Rotating electric machine

Abstract

This rotating electric machine comprises a stator core and a stator coil. The stator coil has two straight line portions and a turn portion that connects the two straight line portions. The turn portion has a top portion, a slope portion that connects the top portion and the straight line portions, and a bend portion that bends outside in the radial direction. The bend portions of respective first and second stator coils are at different positions in the circumferential direction. The bend portion of the first stator coil is formed in the slope portion of the first stator coil. The bend portion of the second stator coil is formed at the top portion of the second stator coil. The turn portion of the second stator coil is closer to the stator core than the turn portion of the first stator coil.

Description

Technical Field

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[0001] The present invention relates to a rotating electric machine.

Background Art

[0002] In the production process of a rotating electric machine, in the step of inserting a coil into a stator core, the coil is inserted into the stator core by directly pushing the coil toward the stator core using an insertion jig. However, since the large-pitch coil and the small-pitch coil are inserted in a structure where they overlap in the axial direction, it is not possible to directly push all the coils from a certain direction. Therefore, for coils that are not fully inserted, adjustment is made by pushing from an oblique direction or the like, but this adjustment may cause defects during coil insertion.

[0003] As the background art of the present invention, Patent Document 1 below discloses a configuration in which the top portions 63A and 63B do not overlap and are radially displaced in the turn portions 62A and 62B of the coil. <​​​​​​​​​​​​​​​​​​​​​​​​​​​ The present invention relates to a rotating electric machine comprising a stator core having a plurality of slots, and a plurality of stator coils arranged in the plurality of slots in the radial direction of the stator core, wherein each stator coil has two straight sections that penetrate the stator core in the axial direction in different slots and in different layers, and a turned section that connects the two straight sections, and the turned section has a top that is the position furthest from the stator core in the axial direction, two inclined sections that connect the top and the straight sections, and a section that bends outward in the radial direction. The stator coil has a curved portion, and the stator coil includes a first stator coil and a second stator coil that overlap each other in the axial direction, wherein the curved portions of the first stator coil and the second stator coil are located at different positions in the circumferential direction, the curved portion of the first stator coil is formed on the inclined portion of the first stator coil, the curved portion of the second stator coil is formed on the top portion of the second stator coil, and the turned portion of the second stator coil is located closer to the stator core in the axial direction than the turned portion of the first stator coil. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a coil for a rotating electric machine that reduces the height of the coil end and improves the defect rate during assembly. [Brief explanation of the drawing]

[0008] [Figure 1] A cross-sectional view showing the overall structure of the stator of a rotating electric machine. [Figure 2] A diagram showing the positional relationship between the conventional insert coil and the stator core. [Figure 3] An explanatory diagram of an insertion coil and a pressing jig according to one embodiment of the present invention. [Figure 4] A diagram showing the positional relationship between an insertion coil and a stator core according to one embodiment of the present invention.

[0009] (One embodiment of the present invention and its overall configuration) Embodiments of the present invention will be described below with reference to the drawings. The following description and drawings are illustrative for illustrating the present invention, and have been omitted and simplified as appropriate for clarity of explanation. The present invention can also be carried out in various other forms. Unless otherwise specified, each component may be singular or plural.

[0010] The positions, sizes, shapes, and ranges of the components shown in the drawings may not represent their actual positions, sizes, shapes, and ranges in order to facilitate understanding of the invention. Therefore, the present invention is not necessarily limited to the positions, sizes, shapes, and ranges disclosed in the drawings.

[0011] (Figure 1) The stator 100 of the rotating electric machine has stator coils 1 and a stator core 2 on the outer circumference of the rotor (not shown). Multiple stator coils 1 are inserted and arranged radially into multiple slots (not shown) of the stator core 2.

[0012] (Figure 2) Let me explain the stator coil 1A that has been conventionally inserted into the stator. When the stator coil 1A is inserted into the stator core 2, the large-segment stator coil 1c and the small-segment stator coil 1d are arranged to overlap. The large-segment stator coil 1c and the small-segment stator coil 1d each have a bent portion 8 that is radially bent at the top portion 6, which is the part furthest from the stator core 2 in the turn portion described later, which is not inserted into the stator core 2, and when viewed from the radial direction, the axis of this bent portion 8, which is the axis of the bent portion 8, overlaps.

[0013] Due to this configuration, when inserting the coils into the stator core 2, the small stator coil 1d overlaps with the large stator coil 1c, making it invisible from a certain direction (from top to bottom in Figure 2(a), and from front to back in Figure 2(b)). Consequently, the small stator coil 1d is difficult to push into the stator core 2 by the insertion jig. This results in variations in coil height after insertion, leading to defects in the production process.

[0014] For example, one way to solve this problem is to make the top 6 even higher to create more space in the circumferential direction so that all the stator coils 1A can be reliably pressed. However, applying this configuration to the already tall, large-span U-shaped stator coil 1a in the axial direction would lead to an increase in the overall size of the rotating electric machine.

[0015] Furthermore, as a way to solve the problem without raising the top portion 6 as described above, conventionally, coils that could not be pressed by the insertion jig were pressed from an oblique direction rather than the axial direction to suppress variations in coil height for adjustment. However, when adjustments were made in this way, for example, the slot liner (not shown) wound around each stator coil 1A was dragged against the slot wall of the stator core 2, which could cause the slot liner to shift position or tear, leading to defects.

[0016] (Figure 3) The configuration of the stator coil 1 according to one embodiment of the present invention will be described. Note that in Figure 3(a), the vertical direction of the paper is the axial direction, and in Figure 3(b), the vertical direction of the paper is the radial direction.

[0017] The stator coil 1 of the present invention has a straight portion 5 and a turn portion 4. The turn portion 4 connects two straight portions 5 and has a top portion 6 and an inclined portion 7. The straight portion 5 is a portion that is inserted into the stator core 2 and penetrates through different layers of the slots. The top portion 6 is the position farthest from the stator core in the axial direction. The two inclined portions 7 connect the top portion 6 and the straight portion 5.

[0018] The thick stator coil 1a and the thin stator coil 1b of the stator coil 1 are overlapped and inserted into the stator core 2. The inclined portion 7 of the thick stator coil 1a is formed longer than that of the thin stator coil 1b. The turn portion 4 of the thin stator coil 1b is closer to the stator core than the turn portion 4 of the thick stator coil 1a.

[0019] The thick stator coil 1a and the thin stator coil 1b are provided with bent portions 8 that do not overlap and are at different positions when viewed from the coil insertion direction (axial direction) (see Fig. 3(b)). That is, the position of the bent portion 8 of the thick stator coil 1a is shifted in the circumferential direction from the top portion 6, so that the top portion 6 and the bent portion 8 of the thin stator coil 1b are exposed when viewed from the axial direction.

[0020] Therefore, when the thick stator coil 1a and the thin stator coil 1b are pushed in the direction of arrow 3c by the insertion jig 3, they can be surely pushed by the thick U-shaped coil pushing reference 3a and the thin U-shaped coil pushing reference 3b of the insertion jig 3. Thus, the respective stator coils 1a and 1b can be surely inserted into the stator core 2, and defects in the production process can be reduced.

[0021] (Fig. 4) [[ID=I7]] Fig. 4(a) is a separated view so that it can be seen that the positions of the bent portions 8 shown in Fig. 3(b) are different between the thick stator coil 1a and the thin stator coil 1b. As shown in Fig. 4(a), the bent axes 8a of the thick stator coil 1a and the thin stator coil 1b are shifted in the axial direction. Further, the bent portion 8 of the thick stator coil 1a is formed at the position of the inclined portion 7 on the outer diameter side rather than at the top portion 6.

[0022] As shown in FIG. 4(b), when the large-width stator coil 1a and the small-width stator coil 1b are inserted into the stator core 2, the top 6 and the bent portion 8 of the small-width stator coil 1b exposed due to the circumferential displacement of the bent portion 8 of the large-width stator coil 1a have an exposed area size such that the insertion jig 3 can be directly and surely pressed.

[0023] In the large-width stator coil 1a, the reason for providing the bent portion 8 on the outer diameter side inclined portion 7 side of the inclined portion 7 is that the exposed area where the insertion jig can surely press the small-width stator coil 1b is larger than forming the bent portion 8 on the inner diameter side inclined portion 7. Due to the large exposed area, even if there is an error in design variation for each stator coil 1, the tolerance can be absorbed, and the insertion jig can surely press the small-width stator coil 1b. However, if an exposed area size where the insertion jig can be surely pressed can be formed, the bent portion 8 may be provided on the inner diameter side inclined portion 7 of the large-width stator coil 1a.

[0024] By doing so, each stator coil la, 1b is directly and uniformly pressed by the insertion jig, so that the variation in height after insertion is eliminated, defects such as slot liner breakage can be reduced, and production defects can be reduced. Also, since the axial position of the top 6 is the same as that of the stator coils 1c, 1d in the conventional stator coil 1A shown in FIG. 2, it can contribute to the miniaturization of the rotating electric machine. Further, by surely inserting the stator coils 1a, 1b, the variation in the twisted portion (end portion of the coil) of the coil can be eliminated.

[0025] According to an embodiment of the present invention described above, the following operational effects are achieved.

[0026] (1) The rotating electric machine of the present invention comprises a stator core 2 provided with a plurality of slots, and a plurality of stator coils 1 arranged in the plurality of slots in the radial direction of the stator core 2. The stator coil 1 has two straight sections 5 that penetrate the stator core 2 in the axial direction in different slots and in different layers, and a turned section 4 that connects the two straight sections 5. The turned section 4 has a top section 6 that is the position furthest from the stator core 2 in the axial direction, two inclined sections 7 that connect the top section 6 and the straight sections 5, and a bent section 8 that bends outward in the radial direction. The stator coil 1 includes a first stator coil 1a and a second stator coil 1b that overlap each other in the axial direction. The bends 8 of the first stator coil 1a and the second stator coil 1b are located at different positions in the circumferential direction. The bend 8 of the first stator coil 1a is formed on the inclined portion 7 of the first stator coil 1a, and the bend 8 of the second stator coil 1b is formed on the top portion 6 of the second stator coil 1b. The turn portion 4 of the second stator coil 1b is located closer to the stator core 2 in the axial direction than the turn portion 4 of the first stator coil 1a. This configuration reduces the height of the coil ends and improves the defect rate during assembly, providing a coil 1 for a rotating electric machine.

[0027] (2) The inclined portion of the first stator coil 1a is longer than that of the second stator coil 1b. This makes it possible to overlap the coils in the axial direction while realizing the configuration of the bent portion 8 of the present invention.

[0028] (3) The bent portion 8 of the first stator coil 1a is positioned on the radially outward inclined portion 7 of the first stator coil 1a. This arrangement allows for a larger exposed area that enables the insertion jig 3 to reliably press the small stator coil 1b.

[0029] It should be noted that the present invention is not limited to the embodiments described above, and various modifications and combinations of other configurations can be made without departing from the spirit of the invention. Furthermore, the present invention is not limited to having all the configurations described in the embodiments described above, and may also include configurations in which some of those configurations are omitted. [Explanation of Symbols]

[0030] 1 Stator coil 1a Large stator coil 1b Small stator coil 1c Conventional large-span stator coil 1d Conventional small stator coil 2 Stator Cores 3 Insertion jig 3a Large-legged U-shaped coil pressing standard 3b Small U-shaped coil pressing standard 3c The direction in which the insertion jig pushes. 4 Turn section 5. Straight section 6 top 7 Slope 8. Flexed section 8a Bent shaft 100 staters

Claims

1. A rotating electric machine comprising a stator core having a plurality of slots, and a plurality of stator coils arranged in the plurality of slots in the radial direction of the stator core, The stator coil has two straight sections that penetrate the stator core in the axial direction in different layers in different slots, and a turned section that connects the two straight sections. The turn portion has a top portion which is the position furthest from the stator core in the axial direction, two inclined portions which connect the top portion and the straight portion, and a bent portion which bends outward in the radial direction. The stator coil includes a first stator coil and a second stator coil that overlap each other in the axial direction. The first stator coil and the second stator coil have different circumferential spacings of their respective straight sections. The first stator coil and the second stator coil have their respective bent portions located at different positions in the circumferential direction. The bent portion of the first stator coil is formed on the inclined portion of the first stator coil, The bent portion of the second stator coil is formed at the top of the second stator coil, The turn portion of the second stator coil is located closer to the stator core in the axial direction than the turn portion of the first stator coil. Rotating electric machine.

2. A rotating electric machine according to claim 1, The first stator coil has a longer inclined portion than the second stator coil. Rotating electric machine.

3. A rotating electric machine according to claim 1, The bent portion of the first stator coil is positioned on the radially outward inclined portion of the first stator coil. Rotating electric machine.

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