Stator

Abstract

In the stator of the present invention, on one end side of a stator core, the front end parts of two leg parts protruding from one 2 * i layer and the other 2 * i-1 layer on one side in the circumferential direction of a first slot and a second slot separated by six slots are joined to each other. The front end parts of two leg parts protruding from one 2 * i layer and the other 2 * i + 1 layer in the circumferential direction of a first slot and a second slot which are separated by six slots are jointed with each other, so that the winding end part of the 2 * i layer is connected with the winding start part of the 2 * i + 1 layer.

Description

Technical Field

[0001] The present invention relates to a stator comprising a stator core having a plurality of slots and a plurality of stator coils wound around the stator core. Background Technology

[0002] Conventionally, a stator is known that includes a stator core having multiple slots arranged circumferentially and three-phase (U-phase, V-phase, W-phase) stator coils wound around the stator core (for example, see Japanese Patent No. 5896250). In this stator, each of the three-phase stator coils includes a multiple of four parallel windings (parallel coils) connected in parallel and connected by a Y-connection. Each parallel winding is formed by the following steps: First, a pair of straight portions (legs) of multiple U-shaped conductor segments (segmented coils) are inserted into the corresponding slots. At this time, the conductor segments are inserted such that one end (twist side) protrudes from the axial direction of the stator core. Furthermore, each straight portion is twisted circumferentially to join the front ends of the corresponding two straight portions together. That is, the multiple conductor segments include a first conductor segment, a second conductor segment, and a third conductor segment. In the first conductor segment, a pair of straight portions are inserted into two first slots spaced five slots apart. In the second conductor segment, a pair of straight portions are inserted into two second slots spaced seven slots apart on either side of the first slot. In the third conductor segment, a pair of straight portions are inserted into a defined first slot and a second slot spaced six slots apart. The pair of straight portions of the first conductor segment are inserted into one 2.i-1 layer (where i=3,2,1 in the example of Japanese Patent No. 5896250) and another 2.i layer on one side (the winding start side) of the two first slots in the circumferential direction. Furthermore, the pair of straight portions of the second conductor segment are inserted across the corresponding first conductor segment, relative to one 2.i-1 layer and the other 2.i layer on one side of the two second slots in the circumferential direction. Moreover, the pair of legs of the third conductor segment are inserted into the following positions. The position refers to one 2.i layer and the other 2.i+1 layer on one side of the circumferential direction of the first and second slots, which are separated by 6 slots. A pair of legs of the three conductor segments form a jumper (57) across the 2.i layer and the 2.i+1 layer on the other end side of the stator core (opposite to the torsion side). Furthermore, on one end side of the stator core, two legs protruding from one 2.i layer and the other 2.i-1 layer on one side of the circumferential direction of the two slots, which are separated by 6 slots, are twisted and their front ends are joined together. Thus, in each parallel winding, the straight portions of the conductor segments are evenly arranged on both sides of the circumferentially adjacent first and second slots. As a result, the deviation in the timing of the induced voltage generated on each magnetic pole of the parallel winding according to the passage of the rotor magnet can be eliminated, thereby preventing the generation of circulating current in each parallel winding.

[0003] Furthermore, conventionally, there are known annular arrangement devices for segmented coils having a first end and a second end (leg) connected to each other via a bend or a curve, arranged in a circular pattern (for example, see Japanese Patent No. 3975891). This annular arrangement device includes an arrangement annular section, a segmented coil insertion section, and a coil guide section. The arrangement annular section includes receiving slots that open along the outer periphery of a cylindrical shape in one direction along the cylindrical axis and are arranged at predetermined intervals, and rotatably support the segmented coils about the first end as a rotation axis, and performs annular rotation about the cylindrical axis. The segmented coil insertion section, in accordance with the annular rotation of the arrangement annular section, inserts the first end of the segmented coil into at least one receiving slot after the last receiving slot into which the first end is inserted. The coil guide section, in accordance with the annular rotation of the arrangement annular section, guides the second end of the segmented coil into a receiving slot different from the receiving slot into which the first end of the segmented coil is inserted. In this annular arrangement device, the first end of the segmented coil is inserted into the receiving slot and the second end of the segmented coil is guided into the receiving slot simultaneously and in parallel according to the annular rotation of the arrangement ring. As a result, the operation time can be shortened and the bending or flexed portions of the multiple segmented coils can be aligned with the radial inclination direction of the stator core so that the multiple segmented coils are arranged in an annular shape. Summary of the Invention

[0004] In electric motors including the stator described in Japanese Patent No. 5896250, the output characteristics are altered based on the number of turns (hereinafter referred to as "effective turns") obtained by dividing the number of straight sections (number of layers) in one slot by the number of parallel windings (number of parallel windings). Sometimes, a stator with a non-integer (e.g., 1.5 or 2.5) number of turns is required from the motor mounting side. Furthermore, according to the stator described in Japanese Patent No. 5896250, even if the effective turns are non-integer, circulating current can be prevented from being generated between multiple parallel windings. In the stator described in Japanese Patent No. 5896250, the portion connecting the pair of legs of the third conductor segment (the portion forming the jumper wire) is inclined in the opposite direction to the radial direction of the stator core to the first and second conductor segments. Therefore, it is impossible to arrange the first to third conductor segments into a ring shape using the ring arrangement device described in Japanese Patent No. 3975891. Therefore, multi-axis robots or similar devices are needed to assemble the third conductor into segments on the stator, which leads to a decrease in stator productivity or an increase in manufacturing costs.

[0005] Therefore, the main objective of this invention is to provide a stator that can suppress the generation of circulating current even when the effective number of turns is not an integer, and can improve productivity while reducing manufacturing costs.

[0006] The stator of the present invention comprises: a stator core including a plurality of slots spaced apart circumferentially in a radially extending manner; and a plurality of segmented coils having a pair of legs inserted into different slots and electrically joined to each other by the front ends of the corresponding legs to form a plurality of stator coils. The stator is characterized in that, when the number of poles is set to "p" and the number of slots is set to "n", n = 6·p, and the plurality of stator coils include 4·m parallel coils connected in parallel, where "m" is 1 to... In one of the slots, an even number of the legs are inserted radially, and the plurality of segmented coils include: a first segmented coil, wherein a pair of legs are inserted into one 2.i-1 layer and another 2.i layer on one side of the circumferential direction of two first slots spaced 5 slots apart, with "i" being an integer greater than or equal to 1, i = 1, ..., imax; a second segmented coil, wherein a pair of legs are inserted into the first slot in a manner that protrudes from one end of the stator core. Two second slots, spaced seven slots apart, are arranged on one side of a 2.i-1 layer and another 2.i layer in the circumferential direction, spanning the corresponding first segment coil and third segment coil. A pair of legs are inserted into one 2.i-1 layer and another 2.i layer on one side of a predetermined first and second slots, spaced six slots apart, protruding from one end of the stator core, forming a winding end in the 2.i layer or a winding start in the 2.i+1 layer. On one end, two legs protruding from one 2.i layer and another 2.i-1 layer on one side of the circumferential direction of the first and second slots, which are spaced six slots apart, are twisted together and their front ends are joined together, and two legs protruding from one 2.i layer and another 2.i+1 layer on one side of the circumferential direction of the first and second slots, which are spaced six slots apart, are twisted together and their front ends are joined together, so that the winding end of the 2.i layer is connected to the winding start of the 2.i+1 layer.

[0007] The stator of this invention includes a first segmented coil, a second segmented coil, and a third segmented coil. The first segmented coil inserts a pair of legs into two first slots spaced five slots apart. The second segmented coil inserts a pair of legs into two second slots spaced seven slots apart on either side of the first slots. The third segmented coil inserts a pair of legs into designated first and second slots spaced six slots apart. The pair of legs of the first segmented coil is inserted into one 2.i-1 layer and the other 2.i layer on one side of the circumferential direction of the two first slots, protruding from one end of the stator core. The pair of legs of the second segmented coil is inserted into one 2.i-1 layer and the other 2.i layer on one side of the circumferential direction of the two second slots. At this time, the pair of legs of the second segmented coil is inserted in a manner protruding from one end of the stator core. This second segmented coil spans the corresponding first segmented coil. A pair of legs of the third segment coil are inserted into one 2.i-1 layer and the other 2.i layer on one side of the circumferential direction of the first and second slots, respectively. At this time, the pair of legs of the third segment coil are inserted in such a way that they protrude from one end of the stator core. The pair of legs of the third segment coil form the winding end portion in the 2.i layer or the winding start portion in the 2.i+1 layer. Furthermore, on one end side of the stator core, two legs protruding from one 2.i layer and the other 2.i-1 layer on one side of the circumferential direction of the first and second slots, which are six slots apart, are joined. The two legs are twisted so that their front ends join together. Moreover, on one end side of the stator core, the winding end portion in the 2.i layer is connected to the winding start portion in the 2.i+1 layer. Specifically, two legs protruding from one 2.i layer and the other 2.i+1 layer on one side of the circumferential direction of the first and second slots, which are six slots apart, are joined. The two feet are twisted and their front ends join together.

[0008] That is, each parallel coil is inserted into two second slots spaced seven slots apart, with the second segment coil inserted across the first segment coil inserted into the two first slots spaced five slots apart. Furthermore, at one end of the stator core, corresponding legs are joined together at a six-slot spacing. Thus, even if the effective number of turns is not an integer, circulating currents caused by the timing deviation of the induced voltage generated by the rotor magnet through the corresponding parallel coil's magnetic poles are canceled in each parallel winding. As a result, circulating currents flowing in the stator coils can be suppressed. Moreover, in the stator of the present invention, the portion where a pair of legs of the third segment coil connects to each other (the bridging portion) has the same radial inclination direction relative to the stator core as the first and second segment coils. Therefore, the first to third segment coils wound on layers 2.i-1 and 2.i can be arranged into a ring shape and assembled onto the stator core using a known ring-arranging device. Therefore, costs can be reduced by shortening cycle time or eliminating the use of multi-axis robots. As a result, in the stator of the present invention, even if the effective number of turns is not an integer, the generation of circulating current can be suppressed, and productivity can be improved while manufacturing costs are reduced. Attached Figure Description

[0009] Hereinafter, with reference to the accompanying drawings, the features, advantages, and technical and industrial significance of exemplary embodiments of the present invention will be described, in which the same reference numerals denote the same elements, and wherein:

[0010] Figure 1 This is a perspective view of the stator of the present invention.

[0011] Figure 2 This is a schematic diagram illustrating an example of the stator coil of the stator of the present invention.

[0012] Figure 3 This is a schematic structural diagram showing the segmented coils of the stator coil that form the stator of the present invention.

[0013] Figure 4 This is an explanatory diagram illustrating the assembly method of the segmented coils of the stator relative to the stator core according to the present invention.

[0014] Figure 5 This is an explanatory diagram illustrating the assembly method of the segmented coils of the stator relative to the stator core according to the present invention.

[0015] Figure 6 This is an explanatory diagram illustrating the assembly method of the segmented coils of the stator relative to the stator core according to the present invention.

[0016] Figure 7 It is a three-dimensional diagram showing the assembly of segmented coils.

[0017] Figure 8It is a three-dimensional diagram showing the assembly sequence of the segmented coil assembly relative to the stator core.

[0018] Figure 9 This is an enlarged perspective view showing the main part of the stator of the present invention.

[0019] Figure 10 This is a schematic diagram showing other stator coils that can be applied to the stator of the present invention. Detailed Implementation

[0020] Next, with reference to the accompanying drawings, the method for carrying out the invention will be described.

[0021] Figure 1 This is a perspective view of the stator 1 of the present invention. Figure 1 The stator 1 shown, together with the rotor (not shown), constitutes a three-phase AC motor (rotating motor). Rotating motors are used, for example, as a driving source or generator for battery electric vehicles or hybrid electric vehicles. In this embodiment, the stator 1 includes an annular stator core 2, stator coils 3u (U-phase coils), stator coils 3v (V-phase coils), and stator coils 3w (W-phase coils).

[0022] The stator core 2 of the stator 1 is formed, for example, by stacking multiple electromagnetic steel plates that have been formed into a generally circular ring shape by stamping and connecting them in the stacking direction, or by forming a ring shape by pressing and sintering a strongly magnetic powder body. Figure 1 As shown, the stator core 2 includes a central hole 2o with a rotor, a plurality of teeth 2t, and a plurality of slots 20 (in this embodiment, for example, 48). The plurality of teeth 2t extend radially from the annular outer periphery (yoke) toward the axis and are adjacent to each other at constant circumferential intervals. The plurality of slots 20 are formed between adjacent teeth 2t. The plurality of slots 20 extend radially along the stator core 2 and are arranged at constant circumferential intervals, opening into the central hole 2o. Furthermore, an insulator (insulating paper, not shown) is disposed within each slot 20. Moreover, the stator 1 has the same number of magnetic poles as the rotor (eight in this embodiment), and when the number of magnetic poles (pole number) of the stator 1 is set to "p" and the number of slots 20 is set to "n", the relationship n = 6·p holds.

[0023] The stator coils 3u, 3v, and 3w are formed by electrically connecting multiple segmented coils (coil wires) 4. For example... Figure 2As shown, stator coil 3u includes four parallel coils U1, U2, U3, and U4 connected in parallel. Stator coil 3v includes four parallel coils V1, V2, V3, and V4 connected in parallel, and stator coil 3w includes four parallel coils W1, W2, W3, and W4 connected in parallel. Furthermore, as... Figure 2 As shown, stator coils 3u, 3v, and 3w are connected to each other via a star connection (Y connection). That is, parallel coils U1-U4, V1-V4, and W1-W4 are connected to each other via a so-called 4Y connection.

[0024] The segmented coil 4 is, for example, a conductor formed by bending a flat wire with an insulating film made of varnish resin on its surface in both the planar width and side width directions. In this embodiment, as... Figure 3 As shown, the segmented coil 4 includes a first segmented coil 4a, a second segmented coil 4b, and a third segmented coil 4c. The first to third segmented coils 4a, 4b, and 4c are formed in a generally U-shape, each having a pair (two) legs 40 and a bridging portion 41 connecting the pair of legs 40 to each other. Furthermore, in the bridging portion 41 of the first to third segmented coils 4a, 4b, and 4c, a folded-back portion 42 is formed, extending obliquely between two flat, wide bends. The two legs 40 of the first to third segmented coils 4a, 4b, and 4c each extend from one end of the stator core 2 (… Figure 1 The upper end of the stator core 2 is inserted into the slots 20 that are different from each other from the other end side. The bridging portions 41 of the first to third segment coils 4a, 4b, and 4c are arranged on the other end side of the stator core 2.

[0025] In this embodiment, the first to third segmented coils 4a, 4b, and 4c are assembled to the stator core 2 with an even number (six in this embodiment) of legs 40 protruding radially adjacently from each of the plurality of slots 20. Furthermore, the plurality of legs 40 form a plurality of layers. The plurality of legs 40 protrude from each of the plurality of slots 20 and are adjacent in the circumferential direction of the stator core 2. Hereinafter, the layer of the plurality of legs 40 (front ends) adjacent in the circumferential direction on the outermost periphery of the stator core 2 will be referred to as "layer 1," the layers on the radially inner side will be referred to as "layer 2," "layer 3," and so on, and the layer of the plurality of legs 40 adjacent in the circumferential direction on the innermost periphery will be referred to as "layer 6." The number of "layers" in the stator 1 is the same as the number of legs 40 arranged in each slot 20.

[0026] Next, refer to Figure 4 Taking stator coil 3u as an example, the assembly method of the first to third segment coils 4a, 4b, and 4c relative to the stator core 2 is explained. Figure 4 As shown, a pair of legs 40 of the first segment coil 4a extend from the other end of the stator core 2 ( Figure 4Insert the paper from the front side. At this time, a pair of legs 40 are inserted from one end of the stator core 2 (on the front side). Figure 4 The paper (back side) protrudes from one 2·i-1 layer and another 2·i layer on one side (winding start side) of the circumferential direction of the two first slots 21 that are 5 slots apart. Wherein, "i" is an integer greater than or equal to 1, i=1, ..., imax (in this embodiment, imax=3).

[0027] More specifically, such as Figure 4 As shown, a pair of legs 40 of the first segment coil 4a of the parallel coil U1 forming the stator coil 3u are inserted into the following positions: the first layer of slot 9 and the second layer of slot 14; the first layer of slot 33 and the second layer of slot 38; the third layer of slot 21 and the fourth layer of slot 26; the third layer of slot 45 and the fourth layer of slot 2; and the fifth layer of slot 33 and the sixth layer of slot 38. Furthermore, as... Figure 4 As shown, a pair of legs 40 of the first segment coil 4a forming the parallel coil U2 are inserted into the following positions: the first layer of slot 21 and the second layer of slot 26; the first layer of slot 45 and the second layer of slot 2; the third layer of slot 33 and the fourth layer of slot 38; the fifth layer of slot 21 and the sixth layer of slot 26; and the fifth layer of slot 45 and the sixth layer of slot 2.

[0028] Moreover, such as Figure 4 As shown, a pair of legs 40 of the first segment coil 4a forming the parallel coil U3 are inserted into the following positions: the first layer of slot 15 and the second layer of slot 20; the first layer of slot 39 and the second layer of slot 44; the third layer of slot 27 and the fourth layer of slot 32; the fifth layer of slot 15 and the sixth layer of slot 20; and the fifth layer of slot 39 and the sixth layer of slot 44. Furthermore, as... Figure 4 As shown, a pair of legs 40 of the first segment coil 4a forming the parallel coil U4 are inserted into the following positions: the first layer of slot 27 and the second layer of slot 32; the third layer of slot 15 and the fourth layer of slot 20; the third layer of slot 39 and the fourth layer of slot 44; the fifth layer of slot 27 and the sixth layer of slot 32; and the fifth layer of slot 3 and the sixth layer of slot 8.

[0029] A pair of legs 40 of the second segment coil 4b are inserted into one 2.i-1 layer and another 2.i layer on one side (winding start side) of the circumferential direction of two second slots 22, which are spaced 7 slots apart on both sides of the first slot 21. At this time, the pair of legs 40 are inserted from the other end of the stator core 2 so as to protrude from one end of the stator core 2. The jumper portion 41 of the second segment coil 4b crosses the jumper portion 41 of the corresponding first segment coil 4a. More specifically, as Figure 4As shown, a pair of legs 40 of the second segment coil 4b of the parallel coil U1 forming the stator coil 3u are inserted into the following positions: the first layer of slot 20 and the second layer of slot 27; the first layer of slot 44 and the second layer of slot 3; the third layer of slot 32 and the fourth layer of slot 39; the fifth layer of slot 20 and the sixth layer of slot 27; and the fifth layer of slot 44 and the sixth layer of slot 3. Furthermore, as... Figure 4 As shown, a pair of legs 40 of the second segment coil 4b forming the parallel coil U2 are inserted into the following positions: the first layer of slot 8 and the second layer of slot 15; the first layer of slot 32 and the second layer of slot 39; the third layer of slot 20 and the fourth layer of slot 27; the third layer of slot 44 and the fourth layer of slot 3; and the fifth layer of slot 32 and the sixth layer of slot 39.

[0030] Moreover, such as Figure 4 As shown, a pair of legs 40 of the second segment coil 4b forming the parallel coil U3 are inserted into the following positions: the first layer of slot 26 and the second layer of slot 33; the third layer of slot 14 and the fourth layer of slot 21; the third layer of slot 38 and the fourth layer of slot 45; the fifth layer of slot 26 and the sixth layer of slot 33; and the fifth layer of slot 2 and the sixth layer of slot 9. Furthermore, as... Figure 4 As shown, a pair of legs 40 of the second segment coil 4b forming the parallel coil U4 are inserted into the following positions: the first layer of slot 14 and the second layer of slot 21; the first layer of slot 38 and the second layer of slot 45; the third layer of slot 26 and the fourth layer of slot 33; the fifth layer of slot 14 and the sixth layer of slot 21; and the fifth layer of slot 38 and the sixth layer of slot 45.

[0031] A pair of legs 40 of the third segment coil 4c are inserted into one 2.i-1 layer and another 2.i layer on one side (winding start side) of the circumferential direction of the first and second slots 21 and 22, which are spaced six slots apart. At this time, the pair of legs 40 are inserted from the other end of the stator core 2 so as to protrude from one end of the stator core 2. One of the pair of legs 40 forms the winding end part in the 2.i layer or the winding start part in the 2.i+1 (=2.(i+1)-1) layer. That is, the parallel coil U1 of the stator coil 3u includes two third segment coils 4c. Figure 4 As shown, a pair of legs 40 of the third segment coil 4c of the parallel coil U1 are inserted into the third layer of slot 9 and the fourth layer of slot 15, forming the winding start portion in the third layer (2·i+1 layer). Figure 4As shown, a pair of legs 40 of another third segment coil 4c of parallel coil U1 are inserted into the fifth layer of slot 8 and the sixth layer of slot 14 to form the winding start part in the fifth layer (2·i+1 layer).

[0032] The parallel coil U2 of stator coil 3u includes two third-segment coils 4c. For example... Figure 4 As shown, a pair of legs 40 of the third segment coil 4c of the parallel coil U2 are inserted into the third layer of slot 8 and the fourth layer of slot 14, forming the winding start portion in the third layer (2·i+1 layer). Furthermore, as... Figure 4 As shown, a pair of legs 40 of another third segment coil 4c of the parallel coil U2 are inserted into the fifth layer of slot 9 and the sixth layer of slot 15, forming the winding start portion in the fifth layer (2·i+1 layers). The parallel coil U3 of the stator coil 3u includes two third segment coils 4c. As... Figure 4 As shown, a pair of legs 40 of the third segment coil 4c of the parallel coil U3 are inserted into the first layer of slot 2 and the second layer of slot 8, forming the winding end portion in the second layer (2.i layer). Furthermore, as... Figure 4 As shown, a pair of legs 40 of another third segment coil 4c of the parallel coil U3 are inserted into the third layer of slot 3 and the fourth layer of slot 9, forming the winding end in the fourth layer (2.i layer). The parallel coil U4 of the stator coil 3u includes two third segment coils 4c. As... Figure 4 As shown, a pair of legs 40 of the third segment coil 4c of the parallel coil U4 are inserted into the first layer of slot 3 and the second layer of slot 9, forming the winding end portion in the second layer (2.i layer). Furthermore, as... Figure 4 As shown, a pair of legs 40 of another third segment coil 4c of parallel coil U4 are inserted into the third layer of slot 2 and the fourth layer of slot 8 to form the winding end part in the fourth layer (2·i layer).

[0033] The first to third segments of the parallel coils V1-V4 forming the stator coil 3V, 4a, 4b, and 4c, are assembled with four slots offset from the first to third segments of the parallel coils U1-U4 forming the U phase. For example... Figure 5 As shown, the offset direction is one side in the circumferential direction ( Figure 4 and Figure 5 (Left side of the middle). Furthermore, the first to third segments of the parallel coils W1-W4 forming the stator coil 3w, coils 4a, 4b, and 4c, are assembled with two slots offset from the first to third segments of the parallel coils U1-U4 forming the U phase. (As shown in the image) Figure 6 As shown, the offset direction is one side in the circumferential direction ( Figure 4 and Figure 5 (Left side of the middle).

[0034] from Figures 4-6 It is known that the bridging portion 41 (bent portion 42) of the first segment coil and the second segment coils 4a and 4b are inclined in the same direction relative to the radial direction of the stator core 2. Similarly, the bridging portion 41 (bent portion 42) of the third segment coil 4c is also inclined in the same direction relative to the radial direction of the stator core 2 as the first segment coil and the second segment coils 4a and 4b. Therefore, the first to third segment coils 4a, 4b, and 4c wound in the multiple slots 20 in layers 2.i-1 and 2.i, i.e., layers 1 and 2, 3 and 4, and 5 and 6, can be arranged in the same manner using a known annular arrangement device. Figure 7 The circular shape is shown. Known circular arrangement devices are disclosed, for example, in Japanese Patent No. 3975891.

[0035] In assembly A, where the first to third segment coils 4a, 4b, and 4c of the two layers are arranged in a ring, the segment coils are configured as follows: Each second segment coil 4b is configured to bridging the corresponding first segment coil 4a with a bridging wire 41. Multiple (six) third segment coils 4c are arranged circumferentially with their bridging wires 41 overlapping each other. The result is as follows: Figure 8 As shown, three assemblies A (segmented coils 4a, 4b, and 4c of the first to third layers) wound on the first, second, third, fourth, fifth, and sixth layers can be sequentially assembled onto the stator core 2. Furthermore, in this embodiment, as... Figure 8 As shown, the first to third segmented coils 4a, 4b, and 4c each include three different types of segmented coils with varying circumferential spacing between a pair of legs 40.

[0036] After the first to third segment coils 4a, 4b, and 4c are assembled onto the stator core 2, the legs 40 of the first to third segment coils 4a, 4b, and 4c protruding from one end (twist side) of the stator core 2 are twisted. The twisting is performed using a twisting device not shown. In this embodiment, a pair of legs 40 of each of the first to third segment coils 4a, 4b, and 4c are twisted to opposite sides in a circumferentially spaced manner (see reference). Figures 4-6 (The dashed line). And, as... Figures 4-6 As shown, the two legs 40 of the first segment coil and the second segment coils 4a and 4b protrude from one 2.i layer and the other 2.i-1 layer on one side (winding start side) of the first slot and the second slots 21 and 22, which are separated by 6 slots. For example, the two legs 40 of the first segment coil and the second segment coils 4a and 4b protrude from the second layer of slot 14 and the first layer of slot 20, etc. The front ends of the two legs 40 of the first segment coil and the second segment coils 4a and 4b are electrically connected to each other by welding (e.g., laser welding, etc.).

[0037] Therefore, multiple bridging terminals 45 are formed on one end of the stator core 2, connecting the corresponding front ends of the first segment coil and the second segment coils 4a and 4b to each other. For example... Figures 4-6 As shown, the direction of the crossing layer of each bridging portion 45 on one end side of the stator core 2 is opposite to the direction of the crossing layer of the bridging portions 41 of the first to third segment coils 4a, 4b, and 4c on the other end side of the stator core 2. For example, the direction of the crossing layer of the bridging portion 45 is from layer 2.i towards layer 2.i-1, and the direction of the crossing layer of the bridging portion 41 is from layer 2.i-1 towards layer 2.i. Furthermore, before soldering, the insulating film is removed from the front end of each leg 40 to expose the conductor.

[0038] And, as Figures 4-6 As shown, at one end of the stator core 2, a leg 40 of the third segment coil 4c forming the winding end portion in layer 2.i is connected to a leg 40 of the third segment coil 4c forming the winding start portion in layer 2.i+1. That is, two legs 40 protrude from one layer 2.i and the other layer 2.i+1 on one side (winding start side) of the circumferential direction of the first slot and the second slots 21, 22, which are separated by six slots. These two legs 40 are twisted, and their front ends are electrically connected to each other by welding. The two legs 40 may protrude, for example, from the second layer of the third slot and the third layer of the ninth slot, or from the fourth layer of the second slot and the fifth layer of the eighth slot.

[0039] More specifically, on one end of the stator core 2, the leg 40 of the third segment coil 4c protrudes from one 2.i+1 layer on one side (winding start side) of the circumferential direction of the first slot and the second slots 21, 22 as specified above. Furthermore, the leg 40 of the first or second segment coils 4a, 4b protrudes from one 2.i layer of a slot 20 that is 6 slots away from one of the specified first slots and the second slots 21, 22. The leg 40 of the third segment coil 4c and the leg 40 of the first or second segment coils 4a, 4b are twisted, and their front ends are electrically connected to each other. The first slot and the second slots 21, 22 as specified above are, for example, Figure 4 The 9th and 15th slots, and the 8th and 14th slots. The leg 40 of the 3rd segment coil 4c, for example, from... Figure 4 The 3rd layer of the 9th slot or the 5th layer of the 8th slot protrudes. One of the 1st slot and the 2nd slots 21 and 22, as specified, is, for example, Figure 4 The 9th slot or 8th slot, etc. The leg 40 of the 1st or 2nd segmented coil 4a, 4b, for example, from... Figure 4The third slot protrudes from the second layer or the fourth layer of the second slot. Furthermore, on one end side of the stator core 2, the leg 40 of the third segment coil 4c protrudes from another 2.i layer on the side opposite to the side (winding start side) of the first and second slots 21, 22 as described above. Furthermore, the leg 40 of the first or second segment coils 4a, 4b protrudes from the 2.i+1 layer of a slot 20 that is 6 slots away from another of the first and second slots 21, 22 as described above. Furthermore, the leg 40 of the third segment coil 4c and the leg 40 of the first or second segment coils 4a, 4b are twisted, and their front ends are electrically connected to each other. The first and second slots 21, 22 as described above are, for example, Figure 4 The second and eighth slots, and the third and ninth slots in the middle. The leg 40 of the third segmented coil 4c, for example, from... Figure 4 The 8th or 9th slot in the middle, for example, protrudes from the 2nd or 4th layer. The leg 40 of the 1st or 2nd segmented coil 4a, 4b, for example, from... Figure 4 The third layer of the 14th slot or the third layer of the 15th slot protrudes.

[0040] Therefore, multiple (see reference) jumper terminals 47 are formed on one end of the stator core 2. Figure 9 (The area enclosed by a single-dot dashed line). The jumper portion 47 connects the leg 40 of the third segment coil 4c forming the winding end portion in layer 2.i and the leg 40 of the first or second segment coil 4a, 4b forming the winding start portion in layer 2.i+1. Alternatively, the jumper portion 47 connects the leg 40 of the first or second segment coil 4a, 4b forming the winding end portion in layer 2.i and the leg 40 of the third segment coil 4c forming the winding start portion in layer 2.i+1. From Figures 4-6 It can be seen that on one end of the stator core 2, the direction of each bridging section 47 across the layer (from layer 2.i towards layer 2.i+1) is the same as that of another bridging section 45 (refer to...). Figure 9 The range enclosed by the double-dotted line in the middle) crosses the opposite direction of the layer (from layer 2·i-1 towards layer 2·i).

[0041] If the front ends of the corresponding legs 40 are joined together, then the first and second layers, the third and fourth layers, and the fifth and sixth layers are wound with the first to third segmented coils 4a, 4b, and 4c via wave windings. Furthermore, as... Figure 4 As shown, the legs 40 inserted into the 8th and 9th slots of the 1st and 6th layers serve as leads for the parallel coils U1, U2, U3, and U4. These legs 40 are electrically connected to the U-phase power line at one end of the stator core 2 via a busbar unit (not shown). Furthermore, as... Figure 4As shown, the legs 40 inserted into the sixth layer of the second and third slots and the first layer of the fourteenth and fifteenth slots serve as the neutral wires for the parallel coils U1, U2, U3, and U4. These legs 40 are electrically connected to the neutral point via a bus unit (not shown).

[0042] And, as Figure 4 As shown, the legs 40 of the first and sixth layers inserted into the 12th and 13th slots serve as leads for the parallel coils V1, V2, V3, and V4. These legs 40 are electrically connected to the V-phase power line via a busbar unit (not shown) at one end of the stator core 2. Furthermore, as... Figure 4 As shown, the legs 40 inserted into the sixth layer of slots 6 and 7, and the first layer of slots 18 and 19, serve as the neutral wires for the parallel coils V1, V2, V3, and V4. These legs 40 are electrically connected to the neutral point via a bus unit (not shown). Furthermore, as... Figure 4 As shown, the legs 40 inserted into the sixth layer of slots 4 and 5, and the first layer of slots 16 and 17, serve as leads for parallel coils W1, W2, W3, and W4. These legs 40 are electrically connected to the W-phase power line at one end of the stator core 2 via a busbar unit (not shown). Furthermore, as... Figure 4 As shown, the legs 40 of the first and sixth layers inserted into the 10th and 11th slots serve as the neutral wires for the parallel coils W1, W2, W3, and W4, and are electrically connected to the neutral point via a bus unit (not shown). Thus, multiple stator coils 3u, 3v, and 3w are wound around the stator core 2 via distributed windings.

[0043] In the plurality of stator coils 3u, 3v, and 3w wound on the stator core 2, the joints of the front ends of the plurality of legs 40 are arranged radially in a predetermined number to form a ring-shaped first coil end protruding outward from one end face of the stator core 2. Furthermore, in the stator 1, as from... Figure 1 , Figures 4-6It is understood that the legs 40 used as leads or neutral wires are concentrated in a relatively narrow area at the end of the first coil. Therefore, when the motor including the stator 1 is cooled by coolant (cooling oil), the stator 1 can be placed inside the housing, etc., so that the legs 40 used as leads or neutral wires are not immersed (soaked). As a result, the cost of insulation for the exposed conductor portion of the lead or neutral wire can be significantly reduced in the stator 1. Furthermore, in the plurality of stator coils 3u, 3v, 3w, the bridging portion 41 of the first to third segment coils 4a, 4b, 4c forms an annular second coil end protruding outward from the end face of the stator core 2 at the other end. In the second coil end, the bridging portion 41 of the second segment coil 4b bridging the bridging portion 41 of the first segment coil 4a, but by suppressing the overlap of the bridging portions 41 to two layers, the increase in shaft length can be effectively suppressed in the stator 1.

[0044] As explained above, the stator 1 includes a first segment coil 4a, a second segment coil 4b, and a third segment coil 4c. In the first segment coil 4a, a pair of legs 40 are inserted into two first slots 21 spaced 5 slots apart. In the second segment coil 4b, a pair of legs 40 are inserted into two second slots 22 spaced 7 slots apart on both sides of the first slot 21. In the third segment coil 4c, a pair of legs 40 are inserted into the first and second slots 21 and 22 spaced 6 slots apart. The pair of legs 40 of the first segment coil 4a are inserted into one 2.i-1 layer and the other 2.i layer on one side of the circumferential direction of the two first slots 21, protruding from one end of the stator core 2. A pair of legs 40 of the second segment coil 4b are inserted into one 2.i-1 layer and the other 2.i layer on one side of the circumferential direction of the two second slots 22, protruding from one end of the stator core 2. The second segment coil 4b is bridging the corresponding first segment coil 4a. A pair of legs 40 of the third segment coil 4c are inserted into one 2.i-1 layer and the other 2.i layer on one side of the circumferential direction of the first slot and the second slot 22, which are separated by 6 slots, protruding from one end of the stator core 2. This forms a winding end in the 2.i layer or a winding start in the 2.i+1 layer. Furthermore, on one end side of the stator core 2, two legs 40 protrude from one 2.i layer and the other 2.i-1 layer on one side of the circumferential direction of the first slot and the second slot 22, which are separated by 6 slots. The two legs 40 are twisted, and their front ends engage with each other. Furthermore, on one end of the stator core 2, two legs 40 protrude from one 2.i layer and the other 2.i+1 layer on one side of the circumferential direction of the first and second slots 22, which are separated by six slots. These two legs 40 are twisted, and their front ends engage with each other. As a result, the winding end in the 2.i layer connects with the winding start in the 2.i+1 layer.

[0045] That is, in each of the parallel coils U1-U4, V1-V4, and W1-W4, the first segment coil 4a is inserted into two first slots 21 spaced 5 slots apart. The second segment coil 4b is inserted into two second slots 22 spaced 7 slots apart, bridging the first segment coil 4a. Furthermore, on one end of the stator core 2, corresponding legs 40 are joined to each other with a 6-slot spacing. The effective number of turns obtained by dividing the number of legs 40 in one slot 20 (number of layers = 6) by the number of parallel coils U-U4 (number of parallel connections = 4) is a non-integer (1.5 in this embodiment). However, with the above structure, circulating current can be canceled in each of the parallel coils U1-U4, V1-V4, and W1-W4, thereby suppressing the flow of circulating current in the stator coils 3u, 3v, and 3w. The circulating current is generated based on the deviation in the timing of the induced voltage generated by the magnetic poles of the parallel coils U1-U4, V1-V4, and W1-W4 as the rotor magnet passes through.

[0046] Taking the parallel coil U1 as an example, it has 8 magnetic poles. Figure 4 As shown, in the range of magnetic poles (windings) formed from slot 8 to slot 15, leg 40 is relative to the center of the magnetic pole (reference). Figure 4 The triangular markings (in the diagram) are evenly arranged on both sides of the circumference (one in slots 8 and 15, and two in slots 9 and 14). Furthermore, in the magnetic poles formed from slots 20 to 27, the legs 40 are evenly arranged on both sides of the circumference relative to the center of the magnetic pole (two in slots 20 and 27, and one in slots 21 and 26). Moreover, in the magnetic poles formed from slots 32 to 39, the legs 40 are evenly arranged on both sides of the circumference relative to the center of the magnetic pole (one in slots 32 and 39, and two in slots 33 and 38). Furthermore, in the range of magnetic poles formed from slot 44 to slot 3, the legs 40 are evenly arranged on both sides of the magnetic pole center in the circumferential direction (two in slot 44 and slot 3, and one in slot 45 and slot 2). Therefore, in these magnetic poles, there will be no deviation at the moment when an induced voltage is generated according to the passage of the magnet.

[0047] On the other hand, in the magnetic poles formed from slots 14 to 21, the legs 40 are disposed on one side of the circumference relative to the center of the magnetic pole (two in slots 14 and 20, and one in slots 15 and 21). Furthermore, in the magnetic poles formed from slots 38 to 45, the legs 40 are disposed on one side of the circumference relative to the center of the magnetic pole (two in slots 38 and 44, and one in slots 39 and 45). Therefore, in these magnetic poles, the timing of the induced voltage generated according to the passage of the magnet is shifted, for example, towards the leading side. In contrast, in the magnetic poles formed from slots 26 to 33, the legs 40 are disposed on the other side of the circumference relative to the center of the magnetic pole (one in slots 26 and 32, and two in slots 27 and 33). Furthermore, in the magnetic poles formed from slots 2 to 9, the legs 40 are offset circumferentially to the opposite side relative to the center of the magnetic pole (one in each of slots 2 and 8, and two in each of slots 3 and 9). Therefore, in these magnetic poles, the timing of the induced voltage generated by the passage of the magnet deviates, for example, from the lagging side. In the parallel coil U1, two circulating currents can be canceled. The first is a circulating current generated due to the deviation in the timing of the induced voltage generated in the magnetic poles formed from slots 14 to 21 and from slots 38 to 45. The second is a circulating current generated due to the deviation in the timing of the induced voltage generated in the magnetic poles formed from slots 26 to 33 and from slots 2 to 9. Furthermore, in stator 1, similarly to parallel coil U1, the circulating current caused by the moment the induced voltage is generated is canceled out in each parallel coil U2-U4, V1-V4, W1-W4.

[0048] Furthermore, in stator 1, the bridging portion 41 (bent portion 42) of the pair of legs 40 connecting the third segment coil 4c is inclined in the same direction relative to the stator core 2 as the first segment coil and the second segment coils 4a and 4b. Therefore, the first to third segment coils 4a, 4b, and 4c wound on layers 2.i-1 and 2.i can be arranged into a ring shape and then assembled into the stator core 2 using a known ring-arranging device. As a result, costs can be reduced by shortening the cycle time or omitting the use of multi-axis robots. Consequently, even if the effective number of turns is not an integer, the generation of circulating current can be suppressed in stator 1, and productivity can be increased while manufacturing costs are reduced.

[0049] Furthermore, in the stator 1, the leg 40 of the third segment coil 4c protrudes from one 2.i+1 layer on one side of the circumferential direction of the designated first slot and second slots 21, 22. Also, the leg 40 protrudes from one 2.i layer of a slot 20 that is 6 slots apart from the designated first slot and second slots 21, 22. At one end of the stator core 2, these legs 40 are twisted so that their front ends join together, thereby forming a jumper portion 47. Moreover, the leg 40 of the third segment coil 4c protrudes from another 2.i layer on the side opposite to the aforementioned side of the designated first slot and second slots 21, 22. Also, the leg 40 protrudes from one 2.i+1 layer of another slot 20 that is 6 slots apart from the designated first slot and second slots 21, 22. On one end of the stator core 2, these legs 40 are twisted so that their front ends engage with each other, thereby forming a bridging portion 47. That is, in the stator 1, the leg 40 of the third segment coil 4c that forms the winding end portion in layer 2.i or the winding start portion in layer 2.i+1 forms a bridging portion 47 with the corresponding other leg 40. The bridging portion 47 spans the layers in the opposite direction to the other bridging portions 45. Thus, each second segment coil 4b can be arranged on the stator core 2 in such a way that it spans the corresponding first segment coil 4a, and on one end of the stator core 2, the corresponding legs 40 engage with each other with a 6-slot pitch.

[0050] Furthermore, a portion of the leg 40 protruding from one end of the stator core 2 serves as a lead wire and is connected to the power lines of the U-phase, V-phase, or W-phase to which power is applied. In the stator 1, multiple stator coils 3u, 3v, and 3w are connected via a Y-connection, and a portion of the leg 40 protruding from one end of the stator core 2 serves as a neutral wire connected to the neutral point. This allows the lead wires or neutral wire to be concentrated at one end of the stator core 2, simplifying the wiring of power lines and the structure of busbar units. The multiple stator coils 3u, 3v, and 3w do not necessarily have to be connected via a Y-connection; they can also be connected via a Δ-connection or an open connection. Moreover, the multiple stator coils 3u, 3v, and 3w can also be connected via... Figure 10 The parallel coils U1-U4, V1-V4, and W1-W4 connected as shown are constituted.

[0051] Furthermore, in stator 1, the number of layers in each slot 20, 2·imax, can be an even number greater than 6, and the number of parallel coils in each stator coil 3u, 3v, 3w can be a multiple of 4, = 4·m (where "m" is an integer greater than 1). Moreover, the combination of the number of layers in each slot 20, 2·imax, and the number of parallel coils in each stator coil 3u, 3v, 3w, 4·m (2·imax, 4·m) is not limited to (6, 4) in the above embodiment, and can be, for example, any one of (10, 4) and (12, 8).

[0052] Furthermore, the present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the present invention. Moreover, the above-described embodiments are merely specific ways of the invention described in the summary section of the invention, and are not limited to the elements of the invention described in the summary section of the invention.

[0053] The invention can be applied to industries such as stator manufacturing.

Claims

1. A stator, comprising: A stator core comprising a plurality of slots spaced apart circumferentially in a radially extending manner; and A plurality of segmented coils, each having a pair of legs inserted into different slots and electrically joined to each other via the front ends of the corresponding legs, form a plurality of stator coils, the stator being characterized in that... When the number of poles is set to "p" and the number of slots is set to "n", n = 6·p. The plurality of stator coils comprises 4.m parallel coils connected in parallel, where "m" is an integer greater than or equal to 1. In one of the slots, an even number of the legs are inserted in a radial arrangement. The plurality of segmented coils includes: The first segmented coil, wherein the pair of legs are inserted into one 2·i-1 layer and another 2·i layer on one side of the circumferential direction of the two first slots spaced 5 slots apart, such that they protrude from one end of the stator core, where "i" is an integer greater than or equal to 1, i = 1, ..., imax; The second segment coil, wherein the pair of legs are inserted into one 2.i-1 layer and the other 2.i layer on one side of the circumferential direction of two second slots spaced 7 slots apart on both sides of the first slot, and spans the corresponding first segment coil; and The third segmented coil, wherein the pair of legs are inserted into one 2.i-1 layer and another 2.i layer on one side of the circumferential direction of the first and second slots, which are spaced six slots apart, in a manner protruding from one end of the stator core, and form a winding end in the 2.i layer or a winding start in the 2.i+1 layer. On one end side of the stator core, two legs protruding from one 2.i layer and another 2.i-1 layer on one side of the circumferential direction of the first and second slots, which are spaced six slots apart, are twisted together and their front ends are joined together, and two legs protruding from one 2.i layer and another 2.i+1 layer on one side of the circumferential direction of the first and second slots, which are spaced six slots apart, are twisted together and their front ends are joined together, so that the winding end of the 2.i layer is connected to the winding start of the 2.i+1 layer.

2. The stator according to claim 1, characterized in that, On one end side of the stator core, the front end of the leg of the third segmented coil, which protrudes from one side of the circumferential direction of the designated first and second slots in a 2.i+1 layer, is twisted with the leg protruding from the 2.i layer of a slot 6 slots away from the side of the designated first and second slots, and the front ends of the two are joined together. On one end side of the stator core, the leg of the third segmented coil, which protrudes from another 2.i layer on the side opposite to the side of the designated first and second slots, is twisted with the leg protruding from the 2.i+1 layer of the slot, which is 6 slots away from the designated first and second slots, and the front ends of the two are joined together.

3. The stator according to claim 1 or 2, characterized in that, A portion of the leg protruding from one end of the stator core is connected to a power line to which electricity is applied.

4. The stator according to claim 3, characterized in that, The plurality of stator coils are connected by a Y-connection. A portion of the leg protruding from one end of the stator core is connected to the neutral point.

5. The stator according to claim 1 or 2, characterized in that, The combination (2·imax, 4·m) of the number of layers in the slot and the number of parallel coils is any one of (6, 4), (10, 4) and (12, 8).

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