Stator coils and stator of rotating motors

Abstract

The stator coil (100) is a stator coil (1) assembled on the stator core (1) of a rotating electric machine and including a plurality of coil conductors (11, 12). The thickness (L3) of the coil conductors (11, 12) arranged at least on one end face side of the stator core (1) in the axial direction (Z) is the same as the thickness (L3) of the coil conductors (11, 12) in the radial direction (Y) at the coil end portion (11e1, 12e1) and is inserted into the stator core (1). The radial (Y) thickness (L4) of the slot insertion portion (11s1, 11s2, 12s1, 12s2) of the slot (S) is the same, and the circumferential width (L1) of the coil conductor (11, 12) at the circumferential (X) end of the coil end portion (11e1, 12e1) is greater than the circumferential width (L2) of the coil conductor (11, 12) at the slot insertion portion (11s1, 11s2, 12s1, 12s2).

Description

Technical Field

[0001] This application relates to stator coils and stators of rotating electrical machines. Background Technology

[0002] In recent years, there has been a strong demand for miniaturization and increased output in motors. To achieve this, it is necessary to increase the duty cycle of the conductors inserted into the stator, thereby reducing copper losses. Previously, when the cross-sectional area of ​​the stator coil conductors was the same throughout the windings, the cross-sectional shape of the coil end portion was the same as the cross-sectional shape of the portion of the coil inserted into the slot. This made it difficult to reduce the resistance at the coil end portion without changing its length.

[0003] Therefore, Patent Document 1 discloses a technology configured as follows: for the conductor of the coil used as the stator core of a rotating electric machine, the portion that serves as the slot insertion part is pre-stamped to make the cross-sectional area smaller than that of the original conductor, so that the cross-sectional area of ​​the conductor that serves as the end part of the coil is larger than the cross-sectional area of ​​the portion that serves as the slot insertion part.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2003-32933 Summary of the Invention

[0007] The technical problem that the invention aims to solve

[0008] When the cross-sectional area of ​​the conductor forming the coil is reduced, the resistance increases and the copper loss increases. As in Patent Document 1, when the cross-sectional area of ​​the conductor at the end of the coil is increased, the copper loss in that part can be reduced. On the other hand, there is a technical problem that the cross-sectional area of ​​the conductors adjacent to each other at the end of the coil is difficult to increase due to the circumferential space limitation, which makes it difficult to increase the difference between the cross-sectional area of ​​the conductor and the slot insertion part.

[0009] This application is made to solve the above-mentioned problems, and aims to provide a stator coil and a stator for a rotating motor that can reduce copper losses by increasing the cross-sectional area of ​​the conductor at the end of the coil compared with the cross-sectional area of ​​the conductor at the slot insertion part while preventing interference between the ends of the coils.

[0010] Technical solutions for solving technical problems

[0011] The stator coil disclosed in this application is a stator coil assembled in the stator core of a rotating electric machine, comprising a plurality of coil conductors. The stator core of the rotating electric machine includes: an annular magnetic yoke portion, a plurality of teeth formed at equal intervals along the circumferential direction from the inner circumferential surface of the magnetic yoke portion and protruding radially inward, and a plurality of slots formed between adjacent teeth.

[0012] The radial thickness of the coil conductor at the end of the coil, provided at least on one end face side of the stator core along the axial direction, is the same as the radial thickness of the slot insertion portion of the coil conductor into the slot of the stator core.

[0013] The circumferential width of the coil conductor at the circumferential end of the coil end is greater than the circumferential width of the coil conductor at the slot insertion portion.

[0014] In addition, the stator of the rotary motor disclosed in this application includes: a stator core of the rotary motor; and the stator coil, wherein the stator core of the rotary motor includes: an annular magnetic yoke portion, a plurality of teeth formed at equal intervals along the circumferential direction from the inner circumferential surface of the magnetic yoke portion and protruding radially inward, and a plurality of slots formed between adjacent teeth.

[0015] Invention Effects

[0016] According to the stator coil and stator of the rotating motor disclosed in this application, a stator coil and stator of the rotating motor can be provided that can reduce copper loss while preventing interference between the ends of the coils. Attached Figure Description

[0017] Figure 1 A perspective view showing the structure of the stator coil in Embodiment 1.

[0018] Figure 2 This is an enlarged view of the main part of the stator formed by assembling stator coils onto a stator core according to Embodiment 1.

[0019] Figure 3 This is a perspective view showing the structure of the stacked coil conductor formed by combining the first coil conductor and the second coil conductor in Embodiment 1.

[0020] Figure 4 A perspective view showing the structure of the first coil conductor constituting the laminated coil conductor in Embodiment 1.

[0021] Figure 5 A perspective view showing the structure of the second coil conductor constituting the laminated coil conductor in Embodiment 1.

[0022] Figure 6This is a top view schematic diagram showing a portion of the stator core and wiring structure for assembling the stator coil in Embodiment 1.

[0023] Figure 7 To show Figure 4 An enlarged view of the area near the boundary between the slot insertion portion and the end portion of the first coil conductor.

[0024] Figure 8 This is a schematic diagram of a combined coil consisting of three stacked coil conductors, viewed from the outer periphery side, according to Embodiment 1.

[0025] Figure 9 For along Figure 3 The diagram shows the stacked coil conductor viewed in the direction of arrow A (axial direction).

[0026] Figure 10 This is a cross-sectional view of embodiment 1, perpendicular to the axial direction of the stator core formed by inserting four combined coils into slots.

[0027] Figure 11 A perspective view showing another example of the stator core of Embodiment 2.

[0028] Figure 12 This is a perspective view of the stacked segmented coil conductors of Embodiment 3.

[0029] Figure 13 This diagram illustrates the connection state between the stacked segmented coil conductors of Embodiment 3.

[0030] Figure 14 This is a cross-sectional schematic diagram illustrating the structure of the stator obtained by combining multiple stacked segmented coil conductors to form a stator coil in Embodiment 3.

[0031] Figure Labels

[0032] 1, 1B: Stator core; 1a: Yoke; 1b: Tooth; 100: Stator coil; 100A: Coil group; 10A, 10B, 10C: Laminated coil conductors; S10: Laminated segmented coil conductors; 10Ae1, 10Ae2, 10Be2, 10Ce2: End portions of laminated coils; 10r: Insulator; 11, 11A, 11B, 11C, 11D: First coil conductor; S11: First segmented coil conductor; 11Ae, 11Be, 11Ce, 11De: End of winding; 11As, 11Bs, 11Cs, 11Ds: Beginning of winding; 1AT1, 11AT2, 11BT1, 11BT2: Cut-off section; 11e1, 11e2, 12e1, 12e2, S11e1, S11e2, S12e1, S12e2: Coil end section; 11s1, 11s2, 12s1, 12s2, S11s1, S11s2, S12s1, S12s2: Slot insertion section; 12: Second coil conductor; S12: Second segmented coil conductor; 4A~4D: Combined coil; 50, 50B: Stator; N: Neutral point; O: Lead-out wire; S: Slot; SP: Spacing; X: Circumferential; Y: Radial; Z: Axial. Detailed Implementation

[0033] Implementation method 1.

[0034] The following description, based on the accompanying drawings, illustrates the stator coil of Embodiment 1 and the stator of the rotating electric machine.

[0035] In this specification, unless otherwise specified, when referring to "axial", "circumferential", "radial", "inner circumferential side", and "outer circumferential side", they respectively refer to the "axial", "circumferential", "radial", "inner circumferential side", and "outer circumferential side" of the sub-coil.

[0036] Figure 1 A perspective view showing the structure of the stator coil 100. However... Figure 1 The entirety of the coil conductors used is not shown in the diagram.

[0037] Figure 2 This is an enlarged view of the main parts of the stator 50, which is formed by assembling the stator coil 100 onto the stator core 1. However... Figure 2 The entirety of the coil conductors used is not shown in the diagram.

[0038] Figure 3 A perspective view showing the structure of the stacked coil conductor 10A.

[0039] Figure 4 A perspective view showing the structure of the first coil conductor 11 constituting the laminated coil conductor 10A.

[0040] Figure 5A perspective view showing the structure of the second coil conductor 12 constituting the laminated coil conductor 10A.

[0041] Figure 6 This is a top view showing a portion of the stator core 1 and wiring structure for assembling the stator coil 100.

[0042] like Figure 6 As shown, the stator 50 of the rotary electric machine has an annular stator core 1 and a stator coil 100 (100A is a part thereof), the stator coil 100 including a plurality of first coil conductors 11 (details will be described later) and a plurality of second coil conductors 12 inserted into slots S of the stator core 1.

[0043] The stator core 1 has an annular magnetic yoke 1a and 96 teeth 1b that are formed circumferentially at equal intervals from the inner circumferential surface of the magnetic yoke 1a and protrude radially inward. Grooves formed between adjacent teeth 1b and extending axially are called grooves S. Four groove insertion portions of the stator coil 100, described later, are inserted into each groove S.

[0044] The stator coil 100 includes four combined coils: 4A, 4B, 4C, and 4D. Figure 1 , Figure 2 Only the combined coils 4A and 4B are shown. In reality, inside combined coil 4B is a combined coil 4C with the same shape as combined coil 4A but a slightly smaller inner diameter, and further inside is a combined coil 4D with the same shape as combined coil 4B but an even smaller inner diameter. (See attached image.) Figure 2 As shown, each of the combined coils 4A to 4D includes three stacked coil conductors 10A, 10B, and 10C. The difference between the stacked coil conductors 10A, 10B, and 10C lies in the fact that the ends of the coils are staggered by six slots in the circumferential direction X, while the coil structures themselves are identical. That is, for example, the ends of each coil in combined coil 4B are staggered by six slots relative to the ends of each coil in combined coil 4A in the circumferential direction X+.

[0045] Next, use Figure 3 , Figure 4 , Figure 5 Taking the laminated coil conductor 10A as an example, the laminated coil conductors 10A to 10C and the first coil conductor 11 and the second coil conductor 12 constituting the laminated coil conductors 10A to 10C will be described. Figure 3 , Figure 4 , Figure 5 The left-right direction of the paper is the circumferential X. For convenience, the right side of the paper is designated as the + side (one direction), and the left side as the - side (the other direction). Additionally, the direction from the front of the paper inwards and its opposite direction is the radial Y. Furthermore, the up-down direction of the paper is the axial Z. For convenience, the upper part of the paper is designated as the + side (one end), and the lower part as the - side (the other end).

[0046] like Figure 3 As shown, the stacked coil conductor 10A is a structure formed by stacking the first coil conductor 11 and the second coil conductor 12 in the radial Y direction.

[0047] like Figure 4 As shown, the first coil conductor 11 includes slot insertion portions 11s1 and 11s2 inserted into the stator core 1 and coil end portions 11e1 and 11e2. The coil end portions 11e1 and 11e2 connect the ends of the slot insertion portions 11s1 and 11s2 on one side of the axial Z axis to each other and the ends on the other side of each other alternately and continuously.

[0048] exist Figure 4 In this configuration, the end of the slot insertion portion 11s1 closest to the circumferential X-side on the axial Z-side is continuously connected to the end of the coil end portion 11e1, which is located closest to the circumferential X-side and extends towards the axial Z+ side. Then, the end of the coil end portion 11e1 on the circumferential X+ side is continuously connected to the end of the next slot insertion portion 11s2, which is inserted into the slot S that is 6 slots away from the circumferential X+ side, on the axial Z-side.

[0049] Then, the end of the slot insertion portion 11s2 on the axial Z+ side is continuously connected to the end of the next coil end portion 11e2 on the circumferential X- side, which extends circumferentially to the X+ side. Then, the end of the coil end portion 11e2 on the circumferential X+ side is continuously connected to the end of the next slot insertion portion 11s1 on the axial Z+ side, which is inserted into the slot S that is 6 slots away from the circumferential X+ side. In this way, in the first coil conductor 11, the slot insertion portions 11s1, 11s2 and the coil end portions 11e1, 11e2 are connected alternately and continuously. That is, by means of the coil end portions 11e1, 11e2 alternately arranged on the two end faces of the stator core 1 in the axial Z direction, the slot insertion portions 11s1, 11s2 are connected alternately and continuously in the axial Z direction.

[0050] Similarly, as Figure 5 As shown, the second coil conductor 12 includes slot insertion portions 12s1 and 12s2 inserted into the stator core 1 and coil end portions 12e1 and 12e2. The coil end portions 12e1 and 12e2 connect the ends of the slot insertion portions 12s1 and 12s2 on one side of the axial Z axis to each other and the ends on the other side of each other alternately and continuously.

[0051] exist Figure 5In this configuration, the end of the slot insertion portion 12s1 closest to the circumferential X-side on the axial Z-side is continuously connected to the end of the coil end portion 12e1, which is located closest to the circumferential X-side and extends towards the axial Z+ side. Then, the end of the coil end portion 12e1 on the circumferential X+ side is continuously connected to the end of the next slot insertion portion 12s2, which is inserted into the slot S that is 6 slots away from the circumferential X+ side, on the axial Z-side.

[0052] Then, the end of the slot insertion portion 12s2 on the axial Z+ side is continuously connected to the end of the next coil end portion 12e2 on the circumferential X- side, which extends towards the circumferential X+ side. Then, the end of the coil end portion 12e2 on the circumferential X+ side is continuously connected to the end of the next slot insertion portion 12s1 on the axial Z+ side, which is inserted into the slot S that is 6 slots away from the circumferential X+ side. In this way, in the second coil conductor 12, the slot insertion portions 12s1, 12s2 and the coil end portions 12e1, 12e2 are connected alternately and continuously. That is, by means of the coil end portions 12e1, 12e2 alternately arranged on the two end faces of the stator core 1 in the axial Z direction, the slot insertion portions 12s1, 12s2 are connected alternately and continuously in the axial Z direction.

[0053] The first coil conductor 11 and the second coil conductor 12 are configured as described above. Figure 3 As shown, the laminated coil conductor 10A is formed by overlapping in the radial Y direction. The structures of the laminated coil conductors 10B and 10C are the same as those of the laminated coil conductor 10A. The laminated coil conductors 10A to 10C are staggered in the circumferential X direction, as shown... Figure 2 The components are assembled into the stator core 1. Regarding the coil end portion 11e1 of the first coil conductor 11 and the coil end portion 12e1 of the second coil conductor 12, when viewed radially along the Y direction, the central portions in the circumferential direction X completely overlap, differing only in shape on both sides in the circumferential direction X. The same applies to the coil end portions 11e2 and 12e2.

[0054] On the other hand, regarding the slot insertion portion 11s1 of the first coil conductor 11 and the slot insertion portion 12s1 of the second coil conductor 12, when viewed radially Y, they are offset in the circumferential direction X by an amount corresponding to one slot S. That is, when the slot insertion portions 11s1 of the first coil conductor 11 and 12s1 of the second coil conductor 12 are respectively inserted into adjacent slots S and assembled into the stator core 1, there is one tooth 1b between each slot insertion portion 11s1, 12s1. The relationship between the slot insertion portions 11s2 of the first coil conductor 11 and 12s2 of the second coil conductor 12 is the same. The first coil conductor 11 and the second coil conductor 12 are covered by an insulating material not shown.

[0055] The coil end portion 11e1 of the first coil conductor 11 and the coil end portion 12e1 of the second coil conductor 12 can be joined together with an insulator 10r in between. The insulator 10r can be made of insulating paper, fiber-reinforced plastic, resin film, adhesive sheet, etc. These materials can also be combined. The same applies to the coil end portions 11e2 of the first coil conductor 11 and 12e2 of the second coil conductor 12. Furthermore, the structure of the combined coils 4B to 4D is the same as that of the combined coil 4A, except for the difference in inner diameter when assembled into the stator core 1.

[0056] Figure 7 To show Figure 4 An enlarged view of the area near the boundary between the slot insertion portion 11s2 and the coil end portion 11e2 of the first coil conductor 11 shown.

[0057] like Figure 2 , Figure 4 , Figure 7 As shown, the circumferential X-width L1 of the first coil conductor 11 at the end portion 11e2 on the circumferential X-side is the same as the circumferential X-width L2 of the slot insertion portion 11s2 of the first coil conductor 11, which is the same as the circumferential X-width SP of the slot S. A slot insertion portion 11s2 with a smaller circumferential X-width is connected to this end portion on the circumferential X-side. The boundary between the slot insertion portion 11s1 of the first coil conductor 11 and the end portion 11e1 is also the same.

[0058] The circumferential width of the first coil conductor 11 at the end of the coil end portion 11e2 on the circumferential X+ side gradually decreases to be the same as the circumferential width of the slot insertion portion 11s1. The radial Y thickness L3 of the coil end portions 11e1 and 11e2 of the first coil conductor 11 is the same as the radial Y thickness L4 of the slot insertion portions 11s1 and 11s2 of the first coil conductor 11. Therefore, the cross-sectional area perpendicular to the long side direction of the coil end portions 11e1 and 11e2 of the first coil conductor 11 is larger than the cross-sectional area perpendicular to the long side direction of the slot insertion portions 11s1 and 11s2. Therefore, the electrical resistance of the coil end portions 11e1 and 11e2 is reduced, and the copper loss of the first coil conductor 11 can be reduced.

[0059] Furthermore, the circumferential X width L1 of the second coil conductor 12 at the circumferential X+ side of the end portion 12e2 is the same as the width obtained by adding the circumferential X spacing SP of the slots S to the width L2 of the slot insertion portion 12s1 of the second coil conductor 12. A slot insertion portion 12s1 with a smaller circumferential X width is connected to this end portion on the circumferential X+ side. The same applies to the boundary between the slot insertion portion 12s2 of the second coil conductor 12 and the end portion 12e1 of the coil.

[0060] The circumferential width of the second coil conductor 12 at the end of the coil end portion 12e2 on the X-side gradually decreases until it is the same as the circumferential width of the slot insertion portion 12s2. The radial thickness L3 of the coil end portions 12e1 and 12e2 of the second coil conductor 12 is the same as the radial thickness L4 of the slot insertion portions 12s1 and 12s2 of the second coil conductor 12. Therefore, the cross-sectional area perpendicular to the long side of the coil end portions 12e1 and 12e2 of the second coil conductor 12 is larger than the cross-sectional area perpendicular to the long side of the slot insertion portions 12s1 and 12s2. As a result, the electrical resistance of the coil end portions 12e1 and 12e2 is reduced, thereby reducing the copper loss of the second coil conductor 12.

[0061] As described above, the slot insertion portion 11s1 of the first coil conductor 11 and the slot insertion portion 12s1 of the second coil conductor 12 are respectively inserted into adjacent slots S in the circumferential direction X, and the slot insertion portions 11s2 of the first coil conductor 11 and the slot insertion portions 12s2 of the second coil conductor 12 are also respectively inserted into adjacent slots S in the circumferential direction X. That is, the slot insertion portions 11s1 of the first coil conductor 11 and the slot insertion portions 12s1 of the second coil conductor 12 are arranged such that the center lines of the slot insertion portions 11s1 and 12s1 are separated by a slot spacing in the circumferential direction X, and there are teeth 1b between them in the circumferential direction X. The relationship between the slot insertion portions 11s2 of the first coil conductor 11 and the slot insertion portions 12s2 of the second coil conductor 12 is the same.

[0062] The slot insertion portion 11s1 of the first coil conductor 11 and the coil end portion 12e2 of the second coil conductor 12 are offset in the radial Y direction and will not contact each other. Similarly, the slot insertion portion 11s2 of the first coil conductor 11 and the coil end portion 12e1 of the second coil conductor 12 are offset in the radial Y direction and will not contact each other.

[0063] Figure 8 This is a schematic diagram showing the combined coil 4A, which is composed of three stacked coil conductors 10A, 10B, and 10C, viewed from the outer periphery. For clarity, the overall structure is depicted as a planar image. The normally invisible teeth 1b are also shown.

[0064] Figure 9 From Figure 3 The diagram shows the view of the stacked coil conductor 10A in the direction of arrow A (axial direction Z).

[0065] The two slot insertion portions 11s1 and 11s2 of the first coil conductor 11, which constitutes the composite coil 4A, are inserted into slots S located six slots away in the circumferential X direction. The two slot insertion portions 12s1 and 12s2 of the second coil conductor 12, which is integrated with the first coil conductor 11, are inserted into slots S next to the slots S where the slot insertion portions 11s1 and 11s2 of the first coil conductor 11 are inserted, on the circumferential X+ side.

[0066] Each slot insertion portion 11s1 to 12S2 of the laminated coil conductor 10B constituting the combined coil 4A is inserted into a slot S that moves two slots away from each slot S in the X+ direction circumferentially where the slot insertion portions 11s1 to 12s2 of the laminated coil conductor 10A constituting the combined coil 4A are inserted. Each slot insertion portion 11s1 to 12S2 of the laminated coil conductor 10C constituting the combined coil 4A is inserted into a slot S that moves two slots away from each slot in the X+ direction.

[0067] As described above, in this embodiment, three laminated coil conductors 10A to 10C are combined to form a combined coil 4A. When combining the laminated coil conductors 10A, 10B, and 10C, to prevent the laminated coil ends 10Ae1, 10Be1, and 10Ce1 of the laminated coil conductors 10A to 10C from interfering with each other, the outermost extensions (tops) of the laminated coil ends 10Ae1 to 10Ce1 need to be bent in a radially Y-directed manner, offset by an amount corresponding to the thickness of the laminated coil conductor 10A. The reason for this will be explained below.

[0068] like Figure 1 , Figure 2 , Figure 8 As shown, the radial Y positions of all slot insertion portions 11s1, 11s2, 12s1, and 12s2 of the laminated coil conductors 10A to 10C constituting the combined coil 4A inserted into the slots S of the stator core 1 are all the same in each slot S, that is, at the outermost position in the radial Y direction. Similarly, the radial Y positions of all slot insertion portions 11s1, 11s2, 12s1, and 12s2 of the laminated coil conductors 10A to 10C constituting the combined coil 4B are all the same in each slot S, that is, at the second position from the outermost position in the radial Y direction.

[0069] However, as Figure 8 As shown, on the outer side of the radial Y direction of the laminated coil end portion 10Ae2 of the laminated coil conductor 10A, there are the laminated coil end portion 10Be2 of the laminated coil conductor 10B and the laminated coil end portion 10Ce2 of the laminated coil conductor 10C. Therefore, in order to accommodate all the slot insertion portions 11s1, 11s2, 12s1, and 12s2 constituting the laminated coil conductor 10A at the same position in the radial Y direction, as... Figure 9As shown, the end portion 10Ae2 of the laminated coil needs to be bent to offset in the radial Y direction by an amount corresponding to the thickness of the radial Y direction of the end portion 10Ae2. The same applies to the end portion 10Ae1 of the laminated coil, and also to the end portions of each laminated coil conductor 10B, 10C.

[0070] Figure 10 This is a cross-sectional view of the stator core 1, which is formed by inserting four combined coils 4A, 4B, 4C, and 4D into slot S, perpendicular to the axis Z.

[0071] As described above, the ends of each coil are bent in the radial Y direction. Therefore, the radial Y thickness of the coil ends 11e1 to 12e2 (not the radial Y thickness of the conductor itself, but the radial thickness of the entire stacked coil ends 10Ae1) is thicker than the radial Y thickness of the slot insertion portion. Therefore, when it is desired to stack the combined coils 4A to 4D in the radial Y direction and insert the slot insertion portions 11s1 to 12s2 of each first coil conductor 11 and second coil conductor 12 into the slot S, when attempting to arrange the slot insertion portions 11s1 to 12s2 close together in the radial Y direction, for example, the three stacked coil ends 10Ae2 to 10Ce2 interfere with each other in the radial Y direction.

[0072] Therefore, by appropriately bending the coil ends 11e1 to 12e2 radially Y from the root, interference at the coil ends is eliminated, allowing the slot insertion portions 11s1 to 12s2 to be inserted as follows: Figure 10 The arrangement shown is dense. In addition, an insulating material such as insulating paper (not shown) can be inserted between the inner wall of the slot S and the first coil conductor 11 and the second coil conductor 12.

[0073] The winding structure of stator coil 100 will be described next.

[0074] As described above, the stator coil 100 of the stator 50 includes four combined coils 4A, 4B, 4C, and 4D. All combined coils 4A to 4D have identical structures. Each combined coil 4A, 4B, 4C, and 4D includes three stacked coil conductors 10A, 10B, and 10C, respectively. Furthermore, each stacked coil conductor 10A to 10C is constructed by stacking and integrating the first coil conductor 11 and the second coil conductor 12.

[0075] The first coil conductor 11 of all (4) stacked coil conductors 10A that make up the combined coils 4A to 4D constitutes a coil group 100A of one phase.

[0076] In addition, the second coil conductor 12 of all the stacked coil conductors 10A that constitute the combined coils 4A to 4D constitutes a coil group of one phase.

[0077] In addition, the first coil conductor 11 of all the stacked coil conductors 10B that make up the combined coils 4A to 4D constitutes a coil group of one phase.

[0078] In addition, the second coil conductor 12 of all the stacked coil conductors 10B that make up the combined coils 4A to 4D constitutes a coil group of one phase.

[0079] In addition, the first coil conductor 11 of all the stacked coil conductors 10C that make up the combined coils 4A to 4D constitutes a coil group of one phase.

[0080] In addition, the second coil conductor 12 of all the stacked coil conductors 10C that make up the combined coils 4A to 4D constitutes a coil group of one phase.

[0081] Next, use Figure 6 The coil group 100A of one phase, which is formed by the first coil conductor 11 of all the stacked coil conductors 10A constituting the combined coils 4A to 4D, will be described.

[0082] Figure 6 The diagram only shows the coil group 100A of one phase, consisting of the four first coil conductors 11 of the four stacked coil conductors 10A constituting the combined coils 4A to 4D; other coil conductors are omitted. The end face of the stator core 1 on the axial Z+ side ( Figure 6 The visible side is designated as the first end face, and the end face on the Z-axis side is designated as the first end face. Figure 6 The side that is not visible in the middle is designated as the second end face. Figure 6 In the diagram, when the end of the coil is visible on one end, it is drawn with a solid line; when it is not visible on the other end, it is drawn with a dashed line.

[0083] In addition, Figure 6 In the diagram, the first coil conductor 11 of the laminated coil conductor 10A constituting the combined coil 4A is shown as the first coil conductor 11A, the first coil conductor 11 of the laminated coil conductor 10A constituting the combined coil 4B is shown as the first coil conductor 11B, the first coil conductor 11 of the laminated coil conductor 10A constituting the combined coil 4C is shown as the first coil conductor 11C, and the first coil conductor 11 of the laminated coil conductor 10A constituting the combined coil 4D is shown as the first coil conductor 11D.

[0084] The four first coil conductors 11A to 11D are arranged in the following order from the radial Y-side outward of the stator core 1: first coil conductor 11A, first coil conductor 11B, first coil conductor 11C, and first coil conductor 11D. The slot insertion portions 11s1 and 11s2 of the first coil conductors 11A to 11D are inserted into the same slot Sn, which is six slots away from slot S1 of the stator core 1, up to slot S91.

[0085] A coil end portion 11e1 is formed on the second end face side, connecting the end of the slot insertion portion 11s1 of the first coil conductor 11A inserted at the outermost radial Y position of slot S1 to the end of the slot insertion portion 11s2 inserted at the outermost radial Y position of slot S7. A coil end portion 11e2 is formed on the first end face side, connecting the end of the slot insertion portion 11s2 inserted at the outermost radial Y position of slot S7 to the end of the slot insertion portion 11s1 inserted at the outermost radial Y position of slot S13. Thus, coil end portions 11e1 and 11e2 are alternately formed on the second and first end face sides of the stator core 1. The structure of the first coil conductor 11C inserted at the third position from the outermost radial Y position of slot S1 is the same as that of the first coil conductor 11A described above.

[0086] The first coil conductor 11B, inserted at the second position from the radial Y outer side of slot S1, has the same structure as the first coil conductor 11D inserted at the fourth position, but differs from the first coil conductor 11A in that the formation of the end portion of each coil is on the opposite side of the axial Z.

[0087] At the first end face of the stator core 1, the winding start end 11As of the first coil conductor 11A extending from the outermost radial Y of slot S1 is engaged with the winding end end 11Ce of the first coil conductor 11C extending from the third position from the outer radial Y of slot S91.

[0088] In addition, the winding start end 11Cs of the first coil conductor 11C extending from the third position on the radial Y side of slot S1 engages with the winding end end 11Ae of the first coil conductor 11A extending from the outermost position on the radial Y side of slot S91.

[0089] At the second end face of the stator core 1, the winding start end 11Bs of the first coil conductor 11B extending from the second position on the radial Y-side of slot S1 engages with the winding end end 11De of the first coil conductor 11D extending from the fourth position on the radial Y-side of slot S91.

[0090] In addition, the winding start end 11Ds of the first coil conductor 11D extending from the fourth position radially outward from the slot S1 engages with the winding end end 11Be of the first coil conductor 11B extending from the second position radially outward from the slot S91.

[0091] Furthermore, the coil end portion 11e2 of the first coil conductor 11A extending from slot S19 and slot S25 toward the first end face side of the stator core 1 is cut off, and the coil end portion 11e2 of the first coil conductor 11B extending from slot S25 and slot S31 toward the first end face side of the stator core 1 is cut off.

[0092] Then, the cut-off portion 11BT1 of the first coil conductor 11B extending from slot S31 is joined with the cut-off portion 11AT1 of the first coil conductor 11A extending from slot S25, so that the first coil conductors 11A to 11D are connected in series to form a coil group 100A of one phase with 6 teeth and 2 turns.

[0093] In addition, the cut-off portion 11BT2 on the other side of the first coil conductor 11B extending from slot S25 is the lead wire O, and the cut-off portion 11AT2 on the other side of the first coil conductor 11A extending from slot S19 is the neutral point N.

[0094] For a coil group consisting of the second coil conductor 12 of all the stacked coil conductors 10A constituting the combined coils 4A to 4D, the slot insertion parts 12s1 and 12s2 are staggered by one slot and arranged in slot Sn, which is 6 slots away from slot S2 to slot S92 along the circumferential direction X.

[0095] In addition, for the coil group of one phase consisting of the first coil conductor 11 of all the stacked coil conductors 10B constituting the combined coils 4A to 4D, the slot insertion parts 11s1 and 11s2 are each staggered by one slot and arranged in slot Sn, which is 6 slots away from slot S3 to slot S93 along the circumferential direction X.

[0096] In addition, for the coil group of one phase consisting of the second coil conductor 12 of all the stacked coil conductors 10B constituting the combined coils 4A to 4D, the slot insertion parts 12s1 and 12s2 are each staggered by one slot and arranged in slot Sn, which is 6 slots away from slot S4 to slot S94 along the circumferential direction X.

[0097] In addition, for the coil group of one phase consisting of the first coil conductor 11 of all the stacked coil conductors 10C constituting the combined coils 4A to 4D, the slot insertion parts 11s1 and 11s2 are each staggered by one slot and placed in slot Sn, which is 6 slots away from slot S5 to slot S95 along the circumferential direction X.

[0098] In addition, for the coil group of one phase consisting of the second coil conductor 12 of all the stacked coil conductors 10C constituting the combined coils 4A to 4D, the slot insertion parts 12s1 and 12s2 are each staggered by one slot and placed in slot Sn, which is 6 slots away from slot S6 to slot S96 along the circumferential direction X.

[0099] Then, the coil group 100A wound around slot Sn (6 slots away from slot S1 to slot S91), the coil group wound around slot Sn (6 slots away from slot S3 to slot S93), and the coil group wound around slot Sn (6 slots away from slot S5 to slot S95) are connected to each other at their neutral points (N) and are Y-connected. The coil group wound around slot Sn (6 slots away from slot S2 to slot S92), the coil group wound around slot Sn (6 slots away from slot S4 to slot S94), and the coil group wound around slot Sn (6 slots away from slot S6 to slot S96) are connected to each other at their neutral points (N) and are Y-connected, thus forming a stator coil 100 including two sets of three-phase AC coil groups.

[0100] Furthermore, at the beginning, end, and connection points of the stator coil 100, the coil conductors are separated from each other by an insulator, becoming only coil conductors. During the joining process, the insulating covering at the joining points is removed.

[0101] According to Embodiment 1, the stator coil 100 and the stator 50 of the rotating motor can provide a stator coil and a stator of the rotating motor that prevent interference between the coil ends and increase the cross-sectional area of ​​the conductor at the coil end to be larger than the cross-sectional area of ​​the conductor at the slot insertion part, thereby reducing copper loss.

[0102] In addition, for two coil conductors having multiple slot insertion portions inserted into adjacent slots in the circumferential direction, the coil ends are overlapped together in the radial direction to form a stacked coil conductor. This allows the width of the conductor on the coil end side of the connection portion between the coil end and the slot insertion portion to be increased to the width obtained by adding the circumferential width of the adjacent slot, thereby reducing the copper loss of the stator coil.

[0103] Furthermore, in this embodiment 1, the slot insertion portions of the first coil conductor 11 and the second coil conductor 12 are arranged in slots S that are away from the six slots, but are not limited to slots S that are away from the six slots.

[0104] Implementation method 2.

[0105] The stator coil and stator of the rotating electric machine of Embodiment 2 will be described below based on the accompanying drawings, focusing on the parts that differ from Embodiment 1.

[0106] Figure 11 A perspective view showing an example of a strip-shaped stator core 1B.

[0107] In Embodiment 1, an annular stator core 1 was used for illustration, and as... Figure 11As shown, the combined coils 4A to 4D are sequentially embedded in the stator core 1B. With the combined coils 4A to 4D embedded in the stator core 1B, the stator core 1B is wound into a ring shape, and the two ends of the stator core 1B are joined together. Then, the combined coils 4A to 4D are appropriately connected together. This also enables the manufacture of a stator 50 with a three-phase AC stator coil 100. However, it is not limited to manufacturing using this method.

[0108] Implementation method 3.

[0109] Based on the accompanying drawings, the stator coil and stator of the rotating electric machine of Embodiment 3 will be described below, focusing on the parts that differ from Embodiment 1.

[0110] In Embodiment 1, a series of first coil conductors 11 and second coil conductors 12 were used for illustration, but it can also be formed by joining segmented coils that are divided in the circumferential X direction together. The ends of the segmented coils are joined together with each other via portions extending from the end face of the stator core 1 in the axial Z direction.

[0111] Figure 12 This is a three-dimensional view of the stacked segmented coil conductor S10.

[0112] The stacked segmented coil conductor S10 includes a first segmented coil conductor S11 and a second segmented coil conductor S12. The slot insertion portions S11s1 and S11s2 of the first segmented coil conductor S11 are continuously connected by a coil end portion S11e, the width L1 in the circumferential direction of S11s1 being greater than the circumferential width L2 of both slot insertion portions S11s1 and S11s2. Similarly, the slot insertion portions S12s1 and S12s2 of the second segmented coil conductor S12 are continuously connected by a coil end portion S12e1, the width L1 in the circumferential direction of S12s1 being greater than the circumferential width L2 of both slot insertion portions S12s2 and S12s2. The first segmented coil conductor S11 and the second segmented coil conductor S12 are stacked radially Y-oriented, separated by an insulator 10r.

[0113] Figure 13 This diagram illustrates the connection state between the stacked segmented coil conductors S10.

[0114] The portion protruding from slot S in the axial direction Z is bent and connected to the adjacent stacked segmented coil conductor S10, forming coil end portion S11e2 and coil end portion S12e2. In this way, a coil is obtained that is installed in the same slot Sn as the stacked coil conductor 10A described above.

[0115] For the coil end portions S11e2 and S12e2, which connect adjacent stacked segmented coil conductors S10 to each other, the width of the circumferential X can be made larger than the width of the circumferential X of each slot insertion portion.

[0116] Figure 14 This is a cross-sectional schematic diagram showing the structure of a stator 50B obtained by mounting a stator coil 100 composed of multiple stacked segmented coil conductors S10.

[0117] As shown in the figure, multiple stacked segmented coil conductors S10 can be stacked in the radial Y direction with a continuous insulator 10r between them, and the multiple stacked segmented coil conductors S10 are integrated.

[0118] The stator coil and the stator of the rotating motor according to Embodiment 3 achieve the same effect as Embodiment 1.

[0119] This application describes various exemplary embodiments and examples, but the various features, forms and functions described in one or more embodiments are not limited to the application in a specific embodiment, but can be applied to the embodiments alone or in various combinations.

[0120] Therefore, numerous variations not illustrated are contemplated within the scope of the technology disclosed in this application. These include variations, additions, or omissions of at least one constituent element, as well as extraction of at least one constituent element and combination with constituent elements of other embodiments.

Claims

1. A stator coil assembled in the stator core of a rotating electric machine, and comprising a plurality of coil conductors, the stator core of the rotating electric machine comprising: an annular yoke portion, a plurality of teeth formed at equal intervals circumferentially from the inner circumferential surface of the yoke portion and projecting radially inward, and a plurality of slots formed between adjacent teeth, wherein, The radial thickness of the coil conductor at the end of the coil, provided at least on one end face side of the stator core along the axial direction, is the same as the radial thickness of the slot insertion portion of the coil conductor into the slot of the stator core. The circumferential width of the coil conductor at the circumferential end of the coil end is greater than the circumferential width of the coil conductor at the slot insertion portion. The coil conductor exists in two forms: a first coil conductor and a second coil conductor. The first coil conductor includes: a plurality of slot insertion portions inserted into slots in the stator core at a predetermined number of slots; and a plurality of coil end portions, wherein the axial ends of the slot insertion portions are alternately and continuously connected to each other at one end and the other end of the stator core; and The second coil conductor includes: a plurality of slot insertion portions inserted into slots of the stator core at a predetermined number of slots; and a plurality of coil end portions, wherein the axial ends of the slot insertion portions are alternately and continuously connected to each other on one end side and the other end side of the stator core. The stator coil has stacked coil conductors, which are formed by stacking the first coil conductor and the second coil conductor radially. When viewed radially, the circumferential central portion of the coil end of the first coil conductor overlaps with the circumferential central portion of the coil end of the second coil conductor. The slots into which the slots of the first coil conductor are inserted are offset by one slot in the circumferential direction from the slots into which the slots of the second coil conductor are inserted.

2. The stator coil according to claim 1, wherein, The circumferential width of the first coil conductor at one circumferential end of the coil end of the first coil conductor and the circumferential width of the second coil conductor at the other circumferential end of the coil end of the second coil conductor are the same as the width obtained by adding the circumferential spacing of the slot to the circumferential width of the slot insertion portion.

3. The stator coil according to claim 1, wherein, A combined coil comprising three of the aforementioned stacked coil conductors, Each slot of the slot insertion portion accommodating the first layer of coil conductors is separated from each slot of the slot accommodating the second layer of coil conductors by two slots in the circumferential direction. Each slot of the slot insertion portion that accommodates the second-layer coil conductor is separated from each slot of the third-layer coil conductor by two slots in the circumferential direction.

4. The stator coil according to claim 2, wherein, A combined coil comprising three of the aforementioned stacked coil conductors, Each slot of the slot insertion portion accommodating the first layer of coil conductors is separated from each slot of the slot accommodating the second layer of coil conductors by two slots in the circumferential direction. Each slot of the slot insertion portion that accommodates the second-layer coil conductor is separated from each slot of the third-layer coil conductor by two slots in the circumferential direction.

5. The stator coil according to claim 3, wherein, The radial position of the slot insertion portion of the first coil conductor constituting the first layered coil conductor within the inserted slot, the radial position of the slot insertion portion of the first coil conductor constituting the second layered coil conductor within the inserted slot, and the radial position of the slot insertion portion of the first coil conductor constituting the third layered coil conductor within the inserted slot are all the same.

6. The stator coil according to claim 4, wherein, The radial position of the slot insertion portion of the first coil conductor constituting the first layered coil conductor within the inserted slot, the radial position of the slot insertion portion of the first coil conductor constituting the second layered coil conductor within the inserted slot, and the radial position of the slot insertion portion of the first coil conductor constituting the third layered coil conductor within the inserted slot are all the same.

7. The stator coil according to any one of claims 3 to 6, wherein, It has multiple of the aforementioned combined coils.

8. The stator coil according to any one of claims 1 to 6, wherein, The stacked coil conductor includes stacked segmented coil conductors that are divided into multiple segments in the circumferential direction.

9. The stator coil according to any one of claims 1 to 6, wherein, The end of the coil is bent radially.

10. A stator of a rotary electric motor, comprising: The stator core of a rotating electric motor includes an annular yoke, a plurality of teeth formed at equal intervals along the circumferential direction from the inner circumferential surface of the yoke and protruding radially inward, and a plurality of slots formed between adjacent teeth; and The stator coil according to any one of claims 1 to 9.

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