Stator, terminal block and rotating electric machine

Abstract

Stator (130) of a rotating electric machine (100), comprising: a stator core (132); a plurality of segment coils projecting from slots (122) of the stator core (132) and arranged in a radial direction; a connecting conductor (145, 146) connecting the segment coils; and an insulating element (141) holding the connecting conductor (145, 146), wherein the insulating element (141) comprises a through-hole (1411) through which the segment coil passes and in which it is arranged, and an opening (1412) through which a coolant flow can enter the through-hole (1411) and which is arranged on an inner circumferential side of the insulating element (141).

Description

Technical field

[0001] The present invention relates to a stator of a rotating electric machine. Current state of the art

[0002] In the present invention, it is required that a rotating electric machine has a high power output, and it is desirable to increase the rotation of a coil.

[0003] The prior art in the present technical field comprises the following. In patent literature 1 (WO 2017 / 195481A), the axial length of the stator is extended to increase its size, and the connection points are located at both ends of the stator core, thus impairing the productivity of the rotating electric machine. A rotating electric machine comprises: a stator core; a stator winding comprising a plurality of segment coils; and a wire terminal plate that attaches a dissimilar-phase terminal for connecting dissimilar-phase segment coils of the stator winding and an in-phase terminal for connecting in-phase segment coils of the stator winding.The stator winding comprises a coil connection section to which the ends of the plurality of segment coils are connected on one side with respect to an axial direction of the stator core, and the wire connection plate is arranged on one side where the coil connection section is located with respect to the stator core. List of quotations Patent literature

[0004] PTL 1: WO 2017 / 195481 A Summary of the invention; Technical task

[0005] With such an increase in the number of revolutions of a stator coil, the problem arises that the temperature rises in the input / output section, where the coils are closely packed. Therefore, cooling of the coil by a coolant (for example, automatic transmission fluid) flowing into the slot is necessary. However, the wire terminal plate attached to the surface of the stator can obstruct the flow of coolant into the slot. For this reason, a wire terminal plate shape is required that does not impede the flow of coolant. Technical solution

[0006] A representative example of the invention disclosed in the application is designed as follows. That is, a stator of a rotating electric machine comprises: a stator core; a plurality of segmented coils projecting from slots in the stator core and arranged radially; a connecting conductor linking the segmented coils; and an insulating element holding the connecting conductor. The insulating element includes a through-hole through which the segmented coil passes and in which it is arranged. An opening through which a coolant can flow into the through-hole is provided on an inner circumferential side of the insulating element. Advantageous effects of the invention

[0007] According to the present invention, the rotor coil can be effectively cooled even when the rotor is equipped with the wire terminal plate. Functions, configurations, and effects beyond those described above will become apparent from the explanation of the following embodiments. List of characters [ Fig. 1] Fig. Figure 1 shows a schematic diagram illustrating an overall configuration of a rotating electric machine according to an embodiment of the present invention. [ Fig. 2] Fig. Figure 2 shows a perspective view illustrating a stator attached to a housing of the present embodiment. [ Fig. 3] Fig. Figure 3 shows a perspective view of a stator removed from the housing of the present embodiment. [ Fig. 4] Fig. Figure 4 shows a perspective view of a wire connection plate of the present embodiment. [ Fig. 5] Fig. Figure 5 shows a perspective view of an input / output connection conductor that is incorporated into the wire terminal plate of the present embodiment. [ Fig. 6] Fig. Figure 6 shows a sectional view of the stator in a state in which the wire terminal plate of the present embodiment is attached. [ Fig. 7] Fig. Figure 7 shows a top view of the stator to which the wire terminal plate of the present embodiment is attached. [ Fig. 8] Fig. Figure 8 shows a top view of the stator in perspective, to which the wire terminal plate of the present embodiment is attached. Description of embodiments

[0008] The following describes embodiments of the present invention with reference to the drawings.

[0009] The rotating electric machine according to the present embodiment is a rotating electric machine suitable for use in powering an automobile. A so-called electric vehicle that uses a rotating electric machine comprises a hybrid electric vehicle (HEV) including both a motor and a rotating electric machine, and a pure electric vehicle (EV) that runs exclusively on a rotating electric machine without the use of a motor; however, the rotating electric machine described below can be used for both types.

[0010] Fig. Figure 1 shows a schematic diagram illustrating an overall configuration of a rotating electric machine 100 according to an embodiment of the present invention. Fig. Figure 1 shows the interior of the rotating electric machine 100, with a cross-sectional view of a portion of the machine. The rotating electric machine 100 is arranged in a housing 10 and comprises a casing 112, a stator 130 with a stator core 132 attached to the casing 112, and a rotor 150 rotatably mounted in the stator 130. The casing 10 can be a motor housing or a gearbox housing.

[0011] The rotating electric machine 100 is a three-phase synchronous motor with a built-in permanent magnet. In the present embodiment, a three-phase synchronous motor is described as an example of the rotating electric machine 100; however, the present invention can also be applied to an induction motor.

[0012] The rotating electric machine 100 of the present embodiment is operated as an electric motor, which rotates the rotor 150 by supplying a three-phase alternating current to a stator coil 138 wound around the stator core 132. When driven by a motor, the rotating electric machine 100 operates as a generator and outputs generated power in the form of a three-phase alternating current. That is, the rotating electric machine 100 has both a function as an electric motor, generating torque based on electrical energy, and a function as a generator, producing power based on mechanical energy, and the functions described above can be used selectively depending on the driving condition of the vehicle.

[0013] The stator 130 is attached to the housing 112. The stator 130 is secured and held in the housing 10 by attaching a flange 115, located in the housing 112, to the housing 10 with a screw 12. The rotor 150, attached to a rotating shaft 118, is supported by bearings 14A and 14B of the housing 10 and is rotatably held in the stator core 132.

[0014] Fig. Figure 2 shows a perspective view illustrating the stator 130 attached to the housing 112 and Fig. Figure 3 shows a perspective view of the stator 130 located away from the housing 112. Fig. 3 is part of the stator core 132 omitted.

[0015] The housing 112 is formed in a cylindrical shape by drawing a steel plate (e.g., a high-strength steel plate) with a thickness of approximately 2 to 5 mm. The flange 115 is arranged at an axial end of the housing 112 and fastened to the box 10 with the screw 12 as previously described (see Fig. 1) The flange 115 is formed integrally with the housing 112 by drawing. The stator 130 can be attached directly to the box 10 without providing the housing 112.

[0016] The stator 130 is attached to the inner circumferential side of the housing 112 and comprises the cylindrical stator core 132, the stator coil 138, and a wire terminal plate 140, which is attached to the stator core 132. The stator core 132 is formed by stacking a multitude of electromagnetic steel sheets 133, produced by stamping or etching, with a thickness of approximately 0.05 to 1.0 mm, for example. The laminated electromagnetic steel sheets 133 are joined and fastened by welding, and deformation of the electromagnetic steel sheets 133 by a fastening force during pressing into the housing 112 is prevented.

[0017] The stator core 132 has a plurality of axially extending slots 122 formed at uniform intervals in the circumferential direction. The number of slots 122 is, for example, 72 in the present embodiment. As shown in Fig. Figure 2 shows the stator coil 138 arranged in slot 122. Fig. In the example shown in Figure 3, slot 122 is an open slot and an opening is formed on the inner circumferential side of the stator core 132. The circumferential width of the opening can be essentially equal to or slightly smaller than the coil mounting section of each slot 122 to which the stator coil 138 is mounted.

[0018] A slot lining 300 is arranged in each slot 122. The slot lining 300 is formed, for example, from a heat-resistant resin into a predetermined shape and has a thickness of 0.1 to 0.5 mm. The slot lining 300 is arranged in the slot 122 or at the coil end. The slot lining 300 is positioned between the coils inserted in the slot 122 and between the coil and the inner surface of the slot 122, and serves as an insulating element to improve the withstand voltage between the coils and between the coil and the inner surface of the slot 122.

[0019] The stator coil 138 is formed by connecting a plurality of U-shaped segment coils together. The segment coil is arranged such that one end of it abuts another segment coil, and the other end of it further abuts another segment coil in such a way that the end of this latter segment coil is exposed to the slot 122 (i.e., to the stator 130). The segment coils whose ends abut each other are connected to each other at their adjacent ends to form the stator coil 138 wound around the stator core 132.

[0020] The wire connection plate 140 for connecting the stator 130 and the circuit is attached to part of the end of the segment coil of the stator coil 138.

[0021] Additionally, the slotted lining 300, arranged at the coil end, is ring-shaped between the coils for interphase and intermediate conductor insulation. As previously described, in the rotating electrical machine 100 of the present embodiment, a required withstanding voltage can be maintained, since the slotted lining 300 is arranged in the slot 122 or at the coil end, even if the insulating film of the coil is damaged or impaired.

[0022] Teeth 121 are formed between slots 122, and each tooth 121 is integrally formed with the annular core back 123. The stator core 132 is an integrated core in which the teeth 121 and the core back 123 are integrally formed. The teeth 121 conduct the rotating magnetic field generated by the stator coil 138 to the rotor 150, causing the rotor 150 to generate torque.

[0023] The rotor 150 comprises a rotor core 152 and a permanent magnet 154, which is held in a magnet insertion hole formed in the rotor core 152.

[0024] In the rotor core 152, rectangular parallelepiped-shaped magnet insertion holes are formed at regular intervals around the circumference near the outer circumferential section. The permanent magnet 154 is embedded in each magnet insertion hole and fixed with an adhesive or the like. The circumference of the magnet insertion hole is such that it is larger than the circumference of the permanent magnet 154, and magnetic gaps 156 are formed on both sides of the permanent magnet 154. The magnetic gap 156 can be filled with an adhesive or can be integrally fixed to the permanent magnet 154 with a resin.

[0025] The permanent magnet 154 forms a field pole of the rotor 150. In the present embodiment, a magnetic pole is formed by a single permanent magnet 154; however, a magnetic pole can also be formed by a plurality of permanent magnets 154. By increasing the number of permanent magnets 154 used to form each magnetic pole, the magnetic flux density of each magnetic pole generated by the permanent magnet 154 increases, and the magnetic moment can be increased. A sintered magnet based on neodymium or samarium, a ferrite magnet, a composite magnet based on neodymium, or the like can be used as the permanent magnet 154; however, the residual magnetic flux density of the permanent magnet 154 is preferably about 0.4 to 1.3 T, and a neodymium-based magnet is more suitable. An additional magnetic pole can be formed between the permanent magnets 154.

[0026] When three-phase alternating current is supplied to the stator coil 138 to generate a rotating magnetic field in the stator 130, the rotating magnetic field acts on the permanent magnet 154 of the rotor 150 to generate a magnetic moment. Since the previously described reluctance torque is generated in the rotor 150 in addition to the magnetic moment, both the magnetic moment and the reluctance torque act as the torque in the rotor 150, and a greater torque can be achieved.

[0027] The wire connection plate 140 is described below in relation to Fig. 4, Fig. 5, Fig. 6 and Fig. 7 described. Fig. Figure 4 shows a perspective view of the wire connection plate 140, Fig. Figure 5 shows a perspective view of an input / output connection conductor 144, arranged in the wire terminal plate 140, Fig. Figure 6 shows a sectional view of the stator 130 in a state in which the wire terminal plate 140 is attached, and Fig. Figure 7 shows a top view of the stator 130, to which the wire terminal plate 140 is attached.

[0028] The wire connection plate 140 includes the input / output connection conductor 144 (see Fig. 5) as a conductor wire connecting the outside of the rotating electric machine 100 and the stator 130, connecting conductors 145 and 146 as relay wires connecting the segment coils, and an insulating element 141 holding the input / output connecting conductor 144 and the connecting conductors 145 and 146. A terminal block 142 is connected to the end of the input / output connecting conductor 144 (see Fig. 2 and Fig. 3).

[0029] The insulating element 141 is designed to hold the input / output connection conductor 144 and the connection conductors 145 and 146 by integrally forming a resin material. The insulating element 141 is open on its inner circumferential side (opening 1412) and forms a honeycomb-shaped resin clamping strip. This opening 1412 serves to introduce cooling oil into the slots 122 of the stator core 132 as described below.

[0030] As in Fig. As shown in Figure 5, the connecting conductors 145 and 146 comprise a phase-in-phase connecting conductor 145, which connects segment coils in phase, and a phase-out-of-phase connecting conductor 146, which connects segment coils in phase. The connecting conductors 144, 145, and 146 are fixed in the insulating element 141 at constant intervals for electrical insulation in the wire terminal plate 140.

[0031] As in Fig. 3, Fig. 4 and Fig. Figure 7 shows that by guiding the end of the segment coil axially into the through-hole 1411 of the wire terminal plate 140, the wire terminal plate 140 is mounted in a position between the axial end of the segment coil and the axial end of the stator core. By mounting the wire terminal plate 140 in this position, the length of the coil end of the stator coil 138 can be shortened and the rotating electric machine 100 can be reduced in size.

[0032] The insulating element 141 is sized such that an inner circumferential surface of it is positioned on an outer circumferential surface of the tip of the teeth 121 at a position attached to the stator 130. Thus, when the rotor 150 is inserted into the stator 130, the wire terminal plate 140 and the rotor 150 are prevented from colliding, and the rotor 150 can be inserted from either the top or the bottom.

[0033] Additionally, the segment coil and the connecting conductors 144, 145, and 146 are connected at the upper section of the stator 130, that is, at the upper section of the wire terminal plate 140 on the axial direction side. By connecting the segment coils and the connecting conductors 144, 145, and 146 at the upper section in the axial direction, the conductors can be easily clamped at the time of connection, the connection section can be arranged close to the stator core 132, and the rotating electric machine 100 can be reduced in size.

[0034] By mounting the wire connection plate 140 to the stator coil 138 in this way, the end of the segment coil and the ends of the connecting conductors 144, 145 and 146 are adjacent to each other and the end of the segment coil and the ends of the connecting conductors 144, 145 and 146 can be connected.

[0035] In particular, the phase-coherent connecting conductor 145 is arranged adjacent to each other in the circumferential direction between the two through-holes 1411 and connects the innermost (first layer) segment coil and the outermost (sixth layer) segment coil in the slot 122 on the upper surface of the wire terminal plate 140 (see Fig. 5).

[0036] Additionally, the end of the segment coil of the second layer and the end of the segment coil of the third layer are connected in slot 122, and the end of the segment coil of the fourth layer and the end of the segment coil of the fifth layer are connected.

[0037] Two input / output connection conductors 144 are provided in each phase; one input / output connection conductor 144 is connected to the segment coil of the innermost perimeter (first layer), and the other input / output connection conductor 144 is connected to the segment coil of the outermost perimeter (sixth layer). Thus, the coils of the two systems are connected to the terminal block 142 of each phase.

[0038] The dissimilar-phase connecting conductor 146 connects the ends of the segment coils of different phases and can extend a neutral point, which forms a neutral point in the insulating element 141, to the upper surface of the insulating element 141.

[0039] In this way, a circuit of the stator coil 138 is formed by the connection between the segment coil and the connecting conductors 144, 145 and 146.

[0040] For example, TIG welding can be used as a method for joining the end section of the segment coil and the end section of the connecting conductors 144, 145 and 146 and as a method for joining the ends of the U-shaped segment coils together; however, other joining methods such as laser welding, electron beam welding and ultrasonic welding can also be used.

[0041] In the present embodiment, the connecting conductors 144, 145 and 146 are arranged adjacent to the innermost circumferential segment coil at positions adjacent to the end section of the segment coil in the circumferential direction, and the end of the conductor does not prevent the flow of cooling oil into the opening 1412. Furthermore, the connecting conductors 144, 145 and 146 are arranged adjacent to the outermost circumferential segment coil at positions radially adjacent to the end section of the segment coil and are cooled by the cooling oil reaching a container 1413 described below.

[0042] The cooling of the coil in the present embodiment is described below with regard to Fig. 7 and Fig. 8 described. Fig. Figure 7 shows a top view of the stator 130, to which the wire terminal plate 140 is attached, and Fig. Figure 8 shows a top view of the stator 130 in perspective, to which the wire terminal plate 140 is attached. Fig. 7 and Fig. Figure 8 shows the flow of cooling oil represented by an arrow.

[0043] Cooling oil flows in the housing 10 of the rotating electric machine 100 of the present embodiment and cools the heat generated by copper loss in the stator coil 138. For example, if the automatic transmission and the rotating electric machine 100 are arranged in a housing, automatic transmission fluid flows into the rotating electric machine 100, and the stator coil 138 is cooled by the automatic transmission fluid flowing around the stator coil 138 in the rotating electric machine 100. Generally, the automatic transmission fluid flows into the slot 122 from the upper surface (for example, the surface of the stator coil 138 on the weld side) of the stator 130 and flows out of the lower surface (for example, the surface on the insertion side of the segment coil) of the stator 130.

[0044] In the rotating electric machine 100 of the present embodiment, since the wire terminal plate 140 is attached to the upper surface of the stator 130, the flow of automatic transmission fluid into the stator 130 can be impaired depending on the shape of the wire terminal plate 140. Therefore, in the wire terminal plate 140 of the present embodiment, the opening 1412 is arranged on the inner circumferential side of the insulating element 141 of the wire terminal plate 140, and the cooling oil flows from the opening 1412 into the through-hole 1411. Thus, the cooling oil can flow into the stator coil 138 arranged below the wire terminal plate 140, and the stator coil 138 arranged below the wire terminal plate 140 can be cooled.

[0045] Additionally, the wire connection plate 140 with the reservoir 1413 is wider than the opening 1412 on the outer circumferential side of the insulating element 141. Thus, the cooling oil flowing into the insulating element 141 from the opening 1412 reaches the reservoir 1413 and remains there, effectively cooling the connecting conductors 144, 145, and 146. Furthermore, because the cooling oil flowing into the insulating element 141 from the opening 1412 cools the insulating element 141, the connecting conductors 144, 145, and 146 located within the insulating element 141 are also cooled.

[0046] In the embodiment described above, the example was described in which the stator coil 138 is cooled by the cooling oil; however, the stator 130 of the present invention can also be cooled by using a cooling medium (liquid or gas) that is not oil.

[0047] As previously described, according to the embodiment of the present invention, the stator 130 of the rotating electric machine 100 comprises the stator core 132, the plurality of segment coils projecting from the slot 122 of the stator core 132 and arranged radially, the connecting conductors 145 and 146 connecting the segment coils, and the insulating element 141 holding the connecting conductors 145 and 146. The insulating element 141 has the through-hole 1411 through which the segment coil passes and in which it is arranged, and has the opening 1412 through which the coolant can flow into the through-hole 1411 on the inner circumferential side of the insulating element 141. Thus, the stator 130 equipped with the wire terminal plate 140 can also effectively cool the stator coil 138.

[0048] Additionally, since the insulating element 141 has the container 1413, in which the cooling oil flowing from the opening 1412 reaches the outer circumferential side of the through-hole 1411, the coolant flows into the container 1413 and the connecting conductors 144, 145 and 146 can be effectively cooled.

[0049] Furthermore, since the connecting conductors 145 and 146 are connected adjacent to the segment coil arranged at the outermost circumference in the radial direction and adjacent to the segment coil arranged at the innermost circumference in the circumferential direction, the flow of the cooling oil into the opening 1412 is not impaired and the cooling oil reaching the container 1413 can be effectively cooled.

[0050] The preceding description is merely an example, and there is no limitation or restriction in the interpretation of the invention regarding the correspondence between the objects described in the preceding embodiment and the objects described in the claims. For example, in the previously described embodiment, a rotating electric machine comprising a permanent magnet in a rotor was described as an example; however, the present invention can be applied similarly to a stator of a rotating electric machine, such as an induction motor. The present invention can also be applied to a rotating electric machine for driving a vehicle other than the rotating electric machine for driving a vehicle.

[0051] Furthermore, the present invention is not limited to the embodiment described above. Various modifications and equivalent configurations may be included within the scope of the claims. For example, the embodiments described above are illustrated in detail to aid in understanding the present invention. The present invention is not limited to providing all of the configurations described above. In addition, some of the configurations of one particular embodiment may be replaced by the configuration of another embodiment. Furthermore, the configurations of the other embodiments may be added to the configurations of one particular embodiment. Additionally, some of the configurations of each embodiment may be added to, omitted from, or replaced with respect to the configuration of the other embodiment. Reference symbol list 10 boxes 12 screws 14A, 14B bearings 100 rotating electric machine 112 cases 115 flange 118 Rotary shaft 121 teeth 122 slots 123 Core back 130 Stator 132 Stator core 133 electromagnetic steel sheet 138 Stator coil 140 wire connection plate 141 Insulating element 1411 Through hole 1412 Opening 1413 containers 142 Input / Output Terminal 144 Input / Output Connection Cable 145, 146 Connecting conductor 150 Rotor 152 Rotor core 154 Permanent magnet 156 Magnetic gap 300 slot lining QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] WO 2017 / 195481 A [0003, 0004]

Claims

[1] Stator of a rotating electrical machine, comprising: a stator core; a multitude of segmented coils protruding from slots in the stator core and arranged in a radial direction; a connecting conductor that connects the segment coils; and an insulating element that holds the connecting conductor, the insulating element comprises a through-hole through which the segment coil penetrates and in which it is arranged, and an opening through which a coolant flow can enter the through-hole and which is located on an inner circumferential side of the insulating element. [2] Stator of the rotating electric machine according to claim 1, wherein the insulating element on an outer circumferential side of the through-hole comprises a container through which the coolant flowing in from the opening is received. [3] Stator of the rotating electric machine according to claim 1, wherein the liaison officer is trained to Connect adjacent to a segment coil arranged on an outermost circumference in a circumferential direction from the plurality of segment coils, and Connect adjacent to a segment coil arranged in a circumferential direction on the innermost circumference of the multitude of segment coils. [4] Terminal block mounted on a stator of a rotating electrical machine, the terminal block comprising: a connecting conductor representing a stator winding, protruding from a slot in a stator core and connecting a plurality of segmented coils aligned in a radial direction; an insulating element that holds the connecting conductor, wherein the insulating element comprises a through-hole through which the segment coil penetrates and in which the latter is arranged, and an opening through which a coolant can flow into the through-hole is arranged on an inner circumferential side of the insulating element. [5] Terminal strip according to claim 4, wherein the insulating element has a container on an outer circumferential side of the through-hole, through which the coolant flowing in from the opening is received. [6] Terminal block according to claim 4, wherein the liaison officer is trained to Connect adjacent to a segment coil arranged on an outermost circumference in a circumferential direction from the plurality of segment coils, and Connect adjacent to a segment coil arranged in a circumferential direction on the innermost circumference of the multitude of segment coils. [7] Rotating electric machine comprising the rotor according to any one of claims 1 to 3.