Stator and rotary electric machine

Abstract

This invention provides a miniaturized stator and rotary motor compared to the prior art. The stator includes: a stator core, which is annular and surrounds a central axis, the stator core having a plurality of slots arranged circumferentially at predetermined intervals around the central axis and extending radially and axially parallel to the central axis; and a plurality of windings comprising a plurality of segmented conductors stacked in a radial or circumferential stacking direction and wound around the slots. Each segmented conductor includes a first segmented conductor portion disposed at a coil end protruding axially from an axial end face of the stator core and a pair of second segmented conductor portions disposed in a pair of opposing slots among the plurality of slots. A portion of the first segmented conductor portions of the plurality of segmented conductors are configured to be bent in the stacking direction.

Description

Technical Field

[0001] This disclosure relates to stators and rotating electrical machines. Background Technology

[0002] In the past, it has been known that, in order to shorten the length of a rotary electric motor in the direction of its rotation axis, distributed winding of the coil across multiple protrusions is not used, but concentrated winding of the coil only on one protrusion is used. For example, Patent Document 1 discloses a rotary electric motor that uses concentrated winding to shorten the length of the coil end in the direction of its rotation axis.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2010-172195 Summary of the Invention

[0006] In recent years, there has been a demand for miniaturization of rotating electric machines while maintaining torque performance.

[0007] The purpose of this disclosure is to provide stators and rotary motors that are miniaturized compared to the prior art.

[0008] The stator of one disclosed technical solution is characterized by comprising: a stator core, which is annular and surrounds a central axis, the stator core having a plurality of slots arranged at predetermined intervals in the circumferential direction around the central axis and extending radially and axially parallel to the central axis; and a plurality of windings comprising a plurality of segmented conductors stacked in a radial or circumferential stacking direction and wound around each slot. Each segmented conductor comprises a first segmented conductor portion disposed at a coil end protruding axially from an axial end face of the stator core and a pair of second segmented conductor portions disposed in a pair of opposing slots in the plurality of slots. A portion of the first segmented conductor portions of the plurality of segmented conductors are configured to be bent in the stacking direction.

[0009] According to this disclosure, it is possible to provide stators and rotary motors that are miniaturized compared to the prior art. Attached Figure Description

[0010] Figure 1 This is a schematic perspective view of the rotary motor according to Embodiment 1.

[0011] Figure 2 This is a schematic perspective view of the rotor of Embodiment 1.

[0012] Figure 3 This is a schematic perspective view of the stator core of Embodiment 1.

[0013] Figure 4 This is a schematic perspective view of an example of the winding in Embodiment 1.

[0014] Figure 5 This is a schematic perspective view showing an example of a unit of the stator in Embodiment 1.

[0015] Figure 6 yes Figure 5 The cross-sectional view of the unit shown is along line VI-VI.

[0016] Figure 7 yes Figure 5 A cross-sectional view of a portion of the unit shown along line VII-VII.

[0017] Figure 8 This is a schematic three-dimensional view representing a portion of the unit used for comparison.

[0018] Figure 9 yes Figure 8 The cross-sectional end view of a portion of the unit shown along line IX-IX.

[0019] Figure 10 This is a schematic cross-sectional view showing an example of a winding shaping device using the layered shaping method.

[0020] Figure 11 This is a flowchart illustrating an example of a method for manufacturing the unit of Embodiment 1.

[0021] Figure 12 This is a cross-sectional end view of a portion of a unit in a modified example 1 of the stator of embodiment 1.

[0022] Figure 13 This is a schematic perspective view of the rotary motor according to Embodiment 2.

[0023] Figure 14 This is a schematic perspective view of the rotor of Embodiment 2.

[0024] Figure 15 This is a schematic perspective view of the stator core of Embodiment 2.

[0025] Figure 16 This is a schematic perspective view of an example of the winding in Embodiment 2.

[0026] Figure 17 This is a schematic perspective view showing an example of a unit of the stator in Embodiment 2.

[0027] Figure 18 This is a schematic perspective view showing an example of a unit of the stator in Embodiment 3.

[0028] Figure 19 yes Figure 18 A cross-sectional view of a portion of the unit shown along line XIX-XIX.

[0029] Figure 20 This is a cross-sectional end view of a portion of a unit in a modified example 2 of the stator unit of embodiment 3.

[0030] Figure 21 This is a cross-sectional end view of a portion of a unit in a modified example 3 of the stator of embodiment 3.

[0031] Figure 22 This is a cross-sectional end view of a portion of a unit in a modified example 4 of the stator unit of embodiment 3.

[0032] Figure 23 This is a schematic perspective view showing an example of a unit of the stator in embodiment 4.

[0033] Figure 24 yes Figure 23 A cross-sectional view of a portion of the unit shown, along line XXIV-XXIV.

[0034] Figure 25 This is a cross-sectional end view of a portion of a unit in a modified example 5 of the stator unit of embodiment 4.

[0035] Figure 26 This is a cross-sectional end view showing a portion of the rotary electric machine using Modified Example 5.

[0036] Figure 27 This is a cross-sectional end view showing a portion of the rotary electric machine using Modified Example 5.

[0037] Figure 28 This is a cross-sectional end view showing a portion of the rotary electric machine using Modified Example 5. Detailed Implementation

[0038] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. However, the structures described below are merely examples of the present disclosure, and the present disclosure is not limited to the embodiments described below. The technology of the present disclosure is not limited thereto, and even in ways other than these embodiments, as long as they do not depart from the technical concept of the present disclosure, various changes, substitutions, additions, omissions, etc., can be made according to the design, etc.

[0039] This disclosure has been fully described with reference to the accompanying drawings and in connection with preferred embodiments; however, various modifications and variations will be apparent to those skilled in the art. Such modifications and variations are to be understood as included therein, provided they do not depart from the scope of this disclosure based on the appended claims.

[0040] In recent years, there has been a desire to miniaturize rotating electric machines while maintaining high torque. A rotating electric machine includes a stator and a rotor that rotates relative to the stator with a predetermined gap. The stator includes a stator core and multiple windings wound around a portion of the stator core. The coil ends, which represent portions of the windings protruding axially from the stator core, do not contribute to torque generation in the rotating electric machine. Therefore, by shortening the axial length of the coil ends, it is possible to miniaturize the stator while maintaining performance, thereby enabling the miniaturization of the rotating electric machine containing this stator.

[0041] The stator disclosed herein includes a stator core and multiple windings. Each of the multiple windings includes multiple protrusions wound around the stator core and segmented conductors stacked in a predetermined direction. A predetermined group of segmented conductor portions located at the coil ends of each segmented conductor is configured to be bent in a predetermined direction. A group of segmented conductor portions that are different from this predetermined group is configured to be bent in the opposite direction to the predetermined direction.

[0042] With this configuration, the stator can be made such that the segmented conductors at the ends of the coils are bent and their axial length is shortened. As a result, the stator and the rotary motor containing the stator can be miniaturized.

[0043] (Implementation Method 1)

[0044] [structure]

[0045] Reference Figures 1-4 The rotary motor 1 of Embodiment 1 of this disclosure is described. Figure 1 This is a schematic perspective view of the rotary motor 1 according to Embodiment 1 of this disclosure. The rotary motor 1 represents a rotating electromechanical device. The rotary motor 1 is, for example, an electric motor. The rotary motor 1 can also be a generator. Figure 1 As shown, the rotary electric machine 1 includes: a rotor 2 having a central axis 50 as its rotation axis; and an annular stator 3 disposed radially outside the rotor 2, the stator 3 including a stator core 30 and a plurality of windings 40. Additionally, the rotary electric machine 1 includes a housing (not shown). The rotor 2 and stator 3 are housed within the housing. Furthermore, in this specification, radial refers to a direction extending radially from the central axis 50 in a plane perpendicular to the central axis 50. Radial inner side refers to the side radially closer to the central axis 50. Radial outer side refers to the side radially away from the central axis 50.

[0046] Figure 2 This is a schematic perspective view of the rotor 2 according to Embodiment 1 of this disclosure. Figure 2 As shown, rotor 2 includes rotor core 20 and shaft 21. Additionally, rotor 2 includes a plurality of magnets 22. Rotor core 20 is arranged radially inside stator core 30 with a predetermined gap. Rotor 2 is rotatable relative to stator 3 about central axis 50. This predetermined gap is an example of a first gap.

[0047] Figure 3 This is a schematic perspective view of the stator core 30 according to Embodiment 1 of this disclosure. Figure 3 As shown, the stator core 30 has the same central axis 50 as the rotor 2, and is configured in a ring shape to surround the central axis 50. The stator core 30 has a magnetic yoke 31, multiple protrusions 32 and multiple slots 33.

[0048] The magnetic yoke 31 is configured in a ring shape to surround the central axis 50. Furthermore, the magnetic yoke 31 extends in a cylindrical shape along the axial direction. In this specification, the axial direction refers to the direction parallel to the central axis 50.

[0049] A plurality of protrusions 32 are arranged circumferentially around the central axis 50 on the inner circumferential side of the magnetic yoke 31 at predetermined intervals. The plurality of protrusions 32 extend from the inner circumferential side of the magnetic yoke 31 toward the central axis 50 in a direction opposite to the radial direction. Additionally, the plurality of protrusions 32 extend axially. Each protrusion 32 has a protrusion base 34 located radially outward and a protrusion end 35 located radially inward. The protrusion base 34 extends from the magnetic yoke 31. Furthermore, in this specification, circumferential direction refers to the direction along the circumference of a circle formed with the central axis 50 as its center.

[0050] Multiple slots 33 are arranged around the central axis 50 at predetermined intervals on the inner circumferential side of the magnetic yoke 31. The multiple slots 33 extend axially and radially, respectively. The multiple slots 33 are respectively arranged between two adjacent protrusions 32.

[0051] The stator 3 is constructed by arranging multiple structures, each having the same shape, in a ring shape. Hereinafter, each of these structures constituting the stator 3 will be referred to as a unit 60. Each unit 60 includes a portion of a yoke 31, one of a plurality of protrusions 32, and a winding 40 wound around that protrusion 32. The stator 3 has multiple units 60 connected in a ring shape. That is, each unit 60 is a component constituting the stator 3.

[0052] Figure 4 This is a schematic perspective view of an example of the winding 40 according to Embodiment 1 of this disclosure. Figure 4 The figure shows the winding 40 included in unit 60. Furthermore, the XYZ coordinate system shown in the figure is for illustrative purposes only and is not intended to limit the invention. The X-axis direction represents the radial direction. The Y-axis direction represents the tangential direction. The Z-axis direction represents the axial direction. In this specification, the tangential direction refers to the direction perpendicular to the radial direction in a plane perpendicular to the central axis 50 that is tangent to the circumference of a circle centered on the central axis 50.

[0053] In Embodiment 1, the winding 40, which serves as a coil, comprises multiple flat wires, or segmented conductors 41, with rectangular cross-sections. These segmented conductors 41 are stacked radially. In this specification, the direction in which the segmented conductors 41 are stacked is also referred to as the stacking direction. The winding 40 is constructed by cascading the multiple segmented conductors 41 together. For example, the winding 40 may also be configured such that the multiple segmented conductors 41 are continuously connected in a spiral shape. In the rotary motor 1 of Embodiment 1, the stacking direction refers to the X-axis direction, i.e., the radial direction. The stacking direction may also be the opposite direction to the radial direction. The winding 40 is wound around the protrusion 32 in a manner extending axially and tangentially. Furthermore, the winding 40 is wound around a slot 33 adjacent to the protrusion 32.

[0054] The stacked conductor segments 41 are separated in a manner that prevents them from contacting each other. To prevent the conductor segments 41 from contacting each other, the winding 40 can be formed by slowly moving radially while being wound around the protrusion 32 in the axial and tangential directions. In addition, to prevent the stacked conductor segments 41 from contacting each other, the surface of the winding 40 is covered with an insulator.

[0055] The winding 40 is formed using a layered molding method based on additive manufacturing technology. This layered molding method is also known as additive manufacturing. There are no particular limitations on the molding methods using additive manufacturing technology; examples include powder bed molding, powder nozzle molding, and binder spraying. The individual conductor segments 41 of the winding 40 are formed using the powder bed molding method.

[0056] Each segment conductor 41 includes a first segment conductor portion 43 and a pair of second segment conductor portions 42. The first segment conductor portion 43 represents the portion of the segment conductor 41 disposed at the coil end protruding axially from the axial end face of the stator core 30. The second segment conductor portion 42 represents the portion of the segment conductor 41 disposed in a pair of opposing slots 33 among a plurality of slots 33.

[0057] The coil end refers to the portion of the winding 40 that protrudes from the stator core 30 when viewed from the side, that is, when the unit 60 is viewed from a direction perpendicular to the axis, such as the X-axis or Y-axis. Each segment conductor 41 may have a first segment conductor portion 43 at the coil ends located at both axial ends of the stator 3, or it may only have a first segment conductor portion 43 at the coil end located at one axial end of the stator 3. In Embodiment 1, each segment conductor 41 of the winding 40 included in the unit 60 has two first segment conductor portions 43 located at both axial ends of the protrusion 32 and two second segment conductor portions 42 located at both circumferential ends of the protrusion 32.

[0058] like Figure 4As shown, the winding 40 has two connection terminals 44. The winding 40 of each unit 60 is electrically connected to the connection terminals 44 of the windings 40 of other units 60 through these connection terminals 44, thereby configuring the windings 40 of each unit 60 to be electrically connected to the windings 40 of other units 60.

[0059] Figure 5 This is a schematic perspective view showing an example of unit 60 of stator 3 in embodiment 1. Figure 5 As shown, the first segment conductor portion 43 protrudes from the axial end face 36 of the protrusion 32. A pair of second segment conductor portions 42 are disposed in a pair of opposing slots 33. Figure 5 As shown, unit 60 is configured such that the first segment conductor portion 43 is bent in a radial or opposite direction.

[0060] exist Figure 5 In this configuration, the winding 40 is wound around one of the multiple protrusions 32. Additionally, the winding 40 is wound around a slot 33 adjacent to the protrusion 32.

[0061] Figure 6 yes Figure 5 The cross-sectional end view of unit 60 along line VI-VI is shown. Figure 6 The diagram shows the representation in Figure 5 An end view of the cut end face of element 60 after being cut along line VI-VI with an imaginary plane perpendicular to the axis. Figure 6 The cut-out end faces of a pair of second segment conductor portions 42, protrusions 32, and yokes 31 are shown. Hereinafter, in this specification, the imaginary plane perpendicular to the axial direction will also be referred to as the "second plane".

[0062] exist Figure 6 In the example shown, the thicknesses of the second segment conductor portions 42 of each segment conductor 41 are formed to be different. The thicker the second segment conductor portion 42 is, the more radially inward the segment conductor 41, that is, the closer the segment conductor 41 is to the central axis 50. The thickness of the second segment conductor portion 42 represents the plate thickness. For example, the thickness of the second segment conductor portion 42 is defined as the dimension in at least one direction, either axial or radial, of the segment conductor 41 located in the slot 33. Furthermore, in Embodiment 1, while the thicknesses of the second segment conductor portions 42 are formed to be different, the thickness is not limited to this. For example, the thicknesses of the second segment conductor portions 42 may be substantially equal to each other in at least a portion of the plurality of second segment conductor portions 42. The fact that the thickness of each second segment conductor portion 42 is substantially equal to each other can mean that the difference in thickness of each second segment conductor portion 42 is within 10% of the thickness, or preferably within 5% of the thickness.

[0063] exist Figure 6In the example shown, the thickness of each segment conductor 41 forming the second segment conductor portion 42 is substantially equal in all locations. That is, the thickness of the second segment conductor portion 42 is constant. "Substantially equal thickness of the second segment conductor portion 42" can mean that the difference in thickness between the second segment conductor portions 42 is within 10% of the thickness, or preferably within 5% of the thickness.

[0064] exist Figure 6 In the example shown, the conductor lengths of the second segment conductor portions 42 of each segment conductor 41 are formed to be different. The conductor length of the second segment conductor portion 42 of each segment conductor 41 is formed such that the conductor length of the segment conductor 41 located radially outward, that is, the segment conductor 41 further away from the central axis 50, is larger. For example, the conductor length of the second segment conductor portion 42 is defined as the dimension in the tangential direction of the segment conductor 41 located in the slot 33. Furthermore, in Embodiment 1, the conductor lengths of each second segment conductor portion 42 are formed to be different, but the conductor length is not limited to this. For example, the conductor lengths of each second segment conductor portion 42 may also be substantially equal to each other in at least a portion of the plurality of second segment conductor portions 42. The conductor lengths of each second segment conductor portion 42 being substantially equal may mean that the difference between the conductor lengths is within 10% of the conductor length, or preferably within 5% of the conductor length.

[0065] The second segment conductor portion 42 of each segment conductor 41 is formed as Figure 6 The cross-sectional areas in the second plane shown are substantially equal to each other. This cross-sectional area is an example of a second cross-sectional area. For example, the cross-sectional area of ​​the radially inner second conductor segment 42A and the radially outer second conductor segment 42B in the second plane are substantially equal to each other. The substantially equal cross-sectional areas of the multiple second conductor segments 42 can mean that the difference in copper loss of each of the multiple second conductor segments 42 is consistent to the extent that it does not affect performance. Alternatively, the substantially equal cross-sectional areas of the multiple second conductor segments 42 can mean that the difference in each cross-sectional area is within 10% of the cross-sectional area, or preferably within 5%. The cross-sectional area of ​​the first conductor segment 43, described later, is also the same. Furthermore, the cross-sectional areas of the second conductor segments 42 and the first conductor segment 43 are also the same.

[0066] Figure 7 yes Figure 5 A cross-sectional end view of a portion of unit 60 along line VII-VII. Figure 7 The diagram shows the representation in Figure 5An end view of a portion of the cut end face of unit 60, cut along line VII-VII with an imaginary plane parallel to an imaginary plane formed along the axial direction and the stacking direction. Figure 7 The cut end face of the first segment conductor portion 43, a portion of the protrusion 32, and a portion of the magnetic yoke 31 are shown. Hereinafter, in Embodiment 1, the imaginary plane parallel to the imaginary plane formed along the axial and stacking directions, i.e., radially, is also referred to as the "first plane".

[0067] As mentioned above, in Figure 7 In the example shown, multiple first-segment conductor portions 43 are bent radially or in the opposite direction. For example... Figure 7 As shown, the first segment conductor portion 43 of the first group, which is part of a plurality of first segment conductor portions 43, bends radially toward the outer periphery of the stator core 30. Radial is an example of a first direction. The first segment conductor portion 43 of the second group, which is different from the first group of first segment conductor portions 43, bends radially toward the inner periphery of the stator core 30, that is, in the opposite direction to radial. In other words, the first segment conductor portion 43 of the first group extends toward the outer periphery of the stator core 30. In addition, the first segment conductor portion 43 of the second group extends toward the inner periphery of the stator core 30. The direction opposite to radial is an example of a second direction.

[0068] With this configuration, the first segment conductor portion 43 can be formed such that its protruding length is shorter compared to the unbent case. The protruding length of the first segment conductor portion 43 is defined as the axial dimension between the axial end of the first segment conductor portion 43 and the axial end face 36 of the stator core 30. The protruding length of the first segment conductor portion 43 can also be defined as the axial dimension of the portion of the segment conductor 41 located at the coil end.

[0069] The thickness of the first segment conductor portion 43 can also be varied. Specifically, the thickness of the first segment conductor portion 43 is configured such that it varies in at least one direction, either axial or radial. That is, the first segment conductor portion 43 can be configured to have a non-uniform thickness. Furthermore, each of the first segment conductor portions 43 can also have a different thickness. Additionally, for example, it can be as follows... Figure 7 As shown, at least a portion of the plurality of first segment conductor portions 43 has a constant thickness. Alternatively, at least another portion of the plurality of first segment conductor portions 43 may have different thicknesses. Alternatively, all the first segment conductor portions 43 may have non-uniform thicknesses.

[0070] For example, in Figure 7In this case, the thickness of the first segment conductor portion 43C located axially away from the stator core 30 is greater than the thickness of the first segment conductor portion 43C located closer to the stator core 30. The thickness of the first segment conductor portion 43 can also be defined as the minimum value among the dimensions in the direction orthogonal to the tangent direction of the segment conductor 41 in the cut end face after being cut with the first plane.

[0071] The first segment conductor portion 43 of each segment conductor 41 is formed as follows Figure 7 The cross-sectional areas in the first plane shown are substantially equal to each other. This cross-sectional area is an example of the first cross-sectional area. For example, the cross-sectional area of ​​the first segment conductor portion 43C in the first plane is substantially equal to the cross-sectional area of ​​the first segment conductor portion 43D located radially inward among the plurality of first segment conductor portions 43 in the first plane.

[0072] By increasing a portion of the thickness of the first segment conductor portion 43, such as the first segment conductor portion 43C, the protruding length of the first segment conductor portion 43 can be shortened. For example, the first segment conductor portion 43C is formed such that the thickness of the first segment conductor portion 43 is locally increased. As a result, the first segment conductor portion 43C can be formed to have a predetermined cross-sectional area instead of bending in a manner that overlaps with the first segment conductor portion 43E located radially outside the first segment conductor portion 43C.

[0073] With this configuration, the protruding length of the first segment conductor 43 can be shortened compared to the case where the thickness of the first segment conductor 43 is constant in each first segment conductor 43. In addition, in each unit 60 of the stator 3, the copper loss of each first segment conductor 43 is substantially equal to that of each other, which can suppress the difference in local heat generation generated by the rotating motor 1.

[0074] In addition, the winding 40 of stator 3 is formed as Figure 6 The cross-sectional area of ​​the second segment conductor portion 42 shown in the second plane is... Figure 7 The cross-sectional areas of the first segment conductor portions 43 shown are substantially equal to each other in the first plane. As a result, in each unit 60 of the stator 3, the copper losses of each second segment conductor portion 42 and each first segment conductor portion 43 are substantially equal to each other, which can suppress the difference in local heat generation generated by the rotating motor 1.

[0075] (Comparative example)

[0076] A comparative example relative to unit 60 in Embodiment 1 will be described. In the comparative example, the main focus is on the... Figure 5 The differences between the examples shown are explained. In the comparative examples, the differences between... Figure 5Examples shown are illustrated with the same or equivalent structural reference numerals. Additionally, in comparative examples, sometimes the same reference numerals are omitted. Figure 5 The example shown is a repeated record.

[0077] Figure 8 This is a schematic perspective view showing a portion of unit 60 of a comparative example relative to unit 60 of stator 3 in Embodiment 1. Figure 8 Only a portion of unit 60 is shown in the image. Figure 5 Similarly, in the comparative example unit 60, a pair of second segment conductor portions 42 of each segment conductor 41 of the winding 40 are arranged in a pair of opposing slots 33 located at the circumferential ends of the protrusion 32. The first segment conductor portion 43 protrudes from the axial end face 36 of the protrusion 32. Furthermore, with... Figure 5 Similarly, in the comparative example of unit 60, the first segment conductor portion 43 protrudes from the axial end face of the protrusion 32 in the -Z direction. Figure 8 The unit 60 shown extends axially rather than bends radially or in the opposite direction in the first segment conductor portion 43. Figure 5 The unit 60 shown is different.

[0078] Figure 9 yes Figure 8 A cross-sectional end view of a portion of unit 60 along line IX-IX. Figure 9 The diagram shows the representation in Figure 8 An end face view of a portion of the cut end face of element 60 after being cut along line IX-IX with the first plane. Figure 9 The diagram shows the cut end face of the first segment conductor portion 43, the protrusion 32, and a portion of the cut end face of the yoke 31. Furthermore, the end face in the second plane associated with the unit 60 of the comparative example is shown... Figure 6 It is constructed in the same way.

[0079] exist Figure 9 In the comparative example of unit 60 shown, the thicknesses of the first segment conductor portions 43 of each segment conductor 41 are formed to be different. The thickness of each first segment conductor portion 43 is greater the closer the segment conductor 41 is to the radially inner side. In the comparative example, the thickness of the first segment conductor portion 43 is defined as the radial dimension of the segment conductor 41. In the comparative example, the cross-sectional areas of each first segment conductor portion 43 in the first plane are formed to be substantially equal to each other.

[0080] In addition, Figure 9In the comparative example of unit 60 shown, the protruding length of the first segment conductor portion 43 of each segment conductor 41 is formed such that the protruding length is larger the segment conductor 41 located radially outward. The protruding length of the first segment conductor portion 43 is defined as the axial dimension between the axial end of the first segment conductor portion 43 and the axial end face 36 of the stator core 30. The protruding length of the first segment conductor portion 43 can also be defined as the axial dimension of the portion of the segment conductor 41 located at the coil end.

[0081] exist Figure 7 In this context, dimension D1 represents the axial dimension between the axial end of the first segment conductor portion 43, which protrudes most axially from the stator core 30 in the winding 40 of Embodiment 1, and the axial end face 36 of the stator core 30. Figure 9 In the comparative example, dimension D2 represents the axial dimension between the axial end of the first segment conductor portion 43, which protrudes most axially from the stator core 30, and the axial end face 36 of the stator core 30 in the winding 40. For example... Figure 7 As shown, by bending the first segment conductor portion 43 in a radial or opposite direction and locally changing the thickness of the first segment conductor portion 43, it is possible to make dimension D1 smaller than dimension D2.

[0082] In addition, such as Figure 7 As shown, when multiple first-segment conductor portions 43 bend in the same direction, the multiple first-segment conductor portions 43 are stacked axially. Therefore, as the number of first-segment conductor portions 43 increases, the protruding length of the first-segment conductor portions 43 becomes longer. As described above, the first-segment conductor portions 43 of the first group of multiple first-segment conductor portions 43 bend radially. Furthermore, the first-segment conductor portions 43 of the second group of multiple first-segment conductor portions 43 bend in the direction opposite to the radial direction. With this configuration, the number of first-segment conductor portions 43 stacked axially can be reduced. Therefore, according to... Figure 7 The structure shown allows for a smaller dimension D1 compared to bending multiple first-segment conductor portions 43 in one direction.

[0083] Figure 10 This is a schematic cross-sectional view showing an example of a molding apparatus 70 employing a layered molding method for the winding 40. As described above, the winding 40 is molded using a powder bed method. The powder bed method is also known as powder bed fusion (PBF). Figure 10As shown, the molding apparatus 70 includes a groove 71 and a laser head 72. In a powder bed configuration, for example, by filling a predetermined groove 71 with metal powder 73, the laser head 72 irradiates a specific area with a laser 74, thereby sintering the metal powder 73 located at that area. For example, the molding apparatus 70 sinters the bottom layer of metal powder 73 for the molded object 75, and then sinters the layer of metal powder 73 above the bottom layer, thereby enabling the molded object 75, that is, the segment conductors 41 of the winding 40, to be gradually stacked.

[0084] Figure 11 This is a flowchart illustrating an example of a method for manufacturing unit 60 according to embodiment 1. First, for example, a molding device 70 shapes a winding 40 for assembly into unit 60, comprising multiple segmented conductors 41 (S11). Next, the surface of the winding 40 is insulated (S12). For example, the winding 40 can be insulated by coating the surface of each segmented conductor 41 with an electrically insulating material such as enamel. Next, the winding 40 is assembled onto the protruding base 34 of the stator core 30 (S13). At this time, the protrusion 32 of the stator core 30 only has the protruding base 34 and does not have the protruding end 35. Next, the protruding end 35 is joined to the protruding base 34 (S14). The protruding end 35 can be joined to the protruding base 34 or fused to the protruding base 34. The stator 3 can be manufactured by combining multiple units 60 thus manufactured into a ring shape. In addition, the rotary motor 1 can be manufactured by inserting the rotor 2 axially into the stator 3.

[0085] Here, the method of manufacturing unit 60 is not limited to the above-described manner, and unit 60 can be manufactured by any method. For example, the winding 40 can also be stacked on a portion of the magnetic yoke 31 and the protruding base 34 by winding around the protruding base 34. Alternatively, the winding 40 can also be shaped by a stacking molding method in a manner that simultaneously forms the conductor portion of the segmented conductor 41 and the insulating layer. In addition, the protruding end 35 can also be shaped by a stacking molding method to be stacked on the protruding base 34.

[0086] The stator core 30 can also be formed using a stacking method. For example, the stator core 30 can be formed using Direct Energy Deposition (DED). According to DED, the stator core 30 can be formed by using a laser, electron beam, or plasma arc as a heat source to spray metal powder from a nozzle in an agglomerated manner, melting and spraying the metal. However, the manufacturing method of the stator core 30 using a stacking method is not limited to DED; different methods can be used to manufacture the stator core 30 depending on the material and application. Similarly, the rotor core 20 can also be formed using a stacking method.

[0087] (Variation Example 1)

[0088] A variation 1 of unit 60 in Embodiment 1 will be described. In variation 1, the main focus is on... Figure 5 The differences in the examples shown will be explained. In variation 1, the differences between... Figure 5 The same or equivalent constituent elements shown in the examples are labeled with the same reference numerals. Additionally, in variation 1, sometimes the same reference numerals are omitted. Figure 5 The example shown is a repeated record.

[0089] Figure 12 This is a cross-sectional end view of a portion of unit 60 in Modified Example 1, representing unit 60 of stator 3 in Embodiment 1. Figure 12 The diagram illustrates the relationship between... Figure 7 The end view shown is similarly a partial end view of the cut end face of element 60 of Modified Example 1, after being cut along the first plane. Figure 12 The image shows the cut end face of the first segment conductor portion 43, the protrusion 32, and a portion of the cut end face of the magnetic yoke 31. (Compared to...) Figure 12 The end face in the second plane associated with the unit 60 shown is... Figure 6 It is constructed in the same way.

[0090] In Modification 1, the first segment conductor portion 43 bends radially or in the opposite direction. For example, the first segment conductor portion 43 of the first group bends towards the outer periphery of the stator core 30. The first segment conductor portion 43 of the second group bends towards the inner periphery of the stator core 30. The first segment conductor portion 43 of Modification 1 maintains a constant thickness compared to... Figure 7 The first segment conductor portion 43 in the example shown is different.

[0091] Similar to the winding 40 of unit 60 in the comparative example, the winding 40 of modified example 1 is formed such that the thickness of the first segment conductor portion 43 located radially inward is greater. Furthermore, similar to the winding 40 described above, the winding 40 of modified example 1 is formed such that… Figure 12 The cross-sectional areas of each of the first segment conductor portions 43 in the first plane shown are substantially equal to each other. This cross-sectional area is an example of the first cross-sectional area.

[0092] exist Figure 12 In this context, dimension D3 represents the axial dimension between the axial end of the first segment conductor portion 43, which protrudes most axially from the stator core 30 in the winding 40 of Modified Example 1, and the axial end face 36 of the stator core 30. For example... Figure 12 As shown, by bending the first segment conductor portion 43 in a radial or opposite direction, the dimension D3 is larger than the dimension D1, but smaller than the dimension D2.

[0093] In this embodiment, the first segment conductor portion 43 is bent in two directions, but the bending direction of the first segment conductor portion 43 is not limited to two directions. For example, the first segment conductor portion 43 may also be configured to be bent in one direction, that is, only radially inward or only radially outward. In this way, the winding 40 can be configured such that at least a portion of the first segment conductor portion 43 is bent in at least one direction, either radially or in the opposite direction. In addition, the winding 40 may also be configured such that at least a portion of the first segment conductor portion 43 is bent in one direction, either radially or in the opposite direction, and the thickness of at least a portion of the first segment conductor portion 43 varies. With this configuration, for example, even if the dimension between the first segment conductor portion 43 located on the inner circumferential side of the stator core 30 and the inner circumferential side end face of the stator core 30 is small, the first segment conductor portion 43 can be formed with a shorter axial protrusion length.

[0094] [Effect]

[0095] The stator 3 according to Embodiment 1 of this disclosure can achieve the following effects.

[0096] The stator 3 includes a plurality of windings 40 and an annular stator core 30 surrounding a central axis 50. The stator core 30 has a plurality of slots 33 arranged at predetermined intervals in the circumferential direction around the central axis 50 and extending radially and axially parallel to the central axis 50. The plurality of windings 40 include a plurality of segmented conductors 41 stacked in a radial stacking direction and wound around each slot 33. Each segmented conductor 41 includes a first segmented conductor portion 43 disposed at a coil end protruding axially from an axial end face 36 of the stator core and a pair of second segmented conductor portions 42 disposed in a pair of opposing slots 33. A portion of the first segmented conductor portions 43 of the plurality of segmented conductors 41 are configured to be bent in the stacking direction.

[0097] With this structure, the axial protrusion length of the first segment conductor portion 43 located at the coil end in the winding 40 can be shortened in the stator 3. That is, the first segment conductor portion 43 can be lowered compared to the case where the first segment conductor portion 43 is not bent. Therefore, the stator 3 can be miniaturized.

[0098] Furthermore, in the stator 3, the thickness of the first segment conductor portion 43 varies in at least one of the axial, radial, and circumferential directions. With this structure, each of the first segment conductor portions 43 of the winding 40 can have a non-uniform thickness. That is, a portion of the first segment conductor portion 43 can be made thicker than other portions of the first segment conductor portion 43. This shortens the protruding length of the first segment conductor portions 43 located at the coil ends in the winding 40. Consequently, the stator 3 can be miniaturized.

[0099] Furthermore, in the stator 3, the first cross-sectional areas of the first segment conductor portions 43 of each of the plurality of segment conductors 41 are substantially equal to each other in a first plane parallel to the plane formed along the stacking direction and the axial direction. According to this structure, the copper losses of each first segment conductor portion 43 in the stator 3 can be substantially equal to each other. Therefore, the stator 3 can maintain performance while being miniaturized.

[0100] Furthermore, in the stator 3, the first cross-sectional area of ​​the first segment conductor portion 43 of each of the plurality of segment conductors 41 in a first plane parallel to the plane formed along the stacking direction and the axial direction, and the second cross-sectional area of ​​the second segment conductor portion 42 of each of the plurality of segment conductors 41 in a second plane perpendicular to the axial direction, are substantially equal to each other. According to this structure, in the stator 3, the copper loss of the first segment conductor portion 43 and the copper loss of the second segment conductor portion 42 in the winding 40 can be substantially equal to each other. Therefore, the stator 3 can maintain performance while being miniaturized.

[0101] Furthermore, in the stator 3, the first segment conductor portion 43 of the first group, which is part of a plurality of first segment conductor portions 43, is configured to be bent in a first direction, which is the stacking direction. The first segment conductor portion of the second group, which is a part of the first segment conductor portions 43 different from the first group, is configured to be bent in a second direction opposite to the first direction. According to this structure, compared with the case where the first segment conductor portion 43 is bent in only one direction, the protruding length of the first segment conductor portion 43 can be shortened. Therefore, the stator 3 can be miniaturized.

[0102] Furthermore, in the stator 3, multiple segmented conductors 41 are stacked radially. The first direction is radial, and the second direction is the opposite direction. According to this structure, the first segmented conductor portion 43 of the first group bends radially outward, and the first segmented conductor portion 43 of the second group bends radially inward. Therefore, compared to the case where the first segmented conductor portion 43 only bends towards the inner or outer circumference of the stator core 30, the protruding length of the first segmented conductor portion 43 can be shortened. Thus, the stator 3 can be miniaturized.

[0103] Furthermore, in the stator 3, each winding 40 is wound in a concentrated manner. With this structure, the protruding length of the first segment conductor portion 43 in the stator 3, where the windings 40 are wound in a concentrated manner, can be shortened. Therefore, the stator 3 can be miniaturized.

[0104] Furthermore, in the stator 3, each winding 40 is formed using a lamination molding method. By forming the winding 40 using the lamination molding method, it is possible to form a winding 40 in which at least a portion of the first segment conductor portion 43 is bent in the lamination direction. In addition, the first segment conductor portion 43, which is each segment conductor 41, can be configured to have a non-uniform thickness. Therefore, the stator 3 can be miniaturized.

[0105] The rotary electric motor includes the stator 3 described above and a rotor 2 disposed radially inside the stator 3 with a predetermined gap and capable of rotating about a central axis 50. In the stator 3, the protruding length of the first segment conductor portion 43, which can be configured as a winding 40, is relatively short, thus enabling the rotary electric motor 1 to be miniaturized.

[0106] (Implementation Method 2)

[0107] The general outline of the rotary motor 1 in Embodiment 2 will be described. In Embodiment 2, the differences from Embodiment 1 will be mainly explained. In Embodiment 2, the same reference numerals will be used to describe the same or equivalent components as in Embodiment 1. In addition, in Embodiment 2, descriptions that are repeated in Embodiment 1 are sometimes omitted.

[0108] As described above, in Embodiment 1, the winding 40 of the stator 3 is wound around the stator core 30 in a concentrated manner. In Embodiment 2, the rotary motor 1 differs from the rotary motor 1 in that the winding 40 of the stator 3 is wound around the stator core 30 in a circular manner.

[0109] Figure 13 This is a schematic perspective view of the rotary motor 1 according to Embodiment 2 of this disclosure. Figure 13 As shown, the rotary motor 1 includes: an annular rotor 2 having a central axis 50 as the axis of rotation; and an annular stator 3 including a stator core 30 and a plurality of windings 40.

[0110] Figure 14 This is a schematic perspective view of rotor 2 in embodiment 2. Figure 14 As shown, rotor 2 includes an annular outer rotor core 20A and an annular inner rotor core 20B. Additionally, rotor 2 includes a plurality of magnets 22 disposed on the outer rotor core 20A and the inner rotor core 20B. The outer rotor core 20A is disposed radially outward of stator core 30 with a predetermined gap. The inner rotor core 20B is disposed radially inward of stator core 30 with a predetermined gap. Rotor 2 is rotatable relative to stator 3 about a central axis 50. This predetermined gap is an example of a first gap.

[0111] Figure 15 This is a schematic perspective view of the stator core 30 according to Embodiment 2. Figure 15As shown, the stator core 30 has the same central axis 50 as the rotor 2 and is configured in a ring shape surrounding the central axis 50. The stator core 30 is disposed radially inside the outer rotor core 20A and radially outside the inner rotor core 20B with a predetermined gap between it and the outer rotor core 20A and the inner rotor core 20B. The stator core 30 has a magnetic yoke 31, a plurality of protrusions 32 and a plurality of slots 33.

[0112] The magnetic yoke 31 is configured in a ring shape to surround the central axis. In addition, the magnetic yoke 31 extends in a cylindrical shape along the axial direction.

[0113] Each protrusion 32 includes an outer protrusion 32A and an inner protrusion 32B. A plurality of outer protrusions 32A are arranged circumferentially around the central axis 50 at predetermined intervals on the outer periphery of the yoke 31. The plurality of outer protrusions 32A extend radially from the outer periphery of the yoke 31 away from the central axis 50. A plurality of inner protrusions 32B are arranged circumferentially around the central axis 50 at predetermined intervals on the inner periphery of the yoke. The plurality of inner protrusions 32B extend radially from the inner periphery of the yoke 31 toward the central axis 50 in a direction opposite to the radial direction. The plurality of outer protrusions 32A and the plurality of inner protrusions 32B extend axially.

[0114] Each groove 33 includes an outer groove 33A and an inner groove 33B. A plurality of outer grooves 33A are arranged around the central axis 50 at predetermined intervals on the outer periphery of the magnetic yoke 31. The plurality of outer grooves 33A extend axially and radially, respectively. The plurality of outer grooves 33A are respectively positioned between two adjacent outer protrusions 32A among the plurality of outer protrusions 32A. A plurality of inner grooves 33B are arranged around the central axis 50 at predetermined intervals on the inner periphery of the magnetic yoke 31. The plurality of inner grooves 33B extend axially and radially, respectively. The plurality of inner grooves 33B are respectively positioned between two adjacent inner protrusions 32B among the plurality of inner protrusions 32B.

[0115] Hereinafter, a portion of the stator 3 will be referred to as unit 60. Unit 60 includes a portion of the yoke 31, one of the plurality of outer slots 33A, and one of the plurality of inner slots 33B. Additionally, unit 60 includes two outer protrusions 32A sandwiching the outer slot 33A and two inner protrusions 32B sandwiching the inner slot 33B. Furthermore, unit 60 includes a winding 40 wound around the yoke 31 via a pair of outer slots 33A and inner slots 33B. The stator 3 has a plurality of units 60 connected in a ring shape.

[0116] Figure 16 This is a schematic perspective view of an example of the winding 40 of Embodiment 2 of this disclosure.

[0117] The winding 40 comprises a plurality of segmented conductors 41 stacked circumferentially. In the rotary electric machine 1, the stacking direction refers to the circumferential direction. The winding 40 is wound in such a way that it extends axially and radially around a yoke 31 located between two protrusions 32 (outer protrusions 32A and inner protrusions 32B) through a pair of outer slots 33A and inner slots 33B. In addition, the winding 40 is wound around a pair of outer slots 33A and inner slots 33B adjacent to the yoke 31.

[0118] The second segment conductor portion 42 refers to a portion of the segment conductor 41 that is opposite to each other in one of the plurality of outer slots 33A and inner slots 33B. One side of the second segment conductor portion 42 of the segment conductor 41 is received in the outer slot 33A, and the other side of the second segment conductor portion 42 of the segment conductor is received in the inner slot 33B. The first segment conductor portion 43 refers to a portion of the segment conductor 41 that is located at the coil end that protrudes axially from the end face 36 of the stator core 30. In Embodiment 2, each segment conductor 41 of the winding 40 included in the unit 60 has two second segment conductor portions 42 located at both radial ends of the yoke 31 and two first segment conductor portions 43 located at both axial ends of the yoke 31.

[0119] Figure 17 This is a schematic perspective view showing an example of unit 60 of stator 3 in embodiment 2. (See diagram below.) Figure 17 As shown, a pair of second-segment conductor portions 42 are disposed in opposing outer grooves 33A and inner grooves 33B located at the radial ends of the yoke 31. The first-segment conductor portion 43 protrudes from the axial end face 36 of the yoke 31. Figure 17 In the middle, winding 40 is wound around yoke 31. In addition, winding 40 is wound on a pair of outer slots 33A and inner slots 33B.

[0120] The winding 40 can be configured such that the first segment conductor portion 43 is bent in the stacking direction, that is, circumferentially. One direction in the circumferential direction is an example of the first direction. The other direction in the circumferential direction is an example of the second direction. For example, it is also possible that the first segment conductor portion 43 of the first group of the first segment conductor portions 43, as part of a plurality of first segment conductor portions 43, is bent circumferentially toward one of the two protrusions 32 that sandwich the outer groove 33A and the inner groove 33B. Alternatively, it is also possible that the first segment conductor portion 43 of the second group of the first segment conductor portions 43, which is different from the first group of first segment conductor portions 43, is bent circumferentially toward the other of the two protrusions 32. In addition, the winding 40 can also be configured such that at least a portion of the first segment conductor portion 43 is bent circumferentially only toward one of the two protrusions 32 that sandwich the outer groove 33A and the inner groove 33B.

[0121] Furthermore, the first segment conductor portion 43 of each segment conductor 41 may be configured such that the thickness of the first segment conductor portion 43 varies in at least one direction, either axial or circumferential. The thickness of the first segment conductor portion 43 may also be defined as the minimum value among the dimensions of the segment conductor 41 at the coil end in a radially orthogonal direction on the cut end face of the segment conductor 41 after being cut with an imaginary plane parallel to an imaginary plane formed along the axial and stacking directions. Hereinafter, in Embodiment 2, the imaginary plane parallel to the imaginary plane formed along the axial and stacking directions, i.e., the circumferential direction, is also referred to as the "first plane." The first plane may also refer to an imaginary plane parallel to an imaginary plane formed along the tangential direction relative to the central axis 50 and the axial direction of each segment conductor 41.

[0122] With this configuration, the stator 3 with the winding 40 wound in a ring-shaped manner and the stator 3 with the winding 40 wound in a concentrated manner can both be configured such that the length of the first segment conductor portion 43 is shorter.

[0123] [Effect]

[0124] The stator 3 according to Embodiment 2 of this disclosure can achieve the following effects.

[0125] The stator 3 includes a plurality of windings 40 and an annular stator core 30 surrounding a central axis 50. The stator core 30 has a plurality of slots 33 arranged at predetermined intervals in the circumferential direction around the central axis 50 and extending radially and axially parallel to the central axis 50. The plurality of windings 40 include a plurality of segmented conductors 41 stacked in a circumferential stacking direction and wound around each slot 33. Each segmented conductor 41 includes a pair of second segmented conductor portions 42 disposed in a pair of opposing slots 33 and a first segmented conductor portion 43 disposed at a coil end protruding axially from an axial end face 36 of the stator core. A portion of the first segmented conductor portions 43 of the plurality of segmented conductors 41 is configured to be bent in the stacking direction. A first group of first segmented conductor portions 43, which is a portion of the plurality of first segmented conductor portions 43, is configured to be bent in a first direction, which is the stacking direction. As a part of the second group of first-segment conductor portion 43, which is different from the first segment conductor portion 43 of the first group, the first segment conductor portion 43 is configured to be bent in a second direction opposite to the first direction. Multiple segment conductors 41 are stacked in the circumferential direction. The first direction and the second direction are two opposite directions in the circumferential direction.

[0126] According to this structure, the first segment conductor portion 43 of the first group bends in a predetermined direction in the circumferential direction, and the first segment conductor portion 43 of the second group bends in a direction opposite to the predetermined direction in the circumferential direction. Therefore, compared with the case where the first segment conductor portion 43 bends only in one direction in the circumferential direction of the stator core 30, the axial protrusion length of the first segment conductor portion 43 can be shortened. Therefore, the stator 3 can be miniaturized.

[0127] Furthermore, in the stator 3, each winding 40 is wound in a ring-shaped manner. With this structure, the protruding length of the first segment conductor portion 43 in the stator 3, where the windings 40 are wound in a ring-shaped manner, can be shortened. Therefore, the stator 3 can be miniaturized. Additionally, the rotary electric machine 1 having this stator 3 can be miniaturized.

[0128] (Implementation Method 3)

[0129] The general outline of the rotary motor 1 in Embodiment 3 will be described. In Embodiment 3, the differences from Embodiment 1 will be mainly explained. In Embodiment 3, the same reference numerals will be used to describe the same or equivalent components as in Embodiment 1. In addition, in Embodiment 3, descriptions that are repeated in Embodiment 1 are sometimes omitted.

[0130] As described above, in Embodiment 1, the cross-sectional area of ​​the second segment conductor portion 42 in the second plane of each segment conductor 41 of the winding 40 is substantially equal to the cross-sectional area of ​​the first segment conductor portion 43 in the first plane. In Embodiment 3, the rotary motor 1 of Embodiment 3 differs from the rotary motor 1 of Embodiment 1 in that the cross-sectional area of ​​the first segment conductor portion 43 in the first plane is larger than the cross-sectional area of ​​the second segment conductor portion 42 in the second plane. Similarly to Embodiment 1, in Embodiment 3, the "first plane" refers to an imaginary plane parallel to an imaginary plane formed along the axial and stacking directions, i.e., radially.

[0131] Figure 18 This is a schematic perspective view showing an example of unit 60 of stator 3 according to Embodiment 3 of this disclosure. Figure 18 Only a portion of unit 60 is shown in the diagram. Similar to unit 60 of embodiment 1, in embodiment 3, a pair of second segment conductor portions 42 of each segment conductor of the winding 40 are disposed in a pair of opposing slots 33 located at the circumferential ends of the protrusion 32. The first segment conductor portion 43 protrudes from the axial end face 36 of the protrusion 32. Furthermore, with... Figure 5 Similarly, in the unit 60 shown in Embodiment 3, the first segment conductor portion 43 protrudes from the axial end face of the protrusion 32 in the -Z direction.

[0132] The stator 3 of embodiment 3 has a plurality of units 60 connected in a ring.

[0133] Figure 19 yes Figure 18 A cross-sectional view of a portion of unit 60 along line XIX-XIX. Figure 19 The diagram shows the representation in Figure 18 An end face view of a portion of the cut end face of element 60 after being cut along line XIX-XIX with the first plane. Figure 19 The diagram shows the cut end face of the first segment conductor portion 43, the protrusion 32, and a portion of the cut end face of the yoke 31. Furthermore, the end face view in the second plane associated with unit 60 of embodiment 3 is shown. Figure 6 Same. Dimension D4 represents the axial dimension between the axial end of the first segment conductor portion 43 that protrudes most axially from the stator core 30 in the winding 40 of Embodiment 3 and the axial end face 36 of the stator core 30.

[0134] As described above, the first segment conductor portion 43 of each segment conductor 41 protrudes axially from the end face 36 of the stator core 30. In Embodiment 3, the winding 40 is formed such that the cross-sectional area of ​​the first segment conductor portion 43 in the first plane is larger than the cross-sectional area of ​​the second segment conductor portion 42 in the second plane. For example, in Embodiment 3, the cross-sectional area of ​​the first segment conductor portion 43 in the first plane is twice the cross-sectional area of ​​the second segment conductor portion 42 in the second plane.

[0135] At least a portion of the plurality of first segment conductor portions 43 are configured such that the thickness of the first segment conductor portion 43 varies in at least one direction, either axial or radial. Furthermore, in Embodiment 3, at least a portion of the first segment conductor portions 43 are formed such that the thickness of the first segment conductor portion 43 in the first plane is greater than the thickness of the first segment conductor portion 43 in Embodiment 1. Additionally, in Embodiment 3, at least a portion of the first segment conductor portions 43 are formed to extend longer in a radial direction or in a direction opposite to the radial direction than the first segment conductor portion 43 in Embodiment 1.

[0136] Furthermore, the first segment conductor portion 43 of the first group, which is part of a plurality of first segment conductor portions 43, bends radially. The first segment conductor portion 43 of the second group, which is a part of the first segment conductor portion 43 different from the first group, bends in the opposite direction to the radial direction.

[0137] By forming it in this way, the cross-sectional area of ​​the first segment conductor portion 43 in the first plane can be configured to be larger than the cross-sectional area of ​​the second segment conductor portion 42 in the second plane. Furthermore, by forming it in this way, the winding 40 can be formed such that the cross-sectional area of ​​the first segment conductor portion 43 in the first plane is larger than the cross-sectional area of ​​the first segment conductor portion 43 in the first plane in the comparative example described above, and the lengthening of dimension D4 is suppressed. For example, the winding 40 can be formed such that dimension D4 is smaller than dimension D2 in the comparative example.

[0138] With this structure, the cross-sectional area of ​​the first conductor segment 43 is larger than that of the second conductor segment 42, which reduces copper losses in the first conductor segment 43. Furthermore, compared to the case where the first conductor segment 43 extends axially like in the comparative example unit 60, unit 60 can be configured such that the cross-sectional area of ​​the first conductor segment 43 is larger than that of the second conductor segment 42 without increasing the axial length of the coil ends. As a result, the temperature rise during operation of the stator 3 constructed based on the unit 60 having this first conductor segment 43 can be suppressed. Suppressing the temperature rise during stator 3 operation can include, for example, reducing the heat generation of the stator 3's components. Additionally, suppressing the temperature rise during stator 3 operation can also include improving the heat dissipation performance of the stator 3's components.

[0139] Furthermore, in the case of a rotary motor 1 where the rotor 2 is located radially inside the stator 3, the first segment conductor portion 43 located on the outer side of the rotor 2 links with the magnetic flux from the rotor 2. When the first segment conductor portion 43 is not bent in a radially or oppositely direction as shown in the comparative example, it links with a large amount of magnetic flux. In contrast, when the first segment conductor portion 43 is bent in a radially or oppositely direction as described above, the magnetic flux linking with the first segment conductor portion 43 is less compared to the comparative example. Therefore, according to embodiment 3, compared to the stator 3 based on unit 60 shown in the comparative example, the eddy current generated in the first segment conductor portion 43 due to this magnetic flux is smaller, and the heating of the stator 3 can be suppressed.

[0140] Thus, according to the stator 3 of embodiment 3, the heating of the rotary motor 1 when the rotary motor 1 containing the stator 3 is in operation can be suppressed, thereby increasing the amount of current supplied to the rotary motor 1 and improving the performance of the rotary motor 1.

[0141] (Variation Example 2)

[0142] A variation 2 of unit 60 in embodiment 3 will be described. In variation 2, the main focus is on... Figure 18 The differences in the examples shown will be explained. In variation example 2, the differences between... Figure 18The same or equivalent constituent elements shown in the examples are labeled with the same reference numerals. Additionally, in variation 2, sometimes the same reference numerals are omitted. Figure 18 The example shown is a repeated record.

[0143] Figure 20 This is a cross-sectional end view showing a portion of unit 60 in Modified Example 2 of stator 3 according to Embodiment 3. Figure 20 The diagram illustrates the relationship between... Figure 7 The end view shown is similarly a partial end view of the cut end face of element 60 of modified example 2, after being cut along the first plane. Figure 20 The image shows the cut end face of the first segment conductor portion 43, the protrusion 32, and a portion of the cut end face of the magnetic yoke 31. (Compared to...) Figure 20 The end face in the second plane associated with the unit 60 shown is... Figure 6 Similarly, it is constructed. Dimension D5 represents the axial dimension between the axial end of the first segment conductor portion 43 that protrudes most axially from the stator core 30 in the winding 40 of Modified Example 2 and the axial end face 36 of the stator core 30.

[0144] and Figure 18 Similarly, in the example shown, in variation 2, the winding 40 is formed such that the cross-sectional area of ​​the first segment conductor portion 43 in the first plane is twice the cross-sectional area of ​​the second segment conductor portion 42 in the second plane.

[0145] In Modification 2, the winding 40 bends only radially. For example, the first segment conductor portion 43F located on the outer periphery of the stator core 30 among the plurality of first segment conductor portions 43 extends radially. Furthermore, the first segment conductor portion 43G located on the inner periphery of the stator core 30 among the plurality of first segment conductor portions 43 does not extend in the direction opposite to radial; only the axial end of the first segment conductor portion 43G extends radially. Additionally, a portion of the plurality of first segment conductor portions 43 is configured such that the thickness of this first segment conductor portion 43 varies in at least one direction, either axial or radial.

[0146] Thus, the winding 40 can also be configured such that the first segment conductor portion 43 bends only radially or only in the direction opposite to radial. With this structure, even if the dimension between the first segment conductor portion 43 located on the inner circumferential side of the stator core 30 and the inner circumferential end face of the stator core 30 is small, the cross-sectional area can be increased while suppressing the increase in dimension D5. Therefore, even with spatial constraints, the stator 3 can increase the cross-sectional area while suppressing the increase in the axial protrusion length of the first segment conductor portion 43.

[0147] (Variation Example 3)

[0148] A variation 3 of unit 60 in embodiment 3 will be described. In variation 3, the main focus is on... Figure 18 The differences in the examples shown will be explained. In variation 3, the differences between... Figure 18 The same or equivalent constituent elements shown in the examples are labeled with the same reference numerals. Additionally, in variation 3, sometimes the reference numerals are omitted. Figure 18 The example shown is a repeated record.

[0149] Figure 21 This is a cross-sectional end view of a portion of unit 60 in Modified Example 3, which shows unit 60 of stator 3 in Embodiment 3. Figure 21 The diagram illustrates the relationship between... Figure 7 The end view shown is similarly a partial end view of the cut end face of element 60 of modified example 3, after being cut along the first plane. Figure 21 The image shows the cut end face of the first segment conductor portion 43, the protrusion 32, and a portion of the cut end face of the magnetic yoke 31. (Compared to...) Figure 21 The end face in the second plane associated with the unit 60 shown is... Figure 6 It is constructed in the same way.

[0150] In variation 3, the winding 40 is configured such that the cross-sectional area ratio of the first segment conductor portion 43 in the first plane is... Figure 18 The cross-sectional area of ​​the first segment conductor portion 43 in the example shown is even larger. For example, in Modified Example 3, the cross-sectional area of ​​the first segment conductor portion 43 in the first plane is four times the cross-sectional area of ​​the second segment conductor portion 42 in the second plane.

[0151] According to this structure, compared with Modification 2, the copper loss of the first segment conductor portion 43 can be further reduced, and the temperature rise of the stator 3 can be suppressed. For example, compared with Modification 2, the heating of the first segment conductor portion 43 when the rotary motor 1 is operating can be suppressed. Therefore, the heating of the rotary motor 1 when it is operating can be suppressed, thus increasing the amount of current supplied to the rotary motor 1 and improving the performance of the rotary motor 1.

[0152] (Variation Example 4)

[0153] A variation 4 of unit 60 in embodiment 3 will be described. In variation 4, the main focus is on... Figure 18 The differences in the examples shown will be explained. In variation 4, the differences between... Figure 18 The same or equivalent constituent elements shown in the examples are labeled with the same reference numerals. Additionally, in variation 4, sometimes the reference numerals are omitted. Figure 18 The example shown is a repeated record.

[0154] Figure 22This is a cross-sectional end view of a portion of unit 60 in variant 4 of stator 3 according to embodiment 3. Figure 22 The diagram illustrates the relationship between... Figure 7 The end view shown is similarly a partial end view of the cut end face of element 60 of modified example 4, after being cut along the first plane. Figure 22 The image shows the cut end face of the first segment conductor portion 43, the protrusion 32, and a portion of the cut end face of the magnetic yoke 31. (Compared to...) Figure 22 The end face in the second plane associated with the unit 60 shown is... Figure 6 It is constructed in the same way.

[0155] In Modification 4, the winding 40 is configured such that the cross-sectional area of ​​the first segment conductor portion 43 in the first plane is larger than the cross-sectional area of ​​the second segment conductor portion 42 in the second plane. Furthermore, the winding 40 is configured such that, in the first plane, the cross-sectional areas of the inner first segment conductor portions 43H and 43I near the central axis 50 are larger than the cross-sectional areas of the outer first segment conductor portions 43J and 43K away from the central axis 50. The inner first segment conductor portions 43H and 43I are examples of a plurality of first segment conductor portions 43 that are radially positioned inside the first segment conductor portion 43 near the central axis 50. The outer first segment conductor portions 43J and 43K are examples of a plurality of first segment conductor portions 43 that are radially positioned outside the first segment conductor portion 43 away from the central axis 50. For example, in Variation 4, the cross-sectional area of ​​the inner conductor portions 43H and 43I of the first segment in the first plane is four times the cross-sectional area of ​​the conductor portion 42 of the second segment in the second plane. Furthermore, the cross-sectional area of ​​the outer conductor portions 43J and 43K of the first segment in the first plane is twice the cross-sectional area of ​​the conductor portion 42 of the second segment in the second plane. The outer conductor portions 43J and 43K of the first segment are examples of the conductor portion 43 of the first segment in the first group. The inner conductor portions 43H and 43I of the first segment are examples of the conductor portion 43 of the first segment in the second group.

[0156] In the case of a rotary motor 1 where the rotor 2 is located radially inside the stator 3, the inner conductor portions 43H and 43I of the first segment have more magnetic flux linkages with the rotor 2 compared to the outer conductor portions 43J and 43K of the first segment. Therefore, the inner conductor portions 43H and 43I of the first segment are more prone to heat generation and temperature rise compared to the outer conductor portions 43J and 43K of the first segment. Furthermore, the housing of the rotary motor 1 is located further away from the central axis 50 than the outer conductor portions 43J and 43K of the first segment. The heat generated in the conductor portion 43 can dissipate from the housing. In this respect, the inner conductor portions 43H and 43I of the first segment are also more prone to temperature rise compared to the outer conductor portions 43J and 43K of the first segment.

[0157] According to element 60 of Modified Example 4, the first cross-sectional area of ​​the inner conductor portions 43H and 43I of the first segment is larger than the first cross-sectional area of ​​the outer conductor portions 43J and 43K of the first segment. Therefore, the heat dissipation performance of the inner conductor portions 43H and 43I of the first segment is improved compared with that of the outer conductor portions 43J and 43K of the first segment.

[0158] According to this structure, compared with the unit 60 shown in Modified Example 3, it is possible to suppress the increase in the axial protrusion length of the first segment conductor portion 43, and with Figure 18 Compared to the unit 60 shown, the temperature rise at the coil end can be suppressed. Furthermore, the temperature rise of the stator 3 having this unit 60 can be effectively suppressed. Therefore, the heating of the rotary motor 1 during operation can be suppressed, thus increasing the amount of current supplied to the rotary motor 1 and improving its performance.

[0159] In embodiment 3, the first cross-sectional area is configured to be two or four times the second cross-sectional area, but the ratio of the cross-sectional areas is not limited to two or four times. The first cross-sectional area can be configured to be larger than the second cross-sectional area. For example, the first cross-sectional area can also be configured to be 1.1 times, 1.2 times, ..., 1.5 times, ..., 2.0 times, 2.1 times, ..., 3.0 times, ..., 4.0 times, ... or 5.0 times the second cross-sectional area.

[0160] In Embodiment 3, the first cross-sectional area of ​​the first segment conductor portion 43 disposed on the inner side is configured to be substantially equal to or twice the first cross-sectional area of ​​the first segment conductor portion 43 disposed on the outer side, but the ratio of the cross-sectional areas is not limited to the ratio described above. The first cross-sectional areas of the first segment conductor portion 43 disposed on the inner side and the first cross-sectional areas of the first segment conductor portion 43 disposed on the outer side may be configured to have different sizes. The first cross-sectional area of ​​the first segment conductor portion 43 disposed on the inner side may be greater than or equal to the first cross-sectional area of ​​the first segment conductor portion 43 disposed on the outer side. For example, the first cross-sectional area of ​​the first segment conductor portion 43 disposed on the inner side may be 1.1 times, 1.2 times, ..., 1.5 times, ..., 2.0 times, 2.1 times, ..., 3.0 times, ..., 4.0 times, ..., or 5.0 times that of the first segment conductor portion 43 disposed on the outer side. Alternatively, the first cross-sectional area of ​​the first segment conductor portion 43 disposed on the outer side may be greater than or equal to the first cross-sectional area of ​​the first segment conductor portion 43 disposed on the inner side.

[0161] In Embodiment 3 described above, the winding 40 is wound around the protrusion 32 of the stator core 30 in a concentrated manner, but the winding method of the winding 40 is not limited to concentrated winding. Similar to the example shown in Embodiment 2, in the unit 60 shown in Embodiment 3, the winding 40 may also be wound around the protrusion 32 in a ring-shaped manner.

[0162] [Effect]

[0163] The stator 3 according to Embodiment 3 of this disclosure can achieve the following effects.

[0164] The stator 3 includes a plurality of windings 40 and an annular stator core 30 surrounding a central axis 50. The stator core 30 has a plurality of slots 33 arranged at predetermined intervals in the circumferential direction around the central axis 50 and extending radially and axially parallel to the central axis 50. The plurality of windings 40 include a plurality of segmented conductors 41 stacked in a radial or circumferential stacking direction and wound around each slot 33. Each segmented conductor 41 includes a first segmented conductor portion 43 disposed at a coil end protruding axially from an end face 36 of the stator core and a pair of second segmented conductor portions 42 disposed in a pair of opposing slots 33. The first cross-sectional area of ​​each of the first segmented conductor portions 43 of the plurality of segmented conductors 41, in a first plane parallel to a plane formed along the stacking direction and axial direction, is larger than the second cross-sectional area of ​​each of the second segmented conductor portions 42 of the plurality of segmented conductors 41, in a second plane perpendicular to the axial direction.

[0165] With this structure, the cross-sectional area of ​​the first conductor segment 43 is larger than that of the second conductor segment 42, thus reducing the copper loss of the first conductor segment 43 compared to the copper loss of the second conductor segment 42. By reducing the copper loss of the first conductor segment 43, the heating of the first conductor segment 43 can be suppressed. Therefore, the temperature rise of the stator 3 constructed based on the unit 60 including the first conductor segment 43 can be suppressed.

[0166] Furthermore, in the stator 3, the first segment conductor portion 43 of a portion of the multiple segment conductors 41 is configured to be bent in the stacking direction. With this structure, the axial protrusion length of the first segment conductor portion 43 located at the coil end in the winding 40 can be shortened in the stator 3. In other words, compared to the case where the first segment conductor portion 43 is not bent, the first segment conductor portion 43 can be made shorter. Therefore, the stator 3 can be miniaturized while suppressing temperature rise.

[0167] Furthermore, in the stator 3, the first cross-sectional area of ​​the first group of first segment conductor portions 43, which are part of a plurality of first segment conductor portions 43, has a different size than the first cross-sectional area of ​​the second group of first segment conductor portions 43. This second group of first segment conductor portions 43 is a different portion of the first segment conductor portions 43 from the first group. With this structure, copper losses in a portion of the plurality of first segment conductor portions 43 can be reduced. Therefore, by selectively increasing the first cross-sectional area of ​​the first segment conductor portion 43 that generates more heat than the other first segment conductor portions 43, the temperature rise of the stator 3 can be suppressed.

[0168] Furthermore, in the stator 3, each winding 40 is formed using a lamination molding method. By using the lamination molding method to form the winding 40, the thickness of the first segment conductor portion 43, which constitutes each segment conductor 41, varies in at least one direction, either axially or radially. Therefore, the first cross-sectional area can be made larger than the second cross-sectional area, which can suppress the temperature rise of the stator 3.

[0169] Furthermore, in the stator 3, a plurality of segmented conductors 41 are stacked radially. A plurality of first segmented conductor portions 43 include a first segment inner conductor portion 43H radially disposed inside the center axis 50 and a first segment outer conductor portion 43K radially disposed outside the center axis 50, further away from the first segment inner conductor portion 43H. The first cross-sectional area of ​​the first segment inner conductor portion 43H is configured to be greater than or equal to the first cross-sectional area of ​​the first segment outer conductor portion 43K.

[0170] The inner conductor portion 43H of the first segment, which is closer to the central axis 50, may generate more heat than the outer conductor portion 43K of the first segment, which is farther from the central axis 50. For example, the inner conductor portion 43H may generate more heat due to eddy currents generated by the magnetic flux from the rotor 2 when the rotating motor 1 is operating, compared to the outer conductor portion 43K. According to the above structure, the first cross-sectional area of ​​the inner conductor portion 43H is larger than the first cross-sectional area of ​​the outer conductor portion 43K. As a result, the temperature rise of the inner conductor portion 43H, which may generate more heat, can be suppressed, thus effectively suppressing the temperature rise of the stator 3.

[0171] Furthermore, in the stator 3, each winding 40 is wound in a concentrated manner. In this way, with the windings 40 wound in a concentrated manner within the stator core 30, the first cross-sectional area of ​​the first segment conductor portion 43 can be made larger than the second cross-sectional area of ​​the second segment conductor portion 42. Therefore, it is possible to suppress temperature rise in the stator 3 constructed based on the unit 60 containing the first segment conductor portion 43.

[0172] Furthermore, in the stator 3, multiple segmented conductors 41 are stacked circumferentially. Each winding 40 is wound in a ring-shaped manner. In this way, in the stator 3 where the windings 40 are wound in a ring-shaped manner within the stator core 30, the first cross-sectional area of ​​the first segmented conductor portion 43 can be made larger than the second cross-sectional area of ​​the second segmented conductor portion 42. Therefore, it is possible to suppress the temperature rise of the stator 3 constructed based on the unit 60 containing the first segmented conductor portion 43.

[0173] The rotary electric motor 1 includes: a housing 4; the aforementioned stator 3; and a rotor 2, which is disposed on at least one of the radially inner and radially outer sides of the stator 3 with a first gap, and is capable of rotating about a central axis 50. The stator 3 and the rotor 2 are housed in the housing 4. Since the first cross-sectional area of ​​the first segment conductor portion 43 in the stator 3 is larger than the second cross-sectional area of ​​the second segment conductor portion 42, the temperature rise of the rotary electric motor 1 can be suppressed.

[0174] (Implementation Method 4)

[0175] The general outline of the rotary motor 1 in Embodiment 4 will be described. In Embodiment 4, the differences from Embodiment 3 will be mainly explained. In Embodiment 4, the same reference numerals will be used to describe the same or equivalent components as in Embodiment 3. In addition, in Embodiment 4, descriptions that are repeated in Embodiment 3 are sometimes omitted.

[0176] like Figure 18 As shown, in Embodiment 3, the ends of a portion of the plurality of first segment conductor portions 43, specifically the ends located radially inward, are configured as straight lines. Additionally, the ends of a portion of the plurality of first segment conductor portions 43, specifically the ends located radially outward, are configured as straight lines. In Embodiment 4, the rotary motor 1 of Embodiment 4 differs from the rotary motor 1 of Embodiment 3 in that at least a portion of the ends of the first segment conductor portions 43 are configured to have curvature along the inner or outer circumference of the stator core 30. Similar to Embodiment 1, in Embodiment 4, the "first plane" refers to an imaginary plane parallel to an imaginary plane formed along the axial and stacking directions, i.e., radially.

[0177] Figure 23This is a schematic perspective view showing an example of unit 60 of stator 3 in Embodiment 4 of this disclosure. Figure 23 Only a portion of unit 60 is shown in the diagram. Similar to unit 60 of embodiment 3, in embodiment 4, a pair of second segment conductor portions 42 of each segment conductor of the winding 40 are disposed in a pair of opposing slots 33 located at the circumferential ends of the protrusion 32. The first segment conductor portion 43 protrudes from the axial end face 36 of the protrusion 32. Furthermore, with... Figure 5 Similarly, in the unit 60 shown in Embodiment 4, the first segment conductor portion 43 protrudes from the axial end face of the protrusion 32 in the -Z direction.

[0178] Similar to embodiment 3, the stator 3 of embodiment 4 has a plurality of units 60 connected in a ring.

[0179] A portion of the plurality of first-segment conductor portions 43 has an end 45 located radially inward and having curvature along the inner periphery of the stator core 30. Additionally, a portion of the plurality of first-segment conductor portions 43 has an end 46 located radially outward and having curvature along the outer periphery of the stator core 30.

[0180] With this structure, the cross-sectional area of ​​the first segment conductor portion 43 in the first plane of the winding 40 is increased. Compared with the stator 3 having a winding 40 with straight ends 45 and 46, the heat dissipation performance of the stator 3 having the winding 40 of embodiment 4 is improved. Therefore, the heat generation of the rotary motor 1 during operation can be suppressed, thus increasing the amount of current supplied to the rotary motor 1 and improving the performance of the rotary motor 1.

[0181] Figure 24 yes Figure 23 A cross-sectional end view of a portion of unit 60 along line XXIV-XXIV. Figure 24 The diagram shows the representation in Figure 23 An end face view of a portion of the cut end face of element 60 after being cut along line XXIV-XXIV with the first plane. Figure 24 The diagram shows the cut end face of the first segment conductor portion 43, the protrusion 32, and a portion of the cut end face of the yoke 31. Furthermore, the end face view in the second plane associated with unit 60 of embodiment 4 is shown. Figure 6 same.

[0182] like Figure 24As shown, the first segment conductor portion 43L is formed to extend in a direction toward the central axis 50. That is, the first segment conductor portion 43L is formed to bend in a direction opposite to the radial direction. The first segment conductor portion 43M is formed to extend axially away from the stator core 30, and the axial end of the first segment conductor portion 43M extends in both radial and radially opposite directions. That is, the first segment conductor portion 43M is formed to bend radially and radially opposite directions. The first segment conductor portion 43N is formed to extend in a direction away from the central axis 50, and the radially outer end of the first segment conductor portion 43N extends axially away from the stator core 30. That is, the first segment conductor portion 43N is formed to bend radially and then axially away from the stator core 30.

[0183] Based on this structure, the cross-sectional area ratio of each first segment conductor portion 43 in the first plane is, for example... Figure 5 In the example shown, the cross-sectional area of ​​each first segment conductor portion 43 is large, which reduces copper loss in the first segment conductor portion 43. Furthermore, compared to the case where the first segment conductor portion 43 extends only axially, the axial protrusion length of the first segment conductor portion 43 can be shortened. As a result, the temperature rise of the stator 3 can be suppressed while preventing the stator 3 from becoming too large based on the unit 60 having the first segment conductor portion 43. Therefore, the heating of the rotary motor 1 during operation can be suppressed, thus increasing the amount of current supplied to the rotary motor 1 and improving its performance.

[0184] (Variation Example 5)

[0185] A variation 5 of unit 60 in embodiment 4 will be described. In variation 5, the main focus is on... Figure 24 The differences in the examples shown will be explained. In variation 5, the differences between... Figure 24 The same or equivalent constituent elements shown in the examples are labeled with the same reference numerals. Additionally, in variation 5, sometimes the reference numerals are omitted. Figure 24 The example shown is a repeated record.

[0186] Figure 25 This is a cross-sectional end view of a portion of unit 60 in variant 5 of stator 3 according to embodiment 4. Figure 25 The diagram illustrates the relationship between... Figure 24 The end view shown is similarly a partial end view of the cut end face of element 60 of modified example 5, after being cut along the first plane. Figure 25 The image shows the cut end face of the first segment conductor portion 43, the protrusion 32, and a portion of the cut end face of the magnetic yoke 31. (Compared to...) Figure 25 The end face in the second plane associated with the unit 60 shown is... Figure 6 It is constructed in the same way.

[0187] like Figure 25 As shown, the first segment conductor portion 43P is formed to extend in a direction away from the central axis 50. That is, the first segment conductor portion 43P is formed to bend radially.

[0188] Based on this structure, and Figure 25 Similarly, the example shown can suppress the increase in temperature of the stator 3 while suppressing the enlargement of the stator 3 constructed based on the unit 60 having the first segment conductor portion 43. Therefore, the heating of the rotary motor 1 during operation can be suppressed, thus increasing the amount of current supplied to the rotary motor 1 and improving its performance.

[0189] (Example 1)

[0190] Example 1 of the rotary motor 1 using the modified example 5 of the unit 60 of embodiment 4 will be described. Figure 26 This is a cross-sectional end view showing a portion of the rotary electric machine 1 using Modified Example 5. Figure 26 In addition to Figure 24 In addition to the end face shown, a portion of the end face of the housing 4 of the rotary motor 1 in the first plane is also shown. As described above, the housing 4 houses the rotor 2 and the stator 3. The first segment conductor portion 43 includes an axial end 47 located axially away from the stator core 30 and a radial end 46 located radially away from the central axis 50. At least one of the ends 46 and 47 is an example of a predetermined end.

[0191] like Figure 25 As shown, the rotary motor 1 has a predetermined gap Da between the axial end 47 of the first segment conductor portion 43 and the inner surface of the housing 4. Additionally, the rotary motor 1 has a predetermined gap Db between the radial end 46 of the first segment conductor portion 43 and the inner surface of the housing 4. The predetermined gaps Da and Db are examples of a second gap.

[0192] In Modification 5, the axial end 47 of the first segment conductor portion 43 of the unit 60 is configured to extend along an imaginary plane perpendicular to the axial direction, with a predetermined gap Da between the end 47 and the inner surface of the housing 4. That is, the axial end 47 of the first segment conductor portion 43 is formed flatly along the housing 4. Furthermore, the radial end 46 of the first segment conductor portion 43 is configured to extend along the inner surface of the housing 4, with a predetermined gap Db between the end 46 and the inner surface of the housing 4.

[0193] With this structure, the end of the first segment conductor portion 43 is positioned close to the housing 4, and the heat from the first segment conductor portion 43 is effectively conducted to the housing 4. Therefore, the heat dissipation performance of the rotary motor 1 according to Embodiment 1 is improved compared to a rotary motor not configured as described above. Consequently, the temperature rise of the rotary motor 1 during operation can be suppressed, thus increasing the amount of current supplied to the rotary motor 1 and improving its performance.

[0194] In addition, Figure 26 In the illustrated embodiment, the stator core 30 is located in the first plane at a position separated from the housing 4 by a predetermined gap, but the position of the stator core 30 is not limited to this. For example, the stator core 30 may also be disposed within the housing 4 in contact with the inner surface of the housing 4 without being separated by the predetermined gap.

[0195] In Embodiment 1, the first segment conductor portion 43 has ends 47 and 46 with predetermined gaps Da and Db between it and the inner surface of the housing 4, but the first segment conductor portion 43 is not limited to this structure. For example, the first segment conductor portion 43 may only have an end 47 with a predetermined gap Da between it and the inner surface of the housing 4. Alternatively, the first segment conductor portion 43 may only have an end 46 with a predetermined gap Db between it and the inner surface of the housing 4.

[0196] (Example 2)

[0197] Example 2, which differs from Example 1, will be described. In Example 2, the main focus is on the rotary motor 1... Figure 26 The differences between the examples shown will be explained. In Example 2, the differences between... Figure 26 The same or equivalent components shown in the examples are described using the same reference numerals. Additionally, in Embodiment 2, sometimes the same reference numerals are omitted. Figure 26 The example shown is a repeated record.

[0198] Figure 27 This is a cross-sectional end view showing a portion of the rotary electric machine 1 using Modified Example 5. Figure 27 The rotary motor 1 shown also includes a heat sink 80. Figure 27 In addition to Figure 26 In addition to the end face shown, a portion of the end face of the heat sink 80 is also shown. The heat sink 80 is a sheet material having a thermal conductivity at least higher than that of air. The heat sink 80 may, for example, be a silicon-based heat sink.

[0199] like Figure 27As shown, in Embodiment 2, the heat sink 80 is configured to cover the first segment conductor portion 43. Furthermore, the heat sink 80 is disposed between predetermined gaps Da and Db. While the heat sink 80 is configured to cover the first segment conductor portion 43 in Embodiment 2, the position of the heat sink 80 is not limited to this. For example, the heat sink 80 may also be disposed between at least one of the predetermined gaps Da and Db.

[0200] According to this structure, the heat from the first segment conductor portion 43 is effectively conducted to the housing 4 via the heat dissipation fin 80. Therefore, the heat dissipation performance of the rotary motor 1 according to Embodiment 2 is improved compared to the rotary motor 1 of Embodiment 1. Consequently, the temperature rise of the rotary motor 1 during operation can be suppressed, thus increasing the amount of current supplied to the rotary motor 1 and improving its performance.

[0201] (Example 3)

[0202] Example 3, which differs from Examples 1 and 2, will be described. In Example 3, the main focus is on the rotary motor 1... Figure 26 The differences between the examples shown will be explained. In Example 3, the differences between the examples shown and the examples shown will be explained. Figure 26 The same or equivalent components shown in the examples are described using the same reference numerals. Additionally, in Embodiment 3, sometimes the same reference numerals are omitted. Figure 26 The example shown is a repeated record.

[0203] Figure 28 This is a cross-sectional end view showing a portion of the rotary electric machine 1 using Modified Example 5. Figure 28 The rotary motor 1 shown also includes resin 81. In Figure 27 In addition to Figure 26 In addition to the end face shown, a portion of the end face of resin 81 is also shown. Resin 81 is a material having a thermal conductivity at least higher than that of air. Resin 81 may be, for example, epoxy resin.

[0204] like Figure 28 As shown, in Embodiment 3, resin 81 is configured to cover the first segment conductor portion 43. Additionally, resin 81 is configured in predetermined gaps Da and Db. Resin 81 is configured to fill the gaps between the plurality of first segment conductor portions 43. For example, resin 81 may fill the gaps between the plurality of first segment conductor portions 43. The configuration of resin 81 is not limited to the configuration described above. For example, resin 81 may also be configured in at least one of the gaps between the plurality of first segment conductor portions 43, predetermined gap Da, and predetermined gap Db.

[0205] According to this structure, the heat from the first segment conductor portion 43 is effectively conducted to the housing 4 via the resin 81. Therefore, the heat dissipation performance of the rotary motor 1 according to Embodiment 3 is improved compared to the rotary motor 1 of Embodiment 1 or Embodiment 2. Consequently, the temperature rise of the rotary motor 1 during operation can be suppressed, thus increasing the amount of current supplied to the rotary motor 1 and improving its performance.

[0206] The rotary motor 1 of the above-described embodiments includes Figure 25 The rotating motor 1 shown is a modified example of unit 60, but its structure is not limited to this. For example, the rotating motor 1 in the above embodiment may also include... Figure 24 The example shown is unit 60. Alternatively, the structure of the embodiment can also be applied to unit 60 in the examples shown in embodiments 1 to 3.

[0207] In embodiments 3 and 4 described above, the winding 40 is wound around the protrusion 32 of the stator core 30 in a concentrated manner, but the winding method of the winding 40 is not limited to concentrated winding. Similar to the example shown in embodiment 2, in the unit 60 shown in embodiments 3 and 4, the winding 40 may also be wound around the protrusion 32 in a ring-shaped manner.

[0208] [Effect]

[0209] The stator 3 according to Embodiment 4 of this disclosure can achieve the following effects.

[0210] The stator 3 includes a plurality of windings 40 and an annular stator core 30 surrounding a central axis 50. The stator core 30 has a plurality of slots 33 arranged at predetermined intervals in the circumferential direction around the central axis 50 and extending radially and axially parallel to the central axis 50. The plurality of windings 40 include a plurality of segmented conductors 41 stacked in a radial stacking direction and wound around each slot 33. Each segmented conductor 41 includes a first segmented conductor portion 43 disposed at a coil end protruding axially from an end face 36 of the stator core and a pair of second segmented conductor portions 42 disposed in a pair of opposing slots 33. The first cross-sectional area of ​​each of the first segmented conductor portions 43 of the plurality of segmented conductors 41, in a first plane parallel to a plane formed along the stacking direction and axial direction, is larger than the second cross-sectional area of ​​each of the second segmented conductor portions 42 of the plurality of segmented conductors 41, in a second plane perpendicular to the axial direction.

[0211] In addition, a plurality of segmented conductors 41 are stacked radially. At least one of the plurality of first segmented conductor portions 43 includes at least one of a radially located end 45 having curvature along the inner periphery of the stator core 30 and an end 46 located in the opposite direction to the radial direction having curvature along the outer periphery of the stator core 30.

[0212] According to this structure, the first cross-sectional area of ​​the first segment conductor portion 43 can be increased compared to a structure in which the first segment conductor portion 43 does not have curvature along the inner or outer periphery of the stator core 30. Therefore, it is possible to suppress the temperature rise of the stator 3 constructed based on the unit 60 containing the first segment conductor portion 43.

[0213] The rotary electric motor 1 includes: a housing 4; the aforementioned stator 3; and a rotor 2, which is disposed on at least one of the radially inner and radially outer sides of the stator 3 with a first gap, and is capable of rotating about a central axis 50. The stator 3 and the rotor 2 are housed in the housing 4. Since the first cross-sectional area of ​​the first segment conductor portion 43 in the stator 3 is larger than the second cross-sectional area of ​​the second segment conductor portion 42, the temperature rise of the rotary electric motor 1 can be suppressed.

[0214] Furthermore, in the rotary motor 1, the first segment conductor portion 43 includes a predetermined end, which is at least one of an axial end 47 and a stacking direction end 46. The predetermined end is configured to extend along the inner surface of the housing 4 through a second gap between the predetermined end and the inner surface of the housing 4. With this structure, the first segment conductor portion 43 is disposed close to the housing 4, and the heat of the first segment conductor portion 43 is effectively conducted to the housing 4. The rotary motor 1 configured as described above has improved heat dissipation performance compared to a rotary motor not configured as described above. Therefore, the temperature rise of the rotary motor 1 during operation can be suppressed, thus increasing the amount of current supplied to the rotary motor 1 and improving its performance.

[0215] Furthermore, the rotary motor 1 also includes a heat sink 80 disposed in the second gap. With this structure, heat from the first segment conductor portion 43 is effectively conducted to the housing 4 via the heat sink 80. Therefore, the temperature rise of the rotary motor 1 during operation can be suppressed, thereby increasing the amount of current supplied to the rotary motor 1 and improving its performance.

[0216] Furthermore, the rotary motor 1 also includes a resin 81 disposed in the second gap. With this structure, heat from the first segment conductor portion 43 is effectively conducted to the housing 4 via the resin 81. Therefore, the temperature rise of the rotary motor 1 during operation can be suppressed, thereby increasing the amount of current supplied to the rotary motor 1 and improving its performance.

[0217] (Summary of the plan)

[0218] As can be clearly seen from the above description, this disclosure includes the following solutions. Hereinafter, reference numerals are used in parentheses only to illustrate the correspondence between the solutions and embodiments.

[0219] (Scheme 1) The stator (3) of this disclosure includes:

[0220] A stator core, which is annular and surrounds a central axis (50), the stator core (30) having a plurality of grooves (33) arranged circumferentially at predetermined intervals around the central axis and extending radially and axially parallel to the central axis; and

[0221] Multiple windings (40) comprising multiple segmented conductors (41) stacked in the radial or circumferential stacking direction and wound in each of the slots,

[0222] Each of the segmented conductors includes a first segmented conductor portion (43) disposed at a coil end protruding axially from the end face (36) of the stator core and a pair of second segmented conductor portions (42) disposed in a pair of opposing slots in the plurality of slots.

[0223] The first segment of one of the plurality of segmented conductors is configured to be bent in the stacking direction.

[0224] (Scheme 2) In the stator (3) of Scheme 1, the first segment conductor portion (43) may be configured such that the thickness of the first segment conductor portion varies in at least one of the axial, radial and circumferential directions.

[0225] (Scheme 3) In the stator (3) of Scheme 1 or Scheme 2, the first cross-sectional areas of the first segment conductor portions (43) of each of the plurality of segment conductors (41) are substantially equal to each other in a first plane parallel to the plane formed along the stacking direction and the axial direction.

[0226] (Scheme 4) In the stator (3) of Schemes 1 to 3, the first cross-sectional area of ​​the first segment conductor portion (43) of each of the plurality of segment conductors (41) in a first plane parallel to the plane formed along the stacking direction and the axial direction is substantially equal to the second cross-sectional area of ​​the second segment conductor portion (42) of each of the plurality of segment conductors in a second plane perpendicular to the axial direction.

[0227] (Scheme 5) In any of the schemes 1 to 4, the stator (3) may also be such that the first segment conductor portion of the first group of the first segment conductor portions (43) is bent in the first direction, which is the stacking direction.

[0228] The first segment of the second group, which is different from the first segment of the first group, is configured to be bent in a second direction opposite to the first direction.

[0229] (Scheme 6) In the stator (3) of Scheme 5, the plurality of segmented conductors (41) may also be stacked in the radial direction.

[0230] The first direction is the radial direction, and the second direction is the direction opposite to the radial direction.

[0231] (Scheme 7) In the stator (3) of Scheme 6, each of the windings (40) can also be wound in a concentrated manner.

[0232] (Scheme 8) In the stator (3) of Scheme 5, the plurality of segmented conductors (41) may also be stacked in the circumferential direction.

[0233] The first direction and the second direction are two opposite directions in the circumferential direction.

[0234] (Scheme 9) In the stator (3) of Scheme 8, each of the windings (40) may be wound in a ring-shaped manner.

[0235] (Scheme 10) In any of the schemes 1 to 9, the stator (3) may be formed by layering and shaping.

[0236] (Scheme 11) The rotary electric motor (1) disclosed herein includes:

[0237] Stator (3) of any one of Schemes 1 to 10; and

[0238] The rotor (2) is disposed on at least one of the radial inner and radial outer sides of the stator with a predetermined gap, and is rotatable about the central axis (50).

[0239] In this specification, terms such as "first," "second," etc., are used for illustrative purposes only and should not be construed as indicating, explicitly or implicitly, relative importance or the order of technical features. Features specified as "first" and "second" expressly or implicitly include one or more of that feature.

[0240] The rotary motor 1 or stator 3 of the above-described embodiments can each be configured to include at least one feature among the features described in other embodiments, provided that there is no contradiction.

[0241] Industrial availability

[0242] According to this disclosure, it is possible to provide stators and rotary motors that are miniaturized compared to the prior art, and thus can be appropriately utilized in this industrial field.

[0243] Explanation of reference numerals in the attached figures

[0244] 1. Rotary motor; 2. Rotor; 3. Stator; 4. Housing; 20. Rotor core; 30. Stator core; 31. Magnetic yoke; 32. Protrusion; 32A. Outer protrusion; 32B. Inner protrusion; 33. Slot; 33A. Outer slot; 33B. Inner slot; 36. End face; 40. Winding; 41. Segmented conductor; 42, 42A, 42B. Second segmented conductor section; 43, 43C, 43D, 43E, 43F, 43G, 43L, 43M, 43N, 43P. First segmented conductor section; 45. End; 46. End; 47. End; 50. Central axis; 60. Unit; 80. Heat sink; 81. Resin.

Claims

1. A stator, wherein, The stator includes: A stator core, which is annular and surrounds a central axis, has a plurality of slots arranged at predetermined intervals circumferentially around the central axis and extending radially and axially parallel to the central axis; and Multiple windings comprising multiple segmented conductors stacked in the radial or circumferential direction and wound in each of the slots. Each of the segmented conductors includes a first segmented conductor portion disposed at a coil end protruding axially from the axial end face of the stator core and a pair of second segmented conductor portions disposed in a pair of opposing slots in the plurality of slots. The first segment of one of the plurality of segmented conductors is configured to be bent in the stacking direction.

2. The stator according to claim 1, wherein, The first segment conductor portion is configured such that the thickness of the first segment conductor portion varies in at least one of the axial, radial, and circumferential directions.

3. The stator according to claim 1, wherein, The first cross-sectional areas of each of the first segmented conductor portions of the plurality of segmented conductors are substantially equal to each other in a first plane parallel to the plane formed along the stacking direction and the axial direction.

4. The stator according to claim 1, wherein, The first cross-sectional area of ​​the first segment of each of the plurality of segmented conductors in a first plane parallel to the plane formed along the stacking direction and the axial direction is substantially equal to the second cross-sectional area of ​​the second segment of each of the plurality of segmented conductors in a second plane perpendicular to the axial direction.

5. The stator according to any one of claims 1 to 4, wherein, The first segment conductor portion of the first group of a plurality of first segment conductor portions is bent in a first direction which is the stacking direction, and the first segment conductor portion of the second group of a plurality of first segment conductor portions which is different from the first segment conductor portions of the first group is configured to be bent in a second direction opposite to the first direction.

6. The stator according to claim 5, wherein, The plurality of segmented conductors are stacked in the radial direction. The first direction is the radial direction, and the second direction is the direction opposite to the radial direction.

7. The stator according to claim 6, wherein, Each of the windings is wound in a concentrated manner.

8. The stator according to claim 5, wherein, The plurality of segmented conductors are stacked in the circumferential direction. The first direction and the second direction are two opposite directions in the circumferential direction.

9. The stator according to claim 8, wherein, Each of the windings is wound in a toroidal manner.

10. The stator according to claim 1, wherein, Each winding is formed using a layered molding method.

11. A rotary electric motor, wherein, The rotary motor includes: The stator as claimed in claim 1; and The rotor is disposed on at least one of the radial inner and radial outer sides of the stator with a predetermined gap, and is rotatable about the central axis.

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