Stator

Abstract

To provide a stator in which interference between coil end portions can be suppressed, and increase in the axial lengths of the coil end portions can be suppressed without pressure molding.SOLUTION: A stator 100 is configured such that: one and the other circumferential-direction inclined portions 22 of a plurality of adjacent coil end portions 20b do not overlap each other in the circumferential direction, and respective circumferential-direction side lateral surfaces of the coil end portions 20b are adjacent to each other; and the lower surface of the circumferential-direction inclined portion 22 of one of the adjacent coil end portions 20b does not overlap an end on the side of an axis-direction inclined portion 21 of a crank portion 23 of the other coil end portion 20b in the axis direction, and are adjacent to each other in the circumferential direction.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a stator. [Background technology]

[0002] BACKGROUND ART Conventionally, a stator is known (for example, Patent Document 1).

[0003] The above-mentioned Patent Document 1 discloses a stator for a rotating electric machine including an annular stator core with a plurality of slots and coils inserted into the slots. In Patent Document 1, at least one axial end of the stator core, the coils are arranged so that crossover sections connecting the radially inner portion of one slot to the radially outer portion of another slot overlap in the circumferential direction and as viewed from the axial direction, thereby forming a coil end section. Furthermore, the crossover sections are twisted so that they cross in a radial direction to prevent interference between the coils. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-225974 Summary of the Invention [Problem to be solved by the invention]

[0005] In the stator core of Patent Document 1, the coil end portions (coils) are twisted and processed so as to intersect when viewed from the radial direction, resulting in a complex shape.

[0006] Furthermore, although not disclosed in Patent Document 1, when coil end portions are formed by twisting, the coil end portions have complex shapes, making processing difficult. Therefore, the dimensions are set larger in advance to take into account shape variations. After processing, the coil end portions are then pressure-molded to reduce their axial length. However, pressure molding places excessive loads on the coil end portions. For this reason, it is desirable to suppress interference between coil end portions without twisting, and to reduce the axial length of the coil end portions without pressure molding.

[0007] The present invention has been made to solve the above-mentioned problems, and one object of the present invention is to provide a stator that can suppress interference between coil end portions and can suppress an increase in the axial length of the coil end portions without performing pressure molding. [Means for solving the problem]

[0008] In order to achieve the above object, a stator in one aspect of the present invention comprises a stator core, and a coil made of a rectangular wire, which is inserted into the stator core and includes a plurality of coil end portions that extend and protrude axially outward from an end face of the stator core, wherein the plurality of coil end portions are provided on the stator core side and have axially inclined portions that are inclined axially outward with respect to the end face of the stator core and extend circumferentially, a circumferential inclined portion that is inclined circumferentially with respect to the axially inclined portion when viewed from the axial direction and extends radially outward, and a crank portion that is configured to connect the axially inclined portion and the circumferential inclined portion and curves axially outward, wherein in adjacent plurality of coil end portions, one and the other circumferential inclined portions do not overlap with each other in the axial direction and the circumferential side surfaces are adjacent and face each other, and in adjacent plurality of coil end portions, the lower surface of the circumferential inclined portion of one coil end portion and the end of the crank portion of the other coil end portion on the axially inclined portion side do not overlap with each other in the axial direction but are adjacent to each other in the circumferential direction.

[0009] In one aspect of the present invention, the stator includes an axially inclined portion, a circumferentially inclined portion, and a crank portion, as described above. The axial length can be adjusted using the axially inclined portion and the circumferentially inclined portion, while the crank portion allows the coil end portions to be positioned so as not to interfere with each other. Furthermore, in adjacent coil end portions, the circumferentially inclined portions of one coil end portion and the other circumferentially inclined portion are adjacent and face each other, allowing the adjacent coil end portions to be positioned without interference along the circumferential direction. This eliminates the need to twist the coil end portions. Furthermore, in adjacent coil end portions, the lower surface of the circumferentially inclined portion of one coil end portion and the end of the crank portion of the other coil end portion on the axially inclined portion side do not overlap in the axial direction and are adjacent in the circumferential direction. This allows the coil end portions to be positioned so as not to overlap in the axial direction, and the crank portion can be positioned lower, preventing the axial length of the coil end portions from increasing. As a result, interference between the coil end portions can be prevented, and the axial length of the coil end portions can be prevented from increasing without pressure molding. Here, "adjacent" means that the two coil end portions are not in contact with each other but are located close to each other.

[0010] In the stator according to the aforementioned aspect, the axial length from the end face of the stator core to the circumferentially inclined portion is preferably greater than the axial length from the end face of the stator core to another portion of the coil end portion.

[0011] With this configuration, the axial length from the end face of the stator core to the circumferential inclined portion is the maximum value of the axial length from the end face of the stator core to the coil end portion, so by arranging the circumferential inclined portions along the circumferential direction, it is possible to easily prevent the axial length from becoming too large.

[0012] In this case, the circumferentially inclined portion is preferably configured to extend along the direction in which the end face of the stator core extends.

[0013] With this configuration, the circumferentially inclined portion, which has the maximum axial length from the end face of the stator core to the coil end portion, can be positioned horizontally in the radial direction, thereby effectively preventing the axial length of the coil end portion from becoming too large.

[0014] In the stator according to the above aspect, preferably, the coil end portion further includes a connection portion connecting the axially inclined portion and the crank portion, and the connection portion is configured to be inclined radially outward with respect to the axially inclined portion when viewed from the axial direction.

[0015] With this configuration, the connecting portions are tilted radially outward, thereby preventing contact with adjacent coil end portions. Furthermore, because the connecting portions can tilt the coil end portions radially outward before they are tilted axially by the crank portion, there is no need to tilt the crank portion radially outward, which prevents the crank portion from becoming complicated in structure.

[0016] In the stator according to the above aspect, the following configuration is also possible.

[0017] (Additional note 1) In the stator according to the above aspect, the coil is configured by joining a plurality of segment coils, each of which includes an axially inclined portion and a circumferentially inclined portion.

[0018] With this configuration, the coil is constructed by joining multiple segment coils that include axially inclined portions and circumferentially inclined portions, so the coil can be easily constructed while preventing the axial length from becoming too large.

[0019] (Additional note 2) In the stator according to the above aspect, the plurality of circumferential inclined portions are arranged so that the circumferential side surfaces thereof face and are adjacent to each other without being twisted.

[0020] With this configuration, the coil can be formed without twisting the multiple circumferentially inclined portions, which prevents the process of forming the coil end portions from becoming complicated. [Brief explanation of the drawings]

[0021] [Figure 1] FIG. 2 is a perspective view showing a stator in the embodiment. [Figure 2] FIG. 2 is a top view of the stator according to the embodiment. [Figure 3] FIG. 2 is an oblique view showing a segment coil in an embodiment. [Figure 4] A top view showing a segment coil in an embodiment. [Figure 5] A top view showing an enlarged portion of the segment coil. [Figure 6] A view of a portion of the segment coil from a radial direction. DETAILED DESCRIPTION OF THE INVENTION

[0022] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0023] The configuration of a stator according to an embodiment will be described with reference to FIGS.

[0024] (Overall configuration of the stator) The stator 100 shown in FIG. 1 constitutes a part of a rotating electric machine (not shown) together with a rotor (not shown) arranged on the R1 side of the stator 100 so as to face the stator 100. The rotating electric machine is, for example, a motor, a generator, or a motor / generator. The stator 100 has a cylindrical shape. A hole through which the rotor is inserted is formed in the center of the stator 100. In the following description, the radial direction of the stator 100 is defined as the R direction, the circumferential direction of the stator 100 is defined as the C direction, and the axial direction in which the rotor is inserted into the stator 100 is defined as the Z direction.

[0025] The stator 100 includes a stator core 1 and a coil 2. The stator 100 is a three-phase AC stator.

[0026] The stator core 1 has a cylindrical shape with a central axis (not shown) along the Z direction. The stator core 1 is formed by stacking a plurality of electromagnetic steel plates (for example, silicon steel plates) in the Z direction.

[0027] The stator core 1 is provided with a plurality of slots 11, which are grooves extending in the Z direction. A coil 2 made up of a plurality of segment coils 20 is inserted into the slots 11.

[0028] As shown in FIG. 2, the coil 2 is formed by joining a plurality of segment coils 20 together. The plurality of segment coils 20 that make up the coil 2 are made of rectangular wire. As an example, the plurality of segment coils 20 are made of copper wire. The coil 2 is configured to generate magnetic flux when supplied with three-phase AC power from a power supply unit (not shown). The segment coils 20 are arranged (wound) along the circumferential direction of the stator core 1 by moving back and forth through the slot portion 11 in the Z direction. The coil 2 is formed by winding the joined plurality of segment coils 20 two or more times along the circumferential direction of the stator core 1.

[0029] The plurality of segment coils 20 include a U-shaped segment coil 20 and an I-shaped segment coil 20.

[0030] The U-shaped segment coil 20 includes a pair of slot insertion portions 20a that are inserted into the slot portions 11 of the stator core 1, and a coil end portion 20b that connects the pair of slot insertion portions 20a. The U-shaped segment coil 20 includes an axially inclined portion 21 and a circumferentially inclined portion 22. The multiple segment coils 20 are arranged adjacent to each other. Here, in this specification, "adjacent" means that the two coil end portions are not in contact with each other but are located close to each other.

[0031] When inserted into the stator core 1, the U-shaped segment coil 20 has coil end portions 20b exposed from one end face in the Z direction of the stator core 1, and both end portions 20c, which are not connected by the coil end portions 20b of the segment coil 20, exposed from the other end face in the Z direction of the stator core 1. The pair of slot insertion portions 20a is configured so that both end portions 20c are inserted across different slot portions 11. Furthermore, the end portions 20c of the multiple segment coils 20 exposed from the other end face in the Z direction of the stator core 1 are connected to each other to form one coil 2.

[0032] In one coil 2 shown in FIG. 2 , an I-shaped segment coil 20 is joined to a U-shaped segment coil 20 at both circumferential ends. The I-shaped coil forms a terminal portion. In this embodiment, two segment coils 20 are inserted into one slot portion 11. Two coils 2 are arranged for each of the U, V, and W phases of the three-phase AC. Each coil 2 for each phase has one end protruding from the outer peripheral surface of the stator core 1 and the other end not protruding from the outer peripheral surface of the stator core 1. Two coils 2 are arranged for each phase, and one end is connected to another component. Two coils 2 are arranged for each phase, and the other end is connected to an intermediate connecting wire connecting the U, V, and W phases. The terminal portion may be arranged on one axial side of the stator core 1 where the joints of the U-shaped segment coils 20 are provided, or on the other axial side of the stator core 1 where the coil end portions 20b are formed.

[0033] 3 and 4, coil end portion 20b has axially inclined portion 21, circumferentially inclined portion 22, crank portion 23, and connecting portion 24. Coil end portion 20b also includes another end portion 25 connected to circumferentially inclined portion 22.

[0034] The segment coils 20 extend in the axial direction from the axial end face of the stator core 1, and then are inclined axially outward by the axially inclined portions 21. After being inclined axially outward by the axially inclined portions 21, they are inclined radially outward by the connection portions 24. They are inclined axially outward by the crank portions 23, and extend along the end face of the stator core 1 by the circumferential inclined portions 22. From the circumferential inclined portion 22, they are curved radially outward and inclined axially inward by the other end side portion 25, and then extend axially toward the end face of the stator core 1 along the axial direction.

[0035] As shown in Figures 5 and 6, the axially inclined portion 21 is provided on the stator core 1 side. The axially inclined portion 21 is rectangular when viewed in the axial and circumferential directions. The axially inclined portion 21 is inclined axially outward with respect to the end face of the stator core 1. The segment coil 20 extends axially outward from the stator core 1 and is then inclined axially outward by the axially inclined portion 21. The axially inclined portion 21 extends along the circumferential direction. In Figure 6, the end face of the stator core 1 is simplified and shown by a dashed line.

[0036] The axially inclined portions 21 of the multiple segment coils 20 are arranged along the inner circumference of the stator core 1. The axially inclined portions 21 of adjacent segment coils 20 are arranged so as to face each other in the axial direction. Note that the axially inclined portions 21 of adjacent segment coils 20 do not need to face the entire upper surface of one segment coil 20 and the entire lower surface of the other segment coil 20; it is sufficient that a portion of the upper surface of one segment coil 20 faces a portion of the lower surface of the other segment coil 20. The axially inclined portions 21 of adjacent segment coils 20 are arranged offset in the circumferential direction.

[0037] The circumferential inclined portion 22 has a rectangular shape when viewed in the axial and circumferential directions. When viewed in the axial direction, the circumferential inclined portion 22 is inclined in the circumferential direction with respect to the axial inclined portion 21. The circumferential inclined portion 22 is inclined to such an extent that it does not come into contact with adjacent segment coils 20 in the circumferential direction. The circumferential inclined portion 22 extends radially outward. The circumferential inclined portion 22 is configured to extend along the direction in which the end face of the stator core 1 extends. In other words, the circumferential inclined portion 22 extends along the radial direction. The circumferential inclined portion 22 is formed approximately horizontal when viewed in the radial direction. Preferably, the circumferential inclined portion 22 is configured to extend parallel to the end face of the stator core 1.

[0038] In the adjacent coil end portions 20b, the circumferential inclined portions 22 on one side and the other side are adjacent to each other and do not overlap each other in the axial direction, and the circumferential side surfaces 22a face each other. In the adjacent coil end portions 20b, the circumferential inclined portions 22 on one side and the other side are formed so that their axial lengths from the end face of the stator core 1 are approximately the same. In addition, the circumferential inclined portions 22 on one side and the other side are both extended along the circumferential direction, but they do not need to be parallel to each other, and one may be inclined with respect to the other. In addition, the circumferential side surfaces 22a of the circumferential inclined portions 22 on one side and the other side are not required to face each other entirely, but may face each other partially. The circumferential inclined portions 22 are arranged so that the circumferential side surfaces 22a face each other and are adjacent to each other without being twisted.

[0039] The axial length from the end face of the stator core 1 to the circumferential inclined portion 22 is configured to be longer than the axial length from the end face of the stator core 1 to other parts of the coil end portion 20b. In other words, the longest part of the axial length from the end face of the stator core 1 to the segment coil 20 is included in the circumferential inclined portion 22. When the circumferential inclined portion 22 is approximately parallel to the end face of the stator core 1, the entire circumferential inclined portion 22 becomes the longest part of the axial length from the end face of the stator core 1 to the segment coil 20, and when the circumferential inclined portion 22 is not parallel to the end face of the stator core 1, only a part of the circumferential inclined portion 22 becomes the longest part of the axial length from the end face of the stator core 1 to the segment coil 20.

[0040] The crank portion 23 is configured to connect between the axially inclined portion 21 and the circumferentially inclined portion 22. The crank portion 23 is curved axially outward. The crank portion 23 includes a first curved portion 23a that curves axially outward and a second curved portion 23b that curves axially inward, and has an S-shape when viewed radially.

[0041] In adjacent coil end portions 20b, the lower surface 22b of the circumferentially inclined portion 22 of one coil end portion 20b and the end portion 23c of the crank portion 23 of the other coil end portion 20b on the axially inclined portion 21 side are configured so as not to overlap in the axial direction but to be adjacent in the circumferential direction. The end portion 23c of the crank portion 23 on the axially inclined portion 21 side refers to the boundary between the crank portion 23 and the connection portion 24. "Adjacent in the circumferential direction" refers to being close to each other even if they are not in contact in the circumferential direction. Regarding the relationship in axial length when adjacent in the circumferential direction, the axial length from the end face of the stator core 1 to the lower surface of the circumferentially inclined portion 22 of one coil end portion 20b and the axial length from the end face of the stator core 1 to the end portion of the crank portion 23 on the inclined portion side of the other coil end portion 20b are not limited to being the same, and may be slightly different. The crank portion 23 configures adjacent segment coils 20 so that the spacing between them increases with increasing distance from the stator core 1 side.

[0042] As shown in FIGS. 5 and 6 , the connection portion 24 is configured to connect the axially inclined portion 21 and the crank portion 23. The connection portion 24 is configured to be inclined axially outward with respect to the end face of the stator core 1, similar to the axially inclined portion 21, when viewed from the circumferential direction. In FIG. 4 , the connection portion 24 and the axially inclined portion 21 are inclined at the same angle with respect to the end face of the stator core 1. In another example, the inclination angle of the connection portion with respect to the end face of the stator core is different from the inclination angle of the axially inclined portion with respect to the end face of the stator core. The connection portion 24 is configured to be inclined radially outward with respect to the axially inclined portion 21 when viewed from the axial direction. The connection portion 24 has a fan-like shape including a pair of arc-shaped portions 24a that curve radially inward when viewed from the axial direction, and a pair of straight portions 24b that connect the pair of arc-shaped portions 24a. The pair of straight portions 24b are configured to connect to the axially inclined portion 21 and the crank portion 23, respectively.

[0043] The stator 100 is formed by laminating electromagnetic steel sheets to form the stator core 1, and then inserting multiple segment coils 20. The multiple segment coils 20 are inserted into the slots to form the coil end portions 20b. At this time, the segment coils 20 are inserted into the slot portions 11 without being twisted. The inserted segment coils 20 are joined together to form the coil 2.

[0044] (Effects of this embodiment) In this embodiment, the following effects can be obtained.

[0045] In the present embodiment, as described above, in the adjacent coil end portions 20b, the one and the other circumferential inclined portions 22 do not overlap with each other in the axial direction, and the circumferential side surfaces 22a are adjacent to and facing each other, and in the adjacent coil end portions 20b, the lower surface of the circumferential inclined portion 22 of one coil end portion 20b and the end portion of the crank portion 23 of the other coil end portion 20b on the axially inclined portion 21 side are configured not to overlap with each other in the axial direction, but to be adjacent to each other in the circumferential direction. Thus, by having the axially inclined portion 21, the circumferential inclined portion 22, and the crank portion 23, the axial length can be adjusted by the axially inclined portion 21 and the circumferential inclined portion 22, and the crank portion 23 can be used to arrange the coil end portions 20b so that they do not interfere with each other. Furthermore, in the adjacent coil end portions 20b, the one and the other circumferential inclined portions 22 do not overlap with each other in the axial direction, and the circumferential side surfaces 22a are adjacent to and facing each other, so that the adjacent coil end portions 20b can be arranged without interfering with each other in the circumferential direction. Therefore, there is no need to twist the coil end portions 20b. Furthermore, in adjacent coil end portions 20b, the lower surface 22b of the circumferentially inclined portion 22 of one coil end portion 20b and the end portion 23c of the crank portion 23 of the other coil end portion 20b on the axially inclined portion 21 side do not overlap in the axial direction and are adjacent to each other in the circumferential direction. This allows the multiple coil end portions 20b to be arranged so that they do not overlap in the axial direction, and the position of the crank portion 23 can be lowered, thereby preventing the axial length of the coil end portions 20b from becoming too long. As a result, interference between the coil end portions 20b can be prevented, and the axial length of the coil end portions 20b can be prevented from becoming too long without performing pressure molding.

[0046] Furthermore, in this embodiment, as described above, the axial length from the end face of the stator core 1 to the circumferential inclined portions 22 is greater than the axial length from the end face of the stator core 1 to other portions of the coil end portions 20b. As a result, the axial length from the end face of the stator core 1 to the circumferential inclined portions 22 is the maximum value of the axial length from the end face of the stator core 1 to the coil end portions 20b. Therefore, by arranging the circumferential inclined portions 22 along the circumferential direction, it is possible to easily prevent the axial length from becoming too large.

[0047] Furthermore, in this embodiment, as described above, circumferential inclined portion 22 is configured to extend along the direction in which the end face of stator core 1 extends. This allows circumferential inclined portion 22, which has the longest axial length from the end face of stator core 1 to coil end portion 20b, to be arranged horizontally in the radial direction, effectively preventing the axial length of coil end portion 20b from becoming too large.

[0048] Furthermore, in this embodiment, as described above, the coil end portion 20b further includes the connection portion 24 that connects the axially inclined portion 21 and the crank portion 23, and the connection portion 24 is configured to be inclined radially outward relative to the axially inclined portion 21 when viewed in the axial direction. This makes it possible to prevent the connection portion 24 from being inclined radially outward and coming into contact with the adjacent coil end portion 20b. Furthermore, because the connection portion 24 can incline the coil end portion 20b radially outward before being inclined axially by the crank portion 23, there is no need to incline the crank portion 23 radially outward, and it is possible to prevent the structure of the crank portion 23 from becoming complicated.

[0049] Furthermore, in this embodiment, as described above, the coil 2 is configured by joining a plurality of segment coils 20, each including an axially inclined portion 21 and a circumferentially inclined portion 22. As a result, the coil 2 is configured by joining a plurality of segment coils 20, each including an axially inclined portion 21 and a circumferentially inclined portion 22, and therefore the coil 2 can be easily configured while preventing the axial length from becoming too large.

[0050] In addition, in this embodiment, as described above, the multiple circumferential inclined portions 22 are arranged so that their circumferential side surfaces face and adjoin each other without being twisted. This allows the coil 2 to be formed without twisting the multiple circumferential inclined portions 22, thereby preventing the process of forming the coil end portion 20b from becoming complicated.

[0051] [Variations] The above-described embodiments disclosed herein should be considered to be illustrative and not restrictive in all respects. The scope of the present invention is defined by the claims rather than the description of the above-described embodiments, and further includes all modifications (variations) within the meaning and scope of the claims.

[0052] For example, in the above embodiment, the segment coil includes a connecting portion, but the present invention is not limited to this. In the present invention, the segment coil may not include a connecting portion, and the axially inclined portion and the crank portion may be directly connected.

[0053] In the above embodiment, the crank portion is S-shaped, but the present invention is not limited to this. In the present invention, the crank portion may be fan-shaped when viewed from the radial direction. In this case, at least one of the axially inclined portion and the circumferentially inclined portion may have a curved portion.

[0054] In the above embodiment, the axial length from the end face of the stator core to the circumferentially inclined portion is greater than the axial length from the end face of the stator core to other portions of the coil end portion, but the present invention is not limited to this. In the present invention, the axial length from the end face of the stator core to the crank portion may be greater than the axial length from the end face of the stator core to the circumferentially inclined portion.

[0055] In the above embodiment, the stator core is a three-phase AC stator, but the present invention is not limited to this. In the present invention, a single-phase AC stator may be used. [Explanation of symbols]

[0056] 1: stator core, 2: coil, 20b: coil end portion, 21: axially inclined portion, 22: circumferentially inclined portion, 23: crank portion, 24: connection portion, 100: stator

Claims

1. A stator core; a coil made of a rectangular wire, the coil being inserted into the stator core and including a plurality of coil end portions that extend axially outward from an end face of the stator core, The plurality of coil end portions are an axially inclined portion provided on the stator core side, inclined axially outward with respect to an end face of the stator core, and extending along a circumferential direction; a circumferential inclined portion inclined in a circumferential direction relative to the axial inclined portion when viewed from the axial direction and extending radially outward; a crank portion configured to connect the axially inclined portion and the circumferentially inclined portion and curved outward in the axial direction, In the adjacent coil end portions, one and the other circumferential inclined portions do not overlap with each other in the axial direction, and circumferential side surfaces thereof face each other and are adjacent to each other, a stator configured so that, in the plurality of adjacent coil end portions, a lower surface of the circumferentially inclined portion of one of the coil end portions and an end portion of the crank portion of the other of the coil end portions on the axially inclined portion side do not overlap in the axial direction but are adjacent in the circumferential direction.

2. The stator according to claim 1 , wherein an axial length from the end face of the stator core to the circumferentially inclined portion is greater than an axial length from the end face of the stator core to other portions of the coil end portion.

3. The stator according to claim 2 , wherein the circumferentially inclined portion is configured to extend along a direction in which the end face of the stator core extends.

4. the coil end portion further includes a connection portion that connects the axially inclined portion and the crank portion, The stator according to claim 1 , wherein the connection portion is configured to be inclined radially outward with respect to the axially inclined portion when viewed in the axial direction.

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