Stator for rotating electrical machine and method for manufacturing same

Abstract

The invention relates to a stator of a rotary electric machine and a manufacturing method thereof. A stator of a rotating electrical machine according to the present invention comprises: a stator core having a plurality of slots spaced apart in a circumferential direction; the stator coil is wound on the stator core; the stator coil includes a plurality of electromagnetic wire modules having: a plurality of electromagnetic wires each having a linear shape arranged in an axial direction; the molding part surrounds and fixes the plurality of electromagnetic wires; the plurality of electromagnetic wire modules are respectively inserted into the plurality of grooves; the plurality of electromagnetic wires are bent in the circumferential direction of the stator core in a mutually contactable manner and then are electrically connected. Thus, bending work of the electromagnetic wire can be suppressed before the electromagnetic wire is inserted into the slot, and the electromagnetic wire can be easily inserted.

Description

Technical Field

[0001] The present invention relates to a stator of a rotating electric machine and a method for manufacturing the same. Background Art

[0002] As is well known, a rotating electric machine is a machine having a stator and a rotor configured to be rotatable relative to the stator.

[0003] Some of the rotating electric machines are configured as generators that convert mechanical energy into electrical energy, while some others are configured as motors that convert electrical energy into mechanical energy. Still some other rotating electric machines are configured to selectively function as either a motor or a generator.

[0004] The stator of the rotating electric machine includes a stator core having slots and teeth, and a stator coil wound through the slots.

[0005] In the stator of the rotating electric machine, the higher the ratio (fill factor) of the conductor cross-sectional area of the stator coil to the inner area of the slot, the more beneficial it is to increase the output.

[0006] In view of this, some stators adopt a stator coil formed by bending a flat copper wire with a relatively large cross-sectional area of the conductor into a "U" shape to form conductor segments, hairpins or magnet wires (hereinafter referred to as "magnet wires") and connecting them in a preset pattern.

[0007] The magnet wire generally includes a conductor having a quadrilateral cross-section and a coating film formed of an insulating material surrounding the outer surface of the conductor.

[0008] The magnet wire includes a pair of insertion portions respectively inserted into the interiors of different slots in the stator core and a connecting portion connecting the ends of the pair of insertion portions.

[0009] The pair of insertion portions of the magnet wire are generally formed in parallel at a preset interval (slot pitch), and the connecting portion is bent into a substantially inverted "U" shape or an inverted "V" shape.

[0010] The pair of insertion portions of the magnet wire are respectively inserted into the interiors of different slots in the stator core, and in the slots of the stator core, the insertion portions of the magnet wire are arranged at intervals in the radial direction to form a plurality of layers.

[0011] However, in such a conventional stator of a rotating electric machine, the magnet wires inserted into different positions (layers) inside the slots of the stator core are formed into different sizes and shapes respectively before being inserted into the corresponding slots of the stator core, so there is a problem that it is time-consuming and laborious to assemble the magnet wires.

[0012] In addition, in the stator of such an existing rotating electric machine, before inserting the electromagnetic wire into the slots of the stator core, in order to insulate the electromagnetic wire and the stator core, insulating paper is first inserted into the slots. Therefore, the problem is that when the electromagnetic wires are joined, interference may occur between the electromagnetic wires and the insulating paper, resulting in damage and displacement of the insulating paper.

[0013] In addition, due to the damage and displacement of the insulating paper, there is a problem of poor insulation of the electromagnetic wire.

[0014] In addition, in the stator of such an existing rotating electric machine, since a structure is adopted in which two insertion portions are correspondingly inserted into two slots circumferentially spaced apart in a plurality of slots of the stator core, the electromagnetic wire requires relatively high shape accuracy. Therefore, when the electromagnetic wire is bent (folded) and formed, bending is achieved with a relatively high pressing force. For example, so-called pinholes or the like are generated in the coating film of the electromagnetic wire, and thus there is a problem that the insulation performance may be reduced.

[0015] In addition, in the stator of such an existing rotating electric machine, after the electromagnetic wire is inserted and joined to the inside of the corresponding slot, an insulating material such as varnish is put into the slot. Therefore, when manufacturing a stator coil using the electromagnetic wire, there is a problem of being relatively time-consuming and laborious.

[0016] Prior Art Documents

[0017] Patent Documents

[0018] Korean Patent Publication No. 10-2021-0129440 (Publication Date: October 28, 2021) Summary of the Invention

[0019] Problems to be Solved by the Invention

[0020] Therefore, an object of the present invention is to provide a stator of a rotating electric machine that can easily insert an electromagnetic wire by suppressing the bending operation of the electromagnetic wire before inserting it into a slot.

[0021] In addition, another object of the present invention is to provide a stator of a rotating electric machine that can suppress interference between an electromagnetic wire and insulating paper when the electromagnetic wire is inserted into a slot.

[0022] In addition, still another object of the present invention is to provide a stator of a rotating electric machine that can omit the process of injecting varnish between the electromagnetic wire and the slot.

[0023] Technical Solution for Solving the Problem

[0024] The technical feature of the stator of the rotating electric machine of the present invention for solving the above problems is that a linear electromagnetic wire module is inserted into a slot.

[0025] Specifically, a plurality of electromagnetic wires in a straight line shape are radially arranged so as to be insertable into the inside of the slots, the plurality of electromagnetic wires are molded to form a plurality of electromagnetic wire modules, and the plurality of electromagnetic wire modules are inserted into the inside of the slots, thereby eliminating the bending operation of the electromagnetic wires before being inserted into the slots.

[0026] Thereby, the electromagnetic wires can be easily inserted into the slots.

[0027] In an embodiment of the present invention, the stator of the rotating electric machine includes: a stator core having a plurality of slots spaced apart in the circumferential direction; and a stator coil wound around the stator core; the stator coil includes a plurality of electromagnetic wire modules, the plurality of electromagnetic wire modules having: a plurality of electromagnetic wires, each electromagnetic wire having a straight line shape arranged in the axial direction; and a molding portion surrounding and fixing the plurality of electromagnetic wires; the plurality of electromagnetic wire modules are respectively inserted into the plurality of slots; the plurality of electromagnetic wires are electrically connected after being bent in contact with each other along the circumferential direction of the stator core.

[0028] Thereby, before being inserted into the slots of the stator core, the bending operation of the electromagnetic wires can be suppressed, and thus the insertion of the electromagnetic wires becomes easy.

[0029] In an embodiment of the present invention, the molding portion includes an outer main body 191 disposed outside the plurality of slots.

[0030] Thereby, the size of the molding portion can be reduced, and the molding portion can be easily manufactured.

[0031] In an embodiment of the present invention, the outer main body 191 includes a stopper portion that contacts the edge of the slot in the axial direction.

[0032] Thereby, the electromagnetic wire module can be accurately combined with the stator.

[0033] In an embodiment of the present invention, the plurality of electromagnetic wires have a bent section bent along the circumferential direction of the stator core,

[0034] A bent section support portion that contacts and supports the bent section is provided on the outer main body 191.

[0035] Thereby, the bending of the plurality of electromagnetic wires can be easily achieved.

[0036] In addition, lateral movement (play) of the plurality of electromagnetic wires can be suppressed.

[0037] In an embodiment of the present invention, the molding portion includes an inner main body disposed inside the slot.

[0038] As a result, the insulation performance of the plurality of electromagnetic wires and the stator core can be improved.

[0039] In an embodiment of the present invention, the inner main body has an outer surface spaced apart from the inner surface of the slot.

[0040] A protruding portion is provided on the outer surface of the inner main body, and the protruding portion contacts the inner surface of the slot.

[0041] As a result, the electromagnetic wire can be spaced apart from the inner surface of the slot by a preset distance.

[0042] Here, the protruding portion can be press-fitted into the inside of the slot.

[0043] As a result, it is possible to suppress the generation of play in the plurality of electromagnetic wires.

[0044] In an embodiment of the present invention, the inner main body includes: two side surfaces disposed on both sides of the inner main body in the circumferential direction of the stator core; and an inner side surface and an outer side surface disposed on both sides of the inner main body in the radial direction of the stator core.

[0045] The protruding portions are provided on both the two side surfaces and the outer side surface.

[0046] As a result, it is possible to suppress the generation of circumferential play and radial play in the plurality of electromagnetic wires.

[0047] In an embodiment of the present invention, the protruding portion is formed to extend in the axial direction.

[0048] Here, the length of the protruding portion may correspond to the axial length of the slot.

[0049] In an embodiment of the present invention, the inner main body includes a protruding end portion that protrudes outward from the slot in the axial direction of the stator core.

[0050] The plurality of electromagnetic wires have a bent section that is bent in the circumferential direction of the stator core.

[0051] A bent section support portion that contacts and supports the bent section of the plurality of electromagnetic wires is provided on the protruding end portion.

[0052] As a result, it is possible to easily bend the plurality of electromagnetic wires.

[0053] In addition, it is possible to suppress the generation of lateral movement (play) in the plurality of electromagnetic wires.

[0054] In an embodiment of the present invention, the plurality of electromagnetic wires arranged in the radial direction of the stator core are alternately bent toward one side and the other side in the circumferential direction of the stator core.

[0055] The bending section support portions of the inner main body are alternately formed on both side surfaces of the inner main body in the circumferential direction of the stator core.

[0056] Thereby, the distance between the bending section support portions can be ensured, and damage to the bending section support portions can be suppressed.

[0057] In an embodiment of the present invention, a plurality of the electromagnetic wires have an insertion section disposed inside the slots along the axial direction of the stator core.

[0058] The inner main body has a length shorter than the length of the slots along the axial direction of the stator core.

[0059] The insertion sections of the plurality of electromagnetic wires include a first section insulated by the inner main body and a second section insulated by an insulating material.

[0060] Thereby, the size (length) of the molding section (inner main body) can be reduced.

[0061] In addition, the size or the amount of the insulating material can be reduced.

[0062] In an embodiment of the present invention, the second section is insulated by being surrounded by a plate-shaped insulating sheet before the plurality of electromagnetic wires are inserted into the plurality of slots.

[0063] Thereby, the process of pre-inserting insulating paper into the slots before inserting the plurality of electromagnetic wires can be omitted.

[0064] According to such a configuration, when inserting the plurality of electromagnetic wires, interference between the plurality of electromagnetic wires and the insulating paper can be avoided.

[0065] Thereby, the plurality of electromagnetic wires can be easily inserted into the slots.

[0066] In an embodiment of the present invention, the insulating material of the second section includes a liquid foaming material filled between the plurality of electromagnetic wires before the plurality of electromagnetic wires are inserted into the plurality of slots and insulating paper surrounding the liquid foaming material.

[0067] Thereby, the plurality of electromagnetic wires can be easily inserted into the slots.

[0068] In addition, the size of the molding section of the plurality of electromagnetic wire modules can be reduced, and the molding section can be easily manufactured.

[0069] In addition, since the insulating paper is not pre-inserted into the slots, interference between the plurality of electromagnetic wires and the insulating paper can be suppressed, and the plurality of electromagnetic wires can be easily inserted into the slots.

[0070] In an embodiment of the present invention, the liquid foaming material is heated and foamed after a plurality of the electromagnetic wires are inserted into the plurality of the slots.

[0071] Thereby, the plurality of the electromagnetic wires are separated from the inner wall of the slot, and the insulation performance can be improved by the foaming material and the insulating paper that foam (expand) in the space between the plurality of the electromagnetic wires and the inner wall of the slot.

[0072] In an embodiment of the present invention, the molding portion includes: an outer main body 191 disposed outside the slot of the stator core, and an inner main body connected to the outer main body 191 and disposed inside the slot.

[0073] Thereby, the insulation performance of the plurality of the electromagnetic wires can be improved.

[0074] In addition, the generation of play in the plurality of the electromagnetic wires can be suppressed.

[0075] In an embodiment of the present invention, a stopper portion that contacts the edge of the slot in the axial direction is provided on the outer main body 191.

[0076] Thereby, the plurality of the electromagnetic wires can be accurately combined at a preset position of the stator core.

[0077] In an embodiment of the present invention, each of the plurality of the electromagnetic wires includes: an axial section disposed along the axial direction; and a circumferential section extending from the axial section in the circumferential direction.

[0078] The axial section passes through the inside of the slot.

[0079] The circumferential section is disposed outside the slot.

[0080] The circumferential sections of the plurality of the electromagnetic wires that are different from each other are electrically connected to each other.

[0081] Thereby, the bending operation of the plurality of the electromagnetic wires can be reduced, and thus the generation of insulation defects caused by the bending operation of the plurality of the electromagnetic wires can be suppressed.

[0082] In addition, the bending operation of the plurality of the electromagnetic wires is reduced, and thus the plurality of the electromagnetic wires can be easily manufactured.

[0083] On the other hand, according to another aspect of the present invention, there is provided a method for manufacturing a stator of a rotating electrical machine, the stator of the rotating electrical machine including: a stator core having a plurality of slots provided in a circumferential direction; and a stator coil including a plurality of electromagnetic wires, each of the electromagnetic wires having a linear shape arranged along an axial direction and capable of being inserted into the slots of the stator core; the method for manufacturing the stator of the rotating electrical machine including: arranging a plurality of the electromagnetic wires at intervals in a radial direction of the stator core, and forming a molding portion surrounding and fixing a periphery of the plurality of electromagnetic wires to form a plurality of electromagnetic wire modules; inserting the plurality of electromagnetic wire modules into the interiors of the plurality of slots respectively; bending the plurality of electromagnetic wires in contact with each other in a circumferential direction of the stator core toward one side or the other side; and electrically connecting the plurality of electromagnetic wires to form the stator coil.

[0084] Thus, before being inserted into the slots, bending operations of the plurality of electromagnetic wires can be suppressed, so that the plurality of electromagnetic wires can be easily inserted into the slots.

[0085] In an embodiment of the present invention, before the step of forming the stator coil, the method further includes a step of cutting ends of the plurality of electromagnetic wires such that the ends of the plurality of electromagnetic wires have the same length along the axial direction from the stator core.

[0086] Thus, welding operations of the plurality of electromagnetic wires can be easily achieved.

[0087] In an embodiment of the present invention, the plurality of electromagnetic wires have an insertion section disposed inside the slots,

[0088] the molding portion has an inner body surrounding a part of the insertion section,

[0089] before the step of inserting the plurality of electromagnetic wires into the interiors of the plurality of slots, the method further includes a step of insulating the remaining part of the insertion section.

[0090] Thus, the size of the molding portion can be reduced, and thus the molding portion can be easily manufactured.

[0091] In addition, by insulating the insertion section before the plurality of electromagnetic wires are inserted into the slots, the plurality of electromagnetic wires can be smoothly inserted into the slots.

[0092] Advantages of the Invention

[0093] As described above, according to an embodiment of the present invention, the stator coil includes a plurality of electromagnetic wire modules each including a plurality of electromagnetic wires having a linear shape arranged along an axial direction and a molding portion surrounding and fixing the plurality of electromagnetic wires, so that bending operations of the plurality of electromagnetic wires can be suppressed before being inserted into the slots.

[0094] In addition, a plurality of the electromagnetic wires can be smoothly inserted into the slots.

[0095] In addition, the molding part includes an outer main body 191 disposed outside the slots, so that the size of the molding part can be reduced and the molding part can be easily manufactured.

[0096] In addition, the outer main body 191 includes a stopper portion that contacts the edge of the slot in the axial direction, so that the electromagnetic wire module can be accurately coupled to the stator.

[0097] In addition, a bending section support portion that contacts and supports the bending section is provided on the outer main body 191, so that a plurality of the electromagnetic wires can be easily bent.

[0098] In addition, the molding part includes an inner main body disposed inside the slots, so that the insulation performance between a plurality of the electromagnetic wires and the stator core can be improved.

[0099] In addition, a protruding portion that contacts the inner surface of the slot is provided on the outer surface of the inner main body, so that the electromagnetic wires can be spaced apart from the inner surface of the slot by a preset distance.

[0100] In addition, a bending section support portion that contacts and supports the bending section is provided at the protruding end of the inner main body, so that a plurality of the electromagnetic wires can be easily bent.

[0101] In addition, the insertion section of a plurality of the electromagnetic wires includes a first section insulated by the inner main body and a second section insulated by an insulating material, so that the size of the molding part is reduced and the molding part can be easily manufactured.

[0102] In addition, the second section is surrounded by a plate-shaped insulating sheet before a plurality of the electromagnetic wires are inserted into the plurality of slots, so that interference between the plurality of the electromagnetic wires and insulating paper during insertion into the slots can be prevented.

[0103] In addition, the second section is insulated by a liquid foaming material filled between a plurality of the electromagnetic wires and insulating paper surrounding the liquid foaming material before a plurality of the electromagnetic wires are inserted into the plurality of slots, so that a plurality of the electromagnetic wires can be smoothly inserted into the slots.

[0104] In addition, the liquid foaming material is heated and foamed after a plurality of the electromagnetic wires are inserted into the plurality of slots, so that a plurality of the electromagnetic wires can be smoothly inserted into the slots and the insulation performance of a plurality of the electromagnetic wires can be improved.

[0105] In addition, the molding portion includes an outer body 191 disposed outside the slots of the stator core and an inner body connected to the outer body 191 and disposed inside the slots, thereby improving the insulation performance of the plurality of electromagnetic wires.

[0106] In addition, each of the plurality of electromagnetic wires includes an axial section disposed along the axial direction and a circumferential section extending in the circumferential direction from the axial section. The axial section passes through the inside of the slot, and the circumferential section is disposed outside the slot. The circumferential sections of the plurality of different electromagnetic wires are electrically connected to each other, thereby suppressing the bending operation of the plurality of electromagnetic wires and suppressing the occurrence of insulation failure of the plurality of electromagnetic wires caused by the bending operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0107] Figure 1 is a perspective view of a stator of a rotating electric machine according to an embodiment of the present invention,

[0108] Figure 2 is Figure 1 a front view of the stator of the rotating electric machine,

[0109] Figure 3 is Figure 1 a top view of the stator of the rotating electric machine,

[0110] Figure 4 is Figure 1 a sectional view of the stator of the rotating electric machine,

[0111] Figure 5 is Figure 1 a circuit configuration diagram of the stator coil,

[0112] Figure 6 is Figure 1 an enlarged view of the slot of the stator core,

[0113] Figure 7 is Figure 1 a side view of the electromagnetic wire before bending,

[0114] Figure 8 is Figure 1 a side view of the electromagnetic wire after bending,

[0115] Figure 9 is Figure 1 a perspective view of the electromagnetic wire module before combination,

[0116] Figure 10 is Figure 9 a sectional view after the electromagnetic wire module is inserted,

[0117] Figure 11 is Figure 9Stereogram of the molding part of

[0118] Figure 12 is Figure 11 Top view of the molding part of

[0119] Figure 13 is Figure 11 Bottom view of the molding part of

[0120] Figure 14 is Figure 13 Enlarged view of the main part of the molding part of

[0121] Figure 15 Cross-sectional view of the stator of the rotating electric machine according to another embodiment of the present invention

[0122] Figure 16 is Figure 15 Stereogram of the stator of the rotating electric machine before the electromagnetic wire module is combined

[0123] Figure 17 is Figure 15 Enlarged view of the main part of the electromagnetic wire module of

[0124] Figure 18 Cross-sectional view of the stator of the rotating electric machine according to still another embodiment of the present invention

[0125] Figure 19 is Figure 18 Stereogram of the stator of the rotating electric machine before the electromagnetic wire module is combined

[0126] Figure 20 is Figure 18 Enlarged view of the main part of the electromagnetic wire module of Detailed implementation mode

[0127] Hereinafter, the embodiments disclosed in this specification will be described in detail with reference to the drawings. In this specification, even if the embodiments are different from each other, the same or similar structural elements will be given the same or similar reference numerals, and their descriptions will be replaced by the initial description. Unless otherwise clearly specified in the context, the singular expressions used in this specification include the plural expressions. In addition, when describing the embodiments disclosed in this specification, if it is determined that the specific description of the related well-known technology may confuse the gist of the embodiments disclosed in this specification, the detailed description thereof will be omitted. In addition, it should be noted that the drawings are only for easily understanding the embodiments disclosed in this specification, and should not be construed as limiting the technical ideas disclosed in this specification by the drawings.

[0128] Figure 1 Stereogram of the stator of the rotating electric machine according to an embodiment of the present invention Figure 2 is Figure 1 Front view of the stator of the rotating electric machine of Figure 3 is Figure 1Top view of the stator of a rotating electric machine Figure 4 is Figure 1 Cross-sectional view of the stator of a rotating electric machine Figure 5 is Figure 1 Circuit configuration diagram of the stator coil. As Figures 1 to 4 shown, the stator 100 of a rotating electric machine according to an embodiment of the present invention includes a stator core 110 and a stator coil 150.

[0129] The stator core 110 may be formed, for example, in a cylindrical shape.

[0130] Inside the stator core 110, a rotor receiving hole 114 may be formed, for example, and a rotor (not shown) is rotatably received in the rotor receiving hole 114.

[0131] The rotor receiving hole 114 may be formed to penetrate the stator core 110 in the axial direction.

[0132] Here, the axial direction refers to the direction parallel to the rotation axis of the rotor.

[0133] The stator core 110 may be formed, for example, by insulating and stacking a plurality of electrical steel sheets 112.

[0134] The stator core 110 may be stacked, for example, in the axial direction.

[0135] The stator core 110 includes a plurality of slots 116 spaced apart in the circumferential direction.

[0136] A plurality of the slots 116 are formed to penetrate the stator core 110 in the axial direction.

[0137] The stator core 110 includes a plurality of teeth 118 spaced apart in the circumferential direction.

[0138] A plurality of the slots 116 and a plurality of teeth 118 are alternately formed in the circumferential direction.

[0139] A plurality of the slots 116 and a plurality of teeth 118 may be composed of 48, respectively.

[0140] In this embodiment, a case where a plurality of the slots 116 are composed of 48 is illustrated, but this is only an example and is not limited thereto.

[0141] The stator coil 150 is wound around the stator core 110.

[0142] The stator coil 150 is configured to be connectable to a three-phase (U-phase, V-phase, W-phase) power supply, for example.

[0143] The stator coil 150 includes a plurality of phase coils 155 respectively connected to a three-phase power supply, for example.

[0144] As shown Figure 5 in FIG.

[0144] , a plurality of the phase coils 155 include, for example, a U-phase coil 155U, a V-phase coil 155V, and a W-phase coil 155W.

[0145] The U-phase coil 155U, the V-phase coil 155V, and the W-phase coil 155W can be configured, for example, to be connected in parallel to the corresponding phase (U-phase, V-phase, W-phase) power supply with each other.

[0146] Specifically, the U-phase coil 155U can include a first U-phase coil 155U1 and a second U-phase coil 155U2 that are connected in parallel to each other.

[0147] The V-phase coil 155V can include a first V-phase coil 155V1 and a second V-phase coil 155V2 that are connected in parallel to each other.

[0148] The W-phase coil 155W can include a first W-phase coil 155W1 and a second W-phase coil 155W2 that are connected in parallel to each other.

[0149] In this embodiment, an example is illustrated in which the U-phase coil 155U, the V-phase coil 155V, and the W-phase coil 155W are configured to respectively include two parallel coils that are connected in parallel to the corresponding phase (U-phase, V-phase, W-phase) power supply, but this is only an example and is not limited thereto.

[0150] The stator coil 150 includes a plurality of electromagnetic wire modules 170 that are respectively inserted into the plurality of slots 116.

[0151] Each of the plurality of electromagnetic wire modules 170 includes: a plurality of electromagnetic wires 180 having a linear shape arranged along the axial direction; and a molding portion 190 that surrounds and fixes the plurality of electromagnetic wires 180.

[0152] The U-phase coil 155U, the V-phase coil 155V, and the W-phase coil 155W each include a plurality of the electromagnetic wire modules 170 in a preset quantity.

[0153] The electromagnetic wires 180 of the plurality of the electromagnetic wire modules 170 in the preset quantity can be connected in series with each other in a preset pattern to form a circuit.

[0154] The stator coil 150 includes a connection ring 220 that connects the plurality of phase coils 155 (U-phase coil 155U, V-phase coil 155V, W-phase coil 155W).

[0155] The connection ring 220 can be configured, for example, to achieve a so-called Y connection that enables the respective one ends of the plurality of phase coils 155 to be connected to be electrically conductive with each other.

[0156] The connecting ring 220 can be formed, for example, in an arc shape.

[0157] The connecting ring 220 includes, for example, a main body 230 formed of an insulating material and having an arc shape.

[0158] In this embodiment, the main body 230 of the connecting ring 220 is formed in an arc shape corresponding to half of the circumference of the stator core 110.

[0159] The connecting ring 220 includes a plurality of power connection portions to enable the plurality of phase coils 155 to be connected to respective phases (U phase, V phase, W phase) of a three-phase AC power supply.

[0160] The plurality of power connection portions include, for example, a U-phase power connection portion, a V-phase power connection portion, and a W-phase power connection portion.

[0161] The plurality of power connection portions (U-phase power connection portion, V-phase power connection portion, and W-phase power connection portion) each include, for example, a lead wire and a connection member. One side of the connection member is connected to the lead wire, and the other side is connected to the phase coil 155.

[0162] One side of the lead wire protrudes axially, and the other side extends circumferentially and is joined to the connection member.

[0163] Connection terminals for connection to an external power supply are provided respectively on the lead wires.

[0164] The connection terminals have a plate shape.

[0165] The connection terminals include through holes and lead wire joining portions joined to the lead wires.

[0166] One side of the connection member is exposed to the outside of the main body 230 of the connecting ring 220, and the other side protrudes from the inside of the main body 230 to the outside of the main body 230.

[0167] Refer to Figure 2 , a lead wire connection portion for connection to the lead wire is provided on one side of the connection member, and a branch portion branched to be able to be connected to two parallel coils respectively is formed on the other side.

[0168] Thus, the current applied from the lead wire can be applied to the parallel coils.

[0169] The connecting ring 220 includes a neutral wire for electrically connecting respective one ends of the plurality of phase coils 155.

[0170] The connection ring 220 includes jumpers that electrically connect a plurality of electromagnetic wires 180 that are arranged at intervals in the circumferential direction of the stator core 110 among the plurality of phase coils 155. The jumpers pass through the inside of the main body 230 of the connection ring 220, and the ends of the jumpers are exposed to the outside.

[0171] On the other hand, as Figure 3 shown, the plurality of phase coils 155 (U-phase coil 155U, V-phase coil 155V, W-phase coil 155W) include: a first type of electromagnetic wire 180a that extends from the stator core 110 in the axial direction by a first length L1; and a second type of electromagnetic wire 180b that extends from the stator core 110 in the axial direction by a second length L2, and the second length L2 is greater than the first length L1 by a preset length.

[0172] Herein, the second length L2 includes the length of an extension portion that extends in the axial direction by a preset length compared to the first length L1.

[0173] Specifically, the plurality of phase coils 155 each include a plurality of electromagnetic wire modules 170, and the plurality of electromagnetic wires 180 of the plurality of electromagnetic wire modules 170 may include the first type of electromagnetic wire 180a and the second type of electromagnetic wire 180b.

[0174] The second type of electromagnetic wire 180b is combined with the connection ring 220.

[0175] Specifically, referring to Figure 8 , among the plurality of electromagnetic wires 180, compared with the first type of electromagnetic wire 180a that is not connected to the connection ring 220, the length of the connection end portion 1813a of the second type of electromagnetic wire 180b that is connected to the connection ring 220 extends in the axial direction by a preset length.

[0176] That is, the length of the covered section 18131a in the connection end portion 1813a of the second type of electromagnetic wire 180b having the extension portion extends in the axial direction by the preset length so as to be able to be combined with the connection ring 220.

[0177] Herein, the extension portion may refer to the covered section 18131a of the second type of electromagnetic wire 180b.

[0178] The length of the stripped section 18132 of the second type of electromagnetic wire 180b may be substantially the same as the length of the stripped section 18132 of the first type of electromagnetic wire 180a.

[0179] The connection ring 220 includes a plurality of insertion portions 2301 into which the respective extension portions (covered sections 18131a) of the plurality of phase coils 155 are inserted.

[0180] A plurality of the insertion portions 2301 penetrate through the main body 230 of the connection ring 220 in the axial direction.

[0181] A plurality of the insertion portions 2301 can be formed in pairs, for example, so that the connection end portions 1813 that need to be connected to each other (connected) or the connection member 244 and the connection end portion 1813a can be in contact with each other. A plurality of connection end portions 1813 that are in pairs with each other and the connection end portion 1813a that is in pair with the end portion of the connection member 244 are arranged close to each other in the circumferential direction or the radial direction, for example.

[0182] Figure 6 is Figure 1 an enlarged view of the slots of the stator core, Figure 7 is Figure 1 a side view of the magnet wire before bending, Figure 8 is Figure 1 a side view of the magnet wire after bending. As Figure 6 shown, magnet wire modules 170 are respectively inserted and combined inside a plurality of slots 116 of the stator core 110.

[0183] The magnet wire module 170 includes: a plurality of magnet wires 180 arranged in the radial direction of the stator core 110; and a molding portion 190 surrounding and fixing the plurality of magnet wires 180.

[0184] A plurality of the magnet wires 180 can be composed of 8, for example.

[0185] In this embodiment, the case where a plurality of the magnet wires 180 are composed of 8 is illustrated, but this is only an example and is not limited thereto. A plurality of the magnet wires can also be composed of 4 or 6.

[0186] Specifically, a plurality of the magnet wires 180 include, for example, a first magnet wire 1801 disposed at the innermost side inside the slot 116, a second magnet wire 1802 disposed outside the first magnet wire 1801 in the radial direction, a third magnet wire 1803 disposed outside the second magnet wire 1802, a fourth magnet wire 1804, a fifth magnet wire 1805, a sixth magnet wire 1806, a seventh magnet wire 1807, and an eighth magnet wire 1808.

[0187] A plurality of the magnet wires 180 each include, for example, an energizable conductor 181 and a covering portion 182 surrounding the outer surface of the conductor 181 to insulate the conductor 181.

[0188] The conductor 181 has a rectangular cross-section, for example.

[0189] The cross-section of the conductor 181 has two long sides facing each other and two short sides facing each other.

[0190] In the present embodiment, the long sides of the cross-sections of the conductors 181 of the plurality of electromagnetic wires 180 are arranged in the circumferential direction of the stator core 110.

[0191] That is, the plurality of electromagnetic wires 180 are respectively inserted into the inside of the slots 116 in such a manner that the long sides of the cross-sections of the conductors 181 are arranged in the width direction of the slots 116.

[0192] The short sides of the cross-sections of the conductors 181 of the plurality of electromagnetic wires 180 are arranged in the radial direction of the stator core 110.

[0193] The molding portion 190 is formed of an insulating material, for example.

[0194] Specifically, the molding portion 190 can be formed by injecting a molten synthetic resin material into the inside of a mold (not shown) after inserting a plurality of electromagnetic wires 180 (the first electromagnetic wire 1801 to the eighth electromagnetic wire 1808) arranged in the radial direction of the stator core 110 into preset positions inside the mold.

[0195] As Figure 7 shown, the plurality of electromagnetic wires 180 have a straight shape before being bent.

[0196] The plurality of electromagnetic wires 180 are inserted into the inside of the slots 116 of the stator core 110 in a state of being arranged along the axial direction.

[0197] The plurality of electromagnetic wires 180 are respectively inserted and joined to the inside of the slots 116 so as to protrude toward both sides of the stator core 110 along the axial direction.

[0198] The plurality of electromagnetic wires 180 respectively have stripping sections 18132 for removing the covering portion 182 so that the conductors 181 can be exposed to the outside. The stripping sections 18132 can be respectively formed at both ends of the plurality of electromagnetic wires 180.

[0199] Thus, the plurality of electromagnetic wires 180 can be electrically connected by welding respectively on both sides (the upper side and the lower side in the figure) of the stator core 110 along the axial direction.

[0200] The plurality of electromagnetic wires 180 are bent (twisted, bent) in one direction or the other direction in the circumferential direction of the stator core 110 in a state of being inserted into the inside of the slots 116 of the stator core 110.

[0201] In this embodiment, a plurality of the electromagnetic wires 180 each have a rectangular cross-section, and the long sides of the rectangular cross-sections are arranged in the circumferential direction. Therefore, when the plurality of electromagnetic wires 180 are bent in the circumferential direction, the cross-sections (long sides) of the plurality of electromagnetic wires 180 are arranged in the axial direction. Thus, after bending, the support strength of the plurality of electromagnetic wires 180 is ensured (increased). Subsequently, when an external force acts, vibration in the circumferential direction interval 1812 of the plurality of electromagnetic wires 180, which will be described later, can be suppressed.

[0202] As Figure 8 shown, the bent electromagnetic wires 180 (first type of electromagnetic wires 180a, second type of electromagnetic wires 180b) include: an axial interval 1811 arranged in the axial direction, a circumferential direction interval 1812 that bends from the axial interval 1811 toward the circumferential direction, and a connecting end portion 1813 that bends from the circumferential direction interval 1812 and is arranged in the axial direction.

[0203] Herein, the connecting end portion 1813 may include: a coated interval 18131 having a coating portion 182, and a peeled interval 18132 where the coating portion 182 is peeled off and the conductor 181 is exposed to the outside.

[0204] The circumferential direction interval 1812 includes, for example: a first circumferential direction interval 18121 arranged on one side (the upper side in the figure) of the axial interval 1811, and a second circumferential direction interval 18122 arranged on the other side (the lower side in the figure) of the axial interval 1811.

[0205] The connecting end portion 1813 is provided in the first circumferential direction interval 18121 and the second circumferential direction interval 18122, respectively.

[0206] Bending intervals 1814 are respectively formed at the boundaries between the axial interval 1811 and the circumferential direction interval 1812.

[0207] Bending intervals 1815 are respectively formed between the circumferential direction interval 1812 and the connecting end portion 1813.

[0208] Herein, the bending interval 1814 formed at the boundary between the axial interval 1811 and the circumferential direction interval 1812 may be referred to as an inner bending interval 1814, and the bending interval 1815 formed between the circumferential direction interval 1812 and the connecting end portion 1813 may be referred to as an outer bending interval 1815.

[0209] Figure 9 is Figure 1 a perspective view before the combination of the electromagnetic wire module, Figure 10 is Figure 9 a cross-sectional view after the electromagnetic wire module is inserted. AsFigure 9 and Figure 10 As shown in Figure 10 , the magnet wire module 170 includes: a plurality of magnet wires 180, each having a linear shape arranged axially; and a molding portion 190 that surrounds and fixes the plurality of magnet wires 180.

[0210] The molding portion 190 is formed of a synthetic resin material.

[0211] The molding portion 190 includes an outer body 191 disposed outside the groove 116.

[0212] The outer body 191 includes a stopper portion 1917 that axially contacts the edge of the groove 116.

[0213] The outer body 191 may be formed in a rectangular parallelepiped shape, for example.

[0214] The outer body 191 includes, for example: two side faces 1911, 1912, facing the circumferential direction of the stator core 110; and an inner face 1913 and an outer face 1914, facing the radial direction of the stator core 110.

[0215] Here, the two side faces 1911, 1912 include a first side face 1911 and a second side face 1912 that are arranged facing each other.

[0216] The outer body 191 includes a top face and a bottom face arranged axially.

[0217] The width of the outer body 191 is greater than the width of the groove 116.

[0218] Compared with the outer side face of the groove 116, the outer face 1914 of the outer body 191 is arranged radially outside.

[0219] In this embodiment, the bottom face of the outer body 191 contacts the edge of the groove 116, restricting the outer body 191 from moving toward the stator core 110 side. Therefore, the bottom face can be referred to as the "stopper portion 1917".

[0220] The molding portion 190 includes an inner body 195 disposed inside the groove 116.

[0221] Thereby, the plurality of magnet wires 180 and the groove 116 can be electrically insulated.

[0222] The inner body 195 may be formed in a rectangular parallelepiped shape, for example.

[0223] The inner main body 195 includes, for example, two side surfaces 1951 and 1952 in the circumferential direction of the stator core 110, and an inner side surface 1953 and an outer side surface 1954 in the radial direction of the stator core 110. Here, the two side surfaces 1951 and 1952 include a first side surface 1951 and a second side surface 1952 that are arranged facing each other.

[0224] The inner main body 195 is connected to the outer main body 191.

[0225] One side (the upper side in the figure) of the inner main body 195 is integrally connected (formed) to the bottom surface of the outer main body 191.

[0226] The other side (the lower side in the figure) of the inner main body 195 can be exposed to the lower side of the stator core 110 through the slot 116 of the stator core 110, for example.

[0227] Figure 11 is Figure 9 a perspective view of the molded part of Figure 12 is Figure 11 a top view of the molded part of Figure 13 is Figure 11 a bottom view of the molded part of Figure 14 is Figure 13 a magnified view of the main part of the molded part of. As Figures 11 to 14 shown, in this embodiment, the molded part 190 includes an outer main body 191 disposed outside the slot 116 of the stator core 110, and an inner main body 195 disposed inside the slot 116.

[0228] The outer main body 191 is formed in a substantially rectangular parallelepiped shape.

[0229] The outer main body 191 surrounds a plurality of the electromagnetic wires 180 (the first electromagnetic wire 1801 to the eighth electromagnetic wire 1808).

[0230] An electromagnetic wire accommodation part 1915 capable of respectively accommodating a plurality of the electromagnetic wires 180 (the first electromagnetic wire 1801 to the eighth electromagnetic wire 1808) is formed inside the outer main body 191.

[0231] The outer main body 191 has an axial length (height) corresponding to the boundaries of the axial interval 1811 and the circumferential interval 1812 of the plurality of the electromagnetic wires 180.

[0232] The inner main body 195 is integrally formed on one axial side (the lower side in the figure) of the outer main body 191.

[0233] The inner main body 195 is formed in a substantially rectangular parallelepiped shape.

[0234] As described above, the molding part 190 may be formed by inserting a plurality of electromagnetic wires 180 (first electromagnetic wire 1801 to eighth electromagnetic wire 1808) arranged radially along the stator core 110 into the interior of a mold and injecting molten synthetic resin into the interior of the mold.

[0235] The inner body 195 includes a protruding end portion that protrudes outward from the stator core 110 when the inner body 195 is combined with the stator core 110 (slot 116).

[0236] The protruding end portion of the inner body 195 may have an axial length (height) corresponding to the boundary between the axial section 1811 and the circumferential section 1812 of the plurality of electromagnetic wires 180.

[0237] Here, the width of the outer body 191 is greater than the width of the slot 116.

[0238] Accordingly, one side (the bottom in the figure) of the outer body 191 may be in contact with the outside of the slot 116 in the axial direction.

[0239] The width of the inner body 195 is less than the width of the slot 116.

[0240] Accordingly, the inner body 195 may be inserted and combined into the interior of the slot 116.

[0241] The inner body 195 includes a plurality of side faces (both side faces 1951, 1952, inner side face 1953, and outer side face 1954) facing the inner surface of the slot 116.

[0242] The inner body 195 may be press-fitted and combined into the interior of the slot 116.

[0243] On the outer surface of the inner body 195, protruding portions 1955 are provided in contact with the inner surface of the slot 116.

[0244] The protruding portions 1955 may be formed, for example, on both side faces 1951, 1952 arranged along the circumferential direction of the stator core 110 on both sides of the inner body 1`95.

[0245] The interval between both end portions of the protruding portions 1955 formed on both side faces 1951, 1952 of the inner body 195 may be greater than the width (circumferential width) of the slot 116.

[0246] This is to make the protruding length of the protrusions 1955 formed on both side faces 1951 and 1952 of the inner body 195 gradually decrease while inserting the inner body 195 into the inside of the groove 116, so that the inner body 195 can be closely attached to the inner surface of the groove 116 when inserted into the inside of the groove 116.

[0247] According to such a configuration, when the inner body 195 is inserted into the inside of the groove 116, no gap will be generated between the protrusion 1955 and the inner wall of the groove 116, thereby being able to suppress the generation of play of the inner body 195.

[0248] A plurality of protrusions 1955 may be provided on each of the two side faces 1951 and 1952 of the inner body 195.

[0249] The protrusion 1955 may be formed to extend in the axial direction.

[0250] In this embodiment, a case where two protrusions 1955 are respectively formed on both side faces 1951 and 1952 of the inner body 195 is illustrated, but this is only an example and is not limited thereto.

[0251] In addition, in this embodiment, a case where the protrusions 1955 of the inner body 195 are continuously formed in the axial direction and have a relatively long length is illustrated, but a plurality of the protrusions 1955 may also be formed at intervals in the axial direction.

[0252] Protrusions 1955 may be formed on the outer side face 1954 of the inner body 195.

[0253] In this embodiment, a case where one protrusion 1955 is formed on the outer side face 1954 of the inner body 195 is illustrated, but it is not limited thereto.

[0254] On the other hand, a bending interval support portion 1916 that contacts and supports the bending intervals 1814 (inner bending intervals) of the plurality of electromagnetic wires 180 is provided on the outer body 191.

[0255] The bending interval support portion 1916 supports, for example, the side faces (inner side face, bottom face) of the inner bending intervals 1814 of the plurality of electromagnetic wires 180 that are close to the stator core 110.

[0256] The bending interval support portion 1916 is formed by being recessed in the axial direction from the outer end portion (the upper end portion in the figure) of the outer body 191.

[0257] Thereby, it is possible to easily achieve the bending of the circumferential direction intervals 1812 for forming the plurality of electromagnetic wires 180.

[0258] The bending interval support portion 1916 includes, for example, a first bending interval support portion 19161 to an eighth bending interval support portion 19168 that respectively support the respective bending intervals 1804 of the first electromagnetic wire 1801 to the eighth electromagnetic wire 1808.

[0259] The first bending interval support portion 19161 to the eighth bending interval support portion 19168 are alternately formed on both side faces 1911 and 1912 of the outer main body 191.

[0260] Specifically, when the first electromagnetic wire 1801 disposed at the innermost side inside the slot 116 bends in a first direction in the circumferential direction of the stator core 110, the first bending interval support portion 19161 is formed on the first side face 1911 of the outer main body 191.

[0261] The second electromagnetic wire 1802 bends in a second direction different from that of the first electromagnetic wire 1801, and the second bending interval support portion 1916 is formed on the second side face 1912 of the outer main body 191.

[0262] In this embodiment, the first electromagnetic wire 1801, the third electromagnetic wire 1803, the fifth electromagnetic wire 1805, and the seventh electromagnetic wire 1807 may bend in the first direction on one axial side (the upper side in the figure) of the stator core 110, respectively.

[0263] The second electromagnetic wire 1802, the fourth electromagnetic wire 1804, the sixth electromagnetic wire 1806, and the eighth electromagnetic wire 1808 may bend in the second direction on one axial side (the upper side in the figure) of the stator core 110, respectively.

[0264] On the first side face 1911 of the outer main body 191, a first bending interval support portion 19161, a third bending interval support portion 1916, a fifth bending interval support portion 1916, and a seventh bending interval support portion 1916 are respectively formed.

[0265] The first bending interval support portion 19161, the third bending interval support portion 1916, the fifth bending interval support portion 1916, and the seventh bending interval support portion 1916 may be formed to be separated by a preset distance in the radial direction of the stator core 110.

[0266] On the second side face 1912 of the outer main body 191, a second bending interval support portion 1916, a fourth bending interval support portion 1916, a sixth bending interval support portion 1916, and an eighth bending interval support portion 19168 are respectively formed.

[0267] Second bending interval support portions 1916, fourth bending interval support portions 1916, sixth bending interval support portions 1916, and eighth bending interval support portions 19168 formed on a second side surface portion 1912 of the outer main body 191 are arranged at a preset distance apart in the radial direction of the stator core 110.

[0268] A bending interval support portion 1956 that supports a plurality of the electromagnetic wires 180 in a bending interval 1814 (inner bending interval) is provided on the inner main body 195.

[0269] In this embodiment, bending intervals 1814 formed between an axial interval 1811 and a first circumferential direction interval 18121 among the plurality of electromagnetic wires 180 and bending intervals 1814 formed between the axial interval 1811 and a second circumferential direction interval 18122 are formed in different directions in the circumferential direction of the stator core 110.

[0270] Specifically, when bending in the first circumferential direction interval 18121 is formed to extend from the axial interval 1811 toward the first direction, the second circumferential direction interval 18122 may be bent to extend from the axial interval 1811 toward a second direction opposite to the first direction.

[0271] In this embodiment, a bending interval 1814 formed between an axial interval 1811 and a first circumferential direction interval 18121 in the first electromagnetic wire 1801 is bent toward the first direction (counterclockwise direction), and a bending interval 1814 formed between the axial interval 1811 and a second circumferential direction interval 18122 in the first electromagnetic wire 1801 is bent toward the second direction (clockwise direction).

[0272] First bending interval support portions 19561 to eighth bending interval support portions 19568 that respectively support bending intervals 1814 of the first electromagnetic wire 1801 to the eighth electromagnetic wire 1808 are formed at protruding end portions of the inner main body 195.

[0273] The first bending interval support portions 19561 to eighth bending interval support portions 19568 are alternately formed on both side surface portions 1951, 1952 of the inner main body 195.

[0274] Accordingly, a second bending interval support portion 19562, a fourth bending interval support portion 19564, a sixth bending interval support portion 19564, and an eighth bending interval support portion 19568 are formed on a first side surface portion 1951 of the inner main body 195.

[0275] On the second side surface portion 1952 of the inner main body 195, the first bending section support portion 19561, the third bending section support portion 19563, the fifth bending section support portion 19565, and the seventh bending section support portion 19567 are formed.

[0276] With such a configuration, the first electromagnetic wire 1801 to the eighth electromagnetic wire 1808 are arranged in the radial direction of the stator core 110, and the first electromagnetic wire 1801 to the eighth electromagnetic wire 1808 are inserted into the interior of a mold (not shown) for forming the molding portion 1901.

[0277] By injecting a molten synthetic resin material into the interior of the mold, a plurality of electromagnetic wire modules 170 are respectively formed.

[0278] After forming a plurality of the electromagnetic wire modules 170, the electromagnetic wire modules 170 are respectively inserted and coupled axially into the interior of the slots 116 of the stator core 110.

[0279] At this time, the inner main body 195 can be press-fitted and coupled into the interior of the slot 116 while the plurality of protruding portions 1955 are deformed.

[0280] After the electromagnetic wire modules 170 are respectively coupled to the slots 116 of the stator core 110, the plurality of electromagnetic wires 180 of the plurality of electromagnetic wire modules 170 are respectively bent in the circumferential direction of the stator core 110 toward the first direction or the second direction.

[0281] At this time, the plurality of electromagnetic wires 180 are supported by the bending section support portions 1916 of the outer main body 191 of the molding portion 190 and the bending section support portions 1956 of the inner main body 195, so that the bending operation of the plurality of electromagnetic wires 180 can be easily performed.

[0282] Here, the connection end portions 1813 can be respectively formed by bending the end portions of the circumferential direction sections 1812 of the plurality of electromagnetic wires 180 in the axial direction.

[0283] Among the plurality of electromagnetic wires 180 inserted into the interior of the slot 116, the circumferential direction length of the electromagnetic wire 180 arranged in the radial direction of the stator core 110 on the inner side (the side closer to the center) of the slot 116 is relatively short, so the connection end portion 1813 can protrude further in the axial direction.

[0284] The lengths of the connection end portions 1813 of the plurality of electromagnetic wires 180 can be adjusted (cut) to the first length L1 or the second length L2 so that the end portions of the plurality of electromagnetic wires 180 are arranged in the axial direction at the same length (height) from the stator core 110.

[0285] After the ends of a plurality of the electromagnetic wires 180 are cut to have constant lengths L1 and L2 along the axial direction from the stator core 110, the connecting ends 1813 of two electromagnetic wires 180 (first - type electromagnetic wires 180a) to be connected to each other are electrically connected by welding.

[0286] Specifically, among the plurality of the electromagnetic wires 180, the connecting ends 1813 in the first circumferential direction section 18121 can be electrically connected to each other by welding, and the connecting ends 1813 in the second circumferential direction section 18122 can be electrically connected to each other by welding.

[0287] If the welding of both ends of the plurality of the electromagnetic wires 180 along the axial direction is completed, the connecting ends 1813a of the plurality of electromagnetic wires 180 (second - type electromagnetic wires 180b) formed with the extension parts can be combined with the connecting ring 220.

[0288] When the ends of the plurality of electromagnetic wires 180 formed with the extension parts are combined with the connecting ring 220, the connecting ends 1813a connected to each other protrude axially from the connecting ring 220 respectively.

[0289] The connecting ends 1813a protruding from the connecting ring 220 are electrically connected by welding.

[0290] Thus, a plurality of the phase coils 155 can be wired (Y - wiring).

[0291] Figure 15 It is a cross - sectional view of the stator of a rotating electric machine according to another embodiment of the present invention. Figure 16 is Figure 15 a perspective view before the electromagnetic wire module is combined. Figure 17 is Figure 15 a main - part enlarged view of the electromagnetic wire module. As Figures 15 to 17 shown, the stator 100a of the rotating electric machine of this embodiment includes a stator core 110 and a stator coil 150a.

[0292] The stator core 110 is formed in a cylindrical shape, for example.

[0293] The stator core 110 can be formed by insulating and stacking a plurality of electrical steel sheets 112.

[0294] The stator core 110 includes a plurality of slots 116 and a plurality of teeth 118 that are alternately arranged in the circumferential direction.

[0295] The stator coil 150a includes a plurality of electromagnetic wire modules 170a.

[0296] The plurality of the electromagnetic wire modules 170a includes, for example: a plurality of electromagnetic wires 180 having a linear shape arranged axially, and a molding part 190a that surrounds and fixes the plurality of the electromagnetic wires 180.

[0297] The molding part 190a includes, for example: an outer body 191 disposed outside the groove 116, and an inner body 195a disposed inside the groove 116.

[0298] The outer body 191 is formed in a substantially rectangular parallelepiped shape.

[0299] The width of the outer body 191 is greater than the width of the groove 116.

[0300] The outer body 191 includes a stopper portion 1917 that contacts the edge of the groove 116 axially.

[0301] The stopper portion 1917 can be formed to contact both side edges of the groove 116 in the circumferential direction of the stator core 110, and contact the outer edge of the groove 116 in the radial direction of the stator core 110.

[0302] The inner body 195a is formed axially on one side (the lower side in the figure) of the outer body 191.

[0303] The inner body 195a is formed in a substantially rectangular parallelepiped shape.

[0304] The width of the inner body 195a is smaller than the width of the groove 116 so as to be able to be inserted into the inside of the groove 116.

[0305] On the outer surface of the inner body 195a, protruding portions 1955 that can contact the inner surface of the groove 116 are provided.

[0306] The inner body 195a can be pressed into the inside of the groove 116.

[0307] The protruding portions 1955 can be formed on both side surfaces of the inner body 195a in the circumferential direction of the stator core 110.

[0308] A plurality of protruding portions 1955 can be respectively formed on both side faces 1951, 1952 of the inner body 195a.

[0309] The distance between the ends of the protruding portions 1955 formed on both side faces 1951, 1952 of the inner body 195a can be slightly greater than the width of the groove 116.

[0310] Thus, when the inner body 195a is inserted, the protruding length of the protruding portion 1955 decreases while being inserted into the inside of the groove 116, so that it can be tightly bonded to the inner surface of the groove 116.

[0311] Two protruding portions 1955 can be respectively formed on both side surfaces 1951 and 1952 of the inner body 195a.

[0312] The protruding portion 1955 can be formed on the outer side surface 1954 of the inner body 195a along the radial direction of the stator core 110.

[0313] For example, one protruding portion 1955 can be formed on the outer side surface 1954 of the inner body 195a.

[0314] The protruding portion 1955 of the inner body 195a can be formed to extend along the axial direction.

[0315] The length of the protruding portion 1955 can correspond to the length of the inner body 195a.

[0316] On the other hand, a plurality of the electromagnetic wires 180 include an insertion section 1801a inserted into the inside of the groove 116 of the stator core 110.

[0317] The length of the inner body 195a is less than the length of the insertion section 1801a.

[0318] For example, the length of the inner body 195a can be formed to be less than half of the length of the insertion section 1801a.

[0319] In this embodiment, for example, the length of the inner body 195a can be formed to be 20-40% of the length of the insertion section 1801a.

[0320] The insertion section 1801a includes, for example: a first section 1801a1 insulated by the inner body 195a, and a second section 1801a2 insulated by an insulating material.

[0321] The insulating material is constituted by, for example, insulating paper 197.

[0322] The insulating paper 197 can be formed into a rectangular shape, for example.

[0323] Specifically, the insulating paper 197 can be formed into a rectangular shape having a width and a length capable of surrounding the periphery of the second section 1801a2 of a plurality of electromagnetic wires 180 (the first electromagnetic wire 1801 to the eighth electromagnetic wire 1808), for example.

[0324] The second interval 1801a2 can be surrounded by the insulating paper 197, for example, before a plurality of the electromagnetic wires 180 are inserted into the inside of a plurality of the slots 116.

[0325] Thereby, the size of the inner main body 195a can be reduced, and thus the molding portion 190a can be easily manufactured.

[0326] With such a configuration, a plurality of the electromagnetic wires 180 (the first electromagnetic wire 1801 to the eighth electromagnetic wire 1808) can be arranged radially with respect to the stator core 110 inside a mold (not shown), and a molten synthetic resin material can be injected into the inside of the mold to form the molding portion 190a.

[0327] Insulation is implemented by wrapping the insulating paper 197 around the second interval 1801a2 of a plurality of the electromagnetic wire modules 170a.

[0328] A plurality of the electromagnetic wire modules 170a are respectively inserted and joined into the inside of a plurality of the slots 116 of the stator core 110.

[0329] A plurality of the electromagnetic wires 180 of a plurality of the electromagnetic wire modules 170a are respectively bent in a first direction or a second direction along the circumferential direction of the stator core 110.

[0330] The end portions of a plurality of the electromagnetic wires 180 are cut so that the end portions of a plurality of the electromagnetic wires 180 have a constant distance from the stator core 110 in the axial direction.

[0331] Two connection end portions 1813 that need to be connected to each other among a plurality of the electromagnetic wires 180 are connected in an energizable manner by welding.

[0332] Next, the connection ring 220 is joined to the connection end portion 1813a of a plurality of the electromagnetic wires 180 (the second type of electromagnetic wire 180b) in which extension portions are formed among a plurality of the electromagnetic wires 180.

[0333] A plurality of phase coils 155 are formed by welding the connection end portions 1813a that respectively protrude axially from the connection ring 220.

[0334] Figure 18 It is a cross-sectional view of a stator of a rotating electric machine according to another embodiment of the present invention. Figure 19 is Figure 18 a perspective view before the electromagnetic wire module is joined. Figure 20 is Figure 18 a main part enlarged view of the electromagnetic wire module. As Figures 18 to 20 shown, the stator 100b of the rotating electric machine of the present embodiment includes a stator core 110 and a stator coil 150b.

[0335] The stator core 110 has a cylindrical shape.

[0336] The stator core 110 may be formed by insulating and stacking a plurality of electrical steel sheets 112.

[0337] The stator core 110 includes a plurality of slots 116 and a plurality of teeth 118.

[0338] The stator coil 150b includes a plurality of electromagnetic wire modules 170b.

[0339] The plurality of electromagnetic wire modules 170b include: a plurality of electromagnetic wires 180 each having a linear shape arranged axially, and a molding part 190b that surrounds and fixes the plurality of electromagnetic wires 180.

[0340] The molding part 190b includes, for example: an outer body 191 disposed outside the slot 116, and an inner body 195b disposed inside the slot 116.

[0341] The outer body 191 is formed in a substantially rectangular parallelepiped shape.

[0342] The width of the outer body 191 is greater than the width of the slot 116.

[0343] The outer body 191 includes a stopper part 1917 that contacts the edge of the slot 116 axially.

[0344] The stopper part 1917 may be formed to contact both side edges of the slot 116 in the circumferential direction of the stator core 110 and contact the outer edge of the slot 116 in the radial direction of the stator core 110.

[0345] The inner body 195b is formed axially on one side (the lower side in the figure) of the outer body 191.

[0346] The inner body 195b is formed in a substantially rectangular parallelepiped shape.

[0347] The width of the inner body 195b is less than the width of the slot 116 so as to be inserted into the inside of the slot 116.

[0348] A plurality of protruding parts 1955 that contact the inner surface of the slot 116 are provided on the outer surface of the inner body 195b.

[0349] In this embodiment, the plurality of protruding parts 1955 may be formed on both side surfaces of the inner body 195b in the circumferential direction of the stator core 110 and on the outer side surface of the inner body in the radial direction of the stator core.

[0350] The inner body 195b is press-fitted and joined to the inside of the slot 116.

[0351] The protruding portion 1955 of the inner body 195b can be deformed to closely adhere to the inner surface of the groove 116 when inserted and engaged inside the groove 116.

[0352] The plurality of electromagnetic wires 180 include an insertion section 1801a inserted (disposed) inside the groove 116.

[0353] The length of the inner body 195b is, for example, less than the length of the insertion section 1801a.

[0354] The length of the inner body 195b can be formed to be, for example, less than half of the length of the insertion section 1801a.

[0355] In this embodiment, the length of the inner body 195b can be formed to be 20 - 40% of the insertion section 1801a.

[0356] The insertion section 1801a of the plurality of electromagnetic wires 180 includes, for example: a first section 1801a1 insulated by the inner body 195b, and a second section 1801a2 insulated by an insulating material.

[0357] In this embodiment, the insulating material surrounding and insulating the second section 1801a2 includes, for example: a liquid foaming material 199 and an insulating sheet 198. The liquid foaming material 199 is coated on the plurality of electromagnetic wires 180 before the plurality of electromagnetic wires 180 are inserted into the inside of the groove 116, and the insulating sheet 198 surrounds the liquid foaming material 199.

[0358] The liquid foaming material 199 can be composed of, for example, liquid epoxy resin.

[0359] The liquid foaming material 199 can be foamed and cured when heated to a preset temperature, for example, after the plurality of electromagnetic wires 180 are inserted and engaged inside the groove 116.

[0360] With such a configuration, the plurality of electromagnetic wires 180 (the first electromagnetic wire 1801 to the eighth electromagnetic wire 1808) can be radially arranged inside the mold along the stator core 110, and a molten synthetic resin member can be injected into the inside of the mold to form the molded portion 190b.

[0361] Then, after forming the molded portion 190b, the liquid foaming material 199 is coated on the second section 1801a2 of the plurality of electromagnetic wire modules 170, and the insulating sheet 198 is used to surround the liquid foaming material 199 to prevent the liquid foaming material 199 from leaking.

[0362] Here, after using the insulating sheet 198 to surround the periphery of the second section 1801a2, the liquid foaming material 199 can be injected into the interior of the insulating sheet 198.

[0363] Insert a plurality of the electromagnetic wire modules 170 into the interiors of a plurality of slots 116 of the stator core 110 respectively and bond them.

[0364] After inserting a plurality of the electromagnetic wire modules 170 into the interiors of a plurality of the slots 116, heat the plurality of the electromagnetic wire modules 170b so that the plurality of the electromagnetic wire modules 170b can rise to a preset temperature.

[0365] Thereby, the liquid foaming material 199 can foam and fill the interior of the slot 116.

[0366] After the foaming material solidifies over time, a plurality of the electromagnetic wires 180 of the plurality of the electromagnetic wire modules 170 can be bent in the circumferential direction of the stator core 110 towards the first direction or the second direction respectively.

[0367] Cut the end portions of a plurality of the electromagnetic wires 180 respectively so that the end portions of the plurality of the electromagnetic wires 180 have a constant distance from the stator core 110 in the axial direction.

[0368] Electrically connect two connecting end portions 1813 that need to be connected to each other among a plurality of the electromagnetic wires 180 by welding.

[0369] Next, couple the connection ring 220 to the connection end portions 1813a of a plurality of the electromagnetic wires 180 (second - type electromagnetic wires 180b) having extensions among a plurality of the electromagnetic wires 180.

[0370] Form a plurality of phase coils 155 by welding the connection end portions 1813a that protrude axially from the connection ring 220 respectively.

[0371] Above, specific embodiments of the present invention have been illustrated and described. However, the present invention can be implemented in various forms without departing from its idea or essential features. Therefore, the embodiments described above should not be limited by the specific content of implementing the invention.

[0372] In addition, even for embodiments not specifically listed one by one in the above - described detailed description, the embodiments should be broadly interpreted within the scope of the technical idea defined in the appended claims. And all changes and modifications within the technical scope of the above - mentioned claims and equivalent thereto should be included in the appended claims.

Claims

1. A stator of a rotating electric machine, wherein, comprising: a stator core having a plurality of slots spaced apart in the circumferential direction; and a stator coil wound around the stator core; the stator coil comprising: a plurality of electromagnetic wire modules having: a plurality of electromagnetic wires, each electromagnetic wire having a straight shape arranged axially; and a molding part surrounding and fixing the plurality of electromagnetic wires; the plurality of electromagnetic wire modules are respectively inserted into the plurality of slots; the plurality of electromagnetic wires are electrically connected after being bent in the circumferential direction of the stator core so as to be in contact with each other.

2. The stator of the rotating electric machine according to claim 1, wherein, the molding part includes an outer main body (191) arranged outside the plurality of slots.

3. The stator of the rotating electric machine according to claim 2, wherein, the outer main body (191) includes a stopper portion in contact with the edge of the slot in the axial direction.

4. The stator of the rotating electric machine according to claim 2, wherein, each of the plurality of electromagnetic wires has a bent section bent in the circumferential direction of the stator core; a bent-section support portion in contact with and supporting the bent section is provided on the outer main body (191).

5. The stator of the rotating electric machine according to claim 1, wherein, the molding part includes an inner main body arranged inside the slot.

6. The stator of the rotating electric machine according to claim 5, wherein, the inner main body has an outer surface spaced apart from the inner surface of the slot; a protruding portion is provided on the outer surface of the inner main body, and the protruding portion is in contact with the inner surface of the slot.

7. The stator of the rotating electric machine according to claim 6, wherein, the inner main body includes: two side surfaces arranged on both sides of the inner main body in the circumferential direction of the stator core; and an inner side surface and an outer side surface arranged on both sides of the inner main body in the radial direction of the stator core; the protruding portions are provided on both the two side surfaces and the outer side surface.

8. The stator of the rotating electric machine according to claim 6, wherein, the protruding portion is formed to extend axially.

9. The stator of the rotating electric machine according to claim 5, wherein, the inner main body includes a protruding end portion protruding outward from the slot in the axial direction of the stator core; the plurality of electromagnetic wires have a bent section bent in the circumferential direction of the stator core; a bent-section support portion in contact with and supporting the bent section of the plurality of electromagnetic wires is provided on the protruding end portion.

10. The stator of the rotating electric machine according to claim 9, wherein, the plurality of electromagnetic wires arranged in the radial direction of the stator core are bent alternately toward one side and the other side in the circumferential direction of the stator core; the bent-section support portions of the inner main body are alternately formed on both side surfaces of the inner main body in the circumferential direction of the stator core.

11. The stator of the rotating electric machine according to claim 5, wherein, the plurality of electromagnetic wires have an insertion section arranged inside the slot in the axial direction of the stator core; the inner main body has a length shorter than the length of the slot in the axial direction of the stator core; the insertion sections of the plurality of electromagnetic wires include: a first section insulated by the inner main body; and A second section, insulated by an insulating material.

12. The stator of a rotating electrical machine according to claim 11, wherein before a plurality of the electromagnetic wires are inserted into the plurality of slots, the second section is surrounded by a plate-shaped insulating sheet.

13. The stator of a rotating electrical machine according to claim 11, wherein the insulating material of the second section includes a liquid foaming material coated on the plurality of electromagnetic wires before the plurality of electromagnetic wires are inserted into the plurality of slots and insulating paper surrounding the liquid foaming material.

14. The stator of a rotating electrical machine according to claim 13, wherein the liquid foaming material is heated and foamed after the plurality of electromagnetic wires are inserted into the plurality of slots.

15. The stator of a rotating electrical machine according to claim 1, wherein the molding part includes: an outer body (191) disposed outside the slots of the stator core; and an inner body connected to the outer body (191) and disposed inside the slots.

16. The stator of a rotating electrical machine according to claim 15, wherein a stopper portion that axially contacts the edge of the slot is provided on the outer body (191).

17. The stator of a rotating electrical machine according to any one of claims 1 to 16, wherein each of the plurality of electromagnetic wires includes: an axial section configured along the axial direction; and a circumferential section extending in the circumferential direction from the axial section; the axial section passes through the inside of the slot; the circumferential section is disposed outside the slot; the circumferential sections of the plurality of electromagnetic wires that are different from each other are electrically connectable to each other.

18. A method for manufacturing a stator of a rotating electrical machine, wherein the stator includes: a stator core provided with a plurality of slots in the circumferential direction; and a stator coil including a plurality of electromagnetic wires, each of the electromagnetic wires having a straight shape configured along the axial direction and capable of being inserted into the slots of the stator core; the method for manufacturing the stator includes: a step of arranging a plurality of the electromagnetic wires at intervals in the radial direction of the stator core and forming a molding part that surrounds and fixes the peripheries of the plurality of electromagnetic wires to form a plurality of electromagnetic wire modules; a step of inserting the plurality of electromagnetic wire modules into the plurality of slots respectively; a step of bending the plurality of electromagnetic wires in contact with each other in the circumferential direction of the stator core toward one side or the other side; and a step of electrically connecting the plurality of electromagnetic wires to form the stator coil.

19. The method for manufacturing a stator of a rotating electrical machine according to claim 18, wherein before the step of forming the stator coil, the method further includes a step of cutting the ends of the plurality of electromagnetic wires so that the ends of the plurality of electromagnetic wires have the same length along the axial direction from the stator core.

20. The method for manufacturing a stator of a rotating electrical machine according to claim 18 or 19, wherein the plurality of electromagnetic wires have an insertion section disposed inside the slot; the molding part has an inner body that surrounds a part of the insertion section; The method for manufacturing the stator further includes a step of insulating the remaining part of the insertion section before the step of inserting a plurality of the electromagnetic wires into the plurality of the slots.

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