Stator of rotary electrical machine, and rotary electrical machine

Abstract

Provided are a stator of a rotary electrical machine, and the rotary electrical machine, comprising a core, a plurality of slots formed in the core, and a plurality of conductors respectively inserted into the plurality of slots and arranged side by side in the radial direction of the core, wherein: the plurality of conductors each include two straight sections, which are portions inserted into the slots, and a turn section connecting end portions of the two straight sections; the turn sections are each provided with two inclined sections inclined in the circumferential direction so as to face each other, and a top section connecting end portions of the two inclined sections and protruding outward in the axial direction from the core; the conductors include first conductors and second conductors that are in the same phase as the first conductors; the first conductors each have a first inclination angle, which is an inclination angle formed by an inclined section with respect to the surface of the core into which a first conductor is inserted, and is the same angle for all of the first conductors; the second conductors each have a second inclination angle, which is an inclination angle formed by an inclined section with respect to the surface of the core into which a second conductor is inserted, and is the same angle for all of the second conductors; and the first inclination angle is greater than the second inclination angle.

Description

Rotating electric machine stators, rotating electric machines

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

[0002] There is a demand for miniaturization of motors from the viewpoint of installation space. To achieve this, the height of a motor is significantly affected by the dimensions of the coil ends, and therefore, these dimensions must be reduced. Patent Document 1 listed below discloses a configuration in which, to achieve a compact motor, the distance between a second straight portion and a first straight portion located outside it is greater than the distance between the first straight portions, and the radial protrusion direction of the turn-back portion relative to the second straight portion is different from the radial protrusion direction of the jumper portion relative to the first straight portion.

[0003] Japanese Patent Application Laid-Open No. 2022-136858

[0004] In view of the configuration described in Patent Document 1, an object is to provide a stator for a rotating electric machine and a rotating electric machine that achieve improved insulation, reduced costs, and miniaturization.

[0005] a stator for a rotating electric machine and a rotating electric machine comprising a core, a plurality of slots formed in the core, and a plurality of conductors inserted into the plurality of slots and arranged side by side in the radial direction of the core, wherein the plurality of conductors comprise two straight portions that are inserted into the slots and a turn portion connecting ends of the two straight portions, and the turn portion comprises two inclined portions that face each other and are inclined in the circumferential direction, and an apex portion that connects ends of the two inclined portions and is formed so as to protrude axially outward from the core, the conductors include a first conductor and a second conductor that is in phase with the first conductor, the first conductor having a first inclination angle that is an inclination angle formed by the inclined portions with respect to a surface of the core into which the first conductor is inserted, the first inclination angle being the same angle as the second conductor, and the second conductor having a second inclination angle that is an inclination angle formed by the inclined portions with respect to a surface of the core into which the second conductor is inserted, the second inclination angle being the same angle as the first conductor, the first inclination angle being greater than the second inclination angle.

[0006] It is possible to provide a stator for a rotating electric machine and a rotating electric machine that achieve improved insulation, reduced cost, and miniaturization.

[0007] 1 is a perspective view of an entire stator of a rotating electrical machine according to one embodiment of the present invention, and a partially enlarged view thereof; 2 is a diagram showing the inclination angle of the coils in the stator according to one embodiment of the present invention; 3 is a diagram explaining the configuration of the coils in the slots according to one embodiment of the present invention; 4 is a diagram explaining the interphase distance of the coils according to one embodiment of the present invention;

[0008] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The following description and drawings are examples for explaining the present invention, and some omissions and simplifications have been made as appropriate for clarity of explanation. The present invention can be implemented in various other forms. Unless otherwise specified, each component may be singular or plural.

[0009] In order to facilitate understanding of the invention, the position, size, shape, range, etc. of each component shown in the drawings may not represent the actual position, size, shape, range, etc. Therefore, the present invention is not necessarily limited to the position, size, shape, range, etc. disclosed in the drawings.

[0010] (One embodiment and overall configuration) (Fig. 1) Fig. 1(a) is an overall perspective view of a stator of a rotating electric machine, and Fig. 1(b) is a diagram showing details of conductors inserted into the stator of the rotating electric machine of Fig. 1(a). The stator 1 of the rotating electric machine has a stator core 3 and coils 2. Parts of the coils 2, which are conductors, are inserted into a plurality of slots 9 formed in the stator core 3 and are arranged side by side in the radial direction of the stator core 3. Coil ends 2a, which are portions of the coils 2 that are not inserted into the slots 9, are exposed axially outside the stator core 3. The coil ends 2a have a top portion 8, which will be described later, and are provided with a bent portion 11 that is bent radially at the top portion 8.

[0011] (Figs. 2 and 3) Fig. 2(a) is an overall perspective view illustrating two conductors with different inclination angles and slot pitches inserted into a stator core 3 according to one embodiment of the present invention, and Fig. 2(b) is a detailed view illustrating the configuration of Fig. 2(a). The coil 2 has a first conductor 4 and a second conductor 5 with different inclination angles and slot pitches. The first conductor 4 and the second conductor 5 are in phase.

[0012] Each of the first conductor 4 and the second conductor 5 has two straight portions 2b that are inserted into the slots 9, and a turn portion 6 that connects the ends of the two straight portions 2b. The turn portion 6 has two inclined portions 7 that face each other and are inclined in the circumferential direction, and an apex portion 8 that connects the ends of the two inclined portions 7 and is formed to protrude axially outward from the stator core 3.

[0013] The first conductor 4 has two inclination angles formed by the inclined portion 7 with respect to the surface of the stator core 3 into which the first conductor 4 is inserted, which are the same. This inclination angle is referred to as the inclined portion angle α1. Similarly, the second conductor 5 has two inclination angles formed by the inclined portion 7 with respect to the surface of the stator core 3 into which the second conductor 5 is inserted, which are the same. This inclination angle is referred to as the inclined portion angle α2. Configuring the first conductor 4 and the second conductor 5 to have the same inclination angle facilitates conductor molding, thereby reducing the amount of copper used and contributing to cost reduction. Note that the inclination angles of the first conductor 4 and the second conductor 5 may be approximately the same.

[0014] In conventional configurations, the inclined portion angle α1 and the inclined portion angle α2 are the same, but in the configuration of the present invention, the inclined portion angle α1 is larger than the inclined portion angle α2. As a result, the height of the top 8 of the second conductor 5 is lower than the height of the top 8 of the second conductor 5 in the conventional configuration, which contributes to miniaturization.

[0015] Furthermore, the first slot pitch P1, which is the slot pitch between the straight portions 2 b in the first conductor 4, is smaller than the second slot pitch P2, which is the slot pitch between the straight portions 2 b in the second conductor 5. In this way, while forming a circuit of the stator 1 having a wave winding structure, the angle of the inclined portion of each coil 2 can be changed for each slot pitch as described above, thereby realizing miniaturization of the stator 1 of the rotating electric machine.

[0016] In the stator core 3, the m-th layer from the radially outer side is referred to as the first layer Lm, and the n-th layer from the radially outer side of the stator is referred to as the second layer Ln. One of the two straight portions 2b in the first conductor 4 and one of the two straight portions 2b in the second conductor 5 are inserted into the first layer Lm of the slot 9. Furthermore, the other of the two straight portions 2b in the first conductor 4 and the other of the two straight portions 2b in the second conductor 5 are inserted into the second layer Ln of the slot 9. Therefore, as shown in the figure, the relational expression m = n + 1 holds. Although not shown, the relational expression m = n - 1 also holds.

[0017] This allows for the formation of a stator 1 circuit having a wave winding structure with a high space factor for the coil 2. Furthermore, by having the two straight portions 2b penetrate different layers of the slot 9, the space factor for the coil 2 within the slot 9 is improved, enabling higher output. Furthermore, no resistance, inductance, or phase difference occurs within the same layer of the slot 9.

[0018] 3 may be applied to only some of the coils 2 inserted into the stator core 3, or may be applied to all of the coils 2 inserted into the stator core 3. By applying the above-described configuration to all of the coils 2 inserted into the stator core 3, it is possible to form a 2Y-connected or 4Y-connected wave winding in the stator core 3.

[0019] (Fig. 4) The interphase distance between coils in the configuration of the present invention will be described. In Fig. 4, the U-phase, V-phase, and W-phase coils are inserted into slots in the stator core 3. The U-phase conductor group consists of U-phase first conductors 20a and U-phase second conductors 20b, the V-phase conductor group consists of V-phase first conductors 21a and V-phase second conductors 21b, and the W-phase conductor group consists of W-phase first conductors 22a and W-phase second conductors 22b.

[0020] Just as the inclination angle of the first conductor 20a is larger than that of the second conductor 20b in the U-phase, the inclination angle of the U-phase first conductor 20a is larger than that of the V-phase second conductor 21b, which is a different phase adjacent to the U-phase first conductor 20a. This allows the interphase distance 10 between the top portion 8 of the U-phase first conductor 20a and the V-phase second conductor 21b to be greater than in the past. Furthermore, this configuration ensures an insulation distance between different phases with a large potential difference at the top portion 8, which is a portion of the coil that is bent and has poor insulation due to the thin enamel, thereby improving insulation, and allows a circuit to be formed without interference between different phase coils.

[0021] The relationship between the top 8 of the V-phase first conductor 21a and the W-phase second conductor 22b of a different phase adjacent to the V-phase first conductor 21a is similar to that described above.The relationship between the top 8 of the W-phase first conductor 22a and the U-phase second conductor 20b of a different phase adjacent to the W-phase first conductor 22a is similar to that described above.

[0022] (First Modification, Second Modification) (FIG. 5) FIG. 5(a) shows the first modification, and FIG. 5(b) shows the second modification. In FIG. 5(a), when one of the U, V, and W phases is configured with three conductors, the inclination angle of one first conductor 4 of the three conductors of the same phase is larger than the inclination angle of two second conductors 5a and 5b that have the same shape, thereby reducing the height of the coil end. Also, in FIG. 5(b), when one of the U, V, and W phases is configured with four conductors, the inclination angle of one first conductor 4 of the four conductors of the same phase is larger than the inclination angle of three second conductors 5a to 5c that have the same shape, thereby reducing the height of the coil end.

[0023] (Third Modification, Fourth Modification) (Fig. 6) Fig. 6(a) and Fig. 6(b) are modifications of the arrangement of the coil 2 shown in Fig. 3. In the stator core 3, the first layer Lm is the mth layer from the radially outer side, the second layer Ln1 is the n1th layer from the radially outer side, and the third layer Ln2 is the n2th layer from the radially outer side. The first layer Lm, the second layer Ln1, and the third layer Ln2 are different layers. The relationship between the first slot pitch P1, which is the slot pitch between the straight portions 2b in the first conductor 4, and the second slot pitch P2, which is the slot pitch between the straight portions 2b in the second conductor 5, is the same as in Fig. 3.

[0024] One of the two straight line portions 2b in the first conductor 4 and one of the two straight line portions 2b in the second conductor 5 are inserted in the first layer Lm of the slot 9. The other of the two straight line portions 2b in the first conductor 4 is inserted in the second layer Ln1 of the other slot 9. The other of the two straight line portions 2b in the second conductor 5 is inserted in the third layer Ln2 of the other slot 9. That is, as shown in FIG. 6(a), the relational expressions m=n1-1, m=n2+1 hold. As shown in FIG. 6(b), the relational expressions m=n1+1, m=n2-1 hold.

[0025] This allows for the formation of a stator 1 circuit having a wave winding structure with a high space factor for the coil 2. Furthermore, by having the two straight portions 2b penetrate different layers of the slot 9, the space factor for the coil 2 within the slot 9 is improved, enabling higher output. Furthermore, no resistance, inductance, or phase difference occurs within the same layer of the slot 9.

[0026] It is also possible to apply a configuration in which the configuration shown in Fig. 3 is a part of the arrangement of the coils 2 in the stator core 3, and the configuration shown in Fig. 6 is the other part of the arrangement of the coils 2 in the stator core 3. In this case, the proportion of the area of ​​the stator core 3 where the arrangement of the coils 2 is shown in Fig. 3 is larger than the proportion of the area of ​​the arrangement of the coils 2 shown in Fig. 6. This allows a 2Y-connected wave winding to be formed in the stator core 3.

[0027] According to the embodiment of the present invention described above, the following advantageous effects are achieved.

[0028] (1) A stator 1 for a rotating electric machine includes a core 3, a plurality of slots 9 formed in the core 3, and a plurality of conductors 2 inserted into the plurality of slots 9 and arranged side by side in the radial direction of the core 3, wherein the plurality of conductors 2 include two straight portions 2b that are inserted into the slots 9 and a turn portion 6 that connects the ends of the two straight portions 2b, and the turn portion 6 includes two inclined portions 7 that face each other and are inclined in the circumferential direction, and a turn portion 6 that connects the ends of the two inclined portions 7 and is extended from the core 3. and a top portion 8 formed to protrude axially outward from the top portion 8, the conductor 2 including a first conductor 4 and a second conductor 5 in phase with the first conductor 4, the first conductor 4 having a first inclination angle α1, which is an inclination angle formed by the inclined portion 7 with respect to a surface of the core 3 into which the first conductor 4 is inserted, and the first and second conductors having a second inclination angle α2, which is an inclination angle formed by the inclined portion 7 with respect to a surface of the core 3 into which the second conductor 5 is inserted, and the second conductors having a second inclination angle α2, which is an inclination angle formed by the inclined portion 7 with respect to the surface of the core 3 into which the second conductor 5 is inserted, and the first inclination angle α1 is larger than the second inclination angle α2. This makes it possible to provide a stator 1 for a rotating electric machine that achieves improved insulation, reduced cost, and miniaturization.

[0029] (2) The first slot pitch P1, which is the slot pitch between the straight portions 2 b in the first conductor 4, is smaller than the second slot pitch P2, which is the slot pitch between the straight portions 2 b in the second conductor 5. In this way, a stator circuit with a wave winding structure can be formed in the stator 1 of the rotating electric machine.

[0030] (3) One of the two straight portions 2 b in the first conductor 4 and one of the two straight portions 2 b in the second conductor 5 are inserted into the first layer Lm of the slot 9, and the other of the two straight portions 2 b in the first conductor 4 and the other of the two straight portions 2 b in the second conductor 5 are inserted into the second layer Ln of the slot 9, the first layer Lm and the second layer Ln being adjacent layers within the slot 9. In this way, a stator circuit with a wave winding structure can be formed in the stator 1 of a rotating electric machine having a high conductor space factor.

[0031] (4) The top portion 8 has a bent portion that is bent in the radial direction. This allows a circuit to be formed in the stator 1 of the rotating electric machine without interfering with the conductor 2.

[0032] (5) One of the two straight portions 2b in the first conductor 4 and one of the two straight portions 2b in the second conductor 5 are inserted into the first layer Lm of the slot 9, the other of the two straight portions 2b in the first conductor 4 is inserted into the second layer Ln1 of the slot 9, the other of the two straight portions 2b in the second conductor 5 is inserted into the third layer Ln2 of the slot 9, the first layer Lm and the second layer Ln1 are adjacent layers within the slot 9, the first layer Lm and the third layer Ln2 are adjacent layers within the slot 9, and the first layer Lm, the second layer Ln1, and the third layer Ln2 are different layers within the slot 9. In this way, a circuit of the stator 1 can be formed that has a wave winding structure with a high space factor of the coil 2.

[0033] (6) A portion of the first conductor 4 and the second conductor 5, namely, one of the two straight portions 2 b in the first conductor 4 and one of the two straight portions 2 b in the second conductor 5, is inserted into the first layer Lm of the slot 9, and the other of the two straight portions 2 b in the first conductor 4 and the other of the two straight portions 2 b in the second conductor 5 are inserted into the second layer Ln of the slot 9, and the first layer Lm and the second layer Ln are adjacent layers within the slot 9. Furthermore, with regard to the other portions of the first conductor 4 and the second conductor 5, one of the two straight portions 2b in the first conductor 4 and one of the two straight portions 2b in the second conductor 5 are inserted into the first layer Lm of the slot 9, the other of the two straight portions 2b in the first conductor 4 is inserted into the second layer Ln of the slot 9, and the other of the two straight portions 2b in the second conductor 5 is inserted into the third layer Ln2 of the slot 9, the first layer Lm and the second layer Ln1 are adjacent layers within the slot 9, the first layer Lm and the third layer Ln2 are adjacent layers within the slot 9, and the first layer Lm, the second layer Ln1, and the third layer Ln2 are different layers within the slot 9. In this manner, a 2Y-connected wave winding can be formed in the stator core 3.

[0034] (7) For all of the first conductors 4 and the second conductors 5, one of the two straight portions 2b in the first conductor 4 and one of the two straight portions 2b in the second conductor 5 are inserted into the first layer Lm of the slot 9, and the other of the two straight portions 2b in the first conductor 4 and the other of the two straight portions 2b in the second conductor 5 are inserted into the second layer Ln of the slot 9, with the first layer Lm and the second layer Ln being adjacent layers within the slot 9. In this way, a 2Y-connected or 4Y-connected wave winding can be formed in the stator core 3.

[0035] (8) A rotating electric machine comprising a core 3, a plurality of slots 9 formed in the core 3, and a plurality of conductors 2 inserted into the plurality of slots 9 and arranged side by side in the radial direction of the core 3, wherein the plurality of conductors 2 comprise two straight portions 2b that are inserted into the slots 9 and a turn portion 6 that connects the ends of the two straight portions 2b, and the turn portion 6 comprises two inclined portions 7 that face each other and are inclined in the circumferential direction, and a turn portion 6 that connects the ends of the two inclined portions 7 and extends from the core 3 in the axial direction. and a top portion 8 formed to protrude outward, the conductor 2 includes a first conductor 4 and a second conductor 5 that is in phase with the first conductor 4, the first conductor 4 has a first inclination angle α1, which is an inclination angle formed by the inclined portion 7 with respect to the surface of the core 3 into which the first conductor 4 is inserted, and the first and second conductors 5 have a second inclination angle α2, which is an inclination angle formed by the inclined portion 7 with respect to the surface of the core 3 into which the second conductor 5 is inserted, and the ... first inclination angle α1 is larger than the second inclination angle α2. This makes it possible to provide a rotating electric machine that achieves improved insulation, cost reduction, and miniaturization.

[0036] The present invention is not limited to the above-described embodiments, and various modifications and combinations of other configurations are possible without departing from the spirit of the present invention. Furthermore, the present invention is not limited to those having all of the configurations described in the above-described embodiments, and includes those in which some of the configurations are omitted.

[0037] DESCRIPTION OF SYMBOLS 1 stator 2 coil 2a coil end 2b straight portion 3 stator core 4 first conductor 5 second conductor 6 turn portion 7 inclined portion 8 top portion 8a U-phase first conductor top portion 9 slot 10 interphase distance 11 bent portion 20 U-phase conductor 20a U-phase first conductor 20b U-phase second conductor 21 V-phase conductor 21a V-phase first conductor 21b V-phase second conductor 22 W-phase conductor 22a W-phase first conductor 22b W-phase second conductor P1 first slot pitch P2 second slot pitch Lm first layer Ln, Ln1 second layer Ln2 third layer α1 first inclined portion angle α2 second inclined portion angle

Claims

1. A stator for a rotating electric machine comprising: a core; a plurality of slots formed in the core; and a plurality of conductors inserted into the plurality of slots and arranged side by side in the radial direction of the core, wherein the plurality of conductors comprise two straight portions that are inserted into the slots and a turn portion connecting ends of the two straight portions, and the turn portion comprises two inclined portions that face each other and are inclined in the circumferential direction, and an apex portion that connects ends of the two inclined portions and is formed so as to protrude axially outward from the core, the conductors include a first conductor and a second conductor that is in phase with the first conductor, the first conductor has a first inclination angle that is an inclination angle formed by the inclined portions with respect to a surface of the core into which the first conductor is inserted, the first inclination angle being the same angle as the second conductor, and the second conductor has a second inclination angle that is an inclination angle formed by the inclined portions with respect to a surface of the core into which the second conductor is inserted, the second inclination angle being the same angle as the first conductor, and the first inclination angle is greater than the second inclination angle.

2. A stator for a rotating electric machine according to claim 1, wherein a first slot pitch, which is the slot pitch between the straight portions of the first conductor, is smaller than a second slot pitch, which is the slot pitch between the straight portions of the second conductor.

3. A stator for a rotating electric machine as described in claim 1, wherein one of the two straight portions in the first conductor and one of the two straight portions in the second conductor are inserted into a first layer of the slot, the other of the two straight portions in the first conductor and the other of the two straight portions in the second conductor are inserted into a second layer of the slot, and the first layer and the second layer are adjacent layers within the slot.

4. A stator for a rotating electric machine according to claim 1, wherein the top portion has a bent portion that is bent in the radial direction.

5. A stator for a rotating electric machine according to claim 1, wherein one of the two straight portions in the first conductor and one of the two straight portions in the second conductor are inserted into a first layer of the slot, the other of the two straight portions in the first conductor is inserted into a second layer of the slot, and the other of the two straight portions in the second conductor is inserted into a third layer of the slot, the first layer and the second layer are adjacent layers within the slot, the first layer and the third layer are adjacent layers within the slot, and the first layer, the second layer, and the third layer are different layers within the slot.

6. A stator for a rotating electric machine according to claim 5, wherein a portion of the first conductor and the second conductor is such that one of the two straight portions in the first conductor and one of the two straight portions in the second conductor are inserted into the first layer of the slot, and the other of the two straight portions in the first conductor and the other of the two straight portions in the second conductor are inserted into the second layer of the slot, the first layer and the second layer being adjacent layers within the slot; With respect to other portions of the first conductor and the second conductor, one of the two straight portions in the first conductor and one of the two straight portions in the second conductor are inserted into the first layer of the slot, the other of the two straight portions in the first conductor is inserted into the second layer of the slot, and the other of the two straight portions in the second conductor is inserted into the third layer of the slot, the first layer and the second layer are layers adjacent to each other within the slot, and the first layer, the second layer, and the third layer are layers different from each other within the slot.

7. A stator for a rotating electric machine according to claim 3, wherein, for all of the first conductors and the second conductors, one of the two straight portions in the first conductor and one of the two straight portions in the second conductor are inserted into the first layer of the slot, and the other of the two straight portions in the first conductor and the other of the two straight portions in the second conductor are inserted into the second layer of the slot, and the first layer and the second layer are adjacent layers within the slot.

8. A rotating electric machine comprising: a core; a plurality of slots formed in the core; and a plurality of conductors inserted into the plurality of slots and arranged side by side in the radial direction of the core, wherein the plurality of conductors comprise two straight portions that are inserted into the slots and a turn portion connecting ends of the two straight portions, and the turn portion comprises two inclined portions that face each other and are inclined in the circumferential direction, and an apex portion that connects ends of the two inclined portions and is formed so as to protrude axially outward from the core, the conductors include a first conductor and a second conductor that is in phase with the first conductor, the first conductor has a first inclination angle that is the same inclination angle formed by the inclined portions with respect to a surface of the core into which the first conductor is inserted, and the second conductor has a second inclination angle that is the same inclination angle formed by the inclined portions with respect to a surface of the core into which the second conductor is inserted, and the first inclination angle is greater than the second inclination angle.

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