Guide component and rotating electrical machine

Abstract

To provide a guide component capable of uniformly filling a slot of a stator core with a molten resin and a rotary electric machine equipped with the same.SOLUTION: This guide component is fitted to the core end surface of a stator core having a structure in which a coil stored in a slot is solidified by a resin. The guide component comprises a frame-shaped holding part having an opening through which the coil is inserted. The holding part is provided with a fixing part fitted in the slot on a surface facing the core end surface, and a projected part which abuts against the core end surface in a state where the fixing part is fitted in the slot. In the guide component, a resin filling gap is formed between the core end surface and the holding part by the projected part in the state of being fitted to the core end surface.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a guide component and a rotating electric machine, and more particularly, to a guide component attached to a core end face of a stator core having a structure in which a coil housed in a slot is solidified with resin, and a rotating electric machine including the same.

Background Art

[0002] Factors that limit the continuous output of general motors such as automotive drive motors include the upper limit temperature of the coil to ensure the insulation of the coil coating, the upper limit temperature of the magnet to prevent demagnetization of the magnet, and the like. Therefore, the cooling structure of the motor is important for continuous output of the motor.

[0003] In a drive motor for an electric vehicle, current flows through the coils of the stator during operation, and the coils generate heat due to the Joule heat of the conductors constituting the coils. In such a cooling mechanism of the drive motor, the heat generated in the coils propagates from the coils to the stator core and then further propagates from the stator core to a refrigerant such as cooling water.

[0004] In a general structure of a stator, the coil is fixed to the stator core by filling and solidifying a resin such as varnish between the coil housed in the slot and the stator core. This solidified resin serves as a heat transfer path for the heat generated in the coil. Therefore, the heat dissipation function of the solidified resin is becoming important.

[0005] Conventionally, a rotating electric machine that achieves both productivity and insulation has been proposed (see Patent Document 1). This rotating electric machine includes a coil guide disposed at at least one opening of the slot of the stator core, typically at the end face of the stator core. This coil guide includes a slot insertion portion located between the slot and the segment conductor, and at least one partition portion located between the segment conductors, and the slot insertion portion and the partition portion are disposed in the slot together with the segment conductor.

Prior Art Documents

Patent Document

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] By the way, when the inventors of the present invention tried to inject molten resin from the end face side of the stator core into the slot provided with the coil guide as described in Patent Document 1, a new technical problem was found that it was difficult to uniformly fill the molten resin because the coil guide had a partition portion.

[0008] The present invention has been made based on such a new technical problem, and an object thereof is to provide a guide component capable of uniformly filling molten resin into the slot of a stator core and a rotating electric machine including the same.

Means for Solving the Problems

[0009] As a result of intensive studies to achieve the above object, the inventors of the present invention have found that the above object can be achieved by forming a gap for resin filling between the end face of the stator core and the holding portion, and have completed the present invention.

[0010] That is, the guide component of the present invention is a guide component attached to the core end face with respect to a stator core having a structure in which a coil housed in a slot is hardened with resin, comprises a frame-shaped holding portion having an opening through which the coil passes, and the holding portion has, on a surface facing the core end face, a fixing portion that fits into the slot and a convex portion that abuts against the core end face in a state where the fixing portion is fitted into the slot, The holding part has a rectangular frame shape with short sides and long sides, the fixing part is arranged on the short sides, and has a plurality of protrusions arranged at regular intervals on the long sides and spaced apart from the core end face, and has a comb-shaped protrusion part, and the side surface of the protrusion on the inner wall surface side of the holding part is flush with the inner wall surface of the holding part, in a state of being attached to the core end face , between the long side and the core end face by the convex part forms a gap for resin filling.

[0011] Furthermore, the rotating electrical machine of the present invention is a rotating electrical machine having a stator core with a structure in which a coil housed in a slot is hardened with resin, and a guide component attached to the core end face. This guide component is the above-described guide component.

Effect of the Invention

[0012] According to the present invention, since a gap for resin filling is formed between the stator core end face and the holding portion, it is possible to provide a guide component capable of uniformly filling molten resin into the slots of the stator core and a rotating electrical machine including the same.

Brief Description of the Drawings

[0013] [Figure 1] It is a perspective view showing an embodiment of the rotating electrical machine of the present invention. [Figure 2] FIG. 2(A) is a top view of the slot portion surrounded by line II of the stator shown in FIG. 1, FIG. 2(B) is a cross-sectional view of the slot portion cut along the radial direction of the stator, and FIG. 2(C) is a cross-sectional view of the slot portion cut along the circumferential direction of the stator. [Figure 3] FIG. 3(A) is an embodiment of the guide component of the present invention, a perspective view of the guide component shown in FIG. 1, FIG. 3(B) is a front view of this guide component, FIG. 3(C) is a plan view of the guide component, FIG. 3(D) is a bottom view of the guide component, FIG. 3(E) is a left side view of the guide component, and FIG. 3(F) is a right side view of the guide component. [Figure 4] It is a perspective view showing a state where the guide component shown in FIG. 1 is attached to the stator core. [Figure 5] FIG. 5(A) is a perspective view showing a state where the guide component shown in FIG. 1 is attached to the stator core, and FIG. 5(B) is a front view showing a state where the guide component shown in FIG. 1 is attached to the stator core. [Figure 6]FIG. 6(A) is a perspective view showing another example of the guide component, FIG. 6(B) is a front view showing another example of the guide component, FIG. 6(C) is a plan view showing another example of the guide component, FIG. 6(D) is a bottom view showing another example of the guide component, FIG. 6(E) is a left side view showing another example of the guide component, FIG. 6(F) is a right side view showing another example of the guide component, and FIG. 6(G) is a cross-sectional view taken along line G-G' of the guide component shown in FIG. 6(B). [Figure 7] It is a perspective view showing still another example of the guide component. [Figure 8] It is a perspective view showing still another example of the guide component. [Figure 9] FIG. 9 is a perspective view showing a state where the guide component shown in FIG. 8 is attached to the stator core. [Figure 10] FIG. 10 is a perspective view showing a state where the guide component shown in FIG. 8 is attached to the stator core.

BEST MODE FOR CARRYING OUT THE INVENTION

[0014] Hereinafter, the guide component and the rotating electrical machine of the present invention will be described in detail with reference to the drawings. Note that the dimensional ratios in the drawings cited below are exaggerated for convenience of explanation and may be different from the actual ratios.

[0015] (Embodiment 1) FIG. 1 is a perspective view showing a main part of an embodiment of the rotating electrical machine of the present invention. As shown in FIG. 1, the rotating electrical machine 1 of the present embodiment includes a stator 10 and a rotor 30, and the guide component 20 of the present invention is attached to the stator 10. The stator 10 includes an annular stator core 11 having a plurality of slots 11A for accommodating coils (not shown). The guide component 20 is attached to the end face 11B of the stator core, specifically, in the vicinity of the opening of the slot 11A on the core end face 11B.

[0016] Figures 2(A) to (C) show the mounting state of the guide component. As shown in these figures, the guide component 20 is attached to the core end face 11B of the stator core 11 having a structure in which the insulated-coated coil 13 housed in the slot 11A is solidified with the resin 15. Here, the arrow Z in Fig. 2(C) indicates the flow direction of the molten resin when injecting the molten resin. In fact, a plurality of coils are wound around the stator core, but are omitted for convenience of explanation. Also, in fact, a rotor shaft, a plurality of magnets, etc. are assembled to the rotor, but are omitted for convenience of explanation.

[0017] (Embodiment 2) Figures 3(A) to (F) show an embodiment of the guide component of the present invention. In these figures, the guide component 20 includes a frame-shaped holding portion 21 having an opening 21A for passing through a coil (not shown). This holding portion 21 has a fixing portion 23 and a convex portion 25 on the opposing surface 21C with the core end face (core end face 11B: see Fig. 1). In the mounted state of the guide component 20, the fixing portion 23 is fitted into the slot 11A (see Fig. 1). At the time of this fitting, the convex portion 25 abuts against the core end face 11B, so that a gap 20A for filling the solidifying resin is formed between the holding portion 21 and the core end face 11B (see Fig. 3(B), Fig. 2(C)).

[0018] In the guide component 20 of the present embodiment, the holding portion 21 has a rectangular frame shape having short side portions 211 and long side portions 213. By arranging the long side portion 213 along the radial direction of the stator core 11 as shown in Fig. 1, the fixing portion 23 is arranged on the short side portion 211, and a gap 20A is formed between the long side portion 213 and the core end face 11B.

[0019] As shown in FIG. 4, by inserting the guide component 20 of the present embodiment into the slot 11A as indicated by the arrow Y, the fixing portion 23 fits into the slot 11A, and the convex portion 25 abuts against the core end face. Then, as shown in FIG. 5, the guide component 20 is attached to the core end face 11B, and a gap 20A for resin filling is formed between the holding portion 21 and the core end face 11B. At this time, since the convex portion 25 functions as a stopper for the fixing portion 23, the gap 20A can be formed easily and surely, and its height can be made uniform.

[0020] As described above, according to the guide component of the present embodiment, since the gap 20A for resin filling is formed between the core end face 11B and the holding portion 21, for example, compared with the case of injecting molten resin between coils, it is difficult for the resin flow to branch or merge. Thus, since the gap 20A is formed between the core end face and the holding portion, it is difficult for the filling pressure to increase during resin injection, and it is also difficult for the flow of the molten resin to be disturbed. Therefore, it is difficult for bubbles or the like to be mixed in during resin filling, and the generation of resin interfaces is also difficult to occur. As a result, the slot of the stator core can be filled with molten resin homogeneously.

[0021] Also, as described above, since the resin filled homogeneously solidifies, the entire solidified resin is homogeneous and has few defects, and the resin strength, coil heat dissipation performance, and coil insulation performance of the rotating electrical machine can be improved. Furthermore, since the guide component of the present embodiment does not have a partition portion for the coil, the occupation ratio of the coil in the slot can be increased. Also, by using this guide component, the insulating paper can be eliminated while ensuring insulation, and the coil heat dissipation performance can be improved.

[0022] If the guide component of the present embodiment is pre-mounted, when inserting the coil into the slot 11A, the contact between the coil and the edge or inner surface of the slot can be suppressed, and the insertion can be smoothed. Thereby, the generation of scratches on the coil surface is suppressed. Thus, this guide component also functions as a coil guide, can narrow the space between the coil and the inner surface of the slot, and can improve the coil heat dissipation performance.

[0023] Furthermore, in the guide component of the present embodiment, the holding portion 21 has a rectangular frame shape having a short side portion 211 and a long side portion 213, the fixing portion 23 is disposed on the short side portion 211 side, and a gap 20A is formed on the long side portion 213 side (FIG. 3). Therefore, the size of the gap 20A can be increased, making it easier to fill a sufficient amount of molten resin into the slots of the stator core 11, and when injecting the molten resin from the stator core end face 11B side, the molten resin can be filled into the slots 11A more homogeneously.

[0024] (Embodiment 3) FIGS. 6(A) to (G) show other embodiments of the guide component of the present invention. In these figures, this guide member 22 has the same configuration as the guide component shown in FIG. 1, except that the holding portion 21 has comb-shaped protrusions 215. Here, the comb-shaped protrusions 215 are composed of a plurality of protrusions 217 arranged at regular intervals on the long side portion 213. Further, the comb-shaped protrusions 215 are arranged at a distance from the core end face 11B. Furthermore, the side surface 217A of the protrusion 217 on the inner wall surface 21B side of the holding portion 21 is formed flush with the inner wall surface 21B of the holding portion 21 (FIGS. 6(D) and (G)).

[0025] By having the predetermined comb-shaped protrusions 215 described above, the guide component of the present embodiment can, in addition to the advantages exhibited by the guide component of Embodiment 2, further suppress the contact between the coil and the edges and inner surfaces of the slots when inserting the coil into the slots 11A. As a result, the generation of scratches on the coil surface is further suppressed. Consequently, according to the guide component of the present embodiment, the space between the coil and the inner surface of the slot can be made even narrower, and the coil heat dissipation performance can be further enhanced.

[0026] (Embodiment 4) FIG. 7 shows still another embodiment of the guide component of the present invention, in which a plurality of guide components 20 are integrated to form a guide component 24 having an arc shape. In the illustrated example, a plurality of guide components 20 are integrated to form a guide component 24 having a 120° arc shape, but the present invention is not limited thereto, and for example, a guide component having an 180° or 90° arc shape may be used.

[0027] (Embodiment 5) FIG. 8 shows still another embodiment of the guide component of the present invention, in which a plurality of guide components 20 are integrated to form a guide component 26 having an annular shape. As shown in FIG. 9, the above-described guide component 26 can be fitted and attached to the slot 11A and the stator core 11 as indicated by the arrow X, and can be attached to the core end face 11B in the same manner as the guide component 20 (see FIGS. 4 and 5). At this time, as shown in FIG. 10, in the guide component 26 of the present embodiment, a gap 20A for resin filling is formed between the holding portion 21 and the core end face 11B, specifically, between the long side portion 213 and the core end face 11B. Note that the arc-shaped guide component 24 of Embodiment 4 can also be attached to the stator core in the same manner with three man-hours, and the gap 20A is formed.

[0028] The above-described guide components 24 and 26 have a structure in which a plurality of guide components 20 are integrated, and thus have some flexibility as a whole, and the degree of freedom in attachment is improved as compared with individually attaching the guide components 20 to each slot, and the man-hours for attaching to the stator core 11 can also be reduced. In addition, since these guide components have an arc shape or an annular shape, they have excellent mechanical strength. Further, since these guide components have an arc shape or an annular shape, they are less affected by the shape error of the slot generated during the forming process, and the accuracy of the coil insertion position can be improved.

[0029] In the guide component of each of the above-described embodiments, a coil may be pre-assembled in the holding portion 21. According to such a guide component with a coil, a partial shape of the guide component can be made thinner, and the occupation ratio of the coil in the slot can be increased. There is also an advantage that the material used for the guide component can be reduced. Further, since the positioning between the stator core and the coil can be performed by the guide component with a coil, adjustments such as the positioning of the coil in the assembly process of the rotating electrical machine are not required, and there is an advantage that the assembly process can be simplified.

[0030] The material for forming the guide component of each of the above-described embodiments is not particularly limited as long as it is an electrically insulating material. Examples of such materials include organic materials such as resins having insulation properties, inorganic materials such as ceramics and glass having insulation properties, and metal materials having their surfaces subjected to insulation treatment. When the guide component is formed of a resin material, for example, the guide component can be manufactured by injection molding or the like. Further, since the coil may slide on the inner wall surface of the holding portion when the coil is inserted, it is preferable that the inner wall surfaces of the holding portion and the fixing portion of the guide component are finished smoothly so as not to damage the coil.

[0031] As described above, the present invention has been described by way of several embodiments, but the present invention is not limited thereto, and various modifications are possible within the scope of the gist of the present invention. For example, the above-described components are not limited to the configurations shown in each embodiment, and it is also possible to change the details of the specifications of the holding portion, the fixing portion, and the convex portion, or to apply the components of each embodiment to other embodiments. Further, in the guide component of each embodiment, a rectangular frame shape having a short side portion and a long side portion as the holding portion has been illustrated and described, but it is not limited thereto as long as it has a shape that fits into the slot. For example, when the shape of the opening of the slot is a fan-shaped frame, the holding portion can be made into a fan-shaped frame.

Description of Reference Numerals

[0032] 1 Rotating electrical machine 10 Stator 11 Stator core 11A Slot 11B Core end face 13 Coil 15 Resin 20, 22, 24, 26 Guide parts 20A Gap 21 Holding part 21A Opening 21B Inner wall surface 21C Opposite surface 211 Short side part 213 Long side part 215 Comb-shaped protrusion 217 Protrusion 217A Side surface 23 Fixing part 25 Convex part 30 Rotor

Claims

1. A guide component to be attached to the core end face of a stator core having a structure in which a coil housed in a slot is hardened with resin, comprising a frame-shaped holding portion having an opening through which the coil passes, wherein the holding portion includes a fixing portion that fits into the slot on a surface facing the core end face, and a convex portion that abuts against the core end face in a state where the fixing portion is fitted into the slot, the holding portion is in a rectangular frame shape having short sides and long sides, the fixing portion is arranged on the short side, the long side has a comb-shaped protrusion portion composed of a plurality of protrusions arranged at regular intervals and spaced apart from the core end face, the side surface of the protrusion on the inner wall surface side of the holding portion is flush with the inner wall surface of the holding portion, a guide component characterized in that, in a state of being attached to the core end face, a resin filling gap is formed between the long side and the core end face by the convex portion.

2. The guide component according to claim 1, wherein the coil is assembled to the holding portion.

3. The guide component according to claim 1 or 2, characterized in that a plurality of guide components attached to the core end face are integrated and have an arc shape or an annular shape.

4. A rotating electrical machine comprising a stator core having a structure in which a coil housed in a slot is hardened with resin, and a guide component attached to the core end face thereof, wherein the guide component is the guide component according to any one of claims 1 to 3.

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