Electric rotary machine

Abstract

Electric rotary machine comprising an armature (10, 10A) configured by mounting an armature winding (20, 40) into an annular armature core (11, 30), wherein slots (13, 33) are formed on the armature core in a ratio of q slots per phase per pole, where q is a natural number greater than or equal to two, wherein the armature winding (20, 40) is configured such that winding bodies (22, 42) with distributed winding are arranged at a pitch of one slot in the circumferential direction, wherein the winding bodies (22, 42) are configured by winding conductor wires (39) into two or three of the slots (13, 33) spaced apart at a pitch of one magnetic pole;characterized in that the respective phase coils forming the armature winding (20, 40) have a number 2q of groups (U101, U102, U201, U202) of small coils, each group (U101, U102, U201, U202) of small coils comprising one circumferential turn by connecting winding bodies (22) in series in the circumferential order of arrangement, and each group (U101, U102, U201, U202) comprising p / 2 winding bodies (22), where p is the number of poles, wherein the winding bodies (22) are received in an identical slot group, which are spaced apart by 360 electrical degrees from each other; and that each of the phase coils is configured by connecting the 2q groups (U101, U102, U201, U202) of small coils in series, such that any two of the 2q groups (U101, U102, U201, U202) of small coils that are included in the identical slot group are arranged consecutively or alternately.

Description

Technical area

[0001] The present invention relates to an electric rotary machine such as an electric motor or a generator, and more particularly to an armature winding connection structure. State of the art

[0002] Recently, compactness, high output power, and high quality have become a requirement for rotating electrical machines used as electric motors or generators. For rotating electrical machines with high output power of this type, the following applies: As high voltages are applied, the electrical potential differences that occur between the coils mounted in an armature core have increased, and it has become necessary to use an insulating material with thicknesses that can withstand these differences.

[0003] However, if the thickness of the insulating material is increased without changing the shape of the armature core, the coil space will be reduced by an amount proportional to the increase in the thickness of the insulating material, which will reduce the efficiency of the rotating electrical machine. If the thickness of the insulating material is increased without changing the coil space, the diameter of the armature core will be increased by an amount proportional to the increase in the thickness of the insulating material, resulting in an increase in the size of the rotating electrical machine.

[0004] In view of these circumstances, various methods have been proposed to eliminate the electrical potential differences that occur between the coils.

[0005] For example, in conventional rotary electric machines such as those described in Patent Literature 1, coils located near the terminals in the respective phase coils are accommodated in slots that are not adjacent to those slots in which other phase coils are accommodated.

[0006] Coils located closer to the star points or neutral points than those coils located at positions circumferentially adjacent to those coils located near the terminals in slots adjacent to these slots are located at positions in the slots in which the coils located near the terminals are located, radially adjacent to the coils located near the terminals. The electrical potential differences that occur between the coils at the coil ends are thus eliminated.

[0007] In conventional rotary electric machines such as the one described in Patent Literature 2, the stator winding formed by connecting the respective phase windings in star connection, which in turn are formed by connecting in series a plurality of coils with distributed windings and overlapped wound coils, is as follows.

[0008] The respective phase windings are arranged such that a first coil connected to an input terminal, a terminal coil connected to a star point, and a plurality of intermediate coils are each arranged in a single row circumferentially so as to have different radial positions in each of the phases. Two intermediate coils among the plurality of intermediate coils in each of the phases are provided so as to be arranged on two circumferential sides of the first coil of the same phase, and the first coil of each of the phases is radially adjacent to an intermediate coil of a different phase or a terminal coil of a different phase, which is electrically connected to an intermediate point closer than the two adjacent intermediate coils of the same phase. Common voltages between adjacent coils of the same phase and different phases are thereby relieved.

[0009] Patent Literature 3 describes a stator mounted on a stator core as the armature core to form a three-phase circuit with coil groups. Each phase includes two coil groups connected in parallel.

[0010] Patent Literature 4 discloses a three-phase dynamoelectric machine. Each of the three phases comprises two stator coils connected in parallel. BibliographyPatent literature Patent Literature 1: Japanese Patent No. JP 4 823 797 B2 Patent Literature 2: Japanese Patent Laid-Open No. JP 2009-278845 A. Patent Literature 3: Japanese Patent Laid-Open Publication JP 2005- 051 981 A Patent Literature 4: Japanese Patent Laid-Open Publication JP 2009-195006 A Summary of the inventionProblems to be solved by the invention

[0011] In conventional rotary electric machines such as the one described in Patent Literature 1, the electric potential differences between the coils of the same phase cannot be suppressed, and there arises a problem that the thickness of the insulating material accommodated within the slots is increased.

[0012] In conventional rotary electric machines such as the one described in Patent Literature 2, since the respective phase windings connect a plurality of coils arranged in the circumferential direction in series, if a winding configuration in which two or more coils are accommodated in one slot (also called "multi-layer winding") is used, situations may occur in which a coil connected on the side near an input terminal and a coil connected on the side near the star point or neutral point are accommodated in an identical slot.

[0013] As a result, a problem has arisen in that the electric potential differences between the coils become maximum and equal to the applied voltage, which prevents the electric potential differences between the coils within the slots from being eliminated, and which makes the thickness of the insulating material that insulates between the coils within the slots thicker.

[0014] In addition, in conventional rotary electric machines such as those described in Patent Literature 2, since crossing portions connecting the coils are longer and the crossing direction of the crossing portions is not unidirectional, further problems arise in that the winding resistance increases, which reduces the efficiency of the rotary electric machine, and also that the diameter of the rotary electric machine increases due to overlapping of the crossing portions.

[0015] The present invention is intended to solve the above problems. Therefore, it is an object of the present invention to provide a rotary electric machine that can suppress the increase in the thickness of the insulating material within the slots by adjusting the connection of the coils constituting the respective phase coils to suppress the electrical potential differences that occur between the conductor wires within the slots, and also enables increased efficiency and a reduction in size by shortening the lengths of the connection portions between the winding bodies constituting the coils. Ways to solve the problem

[0016] To achieve the above object, according to the present invention, an electric rotary machine having the features according to one of the independent claims 1, 2, 4 or 5 is provided. An advantageous development of the electric rotary machine of the present invention is specified in claim 3. Effects of the invention

[0017] According to the present invention, the respective phase coils constituting an armature winding include coils formed by connecting in series, in the order of arrangement in the circumferential direction, winding bodies separated from each other by 360 electrical degrees.

[0018] Consequently, the intersections connecting the winding bodies are shorter, preventing an increase in diameter caused by overlapping intersections and allowing for a reduction in size. Each of the phase coils is configured by connecting all the coils in series, either continuously or alternately, so that the coils accommodated in an identical slot group are positioned.

[0019] Consequently, the electrical potential differences occurring between the conductor wires within the slots are reduced, allowing the thickness of the insulating material between the conductor wires within the slots to be reduced. As a result, the space factor can be increased by proportionally increasing the cross-sectional area of ​​the conductor sections of the conductor wires, enabling increased efficiency as well as improvements in heat dissipation characteristics. Short description of the drawings

[0020] The drawings show: Fig. 1 is a half-sectional view showing an electric rotary machine according to Embodiment 1 of the present invention; Fig. 2 is an oblique projection showing a part of the rotary electric machine according to Embodiment 1 of the present invention; Fig. 3 is an oblique projection showing an armature used in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 4 is an oblique projection showing a core block constituting an armature used in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 5 is an oblique projection showing a winding arrangement constituting an armature winding of an armature used in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 6 is an oblique projection showing a winding body constituting the winding assembly of the rotary electric machine according to Embodiment 1 of the present invention; Fig. 7 is a front view showing the winding body constituting the winding assembly in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 8 is a side view showing the winding body constituting the winding assembly in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 9 is an oblique projection of the winding body constituting the winding assembly of the rotary electric machine according to Embodiment 1 of the present invention, viewed obliquely from above a front surface; Fig. 10 is an end elevational view of the armature in the rotary electric machine according to Embodiment 1 of the present invention, viewed from a side near a second axial end; Fig. 11 is a connection diagram for groups of small coils constituting a U-phase coil of the armature winding in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 12 is an oblique projection showing the groups of small coils constituting the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 13 is an oblique projection showing an arranged state of the groups of small coils in the winding assembly in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 14 is a connection diagram for the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 15 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 16 is a diagram explaining a method of constructing the armature of the rotary electric machine according to Embodiment 1 of the present invention; Fig. 17 is a diagram explaining the method of constructing the armature of the rotary electric machine according to Embodiment 1 of the present invention; Fig. 18 is a diagram explaining the method of constructing the armature of the rotary electric machine according to Embodiment 1 of the present invention; Fig. 19 is a diagram explaining the method of constructing the armature of the rotary electric machine according to Embodiment 1 of the present invention; Fig. 20 is a connection diagram for a U-phase coil of the armature winding in a rotary electric machine according to Embodiment 2 of the present invention; Fig. 21 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 2 of the present invention; Fig. 22 is an oblique projection showing the armature winding in the rotary electric machine according to Embodiment 2 of the present invention; Fig. 23 is a connection diagram for a W-phase coil of an armature winding in a rotary electric machine according to Embodiment 3 of the present invention; Fig. 24 is an oblique projection showing the armature winding in the rotary electric machine according to Embodiment 3 of the present invention; Fig. 25 is a connection diagram for a U-phase coil of an armature winding in a rotary electric machine according to Embodiment 4 of the present invention; Fig. 26 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 4 of the present invention; Fig. 27 is a schematic diagram showing the U-phase coil of an armature winding in a rotary electric machine according to Embodiment 5 of the present invention; Fig. 28 is a half-sectional view showing an electric rotary machine according to Embodiment 6 of the present invention; Fig. 29 is an oblique projection showing a part of the rotary electric machine according to Embodiment 6 of the present invention; Fig. 30 is an oblique projection showing an armature used in the rotary electric machine according to Embodiment 6 of the present invention; Fig. 31 is an oblique projection showing a core block constituting an armature used in the rotary electric machine according to Embodiment 6 of the present invention; Fig. 32 is an oblique projection showing a winding body constituting the winding assembly of the rotary electric machine according to Embodiment 6 of the present invention; Fig. 33 is a plan view showing a winding body constituting the winding assembly in the rotary electric machine according to Embodiment 6 of the present invention; Fig. 34 is a schematic diagram explaining a state in which the winding bodies constituting the armature winding in the rotary electric machine according to Embodiment 6 of the present invention are accommodated in slots; Fig. 35 is an oblique projection showing a winding arrangement constituting an armature winding of an armature used in the rotary electric machine according to Embodiment 6 of the present invention; Fig. 36 is a diagram explaining a method of constructing the armature of the rotary electric machine according to Embodiment 6 of the present invention; Fig. 37 is a diagram explaining the method of constructing the armature of the rotary electric machine according to Embodiment 6 of the present invention; Fig. 38 is an end elevational view of the armature in the rotary electric machine according to Embodiment 6 of the present invention, viewed from a side near a second axial end; Fig. 39 is a connection diagram for the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 6 of the present invention; Fig. 40 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 6 of the present invention; Fig. 41 is a partial oblique projection showing the vicinity of electric power supply portions of the armature winding in the rotary electric machine according to Embodiment 6 of the present invention; Fig. 42 is a connection diagram for a U-phase coil of an armature winding in a rotary electric machine according to Embodiment 7 of the present invention; Fig. 43 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 7 of the present invention; Fig. 44 is a connection diagram for a U-phase coil of an armature winding in a rotary electric machine according to Embodiment 8 of the present invention; Fig. 45 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 8 of the present invention; Fig. 46 is an oblique projection showing an armature used in the rotary electric machine according to Embodiment 9 of the present invention; Fig. 47 is an oblique projection showing a winding body constituting an armature winding of an armature used in the rotary electric machine according to Embodiment 9 of the present invention; Fig. 48 is a plan view showing connecting wire portions of the armature winding in the rotary electric machine according to Embodiment 9 of the present invention; Fig. 49 is a connection diagram for the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 9 of the present invention; Fig. 50 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 9 of the present invention; and Fig. 51 is a connection diagram for a U-phase coil of an armature winding in a rotary electric machine according to Embodiment 10 of the present invention. Description of the embodiments

[0021] Preferred embodiments of an electric rotary machine according to the present invention will now be explained with reference to the drawings. Embodiment 1

[0022] Fig. 1 is a half-sectional view showing an electric rotary machine according to Embodiment 1 of the present invention; Fig. 2 is an oblique projection showing a part of the rotary electric machine according to Embodiment 1 of the present invention; Fig. 3 is an oblique projection showing an armature used in the rotary electric machine according to Embodiment 1 of the present invention.

[0023] Fig. 4 is an oblique projection showing a core block constituting an armature used in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 5 is an oblique projection showing a winding arrangement constituting an armature winding of an armature used in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 6 is an oblique projection showing a winding body constituting the winding assembly of the rotary electric machine according to Embodiment 1 of the present invention.

[0024] Fig. 7 is a front view showing the winding body constituting the winding assembly in the rotary electric machine according to Embodiment 1 of the present invention; Fig. Fig. 8 is a side view showing the winding body constituting the winding assembly in the rotary electric machine according to Embodiment 1 of the present invention; and Fig. 9 is an oblique projection of the winding body constituting the winding assembly of the rotary electric machine according to Embodiment 1 of the present invention, viewed from obliquely above a front surface.

[0025] In the Fig. 1 and Fig. 2, an electric rotary machine 100 is shown, which comprises: a housing 1 having a bottomed cylindrical frame 2; and an end plate 3 closing an opening of the frame 2; an armature 10 fixed to a cylindrical portion of the frame 2 in an internally fitted state; and a rotor 5 fixed to a rotary shaft 6 rotatably supported in the bottom portion of the frame 2 and the end plate 3 by means of bearings 4 so as to be rotatably arranged on the inner peripheral side of the armature 10.

[0026] The rotor 5 is a permanent magnet rotor, including a rotor core 7 fixed to the rotating shaft 6 through a central portion thereof; and permanent magnets 8 embedded near the outer peripheral surface of the rotor core 7 so as to be arranged at a predetermined pitch in the circumferential direction to form magnetic poles. Furthermore, the rotor 5 is not limited to a permanent magnet rotor.

[0027] A squirrel-cage rotor may also be used, in which uninsulated rotor conductors are accommodated in slots of a rotor core so that two sides are short-circuited by means of a short-circuit ring, or a slip-ring rotor may be used, in which insulated conductor wires are mounted in slots of a rotor core, etc.

[0028] The configuration of the armature 10 is described in detail below with reference to the Fig. 3 to 9 explained.

[0029] As in Fig. As shown in Figure 3, the armature 10 includes an armature core 11; and an armature winding 20 mounted on the armature core 11. To simplify the explanation, the number of poles p in the rotor 5 is eight, the number of slots s in the armature core 11 is forty-eight, and the armature winding 20 is a three-phase winding. In other words, the number of slots q per phase per pole is two.

[0030] As in Fig. 4, core blocks 12 are formed by dividing the annular armature core 11 into forty-eight equal portions in the circumferential direction, and include: a rear core portion 12a having an annular arc-shaped cross section formed by laminating and integrating a predetermined number of electromagnetic steel sheets; and a tooth 12b arranged to extend radially inward from a wall surface on the inner circumference of the rear core portion 12a.

[0031] The armature core 11 is constructed in a ring shape by arranging and integrating 48 blocks in the circumferential direction. Specifically, the circumferential side surfaces of the rear core portions 12a are arranged adjacent to each other so that the teeth 12b are oriented radially inward. The grooves 13 formed by circumferentially adjacent core blocks 12 are arranged at a uniform pitch angle in the circumferential direction so as to be open on an inner circumferential side.

[0032] The teeth 12b are formed to have a tapered shape with the width gradually narrowing radially inward in the circumferential direction, and the cross section of the grooves 13 perpendicular to the central axis of the armature core 11 is rectangular.

[0033] In Fig. 6 to 9, the winding bodies 22 are hexagonal coils formed by helically winding a conductor wire of rectangular cross-section formed of a non-jointed continuous copper wire or aluminum wire and insulated using an enamel resin, for example, for four windings into an approximately hexagonal shape so that flat surfaces formed by the long sides of the rectangular cross-sections face each other, and so that a gap d approximately equal to the length of the short sides of the rectangular cross-section is ensured between the respective facing flat surfaces.

[0034] The winding bodies 22 are formed, for example, by helically winding the conductor wire for four turns into an edgewise winding to form a tubular coil body, and then forming the coil body into an approximately hexagonal shape using a coil forming machine. Alternatively, the winding bodies 22 can be manufactured using a folding and bending process by bending a conductor wire into an approximately hexagonal shape while helically winding it.

[0035] The winding bodies 22 include first and second rectilinear portions 22a and 22b forming two columns divided at a pitch angle of six slots, four of which are arranged in a direction of the short sides of the rectangular cross sections, so that gaps (spaces) d are left in each of the columns; and first and second coil ends 22c and 22d alternately connecting the first longitudinal ends and connecting the second longitudinal ends between the gaps of the first and second rectilinear portions 22a and 22b. Furthermore, the pitch angle of six slots is a pitch between slot centers of slots 13 on two sides of six consecutive teeth 12b, and corresponds to the pitch of a single magnetic pole.

[0036] The first coil ends 22c extend outward at a predetermined inclination longitudinally outward relative to the first and second rectilinear portions 22a and 22b, from first ends of the first rectilinear portions 22a in a first column toward second rectilinear portions 22b in a second column, are bent approximately at right angles at central portions (first upper portions 22e) between the columns of the first and second rectilinear portions 22a and 22b, and are offset by a distance d in the direction of arrangement of the first and second rectilinear portions 22a and 22b, and are subsequently bent approximately at right angles and extend longitudinally inward relative to the first and second rectilinear portions 22a and 22b toward the second rectilinear portions 22b in the second column at a predetermined inclination,and are connected to first ends of the second rectilinear region 22b in the second column.,

[0037] The second coil ends 22d similarly extend outwardly at a predetermined inclination longitudinally outward relative to the first and second rectilinear portions 22a and 22b from second ends of the second rectilinear portions 22b in the second column toward the first rectilinear portions 22a in the first column, are bent approximately at right angles at central portions (second upper portions 22f) between the columns of the first and second rectilinear portions 22a and 22b, and are offset by a distance d in the direction of arrangement of the first and second rectilinear portions 22a and 22b, and are subsequently bent approximately at right angles and extend longitudinally inward relative to the first and second rectilinear portions 22a and 22b toward the first rectilinear portions 22a in the first column at a predetermined inclination,and are connected to second ends of the first rectilinear regions 22a in the first column.,

[0038] In the winding bodies 22 configured in this manner, the first and second rectilinear portions 22a and 22b and the first and second coil ends 22c and 22d are respectively arranged in the direction of the short sides of the rectangular cross sections of the conductor wire with a pitch (2d) that is approximately twice the length of the short sides, so that the flat surfaces formed by the long sides of the rectangular cross sections of the conductor wire face each other.

[0039] The first rectilinear portions 22a and the second rectilinear portions 22b, which are connected by the first upper portions 22e and the second upper portions 22f, are offset in the arrangement direction by a distance d. The winding bodies 22 also include: a winding end 22g extending outward in the longitudinal direction from the second end of a first rectilinear portion 22a located at a first end in the arrangement direction of the first column; and a winding end 22h extending outward in the longitudinal direction from the second end of a second rectilinear portion 22b located at a second end in the arrangement direction of the second column.

[0040] As in Fig. 5, the winding assembly 21 is configured by arranging the winding bodies 22 in the circumferential direction at a pitch of a single slot. As shown in Fig. 3, the winding assembly 21 is mounted on the armature core 11 such that the respective winding bodies 2, which are arranged in the circumferential direction with a pitch of a single slot, are received in pairs of slots 13 extending over six consecutive teeth 12b.

[0041] Coil ends 22g each protrude axially outward and are arranged on the radially inner side of the coil assembly 21 with a pitch of a single slot in the circumferential direction. Coil ends 22h each protrude axially outward and are arranged on the radially outer side of the coil assembly 21 with a pitch of a single slot in the circumferential direction. A predetermined joining process (described below) is applied to the coil ends 22g and 22h of the coil assembly 21 to form the coil assembly 20.

[0042] A connection method for the winding assembly 21 will be described below with reference to Fig. 10 to 15 explained. Fig. 10 is an end elevational view of the armature in the rotary electric machine according to Embodiment 1 of the present invention, viewed from a side near a second axial end; Fig. 11 is a connection diagram for groups of small coils constituting a U-phase coil of the armature winding in the rotary electric machine according to Embodiment 1 of the present invention.

[0043] Fig. 12 is an oblique projection showing the groups of small coils constituting the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 1 of the present invention; Fig. 13 is an oblique projection showing an arranged state of the small coil groups in the winding assembly in the rotary electric machine according to Embodiment 1 of the present invention.

[0044] Fig. 14 is a connection diagram for the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 1 of the present invention; and Fig. 15 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 1 of the present invention. In Fig. 10, 1, 7, 13, etc. to 43 are the groove numbers which have been assigned to the grooves 13 sequentially in the circumferential direction.

[0045] First of all, Fig. 10 The following: U1-1A, U1-2A etc. to U1-8A and U1-1B, U1-2B etc. to U1-8B are winding ends of the winding bodies 22 forming a U1 phase, which are mounted in a group of slots 13 at the slot numbers (1 + 6n), where n is a natural number including 0. U2-1A, U2-2A etc. to U2-8A, U2-2A and U2-1B, U2-2B, etc. to U2-8B are winding ends of the winding bodies 22 forming a U2 phase, which are mounted in a group of slots 13 at the slot numbers (2 + 6n).

[0046] Winding bodies 22 are also mounted in a slot group at slot numbers (3 + 6n) to form a V1 phase, and winding bodies 22 are mounted in a slot group at slot numbers (4 + 6n) to form a V2 phase. Winding bodies 22 are also mounted in a slot group at slot numbers (5 + 6n) to form a W1 phase, and winding bodies 22 are mounted in a slot group at slot numbers (6 + 6n) to form a W2 phase.

[0047] To simplify the explanation, only the following are shown here: V1-1A, V1-2A, V1-1B and V1-2B (winding ends of the winding bodies 22 forming the V1 phase); V2-1A, V2-2A, V2-1B and V2-2B (winding ends of the winding bodies 22 forming the V2 phase); W1-1A, W1-2A, W1-1B and W1-1B (winding ends of the winding bodies 22 forming the W1 phase); and W2-1A, W2-2A, W2-1B and W2-2B (winding ends of the winding bodies 22 forming the W2 phase)

[0048] A method of connecting a first to fourth group U101, U102, U201, U202 of small coils constituting a U-phase will be described below with reference to Fig. 11.

[0049] U1-1B and U1-3A, U1-3B and U1-5A, as well as U1-5B and U1-7A of the winding bodies 22, which are separated from each other by 360 electrical degrees, are connected to form the first group U101 of small coils. Similarly, U1-2B and U1-4A, U1-4B and U1-6A, as well as U1-6B and U1-8A of the winding bodies 22, which are separated from each other by 360 electrical degrees, are connected to form the second group U102 of small coils.

[0050] Similarly, U2-1B and U2-3A, U2-3B and U2-5A, as well as U2-5B and U2-7A of the winding bodies 22, which are separated by 360 electrical degrees from each other, are connected to form the third group U201 of small coils. Similarly, U2-2B and U2-4A, U2-4B and U2-6A, as well as U2-6B and U2-8A of the winding bodies 22, which are separated by 360 electrical degrees from each other, are connected to form the fourth group U202 of small coils.

[0051] As in Fig. As shown in Figure 12, the first group U101 of small coils is formed by connecting four winding bodies 22 arranged to be spaced 360 electrical degrees circumferentially in series in the order of circumferential arrangement. Consequently, the distances between the winding ends 22g and 22h of the connected winding bodies 22 are shorter.

[0052] This allows the winding bodies 22 to be connected to each other by extending the winding ends 22g and using them as crossing portions. The second to fourth groups U102, U201, U202 of small coils are also formed by connecting four winding bodies 22 arranged to be spaced 360 electrical degrees apart in the circumferential direction in series in the order of circumferential arrangement.

[0053] The first to fourth small coil groups U101, U102, U201, U202 are each coils mounted to make approximately one turn (360 mechanical degrees) in the circumferential direction around the armature core 11. Although not shown, a V-phase coil and a W-phase coil are also formed in a similar or identical manner. Fig. 13 shows a state in which twelve groups of small coils, each formed by connecting four winding bodies in series, are arranged so that the phases are spaced apart by an electrical angle of π / 6, that is, at a pitch of a single slot.

[0054] Therefore, in Embodiment 1, the number of slots per phase per pole q is two, the number of poles p is eight, the number of winding bodies 22 accommodated in a single slot 13 is two, and the number (2q) of small coil groups per phase is four. Therefore, the number of winding bodies 22 constituting each of the small coil groups connected in series is four (p / 2).

[0055] Hereinafter, a method of making connections between the first to fourth groups U101, U102, U201, U202 of small coils constituting the U-phase coil will be described with reference to Fig. 14 and Fig. 15. Since the V-phase coil and the W-phase coil are also connected in a similar manner, their explanation is omitted here.

[0056] The first group of small coils U101 and the second group of small coils U102 are housed in a slot group at slot numbers (1 + 6n). The third group of small coils U201 and the fourth group of small coils U202 are housed in a slot group at slot numbers (2 + 6n). The first group of small coils U101 and the second group of small coils U102 are connected in series by connecting U1-7B and U1-8B using a crossover wire 71.

[0057] The third group of small coils U201 and the fourth group of small coils U202 are connected in series by connecting U2-7B and U2-8B using a crossover wire 72. The first to fourth groups of small coils U101, U102, U201, U202 are connected in series by connecting U1-2A and U2-A using a crossover wire 73, thus forming the U-phase coil.

[0058] In other words, the first group U101 of small coils and the second group U102 of small coils accommodated in an identical slot group are coupled by connecting winding bodies 22 to each other, which are inserted into slots 13 spaced apart by an electrical angle of π, using the crossing wire 71. The third group U201 of small coils and the fourth group U202 of small coils accommodated in an identical slot group are coupled by connecting winding bodies 22 to each other, which are inserted into slots 13 spaced apart by an electrical angle of π, using the crossing wire 72.

[0059] In addition, the first and second groups U101, U102 of small coils and the third and fourth groups U201, U202 of small coils are coupled by connecting winding bodies 22 inserted into slots 13 spaced apart by an electrical angle of π using the crossing wire 73. A U-phase coil in which sixteen winding bodies 22 are connected in series is thereby obtained.

[0060] Here, due to limitations in manufacturing conditions, the U-phase coil can be manufactured by connecting U1-1A and U1-2A using the crossover wire 71, by connecting U2-1A and U2-2A using the crossover wire 72, and by connecting U1-8B and U2-7B using the crossover wire 73. The crossover wires 71, 72, and 73 are fabricated using a conductor sheet made of copper, etc., and extend circumferentially so as to be electrically insulated from each other, axially outside the second coil ends 22d of the forty-eight winding bodies 22 assembled into the armature core 11, so as to be arranged at a pitch of a single slot in the circumferential direction.

[0061] The U-phase coil, V-phase coil, and W-phase coil obtained in this way are multi-layer winding structures, with two groups of small coils accommodated in a single slot 13. The armature winding 20 is obtained by connecting the U-phase coil, V-phase coil, and W-phase coil in a star connection. This armature winding 20 forms a three-phase AC winding, which is a distributed winding of full-pitch windings.

[0062] Furthermore, "distributed windings" are windings formed by winding conductor wires into slots separated by more than or equal to two slots. In other words, diameter windings are windings wound so that a conductor wire extending outward from one slot spans two or more consecutive teeth and then enters another slot.

[0063] A rotary electric machine 100 using the armature winding 20 constructed in this manner operates as an eight-pole, forty-eight-slot, internal-rotor, three-phase motor when a predetermined alternating current is supplied to the armature winding 20.

[0064] In addition, the insulation between the welding portions of the first and second coil ends 22g and 22h of the coil bodies 22 is not described at all, but, for example, an electrical insulating resin should be used at the welding portions.

[0065] In the rotary electric machine 100 constructed in this manner, since the groups of small coils constituting each of the phase coils are each configured by connecting four winding bodies 22 arranged to be spaced apart by 360 electrical degrees in the circumferential direction in series in the order of arrangement in the circumferential direction, the lengths of the crossing portions connecting the winding bodies 22 to each other can be shortened.

[0066] As a result, downsizing can be achieved without axially extending the coil ends, as in conventional rotary electric machines such as the one described in Patent Literature 2. Since the lengths of the crossing portions connecting the winding bodies 22 are shorter, the resistance in each of the phase coils constituting the armature winding 20 also decreases. This enables increased efficiency.

[0067] The phase coils are configured by connecting four groups of small coils in series. Since two groups of small coils housed in an identical slot group are connected sequentially, electrical potential differences that occur between the conductor wires within the slots 13 can be prevented.

[0068] Since the insulating material between the conductor wires within the grooves 13, such as the thickness of the insulating coating applied to the conductor wire, can be made thinner, the cross-sectional area of ​​the conductor portion of the conductor wire can be proportionally increased to increase the space factor. This is expected to result in increased efficiency and improvements in heat dissipation performance.

[0069] Since the small coil groups are connected to each other by means of crossover wires 71, 72, and 73 extending circumferentially axially outside the second coil ends 22d, an increase in the diameter of the armature winding 20 can be prevented. Since the connection of the small coil groups can be changed by simply changing the shapes and positions of the conductor sheets forming the crossover wires 71, 72, and 73, changes in the design of the armature winding 20 can be easily accommodated.

[0070] In Embodiment 1, it was further possible to confirm that the electrical potential differences between the conductor wires within the slots 13 can be attenuated to a maximum of 48.4% of the voltages between the phases. To determine this electrical potential difference, the voltage drop occurring in a single turn of the winding bodies 22 was calculated. The electrical potential difference occurring in the conductor wires accommodated in an identical slot was calculated and compared across all slots 13. The maximum electrical potential difference was then used.

[0071] A method of constructing the armature 10 will be described below with reference to Fig. 16 to 19 described. Fig. 16 to 19 are diagrams explaining a method of constructing the armature in the rotary electric machine according to Embodiment 1 of the present invention. Fig. 16 and Fig. 17 shows the state before assembly of the armature. Fig. 18 shows the state after assembly of the armature. Fig. Figure 19 shows the state after assembly of the armature, in an enlarged view. For the sake of simplicity, only the first and second rectilinear portions 22a and 22b of the winding arrangement 21 are shown in the Fig. 17 to 19 shown.

[0072] First, forty-eight columns of eight first and second rectilinear regions 22a and 22b are arranged in a winding arrangement 21 at an approximately uniform pitch angle.

[0073] Thereafter, forty-eight core blocks 12 are arranged at an approximately uniform pitch angle in the circumferential direction so that the respective teeth are arranged on the radially outer side between adjacent gaps of the first and second linear portions 22a and 22b of the winding assembly 21, as shown in the Fig. 16 and Fig. 17. Thereafter, the core blocks 12, which are arranged in the circumferential direction, are simultaneously moved radially inward.

[0074] The respective teeth 12b of the core blocks 12 are thereby inserted between the adjacent gaps of the first and second rectilinear portions 22a and 22b, and the circumferential side surfaces of the adjacent core blocks 12 abut against each other so that a movement of the core blocks 12 radially inward is prevented, and the winding assembly 21 is thereby mounted on the armature core 11 as shown in FIGS. Fig. 18 and Fig. 19 shown.

[0075] Within each groove 13, eight first and second rectilinear portions 22a and 22b are received such that the longitudinal sides of the rectangular cross sections are circumferentially aligned so as to be neatly aligned in a single column in the radial direction.

[0076] Consequently, by moving the core blocks 12 arranged in a row in the circumferential direction radially inward so as to be inserted into the winding assembly 21, the first and second rectilinear portions 22a and 22b, which are irregularly aligned in the radial direction, are neatly aligned in a column by the movement which narrows the spacing between the teeth 12b of the adjacent core blocks 12.

[0077] In addition, gaps between each of the first and second rectilinear portions 22a and 22b arranged neatly in a column in the radial direction are reduced and eliminated by the radially inward movement of the rear core portions 12a of the core blocks 12. Consequently, the space factor of the conductor wires within the grooves 13 can be improved.

[0078] Since the conductor wires within the slots 13 and the core blocks 12 contact each other, and since the heat transfer performance from the winding assembly 21, which forms a heat-generating body during the flow of electric current, to the armature core 11 can be improved, temperature increases in the winding assembly 21 are suppressed, which makes it possible to suppress an increase in electrical resistance.

[0079] Since the core blocks 12 are inserted such that the gap between the adjacent teeth 12b gradually becomes narrower, sliding movement at the contact surfaces between the armature winding 20 and the core blocks 12 is prevented. This makes it possible to prevent damage to the insulating coatings of the conductor wires.

[0080] Winding bodies 22 are configured such that first and second coil ends 22c and 22d at the first and second upper portions 22e and 22f are radially displaced by a distance d approximately equal to the radial dimensions of the first and second rectilinear portions 22a and 22b. Consequently, one winding body 22 can be mounted on another winding body 22 without interference by aligning the axial height positions and moving it toward the other winding body 22 in the circumferential direction. This allows the assembly of the winding assembly 21 to be improved.

[0081] In a step in which the teeth 12b of the core blocks 12 are inserted between the first and second straight portions 22a and 22b from an outer peripheral side of the winding assembly 21, since tapered teeth 12b are inserted between each of the columns of the first and second straight portions 22a and 22b radially from the outside and moved radially inward, the armature 10 is constructed so that the first and second straight portions 22a and 22b are neatly arranged in individual columns. Embodiment 2

[0082] Fig. 20 is a connection diagram for a U-phase coil of the armature winding in a rotary electric machine according to Embodiment 2 of the present invention, Fig. 21 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 2 of the present invention, and Fig. 22 is an oblique projection showing the armature winding in the rotary electric machine according to Embodiment 2 of the present invention.

[0083] In Embodiment 2, a first group U101 of small coils, a second group U102 of small coils, a third group U201 of small coils, and a fourth group U202 of small coils are constructed in a similar or identical manner to those of Embodiment 1 described above. As shown in Fig. 20, the first group U101 of small coils and the third group U201 of small coils are connected in series by connecting U1-7B and U2-1A using a crossing wire 71.

[0084] Similarly, the second group U102 of small coils and the fourth group U202 of small coils are connected in series by connecting U1-2A and U2-8B using a crossover wire 72. U1-8B and U2-7B are also connected using a crossover wire 73. This results in a U-phase coil connected sequentially in the order of the first group U101 of small coils, the third group U201 of small coils, the second group U102 of small coils, and the fourth group U202 of small coils, when viewed from the end of the electric power supply. As shown in Fig. As shown in Figure 21, this U-phase coil is configured by alternately connecting groups of small coils accommodated in identical slot groups.

[0085] In the U-phase coil formed in this manner, the first group U101 of small coils and the third group U201 of small coils are connected in series, and the second group U102 of small coils and the fourth group U202 of small coils are connected in series using the crossing wires 71 and 72 without changing the lead wires of the winding bodies 22.

[0086] In addition, the V-phase coil and the W-phase coil are designed in a similar or identical manner. As shown in Fig. As shown in Fig. 22, U2-2A of the U-phase coil, V2-2A of the V-phase coil, and W2-2A of the W-phase coil are connected by a star-point cross-wire 74. Thus, an armature winding 20A is obtained, which is a three-phase AC winding, which is a distributed winding of full-pitch windings formed by connecting a U-phase coil, a V-phase coil, and a W-phase coil in a star connection, in each of which sixteen winding bodies 22 are connected in series.

[0087] In Embodiment 2, since groups of small coils (coils) constituting each of the phases are each configured by connecting four winding bodies 22 arranged to be spaced apart by 360 electrical degrees in the circumferential direction in series in the order of arrangement in the circumferential direction, the lengths of the crossing portions connecting the winding bodies 22 to each other can also be shortened, which makes it possible to achieve downsizing.

[0088] The phase coils are formed by connecting four groups of small coils in series. Since two groups of small coils housed in an identical slot group are alternately connected, electrical potential differences that occur between the conductor wires within the slots 13 can be suppressed.

[0089] Since the insulating material between the conductor wires within the grooves 13, such as the thickness of the insulating coating applied to the conductor wire, can be made thinner, the cross-sectional area of ​​the conductor portion of the conductor wire can be proportionally increased to increase the space factor. This is expected to result in increased efficiency and improvements in heat dissipation performance.

[0090] In Embodiment 1, it was further possible to confirm that the electrical potential differences between the conductor wires within the slots 13 can be attenuated to a maximum of 73.4% of the voltages between the phases. To determine this electrical potential difference, the voltage drop occurring in a single turn of the winding bodies 22 was calculated. The electrical potential difference occurring in the conductor wires accommodated in an identical slot was calculated and compared across all slots 13. The maximum electrical potential difference was then used.

[0091] The star point crossing wire 74 is made using a conductor sheet made of copper, etc., and extends in the circumferential direction so as to be electrically insulated from the crossing wires 71, 72, and 73, axially outside the second coil ends 22d of the forty-eight winding bodies 12 mounted in the armature core 11 so as to be arranged at a pitch of a single slot in the circumferential direction. Embodiment 3

[0092] Fig. 23 is a connection diagram for a W-phase coil of an armature winding in a rotary electric machine according to Embodiment 3 of the present invention, and Fig. 24 is an oblique projection showing the armature winding in the rotary electric machine according to Embodiment 3 of the present invention.

[0093] In embodiment 3, as shown in Fig. As shown in Figure 23, W1-1B and W1-3A, W1-3B and W1-A, and W1-5B and W1-7A of the winding bodies, which are separated from each other by 360 electrical degrees, are connected to form the first group W101 of small coils. Similarly, W1-8B and W1-2A, W1-2B and W1-4A, and W1-4B and W1-6A of the winding bodies 22, which are separated from each other by 360 electrical degrees, are connected to form the second group W102 of small coils.

[0094] Similarly, W2-1B and W2-3A, W2-3B and W2-5A, and W2-5B and W2-7A of the winding bodies 22, which are separated from each other by 360 electrical degrees, are connected to form the third group W201 of small coils. Similarly, W2-8B and W2-2A, W2-2B and W2-4A, and W2-4B and W2-6A of the winding bodies 22, which are separated from each other by 360 electrical degrees, are connected to form the fourth group W202 of small coils.

[0095] Next, the first group of small coils W101 and the third group of small coils W201 are connected in series by connecting W1-7B and W2-1A using a crossover wire 71. Similarly, the second group of small coils W102 and the fourth group of small coils W202 are connected in series by connecting W1-8A and W2-6B using a crossover wire 72. U1-6B and U2-7B are also connected using a crossover wire 73.

[0096] This results in a W-phase coil connected sequentially in the order of the first group of small coils W101, the third group of small coils W201, the second group of small coils W102, and the fourth group of small coils W202, as viewed from the power supply end. This W-phase coil is configured by connecting groups of small coils housed in an identical slot group, spaced one apart.

[0097] In the W-phase coil formed in this way, the first group W101 of small coils and the third group W201 of small coils are connected in series, and the second group W102 of small coils and the fourth group W202 of small coils are connected in series using the crossing wires 71 and 72 without changing the lead wires of the winding bodies 22.

[0098] A V-phase coil is also formed in a similar or identical manner to that of the above-described W-phase coil. A U-phase coil, on the other hand, is formed in a similar or identical manner to that of the above-described Embodiment 2. As shown in Fig. 24, U2-2A of the U-phase coil, V2-8A of the V-phase coil, and W2-8A of the W-phase coil are connected by a star point cross wire 74.

[0099] Thereby, an armature winding 20B is obtained which is formed of a three-phase AC winding which is a distributed winding of diameter windings (full-pitch) formed by connecting a U-phase coil, a V-phase coil and a W-phase coil in star connection, in each of which sixteen winding bodies 22 are connected in series.

[0100] In a rotary electric machine using an armature winding 20B connected in this manner, the terminals of the groups of small coils (the coils) are concentrated in the circumferential direction. This enables further size reductions to be achieved.

[0101] In Embodiment 3, since the groups of small coils constituting each of the phases are each configured by connecting four winding bodies 22 arranged to be spaced apart by 360 electrical degrees in the circumferential direction in series in the order of arrangement in the circumferential direction, the lengths of the crossing portions connecting the winding bodies 22 to each other can also be shortened, which makes it possible to achieve downsizing.

[0102] The phase coils are formed by connecting four groups of small coils in series. Since every other pair of the groups of small coils, which are housed in an identical slot group, is connected, electrical potential differences that occur between the conductor wires within the slots 13 can be prevented.

[0103] Since the insulating material between the conductor wires within the grooves 13, such as the thickness of the insulating coating applied to the conductor wire, can be made thinner, the cross-sectional area of ​​the conductor portion of the conductor wire can be proportionally increased to increase the space factor. This is expected to result in increased efficiency and improvements in heat dissipation performance. Embodiment 4

[0104] Fig. 25 is a connection diagram for a U-phase coil of an armature winding in a rotary electric machine according to Embodiment 4 of the present invention, and Fig. 26 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 4 of the present invention.

[0105] In Embodiment 4, a first group U101 of small coils, a second group U102 of small coils, a third group U201 of small coils, and a fourth group U202 of small coils are constructed in a similar or identical manner to those of Embodiment 1 described above. The first group U101 of small coils and the third group U201 of small coils are coupled in series by connecting U1-7B and U2-1A of the winding bodies 22, which are inserted into slots 13 spaced apart by an electrical angle of (π - π / 6), using the crossing wire 71.

[0106] Similarly, the second group U102 of small coils and the fourth group U202 of small coils are coupled in series by connecting U1-2A and U2-2A of the winding bodies 22, which are inserted into slots 13 spaced apart by an electrical angle of (π / 6), using a crossing wire 72.

[0107] Furthermore, U1-1A and U1-8B are connected using a crossover wire 73, and U2-7B and U2-8B are connected using a crossover wire 73. This forms a U-phase coil formed by connecting two partial coils in parallel, in which eight winding bodies 22 are connected in series. In each of the partial coils connected in parallel in this U-phase coil, two groups of small coils accommodated in an identical slot group are connected at positions having an identical order when viewed from the power supply end.

[0108] In other words, the first group U101 of small coils and the second group U102 of small coils, housed in an identical slot group, are connected such that they are in a first position from the end of the electrical power supply of each of the parallel-connected sub-coils. The third group U201 of small coils and the fourth group U202 of small coils, housed in an identical slot group, are similarly connected such that they are in a second position from the end of the electrical power supply of each of the parallel-connected sub-coils.

[0109] A V-phase coil and a W-phase coil are also formed in a similar or identical manner to that of the U-phase coil. An armature winding is thus obtained, which is formed from a three-phase AC winding, which is a distributed winding of full-pitch windings formed by connecting a U-phase coil, a V-phase coil, and a W-phase coil in a star connection.

[0110] In Embodiment 4, since groups of small coils (coils) constituting each of the phases are each configured by connecting four winding bodies 22 arranged to be spaced apart by 360 electrical degrees in the circumferential direction in series in the order of arrangement in the circumferential direction, the lengths of the crossing portions connecting the winding bodies 22 to each other can also be shortened.

[0111] The phase coils are configured by connecting two partial coils in parallel, which are made by connecting in series a group of small coils accommodated in a first slot group and a group of small coils accommodated in a second slot group.

[0112] Since groups of small coils accommodated in an identical slot group are connected so as to be located at positions having the same order when viewed from the end of the electrical power supply in each of the partial coils connected in parallel, electrical potential differences occurring between the conductor wires within the slots 13 can be reduced.

[0113] Since the insulating material between the conductor wires within the grooves 13, such as the thickness of the insulating coating applied to the conductor wire, can be made thinner, the cross-sectional area of ​​the conductor portion of the conductor wire can be proportionally increased to increase the space factor. This is expected to result in increased efficiency and improvements in heat dissipation performance.

[0114] In Embodiment 4, it was further possible to confirm that the electrical potential differences between the conductor wires within the slots 13 can be attenuated to a maximum of 46.9% of the interphase voltages. To determine this electrical potential difference, the voltage drop occurring in a single turn of the winding bodies 22 was calculated. The electrical potential difference occurring in the conductor wires accommodated in an identical slot was calculated and compared across all slots 13. The maximum electrical potential difference was then used. Embodiment 5

[0115] Fig. 27 is a schematic diagram showing the U-phase coil of an armature winding in a rotary electric machine according to Embodiment 5 of the present invention.

[0116] In Embodiment 5, the number of slots q per phase per pole is three, the number of poles p is eight, the number of slots s is seventy-two, and the number of winding bodies 22 accommodated in a single slot 13 is two. Consequently, the number of small coil groups per phase (2q) is six, and the number of winding bodies 22 connected in series to form each of the small coil groups (p / 2) is four.

[0117] The winding bodies 22 are formed by winding conductor wires in pairs of slots arranged on two sides of nine circumferentially consecutive teeth, ie, in pairs of slots spaced by one pitch from a single magnetic pole.

[0118] A first group U101 of small coils and a second group U102 of small coils are each formed by connecting in series four winding bodies 22 accommodated in an identical slot group, and they are coils mounted to make approximately one circuit (360 mechanical degrees) in the circumferential direction around an armature core.

[0119] A third group U201 of small coils and a fourth group U202 of small coils are each formed by connecting in series four winding bodies 22 which are accommodated in a slot group adjacent to a first circumferential side of the slot group in which the first group U101 and the second group U102 of small coils are accommodated, and they are coils which are mounted so as to make approximately one circuit (360 mechanical degrees) in the circumferential direction around the armature core.

[0120] A fifth group U301 of small coils and a sixth group U302 of small coils are each formed by connecting in series four winding bodies 22 which are accommodated in a slot group adjacent to a first circumferential side of the slot group in which the third group U201 and a fourth group U202 of small coils are accommodated, and they are coils which are mounted so as to make approximately one circuit (360 mechanical degrees) in the circumferential direction around the armature core.

[0121] The first group U101 of small coils, the third group U201 of small coils, and the fifth group U301 of small coils, housed in slots 13 offset from each other by an electrical angle of (π + π / 9), are coupled in series. Similarly, the second group U102 of small coils, the fourth group U202 of small coils, and the sixth group U302 of small coils, housed in slots 13 offset from each other by an electrical angle of (π + π / 9), are coupled in series.

[0122] In addition, a sub-coil in which the first group of small coils U101, the third group of small coils U201, and the fifth group of small coils U301 are connected in series, and a sub-coil in which the second group of small coils U102, the fourth group of small coils U202, and the sixth group of small coils U302 are connected in series are connected in parallel. This results in a U-phase coil formed by connecting two sub-coils in parallel, in which twelve winding bodies 22 are connected in series.

[0123] In each of the sub-coils connected in parallel in this U-phase coil, two groups of small coils housed in an identical slot group are connected at positions that have an identical order when viewed from the power supply end. In other words, the first group U101 of small coils and the second group U102 of small coils housed in an identical slot group are connected so that they are in a first position from the power supply end of each of the parallel-connected sub-coils.

[0124] The third group U201 of small coils and the fourth group U202 of small coils, housed in an identical slot group, are similarly connected so that they are at a third position from the end of the electrical power supply of each of the parallel-connected sub-coils. The fifth group U301 of small coils and the sixth group U302 of small coils, housed in an identical slot group, are similarly connected so that they are at a second position from the end of the electrical power supply of each of the parallel-connected sub-coils.

[0125] A V-phase coil and a W-phase coil are also formed in a similar or identical manner to that of the U-phase coil. This results in an armature winding consisting of a three-phase AC winding, which is a distributed winding of full-pitch windings formed by connecting a U-phase coil, a V-phase coil, and a W-phase coil in a star connection.

[0126] In Embodiment 5, since groups of small coils (coils) constituting each of the phases are each configured by connecting four winding bodies 22 arranged to be spaced apart by 360 electrical degrees in the circumferential direction in series in the order of arrangement in the circumferential direction, the lengths of the crossing portions connecting the winding bodies 22 to each other can also be shortened.

[0127] The phase coils are configured by connecting two partial coils in parallel, which are formed by connecting a group of small coils accommodated in each of the slot groups in series. Since groups of small coils accommodated in an identical slot group are connected in positions that have the same order when viewed from the end of the electrical power supply, in each of the partial coils connected in parallel, electrical potential differences that occur between the conductor wires within the slots 13 can be reduced.

[0128] Since the insulating material between the conductor wires within the grooves 13, such as the thickness of the insulating coating applied to the conductor wire, can be made thinner, the cross-sectional area of ​​the conductor portion of the conductor wire can be proportionally increased to increase the space factor. This is expected to result in increased efficiency and improvements in heat dissipation performance.

[0129] In Embodiment 5, it was further possible to confirm that the electrical potential differences between the conductor wires within the slots 13 can be attenuated to a maximum of 46.9% of the interphase voltages. To determine this electrical potential difference, the voltage drop occurring in a single turn of the winding bodies 22 was calculated. The electrical potential difference occurring in the conductor wires accommodated in an identical slot was calculated and compared across all slots 13. The maximum electrical potential difference was then used.

[0130] Furthermore, in the above embodiments 1 to 5, the winding bodies 22 are configured by helically winding continuous conductor wires without joints. However, the winding bodies can also be configured, for example, by helically winding conductor wires formed by connecting short conductors. Embodiment 6

[0131] Fig. 28 is a half-sectional view showing an electric rotary machine according to Embodiment 6 of the present invention; Fig. 29 is an oblique projection showing a part of the rotary electric machine according to Embodiment 6 of the present invention; Fig. 30 is an oblique projection showing an armature used in the rotary electric machine according to Embodiment 6 of the present invention.

[0132] Fig. 31 is an oblique projection showing a core block constituting an armature used in the rotary electric machine according to Embodiment 6 of the present invention; Fig. 32 is an oblique projection showing a winding body constituting the winding assembly of the rotary electric machine according to Embodiment 6 of the present invention; Fig. 33 is a plan view showing a winding body constituting the winding assembly in the rotary electric machine according to Embodiment 6 of the present invention.

[0133] Fig. 34 is a schematic diagram explaining a state in which the winding bodies constituting the armature winding in the rotary electric machine according to Embodiment 6 of the present invention are accommodated in slots; Fig. 35 is an oblique projection showing a winding arrangement constituting an armature winding of an armature used in the rotary electric machine according to Embodiment 6 of the present invention.

[0134] Fig. 36 is a diagram explaining a method of constructing the armature of the rotary electric machine according to Embodiment 6 of the present invention; and Fig. 37 is a diagram explaining the method of constructing the armature of the rotary electric machine according to Embodiment 6 of the present invention. In Fig. 34, 1, 2, 6, 7, 8, 12 and 13 are the groove numbers which have been assigned to the grooves 33 sequentially in the circumferential direction.

[0135] In the Fig. 28 and Fig. 29, there is shown an electric rotary machine 101 comprising: a casing 1 having a bottomed cylindrical frame 2; and an end plate 3 closing an opening of the frame 2; an armature 10A fixed to a cylindrical portion of the frame 2 in an internally fitted state; and a rotor 5 fixed to a rotary shaft 6 rotatably supported in the bottom portion of the frame 2 and the end plate 3 by means of bearings 4 so as to be rotatably disposed on the inner peripheral side of the armature 10A.

[0136] Moreover, the rotary electric machine 101 is configured in a similar or identical manner to that of the rotary electric machine 100 according to the above Embodiment 1, except that the armature 10A is used instead of the armature 10.

[0137] The configuration of the armature 10A is described in detail below with reference to the Fig. 30 to 35 explained.

[0138] As in Fig. 30, the armature 10 includes an armature core 30; and an armature winding 40 mounted on the armature core 30. To simplify the explanation, the number of poles p is 10, the number of slots s in the armature core 30 is 60, and the armature winding 40 is a three-phase winding. In other words, the number of slots per phase and per pole q is two.

[0139] As in Fig. 31, core blocks 31 are formed by dividing the annular armature core 30 into thirty equal portions in the circumferential direction, and include: a rear core portion 31a having an annular arc-shaped cross section formed by laminating and integrating a predetermined number of electromagnetic steel sheets; and a tooth 31b arranged to extend radially inward from a wall surface on the inner circumference of the rear core portion 31a.

[0140] The armature core 30 is constructed in a ring shape by arranging and integrating thirty core blocks 31 in the circumferential direction. The circumferential side surfaces of the rear core portions 31a are arranged adjacent to each other so that the teeth 31b are oriented radially inward. The grooves 33 formed by circumferentially adjacent teeth 31b are arranged at a uniform pitch angle in the circumferential direction so as to be open on an inner circumferential side. The teeth 31b are formed to have a tapered shape, with the width gradually narrowing radially inward in the circumferential direction, and the cross section of the grooves 33 perpendicular to the central axis of the armature core 30 is rectangular.

[0141] In the Fig. 32 and Fig. 33 shows the following: A winding body 42 is formed by winding a conductor wire 39 with a circular cross-section of diameter d, formed, for example, from a jointless copper wire or aluminum wire coated with an insulating enamel resin, into a δ-shaped coil pattern (described below). Furthermore, a conductor wire with a rectangular cross-section may be used in the winding body 22 instead of the conductor wire 39 with a round cross-section.

[0142] The winding body 42 is manufactured by winding the conductor wire 39 into a δ-shaped coil pattern formed by: a first straight portion 42a, a first coil end portion 42e, a second straight portion 42b, a second coil end portion 42f, a third straight portion 42c, a third coil end portion 42g, and a fourth straight portion 42d.

[0143] This winding body 42 is inserted into three slots 33 which are spaced apart from each other at a pitch angle of six slots (a pitch of one magnetic pole), as shown in Fig. 34. Specifically, the winding body 42 is mounted into the armature core 30 such that the first linear portion 42a is inserted into the slots 33 at number 1, the second and fourth linear portions 42b and 42d are inserted into the slots 33 at number 7, and the third linear portion 42c is inserted into the slots 33 at number 13.

[0144] The first, second, and third coil end portions 42e, 42f, and 42g each have an arm portion radially offset by d. The first, second, third, and fourth rectilinear portions 42a, 42b, 42c, and 42d are thus inserted into three grooves 33 spaced apart by a pitch angle of six grooves (a pitch of one magnetic pole), so that radial areas within the grooves 33 are changed radially inward from a radially outer side.

[0145] A winding start of the conductor wire 39 extending outward near a first end of the armature core 30 from the first linear portion 42a, which is inserted into the radially outermost position within the slots 33 at number 1, becomes a winding end 42h, and a winding termination of the conductor wire 39 extending outward near the first end of the armature core 30 from the fourth linear portion 42d, which is inserted into the radially innermost position within the slots 33 at number 7, becomes a winding end 42i. These winding ends 42h and 42i are connected to other winding bodies 42, to electric power supply portions, or to neutral points, etc.

[0146] Sixty winding bodies 42 formed in this manner are arranged circumferentially at a pitch of a single slot to form a winding assembly 41 as shown in Fig. 35. In the winding assembly 41 constructed in this manner, sixty columns of four (first, second, third, and fourth) rectilinear portions 42a, 42b, 42c, and 42d are arranged circumferentially at an approximately uniform pitch angle.

[0147] To construct the armature 10A, thirty core blocks 31 are first arranged at an approximately uniform pitch angle in the circumferential direction so that the respective teeth 31b are arranged on the radially outer side between adjacent columns of first, second, third and fourth rectilinear portions 42a, 42b, 42c and 42d of the winding assembly 41, as shown in Fig. 36. Thereafter, the core blocks 31 arranged in the circumferential direction are simultaneously moved radially inward. The respective teeth 31b of the respective core blocks 31 are thereby positioned between the adjacent gaps of the first, second, third, and fourth rectilinear portions 42a, 42b, 42c, and 42d.

[0148] The surfaces on the circumferential side of the adjacent core blocks 31 thereby abut each other, which prevents movement of the core blocks 31 radially inward, and the winding assembly 41 is thereby mounted on the armature core 30, as shown in Fig. 37. Within each of the slots 33, four first, second, third, and fourth rectilinear portions 42a, 42b, 42c, and 42d are received so as to be radially aligned within a single column. A predetermined joining process (described below) is applied to the winding ends 42h and 42i of the winding assembly 41 to form the winding assembly 40. The armature 10A is thus manufactured.

[0149] A method of constructing the armature 40 will be described below with reference to Fig. 38 to 41. Fig. 38 is an end elevational view of the armature in the rotary electric machine according to Embodiment 6 of the present invention, viewed from a side near a second axial end, Fig. 39 is a connection diagram for the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 6 of the present invention.

[0150] Fig. 40 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 6 of the present invention, and Fig. 41 is a partial oblique projection showing the vicinity of electric power supply portions of the armature winding in the rotary electric machine according to Embodiment 6 of the present invention. In Fig. 38, 1, 7, 13, etc. to 55 are the groove numbers which have been assigned to the grooves 33 sequentially in the circumferential direction.

[0151] First of all, Fig. 38 The following: U1-1a, U1-2a etc. to U1-10a and U1-1b, U1-2b etc. to U1-10b are winding ends 42h and 42i of the winding bodies 42 forming a U1 phase, which are mounted in a group of slots 33 at the slot numbers (1 + 6n), where n is a natural number including 0. U2-1a, U2-2a etc. to U2-10a and U2-1b, U2-2b etc. to U2-10b are winding ends 42h and 42i of the winding bodies 42 forming a U2 phase, which are mounted in a group of slots 33 at the slot numbers (2 + 6n).

[0152] Winding bodies 42 are also mounted in a slot group at slot numbers (3 + 6n) to form a V1 phase, and winding bodies 42 are mounted in a slot group at slot numbers (4 + 6n) to form a V2 phase. Winding bodies 42 are also mounted in a slot group at slot numbers (5 + 6n) to form a W1 phase, and winding bodies 42 are mounted in a slot group at slot numbers (6 + 6n) to form a W2 phase.

[0153] To simplify the explanation, only the following are shown here: V1-1a and V1-1b (winding ends of the winding bodies 42 forming the V2 phase); V2-1a and V2-1b (winding ends of the winding bodies 42 forming the V2 phase); W1-1a and W1-1b (winding ends of the winding bodies 42 forming the W1 phase); and W2-1a and W2-1b (winding ends of the winding bodies 42 forming the W2 phase).

[0154] A method of connecting a first to fourth group U101, U102, U201, U202 of small coils constituting a U-phase coil will be described below with reference to Fig. 39. In addition, since the V-phase coil and the W-phase coil are also connected in a similar manner to the U-phase coil, their explanation is omitted here.

[0155] U1-1b and U1-3a, U1-3b and U1-5a, U1-5b and U1-7a, and U1-7b and U1-9a of winding bodies 42, which are separated from each other by 360 electrical degrees, are connected by welding, etc., to form the first group U101 of small coils. Similarly, U1-2b and U1-4a, U1-4b and U1-6a, U1-6b and U1-8a, and U1-8b and U1-10a of winding bodies 42, which are separated from each other by 360 electrical degrees, are connected by welding, etc., to form the second group U102 of small coils.

[0156] In addition, U1-9b and U1-10b of the winding bodies 42, which are inserted into the slots 33 spaced apart from each other by an electrical angle of π, are connected using a conductor wire U71 to form a U1-1 phase coil, which is configured by connecting the first group 101 of small coils and the second group 102 of small coils in series.

[0157] Similarly, U2-1b and U2-3a, U2-3b and U2-5a, U2-5b and U2-7a, and U2-7b and U2-9a of winding bodies 42 spaced 360 electrical degrees apart are connected together by welding, etc., to form the third group U201 of small coils. Similarly, U2-2b and U2-4a, U2-4b and U2-6a, U2-6b and U2-8a, and U2-8b and U2-10a of winding bodies 42 spaced 360 electrical degrees apart are connected together by welding, etc., to form the fourth group U202 of small coils.

[0158] In addition, U2-1b and U2-2b of the winding bodies 42 inserted into the slots 33 spaced apart by an electrical angle of π are connected using a conductor wire U72 to form a U2-phase coil configured by connecting the third group U201 of small coils and the fourth group U202 of small coils in series.

[0159] The first, second, third, and fourth groups U101, U102, U201, and U202 of small coils formed in this manner are each coils mounted to make approximately one circuit (360 mechanical degrees) in the circumferential direction around the armature core 30.

[0160] U2-10b of the U2-phase coil is extended and connected to U1-2a of a winding body 42 inserted into the slots 33 spaced apart by an electrical angle of (π - π / 6) to form a U-phase coil formed by connecting the U1-phase coil and the U2-phase coil in series.

[0161] A U-phase coil connected in series in the order of the first group U101 small coils, the second group U102 small coils, the third group U201 small coils, and the fourth group U202 small coils from the electric power supply portion toward the neutral point is obtained by making U1-1a, which forms one terminal of the U-phase coil, an electric power supply portion, and by making U2-9b, which also forms one terminal of the coil, a neutral point, as shown in Fig. 40 shown.

[0162] Furthermore, Fig. 40 The following: U1-1, U1-2 etc. to U1-10 form a winding body 42 which is mounted in the slot group at the slot numbers (1 + 6n), where U1-1 corresponds to a winding body 42 in which a winding end 42h is inserted into the slots 33 at number 1, where U1-2 corresponds to a winding body 42 in which a winding end 42h is inserted into the slots 33 at number 7, and where U1-10 corresponds to a winding body 42 in which a winding end 42h is inserted into the slots 33 at number 55.

[0163] U2-1, U2-2, etc. to U2-10 form a winding body 42 which is mounted in the slot group at the slot numbers (2 + 6n), where U2-1 corresponds to a winding body 42 in which a winding end 42h is inserted into the slots 33 at number 2, where U2-2 corresponds to a winding body 42 in which a winding end 42h is inserted into the slots 33 at number 8, and where U2-10 corresponds to a winding body 42 in which a winding end 42h is inserted into the slots 33 at number 56.

[0164] In the armature winding 40, which is connected in this way, as in Fig. 41 shows the following: Crossing wires U71, V71, and W71 are arranged to run circumferentially along an inner peripheral side of the coil ends so that they are electrically insulated from each other. Crossing wires U72, V72, and W72 are arranged to run circumferentially along an outer peripheral side of the coil ends so that they are electrically insulated from each other. The conductor wire constituting U2-10b is extended and connected to U1-2a, but U1-2a and U2-10b can also be connected using a crossing wire.

[0165] Here, the U-phase coil, the V-phase coil and the W-layer coil are multi-layer winding structures in which three groups of small coils are accommodated in a single slot 33. As shown in Fig. As shown in Figure 41, U2-9b, V2-9b, and W2-9b are connected using a star-crossing wire 74 to obtain an armature winding 40 formed by connecting the U-phase coil, the V-phase coil, and the W-layer coil in a star connection. The armature winding 40 forms a three-phase AC winding that is a distributed winding of full-pitch windings.

[0166] Consequently, the 100A rotary electric machine forms a ten-pole, sixty-slot, internal-rotor, three-phase motor. Furthermore, in the 100A rotary electric machine, the number of slots per phase per pole q is two, the number of poles p is ten, the number of winding bodies 42 accommodated in a single slot 33 is three, and the number of small coil groups per phase (2q) is four. Therefore, the number of winding bodies 22 constituting each of the series-connected small coil groups is five (p / 2).

[0167] In Embodiment 6, since groups of small coils constituting each of the phases are each configured by connecting five winding bodies 42 arranged to be spaced apart by 360 electrical degrees in the circumferential direction in series in the order of arrangement in the circumferential direction, the lengths of the crossing portions connecting the winding bodies 42 to each other can also be shortened.

[0168] Consequently, downsizing can be achieved without axially extending the coil ends of the armature winding 40. Since the lengths of the crossing portions connecting the winding bodies 42 are shorter, the resistance in each of the phase coils constituting the armature winding 40 also decreases. This enables increased efficiency.

[0169] The phase coils are formed by connecting four groups of small coils in series. Since two groups of small coils accommodated in an identical slot group are connected sequentially, electrical potential differences that occur between the conductor wires within the slots 33 can be suppressed.

[0170] In other words: As indicated by the arrows in Fig. 40, the winding bodies U1-1 and U1-2 are inserted into one and the same slot 33, and the winding bodies U2-10 and U2-9 are inserted into one and the same slot 33. This maximizes the electrical potential differences that occur between the conductor wires within the slot 33, but the respective electrical potential differences are reduced to approximately half the phase voltage.

[0171] Since the small coil groups are connected by crossover wires U71, U72, V71, V72, W71, and W72, the connection of the small coil groups can be easily changed by changing the shapes and positions of the conductor wires that connect the crossover wires U71, U72, V71, V72, W71, and W72. This allows changes in the design of the armature winding 40 to be easily accommodated. Embodiment 7

[0172] Fig. 42 is a connection diagram for a U-phase coil of an armature winding in a rotary electric machine according to Embodiment 7 of the present invention, and Fig. 43 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 7 of the present invention.

[0173] In the Fig. 42 and Fig. 43, the following applies: U1-1b and U1-3a, U1-3b and U1-5a, U1-5b and U1-7a and U1-7b and U1-9a of winding bodies 42, which are separated from each other by 360 electrical degrees, are connected by welding, etc., so that they form a first group U101 of small coils.

[0174] Similarly, U1-6b and U1-8a, U1-8b and U1-10a, U1-10b and U1-2a, and U1-2b and U1-4a of the winding bodies 42, which are separated from each other by 360 electrical degrees, are connected by welding, etc., to form a second group U102 of small coils. Furthermore, U1-9b and U1-4b of the winding bodies 42, which are inserted into the slots 33 spaced from each other by an electrical angle of 5π, are connected using a conductor wire U71 to form a U1-phase coil, which is configured by connecting the first group 101 of small coils and the second group 102 of small coils in series.

[0175] Similarly, U2-1b and U2-3a, U2-3b and U2-5a, U2-5b and U2-7a, and U2-7b and U2-9a of winding bodies 42 spaced 360 electrical degrees apart are connected together by welding, etc., to form a third group U201 of small coils. Similarly, U2-6b and U2-8a, U2-8b and U2-10a, U2-10b and U2-2a, and U2-2b and U2-4a of winding bodies 42 spaced 360 electrical degrees apart are connected together by welding, etc., to form a fourth group U202 of small coils.

[0176] In addition, U2-6a and U2-1a of the winding body 42, which are inserted into the slots 33 spaced apart by an electrical angle of 5π, are connected using a conductor wire U72 to form a U2-phase coil, which is configured by connecting the third group U201 of small coils and the fourth group U202 of small coils in series.

[0177] The first, second, third, and fourth groups U101, U102, U201, and U202 of small coils formed in this manner are each coils mounted to make approximately one circuit (360 mechanical degrees) in the circumferential direction around the armature core 30.

[0178] U2-4b of the U2-phase coil is extended and connected to U1-6a of a winding body 42 inserted into the slots 33 spaced apart by an electrical angle of (2π - π / 6) to form a U-phase coil formed by connecting the U1-phase coil and the U2-phase coil in series.

[0179] A U-phase coil connected in series in the order of the first group U101 small coils, the second group U102 small coils, the third group U202 small coils, and the fourth group U201 small coils from the electric power supply portion toward the neutral point is obtained by making U1-1a, which forms one terminal of the U-phase coil, an electric power supply portion, and by making U2-9b, which also forms one terminal of the coil, a neutral point, as shown in Fig. 43 shown.

[0180] A V-phase coil and a W-phase coil are also manufactured in a similar or identical manner to that of the U-phase coil.

[0181] In addition, the rest of the configuration is formed in a similar or identical manner to that in Embodiment 6 above.

[0182] In Embodiment 7, the groups of small coils constituting each of the phases are each configured by connecting five winding bodies 42 arranged to be spaced apart by 360 electrical degrees in the circumferential direction in series in the order of arrangement in the circumferential direction.

[0183] The phase coils are formed by connecting four groups of small coils in series, and two groups of small coils accommodated in an identical slot group are sequentially connected. Furthermore, the groups of small coils are connected to each other by crossover wires. As a result, similar or identical effects to those of the above Embodiment 6 can also be obtained in Embodiment 7.

[0184] In Embodiment 7, the second group U102 of small coils is configured by connecting five winding bodies in series in the order of U1-4, U1-2, U1-10, U1-8, and U1-6. The fourth group U202 of small coils is configured by connecting five winding bodies in series in the order of U2-4, U2-2, U2-10, U2-8, and U2-6.

[0185] As indicated by the arrows in Fig. 43, the winding bodies U1-1 and U1-10, as well as the winding bodies U2-10 and U2-9, are inserted into identical slot groups 33, which maximizes the electrical potential differences occurring between the conductor wires within the slots 13. However, the electrical potential differences are smaller than the maximum electrical potential differences in the above embodiment 6.

[0186] Consequently, the maximum electrical potential differences occurring between the conductor wires within the slots 33 can be minimized by changing the connection order of the winding bodies forming the small coil groups. Since the crossover wires are used by connecting the small coil groups, the connection can be made easily, even if the connection distances between the small coil groups are extended. Embodiment 8

[0187] Fig. 44 is a connection diagram for a U-phase coil of an armature winding in a rotary electric machine according to Embodiment 8 of the present invention, and Fig. 45 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 8 of the present invention.

[0188] In the Fig. 44 and Fig. 45, the following applies: U1-1b and U1-3a, U1-3b and U1-5a, U1-5b and U1-7a, and U1-7b and U1-9a of winding bodies 42, which are separated from each other by 360 electrical degrees, are connected by welding, etc., to form a first group U101 of small coils. Similarly, U1-2b and U1-4a, U1-4b and U1-6a, U1-6b and U1-8a, and U1-8b and U1-10a of winding bodies 42, which are separated from each other by 360 electrical degrees, are connected by welding, etc., to form the second group U102 of small coils.

[0189] Similarly, U2-2b and U2-4a, U2-4b and U2-6a, U2-6b and U2-8a, and U2-8b and U2-10a of winding bodies 42 spaced 360 electrical degrees apart are connected together by welding, etc., to form the third group U201 of small coils. Similarly, U2-1b and U2-3a, U2-3b and U2-5a, U2-5b and U2-7a, and U2-7b and U2-9a of winding bodies 42 spaced 360 electrical degrees apart are connected together by welding, etc., to form a fourth group U202 of small coils.

[0190] The first, second, third, and fourth groups U101, U102, U201, and U202 of small coils formed in this manner are each coils mounted to make approximately one circuit (360 mechanical degrees) in the circumferential direction around the armature core 30.

[0191] U1-9b and U2-1a of the winding bodies 42, which are inserted into the slots 33 spaced apart by an electrical angle of (π + π / 6), are connected using a conductor wire U71 to form a partial coil configured by connecting the first group of small coils 101 and the second group of small coils 202 in series. U1-2a and U2-10b of the winding bodies 42, which are inserted into the slots 33 spaced apart by an electrical angle of (π - π / 6), are connected using a conductor wire U72 to form a partial coil configured by connecting the second group of small coils 102 and the third group of small coils 201 in series.

[0192] Furthermore, U1-1a and U1-10b are connected using a crossover wire U73, and U2-2a and U1-9b are connected using a crossover wire U73. This forms a U-phase coil formed by connecting two partial coils in parallel, in which ten winding bodies 42 are connected in series. The connecting portion of U1-1a and U1-10b becomes an electric power supply portion, and the connecting portion of U2-2a and U1-9b becomes a neutral point.

[0193] In each of the sub-coils connected in parallel in this U-phase coil, two groups of small coils housed in an identical slot group are connected at positions that have an identical order when viewed from the power supply end. In other words, the first group U101 of small coils and the second group U102 of small coils housed in an identical slot group are each connected to be in a first position from the power supply end of each of the sub-coils.

[0194] The third group U201 of small coils and the fourth group U202 of small coils accommodated in an identical slot group are connected in a similar manner so as to be in a second position from the end of the electrical power supply of each of the sub-coils.

[0195] A V-phase coil and a W-phase coil are also manufactured in a similar or identical manner to that of the U-phase coil.

[0196] In addition, the rest of the configuration is formed in a similar or identical manner to that in Embodiment 6 above.

[0197] In Embodiment 8, since the groups of small coils constituting each of the phases are each configured by connecting five winding bodies 42 arranged to be spaced apart by 360 electrical degrees in the circumferential direction in series in the order of arrangement in the circumferential direction, the lengths of the crossing portions connecting the winding bodies 42 to each other can also be shortened, which makes it possible to achieve downsizing.

[0198] The phase coils are configured by connecting two partial coils in parallel, which are formed by connecting a group of small coils accommodated in each of the slot groups in series. Since groups of small coils accommodated in an identical slot group are connected in such a way that they are located at positions that have the same order when viewed from the end of the electrical power supply in each of the partial coils connected in parallel, electrical potential differences that occur between the conductor wires within the slots 33 can be reduced.

[0199] Furthermore, in the above embodiments 6 to 8, the winding bodies are manufactured by winding conductor wires into a δ-shaped coil pattern, but the winding bodies may also be manufactured by winding conductor wires into a δ-shaped coil pattern several times consecutively. Embodiment 9

[0200] Fig. 46 is an oblique projection showing an armature used in the rotary electric machine according to Embodiment 9 of the present invention, Fig. 47 is an oblique projection showing a winding body constituting an armature winding of an armature used in the rotary electric machine according to Embodiment 9 of the present invention.

[0201] Fig. 48 is a plan view showing connecting wire portions of the armature winding in the rotary electric machine according to Embodiment 9 of the present invention, Fig. 49 is a connection diagram for the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 9 of the present invention, and Fig. 50 is a schematic diagram showing the U-phase coil of the armature winding in the rotary electric machine according to Embodiment 9 of the present invention.

[0202] As in Fig. As shown in Figure 46, an armature 10B includes an armature core 30; and an armature winding 50 mounted on the armature core 30. To simplify the explanation, the number of poles p is 10, the number of slots s in the armature core 30 is 60, and the armature winding 50 is a three-phase winding. In other words, the number of slots per phase and per pole q is two.

[0203] As in Fig. 47, a coil 52 is formed by winding a conductor wire 39 with a circular cross section of diameter d, formed of a spliceless copper wire or aluminum wire coated with an insulating enamel resin, for example, approximately one turn in a wave winding on the armature core 30. Furthermore, a conductor wire with a rectangular cross section may be used in the coil 52 instead of the conductor wire 39 with a round cross section.

[0204] The coil 52 includes: ten rectilinear portions 52a arranged at a pitch angle of six grooves (a pitch of a single magnetic pole) in the circumferential direction; and coil end portions 52b alternately connecting first longitudinal end portions of adjacent rectilinear portions 52a to each other and second longitudinal end portions of adjacent rectilinear portions 52a to each other in the circumferential direction.

[0205] The coil end regions 52b each have an arm region that is radially offset by d. The ten rectilinear regions 52a are thus arranged in the circumferential direction so that they alternate their radial position between a radial inner side and a radial outer side. A winding start of the coil 52 is a starting point 52c, and a winding end forms an end point 52d.

[0206] A winding assembly 51 is manufactured by radially arranging coil groups in two layers, and the coil groups are manufactured by arranging twelve of these coils 52 with a pitch of a single slot in the circumferential direction. In the winding assembly 51 manufactured in this manner, sixty columns of four rectilinear regions 52a, radially aligned in a single column, are arranged with a pitch of one slot in the circumferential direction.

[0207] To construct the armature 10B, thirty core blocks 31 are arranged at an approximately uniform pitch angle in the circumferential direction so that the respective teeth 31b are located on the radially outer side between adjacent columns of straight portions 52a of the winding assembly 51. Thereafter, the core blocks 31 arranged in the circumferential direction are simultaneously moved radially inward. The respective teeth 31b of the core blocks 31 are thereby arranged between the adjacent columns of the straight portions 52a.

[0208] The peripheral surfaces of the adjacent core blocks 31 are thereby abutted against each other, preventing radial inward movement of the core blocks 31, and the winding assembly 51 is thereby mounted on the armature core 30. A predetermined joining process (described below) is applied to the starting points 52c and the ending points 52d of the coils 52 constituting the winding assembly 51 to form the armature winding 50. Thus, the armature 10B is manufactured.

[0209] A connection method for the winding assembly 51 will be described below with reference to Fig. 48 and Fig. 49. The winding arrangement 51 is made by interlacing twenty-four coils 52. As shown in Fig. 48, the forty-eight starting points 52c and ending points 52d, which form the end portions of the twenty-four coils 52, are concentrated in an area of ​​a pitch of two magnetic poles in the circumferential direction.

[0210] To explain the connection method, the starting points 52c and the end points 52d of each coil 52 are designated here by a five-character character string as a convenient means. A first (numeric) character of the character string indicates the radial positions within the grooves 33 of the straight line portions 52a connecting the starting points 52c and the end points 52d. Specifically, cases where the straight line portions connecting the starting points 52c and the end points 52d are received first and second from a radially outer side within the grooves 33 are designated by "1."

[0211] Cases in which they are accommodated in the third and fourth positions from the radial outside within the slots 33 are designated "2." The second (alphabetic) character of the character string indicates the phase to which the coil 52 belongs. The third (numeric) character of the character string indicates the slot group in which the coil 52 is accommodated, with a first slot group being designated "1" and a second slot group being designated "2."

[0212] The following applies to the fourth (numeric) character of the character string: In a group of coils 52 for which the first three characters in the character string are identical, the starting positions 52c and the ending positions 52d of the coils 52, which are connected to one end near the electrical power supply, are designated by "1", and the starting positions 52c and the ends 52d of the coils 52, which are connected to the opposite end of the electrical power supply, are designated by "2". For the fifth character of the character string, the starting positions 52c of the coils 52 are designated by "a", and the ending positions 52d are designated by "b".

[0213] 1U11b and 2U11a are first connected by welding, etc., to form a first group U101 of small coils with two windings in which two coils 52 are connected in series, and 2U12a and 1U12b are connected by welding, etc., to form a second group U102 of small coils with two windings in which two coils 52 are connected in series. Thereafter, 2U11b and 2U12b are connected using a crossover wire U71 to form a U1-2-phase coil configured by connecting the first and second groups of small coils U101 and U102 in series.

[0214] Next, 2U22a and 1U22b are connected by welding, etc., to form a third group U201 of small coils with two windings in which two coils 52 are connected in series, and 1U21b and 2U21a are connected by welding, etc., to form a fourth group U202 of small coils with two windings in which two coils 52 are connected in series. Next, 1U22a and 1U21a are connected using a crossover wire U72 to form a U2-phase coil formed by connecting the third and fourth groups of small coils U201 and U202 in series.

[0215] Next, 1U12a and 2U22b are connected to form a U-phase coil, which is configured by connecting the U1-phase coil and the U2-phase coil in series. A U-phase coil connected in series in the order of the first group U101 small coils, the second group U102 small coils, the third group U201 small coils, and the fourth group U202 small coils from the electric power supply portion toward the neutral point is obtained by making 1U11a, which forms one terminal of the U-phase coil, an electric power supply portion, and by making 2U21b, which also forms one terminal of the coil, a neutral point, as shown in Fig. 50 shown.

[0216] A V-phase coil and a W-phase coil are also formed in a similar or identical manner to that of the U-phase coil. An armature winding 50 is thus obtained, which is formed of a three-phase AC winding, which is a distributed winding of full-pitch windings formed by connecting a U-phase coil, a V-phase coil, and a W-phase coil in a star connection.

[0217] In Embodiment 9, since the phase coils are configured by connecting the four first to fourth groups U101, U102, U201, U202 of small coils in series, and since groups of small coils accommodated in identical slot groups are connected one after another, the electric potential differences occurring between the lead wires within the slots 33 can also be maintained at approximately half the phase voltage.

[0218] In Embodiment 9, groups of small coils housed in identical slot groups are connected sequentially, but the groups of small coils housed in identical slot groups may also be alternately connected. In other words, the phase coils may be formed by connecting the first group of small coils U101, the third group of small coils U201, the second group of small coils U102, and the fourth group of small coils U202 in series in this order. Embodiment 10

[0219] Fig. 51 is a connection diagram for a U-phase coil of an armature winding in a rotary electric machine according to Embodiment 10 of the present invention.

[0220] In Embodiment 10, a first group U101 of small coils, a second group U102 of small coils, a third group U201 of small coils, and a fourth group U202 of small coils are constructed in a similar or identical manner to those of Embodiment 9 described above. A partial coil is manufactured in which the first group U101 of small coils and the third group U201 of small coils are connected in series by connecting 2U11b and 1U22a using a crossover wire 71. Similarly, a partial coil is manufactured in which the second group U102 of small coils and the fourth group U202 of small coils are connected in series by connecting 2U12b and 1U21a using a crossover wire 72.

[0221] In addition, 1U11a and 1U12a are connected using a crossing wire 73, and 2U22b and 2U21b are connected using a crossing wire 73. As in Fig. 51, a U-phase coil is thereby obtained which is formed by connecting two partial coils in parallel, in which four coils 52 are connected in series.

[0222] In each of the partial coils connected in parallel in this U-phase coil, two groups of small coils accommodated in an identical slot group are connected at positions having an identical sequence when viewed from the end of the electrical power supply.

[0223] In other words, the first group U101 of small coils and the second group U102 of small coils accommodated in an identical slot group are connected so as to be in a first position from the end of the electric power supply of each of the parallel-connected partial coils.

[0224] The third group U201 of small coils and the fourth group U202 of small coils accommodated in an identical slot group are connected in a similar manner so that they are in a second position from the end of the electrical power supply of each of the parallel-connected sub-coils.

[0225] A V-phase coil and a W-phase coil are also formed in a similar or identical manner to that of the U-phase coil. An armature winding is thus obtained, which is formed from a three-phase AC winding, which is a distributed winding of full-pitch windings formed by connecting a U-phase coil, a V-phase coil, and a W-phase coil in a star connection.

[0226] In Embodiment 10, the phase coils are also configured by connecting in parallel two sub-coils which are made by connecting in series a group of small coils accommodated in a first slot group and a group of small coils accommodated in a second slot group.

[0227] Since groups of small coils accommodated in an identical slot group are connected so as to be located at positions having the same order when viewed from the end of the electrical power supply in each of the partial coils connected in parallel, electrical potential differences occurring between the conductor wires within the slots 13 can be reduced.

[0228] Furthermore, in Embodiments 9 and 10 above, four coils are accommodated in identical slot groups, but the number of coils accommodated in identical slot groups is not limited to four, as long as it is 2m, where m is a natural number greater than or equal to two. The small coil groups should be configured by serially connecting two coils formed by radially adjacent conductor wires among the 2m conductor wires arranged in a single column within the slots.

[0229] In the above embodiments 9 and 10, the slots are formed in a ratio of two slots per phase per pole, but the slots may also be formed in a ratio of three or more slots per phase per pole.

[0230] In each of the above embodiments, an inside-rotor type electric motor was explained, but similar or identical effects can also be achieved if the present invention is applied to an outside-rotor type electric motor.

[0231] In each of the above embodiments, cases were described in which the present application was applied to an electric motor, but similar or identical effects can also be achieved when the present application is applied to a generator.

[0232] In each of the above embodiments, winding bodies were manufactured using conductor wires coated with insulation. However, insulation coating treatment may be applied to winding bodies manufactured using conductor wires that are not coated with insulation.

Claims

[1] An electric rotary machine comprising an armature (10, 10A) configured by mounting an armature winding (20, 40) in an annular armature core (11, 30), wherein slots (13, 33) are formed on the armature core in a ratio of q slots per phase per pole, where q is a natural number greater than or equal to two, wherein the armature winding (20, 40) is formed such that winding bodies (22, 42) with distributed winding are arranged at a pitch of one slot in the circumferential direction, wherein the winding bodies (22, 42) are configured by winding conductor wires (39) into two or three of the slots (13, 33) which are spaced from each other at a pitch of one magnetic pole; characterized byin that the respective phase coils forming the armature winding (20, 40) comprise a number 2q of groups (U101, U102, U201, U202) of small coils, each group (U101, U102, U201, U202) of small coils each comprising one circuit in the circumferential direction, by connecting winding bodies (22) in series in the order of arrangement in the circumferential direction and each group (U101, U102, U201, U202) comprising p / 2 winding bodies (22), where p is the number of poles, the winding bodies (22) being accommodated in an identical slot group which are spaced apart from one another by 360 electrical degrees; and that each of the phase coils is configured by connecting the 2q groups (U101, U102, U201, U202) of small coils in series such that two of the 2q groups (U101, U102, U201, U202) of small coils accommodated in the identical slot group are arranged consecutively or alternately. [2] An electric rotary machine comprising an armature (10, 10A) configured by mounting an armature winding (20, 40) in an annular armature core (11, 30), wherein slots (13, 33) are formed on the armature core in a ratio of q slots per phase per pole, where q is a natural number greater than or equal to two, wherein the armature winding (20, 40) is formed such that winding bodies (22, 42) with distributed winding are arranged at a pitch of one slot in the circumferential direction, wherein the winding bodies (22, 42) are configured by winding conductor wires (39) into two or three of the slots (13, 33) which are spaced from each other at a pitch of one magnetic pole; characterized byin that the respective phase coils forming the armature winding (20, 40) comprise a number 2q of groups (U101, U102, U201, U202) of small coils, each group (U101, U102, U201, U202) of small coils each comprising one circuit in the circumferential direction, by connecting winding bodies (22) in series in the order of arrangement in the circumferential direction and each group (U101, U102, U201, U202) comprising p / 2 winding bodies (22), where p is the number of poles, the winding bodies (22) being accommodated in an identical slot group which are spaced apart from one another by 360 electrical degrees; that each of the phase coils is configured by connecting two partial coils in parallel, the partial coils being configured by connecting a part of the 2q groups (U101, U102, U201, U202) of small coils in series, which are accommodated in different slot groups;and that two of the 2q groups (U101, U102, U201, U202) of small coils accommodated in an identical slot group are arranged at an identical position of the order counted from an electric power supply portion of each of the two sub-coils; [3] An electric rotary machine according to claim 1 or 2, wherein the connection between the coils is made using a cross wire (71, 72, 73, 74) which is made as a separate part from the conductor wires (39). [4] An electric rotary machine comprising an armature (10B) configured by mounting an armature winding (50) into an annular armature core (30), wherein slots (33) are formed on the armature core in a ratio of q slots per phase per pole, where q is a natural number greater than or equal to two, characterized bythat the armature winding (50) comprises a plurality of coils (52), each formed by winding a conductor wire (39) in a wave winding for circumferential circulation in a slot group formed by the slots (33) at a pitch of one magnetic pole to alternately occupy a radially inner side and a radially outer side within the slots, wherein 2m of the conductor wires (39) are arranged in a single column radially in each of the slots, where m is a natural number greater than or equal to two; that the respective phase coils forming the armature winding (50) comprise (m × q) groups (U101, U102, U201, U202) of small coils formed by connecting coils (52) in series, in which the conductor wires (39) radially adjoin one another within the slots (33);and that each of the phase coils is configured by connecting the (m × q) groups of small coils in series so that m groups of small coils accommodated in an identical slot group are arranged sequentially or alternately.; [5] An electric rotary machine comprising an armature (10B) configured by mounting an armature winding (50) into an annular armature core (30), wherein slots (33) are formed on the armature core in a ratio of q slots per phase per pole, where q is a natural number greater than or equal to two, characterized bythat the armature winding (50) comprises a plurality of coils (52), each formed by winding a conductor wire (39) in a wave winding for circumferential circulation in a slot group formed by the slots (33) at a pitch of one magnetic pole to alternately occupy a radially inner side and a radially outer side within the slots, wherein 2m of the conductor wires (39) are arranged in a single column radially in each of the slots, where m is a natural number greater than or equal to two; that the respective phase coils constituting the armature winding 101 comprise (m × q) groups (U101, U102, U201, U202) of small coils formed by connecting coils (52) in series, in which the conductor wires (39) radially adjoin one another within the slots (33);that each of the phase coils is configured by connecting m sub-coils in parallel, the sub-coils being configured by connecting q of the groups of small coils accommodated in different slot groups in series; and that m of the groups of small coils accommodated in an identical slot group are arranged at an identical position in the order counted from an electric power supply area of ​​each of the m sub-coils.;

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