of rotation axis. The surface of the electromagnetic steel plate 5a in contact with adjacent electromagnetic steel plates 5a is a smooth surface with an insulating coating (without any uneven surfaces for bonding), which insulates the layers of the stacked electromagnetic steel plates 5a, thereby reducing eddy current losses caused by changes in magnetic flux. The stator core 5 is formed by a stamping process. Due to stamping deformation and other effects, the stacked surfaces are not perfectly flat, and there are tiny gaps between the layers. When the resin winding frame 6 is formed, pressure is applied to the stator core 5 in the stacking direction, causing the electromagnetic steel plates to elastically deform and, in a state where the gaps between the layers collapse, bonding the resin winding frame 6 to the insulating paper 1. After injection molding, the elastically deformed electromagnetic steel plate 5a generates a rebound force (restoring force) in the direction of the interlayer gap (stack direction). However, the distance between the resin winding frames 61 and 62 at both ends of the stack direction is limited by the length of the insulating paper 1. The rebound force of the electromagnetic steel plate 5a is balanced with the tension of the insulating paper 1. Thus, the stator core 5 maintains the state in which multiple electromagnetic steel plates 5a are assembled into one piece.

[0056] Here, the effect of setting the surface of the electromagnetic steel plate 5a as a smooth surface (without uneven surfaces for convergence) will be explained.

[0057] The conventional method of using plastic deformation of the concave and convex portions to bond laminated steel sheets (electromagnetic steel sheets) has the following problems.

[0058] Convergence is the process of plastic deformation caused by the collapse of gaps between adjacent laminated steel plates under applied pressure. Since steel plates possess elastic deformation zones, minute gaps remain between them when the pressure is removed. In the case of directly molding a resin-coated body onto such a stator core, the steel plate surface is subjected to both the mold clamping force and the injection pressure of the resin. Therefore, the laminated steel plates, deformed by gap collapse under the mold clamping force, further deform by the collapse of gaps between the laminated steel plates. This deformation creates gaps between the mold and the laminated steel plates, leading to resin leakage and resulting in burrs.

[0059] To reduce molding burrs, the gaps between the stacked steel plates must be closed before resin injection to suppress deformation of the stator core caused by resin injection pressure. This necessitates increasing the clamping force, leading to larger molds and injection molding machines, thus increasing costs.

[0060] In addition, the thickness deviation of the laminated steel plates or the wear of the mold can cause changes in the convergence state. The deviation of the dimensions in the lamination direction and the deviation of the load used to close the gap between the laminated steel plates are large, so there is a risk of excessive mold closing force.

[0061] Furthermore, during coil winding, the amount of deformation differs between the convergent and non-convergent areas, making stator core warping more likely. When stator core warps, it exerts a force in the stretching direction on the insulating paper, leading to poor insulation such as damage at the joint between the resin winding frame and the insulating paper.

[0062] Furthermore, the magnetic properties of the uneven parts of the laminated steel plates and the plastic deformation parts formed by their convergence deteriorate, resulting in a decrease in the efficiency of the rotating motor due to increased iron loss.

[0063] According to this embodiment, in the stator core 5, the contact surfaces (surfaces) of adjacent electromagnets 5a in the stacking direction are smooth planes, so that adjacent stacked steel plates 5a can be easily brought into close contact. Since resin injection molding is performed in a state where the stacked steel plates 5a are in close contact, the deformation of the stacked steel plates 5a caused by injection pressure is small, thereby suppressing the generation of molding burrs. In addition, the stacked steel plates 5a are compressed in the stacking direction by the application of clamping force and resin injection pressure. In this compressed state, resin winding frames 61 and 62 are formed at both ends of the stator core 5, and the formed resin winding frames 61 and 62 are connected by insulating paper 1. Therefore, after injection molding, the restoring force of the stacked steel plates 5a (the restoring force that increases the length dimension of the electromagnets in the stacking direction) is balanced with the tension of the insulating paper 1, thereby keeping the stacked steel plates 5a in a close contact state. At this point, by making the contact surfaces (surfaces) of the adjacent electromagnetic steel plates 5a in the stacking direction smooth planes, and by making the restoring forces equal on the inner and outer circumferential sides of the stacked surface of the electromagnetic steel plates, the close contact of the stacked steel plates can be stably maintained in a state balanced with the tension of the insulating paper. Therefore, the workability will not deteriorate during the assembly of the stator core 5 and the stator 100.

[0064] Furthermore, since the contact surfaces (surfaces) of adjacent electromagnetic steel plates 5a in the stacking direction are smooth planes, the amount of deformation of the stator core does not vary with position during coil winding, thereby suppressing stator core warping. Suppressing stator core warping is particularly effective in ensuring equal restoring forces on the inner and outer circumferences of the electromagnetic steel plate stacking surfaces. As a result, insulation defects such as damage to the insulating paper are prevented, improving insulation reliability.

[0065] Furthermore, by eliminating the convergence that causes plastic deformation of the concave and convex portions, the deterioration of the magnetic properties of the laminated steel sheet 5a can be suppressed. Moreover, since the laminated steel sheets 5a are not bonded together, it becomes easier to stabilize the laminate thickness deviation caused by the thickness deviation of the laminated steel sheets 5a by adjusting the number of laminated blocks, thereby stabilizing the injection molding conditions.

[0066] In this embodiment, to ensure the bonding strength between the insulating paper 1 and the stator core 5, the difference between the length dimension L1 of the insulating paper 1 and the length dimension L5 of the stator core 5 must be sufficiently large. According to this embodiment, the influence of the gap between the laminated steel plates 5a can be reduced, thus reducing the variation of the joint 64 and reliably ensuring the area of ​​the joint 64.

[0067] Furthermore, when the surface of the laminated steel plates is provided with irregularities, one electromagnetic steel plate located at one end of the stator core in the direction of rotation must be a laminated steel plate without irregularities. This is to prevent the protrusions formed by the irregularities from protruding from one end face of the stator core 5. When the laminated steel plates are manufactured by punching from a single plate-shaped member, laminated steel plates with irregularities and those without are combined. Therefore, when adjusting the thickness deviation of the laminated steel plates caused by the thickness deviation of the plates by adjusting the number of laminated plates, the laminated steel plate with irregularities must be pulled out between the two non-irregular laminated steel plates to adjust the length L5 of the stator core 5. Thus, the process for adjusting the length L5 of the stator core 5 becomes complex.

[0068] In this invention, by smoothing the surface of the electromagnetic steel plate 5a, all the electromagnetic steel plates 5a being stacked can be made to have the same shape. Therefore, a stacked plate formed by continuously stacking electromagnetic steel plates 5a punched from a single plate-shaped member in a punching sequence can be prepared, and a stator core 5 can be constructed by extracting stacked steel plates of a specified length from the stacked plate. Thus, the next stator core 5 can be constructed by continuously stacking the electromagnetic steel plates 5a following the last electromagnetic steel plate 5a that constitutes the previous stator core 5. Therefore, the stator core 5 can be constructed without the need to extract the electromagnetic steel plates 5a, thereby simplifying the assembly operation of the stator core 5.

[0069] Figure 6 This is a partial cross-sectional view of the stator core 5 of an embodiment of the present invention, perpendicular to the axial direction of the rotating shaft 12.

[0070] The insulating paper 1 has sufficient lengths L1b and L1c to cover the concentrated winding coil 7 disposed on the side of the stator core 5 after the concentrated winding coil 7 is wound. That is, the bent portions 1b and 1c of the insulating paper 1 have sufficient lengths L1b and L1c to cover the side of the stator coil 7 opposite to the side of the stator core 5. By setting the insulating paper 1 to cover the concentrated winding coil 7 during the assembly of the stator 100, insulation between adjacent concentrated winding coils 7 can be maintained.

[0071] As explained above, according to this embodiment, even without the tightening under convergence, the electromagnetic steel plate 5a constituting the stator core 5 can be treated as a single component, thus preventing a decrease in workability during assembly. Furthermore, it can suppress warping of the stator core during coil winding, thereby improving insulation reliability. In addition, it can reduce eddy current losses. Furthermore, by using insulating paper 1 to insulate the rotational side of the stator core 5, the insulation layer can be thinned compared to using a conventional resin winding frame for insulation. Furthermore, the insulating paper 1 can be easily placed between adjacent concentrated winding coils 7, thereby improving the insulation reliability between adjacent coils and reducing the gaps between adjacent coils that form the insulation layer.

[0072] By reducing the insulation layer of the concentrated winding coil 7, more coils can be wound, thereby reducing copper losses due to lower coil resistance and improving the characteristics of the rotating motor due to increased coil turns. Furthermore, when setting the stator core 5 in the resin molding mold, it becomes easier to change the number of stacked blocks. By adjusting the number of electromagnetic steel plates 5a according to the thickness deviation of the electromagnetic steel plate 5a and the size of the mold, and setting them in the mold in a way that the length dimension L5 of the stator core 5 becomes the appropriate size, stable resin molding can be achieved.

[0073] Furthermore, according to this embodiment, the tightness of the laminated steel plates can be improved, thus improving the axial dimensional accuracy of the stator core. This also has the advantage of reducing deviations in motor characteristics. In addition, the improved dimensional accuracy of the stator core allows for stable fixing of adjacent segmented cores, thereby increasing reliability.

[0074] As described above, according to this embodiment, the insulation reliability of the rotating electric motor RM can be improved, losses reduced, and characteristics enhanced without deteriorating workability. In this embodiment, the stator core 5 has no holes. Even if holes are present for positioning or other purposes, as long as there are no protrusions on the adjacent electromagnet plates 5a in the stacking direction, they can be considered as smooth electromagnet plates 5a, thereby achieving the same effect as in this embodiment.

[0075] Furthermore, in this embodiment, the cross-sectional area of ​​the concentrated winding coil 7 is set to circular, but it can also be square. By setting it to square, the concentrated winding coil 7 can be wound at a high density, thus improving the efficiency of the rotary motor RM. In addition, in this embodiment, by using insulating paper 1 on a part of the winding frame 6, the thickness of the insulation part of the winding frame 6 can be reduced, and the duty cycle of the stator coil (concentrated winding coil) 7 can be increased.

[0076] Furthermore, the present invention includes various modifications and is not limited to the above embodiments.

[0077] For example, the above embodiments are detailed descriptions provided to illustrate the invention in an easily understandable manner, and are not necessarily limited to having all the configurations. Furthermore, other configurations may be added, deleted, or replaced in connection with parts of the embodiments.

[0078] Symbol Explanation

[0079] 1…Insulating paper, 2…Terminal plate, 3…Conductor, 5…Stator core, 6…Winding frame, 7…Concentrated winding coil (stator coil), 8…Concentrated winding stator core, 9…Outer shell, 51…Yoke, 52a, 52b…Stator core end face, 61…Resin winding frame on the terminal plate side, 62…Resin winding frame on the opposite side of the terminal plate, 70…Coil end, 91…Through hole, 100…Stator, 200…Rotor, 701…Coil end at the start of winding, 702…Coil end at the end of winding.

Claims

1. A stator of a rotary electric motor, comprising a stator core formed by stacking multiple electromagnetic steel plates and stator coils wound around the stator core with an insulator between them, characterized in that, The insulator is composed of a first winding frame portion, a second winding frame portion, and an insulating sheet. The first and second winding frame portions are located at both ends in the direction of the rotation axis of the rotary motor and are made of resin. The insulating sheet covers the side of the stator core between the first and second winding frame portions. In the electromagnetic steel plate, the contact surface with the electromagnetic steel plate adjacent in the stacking direction is composed of a smooth plane. The electromagnetic steel plate is compressed in the lamination direction by applying a clamping force and resin injection pressure. Under this compressed state, the first winding frame portion and the second winding frame portion are formed at both ends of the stator core, while the insulating sheet connects the first winding frame portion and the second winding frame portion. After injection molding, the restoring force that increases the length dimension of the electromagnet plates in the stacking direction in the stator core is balanced with the tension of the insulating sheet to keep the multiple electromagnet plates tightly connected together.

2. The stator of the rotary electric motor according to claim 1, characterized in that, The restoring force is equal on the inner and outer circumferential sides of the laminated surface of the electromagnetic steel plate.

3. The stator of the rotary electric motor according to claim 1, characterized in that, The insulating sheet has a central portion covering the side of the stator core and bent portions disposed on both sides of the central portion in the radial direction of the stator. The bent portion covers the side of the stator coil opposite to the side of the stator core.

4. A rotary electric machine characterized by have: The stator according to claim 1; and The rotor is disposed on the inner circumferential side of the stator with a gap between it and the rotor.

5. A method for assembling the stator of a rotary electric machine, the stator having a stator core formed by stacking multiple electromagnetic steel plates and a stator coil wound around the stator core with an insulator in between, the insulator being composed of a first winding frame portion, a second winding frame portion, and an insulating sheet, the first and second winding frame portions being located at opposite ends along the rotation axis of the rotary electric machine and being made of resin, the insulating sheet covering the side surface of the stator core between the first and second winding frame portions, the method for assembling the stator of this rotary electric machine being characterized in that… The electromagnetic steel plates are constructed by using electromagnetic steel plates of the same shape whose contact surfaces, which are adjacent to each other in the stacking direction, are composed of smooth planes. The electromagnetic steel sheets are produced by punching from plate-shaped components, and the electromagnetic steel sheets are continuously stacked in the punching sequence to form a stator core. The next stator core is formed by continuously stacking the electromagnetic steel sheets from the last electromagnetic steel sheet that forms the previous stator core. The electromagnetic steel plate is compressed in the lamination direction by applying a clamping force and resin injection pressure. Under this compressed state, the first winding frame portion and the second winding frame portion are formed at both ends of the stator core, while the insulating sheet connects the first winding frame portion and the second winding frame portion. After injection molding, the restoring force that increases the length dimension of the electromagnet plates in the stacking direction in the stator core is balanced with the tension of the insulating sheet to keep the multiple electromagnet plates tightly connected together.

6. The method for assembling the stator of a rotary electric machine according to claim 5, characterized in that, Electromagnetic steel sheets are stacked in such a way that the restoring force on the inner and outer circumferential sides of the stacking surface becomes equal in order to increase the length dimension of the electromagnetic steel sheets in the stacking direction.

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