Dynamo-electric machine

Abstract

Stator (20) of a dynamo-electric machine, comprising: a stator iron core (132) in which a plurality of circumferentially oriented slots (420) are formed; a multitude of segment windings inserted into the slots (420) and formed in an almost U-shape; and a ring-shaped insulator (300) arranged at a welding-side coil end (62) between the segment windings, wherein the insulator (300) has a part of the insulator (300) that is thicker than the other part of the insulator (300), wherein the insulator (300) is designed such that, in the aligned segment windings, it is longer than the circumferential length of the stator (20); and a thicker part of the insulator (300) is formed by overlapping a part (302) that includes both ends of the insulator (300) in the circumferential direction, wherein a segment conductor (28) in the segment windings, which overlaps with the thicker part of the insulator (300), leads to a supply wire, and wherein the overlapping part (302) is arranged in a direction that is identical to the bending direction of the coil.

Description

TECHNICAL AREA

[0001] The present invention relates to a stator and a dynamoelectric machine that uses the stator. In particular, the present invention relates to a dynamoelectric machine that generates torque for powering a vehicle or generates current during braking. STATE OF THE ART

[0002] In a dynamo-electric machine, a rotating magnetic field is generated by applying alternating current to a winding wire of the stator, causing a rotor to rotate through this field. Furthermore, it is also possible to convert the mechanical energy supplied to the rotor into electrical energy and output alternating current from a coil. In this way, a dynamo-electric machine operates like an electric motor or an electric generator.

[0003] A configuration of terminals for segmented windings is known as the stator of such a dynamoelectric machine, formed by welding (see, e.g., JP 2011-151975A). Furthermore, US 2015 / 0022045A1 discloses a stator for a rotating electric machine in which U-shaped segmented conductors are inserted into slots of a stator core, with an annular interphase insulator arranged at one coil end to separate the windings of the different phases. JP 2012-080699A discloses a stator in which an annular insulating paper is inserted between the layers of the segmented windings at the coil end to create a local thickening by folding back one end of this insulating paper. US 5,659219A discloses a stator and a method for its manufacture in which a shaped insulating paper is inserted between the coil ends of the windings.This insulating paper features flat sections for radial separation and integrally formed, folded-back sections for separating the circumferentially adjacent windings. JP 2014 / 096855A discloses an interphase insulator for a stator, consisting of annular insulating sections and connecting bridge webs. To minimize stiffness, the width of the overlap area where the ring is closed is less than or equal to the width of the bridge webs. Finally, JP H02-133046A discloses an insulation arrangement for electric motors in which the connection points between winding ends and leads are protected. Specifically, a strip of insulating paper, already used for phase insulation between the coil heads, is folded at certain points to form pockets.The connection points are contained in these pockets, after which the pockets are thermally sealed to enclose and insulate the connections.

[0004] When such a dynamo-electric machine is installed in an automobile, downsizing is necessary because the machine is mounted in a very confined space. This downsizing required low-profile coil ends. To achieve this, the height of the coil end section had to be reduced, and an insulation distance had to be maintained within a very small space. Ensuring a stable insulation distance in a segmented winding was a challenge. Furthermore, after the switching operation of a switching element in an inverter device, a steep impulse voltage is applied from the inverter device to the input point of each phase.Although it is desirable to optimize the thickness of an insulating film in relation to the voltage division ratio of each coil, increasing the thickness of the insulating film of each coil can be difficult, as increasing the thickness causes a deterioration in productivity from the point of view of the coil's malleability. SUMMARY OF THE INVENTIONAL PROBLEM

[0005] The present invention relates to a stator of a dynamoelectric machine with the features of claim 1 and a dynamoelectric machine with the features of claim 4. Advantageous embodiments are defined in the dependent claims. SOLUTION TO THE PROBLEM

[0006] The present invention makes it possible to improve the reliability of the insulation of a dynamoelectric machine. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 shows a sectional view of a dynamoelectric machine 10 according to the present embodiment; Fig. Figure 2 shows a perspective overall view of a stator 20; Fig. Figure 3 shows a perspective overall view of a stator iron core 132; Fig. Figure 4 shows a sectional view showing cross-sections of a rotor 11 and a stator iron core 132; Fig. Figure 5 shows a perspective overall view showing a stator coil 60; Fig. Figure 6 shows a conceptual diagram representing a connection state of a stator coil 60; Fig. 7A and Fig. Figure 7B shows concept diagrams that explain the segment conductors 28 that make up a stator coil 60; Fig. Figure 8 shows a perspective view of a U-phase coil 60U, which is part of a phase of a stator coil 60, as in Fig. 5 shown corresponds to; Fig. Figure 9 shows a perspective view showing a U1 phase coil 60U1; Fig. Figure 10 shows a perspective view of a U2 phase coil 60U2. As in Fig. 9 and Fig. Figure 10 shows a neutral point connecting conductor 40N1 connected to another end of a U1 phase coil 60U1 and a neutral point connecting conductor 40N2 connected to another end of a U2 phase coil 60U2; Fig. Figure 11 shows a view of the ends 28E1 to 28E4 of the segment conductor 28 after bending work on a weld-side coil end 62; Fig. Figure 12 shows a perspective view in front of insulators 300, each of which has an overlapping part 302 inserted between segment conductors 28 at a weld-side coil end 62; Fig. Figure 13 shows a perspective view immediately in front of the insulators 300, each of which has an overlapping part 302 inserted between the segment conductors 28 at a weld-side coil end 62; Fig. Figure 14 shows an insulator 300 from the direction parallel to the axis of rotation of a dynamo-electric machine 10; Fig. Figure 15 shows an insulator 300 according to another embodiment, viewed from the direction parallel to the axis of rotation of a dynamoelectric machine 10; Fig. Figure 16 shows an insulator 300 according to another embodiment, viewed from the direction parallel to the axis of rotation of a dynamoelectric machine 10; Fig. Figure 17A shows a side view of an insulator 300 before an overlapping part 302 is folded according to another embodiment; Fig. Figure 17B shows a side view of an insulator 300 after an overlapping part 302 has been folded according to another embodiment; Fig. Figure 17C shows an insulator 300 according to a further embodiment, viewed from the direction parallel to the axis of rotation of a dynamoelectric machine 10; Fig. Figure 18 shows a schematic configuration of a hybrid electric vehicle, above which a dynamoelectric machine 10 is mounted according to the present embodiment. DETAILED DESCRIPTION OF PREFERRED EXECUTION FORMS

[0007] Embodiments for carrying out the present invention are described below with reference to Fig. 18 explained. A dynamoelectric machine 10 according to the present embodiment is a dynamoelectric machine suitable for use in the operation of an automobile. Here, as so-called electric vehicles, each using a dynamoelectric machine 10, there is a hybrid electric vehicle (HEV) with both a motor ENG and a dynamoelectric machine 10, and a true electric vehicle (EV) powered solely by a dynamoelectric machine 10 without the use of a motor ENG. A dynamoelectric machine described below can be used in both types, so explanations are given based on a dynamoelectric machine used here as a representative example in a hybrid vehicle.

[0008] Furthermore, in the following explanations, an "axial direction" refers to a direction parallel to the axis of rotation of a dynamo-electric machine. A circumferential direction refers to a direction parallel to the direction of rotation of a dynamo-electric machine. A "radial direction" refers to the direction of a radius of motion (a radius direction) that extends radially from the axis of rotation of a dynamo-electric machine. An "inner circumferential side" refers to an inner side in the radial direction (inner diameter side), and an "outer circumferential side" refers to the opposite side, namely an outer side in the radial direction (outer diameter side). Schematic diagram of the vehicle:

[0009] First, a schematic configuration of a vehicle in which a dynamo-electric machine is mounted is presented with reference to Fig. Figure 18 explains. A vehicle has a motor ENG and a dynamo-electric machine 10 as the main drive on the front wheel side. The power generated by the motor ENG and the dynamo-electric machine 10 is switched by a gearbox TR and transmitted to the front side-drive wheels FW. Furthermore, with regard to the drive of the rear wheels, a dynamo-electric machine 10 located on the rear wheel side and the rear side-drive wheels RW are mechanically connected, and power is transmitted. The dynamo-electric machine 10, which is an energy source on the front wheel side, is located between the motor ENG and the gearbox TR.

[0010] The dynamoelectric machine 10 starts the motor and, depending on the vehicle's operating state, switches between generating motive power and generating electricity to recover energy as electrical energy during vehicle deceleration. The drive and power generation processes in the dynamoelectric machine 10 are controlled by an inverter INV, allowing the torque and number of revolutions to be optimized according to the vehicle's driving situation. The electrical energy required to drive the dynamoelectric machine 10 is supplied from a battery BAT via the inverter INV. Furthermore, when the dynamoelectric machine 10 is in power generation mode, electrical energy is transferred to the battery BAT by the inverter INV.

[0011] The dynamoelectric machine 10 is a three-phase synchronous motor with an integrated permanent magnet. The dynamoelectric machine 10 acts as an electric motor to rotate a rotor by supplying three-phase alternating current to a stator coil. Furthermore, the dynamoelectric machine 10 functions as a power generator, outputting the generated three-phase electrical power when driven by a motor. That is, the dynamoelectric machine 10 functions both as an electric motor to generate rotational torque based on electrical energy and as a power generator to produce electricity based on mechanical energy, and can selectively utilize these functions depending on the operating condition of a vehicle. Explanation of the dynamo-electric machine 10:

[0012] Fig. Figure 1 shows a sectional view of a dynamo-electric machine 10 according to the present embodiment. In the present embodiment, the dynamo-electric machine 10 is arranged inside a liquid-cooled jacket 130. The liquid-cooled jacket 130 includes a housing made of a motor ENG and a housing made of a gearbox TR. The dynamo-electric machine 10 includes a stator 20, a housing 50 for holding the stator 20, and a rotor 11.

[0013] The water-cooled jacket 130 is attached to the outer circumferential side of the housing 50. A refrigerant flow channel 153 for a liquefied refrigerant RF, such as oil, is formed by an inner wall of the water-cooled jacket 130 and an outer wall of the housing 50. A shaft 13, to which the rotor 11 is attached, is rotatably mounted by a bearing 144 and a bearing 145, which are arranged in the liquid-cooled jacket 130. For this reason, the liquid-cooled jacket 130 is also referred to as a bearing support.

[0014] As in the present case of a direct liquid cooling system, a liquid that accumulates in a refrigerant storage chamber 150 flows through the refrigerant flow channel 153 to the stator 20 through a refrigerant flow channel 154 and a refrigerant flow channel 155 and cools the stator 20. The refrigerant RF can also be an oil for cooling.

[0015] The stator 20 is mounted on the inner circumferential side of the housing 50. The rotor 11 is rotatably mounted on the inner circumferential side of the stator 20. The housing 50 is formed into a cylindrical shape by machining an iron material such as carbon steel, casting steel or an aluminum alloy, or pressing, and forms the outer casing of the dynamo-electric machine 10. The housing 50 is also referred to as the frame body or frame.

[0016] The housing 50 is formed into a cylindrical shape by tensile forming of a steel plate (high-strength steel plate or the like) approximately 2 to 5 mm thick. Several flanges (not shown in the figure), attached to the liquid-cooled jacket 130, are arranged in the housing 50. The flanges project outwards in a radial direction from an edge on an end plane of the cylindrical housing 50. At one end formed during tensile forming, the flanges are formed by cutting out the portion that is not the flanges themselves, and these are integrated into the housing 50. It is also possible to attach the stator 20 directly to the liquid-cooled jacket 130, i.e., without forming the housing 50.

[0017] Fig. Figure 2 shows a perspective overall view of a stator 20. Fig. Figure 3 shows a perspective overall view of a stator iron core 132. As in Fig. As shown in Figure 2, the stator 20 comprises a stator iron core 132 and a stator coil 60. The stator iron core 132 is formed by stacking thin silicon steel sheets. The stator coil 60 is wound around several slots 420 formed on the inner circumferential part of the stator iron core 132. The heat generated by the stator coil 60 is transferred through the stator iron core 132 to a liquid-cooled jacket 130 and dissipated by a refrigerant RF flowing in the liquid-cooled jacket 130.

[0018] As in Fig. As shown in Figure 1, a rotor 11 comprises a rotor iron core 12 and a shaft 13. Fig. Figure 4 shows a sectional view showing cross-sections of a rotor 11 and a stator iron core 132. Here, the shaft 13 of Fig. 4 excepted. The rotor iron core 12 is formed by stacking thin silicon steel sheets. The shaft 13 is fixed in the center of the rotor iron core 12. The shaft 13 is rotatably held by a bearing 144 and a bearing 145, which are attached to the liquid-cooled jacket 130, as shown in Fig. 1 is shown and rotates at a predetermined position facing the stator 20 in the stator 20. Furthermore, permanent magnets 18 and end rings are arranged in the rotor 11, although they are from Fig. 1 are excluded.

[0019] As in Fig. As shown in Figure 3, several slots 420 are formed in the stator iron core 132 parallel to the axial direction of the stator iron core 132 at equal intervals in the circumferential direction. The number of slots 420 is, for example, 72 in the present embodiment, and the stator coil 60 is contained within the slots 420. Each of the slots 420 opens on the inner circumference side, and the width of the opening in the circumferential direction is approximately equal to or slightly less than the width of the part in which the stator coil 60 is installed, i.e., the slot 420.

[0020] Teeth 430 are formed between the slots 420 and are integrated with an annular core back 440. That is, the stator iron core 132 is a monolithic core formed by the integral forming of the teeth 430 and the core back 440. The teeth 430 transmit a rotating field generated by the stator coil 60 to the rotor 11 and generate a torque at the rotor 11.

[0021] The stator core 132 is formed by punching an electrical steel sheet approximately 0.05 to 1.0 mm thick and stacking several punched, ring-shaped electrical steel sheets. The welded parts 200 are arranged parallel to the axial direction of the stator core 132 on the outer circumferential parts of the cylindrical stator core 132 by TIG welding (tungsten inert gas welding), laser welding, or similar processes. It is also possible to fix the stator core 132 by riveting or similar means and to insert the stator core 132 directly into a housing without providing welded parts 200.

[0022] Fig. Figure 4 shows a sectional view of a rotor 11 and a stator 20, which were photographed on a plane perpendicular to the axial direction. Magnet insertion holes 810 are formed at equal intervals in a rotor iron core 12, into which rectangular permanent magnets 18 are inserted. Each of the permanent magnets 18 is attached to each of the magnet insertion holes 810 by an adhesive, powder resin, a mold, or the like. The circumferential width of each of the magnet insertion holes 810 is set larger than the circumferential width of each of the permanent magnets 18, and magnetic gaps 156 are formed on both sides of each permanent magnet 18. The magnetic gaps 156 can either be filled with an adhesive or integrally attached to the permanent magnets 18 by a molding resin. The permanent magnets 18 form field poles in the rotor 11.Although in the present embodiment a permanent magnet 18 represents a magnetic pole, the number of permanent magnets 18 forming each field pole can be increased to two or more, and by increasing the number of permanent magnets 18 it is possible to increase the magnetic flux density of each magnetic pole generated by each permanent magnet and to increase a magnetic moment.

[0023] The magnetization direction of each of the permanent magnets 18 is radial, and the magnetization direction is reversed at each field pole. That is, if the stator side plane of a permanent magnet 18 is magnetized to form an N pole and the axial plane to form an S pole, the stator side plane of an adjacent permanent magnet 18 will be magnetized to form an S pole and the axial plane to form an N pole. The permanent magnets 18 are magnetized such that the magnetization directions of the magnetic poles can alternately change circumferentially. In the present embodiment, twelve permanent magnets 18 are arranged at equal intervals, and the rotor 11 forms twelve magnetic poles.

[0024] A sintered magnet or ferrite magnet of a neodymium or samarium series, a bonding magnet of a neodymium series, or the like can be used as the permanent magnet 18. In the present embodiment, auxiliary magnetic poles 160 are formed between the permanent magnets 18, which form the magnetic poles. The auxiliary magnetic poles 160 act in such a way that they reduce the magnetic resistance of a magnetic flux on the q-axis generated by the stator coil 60. Thus, the magnetic resistance of the magnetic flux on the q-axis becomes very small compared to the magnetic resistance of the magnetic flux on the d-axis due to the auxiliary magnetic poles 160, and a large reluctance moment is generated.

[0025] Fig. Figure 5 shows a perspective overall view showing a stator coil 60. Fig. Figure 6 shows a conceptual diagram representing a connection state of a stator coil 60. In the present embodiment, the stator coil 60 is assumed to be a stator coil with a two-star configuration, in which two star connections are arranged parallel to each other, as shown in Fig. Figure 6 shows that the stator coil 60 includes a star connection of a U1 phase coil 60U1, a V1 phase coil 60V1 and a W1 phase coil 60W1, and a star connection of a U2 phase coil 60U2, a V2 phase coil 60V2 and a W2 phase coil 60W2. N1 and N2 are the star points of the respective star connections.

[0026] The stator coil 60 can have a cross-section of either a round or square shape. However, since such a structure, which utilizes the cross-section of the interior of a slot 420 as effectively as possible and reduces the space in the slot, tends to lead to an improvement in efficiency, a square cross-section is desirable from an efficiency-enhancing point of view. Here, the lengths of the sides of a square cross-section can be adjusted such that the length of the side in the radial direction of a stator iron core 132 can be longer, or conversely, the length of the side in the circumferential direction can be longer.

[0027] In the stator coil 60, a flat wire with a rectangular cross-section is used according to the present embodiment. The longitudinal sides of the rectangular cross-sections are aligned in the slots 420 in the circumferential direction of a stator iron core 132, and the end faces are aligned in the radial directions of the stator iron core 132. The outer circumference of the flat wire is covered with an insulating film. Oxygen-free or oxygenated copper is used as the stator coil 60. For example, in the case of oxygenated copper, the oxygen content is between 10 ppm and 1,000 ppm.

[0028] Fig. 7A and Fig. Figure 7B shows diagrams that explain the segment conductors 28 that make up a stator coil 60. Fig. Figure 7A shows the shape of a segment conductor 28 before installation in a stator iron core 132. Fig. Figure 7B shows the shapes of the segment conductors 28 after installation in the stator iron core 132. A segment conductor 28 comprises a flat wire and is almost U-shaped, with a pair of legs 28B and a vertex 28C that connects the legs 28B.

[0029] If a coil of each phase is formed by connecting segment conductors 28 together, as in Fig. As shown in Figure 7B, a pair of legs 28B of a segment conductor 28 is inserted into various slots 420 from one side in the axial direction of a stator iron core 132. Subsequently, a leg 28B, which projects axially from the stator iron core 132 towards the other side, is folded towards another segment conductor 28 to be connected, and the edge 28E of leg 28B is welded to an edge 28E of the other segment conductor 28.

[0030] An arrangement of the vertices 28C, which project from one side of a stator iron core 132, forms a coil end 61 on one side of a stator coil 60, as shown in Fig. Figure 5 shows an arrangement of edges 28E projecting towards the other side of the stator iron core 132, forming a coil end 62 on the other side of the Fig. 5 stator coil 60 shown. The coil end 62 is referred to as the weldable coil end 62 and the coil end 61 as the weldable coil end 61.

[0031] As in Fig. 5 and Fig. As shown in Figure 6, a lead wire 41U1, connected to one end of a U1 phase coil 60U1, and a lead wire 41U2, connected to one end of a U2 phase coil 60U2, are taken from the weldable coil end 61. The lead wire 41U1 and the lead wire 41U2 are integrated into a unit via an AC terminal 42U. Similarly, on the weldable coil end 61, a lead wire 41V1 ​​and a lead wire 41V2, connected to the ends of a V1 phase coil 60V1 and a V2 phase coil 60V2 respectively, are integrated into a unit via an AC terminal 42V. A supply wire 41W1 and a supply wire 41W2, which are connected to the ends of a W1 phase coil 60W1 and a W2 phase coil 60W2 respectively, are integrated into a unit by an AC terminal block 42W.

[0032] Furthermore, a neutral point connecting conductor 40N1 and a neutral point connecting conductor 40N2 are arranged on the side of the weld-resistant coil end 61. The neutral point connecting conductor 40N1 refers to a neutral point N1 (see Fig. 6) of a star connection and the neutral point connecting conductor 40N2 to a neutral point N2 of the other star connection.

[0033] A stator coil 60 is wound by a distributed winding method. Distributed winding is a winding method for winding a phase winding wire around a stator iron core 132, such that the phase winding wire can be accommodated in two distant slots 420 in such a way that several slots 420 are bridged (see Fig. 3) The distributed winding is adopted as a wire-wing method in the present embodiment, and thus the present embodiment has the feature that the resulting magnetic flux distribution is almost sinusoidal compared to lumped wiring, and a reluctance torque is likely to be generated. As a result, a dynamo-electric machine 10 allows for improved controllability of the field weakening control and the control of the use of reluctance torques, enabling it to be used over a wide speed range from low to high speed and to obtain excellent motor characteristics suitable for an electric vehicle.

[0034] Fig. Figure 8 shows a perspective view showing a U-phase coil 60U, which is a part corresponding to one phase of a stator coil 60, as in Fig. 5 shown. As in Fig. Figure 6 shows a U-phase coil 60U comprising a U1-phase coil 60U1 of a star connection and a U2-phase coil 60U2 of the other star connection. Fig. Figure 9 shows a perspective view showing a U1 phase coil 60U1. Fig. Figure 10 is a perspective view showing a U2 phase coil 60U2. As in Fig. 9 and Fig. As shown in Figure 10, a neutral point connecting conductor 40N1 is connected to the other end of the U1 phase coil 60U1 and a neutral point connecting conductor 40N2 is connected to the other end of the U2 phase coil 60U2. Manufacturing process of the stator - bending work

[0035] A manufacturing process for a stator 20 according to the present embodiment is explained below. As already mentioned, after a segment conductor 28 is inserted into the, in Fig. 7A, the shown state was inserted into the slots of a stator iron core 132, the legs 28B in the direction of other segment conductors 28 to be connected, as in Fig. 7B is shown, bent. A leg 28B drawn out of each of the slots 420 is bent in the direction of a segment conductor 28 to be connected. For example, a leg 28B1 protruding from a slot 420 is bent circumferentially to the left. In contrast, a leg 28B2 with an end 28E2 is bent circumferentially to the right. Then, an end 28E1 and the end 28E2 are arranged such that they adjoin each other radially.

[0036] Fig. Figure 11 shows a view showing an end 28E1 to an end 28E4 of the segment conductor 28 after bending work on a weld-side coil end 62.

[0037] Segmented ladders 28, consisting of four rows, are inserted radially into a slot 420. The supports 28B1 to 28B4, which are pulled out of a slot 420, are bent in the direction of the segmented ladders 28 to be connected.

[0038] Slot linings 310 are arranged on the legs 28B1 to 28B4 inserted into the slot 420. The arrangement of the slot linings 310 improves the dielectric strength between the segment conductors 28 and between a segment conductor 28 and the inner surface of a slot 420. Here, insulating foils are removed from the parts of the ends 28E1 to 28E4 to be joined, exposing the conductors.

[0039] To align the heights of the tips of ends 28E1 to 28E4 and reduce the height of a coil end, cutting operations are performed at ends 28E1 to 28E4. If the height of the coil end is balanced, cutting operations can be avoided.

[0040] By welding the tips of the ends together, as in Fig. As shown in Figure 11, end 28E1 is connected to end 28E2, and end 28E3 is connected to end 28E4. A welded section is formed such that it bridges end 28E1 and end 28E2 by melting and solidifying a base material. Furthermore, a welded section is formed to bridge end 28E3 and end 28E4 by melting and solidifying a base material. Arc welding, TIG welding, plasma welding, or similar processes are used to melt and join the base material of a segmented conductor 28. Argon, helium, a mixed gas of argon and helium, or similar gases are used as shielding gases.

[0041] Furthermore, insulators 300 are arranged between the segment conductors 28 in rows of four, aligned radially at the weld-side coil end 62. According to the Fig. As shown in Figure 18, the increase in the switching speed of an inverter INV increases the overvoltage level, leading to insulation damage in a coil of a dynamoelectric machine 10 and affecting the service life of the dynamoelectric machine 10. Similarly, if a paint film is thickened, the thickening of the paint film deteriorates the operating accuracy of a coil. Furthermore, the cost of the parts increases by the amount of paint film thickening.

[0042] By arranging overlapping parts 302 of the insulators 300 on a supply wire 41U1 and a supply wire 41U2 (see Fig. 8) By connecting leads 41V1 ​​and 41V2, as well as leads 41W1 and 41W2, into which a steep impulse voltage is fed by an inverter INV on the side of the welding-side coil end 62, the withstanding voltage between the segment conductors 28 is improved. In addition, it is acceptable to arrange insulators 300 also on the side of the weld-proof coil end 61, and overlapping parts 302 are arranged around a lead wire 41U1 and a lead wire 41U2, a lead wire 41V1 ​​and a lead wire 41V2, as well as a lead wire 41W1 and a lead wire 41W2.

[0043] Fig. Figure 12 shows a perspective view before the insulators 300, each of which has an overlapping part 302, are inserted between segment conductors 28 at a weld-side coil end 62.

[0044] Fig. Figure 13 shows a perspective view immediately before the insertion of the insulators 300 between the segment conductors 28 according to the present embodiment.

[0045] The insulators 300 are arranged in a ring between the segment conductors 28 to improve the phase-to-phase insulation and the conductor-to-conductor insulation at a weld-side coil end 62. Here, an insulator 300 also acts as a retaining element to prevent a resin element (e.g., polyester or epoxy liquid varnish) from leaking out over all or part of a stator coil 60 if the resin element falls.

[0046] Since insulators 300 and slot linings 310 are arranged on the inside of the slots and at one coil end, a required withstanding voltage can be maintained even if an insulating foil of a segment conductor 28 is damaged or wears down. For example, an insulator 300 is an insulating plate made of heat-resistant polyamide paper and has a thickness of approximately 0.1 to 0.5 mm. An overlapping part 302 is thicker, with a thickness of approximately 0.2 to 1.0 mm.

[0047] Insulators 300 are arranged such that the overlapping parts 302 can be positioned at the locations of the segment conductors 28 leading to a conductor wire 41U1 and a conductor wire 41U2, a conductor wire 41V1 ​​and a conductor wire 41V2, and a conductor wire 41W1 and a conductor wire 41W2 when the insulators 300 are inserted into a weldable coil end 62. By arranging the overlapping part of an insulator 300 in a direction identical to the bending direction of a coil (by adjusting the circumferential length of an insulator 300 so that it is longer than the circumferential length of a stator coil 60), it is possible to prevent an insulating sheet, such as an insulator 300, from deviating vertically and being inserted when the coil is bent.

[0048] Although the overlapping part 302 of an insulator 300 is arranged at the position of a segment conductor 28 which in the present embodiment leads to a supply wire 41U1 and the like, it is also possible to arrange an overlapping part 302 at a position where a segment conductor 28 is very likely to be deformed by an external force.

[0049] Fig. Figure 14 shows an insulator 300 from the direction parallel to the axis of rotation of a dynamo-electric machine 10. In an insulator 300, an insulating foil element is formed from an almost rectangular shape into a nearly ring-shaped form, and an overlapping part 302 is produced. By arranging the overlap of an insulator 300 in a direction identical to the bending direction of a coil, it is possible to prevent an insulating sheet such as an insulator 300 from deviating in height and being inserted when the coil is bent.

[0050] Fig. Figure 15 shows an insulator 300 according to another embodiment, viewed from the direction parallel to the axis of rotation of a dynamoelectric machine 10. An insulator 300 according to the present embodiment can further improve the insulation properties by forming and using a recessed portion as an overlapping portion 302. By arranging the overlap of an insulator 300 in a direction identical to the bending direction of a coil, it can be prevented that an insulating sheet such as an insulator 300 deviates in height and is introduced when the coil is bent.

[0051] Fig. Figure 16 shows an insulator 300 according to another embodiment, viewed from the direction parallel to the axis of rotation of a dynamo-electric machine 10. In an insulator 305 according to the present embodiment, thick resin parts 304, which are thicker than the other part, are arranged in the areas where segment conductors 28, leading to a conductor wire 41U1 and a conductor wire 41U2, a conductor wire 41V1 ​​and a conductor wire 41V2, and a conductor wire 41W1 and a conductor wire 41W2, are arranged. The insulator 305 is formed by molding a resin. The insulator 305 can be easily inserted into a weldable coil end 62, and its processability is improved. A resin-shaped product prevents deviations and rolling during coil bending.

[0052] Fig. Figure 17A shows a side view of an insulator 300 before an overlapping part 302 is folded according to another embodiment. Fig. Figure 17B shows a side view of an insulator 300 after an overlapping part 302 has been folded according to another embodiment. Fig. Figure 17C shows an insulator 300 according to a further embodiment, viewed from the direction parallel to the axis of rotation of a dynamoelectric machine 10.

[0053] In an insulator 300, an overlapping section 302 is arranged in an area where segment conductors 28, leading to a conductor wire 41U1 and a conductor wire 41U2, a conductor wire 41V1 ​​and a conductor wire 41V2, and a conductor wire 41W1 and a conductor wire 41W2, are arranged. By bending an insulating film to the side of the axial direction, it can be prevented that an insulating film, such as an insulator 300, deviates in height and is inserted during coil bending.

[0054] Although various embodiments and modifications have been described above, the present invention is not limited to these. Other embodiments conceivable within the scope of the technological school of thought of the present invention are also included within its scope. DESCRIPTION OF REFERENCE NUMBERS 10 Dynamoelectric machine 11 Rotor 20 Stator 28 segment leaders 28B1 to 28B4 Legs 28°C vertex 28E End 28E1 to 28E6 End 60 Stator coil 62 weldable spool ends 132 Stator iron core 300 insulator 302 overlapping part 304 thick resin part 305 Insulator 420 slots

Claims

[1] Stator (20) of a dynamo-electric machine, comprising: a stator iron core (132) in which a plurality of circumferentially oriented slots (420) are formed; a multitude of segment windings inserted into the slots (420) and formed in an almost U-shape; and a ring-shaped insulator (300) arranged at a welding-side coil end (62) between the segment windings, wherein the insulator (300) has a part of the insulator (300) that is thicker than the other part of the insulator (300), wherein the insulator (300) is designed such that, in the aligned segment windings, it is longer than the circumferential length of the stator (20); and a thicker part of the insulator (300) is formed by overlapping a part (302) that includes both ends of the insulator (300) in the circumferential direction, wherein a segment conductor (28) in the segment windings, which overlaps with the thicker part of the insulator (300), leads to a supply wire, and wherein the overlapping part (302) is arranged in a direction that is identical to the bending direction of the coil. [2] Stator (20) of a dynamo-electric machine according to claim 1, wherein the conducting wire comprises a plurality of conducting wires, each corresponding to a U-phase, a V-phase and a W-phase. [3] Stator (20) of a dynamo-electric machine according to claim 1, wherein the overlapping part (302) is arranged in a region in which segment conductors (28) are arranged leading to a first supply wire (41U1, 41U2), a second supply wire (41V1, 41V2) and a third supply wire (41W1, 41W2). [4] A dynamo-electric machine (10) configured to generate a rotating magnetic field by supplying alternating current to a coil (60) of the stator (20) and thereby rotating a rotor (11), and further configured to convert mechanical energy supplied to the rotor (11) into electrical energy and to output alternating current from the coil (60), wherein the stator (20) is a stator according to any one of claims 1 to 3.

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