Motor and its winding method

Abstract

This invention provides a winding method that leads to increased space utilization of motor windings and miniaturization of motors. [Solution] By using removable winding guides 21, 22, and 23 to align and efficiently direct-wind the windings 13 of a fully wound switch reluctance motor SRM, the space utilization ratio within the slot is greatly improved. In addition, the winding connections at the coil ends are grouped and arranged separately in the circumferential direction for each group, making winding easier, reducing the amount of insulating paper, and reducing the axial length of the coil ends. Furthermore, design changes, production of various types of motors, and production of small-lot motors are relatively easy. As a result, it leads to higher efficiency, miniaturization, weight reduction, and lower costs for the motor.

Description

Technical Field

[0001] The present invention relates to a method for winding a motor winding. The motor winding needs to increase the copper wire occupation ratio in the slot, shorten the coil end length, reduce the rotor axial length including the stator winding, and efficiently manufacture the winding including automation. This leads to higher efficiency, smaller size, lighter weight, and lower cost of the motor.

[0002] The present invention relates to a winding method of a switched reluctance motor SRM with full-pitch windings, a connection method of full-pitch windings between slots in the coil end portion, and a form. The switched reluctance motor SRM with full-pitch windings has been studied by universities and companies such as Patent No. 3157162 of Patent Document 3, but due to the difficulty that the induced voltage is complex and excessive, it has hardly been put into practical use. And the winding form of the switched reluctance motor SRM with full-pitch windings is different from that of other motors in that it is a full-pitch winding and the slot opening is large, but the winding method of this switched reluctance motor SRM with full-pitch windings has not been noticed because there is no demand for motors.

Background Art

[0003] For the winding of motors, various winding methods are selected according to the type and form of the motor. For example, the motors for home appliances have a concentrated winding configuration, and there are many motors applying permanent magnets. This winding is wound by a winding machine by inserting a thin winding nozzle from the opening of the slot and aligning it with the corresponding teeth of the stator and winding it concentrically. It is a simple configuration in which the winding is concentrically wound on one tooth, and the winding process is often automated by a winding machine, and it also has excellent productivity. However, a gap for inserting the winding nozzle is required in the circumferential direction of each winding, and there is still room for space utilization in that regard.

[0004] Figure 18 shows a cross-sectional view of a conventional concentrated-winding switch reluctance motor (SRM). 181 is the stator, specifically the back yoke portion of the stator core. 182 are the salient poles of the stator, also called teeth. There are 12 teeth arranged circumferentially, and the spaces between the teeth are the slots around which the windings are wound. The circumferential width of the teeth is Wst, and the inner diameter side of the slots between the teeth is called the slot opening, with Wop being its circumferential width. In the example in Figure 18, the circumferential width of the teeth (Wst) is shown to be equal to the width of the slot opening (Wop). Tslot is the circumferential period of the slot.

[0005] In Figure 18, 186 is the rotor, and 187 is the rotor's salient pole. Wrt is the circumferential width of the rotor's salient pole 187, and Figure 18 shows an example where the circumferential width Wrt of the rotor's salient pole 187 is equal to the circumferential width Wst of the stator teeth. The torque of the concentrated-winding switched reluctance motor SRM in Figure 18 is generated by the attractive force between the stator's salient pole and the rotor's salient pole. Furthermore, the concentrated-winding switched reluctance motor SRM in Figure 18 is an SRM with two sets of the basic and well-known representative SRM configuration, consisting of six stator salient poles and four rotor salient poles, arranged circumferentially. The phase name is appended to each stator salient pole. In the concentrated winding of the switch reluctance motor SRM, for example, the cross-section of the winding is shown by 183 and 184, and 185 shows the connection relationship of the coil end. For example, 182 and 188 are salient poles of the A-phase stator, and 189 and 18A are salient poles of the A / -phase, which is the opposite phase of the A-phase. 18B and 18C are A-phase windings, and when energized as a motor, they conduct the A-phase current Ia and are dedicated concentrated windings for the A-phase that excite the A-phase stator salient poles 182 and 188. Thus, each concentrated winding in Figure 18 is a dedicated concentrated winding that excites each tooth which is a salient pole of the stator.

[0006] The motor configuration shown in Figure 18 is simple because it concentrates a set of windings around the teeth, which are salient poles of a single stator. Similar to the windings of motors using concentrated windings with permanent magnets, the windings can be aligned and wound using the winding nozzle of a winding machine. Although space is required to insert the winding nozzle, high-density winding is possible. The sum of the cross-sectional areas of the copper wire portion relative to the cross-sectional area of ​​the slot is called the winding space factor PW, and the winding space factor PW can be made relatively large. In addition, since winding can be done at high speed using the winding nozzle on a winding machine, the production cost of winding can be reduced. However, the need for space to insert the winding nozzle is undesirable in terms of winding space factor.

[0007] Furthermore, while concentrated-winding switched reluctance motors (SRMs) have a simpler motor configuration and lower cost compared to concentrated-winding permanent magnet motors because they do not require permanent magnets, their low torque output limits their use to very limited applications. The reason for the lower torque output is that, for example, compared to the winding utilization rate of 2 / 3 when a concentrated-winding permanent magnet motor is driven at 120° energization, the winding utilization rate of a 3-phase, concentrated-winding switched reluctance motor (SRM) is only 1 / 3, resulting in increased copper losses. The continuous rated current needs to be estimated by reducing it to 1 / 1.414 = 0.7071. In addition, in the case of small concentrated-winding switched reluctance motors (SRMs), the magnetic flux excitation current component adds to the burden, which is one reason for the decrease in continuous rated torque.

[0008] Furthermore, as described in paragraph

[0002] , fully wound switch reluctance motors (SRMs) have been largely unused due to the difficulty of the complex and excessive induced voltage, although examples such as Patent No. 3157162 in Patent Document 3 exist. The reason why the induced voltage of fully wound motors is complex and excessive is that, as shown by Faraday's law of electromagnetic induction, all phase flux components link together in the fully wound motor, resulting in all phase voltage components, such as square waves, being superimposed on the fully wound motor.

[0009] This invention relates to a winding method for a fully wound switched reluctance motor (SRM), for which there has been little demand. The problem of the induced voltage being complex and excessive has been solved by the technology described in Patent No. 7267564 of Patent Document 2. A fully wound switched reluctance motor (SRM) can eliminate the problem of reduced continuous rated torque that occurs with concentrated-winding switched reluctance motors (SRMs). Furthermore, improvements in the winding space factor according to this invention have made it possible to configure an SRM motor system that is superior to current synchronous motors using permanent magnets. Paragraphs

[0030] to

[0032] will briefly explain the advantages of the fully wound switched reluctance motor (SRM) in relation to these changes in circumstances and other factors. This explanation is intended to ensure "industrial applicability," which is one of the patent requirements, and is not related to the technology of the present invention itself.

[0010] In recent years, in particular, the main motors for hybrid electric vehicles (HEVs) and electric vehicles (EVs) have attracted attention, and major automobile manufacturers have developed winding methods for them. Specifically, this is a winding method called SC winding (segment conductor winding), and in order to compare it with the winding method of the present invention, paragraphs

[0057] to

[0067] show the relationship formula for the superiority of the present invention compared with SC winding, and quantitatively explain specific numerical examples. This explanation is also intended to ensure "industrial applicability," which is one of the patent requirements, and is not related to the technology of the present invention itself.

[0011] Furthermore, for motors with full-slot windings, in small-batch production, the windings are made by winding them from a winding drum into a bundle, and then manually inserting them into each slot to assemble the motor windings. In this case, the ratio of the total cross-sectional area of ​​the copper wire portion of the windings within a slot to the cross-sectional area of ​​the slot is about 40%. This presents problems with productivity and the low winding space utilization ratio.

[0012] When mass production lots for fully wound motors become large, a mechanical winding assembly method called the inserter method is used. However, this method has problems such as requiring larger equipment and making operation and adjustment more complex. The winding space factor is limited to around 40%, and the coil end length of the windings becomes long. Insulated round copper wires with a diameter of approximately 0.5 mm to 1.0 mm are used, and winding bundles are manufactured in parallel according to the rated current and installed in the slots. Both methods have problems such as the motor becoming larger due to limitations in winding space factor and productivity issues. [Prior art documents] [Patent Documents]

[0013] [Patent Document 1] Japanese Patent Publication No. 2002-34191 [Patent Document 2] Patent No. 7267564 [Patent Document 3] Patent No. 3157162 [Overview of the project] [Problems that the invention aims to solve]

[0014] The objective of this invention is to increase the copper wire space ratio within the slots of a fully wound switch reluctance motor (SRM), shorten the coil end length, reduce the rotor axial length including the stator windings, and efficiently manufacture the windings, including through automation. As a result, this leads to higher efficiency, miniaturization, weight reduction, and lower costs for the motor.

[0015] The first objective of the present invention is to provide a concrete method for winding the windings onto the stator core. The second objective of the present invention is to arrange the windings at the coil end more flatly and uniformly by appropriately arranging each winding and the winding order of each winding, thereby shortening the rotor axial length including the coil end of the stator. This also leads to simplification of the winding process and a reduction in the amount of insulating material such as insulating paper used in the winding process. [Means for solving the problem]

[0016] The invention described in claim 1 is characterized in that the teeth ST of the stator and the slots SL around which the stator winding SW is wound are alternately arranged in the circumferential direction of the stator, the magnetic opening width Wop of the slots SL facing the air gap is 30% or more of the slot period Tslot in the circumferential direction over the air gap between the stator and the rotor, a winding guide WAN that can be attached to the rotor axial end face of the stator core SC constituting the magnetic circuit is attached as needed when winding the stator winding SW, the winding guide WAN is removed if it interferes with winding other windings or forming windings, and the stator winding SW is supplied and directly wound onto the stator core SC and the slots SL. The motor and its winding method are characterized by comprising a winding nozzle WN, a multi-axis drive device MDD that drives the stator core SC and the winding nozzle WN relatively in the C-axis direction, which is the circumferential direction of the stator core SC, the Z-axis direction, which is the rotor axis direction of the stator core SC, the X-axis direction perpendicular to the Z-axis direction, and the Y-axis direction perpendicular to the Z-axis direction and the X-axis direction, and winding supplied from a winding drum or the like by the winding nozzle WN, and winding SW onto various parts such as the rotor axis direction end face of the stator core SC and the slot SL, with the position of the C-axis, X-axis, Y-axis, and Z-axis controlled by the multi-axis drive device MDD. With this configuration, a detachable winding guide WAN can be attached to the end face of the stator core SC as needed, and the winding can be removed and the winding can be wound around it. This makes it possible to wind the winding at the coil end, which tends to have a complex shape, into the desired shape, and ultimately to shape the winding portion at the coil end.

[0017] The invention described in claim 2 is a motor and winding method characterized in that the teeth ST of the stator and the slots SL around which the stator winding SW is wound are alternately arranged in the circumferential direction of the stator, the magnetic opening width Wop of the slots SL facing the air gap is 30% or more of the slot period Tslot in the circumferential direction on the air gap between the stator and the rotor, the stator winding SW is wound outside the stator core SC that constitutes the magnetic circuit and is to be inserted into the slots SL, the portion to be inserted into the slots SL is made rigid, and the portion of the winding bundle corresponding to the coil end is made flexible and bendable, the coils have two or more shapes, the shapes are such that when the coils are inserted into the slots SL in a predetermined order, the shapes of the coils and the slots SL do not interfere with each other, and two or more types of coils are inserted into the slots SL sequentially. This configuration allows for the efficient manufacturing of the coil bundle outside the stator core SC without structural constraints, and the coil is then inserted into the slot SL, resulting in superior productivity.

[0018] The invention described in claim 3 is characterized in that the teeth ST of the stator and the slots SL around which the stator winding SW is wound are alternately arranged in the circumferential direction of the stator, the magnetic opening width Wop of the slots SL facing the air gap is 30% or less of the slot period Tslot in the circumferential direction on the air gap between the stator and the rotor, a winding guide WAN that can be attached to the rotor axial end face of the stator core SC constituting the magnetic circuit is attached as needed when winding the stator winding SW, and the winding guide WAN is removed if it becomes an obstruction when winding the stator winding SW. The system includes a winding nozzle WN that supplies the stator winding SW to the stator core SC and the slot SL for direct winding, and a multi-axis drive unit MDD that drives the stator core SC and the winding nozzle WN relatively in the C-axis direction, which is the circumferential direction of the stator core SC, the Z-axis direction, which is the rotor axis direction of the stator core SC, the X-axis direction perpendicular to the Z-axis direction, and the Y-axis direction perpendicular to both the Z-axis and X-axis directions, and a transient winding guide KAWAN capable of gripping and separating the winding is provided near the rotor axis end face of the stator core SC, and when the winding passes through the opening KAS of the slot SL, the transient winding guide KAWAN grips a part of the winding, and the other winding nozzle WN identifies the position of the winding and controls the position of the winding so that it can pass through the opening KAS. This motor and winding method is characterized by the following steps: after winding the winding into the slot SL, the grip of the winding by the transient winding guide KAWAN is released and separated; the winding supplied from the winding drum or the like is wound onto the rotor axial end face of the stator core SC and the slot SL using the winding nozzle WN, and the winding guide WAN provided as needed, with the position of the stator winding SW controlled by the multi-axis drive device MDD for the C, X, Y, and Z axes. This configuration includes a transient winding guide KAWAN capable of gripping and releasing windings. By gripping the winding as needed to locate its position, and then releasing the grip to release it, the winding position can be controlled as appropriate, allowing for precise winding.

[0019] The invention described in claim 4 is a motor and winding method characterized in that, in either claim 1 or claim 3, a compression means PRS for compressing the winding wound in the slot SL in the radial direction is inserted into the slot SL, and the winding in the slot SL is made denser by the compression means PRS. With this configuration, the windings within the winding slot SL are compressed and formed, which increases the density of the windings within the slot SL and improves the winding's space factor.

[0020] The invention according to claim 5 is, in any one of claims 1, 2, and 3, wherein the windings inserted into the slots SL are divided into a plurality of groups, and the plurality of stator windings SW of the first group are wound at positions circumferentially separated from each other in the vicinity of the coil end portion in the rotor axis direction of the stator core SC. An electrical first insulating material DZ is disposed between the plurality of stator windings SW of the first group and the windings SW of the second group wound next thereto. On the first insulating material DZ, each winding SW of the second group wound at positions circumferentially separated from each other is wound. When there is a winding of a third group, similarly, a second insulating material DZ is disposed, and each winding SW of the third group is wound. When there is a winding of a fourth group, similarly, a third insulating material DZ is disposed, and each winding SW of the fourth group is wound. A motor and a winding method thereof characterized by this are provided. According to this configuration, in the vicinity of the coil end portion, the windings of each winding group can be arranged by being distributed almost uniformly in the circumferential direction, so that the length of the stator in the rotor axis direction can be shortened. At the same time, the number of insulating materials such as phase insulating paper between the windings of each phase can be reduced.

[0021] The invention according to claim 6 is, in any one of claims 1, 2, and 3, wherein after removing a part or all of the winding guide WAN, the coil end portion of the winding is compressed and formed by a forming die for the coil end portion. A motor and a winding method thereof characterized by this are provided. According to this configuration, after removing the winding guide WAN required during winding, the coil end portion is compressed and formed, so that the length of the stator in the rotor axis direction can be shortened.

Brief Description of the Drawings

[0022] [Figure 1] Cross-sectional view showing the winding arrangement of the motor of the present invention and the connection of the coil end portion [Figure 2] Basic configuration of stator core and winding method [Figure 3] Example of winding guide, winding, and stator core with eccentric configuration [Figure 4]Example of a tapered winding guide, winding, and stator core. [Figure 5] Examples of resin-based winding guides, windings, and stator cores. [Figure 6] Examples of fan-shaped slots and rectangular slots for SC windings. [Figure 7] This is a comparison example of the shapes of a fan-shaped slot and a rectangular slot. [Figure 8] Example of winding arrangement and connection for a 7-phase, fully wound, switchable reluctance motor SRM. [Figure 9] Molded coil and stator core [Figure 10] Basic configuration diagram of stator core and winding method [Figure 11] Basic configuration diagram of stator core and winding method [Figure 12] Configurations for gripping windings with transient winding guides, and configurations for separating windings. [Figure 13] A configuration in which windings stacked within a slot are compressed. [Figure 14] Example of winding arrangement and connection for a 7-phase, fully wound, switchable reluctance motor SRM. [Figure 15] Example of winding arrangement and connection for a 5-phase, fully wound, switchable reluctance motor SRM. [Figure 16] Example of winding arrangement and connection for a 3-phase, fully wound, switchable reluctance motor (SRM). [Figure 17] The windings at the coil end are formed after the winding guides are removed. [Figure 18] Example of winding arrangement and connection for a conventional 3-phase concentrated winding switch reluctance motor SRM [Modes for carrying out the invention] [Examples]

[0023] Figure 1 shows an example of a cross-sectional view of a fully wound switch reluctance motor SRM (Simulated Reel Motor) that is the target of the winding method according to claim 1. In Figure 1, the stator 181, the stator salient poles 182, the rotor 186, and the rotor salient poles 187 are the same as in Figure 18. This is an SRM with two sets of the basic and well-known representative SRM configuration, consisting of six stator salient poles and four rotor salient poles, arranged in the circumferential direction. The circumferential width of the teeth at the intersection of the extension lines of the stator salient poles with respect to the central circle on the air gap is Wst, and the inner diameter side of the slot sandwiched between the teeth is called the slot opening, and its circumferential width is similarly Wop. In the example in Figure 18, an example is shown where the circumferential width of the teeth Wst and the width of the slot opening Wop are equal. The circumferential width Wrt of the rotor salient pole 187 is also shown as being the same value as the circumferential width of the stator teeth Wst. Tslot is the period of the slot, and the relationship is Tslot = Wst + Wop. The ratio PAS of the slot opening width Wop to the slot period Tslot is given by the following equation. PAS=Wop / (Wst+Wop)=Wop / Tslot (1) Note that Tslot, Wst, Wop, and Wrt are treated here as the angular width between intersections extended to the circle at the center of the air gap, but in Figures 1 and 18, they are shown as the linear distance of each width for ease of illustration. Claim 1 applies to a fully wound switch reluctance motor SRM in which the magnetic opening width Wop facing the air gap of the slot SL is 30% or more of the slot period Tslot. Increasing the circumferential width Wst of the stator teeth and the circumferential width Wrt of the salient magnetic poles 187 of the rotor increases the torque generation range, while conversely, magnetic interference with adjacent poles increases. The width Wop of the slot opening is determined by the required motor specifications.

[0024] Each winding in each slot in Figure 1 is a full-slot winding, and the connection relationship of the windings in each slot differs from that of the concentrated-winding reluctance motor SRM in Figure 18. 182 and 188 are A-phase stator poles, and 189 is the A / -phase stator pole, which is the opposite phase of A-phase. 15 is the B-phase stator pole, and 16 is the B / -phase stator pole, which is the opposite phase of B-phase. 17 is the C-phase stator pole, and 18 is the C / -phase stator pole, which is the opposite phase of C-phase. The phase of each stator pole in Figure 1 is noted for reference. 11 and 12 are AB-phase windings that excite both A-phase and B-phase, carrying the AB-phase current Iab, and 13 shows the connection relationship of the coil end windings between AB-phase windings 11 and 12 in the slot.

[0025] Similarly, the winding connection at the coil end of coil 19 is a BC-phase winding that energizes both phase B and phase C, carrying a BC-phase current Ibc. Likewise, the winding connection at the coil end of coil 1A is a CA-phase winding that energizes both phase C and phase A, carrying a CA-phase current Ica. The connection relationships between the full-slot windings and the coil end windings in the remaining half of each slot are the same. Also, the winding connection relationships in each slot shown in Figure 1 are just one example, and the connection relationships can be changed depending on the winding order and other factors.

[0026] Furthermore, the circumferential width Wst of the teeth, which are the salient poles of the stator, can be varied according to the required torque characteristics and voltage characteristics. The circumferential width Wrt of the salient poles 187 of the rotor can also be varied according to the required torque characteristics and voltage characteristics. In claim 1, the magnetic opening width Wop facing the air gap of the slot SL is 30% or more of the slot period Tslot. The ratio PAS of the opening KAS of the slot SL in equation (1) is 0.3 or more. This is a winding method for motors with a large opening width Wop.

[0027] The winding method of claim 1 mainly relates to a winding method for a fully wound switch reluctance motor SRM. However, the winding method of the present invention is not limited to fully wound switch reluctance motor SRMs, and can be applied to motors of similar shape. Hereafter, "fully wound switch reluctance motor SRM" will be abbreviated as "fully wound SRM," and "concentrated winding switch reluctance motor SRM" will be abbreviated as "concentrated winding SRM."

[0028] Next, the naming conventions for the number of stator poles, rotor poles, poles, and pole pairs of an SRM in this specification will be explained. In this specification, when the number of stator poles of an SRM is Nsp and the number of rotor poles is Nrp, the configuration of that SRM is abbreviated as NspSNrpR. For example, when the number of stator poles Nsp = 6 and the number of rotor poles Nrp = 4, the configuration of the SRM is abbreviated as "6S4R".

[0029] Furthermore, there is the issue of how to express and refer to the configuration of the SRM in relation to the number of poles and pole pairs in a synchronous motor. For example, there are several differing opinions in the motor industry regarding how the SRM in Figure 1 should be referred to as a "motor with a certain number of poles" or a "motor with a certain number of pole pairs," which can lead to misunderstandings. Therefore, in the SRM of this invention, it is decided to express it as "the number of configurations including the basic stator poles and rotor poles, PNSRM." For example, the SRM in Figure 1 has 12 stator poles and 8 rotor poles, so it is 12S8R. The basic configuration has 6 stator poles and 4 rotor poles, so it is 6S4R, and in that case, PNSRM is 2.

[0030] Next, the problems described in paragraphs

[0007] ,

[0008] , and

[0009] regarding the fully wound SRM that is the target of the winding method of the present invention will be explained. In a fully wound SRM, as shown by Faraday's law of electromagnetic induction, all phase flux components are linked in each fully wound winding, so all phase voltage components such as square waves are superimposed on the fully wound winding. As a result, there is a difficulty in that the induced voltage of the fully wound winding is complex and excessive. Consequently, to the best of the inventor's knowledge, fully wound SRMs have hardly been put into practical use. However, this problem can be solved by the technology of Patent No. 7267564 in Patent Document 2, which solves the difficulty of the induced voltage being complex and excessive.

[0031] One problem with concentrated winding SRMs is that, as described in paragraph

[0007] , they have a lower winding utilization rate compared to current permanent magnet motors. This problem of low winding utilization rate can be solved by changing from concentrated winding SRMs to fully wound SRMs, which are the target motors of this invention, thereby improving the continuous rated current and continuous rated torque. Furthermore, in the case of small, concentrated-winding SRMs, it has been pointed out that the burden of the excitation current component of the magnetic flux is large, leading to a decrease in continuous rated torque. However, by changing to an SRM with all-section windings, the excitation current component of the magnetic flux is distributed across two full-section windings, reducing the voltage burden of the excitation current component on both windings by half, and the winding resistance decreases, thus reducing the copper loss component by half. In addition, in applications such as main motors for hybrid electric vehicles (HEVs) and electric vehicles (EVs), the motor size is large, so the problem of the excitation current component of the magnetic flux in an SRM with all sections is relatively limited. Although not directly related, even in current IPMSMs (Integrated Magnet Synchronous Motors) for HEVs and EVs, the power factor decreases and apparent power increases in the low-speed, high-torque region, and the power factor decreases and apparent power increases in the field-weakening region of the high-speed rotation region, increasing the field-weakening current component. Therefore, we believe that the problem of the excitation current component of the magnetic flux in an SRM with all sections is limited when considered in comparison to other applications. As will be explained later, the present invention improves the winding space factor of a fully wound SRM, thereby improving the continuous rated torque. Overall, a fully wound SRM has the potential to achieve a continuous rated torque equivalent to or better than the built-in magnet synchronous motor IPMSM currently used in HEVs and EVs. As a result, it is possible to secure a foothold for "industrial applicability," one of the patent requirements for this invention.

[0032] Furthermore, since fully wound SRMs do not require expensive permanent magnets, they are low-cost. Also, as shown in Patent No. 7267564 of Patent Document 2, by taking advantage of the benefits of DC drive, it may be possible to significantly reduce the current capacity of the transistors in the drive circuit, potentially leading to lower costs and smaller sizes for inverters. In addition, by adding permanent magnets, it is possible to increase the torque, miniaturize, and lighten the fully wound SRM. However, these technologies are not directly related to the technology of the present invention. Nevertheless, given this technical background, we believe that the winding method for the fully wound SRM of the present invention is useful and important.

[0033] Next, Figure 2 will be explained. As the target motor of claim 1, Figure 1 shows an example of a fully wound SRM 12S8R. Parts with the same reference numerals in Figure 1 and Figure 2 refer to the same parts. Figures 2 to 5 show the basic configuration of the winding machine that explains the winding method and illustrate the concept of the winding method. Figure 2 illustrates how the winding is directly wound into the slot by the winding nozzle 20. 181 in Figure 2 is the stator and refers to the back yoke portion of the stator core, which is the same as the stator core 181 in Figure 1. 188 and 182 are A-phase stator poles. 189 is the A / -phase stator pole, which is the opposite phase of the A-phase. 15 is the B-phase stator pole, and 16 is the B / -phase stator pole, which is the opposite phase. The winding 13 being wound in Figure 2 is the AB-phase winding that excites the A-phase, A / -phase, B-phase, and B / -phase stator poles, and when the motor is energized, it will carry the AB-phase current Iab.

[0034] In other words, the AB phase winding 13 is a winding shared for the excitation of both the A phase and the B phase, and the winding utilization rate can be doubled compared to the concentrated winding SRM in Figure 18. On the other hand, as mentioned above, not only does the induced voltage of all the windings become complex, but the winding method also becomes complex, as shown in Figure 2. Thus, although the fully wound SRM comes with several difficulties, it can be said that it is a motor with excellent potential.

[0035] In Figure 2, 25 is a winding drum that supplies winding 26. 27 is a winding removal device that removes winding from winding drum 25, 28 is a pulley that changes the winding direction, and 29 is a winding supply device that supplies winding 2A to winding nozzle 20. In particular, it is preferable for the winding supply device 29 to maintain a constant winding tension of winding 2A in order to improve the positional accuracy of winding in a direct winding. 24 is a rotary table that eliminates twisting of the winding in the slot and winding 2A. 2B is the starting part of the winding. Note that round wires are symbolically indicated by dashed circles at the end faces and bends of each winding.

[0036] 21, 22, and 23 are winding guides WAN, which are necessary to temporarily fix the position of the windings so that the winding nozzle 20 can directly wind the windings 2A into each slot and near the coil ends. In Figure 2, the winding guides 21, 22, and 23 are symbolically represented and shown with simple double-circle symbols. Later, Figures 3, 4, and 5 will show specific examples to explain the concept of winding guides and the various shapes that are possible. A major feature is that the winding guides can be removed when they are no longer needed. The winding guides can also be installed when they are needed. By making it possible to install and remove the winding guides, the flexibility of winding guide shape design can be greatly improved. Winding guides with complex shapes can also be designed. After winding the wires and temporarily fixing the windings in the slots, these winding guides can be removed, and the windings at the coil ends can be molded in the direction of the stator core using a resin mold or the like to reduce their size, thereby reducing the overall rotor axial length of the stator. By combining and appropriately arranging these winding guides according to the winding requirements, the windings can be wound directly onto the stator core and precisely wound into the slots, such as in aligned windings. Furthermore, 2C is an example of a plate-shaped winding fixing member used to prevent the windings from flying out once they are wound into the slots. Along with improvements to the slot design, various types and shapes of winding fixing members can be used. In a simpler example, temporary fixing can be achieved by impregnating the windings in the slots with varnish or adhesive, and then permanent fixing can be achieved by heat drying.

[0037] Thus, because the circumferential width of the slot opening is large, the degree of freedom of the winding during winding is large, and by controlling the position of the winding nozzle 20, it is possible to directly wind the entire section of the winding to the two slots and the coil end at the rotor axial end of the stator 181, for example, as shown in winding 13 in Figure 2. In particular, in order to improve the space factor of the winding within the slot, the winding is wound with position control so that it is aligned. In the case of direct winding, in order to wind the winding as shown in Figure 2, winding guides are required, which are located on the front and back sides of the paper in Figure 2 and are positioned near the coil end, and this greatly affects the accuracy of the winding position within the slot and the winding speed.

[0038] Figure 3 shows an example of a winding guide, which uses an eccentric shaft to enable the attachment and removal of the winding guide. 31 in Figure 3 is a stator core made of overlapping electromagnetic steel sheets in the left-right direction of the paper, and the left end of the stator core 31 is its coil end. 36 is a winding guide section that guides the winding 32 during winding. 33 and 35 are support rods with a hexagonal hole 33 and an eccentric shaft section 35 of a hexagonal bolt, supporting the winding guide section 36 against the tension applied to the winding 32. The support rods 33 and 35 are inserted into holes in the stator core 31 and are rotatable, but are configured not to tip over due to the tension of the winding 32. 34 is an intermediate member positioned between the winding guide section 36 and the eccentric shaft section 35. Its inner diameter side is a hole that contacts the eccentric shaft 35, and its outer side contacts the winding guide section 36, with the contact portion being planar. The intermediate member 34 should preferably be made of a material with good sliding properties and a low coefficient of friction.

[0039] In the state shown in Figure 3(a), the winding guide section 36 is supported by the support rods 33 and 35 and the intermediate member 34, and is fixed to the stator core 31. In this state, the winding 32 is guided by the winding guide section 36 and can be wound into the slot under tension. Similarly, the windings in the other slots can be wound one after another, and the windings in each slot can be wound. When the windings in the slots are temporarily fixed in place by the winding fixing member 2C at the slot opening, there is no longer a need for the winding guide section 36 to fix the winding 32. At that point, as shown in Figure 3(b), rotating the hexagonal hole section 33 by half a turn causes the eccentric shaft section 35 to rotate, creating a gap between the intermediate member 34 and the winding guide section 36. This allows the support rods 35, the intermediate member 34, and the winding guide section 36 to be removed, and they can be removed from the stator core 31. In this way, the winding guide section 36 is used to apply tension to the winding 32 during winding, and the support rods 33, 35, intermediate member 34, and winding guide section 36 can be removed at any time once the winding guide section 36 is no longer needed after winding. Furthermore, the support rods 33 and 35, intermediate member 34, and winding guide section 36 can be designed in various shapes and are deformable. As will be described later, after removing the support rods 33, 35, intermediate member 34, and winding guide section 36, the coil end portion of the winding 32 can be compactly molded toward the stator core 31 using a winding molding mold or the like, thereby shortening the rotor axial length of the entire stator including the winding.

[0040] Figure 4 shows an example of a winding guide that utilizes a tapered shape to allow for the attachment and removal of the winding guide. It can be used in a similar manner to the winding guide shown in Figure 3. 41 is an example of a winding. 42 is the winding guide section. 43 is a support member with a tapered section 44, which is inserted into a hole in the stator core 31 and, in the state shown in Figure 4(a), is configured to prevent it from falling over due to tension on the winding 32. In this state, the tapered section 44 and the winding guide section 42 are in contact and are supported so as not to move upward in the plane of Figure 4.

[0041] In the state shown in Figure 4(a), the winding 41 is wound along the winding guide 42 under tension. Once the winding in the slot is temporarily fixed in place by the winding fixing member 2C at the slot opening, the winding guide 42 no longer needs to hold the winding 41 in place. At this point, as shown in Figure 4(b), if the support member 43 is pulled out in the direction of the arrow, to the left on the page, a gap is created between the support member 43 and the winding guide 42, releasing the tension on the winding 41, and the support member 43 and winding guide 42 can be easily removed from the stator core 31. The tension on the winding 41 can be released with only a slight movement. The configuration and operation are simple, making miniaturization easy. The winding guide 42 and support member 43 can be designed in various shapes. Furthermore, as will be described later, after removing the support member 43 and the winding guide portion 42, the coil end portion of the winding 41 can be compactly molded toward the stator core 31 using a winding molding mold or the like, thereby shortening the rotor axial length of the entire stator, including the winding.

[0042] Figure 5 shows a method in which a resin winding guide is created and installed, the winding is wound, then heated to soften it, and the resin guide and winding at the coil end are compactly molded using a mold for winding molding at the coil end. Before and after molding the coil end, the winding inside the slot can be impregnated with varnish for insulation, fixing, and heat conduction, and then heated to harden it.

[0043] Figure 5 shows an example of a winding, with 51 being an example of a winding. 52 is a winding guide made of resin that softens upon heating. As shown in Figure 5(a), the winding guide 52 is positioned to facilitate winding the winding 51 into the slot under tension, and the winding 51 is then wound. With the winding in the slot temporarily fixed in place by the winding fixing member 2C at the slot opening, the winding 51 and the winding guide 52 are heated to soften the resin winding guide 52. In this state, the coil end portion of the winding 51 and the winding guide 52 are compactly molded together as the winding 53 and winding guide 54 using a winding molding mold, as shown in Figure 5(b). As a result, the rotor axial length of the entire stator, including the winding, can be shortened. Before or after this molding, the winding in the slot can be impregnated with varnish for insulation, fixing, and heat conduction, and then heated to harden it. In other words, the heating and softening of the resin winding guide section 52 and the heating and hardening of the varnish can be linked, simplifying the heat treatment process.

[0044] Figures 3, 5, and 6 of Reference 1 show examples of fixed winding guides that secure the windings at the coil ends of the motor, but these are fixed and not designed to be removable. Consequently, the overall rotor axial length of the stator is large. Furthermore, the degree of freedom in the shape of the winding guide during design is small, and it has not been possible to realize a winding guide shape that guides the winding position assuming a series winding, etc.

[0045] Here, the purpose of the winding guide of the present invention shown in Figures 3, 4, and 5 is to accurately guide the winding position at the coil end portion in order to increase the space factor of the windings within the slots in a direct winding method as shown in Figure 2, and to enable the coil end portion to be formed in the rotor axis direction after windings have been wound around each slot, thereby reducing the rotor axis length of the entire stator.

[0046] The means and configuration conditions for the winding guide of the present invention shown in Figures 3, 4, and 5 are that the winding guide can be removed after winding, and that the guide configuration is such that the winding can be guided with high precision assuming that the winding guide is removed midway through the winding process. It is preferable that the winding guide can be easily attached and removed.

[0047] The effects of the winding guide of the present invention, as shown in Figures 3, 4, and 5, are that even if the winding guide becomes somewhat larger or more complex, it has little effect on the final size of the stator, thus enabling the design of a more precise winding guide, which in turn improves the space factor of the windings within the slots, and reduces the overall rotor axial length of the stator by shaping the windings at the coil ends.

[0048] Next, the method for controlling the position of the winding nozzle 20 in Figure 2 will be explained. The relative position of the stator 181 and the winding nozzle 20 can be controlled, for example, using the X, Y, Z, and C axes shown in Figure 2. Various combinations are possible. This is similar to the concept of multi-axis control in machine tools or multi-axis robots. The tilt of the winding nozzle 20 does not need to be freely controllable in any direction, but if several specific tilts can be selected, winding can be made easier.

[0049] For example, in the multi-axis control example shown in Figure 2, the stator 181 can be controlled by controlling the X-axis, Y-axis, and the C-axis that rotates the stator 181, similar to a machine tool, while the winding nozzle 20 can be controlled by controlling the Z-axis and selecting a specific angle for the winding nozzle 20. This configuration, in which the position of the stator 181 is controlled by placing a C-axis rotary table on top of an XY table, and the winding nozzle 20 is controlled by moving it in the Z-axis direction, is not particularly complex. In Figure 2, the position control devices CNCW and position control mechanisms MCW for each axis are not shown. These are similar to the position control mechanisms and position control devices of machining centers in machine tools.

[0050] The winding 13 in Figure 2 can be wound so that it is aligned within the slot by using a position control device CNCW and a position control mechanism MCW, and by placing a winding guide WAN, as shown in Figures 3, 4, and 5, near the coil end of the stator 181. However, if the winding is too thin, alignment becomes difficult, and if it is too thick, problems arise regarding strength and space within the limited slot. From the perspective of alignment and productivity, including the number of parallel windings, a winding diameter of 1.3 [mm] or more is preferable.

[0051] In Figure 2, the winding of winding 13 involves winding all sections of the AB phase windings in the slot between the A phase stator pole 188 and the B phase stator pole 16, and in the slot between the A phase stator pole 189 and the B phase stator pole 15. The winding path in Figure 2 shows that the winding nozzle 20 winds winding 2A into the slot between the A phase stator pole 188 and the B phase stator pole 16. After this, it passes near the coil end on the reverse side of the paper in Figure 2, and guided by the nearby winding guides, it winds into the slot between the A phase stator pole 189 and the B phase stator pole 15. Guided by the winding guides 21, 22, 23, etc., near the coil end on the reverse side of the paper in Figure 2, it winds again into the slot between the A phase stator pole 188 and the B phase stator pole 16.

[0052] Near the coil end, the winding position on the winding guide is selected based on the anticipated winding position in the next slot. Within the slot, the winding position is selected so that the windings are aligned and high-density winding is achieved. If the winding tension is not maintained appropriately both when approaching the winding guide and within the slot, the winding will loosen and its position will shift, preventing high-density winding within the slot and reducing the winding's space factor. Regarding the winding's space factor, as shown in Figure 13 which will be explained later, the windings within the slot are compressed to increase density, but if the windings are not aligned, the compression efficiency will decrease.

[0053] Once the windings 13 of phases A and B are completed winding between the slots in this manner, The windings within the slots can be temporarily fixed by the winding fixing member 2C at the slot opening. At this time, the winding guide used to wind the AB phase windings 13 can also be removed. Subsequently, when winding the windings of other phases into other slots, the winding guides for those other phases may get in the way. In such cases, the winding guides for the phases whose windings have been temporarily fixed can be removed. Furthermore, winding guides for the windings of the phases to be wound can also be installed. In this way, all phase windings can be wound.

[0054] Next, we will explain the parallel winding. The thickness of the winding is determined by the motor's continuous rated current, etc. When winding in the system shown in Figure 2, the thickness of the winding is limited to a range of minimum and maximum diameters. Therefore, in the case of large currents, it is necessary to wind the windings in parallel. In a series-wound system like the one shown in Figure 2, winding multiple windings simultaneously is difficult due to interference between windings and winding nozzles. Furthermore, twisting of the multiple windings also occurs.

[0055] The method for achieving parallel winding is to have multiple configurations from the winding nozzle 20 to the rotary table 24, each with Npara of parallel windings, and to wind the wires alternately with Nw of turns each. For example, let's describe the case where the number of parallel windings Npara = 3, the windings are WAA, WBB, and WCC, and the windings are wound alternately with Nw = 5 of turns each. The winding nozzles are 20AA, 20BB, and 20CC. Three sets of configurations from the winding nozzle 20 to the rotary table 24 are arranged in parallel next to the stator core 181. First, winding WAA is wound 5 turns into the corresponding slot, and winding nozzle 20AA is left waiting near the coil end. Next, winding WBB is wound 5 turns into the corresponding slot, and winding nozzle 20BB is left waiting near the coil end. Next, winding WCC is wound 5 turns into the corresponding slot, and winding nozzle 20CC is left waiting near the coil end. This completes the winding process, with each of the three windings WAA, WBB, and WCC being wound 5 times. Parallel winding can be achieved by repeating this process. The number of parallel windings (Npara) and the number of turns (Nw) can be freely selected.

[0056] Next, we will explain measures to prevent twisting of the winding. When winding is performed using the system shown in Figure 2, the winding 2A twists as it is wound. This twisting can either cancel out the winding in the winding drum 25, or it can be added to the twisting. Even if the twisting cancels out the winding, this twisting of the winding can still be a problem. In such cases, the rotary table 24 can be used to rotate and eliminate the twisting of the winding.

[0057] Next, although not directly related to the winding method of the present invention, as mentioned in paragraph

[0010] , we will analyze and compare the technical problems and the cross-sectional area of ​​the copper wire portion of the winding within the slot with that of SC winding (segment conductor winding) and explain the advantages of the present invention. In recent years, the main motors for hybrid electric vehicles (HEVs) and electric vehicles (EVs) have attracted attention, and major automobile manufacturers have developed, commercialized, and mass-produced winding methods for them. The shape, performance, characteristics, and actual photographs of these SC windings have been published in patents, papers, and online information, and are known as a characteristic of these motors.

[0058] Figure 6 is a cross-sectional view of the motor, showing the conventional slot shape 61, the narrowed slot opening shape 62, and the shape of the stator magnetic pole teeth 63 on the left half of the page. 64 is an example illustrating the winding insertion. The shape of the teeth 63 is rectangular with a uniform width, as it is necessary to allow a certain maximum magnetic flux to pass through. On the other hand, the shape of the slot 61 is the remaining part of the teeth 63, and as shown, it is a fan-shaped slot with a wider outer diameter and a narrower inner diameter. The width of Wspm shown is the width of the intersection with the center circle of the air gap when the shape of the slot 61 is extended inward. In this case, the narrowed slot opening shape 62 is ignored.

[0059] On the other hand, the right half of Figure 6 shows the slot shape 65 in the case of the SC winding, the shape with a narrowed slot opening 66, and the shape of the teeth 67 which are the stator magnetic poles. 68 is an example illustrating the insertion of a flat copper wire winding. Note that the motor cross-section in Figure 6 is an example with a small number of slots (12), so you may feel that the shapes of each part and the shape of the flat copper wire are unusual, but please bear with us as this is a theoretical explanation. For main motors of HEVs, EVs, etc., 48-slot and 72-slot designs are known. The shape of the slot 65 is almost rectangular. On the other hand, the shape of the teeth 67 is the remaining part of the slot 65, so as shown in the figure, it is a fan-shaped tooth with a wider outer diameter and a narrower inner diameter. The function of the teeth 67 is to pass the magnetic flux from the rotor side to the back yoke side of the stator, so the outer diameter side of the teeth 67 is unnecessarily wide, resulting in wasted space. The width of Wssc shown is the width of the intersection with the center circle of the air gap when the shape of the slot 65 is extended inward. In this case, the narrowed slot opening shape 66 is ignored. Diameter D3 is the inner diameter of the stator, diameter D2 is the outer diameter of the slot shape, and diameter D1 is the outer diameter of the stator.

[0060] Next, based on the shapes in Figure 6, Figure 7 shows an enlarged view of the shape obtained by superimposing the conventional slot shape 61 and the SC winding slot 65. 74 is an enlarged view of the conventional fan-shaped slot shape 61, and 75 is an enlarged view of the SC winding slot 65, with the directions aligned. The triangular areas of 71 and 72 are areas that are wasted space in the case of the SC winding configuration. The slot width Wscc of the SC winding in Figure 7 is the same value as Wscc in Figure 6. As can be seen visually from Figure 7, the area Ssc of the SC winding slot shape 75 is smaller than the area Sslot of the fan-shaped slot shape 74, making it an unfavorable shape for winding. Note that for the purpose of a preliminary evaluation, the shapes of the slot openings 62 and 66 are ignored.

[0061] Here, we determine the area Sslot of the enlarged diagram 74 of the conventional fan-shaped slot and the area Ssc of the enlarged diagram 75 of the SC winding slot, and then calculate the area ratio PRR. PRR represents the ratio of the winding space that is utilized. PRR = Ssc / Sslot (2) Let Rs be the slot width ratio, which is the ratio of the model circumferential width Wspm and Wssc of the slot to the circumferential period Tslot of the slot. Rs = Wspm / Tslot (3) Pslot is defined as the radial ratio, which is the ratio of the inner diameter D3 of the slot shape to the outer diameter D2 of the slot shape. Pslot=D3 / D2 (4) Let Nslot be the number of slots in the stater.

[0062] The circumferential width Wt of a conventional tooth, shown on the left side of Figure 6, is given by the following equation (5). Wt = (1 - Rs) · π · D3 / Nslot (5) The slot width Wsc for the SC winding is given by the following equation (6). Wsc = Rs·π·D3 / Nslot (6) The slot area Ssc of the SC winding is given by the following equation (7). Ssc=Rs·π·D3 / Nslot·(D2-D3) / 2 =π / 2·Rs·D3·(D2-D3) / Nslot (7) The conventional cross-sectional area St of a tooth is given by the following equation (8). St=π / 2·(1-Rs)·D3·(D2-D3) / Nslot (8) The conventional fan-shaped slot area Sslot is given by the following equation (9). Sslot=(π·((D2 / 2)·(D2 / 2)-(D3 / 2)·(D3 / 2))) / Nslot-St =π / (4·Nslot)·((D2·(D2-D3)-D3·(D2-D3) +2·Rs·D3·(D2-D3)) (9) The area ratio PRR of the SC winding slot area Ssc to the sector-shaped slot area Sslot, given by equation (2), is given by the following equation (10). PRR = Ssc / Sslot =π / (2Nslot)·Rs·D3·(D2-D3) / (π / (4·Nslot)·((D2·(D2-D3) -D3 (D2-D3)+2 Rs D3 (D2-D3))) =2·Rs·D3 / ((D2-(1-2·Rs)·D3) (10)

[0063] The ratio PRR of the slot area Ssc of an SC winding to the original sector-shaped slot area Sslot is parameterized by equation (3), which is the ratio of the circumferential width of the slot to the circumferential period Tslot of the slot, and equation (4), which is the ratio in the diametrical direction of the slot. Once these values ​​are determined, the ratio can be calculated using equation (10). The area ratio PRR in equation (10) can be said to be a coefficient that indicates how much of an area disadvantage the SC winding is compared to the conventional sector-shaped winding. Another point to note in equation (10) is that the area ratio PRR is independent of the number of slots Nslot of the motor. Visually, looking at the slot shape in Figure 6, one might imagine that as the number of slots increases to 48 and 72 slots, the slot shape becomes more elongated, thus reducing the shape disadvantage of the SC winding. However, the area ratio PRR is a coefficient that is not affected by the number of slots Nslot, as shown in equation (10).

[0064] Furthermore, to represent the winding density of the motor, it is expressed by the winding space factor PW in the following formula. PW = (Sum of the cross-sectional areas of the copper in the slot windings) / (Cross-sectional area of ​​the slot) (11) As shown in paragraph

[0012] , conventionally the value of the space factor PW was around 40%. The subject of discussion here is whether the denominator (slot cross-sectional area) in the case of SC windings (11) should be the area Ssc of the slot shape 75 of the SC winding in Figure 7, or the area Sslot of the sector-shaped slot 74. In most cases, there is no specification, so the inventors surmise that the value of the area Ssc of the slot shape 75 is used in the calculation of the space factor.

[0065] As a specific example of shape, if the slot width ratio Rs is 0.5 and the radial ratio Pslot = D3 / D2 = 3 / 4, then the area ratio PRR in equation (10) becomes 0.75. Figure 7 shows that the area Ssc of slot 75 of the SC winding is 75% of the area Sslot of the conventional fan-shaped slot 74. In this case, for example, if the winding space factor PW of the SC winding is said to be 70%, then when converted to the area Sslot of the conventional fan-shaped slot 74, it is estimated that the actual winding space factor PW of the SC winding is 70%·0.75 = 52.5% by multiplying the winding space factor PW of 70% by the area ratio PRR of 0.75. Note that when the slot width ratio Rs is 0.5, the motor's magnetic load and electrical load are such that the cross-sectional area of ​​the winding is larger, and the magnetic flux is slightly lower in this motor design.

[0066] As another example of shape, if the slot width ratio Rs is 0.35 and the radial ratio Pslot = D3 / D2 = 3 / 4, the area ratio PRR in equation (10) becomes 0.6774. Figure 7 shows that the area Ssc of slot 75 of the SC winding is 67.74% of the area Sslot of the conventional fan-shaped slot 74. In this case, for example, the value said to be a winding space factor PW of 70% of the SC winding, when converted to the area Sslot of the conventional fan-shaped slot 74, is estimated to be 47.42% of the actual winding space factor PW of the SC winding, by multiplying the winding space factor PW of 70% by the area ratio PRR of 0.6774. This is a considerably small value. Note that a motor with a slot width ratio Rs of 0.35 is a motor design that slightly increases the magnetic flux to increase torque, and this ratio of the air gap is a value that is often adopted in motor design. This results in a motor design where the magnetic load increases and the magnetic flux becomes larger.

[0067] Furthermore, by making the SC winding a value greater than the radial ratio Pslot = D3 / D2 = 3 / 4, the area ratio PRR in equation (10) can be made larger. However, in that case, the slot area will be reduced, and the continuous rated current will decrease. The appropriate values ​​for these slot width ratio Rs and radial ratio Pslot are not discussed in this invention.

[0068] Next, Figure 8 shows an example of a cross-sectional view of a motor that is the subject of claim 1 and has more stator poles than the fully wound SRM in Figure 1. 80 is the stator. Figure 8 is a fully wound SRM, a 28S16R motor. Compared to the 3-phase SRM in Figure 1, it has two sets of 7-phase 14S8R in the circumferential direction, and the number of configurations including the basic stator poles and rotor poles is 2. The winding pitch is the circumferential width of the 7 slots, which is 180° in electrical angle and 90° in mechanical angle. Figure 8 will be explained in detail in the following paragraphs

[0083] to

[0090] . In addition to 3-phase motors, motors subject to claim 1 include multi-phase fully wound SRMs such as 5-phase, 7-phase, 11-phase, and 13-phase. These will be shown and explained later in Figures 14, 15, and 16. As will be shown later in Figures 8 and 14, the connection relationships and arrangement of the coil ends, as well as phase-to-phase insulation and compression molding, are also important winding technologies for achieving miniaturization and cost reduction of the stator.

[0069] As explained above, the winding method for a fully wound SRM described in claim 1 allows for the winding of aligned windings into each slot of the fully wound SRM using a winding guide that can be attached and removed, as shown in Figures 3, 4, and 5. Parallel winding is required depending on the magnitude of the motor's continuous rated current, and this can be done alternately with multiple winding nozzles; there is no particular limit on the number of parallel windings. The slot shape allows for many windings in the fan-shaped slot cross-section 74 shown in Figure 7. Furthermore, as will be explained later, it is possible to improve winding density by compressing the wound windings as shown in Figure 13. It has also been shown that substantially more windings can be wound compared to the SC winding method, which is the main winding method used by major automobile manufacturers. Additionally, changes to the winding design are easy, and the production of various types of motors and small-lot motor production are relatively easy. The winding equipment is not particularly complex, and the winding equipment can be configured relatively simply. The winding shaping of the coil end will be discussed later.

[0070] Next, claim 2 will be described. This winding method involves manufacturing the windings to be placed in the slots as high-density coils outside the stator 181, and then inserting these coils into the slots. This method allows for high-density winding and offers excellent productivity. Figure 9 is an enlarged view of the portion corresponding to the lower left side of Figure 1. In particular, the AB phase windings 11, 12, and 13 in Figure 1 have been modified as shown in Figure 9. Other windings are not described here. In Figure 9, the same reference numerals as in Figure 1 indicate the same configuration.

[0071] 91 and 92 are inserted into the same slot and form the AB phase winding, corresponding to AB phase winding 11 in Figure 1. 93 and 94 are inserted into the same slot and form the AB phase winding, corresponding to AB phase winding 12 in Figure 1. 95 and 96 show the connection relationship of the back yoke portion of the AB phase winding, corresponding to 13 in Figure 1. In the winding of Figure 9, the AB phase winding is divided into two AB winding coils 1 and 2. AB phase winding coil 1 consists of 91, 93, and 95. AB phase winding coil 2 consists of 92, 94, and 96.

[0072] The AB-phase winding coil 1 and AB-phase winding coil 2 are manufactured as coils by high-density winding outside the stator 181. Because there are few morphological and physical constraints during manufacturing, they can be wound with high precision and efficiency onto dedicated winding molds. The portion to be inserted into the slot is solidified or partially solidified, while the connection portion of the coil end is manufactured to be flexible enough to allow insertion and assembly into the stator 181.

[0073] The shapes of coil sections 91, 92, 93, and 94 must be such that they can be inserted and assembled because the slot openings are narrow. For example, in the case of the shape shown in Figure 9, coils 91 and 93 are inserted first, and then coils 92 and 94 are inserted. The coil shape is determined by considering the assembly order in this way. They cannot be assembled in the reverse order. Also, the number of coil divisions to be inserted into each slot is not limited to two as in Figure 9, but can be divided into three. The coil shape is determined by considering the assembled state of the coils, ease of assembly, and productivity. The other windings shown in Figure 1 can also be assembled to the stator 181 sequentially in the same manner. Note that the windings at the coil ends are flexible and therefore have an irregular shape, but they can be compressed later in the rotor axis direction using a coil end molding die.

[0074] The winding configuration shown in Figure 9 has several advantages: it allows for a large space factor of windings within the slots, reduces coil manufacturing costs because the coils can be produced outside the stator 181, and makes assembly to the stator 181 easy.

[0075] Next, claim 3 will be described. This is a winding method when the slot opening of the stator is narrow. With respect to the circumferential slot period Tslot on the air gap between the stator and the rotor, the magnetic opening width Wop of the slot SL facing the air gap is 30% or less of the slot period Tslot. As shown in the example in Figure 10, from the viewpoint of generating good torque with little torque ripple of the motor, it is preferable for the magnetic opening width Wop to be small and narrow. Conversely, from the viewpoint of winding when inserting the winding into the slot, a wider slot opening width Wop is more productive and allows for more aligned insertion of the winding, thus improving motor performance in terms of winding space factor improvement. There is a trade-off relationship with the slot opening width Wop. The type of motor targeted by claim 3 is not specified, but can be a synchronous reluctance motor SynRM or a permanent magnet type synchronous motor. Figure 10 is a diagram showing an example of a method for winding a winding onto the stator 101. Components in Figure 10 that have the same reference numerals as in Figure 2 are the same components.

[0076] In Figure 10, the winding nozzle 20 is winding the windings into slots 103 and 104 in a direct winding manner, as with winding 102. 105 and 106 are winding guides, and 107 and 108 are other types of winding guides. In Figure 10, the stator 101 has a small and narrow slot opening (Wop), and the slot opening is long in the rotor axis direction, making it difficult for the winding nozzle 20 to guide the windings through the slot openings. To address this, Figure 10, compared to Figure 2, is equipped with a transient winding guide KAWAN 109 that can grip and separate the windings.

[0077] The transient winding guide 109 supports a portion of the winding 10A at the tip of the winding nozzle 20, assisting the portion of the winding 10A to pass through the slot opening. Figure 10 shows the state where a portion of the winding 10A at the tip of the winding nozzle 20 is held precisely by the transient winding guide 109. In this state, as shown in Figure 11, when the winding nozzle 20 is moved in the Z-axis direction, the winding 10B can be made parallel to the opening of the slot 103. Furthermore, when the stator 101 is moved in the Y-axis direction from this state, the winding 10B will pass through the opening of the slot 103.

[0078] Figure 12 shows and explains the configuration and operation of the transient winding guide 109. Figure 12(a) shows the transient winding guide 109 gripping the winding 121, moving as indicated by the arrow to grip the winding 121 as shown in Figure 12(b). The transient winding guide 109 is configured not to restrict movement in the winding direction. As shown in Figure 11, when the winding nozzle 20 moves, the position of the transient winding guide 109 is fixed as shown in Figure 12(c), acting to bring the winding 122 to the intended position. Then, after the winding 10B passes through the opening of the slot 103, the transient winding guide 109 opens in the direction of the arrow as shown in Figure 12(d), separating and releasing the winding 122, allowing the winding nozzle 20 to continue winding the winding. Furthermore, the transient winding guide 109 remains stationary around the winding nozzle 20, except when the winding nozzle 20 is passing through the opening of the slot 103, so as not to interfere with the operation of the winding nozzle 20.

[0079] Claim 3, as shown in Figures 10, 11, and 12, allows the motor winding to be wound in a direct winding manner by utilizing the transient winding guide KAWAN, which passes through the opening in a long and narrow manner in the Z-axis direction. Here, the transient winding guide KAWAN is capable of gripping and separating the winding, and is configured and operates in a way that does not interfere with the operation of the winding nozzle 20 when not in use.

[0080] Next, claim 4 will be described. Claim 4 is a method for compressing a winding in a slot to a high density using a compression means PRS while winding the winding in the slot. Figures 13(a) and 13(b) show examples of compressing the winding of an SRM with full winding, such as in Figure 1. In Figure 13(a), when the winding has been wound about halfway around the slot, the winding 135 is compressed by the compression means PRS 132. In Figure 13(b), when the winding has been wound about 80% around the slot, the winding 136 is compressed by the compression means PRS 132. The winding can be compressed in multiple stages as needed.

[0081] Figures 13(c) and 13(d) show examples of compressing windings in synchronous reluctance motors such as the SynRM shown in Figure 1, and permanent magnet type synchronous motors. In Figure 13(c), winding 136 is compressed by the compression means PRS 134 when the winding has been wound approximately halfway around the slot. In Figure 13(d), winding 137 is compressed by the compression means PRS 134 when the winding has been wound approximately 80% around the slot. The windings can be compressed in multiple stages as needed. Note that in the examples of Figures 13(c) and 13(d), the slot opening is narrow, making it difficult to insert the compression means 134 from the end in the rotor axis direction. However, compression can be performed without problems by modifying the shape of the insertion part.

[0082] As a result of claim 4, the winding density within the slot can be improved, enabling higher torque and miniaturization of the motor. In conventional motor winding inserter methods and high-density fabrication of rectangular coils, mechanical power can be used to compress the copper wire winding to a degree that deforms it, and this is known as high-density winding. The present invention also enables similar compression. Furthermore, when the deformation of the copper wire increases, the thickness of the insulating coating on the copper wire also tends to increase. While this improves the winding space factor, the increase in the thickness of the insulating coating on the copper wire negatively impacts the improvement of the space factor of the cross-sectional area of ​​the copper wire. The insulating material and the thickness of the insulating coating on the winding are determined by the usage conditions of the winding, including SC windings, and their spatial ratios are not insignificant. Including claim 4, the winding method of the present invention is also a method that can reduce the ratio of insulating material.

[0083] Next, claim 5 will be described. An embodiment thereof is shown in Figure 8. Claim 5 is a technology relating to the connection relationship of the windings at the coil end, the uniformity of the windings at the coil end, the reduction of interphase insulating material such as insulating paper, and the reduction of the rotor axial dimension. Figure 8, which is also an embodiment of claim 5, was briefly explained in paragraph

[0068] as an example of a motor that is the subject of claim 1. 80 is the stator. Figure 8 is a fully wound SRM, a 28S16R motor. Compared to the simple configuration of the 3-phase SRM in Figure 1, the PNSRM is a little more complex, with two sets of 7-phase 14S8R in the circumferential direction, and the number of configurations including the basic stator poles and rotor poles is 2. The winding pitch is the circumferential width of the 7 slots, which is 180° in electrical angle and 90° in mechanical angle. 81 is the A-phase stator pole, 82 is the B-phase stator pole, 83 is the C-phase stator pole, 84 is the D-phase stator pole, 85 is the E-phase stator pole, 86 is the F-phase stator pole, and 87 is the G-phase stator pole. For reference, the name of each stator pole is attached. The dashed circles at the coil ends are a visual aid to indicate the grouping of each winding and do not indicate the winding position at the coil end. 8H is the dashed circle indicating the first group of windings, 8J is the dashed circle indicating the second group of windings, 8K is the dashed circle indicating the third group of windings, 8L is the dashed circle indicating the fourth group of windings, and 8M is the dashed circle indicating the fifth group of windings.

[0084] 88 energizes the AD phase excitation winding with a current Iad, exciting the A phase stator pole 81, or the D phase stator pole 84, or both stator poles simultaneously. The current Iad is Iad = Ia + Id, and is the sum of the excitation current Ia for the A phase stator pole 81 and the excitation current Id for the D phase stator pole 84 when the SRM in Figure 8 has a concentrated winding configuration. 89 energizes the BE phase excitation winding with a current Ibe, exciting the B phase stator pole 82, or the E phase stator pole 8N, or both stator poles simultaneously. The current Ibe is Ibe = Ib + Ie, and is the sum of the excitation current Ib for the B phase stator pole 82 and the excitation current Ie for the E phase stator pole 8N when the SRM in Figure 8 has a concentrated winding configuration. 8A energizes the CF phase excitation winding with a current Icf, exciting the C phase stator pole 83, or the F phase stator pole 86, or both stator poles simultaneously. The current Icf is Icf = Ic + If, and is the sum of the excitation current Ic for the C phase stator pole 83 and the excitation current If for the F phase stator pole when the SRM in Figure 8 has a concentrated winding configuration. 8B energizes the DG phase excitation winding with a current Idg, exciting the D phase stator pole 84, or the G phase stator pole 87, or both stator poles simultaneously. The current Idg is Idg = Id + Ig, and is the sum of the excitation current Id for the D phase stator pole 84 and the excitation current Ig for the G phase stator pole 87 when the SRM in Figure 8 has a concentrated winding configuration. 8C is the excitation winding for the EA phase, energizing current Iea to energize the E phase stator pole 85, or the A phase stator pole 81, or both stator poles simultaneously. The current Iea is Iea = Ie + Ia, and is the sum of the excitation current Ie for the E phase stator pole 85 and the excitation current Ia for the A phase stator pole 81 when the SRM in Figure 8 has a concentrated winding configuration. 8D is the excitation winding for the FB phase, energizing current Ifb, and energizing the F phase stator pole 86, or the B phase stator pole 8P, or both stator poles simultaneously. The current Ifb is Ifb = If + Ib, and is the sum of the excitation current If for the F phase stator pole 86 and the excitation current Ib for the B phase stator pole 8P when the SRM in Figure 8 has a concentrated winding configuration.8E is the excitation winding for the GC phase, which carries a current Igc to excite the G phase stator pole 87, or the C phase stator pole 8Q, or both stator poles simultaneously. The current Igc is Igc = Ig + Ic, and in the case of the SRM in Figure 8 having a concentrated winding configuration, it is the sum of the excitation current Ig for the G phase stator pole 87 and the excitation current Ic for the C phase stator pole 8Q. Note that the symbols in Figure 8 are only assigned to about half of the configurations, and therefore, the same-phase configuration in Figure 8 is not described, and for example, the A / phase stator pole, which is the opposite phase of the A phase stator pole 81, is not explained for simplification because it has a symmetrical structure. The SRM with all sections wound in Figure 8 has a 28S16R configuration, where 8F is the rotor, and 8G is the salient pole of the rotor, and the circumferential width of the salient pole is the same as the salient pole width of the stator.

[0085] Next, we will explain the grouping of the phase windings of the motor in Figure 8 and the winding arrangement at the coil end. In Figure 8, the first group 8H consists of three windings: the AD phase excitation winding 88, the FB phase winding 8D, and the CF phase winding 8R. In Figure 8, the connection relationships of each slot are shown on the innermost dashed circle 8H, but this does not mean that they are placed on the inner diameter side near the coil end, but rather that it indicates the winding order. The relative relationship between the AD phase excitation winding 88, the FB phase winding 8D, and the CF phase winding 8R, which are the windings of the first group 8H, is that the three windings are separated with gaps in the circumferential direction. The advantages of this arrangement are that there is already space between the three windings in the circumferential direction, so there is less interference between windings and winding in series is easy, inter-phase insulation between the three windings is not required, thus simplifying the overall insulation, and the three windings of each winding group are distributed in the circumferential direction, which ultimately reduces the thickness in the rotor axis direction.

[0086] Next, the windings for the second group 8J are wound, with one layer of insulating material, such as interphase insulating paper, placed circumferentially between the three windings of the first group 8H and the three windings of the second group 8J. The windings for the second group 8J are the EA phase winding 8C, the BE phase winding 8T, and the DG phase winding 8S, which are separated from each other in the circumferential direction. This is the same relationship as the three windings of the first group 8H.

[0087] Next, the windings for the third group 8K are wound. An insulating material, such as interphase insulating paper, is placed in a circumferential layer between the three windings of the second group 8J and the three windings of the third group 8K. The windings of the third group 8K are the BE phase winding 89, the CF phase winding 8A, and the GC phase winding 8U, which are separated from each other in the circumferential direction. This is the same relationship as the three windings of the first group 8H.

[0088] Next, the windings for the fourth group 8L are wound. An insulating material, such as interphase insulating paper, is placed in a circumferential layer between the three windings of the third group 8K and the three windings of the fourth group 8L. The windings of the fourth group 8L are the DG phase winding 8B, the AD phase winding 8V, and the FB phase winding 8W, which are separated from each other in the circumferential direction. This is the same relationship as the three windings of the first group 8H.

[0089] Next, the remaining two windings of the fifth group 8M are wound. An insulating material, such as interphase insulating paper, is placed in a circumferential layer between the three windings of the fourth group 8L and the two windings of the fifth group 8M. The windings of the fifth group 8M consist of the GC phase winding 8X and the EA phase winding 8Y, which are separated from each other in the circumferential direction. This is the same relationship as the three windings of the first group 8H.

[0090] In the seven-phase 28S16R fully wound SRM shown in Figure 8, despite having seven phases, only four sheets of inter-phase insulating paper are needed. The advantages of dividing the windings into groups from the first group 8H to the fifth group 8M and winding the windings for each phase are that there is already space between the three windings, resulting in less interference between windings and easier direct winding; inter-phase insulation between the three windings is not required, thus simplifying the overall insulation; and the three windings in each winding group are distributed circumferentially, resulting in a smaller thickness in the rotor axis direction. As will be shown later, in Figures 14, 15, and 16, the connection relationship of the coil ends allows for uniformity of windings and simplification of insulating materials such as inter-phase insulating paper. The connection relationship and arrangement of the coil ends, inter-phase insulation, and compression molding are also important winding technologies for achieving miniaturization and cost reduction of the stator. Next, Figures 14, 15, and 16 will be used to explain the similarities in different motors.

[0091] Figure 14 shows an example of a 7-phase 56S32R fully wound SRM motor configuration, which is twice the circumferential configuration of the 7-phase 28S16R motor configuration in Figure 8. Due to the large number of stator poles and slots, it is difficult to represent them all in the diagram, so the diagram has been simplified to focus on the winding connections between slots. In Figure 14, the letters A, B, C, etc. indicate the approximate circumferential positions of the stator poles of each phase, and the circles indicate the slots between the stator poles.

[0092] The symbols in Figure 14 are the same as those in Figure 8; they are not identical, but they have a similar meaning. In Figure 14, as in Figure 8, 8H is a dashed circle indicating the first group of windings. 8J is a dashed circle indicating the second group of windings, 8K is a dashed circle indicating the third group of windings, 8L is a dashed circle indicating the fourth group of windings, and 8M is a dashed circle indicating the fifth group of windings. 88 is the AD phase excitation winding which carries current Iad. 89 is the BE phase excitation winding which carries current Ibe. 8A is the CF phase excitation winding which carries current Icf. 8B is the DG phase excitation winding which carries current Idg. 8C is the EA phase excitation winding which carries current Iea. 8D is the FB phase excitation winding which carries current Ifb. 8E is the GC phase excitation winding which carries current Igc. However, since there are four slots of the same phase on the circumference, the connection destination of the coil end can be changed to another slot of the same phase for various reasons.

[0093] In Figure 14, the first group 8H winding has seven windings, shown by solid lines, arranged on the circumference shown by dashed lines. These seven windings are separated in the circumferential direction. This is achieved by selecting the optimal number of slots, 56 slots for seven phases. Similarly, the second group 8J winding, the third group 8K winding, and the fourth group 8L winding each have seven windings. The fifth group 8M winding is omitted. As a result, in the example of the 7-phase 56S32R full-winding SRM in Figure 14, only three layers of insulating material, such as inter-phase insulating paper, are required between each winding group. Since only three layers of inter-phase insulating paper are required for a 7-phase motor, it is superior in terms of cost and productivity. As mentioned above, there are several advantages to this design: there is already space between the seven windings in the circumferential direction, resulting in less interference between windings and easier winding in series; phase-to-phase insulation is not required between the seven windings in the circumferential direction, thus simplifying the overall insulation; and the seven windings in each winding group are distributed circumferentially, ultimately reducing the thickness in the rotor axial direction.

[0094] As shown in Figure 14, there is no need in claim 5 to arrange the maximum number of windings precisely while separating them in the circumferential direction, but there is an optimal relationship between the number of phases Nph and the number of slots Nslot. This optimal relationship can be written by the following equation. Nslot = Nph·(Nph+1)·NN (12) Here, NN is an integer greater than or equal to 1. When the number of phases Nph is 7, the optimal value is an integer multiple of 56 slots; when the number of phases Nph is 5, it is an integer multiple of 30 slots; and when the number of phases Nph is 3, it is an integer multiple of 12 slots. In the case of two distributed windings, the number of phases Nph can be doubled and calculated using equation (12).

[0095] Next, another application example of claim 5 is shown in Figure 15. This is an example of a fully wound SRM of a 5-phase 30S18R. Similar to Figures 8 and 14, 151 is a dashed circle indicating the first group of windings, 152 is a dashed circle indicating the second group of windings, and 153 is a dashed circle indicating the third group of windings. Each dashed circle indicates a group of windings, not the position of the windings at the coil end.

[0096] 154 is the A-phase stator pole, 155 is the B-phase stator pole, 156 is the C-phase stator pole, 157 is the D-phase stator pole, and 154 is the E-phase stator pole. For reference, the phase names A, A / , B, B / , etc., are appended to each stator pole.

[0097] Winding 159 is the AC phase excitation winding, which carries a current Iac, exciting the A phase stator pole 154, or the C / phase stator pole 15E, or both stator poles simultaneously. The current Iac is Iac = Ia + Ic, and in the case where SRM in Figure 15 is a concentrated winding configuration, it is the sum of the excitation current Ia for the A phase stator pole 154 and the excitation current Ic for the C / phase stator pole 15E. Also, the current Iac of the AC phase excitation winding 159 also excites the A / phase stator pole 15F and the C phase stator pole 156. Similarly, 15A is the BD phase excitation winding, which carries a current Ibd. 15B is the CF phase excitation winding, which carries a current Icf. 15C is the DA phase excitation winding, which carries a current Ida. 15D is the excitation winding for the EB phase, which conducts the current Ieb.

[0098] As shown in Figure 15, five windings can be arranged on the same circumference, separated in the circumferential direction. The 15 windings can then be divided into three winding groups 151, 152, and 153 for winding. As a result, although it is a five-phase motor, only two sheets of insulating paper are required for inter-phase insulation. Similar to the motor in Figure 14, series winding is easy, and the thickness in the rotor axial direction can be reduced.

[0099] Next, another application example of claim 5 is shown in Figure 16. This is an example of a fully wound SRM of a three-phase 12S8R. Similar to Figure 15, 161 is a dashed circle indicating the first group of windings, and 162 is a dashed circle indicating the second group of windings. Each dashed circle indicates a group of windings, not the position of the windings at the coil end.

[0100] 163 is the stator pole for phase A, 164 is the stator pole for phase B, and 165 is the stator pole for phase C. For reference, the phase names A, A / , B, B / , etc., for each stator pole are noted next to them.

[0101] Winding 166 is the excitation winding for phases AB, energizing current Iab to energize phase A stator pole 163, or phase B stator pole 169, or both stator poles simultaneously. Current Iab is Iab = Ia + Ib, and is the sum of the excitation current Ia for phase A stator pole 163 and the excitation current Ib for phase B stator pole 169 when the SRM in Figure 16 is a concentrated winding configuration. Also, the current Iab of the excitation winding 166 for phases AB energizes phase A stator pole 16A and phase B stator pole 164. Similarly, winding 167 is the excitation winding for phases BC, energizing current Ibc. Winding 15B is the excitation winding for phases CF, energizing current Icf. Winding 168 is the excitation winding for phases CA, energizing current Ica.

[0102] As shown in Figure 16, three windings can be arranged on the same circumference, separated in the circumferential direction. The six windings can then be divided into two winding groups 161 and 162 for winding. As a result, although it is a three-phase motor, only one sheet of insulating paper is required for inter-phase insulation. Similar to the motor in Figure 14, series winding is easy, and the thickness in the rotor axial direction can be reduced.

[0103] Next, claim 6 will be described. This invention relates to forming the coil ends of windings wound around a stator using various winding guide WANs, wherein the winding guide WANs are removed, and the coil ends are formed using a molding die for coil ends so that the rotor axial length of the coil end portion is reduced.

[0104] Figure 17 is a schematic cross-sectional view showing the coil end forming process, and only the cross-section is shown. 175 is the stator core, 172 is the winding in the slot, 173 and 174 are the coil ends before forming, and 175 and 176 are the molds for forming the coil ends. Figure 17(a) shows the state before forming the coil ends, with various winding guides removed from the stator. Figure 17(b) shows the state after forming the coil ends. By moving the coil end molds 175 and 176 in the direction of the arrows, the coil ends 173 and 174 can be compressed, and the coil ends can be compressed in the rotor axis direction as shown in 177 and 178.

[0105] If the shapes of the coil ends before molding (173, 174) differ significantly from those after molding (177, 178), pre-treatment may be performed before molding with the mold, or the molding may be carried out in multiple stages using multiple molds. Furthermore, compression molding of both sides of the coil end may be performed one direction at a time, rather than simultaneously. The molding molds are preferably made of a soft resin or similar material to avoid damaging the insulating coating of the copper wire.

[0106] The present invention has been described above, but various modifications are possible. While the description mainly focuses on insulated round copper wire, insulated aluminum wire may also be used. Regarding motor types, it can be applied to various similar motors. [Industrial applicability]

[0107] This invention significantly improves the slot occupancy ratio by efficiently direct-winding the windings of fully wound switch reluctance motors (SRMs) and other motors in alignment using removable winding guides. Furthermore, by grouping the winding connections at the coil ends and arranging them circumferentially, winding is facilitated, reducing the amount of insulating paper and decreasing the axial length of the coil ends. Design changes, production of various motor types, and small-lot motor production are also relatively easy. As a result, this leads to higher efficiency, miniaturization, weight reduction, and lower costs for motors. Therefore, it can be used in main motors for electric vehicles, industrial motors, and home appliance motors. [Explanation of Symbols]

[0108] 11, 12 Windings in the slots of the AB phase windings 13 Connection of the coil end of the AB phase winding 15 B-phase stator poles 16 B-phase reversed B / phase stator poles 20 Winding Nozzles 21, 22, 23 Winding Guide WAN 25 Winding Drum 26 windings 27. Winding extraction device 28 Pulley 29. Winding supply device 2A winding 2B The beginning of the winding 181 stata 182 A-phase stator magnetic poles 188 A-phase stator magnetic poles 189 A-phase reversed A / phase stator poles

Claims

1. The teeth ST of the stator and the slots SL around which the stator winding SW is wound are arranged alternately in the circumferential direction of the stator. With respect to the circumferential slot period Tslot on the air gap between the stator and the rotor, the magnetic opening width Wop of the slot SL facing the air gap is 30% or more of the slot period Tslot. A detachable winding guide WAN is attached to the rotor axial end face of the stator core SC that constitutes the magnetic circuit as needed when winding the stator winding SW, and the winding guide WAN is removed if it interferes with the winding of other windings or winding shaping. The stator winding SW is supplied to the winding nozzle WN which directly winds the stator core SC and the slot SL, The stator core SC and the winding nozzle WN are driven relatively in the C-axis direction, which is the circumferential direction of the stator core SC; the Z-axis direction, which is the rotor axis direction of the stator core SC; the X-axis direction, which is perpendicular to the Z-axis direction; and the Y-axis direction, which is perpendicular to both the Z-axis and X-axis directions, by a multi-axis drive device MDD. The windings supplied from the winding drum and the like are wound onto the rotor axial end face and slots SL of the stator core SC using the winding nozzle WN and the winding guide WAN which can be attached and detached as needed, with the position of the C, X, Y, and Z axes controlled by the multi-axis drive device MDD. A motor characterized by the same winding method.

2. The teeth ST of the stator and the slots SL around which the stator winding SW is wound are arranged alternately in the circumferential direction of the stator. With respect to the circumferential slot period Tslot on the air gap between the stator and the rotor, the magnetic opening width Wop of the slot SL facing the air gap is 30% or more of the slot period Tslot. A coil is manufactured in which the stator winding SW is wound outside the stator core SC that constitutes the magnetic circuit and inserted into the slot SL, the portion to be inserted into the slot SL is made rigid, and the portion of the winding bundle corresponding to the coil end is made flexible and bendable. The aforementioned coil has two or more shapes, and when the coil is inserted into the slot SL in a predetermined order, it is shaped in such a way that the coil and the shape of the slot SL do not interfere with each other. Two or more types of the aforementioned coils are sequentially inserted into the slot SL. A motor characterized by the same winding method.

3. The teeth ST of the stator and the slots SL around which the stator winding SW is wound are arranged alternately in the circumferential direction of the stator. With respect to the circumferential slot period Tslot on the air gap between the stator and rotor, the magnetic opening width Wop of the slot SL facing the air gap is 30% or less of the slot period Tslot. A winding guide WAN, which can be attached to the rotor axial end face of the stator core SC constituting the magnetic circuit, is installed as needed when winding the stator winding SW, and if the winding guide WAN obstructs the winding of the stator winding SW, it is removed. The stator winding SW is supplied to the winding nozzle WN which directly winds the stator core SC and the slot SL, The stator core SC and the winding nozzle WN are driven relatively in the C-axis direction, which is the circumferential direction of the stator core SC; the Z-axis direction, which is the rotor axis direction of the stator core SC; the X-axis direction, which is perpendicular to the Z-axis direction; and the Y-axis direction, which is perpendicular to both the Z-axis and X-axis directions, by a multi-axis drive device MDD. Near the rotor axial end face of the stator core SC, a transient winding guide KAWAN capable of gripping and separating the windings is provided. When the winding passes through the opening KAS of the slot SL, the transient winding guide KAWAN grips a portion of the winding, and the other winding nozzle WN identifies the position of the winding and controls its position so that it can pass through the opening KAS. After winding the winding into the slot SL, the grip of the winding by the transient winding guide KAWAN is released and separated. The windings supplied from the winding drum and the like are wound onto the rotor axial end face and slots SL of the stator core SC by the winding nozzle WN, utilizing the winding guide WAN provided as needed, with the position of the C, X, Y, and Z axes controlled by the multi-axis drive device MDD. A motor characterized by the same winding method.

4. In either claim 1 or claim 3, A compression means PRS for compressing the winding wound in the slot SL in the radial direction is inserted into the slot SL. The compression means PRS increases the density of the windings in the slot SL. A motor characterized by the same winding method.

5. In any of claim 1, claim 2, and claim 3, The winding to be inserted into the aforementioned slot SL is divided into multiple groups, The multiple stator windings SW of the first group are wound around the coil end portion in the rotor axis direction of the stator core SC at positions that are separated from each other in the circumferential direction. An electrical first insulating material DZ is placed between the multiple stator windings SW of the first group and the windings SW of the second group that are wound next to them. Each of the second group of windings SW is wound on the first insulating material DZ, at positions that are separated from each other in the circumferential direction. If there is a third group of windings, similarly, the second insulating material DZ is placed and each winding SW of the third group is wound around it. If there is a fourth group of windings, similarly, the third insulating material DZ is placed and each winding SW of the fourth group is wound around it. A motor characterized by the same winding method.

6. In any of claim 1, claim 2, and claim 3, After removing part or all of the winding guide WAN, the coil end portion of the winding is compressed and shaped using a molding die for the coil end portion. A motor characterized by the same winding method.

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