stata

Abstract

To provide a stator that can suppress the increase in size of assembly equipment and cases, while also improving ease of assembly to the case. [Solution] The stator of this disclosure is disposed within a case and includes a stator core, a stator coil wound around the stator core, a sensor holding member integrated with a conductor included in the stator coil and holding a temperature sensor, and a connector support portion formed on the sensor holding member to detachably support a connector connected to the temperature sensor via a cable.

Description

Technical Field

[0001] The present disclosure relates to a stator of a rotating electric machine disposed within a case.

Background Art

[0002] Conventionally, a stator unit including a stator and a thermistor for detecting the temperature of the stator has been known (see, for example, Patent Document 1). The thermistor has a fixing portion fixed to the stator, and a holder is attached to the fixing portion. Further, the wiring of the thermistor includes a first portion exposed to the outside and a second portion covered with a tube. Furthermore, the holder includes a hooking portion for hooking the first portion of the wiring of the thermistor and a holding portion for holding the tube in a state of being bent a plurality of times. In such a stator unit, the hooking portion restricts the position where the first portion is present, and the holding portion positions the tube of the second portion. Thereby, it is possible to facilitate the positioning of the wiring of the thermistor and prevent the exposed portion of the wiring from contacting the stator core.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, with the conventional stator unit described above, when assembling it into the case, the connectors and tubes connected to the thermistor wiring fixed to the stator may move and interfere with the case, etc. Therefore, it becomes necessary to ensure a large range of motion for the connectors, etc., or to suppress interference between the moving connectors, etc. and the case, etc., which makes it difficult to keep the assembly equipment and case size down. In addition, if the connector moves, it becomes difficult for a robot to grasp the connector and connect it to the receptacle provided on the case, forcing the connector to be connected to the receptacle manually.

[0005] Therefore, the primary objective of this disclosure is to provide a stator that can suppress the enlargement of assembly equipment and cases, while also improving ease of assembly to the case. [Means for solving the problem]

[0006] The stator of this disclosure is disposed within a case and includes a stator core, a stator coil wound around the stator core, a sensor holding member, and a connector support portion. The sensor holding member is integrated with a conductor included in the stator coil and holds a temperature sensor. The connector support portion is formed on the sensor holding member to detachably support a connector connected to the temperature sensor via a cable. As a result, when assembling the stator into the case, supporting the temperature sensor connector with the connector support portion restricts the movement of the connector and narrows the range of movement of the connector and cable. Consequently, the need to ensure a large range of movement for the connector and other components, or to suppress interference between the moving connector and the case, is reduced, making it possible to suppress the enlargement of the stator assembly equipment and case. Furthermore, in the stator of this disclosure, the connector detachably supported by the connector support portion can be easily grasped by a robot and coupled to the corresponding receptacle. As a result, the need to manually couple the connector to the receptacle is eliminated, further improving the ease of assembling the stator into the case.

[0007] Furthermore, the connector may be coupled to a receptacle installed in the case, and the connector support portion may be formed to hold a cable extending between the temperature sensor and the connector coupled to the receptacle. In addition, the sensor holding member may include a cable support portion that slidably supports the cable connected to the temperature sensor and the connector. The connector support portion may also include an insertion portion that is detachably inserted into a recess formed in the connector, or a mating portion into which the connector is detachably fitted. Furthermore, the conductor may be a power line or neutral line connected to the stator coil. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic diagram showing the status of this disclosure. [Figure 2] This is a perspective view showing the essential parts of the stater of this disclosure. [Figure 3] This is a perspective view showing a sensor holding member included in the stator of this disclosure. [Figure 4] This is a partial cross-sectional view showing a sensor holding member included in the stator of this disclosure. [Figure 5] This is a perspective view showing a sensor holding member included in the stator of this disclosure. [Figure 6] This is a partial cross-sectional view showing another embodiment of a sensor holding member included in the stator of this disclosure. [Modes for carrying out the invention]

[0009] Next, with reference to the drawings, embodiments for carrying out the invention of this disclosure will be described.

[0010] Figure 1 is a schematic diagram showing the stator 1 of this disclosure. The stator 1 shown in the figure, together with a rotor (not shown), constitutes a three-phase AC motor used as a driving source or generator for electric vehicles (BEVs), fuel cell vehicles (FCVs), or hybrid vehicles (PHEVs, HEVs), for example. As shown in the figure, the stator 1 includes a stator core 2 and three-phase (U-phase, V-phase, and W-phase) stator coils 3u, 3v, and 3w wound around the stator core 2.

[0011] The stator core 2 is formed by laminating multiple electromagnetic steel sheets and connecting them in the lamination direction by crimping. However, the stator core 2 may also be formed in an annular shape by, for example, pressure molding and sintering ferromagnetic powder. The stator core 2 includes a central hole in which the rotor is arranged, multiple teeth extending radially from the annular outer circumference (yoke portion) toward the axis and adjacent to each other at regular intervals in the circumferential direction, and multiple slots (for example, 48 in this embodiment) formed between adjacent teeth. Each of the multiple slots extends radially from the stator core 2 and is arranged circumferentially at regular intervals, opening at the central hole.

[0012] The stator coils 3u, 3v, and 3w are each formed by electrically joining multiple segment coils (coil wires) 30, and are connected to each other, for example, by a star connection (Y connection). However, the stator coils 3u, 3v, and 3w may also be so-called open windings. The segment coils 30 are electrical conductors formed by bending a flat rectangular wire, for example, one coated with an insulating film made of enamel resin, into a roughly U-shape, and have a pair (two) of legs. The two legs of each segment coil 30 are inserted from one end face (top face in Figure 1) of the stator core 2 into different slots of the stator core 2, and the legs of each segment coil 30 protruding from the other end face (bottom face in Figure 1) of the stator core 2 are bent.

[0013] Furthermore, straight, rod-shaped segment coils (I-segments) 31, formed from flat wire with an insulating coating made of, for example, enamel resin, are inserted from one end face into a predetermined number of slots (for example, six in this embodiment) of the stator core 2, and the segment coils 31 protruding from the other end face of the stator core 2 are also bent. After the bending is complete, the tips of each segment coil 30, 31 are electrically joined by welding to the tips of other corresponding segment coils 30 adjacent to each other in the radial direction of the stator core 2. As a result, multiple stator coils 3u, 3v, 3w are wound around the stator core 2. In addition, the annular coil end portions 3a of the stator coils 3u, 3v, 3w protrude from one end face of the stator core 2, and the annular coil end portions 3b of the stator coils 3u, 3v, 3w protrude from the other end face of the stator core 2.

[0014] Furthermore, of the multiple (for example, six in this embodiment) segment coils 31 inserted into the slots of the stator core 2, the tips of three segment coils 31 are electrically joined by welding to the base ends of the corresponding U-phase power line 4u, V-phase power line 4v, or W-phase power line (not shown). In addition, the tips of the remaining three segment coils 31 are electrically joined by welding to the base end of the neutral wire 4n (see Figure 2). The power lines 4u, 4v and the neutral wire 4n are all electrical conductors such as busbars. The tips 40u, 40v, and 40n of the power lines 4u, etc., function as terminals and are electrically connected to a terminal block 11 installed (fixed) on the case 10 when the stator 1 is assembled to the case 10 of the rotating electric machine. The power lines 4u, 4v, etc. are then electrically connected to an inverter (not shown) via power lines (not shown) connected to the terminal block 11, and each neutral wire 4n is electrically connected to a neutral point (not shown).

[0015] Furthermore, in this embodiment, as shown in Figures 1 and 2, the sensor holding member 5 is integrated (fixed) to, for example, the V-phase and W-phase power lines 4v and 4w. The sensor holding member 5 holds (builds in) a temperature sensor (thermistor) 6 that detects the temperature of the power line 4v or 4w, i.e., the stator coil 3v or 3w. The temperature sensor 6 is electrically connected to a connector (connector plug) 8 via a cable 7 that includes two wires 7w and a tube 7t covering the two wires 7w. As shown in Figure 2, the connector 8 connected to the temperature sensor 6 is coupled to a corresponding receptacle 12 installed in the case 10, thereby connecting the temperature sensor 6 to an electronic control device (not shown) via the connector 8 and the receptacle 12.

[0016] As shown in Figures 2 and 3, the sensor holding member 5 includes a main body 50, a connector support portion 51 extending from the main body 50, and a cable support portion 55 integrally formed with the main body 50. In this embodiment, the sensor holding member 5 is integrally formed with the power line 4v or 4w and the temperature sensor 6 by injecting resin into a mold in which the power line 4v or 4w and the temperature sensor 6 are inserted. The main body 50 holds the temperature sensor 6 such that the two wires 7w connected to the sensor element are exposed on the tip 40v or 40w side (lower in the figure) of the power line 4v or 4w. The tube 7t of the cable 7 covers the two wires 7w such that they are slightly exposed near the temperature sensor 6 (main body 50) and near the connector 8.

[0017] The connector support portion 51 of the sensor holding member 5 extends from the main body 50 to the opposite side (upward in the figure) from the tip portion 40v or 40w side, and the tip portion 52 of the connector support portion 51 is formed to be insertable into a recess 80 formed in the connector 8, as shown in Figures 4 and 5. In addition, a notch 53 is formed in the tip portion 52 of the connector support portion 51 that can hold (grip) the tube 7t of the cable 7. The cable support portion 55 extends outward from the side of the main body 50 and is formed to slidably support the tube 7t of the cable 7 in the extending direction of the connector support portion 51 (up and down direction in the figure), as shown in Figure 5.

[0018] The power lines 4v and 4w, which are integrated with the sensor holding member 5, are connected to the stator coils 3v and 3w. Once other components are attached and the stator 1 is complete, the stator 1 is assembled to the case 10 with the connector 8 supported by the tip 52 of the connector support part 51, and the tube 7t of the cable 7 slidably supported by the cable support part 55 (see Figure 5). In this way, by supporting the connector 8 of the temperature sensor 6 on the connector support part 51 of the sensor holding member 5 when assembling the stator 1 to the case 10, the movement of the connector 8 can be restricted, narrowing the range of movement of the connector 8 and the cable 7. As a result, the need to ensure a large range of movement for the connector 8, etc., and to suppress interference between the moving connector 8, etc., and the case 10, etc., is reduced, making it possible to suppress the enlargement of the assembly equipment for the stator 1 and the case 10. Furthermore, in the stator 1, the connector 8, which is detachably supported by the connector support portion 51, can be grasped by a robot (not shown) and coupled to the corresponding receptacle 12 of the case 10. As a result, the need to manually connect the connector 8 to the receptacle 12 is eliminated, thereby further improving the ease of assembling the stator 1 to the case 10.

[0019] Also, in the stator 1, the connector 8 of the temperature sensor 6 is coupled to the receptacle 12 installed in the case 10, and the connector support portion 51 of the sensor holding member 5 has a notch 53 capable of holding the tube 7t of the cable 7 that extends between the temperature sensor 6 and the connector 8 coupled to the receptacle 12. That is, in the stator 1, as shown in FIG. 2, the notch 53 (tip portion 52) of the connector support portion 51 of the sensor holding member 5 integrated with the V-phase power line 4v holds the tube 7t of the cable 7 that extends between the temperature sensor 6 held by the sensor holding member 5 integrated with the W-phase power line 4w and the connector 8 coupled to the corresponding receptacle 12. Thereby, while suppressing an increase in the number of parts, it becomes possible to route the cable 7 in the case 10 so as not to interfere with other parts or the like.

[0020] However, the cable 7 (tube 7t) held by the notch 53 of the connector support portion 51 is not limited to being connected to the temperature sensor 6 held by a sensor holding member 5 other than the sensor holding member 5 including the connector support portion 51. That is, the cable 7 held by the notch 53 of the connector support portion 51 may be connected to the temperature sensor 6 held by the sensor holding member 5 including the connector support portion 51. For example, in FIG. 2, the notch 53 (tip portion 52) of the connector support portion 51 of the sensor holding member 5 integrated with the W-phase power line 4w may hold the cable 7 that extends between the temperature sensor 6 held by the sensor holding member 5 integrated with the W-phase power line 4w and the connector 8 coupled to the corresponding receptacle 12.

[0021] Furthermore, the sensor holding member 5 includes a cable support portion 55 that slidably supports the cable 7 (tube 7t) connected to the temperature sensor 6 and the connector 8. Thereby, since the length of the cable 7 drawn out from the stator 1 side (sensor holding member 5) can be adjusted, it becomes possible to properly route the cable 7 in the case 10.

[0022] Furthermore, the connector support portion 51 of the sensor holding member 5 includes a tip portion 52 that serves as an insertion portion that is detachably inserted into a recess 80 formed in the connector 8. This makes it possible to form a connector support portion 51 that detachably supports the connector 8 on the sensor holding member 5 without complicating the structure of the sensor holding member 5. However, the connector support portion 51 does not necessarily have to include an insertion portion that is inserted into the connector 8. That is, as shown in Figure 6, a mating portion (recess) 54 into which the connector 8 is detachably fitted may be formed on the tip portion 52 of the connector support portion 51. In this embodiment as well, it is possible to form a connector support portion 51 that detachably supports the connector 8 on the sensor holding member 5 without complicating the structure of the sensor holding member 5. The tip portion 52 of the connector support portion 51 shown in Figure 6 may also be formed to be able to hold the tube 7t of the cable 7.

[0023] Furthermore, the conductor into which the sensor holding member 5 is integrated is not limited to the power lines 4v and 4w connected to the stator coils 3v and 3w, but may be at least one of the neutral lines 4n connected to the stator coils 3u, 3v, and 3w. Also, the conductor into which the sensor holding member 5 is integrated may be at least one of the segment coils 30 and 31 formed by the stator coils 3u, 3v, and 3w.

[0024] As described above, the stator 1 of this disclosure is disposed within a case 10 and includes a stator core 2, stator coils 3u, 3v, 3w wound around the stator core 2, a sensor holding member 5, and a connector support portion 51. The sensor holding member 5 is integrated with power lines 4v, 4w or neutral line 4n as conductors included in the stator coils 3v, 3w, and also holds a temperature sensor 6. The connector support portion 51 is formed on the sensor holding member 5 to detachably support a connector 8 connected to the temperature sensor 6 via a cable 7. This makes it possible to suppress the enlargement of the assembly equipment for the stator 1 and the case 10, and to improve the ease of assembling the stator 1 to the case 10.

[0025] It should be noted that the invention disclosed herein is not limited in any way to the embodiments described above, and various modifications can be made within the scope of this disclosure. Furthermore, the embodiments described above are merely one specific form of the invention described in the summary of the invention, and do not limit the elements of the invention described in the summary of the invention. [Industrial applicability]

[0026] The invention disclosed herein can be used in industries such as the manufacturing of stators and rotating electric machines. [Explanation of Symbols]

[0027] 1 Stator, 2 Stator core, 3a, 3b Coil end sections, 3u, 3v, 3w Stator coil, 30, 31 Segment coil, 4u, 4v Power line, 4n Neutral wire, 5 Sensor holding member, 50 Main body, 51 Connector support section, 52 Tip section, 53 Notch section, 55 Cable support section, 6 Temperature sensor, 7 Cable, 7t Tube, 7w Wire, 8 Connector, 80 Recess, 10 Case, 11 Terminal block, 12 Receptacle.

Claims

1. In a stator located inside a case, Stator core and The stator coil wound around the stator core, A sensor holding member, which is integrated with the conductor included in the stator coil and holds a temperature sensor, A connector support portion is formed on the sensor holding member to detachably support a connector connected to the temperature sensor via a cable, A stator equipped with the following features.

2. In the stator according to claim 1, The connector is coupled to a receptacle installed in the case. The connector support portion is a stator formed to hold the cable extending between the temperature sensor and the connector coupled to the receptacle.

3. In the stator according to claim 1 or 2, The sensor holding member is a stator that includes a cable support portion that slidably supports the cable connected to the temperature sensor and the connector.

4. In the stator according to claim 1 or 2, The connector support portion is a stator including an insertion portion that is detachably inserted into a recess formed in the connector, or a mating portion into which the connector is detachably fitted.

5. In the stator according to claim 1 or 2, The conductor is a stator, which is a power line or neutral line connected to the stator coil.

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