Stator and method for manufacturing stator
By constructing a stator using core segments and shaping them into an annular form through linear expansion, the manufacturing process is simplified, enabling easier tip portion formation and improving torque and torque ripple rates in rotating electrical machines.
Patent Information
- Application Number
- JP2024122385
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-07-29
- Publication Date
- 2026-02-10
AI Technical Summary
Existing methods for manufacturing stators for rotating electrical machines are inefficient and lack sufficient workability in arranging stator windings.
A stator is constructed using a plurality of core segments that form a stator core, with multi-phase coil conductors inserted into slots, and the core segments and coil conductors are shaped into an annular form by first expanding them linearly and then forming the stator core into a ring shape.
This method simplifies the manufacturing process, allows easy formation of tip portions on the inner circumference, and improves torque and reduces torque ripple rates in the rotating electrical machine.
Smart Images
Figure 2026020816000001_ABST
Abstract
Description
[Technical Field]
[0001] An embodiment of the present invention relates to a stator for a rotating electrical machine and a method for manufacturing the stator. [Background technology]
[0002] Generally, when manufacturing a stator for a rotating electric machine, a process is often performed in which a coil conductor made of rectangular wire is formed into a hairpin shape, inserted into a stator core, and the coil ends are formed and then welded. This process is very time-consuming and inefficient, so various configurations and methods have been proposed to make it easier to manufacture stators. [Prior art documents] [Patent documents]
[0003] [Patent Document 1] Patent No. 3982446 [Patent Document 2] Japanese Patent Application Laid-Open No. 2009-11116 Summary of the Invention [Problem to be solved by the invention]
[0004] However, the methods and configurations disclosed in Patent Documents 1 and 2 are intended to improve the workability when arranging the stator winding on the stator, but the workability is not sufficiently good. Therefore, the present invention provides a stator for a rotating electrical machine that can be manufactured more simply and a method for manufacturing the stator. [Means for solving the problem]
[0005] The stator of this embodiment includes a plurality of core segments that form a stator core, and multi-phase coil conductors inserted into the slots of the stator core, the coil conductor is a continuous coil in which straight portions housed in slot portions of the stator core and bridge portions between the slots at coil end portions alternate, The coil conductor is inserted into a slot formed by arranging the plurality of core segments on a plane, and then the core segments and the coil conductor are formed into an annular shape. [Brief explanation of the drawings]
[0006] [Figure 1] 1A is an axial end view of a split core according to a first embodiment, FIG. 1B is a plan view of the split core, and FIG. 1C is a perspective view of the split core according to the first embodiment. [Figure 2] (a) A perspective view showing the state immediately before inserting a connecting pin into a split core, (b) A perspective view showing the state after inserting the connecting pin, and (c) A perspective view showing the state immediately before connecting another split core. [Figure 3] (a) A perspective view showing two split cores connected together, (b) a plan view of the same. [Figure 4] (a) is a perspective view showing a state in which multiple split cores are connected and linearly expanded, and (b) is an axial end view of the state in (a) turned upside down. [Figure 5] FIG. 10 is a perspective view showing a state immediately before a coil conductor in a linearly expanded state is inserted into a stator core in a linearly expanded state; [Figure 6] (a) Axial end view showing the initial stage of forming the stator core into a ring shape from a linearly expanded state, (b) Axial end view showing the stator core formed into a ring shape [Figure 7] A diagram explaining the difference in characteristics depending on whether or not there is a tip portion in the stator core. [Figure 8] 2. Second Embodiment: (a) an axial end view of a split core, (b) a plan view, and (c) a perspective view. [Figure 9] (a) A perspective view showing the state immediately before inserting a connecting pin into a split core, (b) A perspective view showing the state after inserting the connecting pin, and (c) A perspective view showing the state immediately before connecting another split core. [Figure 10] (a) is a perspective view showing a state in which two split cores are being connected, and (b) is a perspective view showing a state in which the connection is completed. [Figure 11] 3A is an axial end view of a split core according to a third embodiment, FIG. 3B is a plan view of the split core, and FIG. 3C is a perspective view of the split core according to the third embodiment. [Figure 12] (a) A perspective view showing the state immediately before inserting a connecting pin into a split core, (b) A perspective view showing the state after inserting the connecting pin, and (c) A perspective view showing the state immediately before connecting another split core. [Figure 13] (a) is a perspective view showing a state in which two split cores are being connected, and (b) is a perspective view showing a state in which the connection is completed. [Figure 14] (a) Axial end view showing the initial stage of forming the stator core into a ring shape from a linearly expanded state, (b) Axial end view showing the stator core formed into a ring shape [Figure 15] 4A is an axial end view of a split core according to a fourth embodiment, FIG. 4B is a plan view of the split core, and FIG. 4C is a perspective view of the split core according to the fourth embodiment. [Figure 16] (a) is a perspective view showing two core segments arranged side by side in opposite directions, (b) is a perspective view showing the two core segments combined, and (c) is a plan view of the same. [Figure 17] 16(c) , (a) is a perspective view showing a state immediately before inserting a connecting pin into the split core in the state of FIG. 16(c), (b) is a perspective view showing a state in the middle of inserting the connecting pin, and (c) is a perspective view showing a state after the insertion is completed. [Figure 18] 5A is an axial end view of a split core according to a fifth embodiment, FIG. 5B is a plan view of the split core, and FIG. 5C is a perspective view of the split core according to a fifth embodiment. [Figure 19] (a) A perspective view showing two core segments arranged side by side in the same direction, (b) A perspective view showing two core segments combined, and (c) A plan view of the same. [Figure 20] 19(c) , (a) is a perspective view showing a state immediately before inserting a connecting pin, (b) is a perspective view showing a state in the middle of inserting the connecting pin, and (c) is a perspective view showing a state after the insertion is completed. [Figure 21] (a) Plan view and (b) Axial end view showing the state in which the coil conductors, which are also linearly expanded, are inserted into the stator core, which is also linearly expanded. [Figure 22] 6A and 6B are a plan view and a perspective view of a core segment according to a sixth embodiment of the present invention; [Figure 23](a) Axial end view of the jig, (b) a perspective view of the same, (c) Axial end view showing a state in which multiple jigs are arranged in a line, (d) Axial end view showing a state in which a split core is arranged on the jig in (c). [Figure 24] (a) is a perspective view corresponding to FIG. 23(c), and (b) is a perspective view corresponding to FIG. 23(d). [Figure 25] 23(d) shows the state in which the inner diameter holding jig and handle are attached, (a) an axial end view, (b) a plan view, and (c) a perspective view. [Figure 26] Diagram (part 1) showing the process of rotating the inner diameter holding jig and handle counterclockwise to form the stator core into a ring shape [Figure 27] Diagram (part 2) showing the process of rotating the inner diameter holding jig and handle counterclockwise to form the stator core into a ring shape [Figure 28] Diagram (part 3) showing the process of rotating the inner diameter holding jig and handle counterclockwise to form the stator core into a ring shape [Figure 29] A diagram showing the completed annular shaping of the stator core DETAILED DESCRIPTION OF THE INVENTION
[0007] (First embodiment) A first embodiment will be described below with reference to Figs. 1 to 7. As shown in Figs. 5 and 6, a stator 1 of a rotating electric machine of this embodiment includes a stator core 2 and coil conductors 3. The stator core 2 is formed by connecting a plurality of core segments 4 shown in Fig. 1. The core segments 4 include a back yoke portion 5 having a generally trapezoidal cross section, and teeth portions 6 that extend from the center of the back yoke portion 5 toward the inner periphery and taper. At the ends of the teeth portions 6, short arc-shaped tip portions 7 extend in the circumferential direction, which is the left-right direction in the drawings.
[0008] 1, cylindrical insertion holes 8a and 8b, which serve as connecting portions, are provided on the outer circumferential side, which is the upper part in the drawing, of back yoke portion 5. The axial length of insertion holes 8a and 8b is half the length of back yoke portion 5, and insertion holes 8a and 8b are positioned closer to one end of back yoke portion 5.
[0009] When connecting two core segments 4(1) and 4(2), a connecting pin 9 is inserted into the insertion hole 8b of the core segment 4(1), as shown in Figure 2. The axial length of the connecting pin 9 is set equal to the length of the back yoke section 5, and when the connecting pin 9 is inserted into the insertion hole 8b, half of the connecting pin 9 is exposed in the axial direction. Then, the other core segment 4(2) is axially opposed to the insertion hole 8b of the core segment 4(1) so that the center of the insertion hole 8b is aligned with the center of the insertion hole 8b of the core segment 4(1), and the exposed connecting pin 9 is inserted into the insertion hole 8b of the core segment 4(2).
[0010] As a result, as shown in Figure 3, the core segments 4(1) and 4(2) are connected via each other's insertion holes 8b and connecting pins 9. Each insertion hole 8a is used for connection in the same way as the insertion hole 8a of the next adjacent core segment 4. By sequentially connecting the core segments 4 in this way, the stator core 2 is expanded linearly, as shown in Figure 4. A slot portion 10 in which the coil conductor 3 is placed is formed between the teeth portions 6(1) and 6(2) of the two core segments 4(1) and 4(2).
[0011] Next, a method for manufacturing the stator 1 will be described. As shown in FIG. 4(a), the stator core 2 is linearly expanded, and as shown in FIG. 4(b), the teeth 6 are arranged so that they face upward in the figure. As shown in FIG. 5, the coil conductor 3, made of rectangular wire, is a continuous coil in which straight sections 11 accommodated in the slots 10 of the stator core 2 alternate with crossover sections 12 between the slots at the coil end. The three-phase coil conductors 3 are pre-wound and linearly expanded. The straight sections 11 of the coil conductors 3 are then accommodated in the slots 10 of the linearly expanded stator core 2. A plan view and an axial end view of this accommodated state are shown in FIG. 21 of the fifth embodiment, which will be described later. The straight sections 11 and crossover sections 12 of the coil conductors 3 are also more clearly shown in FIG. 21.
[0012] Then, as shown in Figure 6(a), one end of the stator core 2 is lifted upward using a jig or the like, thereby integrally forming the stator core 2 and the coil conductor 3 into an arc shape. Finally, as shown in Figure 6(b), the two core segments 4 located at both ends of the stator core 2 are connected via connecting pins 9, thereby forming the stator core 2 into an annular shape. This completes the stator 1. Note that the coil conductor 3 is omitted from Figure 6.
[0013] Here, in a conventional manufacturing process in which coil conductors are inserted into a stator core that has been formed into a circular ring shape in advance, it is difficult to form tip portions on the inner circumferential side of the stator core because the tip portions get in the way when inserting the coil conductors. In contrast, with the stator 1 of this embodiment, as described above, by first developing the stator core 2 and the coil conductors 3 linearly and then forming the stator core 2 into a circular ring shape, tip portions 7 can be easily formed on the inner circumferential side of the stator core 2.
[0014] As shown in Figure 7, when a simulation was conducted on the torque and torque ripple rate depending on whether or not a tip portion was present in a rotating electrical machine of a certain specification, the results showed that the presence of a tip portion resulted in a higher torque and a lower torque ripple rate. This suggests that the deterioration in characteristics caused by configuring the stator core 2 from multiple core segments 4 can be fully recovered.
[0015] As described above, according to this embodiment, the stator 1 includes a plurality of core segments 4 that constitute the stator core 2, and multi-phase coil conductors 3 that are inserted into the slots 10 of the stator core 2. The coil conductors 3 are continuous coils in which straight sections 11 that are housed in the slots 10 alternate with crossover sections 12 that connect the slots at the coil end portions. The stator 1 is completed by inserting the coil conductors 3 into the slots 10 that are formed by arranging a plurality of core segments 4 on a plane, and then shaping the core segments 4 and the coil conductors 3 into an annular shape. This eliminates the time-consuming manufacturing process of inserting coil conductors into a stator core that has already been shaped into an annular shape, as in the conventional method, and makes it possible to easily manufacture the stator 1.
[0016] (Second embodiment) Hereinafter, the same parts as in the first embodiment will be assigned the same reference numerals and their explanation will be omitted, and only the differences will be explained. Note that the following embodiments show variations in the configuration of the core segments. As shown in FIG. 8, the core segment 21 of the second embodiment has a back yoke portion 22 instead of the back yoke portion 5. In the core segment 4 of the first embodiment, the insertion holes 8 were arranged so as to protrude outward from the outer peripheral surface of the back yoke portion 5. In contrast, in the core segment 21, the insertion holes 23 are formed inside the back yoke portion 22.
[0017] When connecting the two core segments 21(1) and 22(2), the process is basically the same as in the first embodiment, and as shown in Fig. 9, a connecting pin 9 is inserted into the insertion hole 23b of the core segment 21(1). Then, the other core segment 21(2) is axially opposed to the insertion hole 23b of the core segment 21(1) so that the center of the insertion hole 23b is aligned with the center of the insertion hole 23b of the core segment 21(1), and then the exposed connecting pin 9 is inserted into the insertion hole 23b of the core segment 21(2). After passing through Fig. 10(a), as shown in Fig. 10(b), the manufacturing process after connecting the core segments 21(1) and 22(2) is the same as in the first embodiment.
[0018] (Third embodiment) As shown in Fig. 11, the core segment 25 of the third embodiment has a back yoke portion 26 that replaces the back yoke portion 22 of the core segment 21, and insertion holes 27a and 27b are formed in the back yoke portion 26. The insertion hole 27b has substantially the same configuration as the insertion hole 23b of the core segment 21. The insertion hole 27a that replaces the insertion hole 23a is formed in a positional relationship that is point-symmetrical to the insertion hole 27b, as shown in Fig. 11(b). The two core segments 25(1) and 25(2) are connected together in the same manner as in the second embodiment, except that the insertion hole 23b is replaced with the insertion hole 27b, as shown in Figs. 12 and 13.
[0019] 14(a) shows the process of inserting a coil conductor 3, which has been linearly expanded, into a stator core 50 formed by connecting multiple core segments 25 and expanding it linearly, and then lifting one end of the stator core 50 upward, thereby integrally forming the stator core 50 and the coil conductor 3 into an arc shape. Finally, as shown in FIG. 14(b), the two core segments 25 located at both ends of the stator core 50 are connected via connecting pins 9, thereby forming the stator core 50 into an annular shape. This completes the stator 51.
[0020] (Fourth embodiment) 15, a core segment 28 of the fourth embodiment includes a back yoke portion 29 in place of the back yoke portion 22 of the core segment 21, and four insertion holes 30a to 30d are formed in the back yoke portion 29. The axial length of the insertion holes 30 is set to 1 / 4 of that of the back yoke portion 29, and the insertion holes 30a and 30c are formed concentrically, and the insertion holes 30b and 30d are formed concentrically.
[0021] 16, when connecting two core segments 28(1) and 28(2), (a) the core segment 28(2) is arranged side by side with the orientation opposite to that of the core segment 28(1), and (b) and (c) the two are engaged. That is, the insertion hole 30b of the core segment 28(1) is positioned between the insertion holes 30b and 30d of the core segment 28(2), and the insertion hole 30d of the core segment 28(1) is arranged to communicate with the insertion hole 30b of the core segment 28(2).
[0022] 17(a), when the split cores 28(1) and 28(2) are engaged, the insertion holes 30d(2), 30b(1), 30b(2), and 30d(1) are connected to each other. Then, the engagement pin 9 is inserted through the insertion hole 30d(2) and, as shown in (b) and (c), is passed through the insertion holes 30b(1), 30b(2), and 30d(1) to connect them.
[0023] (Fifth embodiment) 18, the core segment 31 of the fifth embodiment includes a back yoke portion 32 in place of the back yoke portion 22 of the core segment 21, and four insertion holes 33a to 33d are formed in the back yoke portion 32. The axial length of the insertion holes 33 is set to 1 / 4 of that of the back yoke portion 32, and the insertion holes 33a and 33c are formed concentrically, and the insertion holes 33b and 33d are formed concentrically.
[0024] 18(b), which is a plan view of the outer peripheral surface side, the insertion hole 33c is located in the upper left, followed by the insertion hole 33d on the right, followed by the insertion hole 33a on the left, followed by the insertion hole 33b on the lower right. In other words, from the upper left to the lower right, the insertion holes 33c, 33d, 33a, and 33b are formed alternately on the left and right, and the four insertion holes 33c, 33d, 33a, and 33b are arranged point-symmetrically.
[0025] As shown in Figure 19, when connecting two core segments 31(1) and 31(2), (a) line up the core segments 31(1) and 31(2) side by side in the same direction, and (b) and (c) engage them. As a result, as shown in Figure 20, the insertion hole 33b of the core segment 31(1), the insertion hole 33a of the core segment 31(2), the insertion hole 33d of the core segment 31(1), and the insertion hole 33c of the core segment 31(2) become connected. Then, the engagement pin 9 is inserted through the insertion hole 33b(1) and passed through the insertion holes 33a(2), 33d(1), and 33c(2) (b) and (c).
[0026] 21 shows (a) a plan view and (b) an axial end view of a state in which a coil conductor 3, which has also been linearly expanded, is inserted into a stator core 34 formed by connecting a plurality of core segments 31 and expanding them linearly. According to the fifth embodiment configured as described above, when connecting the two core segments 31(1) and 31(2), there is no need to arrange them in opposite directions as with the core segment 28 of the fourth embodiment, making it easier to assemble the stator core.
[0027] (Sixth embodiment) As shown in Fig. 22, the core segments 35 of the sixth embodiment are obtained by removing the insertion holes 8 from the core segments 4 of the first embodiment and have no connecting portions. When forming such core segments 35 into an annular shape, a jig 36 shown in Fig. 23 is used. (a) and (b) show the axial end face and perspective view of the jig 36 alone. The jig 36 has a rectangular parallelepiped base 37 and an engaging portion 38 located above the base 37 in the figure.
[0028] As shown in FIG. 23(a), the jig 36 has a generally T-shaped configuration when viewed from the axial end face, and a protrusion 39 is formed on the right side of the engaging portion 38 in the drawing. FIG. 23(c) shows a state in which multiple jigs 36 are linearly arranged, engaged with the engaging portions 38. FIG. 23(d) shows a state in which core segments 35 are arranged one-to-one above the linearly arranged jigs 36. FIGS. 24(a) and 24(b) are perspective views of FIGS. 23(c) and 23(d), respectively. That is, in FIGS. 23(d) and 24(b), a stator core 40 in which the core segments 35 are not connected to each other but are linearly expanded is arranged above the linearly arranged jigs 36.
[0029] The process of forming the stator core 40 into an annular shape will be described below. The coil conductors 3 are not shown. As shown in FIG. 25(a), a cylindrical inner diameter holding jig 41 is placed above the core segment 35 located at the right end of the stator core 40 in the drawing. The diameter of the inner diameter holding jig 41 is equal to the inner diameter of the stator core 40 to be formed into an annular shape. Furthermore, as shown in FIG. 25(b), the axial length of the inner diameter holding jig 41 is equal to the axial length of the stator core 40.
[0030] Insertion holes for inserting each end of a U-shaped handle 42 are formed in the center of the inner diameter holding jig 41 and in the base 37 of the core split 35 located at the right end of the stator core 40. The inner diameter holding jig 41 is stabilized by inserting each end of the handle 42 into the respective insertion holes. From this state, as shown in FIGS. 26 to 28, the handle 42 is rotated counterclockwise together with the inner diameter holding jig 41 while lifting the core split 35 side of the handle 42. Finally, as shown in FIG. 29, both ends of the stator core 40 come into contact, and the stator core 40 is formed into an annular shape.
[0031] (Other embodiments) The tip portion 7 may be formed as needed. The specific configuration of the connecting portion is not limited to the example shown. The coil conductor is not limited to a wave-wound one, but may be any continuous coil. For example, the axial length of the insertion hole 8 in the first embodiment may be less than half the length of the back yoke portion 5 . Furthermore, for example, the axial length of the insertion hole 30 in the fourth embodiment may be less than ¼ of the length of the back yoke portion 29 .
[0032] Although several embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, and are also included in the scope of the invention and its equivalents as defined in the claims. [Explanation of symbols]
[0033] In the drawings, 1 is a stator, 2 is a stator core, 3 is a coil conductor, 4 is a split core, 5 is a back yoke portion, 6 is a teeth portion, 7 is a tip portion, 8 is an insertion hole, 9 is a connecting pin, 10 is a slot portion, 11 is a straight portion, 12 is a jumper portion, 21 is a stator core, 22 is a back yoke portion, 23 is an insertion hole, 24 is a stator core, 25 is a split core, 26 is a back yoke portion, 27 is an insertion hole, 28 is a split core, 29 is a back yoke portion, 30 is an insertion hole, 31 is a split core, 32 is a back yoke portion, 33 is an insertion hole, 34 is a stator core, 35 is a split core, 36 is a jig, 40 is a stator core, 41 is an inner diameter holding jig, 42 is a handle, 50 is a stator core, and 51 is a stator.
Claims
1. a plurality of core segments constituting a stator core; and multi-phase coil conductors inserted into the slots of the stator core, the coil conductor is a continuous coil in which straight portions housed in slot portions of the stator core and bridge portions between the slots at coil end portions alternate, The stator is formed by arranging the plurality of core segments on a plane, inserting the coil conductor into slots formed therein, and then shaping the core segments and the coil conductor into an annular shape.
2. 2. The stator according to claim 1, wherein the core segments have teeth extending radially inward from the back yoke and have a generally T-shaped cross section.
3. 3. The stator according to claim 2, wherein the teeth have tip portions at their ends, the tip portions extending in the circumferential direction.
4. 4. The stator according to claim 2, wherein the back yoke portions of the core segments have connecting portions for connecting the back yoke portions of adjacent core segments.
5. the connecting portion is an insertion hole that is arranged along the axial direction and has a length that is equal to or less than half the axial length of the back yoke portion, 5. The stator according to claim 4, wherein adjacent split cores are connected by inserting a connecting pin through each of the insertion holes with the centers of the insertion holes of the adjacent split cores overlapping each other in the axial direction.
6. the connecting portion is an insertion hole having a length equal to or less than ¼ of the axial length of the back yoke portion, 6. The stator according to claim 5, wherein the insertion holes are arranged in a point-symmetrical relationship, with two on each of one side and the other side in the circumferential direction of the back yoke portion.
7. 2. The stator according to claim 1, wherein the cross section of the coil conductor is rectangular.
8. A method for manufacturing a stator for a rotating electric machine, comprising: Each slot is formed by arranging multiple core segments that make up the stator core on a plane. The coil conductor is a continuous coil in which the straight portions accommodated in the slot portions and the crossover portions between the slots at the coil end portions alternate, and then the coil conductor is arranged in a straight line. A method for manufacturing a stator, comprising forming the core segments and the coil conductors into an annular shape.
9. The split core has a generally T-shaped cross section with teeth extending from a back yoke portion to an inner diameter side, the back yoke portion has a connecting portion for connecting the back yoke portions of adjacent core segments, the connecting portion is an insertion hole that is arranged along the axial direction and has a length that is equal to or less than half the axial length of the back yoke portion, 9. The method for manufacturing a stator according to claim 8, wherein adjacent split cores are connected by inserting a connecting pin through each of the insertion holes in a state where the centers of the insertion holes of the split cores are aligned with each other in the axial direction.
Citation Information
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