Stator for a rotating electric machine

Abstract

The present invention relates to a stator for a rotary electric machine. A stator for a rotary electric machine is disclosed, comprising a stator core having a plurality of slots, and a multiphase stator coil wound in a double-layer winding on the stator core, the multiphase stator coil being formed by winding the stator core with a plurality of double-wound coils concentrically and with different circumferences for each phase, the double-wound coil being formed by a longer-circumference coil portion and a shorter-circumference coil portion, and the total number of coil roots of the longer-circumference coil portion of the above-mentioned double-wound coil inserted into the plurality of slots being the same as the total number of coil roots of the shorter-circumference coil portion inserted into the plurality of slots.

Description

Technical Field

[0001] This invention relates to stators for rotary electric machines. Background Technology

[0002] It is known that there is a stator of a rotating motor in which multiple coils of different phases are arranged in a circumferentially overlapping configuration on a portion of multiple slots.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2018-182963

[0004] However, in the prior art described above, since the structure consists of alternating double-wound coil portions and single-wound coil portions along the circumference for each phase, there is a problem that the types of coils forming the stator coils increase and the winding method becomes more complex. Summary of the Invention

[0005] Therefore, in one aspect, the object of the present invention is to utilize a type of double-wound coil and achieve a reduction in spatial harmonics.

[0006] According to one aspect of the present invention, a stator for a rotary electric motor is provided, comprising:

[0007] Stator core, which has multiple slots; and

[0008] Multiphase stator coils, which are wound in double layers on the aforementioned stator core,

[0009] The aforementioned multiphase stator coils are formed by winding multiple concentric double-wound coils with different circumferences around the stator core for each phase.

[0010] The aforementioned double-wound coil is formed by a coil section with a longer circumference and a coil section with a shorter circumference.

[0011] The total number of coils inserted into the plurality of slots in the longer circumference portion of the aforementioned double-wound coil is the same as the total number of coils inserted into the plurality of slots in the shorter circumference portion of the aforementioned double-wound coil.

[0012] In one aspect, according to the invention, it is possible to utilize a type of double-wound coil and achieve a reduction in spatial harmonics. Attached Figure Description

[0013] Figure 1 This is a cross-sectional view of the stator of the rotary electric motor in Embodiment 1.

[0014] Figure 2 It is a diagram showing a portion of the inner periphery of the stator 10 unfolded into a planar shape.

[0015] Figure 3 This is a simplified sectional view of a part of stator 10.

[0016] Figure 4A This is an explanatory diagram of the coil end structure of the stator coil in this embodiment.

[0017] Figure 4B It is a diagram showing a portion of the inner periphery of the stator of the first comparative example unfolded into a planar shape.

[0018] Figure 5A This is a diagram showing the structure within the slot of the second comparative example.

[0019] Figure 5B This is a diagram showing a portion of the inner periphery of the stator of the second comparative example unfolded into a planar shape.

[0020] Figure 5C It is a diagram showing a portion of the inner periphery of the stator in a modified example unfolded into a planar shape.

[0021] Figure 5D It is a diagram showing a portion of the inner periphery of the stator of another variation, unfolded into a planar shape.

[0022] Figure 6 This is a simplified top view of a preferred example of a double-wound coil viewed radially.

[0023] Figure 7 This is a simplified top view of other examples of double-wound coils viewed radially.

[0024] Figure 8 This is when N=4 Figure 6 To achieve this, a double-wound coil is used. Figure 1 A diagram illustrating the condition of the stator coils.

[0025] Figure 9 This is a cross-sectional view of the stator of the rotary motor in Embodiment 2.

[0026] Figure 10A This is an explanatory diagram of the stator coil assembly method in Example 2, and a diagram showing the overall structure of the stator coil.

[0027] Figure 10B This is an explanatory diagram of the stator coil assembly method of Embodiment 2, which shows the inner periphery of the stator unfolded into a planar shape.

[0028] Figure 11A This is a top view illustrating the assembly process of the first double-wound coil of the U phase in Embodiment 2.

[0029] Figure 11B This is a diagram illustrating the assembly process of the first double-wound coil of phase U in Embodiment 2.

[0030] Figure 12AThis is a top view illustrating the assembly process of the second double-wound coil of phase U in Embodiment 2.

[0031] Figure 12B This is a diagram illustrating the assembly process of the second double-wound coil of phase U in Example 2.

[0032] Figure 13A This is a top view illustrating the assembly process of the first double-wound coil of phase V in Embodiment 2.

[0033] Figure 13B This is a diagram illustrating the assembly process of the first double-wound coil of phase V in Example 2.

[0034] Figure 14A This is a top view illustrating the assembly process of the second double-wound coil of phase V in Embodiment 2.

[0035] Figure 14B This is a diagram illustrating the assembly process of the second double-wound coil of phase V in Example 2.

[0036] Figure 15A This is a top view illustrating the assembly process of the first double-wound coil of phase W in Embodiment 2.

[0037] Figure 15B This is a diagram illustrating the assembly process of the first double-wound coil of phase W in Example 2.

[0038] Figure 16A This is a top view illustrating the assembly process of the second double-wound coil of phase W in Embodiment 2.

[0039] Figure 16B This is a diagram illustrating the assembly process of the second double-wound coil of phase W in Example 2. Detailed Implementation

[0040] Hereinafter, each embodiment will be described in detail with reference to the accompanying drawings.

[0041] [Example 1]

[0042] Figure 1 This is a cross-sectional view of the stator 10 of a rotary electric machine according to one embodiment (Example 1). In the following description, the axial direction refers to the direction in which the rotation axis (rotation center) I of the rotary electric machine extends, and the radial direction refers to the radial direction centered on the rotation axis I. Therefore, the outer radial direction refers to the side away from the rotation axis I, and the inner radial direction refers to the side facing the rotation axis I. Furthermore, the circumferential direction corresponds to the rotation direction about the rotation axis I. Additionally, in Figure 1 In order to facilitate observation, sometimes only a portion of the parts with the same attribute that exist are marked with reference symbols.

[0043] exist Figure 1The image shows a cross-section of the stator 10 when cut with a vertical section along the axial direction. Furthermore, in... Figure 1 (The following) Figure 2 In the same manner, the coil portion (slot insertion portion) inserted into the slot 15 is indicated by a symbol marked with an "×" inside a circle or a small "●" inside a circle. The difference in this symbol corresponds to the different directions of current flow when energized (i.e., the direction through the paper in the axial direction or the direction away from the paper).

[0044] The rotary motor is of the internal rotor type, with the stator 10 arranged radially outside the rotor (not shown). The rotary motor can be, for example, a vehicle drive motor used in hybrid vehicles or electric vehicles. However, it can also be a rotary motor used for any other purpose.

[0045] The stator 10 has a stator core 11 and a stator coil 12.

[0046] The stator core 11 can be formed, for example, from a stack of steel plates containing annular magnetic materials. Radial teeth 14 are formed on the inner circumference of the stator core 11, projecting radially inward. Multiple teeth 14 divide adjacent teeth 14 into multiple slots 15. The number of teeth 14 and the accompanying slots 15 is arbitrary, but in this embodiment, as an example, 36 are provided. Figure 1 In this diagram, the numbers 1 to 36 are represented within circles corresponding to the 36 slots 15. Hereinafter, when referring to a specific slot 15, it will be marked as slot 15-k (k = 1 to 36). For example, slot 15-1 represents the slot 15 corresponding to the circle marked with the number "1". Furthermore, such "k" will also be referred to as slot numbering below. In this embodiment, although a three-phase six-pole 36-slot rotary motor is used as an example, the number of slots can be appropriately varied. Furthermore, in the case of a three-phase six-pole 36-slot rotary motor, slot 6 represents the coil spacing of the full-pitch winding; therefore, slots 5 and below represent the coil spacing of the short-pitch winding, and slots 7 and above represent the coil spacing of the long-pitch winding.

[0047] The stator coil 12 is wound around the teeth 14 (i.e., within the slot 15) of the stator core 11. The stator coil 12 is wound in a double-layer winding on the stator core 11. In addition, the stator coil 12 can be electrically connected at the neutral point of a Y-connected circuit, for example, in more than one parallel connection, or it can be electrically connected in a Δ connection.

[0048] Furthermore, in double-layer windings, the change (distribution) of magnetomotive force corresponding to changes in angle is made more stable (the waveform of the magnetomotive force is closer to a sine wave), thus reducing space harmonics. In other words, NV (Noise Vibration) performance becomes better.

[0049] In this embodiment, the stator coil 12 is formed by double-wound coils 121U, 121V, and 121W, each wound concentrically with different circumferences for each of the U, V, and W phases. Double-wound coils 121U are used for the U phase, and in this embodiment, six are provided. Similarly, double-wound coils 121V are used for the V phase, and six are provided; double-wound coils 121W are used for the W phase, and six are provided. Furthermore, the double-wound coils 121U, 121V, and 121W will be referred to simply as "double-wound coil 121" without distinguishing between the phases.

[0050] A double-wound coil 121 has two concentric coil portions that are approximately hexagonal in shape when viewed radially. The coil portion with the longer circumference (circumferential length) will be referred to as the "outer box-shaped coil portion," and the coil portion with the shorter circumference will be referred to as the "inner box-shaped coil portion." Furthermore, a preferred example of the double-wound coil 121 is shown below. Figure 6 This will be discussed later.

[0051] A double-wound coil 121 is inserted into four slots 15. That is, the outer box-shaped coil portion is inserted into two slots 15, and the inner box-shaped coil portion is inserted into the other two slots 15. Furthermore, the number of coils is referred to as "one (unit)" using the approximately hexagonal coil portion that enters the two slots 15 as the unit of coil count. In this case, the double-wound coil 121 with an approximately hexagonal double configuration has two coils.

[0052] Specifically, the outer box-shaped coil portion of a double-wound coil 121 is inserted into a pair of circumferentially outer slots 15, and the inner box-shaped coil portion of the double-wound coil 121 is inserted into a pair of circumferentially inner slots 15. In this case, the pair of circumferentially outer slots 15 sandwich five slots 15 in the circumferential direction (i.e., the outer box-shaped coil portion is a long-pitch winding). That is, the outer box-shaped coil portion of a double-wound coil 121 is arranged with seven slots 15 circumferentially. Additionally, the pair of circumferentially inner slots 15 sandwich three slots 15 in the circumferential direction (i.e., the inner box-shaped coil portion is a short-pitch winding). That is, the inner box-shaped coil portion of a double-wound coil 121 is arranged with five slots 15 circumferentially. Furthermore, in this case, the circumference of the outer box-shaped coil portion is the circumference of seven slots, and the circumference of the inner box-shaped coil portion is the circumference of five slots, corresponding to the respective coil spacing.

[0053] For example, in one of the six double-wound coils 121U, Figure 1The outer box-shaped coil portion of a double-wound coil 121U corresponding to the star mark is inserted into a pair of slots 15-2 and 15-8 on the outer circumferential direction, while the inner box-shaped coil portion is inserted into a pair of slots 15-3 and 15-7 on the inner circumferential direction. In this case, the circumferential center of the pair of slots 15-2 and 15-8 on the outer circumferential direction coincides with the circumferential center of the pair of slots 15-3 and 15-7 on the inner circumferential direction, which is the position of slot 15-5. The above is basically the same for the other double-wound coils 121U and each double-wound coil 121V and 121W. That is, the only difference is that the double-wound coils 121U, 121V, and 121W are each arranged with the U phase, V phase, and W phase offset by 120° in the circumferential direction, and the overlapping part is offset (skewed) radially.

[0054] Next, with Figure 1 Refer to together Figure 2 The structure of stator coil 12 will be explained in more detail in the following diagrams.

[0055] Figure 2 as well as Figure 3 This is an explanatory diagram of the double-layer winding of the stator coil 12 in this embodiment. Figure 2 It is a diagram showing a portion of the inner periphery of the stator 10 unfolded into a planar shape. Figure 3 This is a simplified cross-sectional view of a portion of stator 10. Figure 2 In this context, direction CD corresponds to the circumferential direction. Additionally, in... Figure 2 In Figure 1 The slot numbers shown correspond to the corresponding slots 15. Below each slot 15, it is shown which phase of the three-phase coil portion (here, the slot insertion portion) is inserted. The R1 side of direction RD indicates the phase whose coil portion is inserted radially outward, and the R2 side of direction RD indicates the phase whose coil portion is inserted radially inward. Furthermore, this is explained later... Figure 10B , Figure 11B , Figure 12B The same applies to the following.

[0056] exist Figure 2 The different wire types are used to schematically represent the various types of double-wound coils 121U, 121V, and 121W. For example... Figure 2 As shown, one double-wound coil 121U and another double-wound coil 121U are inserted in slot 15-8, and one double-wound coil 121U and one double-wound coil 121V are inserted in slot 15-9, and so on. Based on this double-layer winding, as described above, space harmonics can be effectively reduced.

[0057] In particular, in this embodiment, the outer box-shaped coil portions of each of the dual-wound coils 121U, 121V, and 121W are inserted into a plurality of specific slots (hereinafter also referred to as "long-pitch winding slots") in a plurality of slots 15 via long-pitch windings. For example, the long-pitch winding slots for the dual-wound coil 121U are slots 15-2, 15-8, 15-14, 15-20, 15-26, and 15-32.

[0058] On the other hand, the inner box-shaped coil portions of each of the dual-wound coils 121U, 121V, and 121W insert a pair of different phases into other specific slots (hereinafter also referred to as "slots for short-pitch windings") via short-pitch windings. For example, the slots for short-pitch windings of the dual-wound coil 121U are slots 15-1, 15-3, 15-7, 15-9, 15-13, 15-15, 15-19, 15-21, 15-25, 15-27, 15-31, and 15-33. Furthermore, in the aforementioned short-pitch winding slots, the inner box-shaped coil portion of the double-wound coil 121W is inserted into slot 15-1, the inner box-shaped coil portion of the double-wound coil 121V is inserted into slot 15-3, the inner box-shaped coil portion of the double-wound coil 121W is inserted into slot 15-7, and the inner box-shaped coil portion of the double-wound coil 121V is inserted into slot 15-9, and so on. Additionally, the inner box-shaped coil portions of different phases are inserted into slot 15 such that the inner box-shaped coil portion of one phase is radially inner and the inner box-shaped coil portion of another phase is radially outer. In this case, four other double-wound coil portions of the same circumference that overlap radially with respect to one double-wound coil 121 (or are circumferentially adjacent to one double-wound coil 121) are inserted into the same slots.

[0059] According to the stator coil 12 of this embodiment, refer to the following: Figures 4A to 5B As explained, this allows for a reduction in the volume of the coil terminals and a reduction in spatial harmonics.

[0060] Here, refer to Figures 4A to 5B The effects of this embodiment will be explained in detail below. Furthermore, the following description pertains to the structure related to the general portion of the so-called stator coil 12; leads and neutral wires are excluded. Additionally, in Figures 4A to 5B In various comparative examples, as in this embodiment, the number of coil pieces (≠ number of coils) inserted into each slot 15 is the same, M.

[0061] Figure 4A This is an explanatory diagram of the coil end structure of the stator coil 12 in this embodiment, which is consistent with the previous diagram. Figure 2 The same diagram shows a portion of the inner periphery of the stator 10 unfolded into a planar shape. Furthermore, in Figure 4AIn the diagram, the axial range of the coil end is schematically shown using ranges A1 and A2, where range A1 is the lead side and range A2 is the reverse lead side. Figure 4B This is an explanatory diagram of the stator coil 12' of the first comparative example. The stator coil 12' of the first comparative example does not use the double-wound coils 121U, 121V, 121W, but instead uses a conventional box-type coil 121' to achieve the same double-layer winding as the stator coil 12 of this embodiment. Furthermore, the conventional box-type coil 121' differs from the double-wound coil 121, which inserts into four slots 15, in that it inserts into two slots. Also, for comparison based on equal conditions of coil number, each of the conventional box-type coils 121' has M / 2 coil pieces (coil pieces inserted into slots 15).

[0062] However, in the first comparative example using such a typical box-type coil 121′, as Figure 4B As illustrated, the individual coils of a typical box-type coil 121' can be wound with each slot edge staggered (full-pitch winding). Therefore, at virtually any position in the circumference, the number of coils is always six, achieving an equal number of coils. This, in turn, allows for a reduction in the volume of the coil ends.

[0063] In this embodiment, as Figure 4A As shown, it can achieve the same as Figure 4B The volume of the coil ends is the same as that of the first comparative example shown (refer to rectangular areas 402, 403). Specifically, in this embodiment, the number of coils is six on both sides of the axial direction of each slot 15, as shown in the rectangular areas 400, 401 of the dotted lines. This can also be seen from... Figure 1 This is based on the same ranges 400 and 401 shown. Additionally, according to... Figure 1 It can be seen that the range of the circumferential slots 15 is also the same, and the number of coils is six. Thus, in this embodiment, at virtually any position in the circumferential direction, the number of coils is six, the same as in the first comparative example above, which can achieve equalization of the number of coils.

[0064] Figure 5A as well as Figure 5B This is an explanatory diagram for the second comparative example. Figure 5A This is a diagram showing the structure within the slot of the second comparative example. Figure 5B The diagram shows a portion of the inner periphery of the stator having the second comparative example stator coil 12A′ unfolded into a planar shape.

[0065] The stator coil 12A′ in this comparative example uses a double-wound coil like the double-wound coil 121 of this embodiment, with the outer and inner box-shaped coil portions arranged radially overlapping in such a way that the same phase is inserted into each slot. Furthermore, in this comparative example, both the outer and inner box-shaped coil portions are arranged radially overlapping, so in… Figure 5BIn the diagram, a single line represents either the overlapping outer or inner box-shaped coil portion. Therefore, in the following explanation, Figure 5B One wire is counted as 2 coils. In addition, each of the double-wound coils forming stator coil 12A′ can have M coil pieces (coil pieces inserted in slot 15), but here, for comparison on an equal basis based on the number of coils, each of the double-wound coils has M / 2 coil pieces.

[0066] However, the double-wound coil 121 achieves the functionality of the typical box-type coil 121' in a single component (see reference). Figure 4B Since there are two parts (i.e., the two coils), the assembly efficiency is good. Furthermore, the same coil frame can be used for simultaneous molding, resulting in good productivity. However, if the double-wound coil 121 is set as... Figure 5A as well as Figure 5B The winding method shown tends to result in larger coil ends. Specifically, as... Figure 5B As schematically shown, on both sides of a slot 15 along its axial direction, within the rectangular area 404 indicated by the dotted line, the number of coils is eight. On the other hand, on both sides of the axial direction of other slots 15, within the rectangular area 405A indicated by the dotted line, the number of coils is six, and on both sides of the axial direction of a tooth 14, within the rectangular area 405B indicated by the dotted line, the number of coils is four. Thus, in the stator coil 12A′ of this comparative example, the number of coils varies along the circumferential direction (resulting in a significant non-uniformity in coil distribution), and there is a tendency for the volume at the coil ends to increase. That is, at the position where the number of coils is eight, the volume at the coil ends is locally increased.

[0067] Figure 5C This is an explanatory diagram of a modified example that can be implemented instead of the above embodiment. It is a diagram showing a portion of the inner periphery of the stator having the stator coil 12” of this modified example unfolded into a planar shape.

[0068] In this modified example, the stator coil 12” uses a double-wound coil with a circumference one slot longer than the double-wound coil 121 of this embodiment to realize a double-layer winding, and the outer box coil portion is set as a long-pitch winding, and the inner box coil portion is set as a full-pitch winding.

[0069] The stator coil 12” according to this variant is similar to that in this embodiment, allowing the use of a single type of double-wound coil and enabling the reduction of space harmonics. A single type of double-wound coil, with a circumference one slot longer than the double-wound coil 121 of this embodiment, is wound around the stator core 11, thereby forming a multiphase stator coil 12” with double-layer windings wound on the stator core 11. Therefore, a single type of double-wound coil can be used, and the reduction of space harmonics can be achieved.

[0070] Furthermore, while the aforementioned effects can be achieved in the stator coil 12” of the modified example, it is disadvantageous from the viewpoint that there is a trend towards larger coil end volume compared to this embodiment. Specifically, as Figure 5C As schematically shown, on both sides of a slot 15, as indicated by the rectangular area 406 of the dotted line, the number of coils is eight. On the other hand, on both sides of the axial direction of other slots 15, as indicated by the rectangular area 407 of the dotted line, the number of coils is seven, and on both sides of the axial direction of a tooth 14, as indicated by the rectangular area 408 of the dotted line, the number of coils becomes five. Thus, in the stator coil 12” of this modified example, the number of coils varies along the circumference (resulting in a significant density of coil distribution), and there is a tendency for the volume at the coil ends to increase. That is, at the position where the number of coils is eight, the volume at the coil ends is locally increased.

[0071] In contrast, according to this embodiment, as described above, the number of coils is six at virtually any position in the circumferential direction, achieving an equalization of the number of coils and a reduction in the volume of the coil ends. Thus, according to this embodiment, a double-wound coil 121 with good stator 10 productivity can be achieved, along with a reduction in the volume of the coil ends and a reduction in spatial harmonics.

[0072] Figure 5D This is an explanatory diagram of a modified example that can be implemented instead of the above-described embodiment. It shows a portion of the inner periphery of the stator having the double-wound coil 121V′ of this modified example unfolded into a planar shape. Furthermore, although the double-wound coil 121V′ of phase V is shown (or explained) here as a double-wound coil forming one phase of the stator coil, the other two phases (phase U and phase W) are actually the same.

[0073] The double-wound coils in this modified example (double-wound coil 121V′ and the other two identical double-wound coils) use double-wound coils with a circumference two slot lengths longer than the double-wound coil 121 in this embodiment to realize double-layer windings, and the outer box coil portion is set as a long-pitch winding, and the inner box coil portion is set as a long-pitch winding.

[0074] In this case, such as Figure 5D As shown, in the double-wound coil 121V′, the outer box coil portion is inserted into the same slot 15 as the outer box coil portions of other phases, and the same phase of the inner box coil portion is inserted into the same slot 15.

[0075] By utilizing the double-wound coil 121V′ of this modified example, similar to the case in this embodiment, it is possible to achieve space harmonic reduction using a single type of double-wound coil. A single type of double-wound coil (double-wound coil 121V′ and the other two identical double-wound coils) with a circumference two slot lengths longer than the double-wound coil 121 of this embodiment is wound in a full circle on the stator core 11, thereby forming a multi-phase stator coil wound with double-layer windings on the stator core 11. Therefore, it is possible to achieve space harmonic reduction using a single type of double-wound coil.

[0076] Next, refer to Figure 6 as well as Figure 7 A preferred example of the double-wound coil 121 will be described. Furthermore, Figure 6 as well as Figure 7 The double-wound coil 121 shown can also be referenced by making the circumference different. Figure 5C as well as Figure 5D The double-wound coil that constitutes the above-described modified example.

[0077] Figure 6 This is an explanatory diagram of a preferred example of the double-wound coil 121, and is a simplified top view viewed radially. Hereinafter, although one double-wound coil 121 will be described, as mentioned above, other double-wound coils 121 are actually the same (the only difference is in the connection points, etc.).

[0078] exist Figure 6 In the example shown, the dual-wound coil 121 includes: a first slot insertion portion 1211; a second slot insertion portion 1212; a third slot insertion portion 1213; a fourth slot insertion portion 1214; first and second overlapping portions 1215A and 1215B; third and fourth overlapping portions 1216A and 1216B; a switching connection portion 1217; and ends 1210 and 1218.

[0079] The double-wound coil 121 is a single component from end 1210 to end 1218, formed by winding one or more coil wires (with circular or rectangular cross-sectional shapes) more than once around a coil frame. Furthermore, the number of slot insertion portions (N, N-1) described below corresponds to the number of coil wires. Figure 6 In the diagram, thick lines indicate a state where there are two or more strands. Additionally, the ends 1210 and 1218 are bent into shape from the straight lines shown in the illustration.

[0080] The first slot insertion portion 1211, the second slot insertion portion 1212, the third slot insertion portion 1213, and the fourth slot insertion portion 1214 are the locations where coil pieces are inserted into slots 15. Furthermore, the slots 15 into which the first slot insertion portion 1211, the second slot insertion portion 1212, the third slot insertion portion 1213, and the fourth slot insertion portion 1214 are inserted are different from each other. In this embodiment, as described above, with respect to a double-wound coil 121, the center between the pair of slots 15 (long-pitch winding slots) into which the first slot insertion portion 1211 and the fourth slot insertion portion 1214 are inserted coincides with the center between the pair of slots 15 (short-pitch winding slots) into which the second slot insertion portion 1212 and the third slot insertion portion 1213 are inserted. Furthermore, regarding a double-wound coil 121, the slot 15 (for long-pitch winding) into which the first slot insertion portion 1211 is inserted and the slot 15 (for short-pitch winding) into which the second slot insertion portion 1212 is inserted are adjacent in the circumferential direction, and the slot 15 (for long-pitch winding) into which the fourth slot insertion portion 1214 is inserted and the slot 15 (for short-pitch winding) into which the third slot insertion portion 1213 is inserted are also adjacent in the circumferential direction. In this case, the first slot insertion portion 1211 and the fourth slot insertion portion 1214, together with the first and second overlapping portions 1215A and 1215B, form the aforementioned outer box-shaped coil portion, and the second slot insertion portion 1212 and the third slot insertion portion 1213, together with the third and fourth overlapping portions 1216A and 1216B, form the aforementioned inner box-shaped coil portion.

[0081] For example, in Figure 1 A double-wound coil 121U corresponding to the star mark is formed by... Figure 6 In the case of the double-wound coil 121 shown, slot 15-8 is a slot for long-pitch winding, slot 15-7 is a slot for short-pitch winding, slot 15-3 is a slot for short-pitch winding, and slot 15-2 is a slot for long-pitch winding.

[0082] The first lap joint 1215A forms the coil end on the lead side (refer to...). Figure 4A (Scope A1). One side of the first lap joint 1215A is connected to the lead wire side end of the first slot insertion part 1211, and the other side is connected to the lead wire side end of the fourth slot insertion part 1214.

[0083] The second lap joint 1215B forms the coil end on the reverse lead side (refer to...). Figure 4A (Scope A2). One side of the second lap joint 1215B is connected to the reverse lead side end of the first slot insertion part 1211, and the other side is connected to the reverse lead side end of the fourth slot insertion part 1214.

[0084] The third lap joint 1216A forms the coil end on the lead side (refer to...). Figure 4A (Scope A1). One side of the third lap joint 1216A is connected to the lead wire side end of the second slot insertion part 1212, and the other side is connected to the lead wire side end of the third slot insertion part 1213.

[0085] The fourth lap joint 1216B forms the coil end on the reverse lead side (refer to...). Figure 4A (Scope A2). One side of the fourth lap joint 1216B is connected to the reverse lead side end of the second slot insertion part 1212, and the other side is connected to the reverse lead side end of the third slot insertion part 1213.

[0086] The switching connection portion 1217 forms a connection between the inner box-type coil portion and the outer box-type coil portion. Specifically, the switching connection portion 1217 is connected to the end of the second slot insertion portion 1212 of the fourth overlap portion 1216B. One circumferential side of the switching connection portion 1217 is connected to the reverse lead side end of a third slot insertion portion 1213 via the fourth overlap portion 1216B, and the other circumferential side is connected to the reverse lead side end of a first slot insertion portion 1211.

[0087] Here, as described above, when forming a double-wound coil 121 with N first slot insertion portions 1211, starting from the end 1210, the process is repeated in the manner of third slot insertion portion 1213, fourth overlapping portion 1216B, second slot insertion portion 1212, third overlapping portion 1216A, third slot insertion portion 1213, and fourth overlapping portion 1216B until N third slot insertion portions 1213 and fourth overlapping portions 1216B are formed. Furthermore, if the Nth fourth overlapping portion 1216B is formed, a switching connection portion 1217 is formed from the Nth fourth overlapping portion 1216B. Then, in the same manner, the process is repeated until N-1 second overlapping portions 1215B are formed, following the sequence of first slot insertion portion 1211, first overlapping portion 1215A, fourth slot insertion portion 1214, second overlapping portion 1215B, first slot insertion portion 1211, first overlapping portion 1215A, fourth slot insertion portion 1214, and second overlapping portion 1215B. Moreover, if the N-1th second overlapping portion 1215B is formed, the end portion 1218 is formed after the Nth first slot insertion portion 1211 is formed.

[0088] Based on this double-wound coil 121, the number of each of the first slot insertion portion 1211 and the fourth slot insertion portion 1214 can differ by only one, and the number of each of the second slot insertion portion 1212 and the third slot insertion portion 1213 can differ by only one. That is, if the number of the first slot insertion portions 1211 is set to N (≥2), then the number of the fourth slot insertion portions 1214 can be set to N-1, the number of the second slot insertion portions 1212 can be set to N-1, and the number of the third slot insertion portions 1213 can be set to N. Furthermore, the switching connecting portion 1217 is connected to one of the N first slot insertion portions 1211, and is connected to one of the N third slot insertion portions 1213 via the fourth overlapping portion 1216B. The ends 1210 and 1218 are also the same, connected to one of the N third slot insertion portions 1213 and one of the N first slot insertion portions 1211, respectively. Furthermore, in a modified example, the switching connection 1217 can be connected to the reverse lead side end of a first slot insertion part 1211 via a portion of the second lap joint 1215B.

[0089] In this double-wound coil 121, the total number of coil pieces (coil strands) inserted into the corresponding slots 15 in the outer box-shaped coil section is the same as the total number of coil pieces (coil strands) inserted into the corresponding slots 15 in the inner box-shaped coil section. That is, if the number of first slot insertion parts 1211 is set to N (≥2), then the total number of each of the first slot insertion parts 1211 and the fourth slot insertion parts 1214 is 2N-1, and the total number of each of the second slot insertion parts 1212 and the third slot insertion parts 1213 is 2N-1, which is the same.

[0090] Furthermore, such a double-wound coil 121 can be easily assembled into the corresponding slot 15 using a clamp (cassette inserter), for example, radially from the inner side to the outer side. In this case, the assembly of the two conventional cassette coils 121' described above can be achieved by assembling one double-wound coil 121, thus achieving assembly efficiency.

[0091] Figure 7 This is an explanatory diagram of another example of a double-wound coil 121A, and is a simplified top view viewed radially.

[0092] Other examples of double-wound coil 121A relative to Figure 6 The double-wound coil 121 shown differs in that the second slot insertion portion 1212, the fourth slot insertion portion 1214, and the switching connection portion 1217 are replaced by the second slot insertion portion 1212A, the fourth slot insertion portion 1214A, and the switching connection portion 1217A, respectively.

[0093] Essentially, the other examples of double-wound coil 121A are relative to Figure 6The dual-wound coil 121 shown has its number of first slot insertion parts 1211, second slot insertion parts 1212A, third slot insertion parts 1213, and fourth slot insertion parts 1214A all equal by changing the position of the switching connection part 1217A. That is, if the number of first slot insertion parts 1211 is set to N, then the number of fourth slot insertion parts 1214A, the number of second slot insertion parts 1212A, and the number of third slot insertion parts 1213 can all be set to N.

[0094] In such a double-wound coil 121A, with Figure 6 The double-wound coil 121 shown is the same. The total number of coil pieces (coil strands) inserted into the corresponding slots 15 in the outer box-type coil section is the same as the total number of coil pieces (coil strands) inserted into the corresponding slots 15 in the inner box-type coil section. That is, if the number of first slot insertion parts 1211 is set to N (≥2), then the total number of each of the first slot insertion parts 1211 and the fourth slot insertion parts 1214A is 2N, and the total number of each of the second slot insertion parts 1212A and the third slot insertion parts 1213 is 2N, which is the same.

[0095] Figure 8 This is when N=4 Figure 6 The double-wound coil 121 is used to achieve this. Figure 1 A diagram illustrating the situation of stator coil 12.

[0096] exist Figure 8 The number "3" or "4" in the diagram indicates the number of each of the first slot insertion parts 1211 to the fourth slot insertion parts 1214 inserted into each slot. Figure 8 Since N=4, a total of seven slot insertion parts are inserted into each slot 15.

[0097] Thus, by using Figure 6 The double-wound coil 121 shown can form a stator 10 into which an odd number of slot insertion parts can be inserted.

[0098] In addition, if using Figure 7 The double-wound coil 121A shown can form a stator (not shown) into which an even number of slot insertion parts can be inserted.

[0099] However, the number of slot insertion portions in each slot 15 of the stator 10 varies depending on the output characteristics that the rotary motor equipped with the stator 10 should achieve. Generally, for rotary motors with higher output, a larger number of slot insertion portions are inserted into each slot 15.

[0100] Therefore, in use Figure 6With the double-wound coil 121 shown, the structure of the rotary electric machine for achieving specific output characteristics can be optimized. For example, when... Figure 8 When the seven slot insertion parts shown are inserted into each slot 15 to achieve specific output characteristics, in the case of utilizing... Figure 7 When the structure shown uses a double-wound coil 121A to insert a total of six slot insertion parts into each slot 15, the output characteristics tend to be insufficient. In contrast, when utilizing... Figure 7 When the structure shown uses a double-wound coil 121A to insert a total of eight slot insertion parts into each slot 15, the output characteristics become too large. In such a case, by utilizing... Figure 6 The double-wound coil 121 shown in the diagram can prevent the aforementioned problems. In other words, it can increase the freedom to determine the number of slot insertion portions that can be inserted into a slot 15.

[0101] In addition, in use Figure 6 In the case of the double-wound coil 121 with the structure shown, N first slot insertion portions 1211 and third slot insertion portions 1213 can be formed, and the first and second overlapping portions 1215A, 1215B and the third overlapping portion 1216A can be fixed in N-1 locations. Therefore, the number of first and second overlapping portions 1215A, 1215B at the coil end can be efficiently reduced, and the volume of the coil end can be reduced.

[0102] [Example 2]

[0103] Figure 9 This is a cross-sectional view of the stator 10A of a rotary electric machine according to one embodiment (Embodiment 2). In the following description of this embodiment, the terms and symbols used in Embodiment 1 above will sometimes be used without redefining them. In addition, in each figure, the same reference numerals are often used to label the same structural elements as in Embodiment 1 above, and the descriptions are omitted.

[0104] exist Figure 9 The image shows a cross-section of the stator 10A when cut with a vertical section along the axial direction.

[0105] The stator 10A in this embodiment differs from the stator 10 in Embodiment 1 above in that the stator coil 12 is replaced with stator coil 12A.

[0106] The stator coil 12A is the same as the stator coil 12 in Embodiment 1 above, and is wound around the teeth 14 (i.e., inside the slot 15) of the stator core 11. The stator coil 12A is wound in a double-layer winding on the stator core 11. In addition, the stator coil 12A is the same as the stator coil 12 in Embodiment 1 above, and is formed by double-wound coils 221U, 221V, and 221W, which are wound concentrically with different circumferences for each of the U phase, V phase, and W phase. The double-wound coils 221U are for the U phase, and in this embodiment, six are provided. Similarly, the double-wound coils 221V are for the V phase, and six are provided, and the double-wound coils 221W are for the W phase, and six are provided. Furthermore, the double-wound coils 221U, 221V, and 221W will be referred to as "double-wound coil 221" below without distinguishing between the phases.

[0107] A double-wound coil 221 is the same as the double-wound coil 121 in Embodiment 1 above, having two concentric coil portions that are approximately hexagonal in shape when viewed radially. In this embodiment, the coil portion with the longer circumference (circumferential length) of the two coil portions will be referred to as the "outer coil portion", and the coil portion with the shorter circumference will be referred to as the "inner coil portion".

[0108] A double-wound coil 221, identical to the double-wound coil 121 in Embodiment 1, is inserted into four slots 15. Specifically, the outer coil portion is inserted into two slots 15, and the inner coil portion is inserted into the other two slots 15. In this case, the pair of slots 15 on the outer circumferential direction sandwich five slots 15 in the middle circumferentially (i.e., the outer coil portion is a long-pitch winding). Additionally, the pair of slots 15 on the inner circumferential direction sandwich three slots 15 in the middle circumferentially (i.e., the inner coil portion is a short-pitch winding).

[0109] For example, in one of the six double-wound coils 221U, Figure 9 The outer coil portion of a double-wound coil 221U corresponding to the star mark is inserted into a pair of circumferentially outer slots 15-2 and 15-8, while the inner coil portion is inserted into a pair of circumferentially inner slots 15-3 and 15-7. In this case, the circumferential center of the pair of circumferentially outer slots 15-2 and 15-8 coincides with the circumferential center of the pair of circumferentially inner slots 15-3 and 15-7, which is the position of slot 15-5. The above applies essentially the same to the other double-wound coils 221U and the various double-wound coils 221V and 221W.

[0110] The double-wound coil 221 in this embodiment is the same as the double-wound coil 121 in Embodiment 1 above. The outer coil portions of each of the double-wound coils 221U, 221V, and 221W are inserted into long-pitch winding slots in a plurality of slots 15 by long-pitch windings, with the same phase of each coil being inserted into the long-pitch winding slots. For example, the long-pitch winding slots for the double-wound coil 221U are slots 15-2, 15-8, 15-14, 15-20, 15-26, and 15-32.

[0111] On the other hand, the inner coil portions of each of the dual-wound coils 221U, 221V, and 221W utilize short-pitch windings, with a pair of different phases inserted into short-pitch winding slots in multiple slots. For example, the short-pitch winding slots for the dual-wound coil 221U are slots 15-1, 15-3, 15-7, 15-9, 15-13, 15-15, 15-19, 15-21, 15-25, 15-27, 15-31, and 15-33. Furthermore, in the aforementioned short-pitch winding slots, the inner coil portion of the dual-wound coil 221V is inserted into slot 15-1, the inner coil portion of the dual-wound coil 221W is inserted into slot 15-3, the inner coil portion of the dual-wound coil 221V is inserted into slot 15-7, and the inner coil portion of the dual-wound coil 221W is inserted into slot 15-9, and so on.

[0112] The inner coil portions of different phases are inserted into slot 15 such that the inner coil portion of one phase is radially inner and the inner coil portion of the other phase is radially outer. The double-wound coil 221 of this embodiment differs from the double-wound coil 121 of Embodiment 1 described above. In any short-pitch winding slot, the inner coil portion of the double-wound coil 221U of phase U (an example of the first phase) is radially outermost, and the inner coil portion of the double-wound coil 221W of phase W (an example of the third phase) is radially innermost. As a result, in any short-pitch winding slot, the inner coil portion of the double-wound coil 221V of phase V (an example of the second phase) is radially inner of the inner coil portion of double-wound coil 221U, or radially outer of the inner coil portion of double-wound coil 221W.

[0113] Specifically, the inner coil portion of the double-wound coil 221U is located radially outward in any short-pitch winding slot compared to the inner coil portions of the other phases of the double-wound coil 221, namely the inner coil portions of the double-wound coil 221V and the inner coil portions of the double-wound coil 221W.

[0114] In addition, the inner coil portion of the double-wound coil 221W is located radially inward in any short-pitch winding slot compared to the inner coil portions of the double-wound coil 221 of other phases, namely the inner coil portions of the double-wound coil 221U and the inner coil portions of the double-wound coil 221V.

[0115] Furthermore, in any short-pitch winding slot, the inner coil portion of the double-wound coil 221V is located radially inward compared to the inner coil portion of the double-wound coil 221U when paired with the inner coil portion of the double-wound coil 221U, and radially outward compared to the inner coil portion of the double-wound coil 221W when paired with the inner coil portion of the double-wound coil 221W.

[0116] According to this embodiment of the stator coil 12A, compared with the stator coil 12 of the above embodiment 1, although the radial positional relationship of each phase of a pair of different phases with respect to the short-pitch winding slot is different as described above, it is based on the same principle as the above embodiment 1 (refer to...). Figures 4A to 5B (The principle explained) enables the reduction of the volume of the coil ends and the reduction of spatial harmonics.

[0117] Furthermore, in this embodiment, the dual-wound coil 221 can have a reference. Figure 6 as well as Figure 7 The double-wound coil 121 of Embodiment 1 described above has the same shape. Therefore, it is also possible to obtain a coil with the same shape as the reference coil. Figure 8 The same effect as in Example 1 described above.

[0118] However, the assembly using the inserter has effects unique to this embodiment; for this, please refer to... Figure 10A The following diagrams will provide a more detailed explanation.

[0119] Next, refer to Figure 10A The following figures will describe the assembly method of the stator coil 12A of the stator 10A in this embodiment. Furthermore, in the preceding... Figure 9 In, with Figure 1 Similarly, corresponding to the 36 slots 15, the numbers 1 to 36 are shown within circles, but below... Figure 11B In the example, only 1 and 36 are shown within the circle, while 2 to 35 are omitted.

[0120] Figure 10A This is an explanatory diagram of the assembly method of stator coil 12A, and a diagram showing the overall structure of stator coil 12A in this embodiment. Figure 10B This is an explanatory diagram of the assembly method of stator coil 12A, showing the inner circumference of stator 10 unfolded into a planar shape. Figure 10B In this context, direction CD can correspond to the circumferential direction, and the direction towards C2 can correspond to the forward rotation direction of the rotating motor. This will be discussed later. Figure 11B , Figure 12B The same applies. Additionally, in Figure 10B In the diagram, other wire types are used to schematically represent the various double-wound coils 221U, 221V, and 221W.

[0121] Figure 11A as well as Figure 11B This is an explanatory diagram of the assembly process of the first double-wound coil 221U-1 of phase U. Figure 12A as well as Figure 12B This is an explanatory diagram illustrating the assembly process of the second double-wound coil 221U-2 of phase U. Furthermore, in Figure 12A as well as Figure 12B The first double-wound coil 221U-1 of the U phase after assembly is shown in the diagram using dots and lines. Figure 13A as well as Figure 13B This is an illustrative diagram illustrating the assembly process of the first double-wound coil 221V-1 of phase V. Figure 14A as well as Figure 14B This is an explanatory diagram illustrating the assembly process of the second double-wound coil 221V-2 of phase V. Furthermore, in Figure 13A as well as Figure 14A The assembled double-wound coils are uniformly illustrated using dotted lines. Additionally, in... Figure 13B as well as Figure 14B The diagram of the assembled U-phase double-wound coils 221U-1 and 221U-2 is omitted. Figure 14B In the diagram, the first double-wound coil 221V-1 of the V phase after assembly is shown using a dotted line diagram. Figure 15A as well as Figure 15B This is an illustrative diagram illustrating the assembly process of the first double-wound coil 221W-1 of phase W. Figure 16A as well as Figure 16B This is an explanatory diagram illustrating the assembly process of the second double-wound coil 221W-2 of phase W. Furthermore, in Figure 15A as well as Figure 16A The assembled double-wound coils are uniformly illustrated using dotted lines. Figure 15B as well as Figure 16B The diagrams of the assembled U-phase double-wound coils 221U-1 and 221U-2 and the V-phase double-wound coils 221V-1 and 221V-2 are omitted. Figure 16B In the diagram, the first double-wound coil 221W-1 of phase W, after assembly, is shown using a dotted line diagram. Additionally, in... Figure 11A , Figure 12A , Figure 13A , Figure 14A , Figure 15A as well as Figure 16A In the image, only the double-wound coil 221 of the assembly object corresponding to each process is shaded.

[0122] Here, as Figure 10AAs schematically shown, stator coils 12A are connected in parallel in two sets per phase, electrically connected at the neutral point of the Y-connection. Specifically, the two sets (a pair) of the first double-wound coil 221U-1 and the second double-wound coil 221U-2 of stator coil 12A in phase U are connected in parallel between the neutral point and the phase U terminal 90U on the power line side. Similarly, the other phases are connected in parallel in two sets (a pair) of the first double-wound coil 221V-1 and the second double-wound coil 221V-2 of stator coil 12A in phase V are connected at the neutral point and the phase V terminal 90V on the power line side. Additionally, the two sets (a pair) of the first double-wound coil 221W-1 and the second double-wound coil 221W-2 of stator coil 12A in phase W are connected in parallel between the neutral point and the phase W terminal 90W on the power line side.

[0123] The first double-wound coil 221U-1 of phase U includes the three sets of double-wound coils 221U (marked as 221U(1) to (3) respectively), forming a total of six coil sections. The second double-wound coil 221U-2 of phase U is the same, including the three sets of double-wound coils 221U (marked as 221U(4) to (6) respectively). This is also the case for the other phases (phase V and phase W).

[0124] The stator coil 12A of this embodiment differs from the stator coil 12 of the above embodiment 1 in that it can be axially assembled relative to the stator core 11 from the outside using an inserter (not shown).

[0125] Specifically, the assembly method of the stator coil 12A in this embodiment first includes a step of assembling the first double-wound coil 221U-1 of phase U from the outer side along the axial direction relative to the stator core 11 using an inserter (not shown).

[0126] For example, in use with Figure 6 as well as Figure 7In the case of the identical double-wound coil 221 shown for the double-wound coils 121 and 121A, the inserter can achieve axial assembly by moving the first and third overlapping portions 1215A and 1216A of the double-wound coils 121 and 121A from one side of the axial direction through the space on the inner diameter side of the stator core 11 relative to the stator core 11. In this case, the inserter can axially insert the first slot insertion portion 1211, the second slot insertion portion 1212, the third slot insertion portion 1213, and the fourth slot insertion portion 1214 of the double-wound coils 121 and 121A into the respective slots 15, and after moving the first and third overlapping portions 1215A and 1216A to the other side of the stator core 11, tilt the first and third overlapping portions 1215A and 1216A radially outward, thereby completing the axial assembly. Alternatively, the inserter can also achieve axial assembly by allowing the second and fourth overlapping portions 1215B and 1216B to pass through the space on the inner diameter side of the stator core 11 and reach from one side of the axis to the other.

[0127] Here, the first double-wound coil 221U-1 of phase U can simultaneously assemble the above three sets of double-wound coils 221U (1) to (3), so compared with assembling each of the above three sets of double-wound coils 221U separately into the stator core 11, efficient assembly can be achieved.

[0128] exist Figure 11A as well as Figure 11B The diagram schematically shows the connecting wires 222U-1 and 222U-2 of the three sets of double-wound coils 221U(1), 221U(2), and 221U(3) that are electrically connected in series to form the first double-wound coil 221U-1 of phase U. When used with... Figure 6 as well as Figure 7 In the case of the same double-wound coil 221 as shown in the double-wound coils 121 and 121A, the bonding wires 222U-1 and 222U-2 can also be made by Figure 6 as well as Figure 7 The ends 1210 and 1218 shown are formed. Specifically, the double-wound coil 221U(1) has a U-phase terminal 90U (see reference). Figure 10A The end 1210 of the terminal U1 is connected to the end 1210 of the double-wound coil 221U(1), and the end 1218 of the other double-wound coil 221U(2) is connected to the end 1210 of another double-wound coil 221U(3) having an end 1218 connected to the neutral point UN1 via the overlap line 222U-2. In addition, the above three sets of double-wound coils 221U(1), 221U(2), and 221U(3) can be formed by a continuous coil wire.

[0129] Next, the assembly method of the stator coil 12A in this embodiment includes the step of assembling the second double-wound coil 221U-2 of the U phase onto the stator core 11 from the outside along the axial direction using an inserter (not shown). Furthermore, the inserter can be the same as the one used when assembling the first double-wound coil 221U-1 of the U phase, and the assembly method can also be the same as when assembling the first double-wound coil 221U-1 of the U phase. This is also the same in the first double-wound coil 221V-1 of the V phase to the second double-wound coil 221W-2 of the W phase, which will be described below.

[0130] exist Figure 12A as well as Figure 12B The diagram schematically illustrates the connection wires 222U-3 and 222U-4 of the three sets of double-wound coils 221U(4), 221U(5), and 221U(6) that are electrically connected in series to form the second double-wound coil 221U-2 of phase U. When used with... Figure 6 as well as Figure 7 In the case of the double-wound coil 221 shown in the double-wound coils 121 and 121A being the same, the bonding wires 222U-3 and 222U-4 can be obtained from... Figure 6 as well as Figure 7 The ends 1210 and 1218 shown are formed. Specifically, the end 1218 of the double-wound coil 221U(4) having the end 1210 connected to the neutral point UN2 is continuous with the end 1210 of another double-wound coil 221U(5) via the tie wire 222U-3. The end 1218 of the other double-wound coil 221U(5) is continuous with the end 1210 of another double-wound coil 221U(6) via the tie wire 222U-4. The other double-wound coil 221U(6) has a terminal 90U formed with the U phase terminal (refer to...). Figure 10A End 1218 of the terminal U2 connected to the terminal. In addition, the above three sets of double-wound coils 221U(4), 221U(5), 221U(6) are the same as the first double-wound coil 221U-1 of the above U phase, and can be formed by a continuous single coil line.

[0131] The second double-wound coil 221U-2 of the U-phase, in relation to the first double-wound coil 221U-1 of the U-phase, does not have a radially different configuration. Specifically, the second double-wound coil 221U-2 of the U-phase can be inserted into the same slot 15 (long-pitch winding slot) as the first double-wound coil 221U-1 of the U-phase, with each outer coil portion arranged radially inward relative to the outer coil portions of the first double-wound coil 221U-1 of the U-phase. Therefore, after the assembly of the first double-wound coil 221U-1 of the U-phase, the second double-wound coil 221U-2 of the U-phase can be assembled axially relative to the first double-wound coil 221U-1 of the U-phase from the radially inward side and relative to the stator core 11 from the axially outward side.

[0132] Therefore, the second double-wound coil 221U-2 of phase U is the same as the first double-wound coil 221U-1 of phase U, and the three sets of 221U(4), 221U(5), and 221U(6) can be assembled simultaneously (for example, in an interconnected state). Thus, compared with assembling each of the three sets of double-wound coils 221U separately on the stator core 11, efficient assembly can be achieved.

[0133] Furthermore, in a modified example, the first double-wound coil 221U-1 and the second double-wound coil 221U-2 of the U-phase can also be assembled axially relative to the stator core 11 from the outer side using an inserter (not shown) in a single assembly process. In this case, the first double-wound coil 221U-1 and the second double-wound coil 221U-2 of the U-phase can be respectively set in the inserter with individual coil wires, or they can be set in the inserter with a continuous single coil wire.

[0134] Next, the assembly method of the stator coil 12A in this embodiment includes the step of assembling the first double-wound coil 221V-1 of phase V onto the stator core 11 from the outside along the axial direction using an inserter (not shown). Furthermore, the inserter can be the same as the inserter used when assembling the first double-wound coil 221U-1 of phase U.

[0135] exist Figure 13A as well as Figure 13B The diagram schematically shows the connection wires 222V-1 and 222V-2 of the three sets of double-wound coils 221V(1), 221V(2), and 221V(3) that are electrically connected in series to form the first double-wound coil 221V-1 of phase V. When used with... Figure 6 as well as Figure 7 In the case of the same double-wound coil 221 as shown in the double-wound coils 121 and 121A, the connection wires 222V-1 and 222V-2 can be obtained from... Figure 6 as well as Figure 7 The ends 1210 and 1218 shown are formed. Specifically, the double-wound coil 221V(1) has a V-phase terminal 90V (see reference). Figure 10A The end 1210 of the terminal V1 is connected to the end 1210 of the double-wound coil 221V(1), and the end 1218 of the double-wound coil 221V(2) is connected to the end 1210 of another double-wound coil 221V(2) via the lap wire 222V-1. The end 1218 of the other double-wound coil 221V(2) is connected to the end 1210 of another double-wound coil 221V(3) with an end 1218 connected to the neutral point VN1 via the lap wire 222V-2. In addition, the above three sets of double-wound coils 221V(1), 221V(2), and 221V(3) can be formed by a continuous coil wire.

[0136] The first double-wound coil 221V-1 of the V phase, in relation to the already assembled double-wound coils 221 (i.e., the first double-wound coil 221U-1 of the U phase and the second double-wound coil 221U-2 of the U phase), does not have a radially different configuration relationship. Specifically, the first double-wound coil 221V-1 of the V phase can be inserted into the same slot 15 (short-pitch winding slot) as the first double-wound coil 221U-1 of the U phase, with one inner coil portion (second slot insertion portion 1212) of each double-wound coil 221V positioned radially inward relative to the inner coil portion (third slot insertion portion 1213) of the first double-wound coil 221U-1 of the U phase. Therefore, after the assembly of the first double-wound coil 221U-1 of the U phase and the second double-wound coil 221U-2 of the U phase, the first double-wound coil 221V-1 of the V phase can be assembled axially from the radially inward relative to them and from the axially outward relative to the stator core 11.

[0137] Therefore, the first double-wound coil 221V-1 of phase V is the same as the first double-wound coil 221U-1 of phase U and the second double-wound coil 221U-2 of phase U, and the three sets of double-wound coils 221V(1), 221V(2), and 221V(3) can be assembled simultaneously (for example, in an interconnected state). Thus, compared with assembling each of the three sets of double-wound coils 221V separately on the stator core 11, efficient assembly can be achieved.

[0138] Next, the assembly method of the stator coil 12A in this embodiment includes the step of assembling the second double-wound coil 221V-2 of phase V onto the stator core 11 from the outside along the axial direction using an inserter (not shown). Furthermore, the inserter can be the same as the one used when assembling the first double-wound coil 221U-1 of phase U.

[0139] exist Figure 14A as well as Figure 14B The diagram schematically shows the connection wires 222V-3 and 222V-4 of the three sets of double-wound coils 221V(4), 221V(5), and 221V(6) that are electrically connected in series to form the second double-wound coil 221V-2 of phase V. When used with... Figure 6 as well as Figure 7 In the case of the same double-wound coil 221 as the double-wound coils 121 and 121A shown, the connection wires 222V-3 and 222V-4 can also be... Figure 6 as well as Figure 7The ends 1210 and 1218 shown are formed. Specifically, the end 1218 of the double-wound coil 221V(4) having the end 1210 connected to the neutral point VN2 is continuous with the end 1210 of another double-wound coil 221V(5) via the tie wire 222V-3. The end 1218 of the other double-wound coil 221V(5) is continuous with the end 1210 of another double-wound coil 221V(6) via the tie wire 222V-4. The other double-wound coil 221V(6) has a connection to the V phase terminal 90V (refer to...). Figure 10A End 1218 of the terminal V2 connected to the terminal. In addition, the above three sets of double-wound coils 221V(4), 221V(5), 221V(6) are the same as the first double-wound coil 221V-1 of the above V phase, and can also be formed by a continuous single coil wire.

[0140] The second double-wound coil 221V-2 of the V phase, in relation to the already assembled double-wound coils 221 (i.e., the first double-wound coil 221U-1 of the U phase, the second double-wound coil 221U-2 of the U phase, and the first double-wound coil 221V-1 of the V phase), does not have a radially different configuration relationship with each other.

[0141] Specifically, the second double-wound coil 221V-2 of phase V can be inserted into the same slot 15 (long-pitch winding slot) as the first double-wound coil 221V-1 of phase V, with each outer coil portion of the double-wound coil 221V arranged radially inward relative to each outer coil portion of the first double-wound coil 221V-1 of phase V. Additionally, the second double-wound coil 221V-2 of phase V can be inserted into the same slot 15 (short-pitch winding slot) as the second double-wound coil 221U-2 of phase U, with one inner coil portion (second slot insertion portion 1212) of each double-wound coil 221V arranged radially inward relative to the inner coil portion (third slot insertion portion 1213) of the second double-wound coil 221U-2 of phase U. Therefore, after the assembly of the first double-wound coil 221U-1 of the U phase, the second double-wound coil 221U-2 of the U phase, and the first double-wound coil 221V-1 of the V phase, the second double-wound coil 221U-2 of the U phase and the first double-wound coil 221V-1 of the V phase can be assembled axially relative to them from the radial inside and from the axial outside relative to the stator core 11.

[0142] Therefore, the second double-wound coil 221V-2 of phase V is the same as the first double-wound coil 221U-1 and the second double-wound coil 221U-2 of phase U, and can be assembled simultaneously (for example, in an interconnected state) with the above three sets of double-wound coils 221V(4), 221V(5), and 221V(6). Thus, compared with assembling each of the above three sets of double-wound coils 221V(4), 221V(5), and 221V(6) separately on the stator core 11, efficient assembly can be achieved.

[0143] Furthermore, in a modified example, the first double-wound coil 221V-1 and the second double-wound coil 221V-2 of phase V can be assembled axially from the outside of the stator core 11 in a single assembly process using an inserter (not shown). In this case, the first double-wound coil 221V-1 and the second double-wound coil 221V-2 of phase V can be respectively provided in the inserter with individual coil wires, or they can be provided in the inserter with a continuous single coil wire.

[0144] Next, the assembly method of the stator coil 12A in this embodiment includes the step of assembling the first double-wound coil 221W-1 of phase W onto the stator core 11 from the outside along the axial direction using an inserter (not shown). Furthermore, the inserter can be the same as the inserter used when assembling the first double-wound coil 221U-1 of phase U.

[0145] exist Figure 15A as well as Figure 15B The diagram schematically shows the connecting wires 222W-1 and 222W-2 of the three sets of double-wound coils 221W(1), 221W(2), and 221W(3) that are electrically connected in series to form the first double-wound coil 221W-1 of phase W. When used with... Figure 6 as well as Figure 7 In the case of the double-wound coil 221 shown in the double-wound coils 121 and 121A being the same, the bonding wires 222W-1 and 222W-2 can be obtained from... Figure 6 as well as Figure 7 The ends 1210 and 1218 shown are formed. Specifically, the double-wound coil 221W(1) has a terminal 90W formed with the W phase terminal (see reference). Figure 10A The end 1210 of the terminal W1 is connected to the end 1210 of the double-wound coil 221W(1), and the end 1218 of the double-wound coil 221W(1) is connected to the end 1210 of the other double-wound coil 221W(2) via the overlap wire 222W-1. The end 1218 of the other double-wound coil 221W(2) is connected to the end 1210 of another double-wound coil 221W(3) having an end 1218 connected to the neutral point WN1 via the overlap wire 222W-2. In addition, the above three sets of double-wound coils 221W(1), 221W(2), and 221W(3) can be formed by a continuous single coil wire.

[0146] The first double-wound coil 221W-1 of the W phase, in relation to the already assembled double-wound coils 221 (i.e., the first double-wound coil 221U-1 of the U phase, the second double-wound coil 221U-2 of the U phase, the first double-wound coil 221V-1 of the V phase, and the second double-wound coil 221V-2 of the V phase), does not have a radially different configuration relationship.

[0147] Specifically, the first double-wound coil 221W-1 of the W phase can be inserted into the same slot 15 (short-pitch winding slot) as the first double-wound coil 221V-1 of the V phase, with one inner coil portion (second slot insertion portion 1212) of each double-wound coil 221W arranged radially inward relative to the inner coil portion (third slot insertion portion 1213) of the first double-wound coil 221V-1 of the V phase, and the other inner coil portion (third slot insertion portion 1213) of each double-wound coil 221W arranged radially inward relative to the inner coil portion (second slot insertion portion 1212) of the first double-wound coil 221U-1 of the U phase. Therefore, after the assembly of the first double-wound coil 221W-1 of phase W, the first double-wound coil 221U-1 of phase U, the second double-wound coil 221U-2 of phase U, the first double-wound coil 221V-1 of phase V, and the second double-wound coil 221V-2 of phase V, phase W can be assembled axially relative to them from the radial inside and from the axial outside relative to the stator core 11.

[0148] Therefore, the first double-wound coil 221W-1 of phase W is the same as the first double-wound coil 221U-1 of phase U and the second double-wound coil 221U-2 of phase U, and the three sets of double-wound coils 221W(1), 221W(2), and 221W(3) can be assembled simultaneously (for example, in an interconnected state). Thus, compared with assembling each of the three sets of double-wound coils 221W separately on the stator core 11, efficient assembly can be achieved.

[0149] Next, the assembly method of the stator coil 12A in this embodiment includes the step of assembling the second double-wound coil 221W-2 of phase W onto the stator core 11 from the outside along the axial direction using an inserter (not shown). Furthermore, the inserter can be the same as the one used when assembling the first double-wound coil 221U-1 of phase U.

[0150] exist Figure 16A as well as Figure 16B The diagram schematically illustrates the connection wires 222W-3 and 222W-4 of the three sets of double-wound coils 221W(4), 221W(5), and 221W(6) that are electrically connected in series to form the second double-wound coil 221W-2 of phase W. When used with... Figure 6 as well as Figure 7 In the case of the same double-wound coil 221 as shown in the double-wound coils 121 and 121A, the bonding wires 222W-3 and 222W-4 can be obtained from... Figure 6 as well as Figure 7 The ends 1210 and 1218 shown are formed. Specifically, the end 1218 of the double-wound coil 221W(4) having the end 1210 connected to the neutral point WN2 is continuous with the end 1210 of another double-wound coil 221W(5) via the tie wire 222W-3. The end 1218 of the other double-wound coil 221W(5) is continuous with the end 1210 of another double-wound coil 221W(6) via the tie wire 222W-4. The other double-wound coil 221W(6) has a terminal 90W formed with the W phase terminal (refer to...). Figure 10A End 1218 of the terminal W2 connected to the terminal. In addition, the above three sets of double-wound coils 221W(4), 221W(5), 221W(6) are the same as the first double-wound coil 221W-1 of the above W phase, and can be formed by a continuous single coil wire.

[0151] The second double-wound coil 221W-2 of the W phase, in relation to the assembled double-wound coils 221 (i.e., the first double-wound coil 221U-1 of the U phase, the second double-wound coil 221U-2 of the U phase, the first double-wound coil 221V-1 of the V phase, the second double-wound coil 221V-2 of the V phase, and the first double-wound coil 221W-1 of the W phase), does not have a radially different configuration relationship with each other.

[0152] Specifically, the second double-wound coil 221W-2 of phase W can be inserted into the same slot 15 (long pitch winding slot) as the first double-wound coil 221W-1 of phase W, with each outer coil portion of the double-wound coil 221W positioned radially inward relative to each outer coil portion of the first double-wound coil 221W-1 of phase W. In addition, the second double-wound coil 221W-2 of the W phase can be inserted into the same slot 15 (short-pitch winding slot) as the second double-wound coil 221U-2 of the U phase, with one inner coil portion (third slot insertion portion 1213) of each double-wound coil 221W arranged radially inward relative to the inner coil portion (second slot insertion portion 1212) of the second double-wound coil 221U-2 of the U phase, and the other inner coil portion (second slot insertion portion 1212) of each double-wound coil 221W arranged radially inward relative to the inner coil portion (third slot insertion portion 1213) of the second double-wound coil 221V-2 of the V phase. Therefore, after the assembly of the first double-wound coil 221U-1 of the U phase, the second double-wound coil 221U-2 of the U phase, the first double-wound coil 221V-1 of the V phase, the second double-wound coil 221V-2 of the V phase, and the first double-wound coil 221W-1 of the W phase, the second double-wound coil 221W-2 of the W phase can be assembled axially relative to them from the radial inside and from the axial outside relative to the stator core 11.

[0153] Therefore, the second double-wound coil 221W-2 of phase W is the same as the second double-wound coil 221U-2 of phase U, and can be assembled simultaneously (for example, in a mutually connected state) with the above three sets of double-wound coils 221W(4), 221W(5), and 221W(6). Therefore, compared with the case where each of the above three sets of double-wound coils 221W(4), 221W(5), and 221W(6) is assembled separately on the stator core 11, efficient assembly can be achieved.

[0154] Furthermore, in a modified example, the first double-wound coil 221W-1 and the second double-wound coil 221W-2 of phase W can be assembled axially from the outside of the stator core 11 in a single assembly process using an inserter (not shown). In this case, the first double-wound coil 221W-1 and the second double-wound coil 221W-2 of phase W can be respectively provided in the inserter with individual coil wires, or they can be provided in the inserter with a continuous single coil wire.

[0155] Thus, according to this embodiment, the first double-wound coil 221U-1 of phase U, the second double-wound coil 221U-2 of phase U, the first double-wound coil 221V-1 of phase V, the second double-wound coil 221V-2 of phase V, the first double-wound coil 221W-1 of phase W, and the second double-wound coil 221W-2 of phase W can be assembled in this order. Furthermore, the assembly can be performed axially from the outside relative to the stator core 11 using an inserter. Therefore, each of the first double-wound coil 221U-1 of phase U, the second double-wound coil 221U-2 of phase U, the first double-wound coil 221V-1 of phase V, the second double-wound coil 221V-2 of phase V, the first double-wound coil 221W-1 of phase W, and the second double-wound coil 221W-2 of phase W can be efficiently assembled in a single assembly operation using the inserter. Furthermore, in the modified example, the first double-wound coil 221U-1 and the second double-wound coil 221U-2 of phase U can be assembled in one assembly operation of the inserter, the first double-wound coil 221V-1 and the second double-wound coil 221V-2 of phase V can be assembled in one assembly operation of the inserter, and the first double-wound coil 221W-1 and the second double-wound coil 221W-2 of phase W can be assembled in one assembly operation of the inserter, thereby maximizing the assembly efficiency.

[0156] While the embodiments have been described in detail above, they are not limited to specific embodiments. Various modifications and alterations are possible within the scope of the technical solutions described. Furthermore, all or more of the structural elements of the above embodiments can be combined.

[0157] Explanation of reference numerals in the attached figures

[0158] 10, 10A…Stator, 11…Stator core, 12, 12A…Stator coil, 15…Slot, 121, 121A, 221…Double-wound coil, 1211…First slot insertion part, 1212, 1212A…Second slot insertion part, 1213…Third slot insertion part, 1214, 1214A…Fourth slot insertion part, 1215A…First overlapping part, 1215B…Second overlapping part, 1216A…Third overlapping part, 1216B…Fourth overlapping part, 1217, 1217A…Connecting part.

Claims

1. A stator for a rotary electric machine, comprising: Stator core, which has multiple slots; and Multiphase stator coils, which are wound in double layers on the aforementioned stator core, The aforementioned multiphase stator coils are formed by winding multiple concentric double-wound coils with different circumferences around the stator core for each phase. The aforementioned double-wound coil is formed by a coil section with a longer circumference and a coil section with a shorter circumference. In each pair of adjacent double-wound coils, the coil portions with the same circumference are inserted into the same slot. The aforementioned coil portion with a longer circumference is connected to a long-pitch winding, allowing a pair of coils of the same phase to be inserted into the long-pitch winding slots among the aforementioned plurality of slots. The aforementioned shorter circumference coil portion, through a short-pitch winding, allows a pair of different phases to be inserted into the short-pitch winding slots among the aforementioned multiple slots. The total number of coils inserted into the plurality of slots in the longer circumference portion of the aforementioned double-wound coil is the same as the total number of coils inserted into the plurality of slots in the shorter circumference portion of the aforementioned double-wound coil.

2. The stator for a rotary electric machine according to claim 1, wherein, One of the above-mentioned double-wound coils includes: The first slot insertion part is inserted into a slot for the aforementioned long pitch winding; The second slot insertion part is inserted into a slot for the aforementioned short-pitch winding; The third slot insertion part is inserted into another slot for the aforementioned short-pitch winding; The fourth slot insertion part is inserted into another slot for the aforementioned long-pitch winding; The first overlapping part has one circumferential side connected to the lead wire side end of the first slot insertion part and the other circumferential side connected to the lead wire side end of the fourth slot insertion part. The second lap joint has one circumferential side connected to the reverse lead side end of the first slot insertion part and the other circumferential side connected to the reverse lead side end of the fourth slot insertion part. The third overlapping portion has one circumferential side connected to the lead-side end of the second slot insertion portion and the other circumferential side connected to the lead-side end of the third slot insertion portion; and The fourth lap joint has one circumferential side connected to the reverse lead side end of the second slot insertion part and the other circumferential side connected to the reverse lead side end of the third slot insertion part. The first slot insertion portion, the fourth slot insertion portion, the first overlapping portion, and the second overlapping portion form the longer circumference coil portion of the double-wound coil, and the second slot insertion portion, the third slot insertion portion, the third overlapping portion, and the fourth overlapping portion form the shorter circumference coil portion of the double-wound coil. The center between the pair of long-pitch winding slots into which the first slot insertion part and the fourth slot insertion part of the aforementioned double-wound coil are respectively inserted coincides with the center between the pair of short-pitch winding slots into which the second slot insertion part and the third slot insertion part of the aforementioned double-wound coil are respectively inserted.

3. The stator for a rotary electric machine according to claim 2, wherein, Each of the above-mentioned double-wound coils has N of the above-mentioned first slot insertion parts and the above-mentioned third slot insertion parts, and has N-1 of the above-mentioned second slot insertion parts and the above-mentioned fourth slot insertion parts, wherein N≥2.

4. The stator for a rotary electric machine according to claim 3, wherein, The long-pitch winding slot and the short-pitch winding slot, into which the first slot insertion portion and the second slot insertion portion of the aforementioned dual-wound coil are respectively inserted, are adjacent in the circumferential direction, and the long-pitch winding slot and the short-pitch winding slot, into which the fourth slot insertion portion and the third slot insertion portion of the aforementioned dual-wound coil are respectively inserted, are adjacent in the circumferential direction.

5. The stator for a rotary electric machine according to claim 4, wherein, One of the aforementioned double-wound coils also includes a switching connection section. One circumferential side of the aforementioned switching connection is connected to the reverse lead end of one of the N third slot insertion parts via a fourth overlapping part, and the other circumferential side is connected to the reverse lead end of one of the N first slot insertion parts.

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