The disclosure of Japanese Patent Application No. 2008-273106 filed on Oct. 23, 2008 including the specification, drawings and abstract is incorporated herein by reference in its entirety.
The present invention relates to a rotating electrical machine including a stator formed by disposing coils of a plurality of phases in slots of a stator core, and a rotor rotatably disposed on the inner peripheral side of the stator.
For example, in a stator for use in a rotating electrical machine, three-phase coils of U-phase, V-phase, and W-phase are disposed in a stator core by using jigs for holding and inserting the three-phase coils on the inner peripheral side of the stator core. After the three-phase coils are disposed in a plurality of slots of the stator core, a coil end conductor portion, which protrudes from an axial end face of the stator core, is deformed radially outward of the stator core.
In a stator manufacturing method of Japanese Patent No. 2523933, first, a coil, which has mountain-shaped front-side coil end portions that are located inside the inner diameter of a stator core, slot coil portions that are disposed in the slots, and mountain-shaped rear-side coil end portions, is formed before the coil is wound up onto the stator core. Moreover, relay coil portions, which are bent inward, are formed between the front-side coil end portions and the slot coil portions. Then, after the coil is inserted from an end face of the stator core from the relay coil portions, and insertion of the coil into the stator core is finished, the front-side coil end portions are deformed outward of the inner diameter of the core.
Thus, the coil can be formed in advance in the inserted shape into the core, and can be inserted into the stator core, whereby deformation of the coil can be prevented when the coil is inserted into the stator core.
In Japanese Patent No. 2523933, however, the front-side coil end portions of the coil are deformed outward of the inner diameter of the core after the coil is inserted into the stator core. Thus, although the coil is not deformed when inserted into the stator core, deforming the coil after insertion into the stator core may degrade a conductor portion or an insulating coating in the deformed portion.
Moreover, if the front-side coil end portions are not deformed outward of the inner diameter of the stator core, and thus, are kept located inward of the core inner diameter, the possibility that the conductor portion or the insulating coating of the front-side coil end portions is degraded is eliminated, but the front-side coil end portions are located close to the rotor. Moreover, if a rotation position detector (e.g., a resolver) for detecting the rotation position of the rotor is disposed on the inner peripheral side of the front-side coil end portions, noise generated in the front-side coil end portions may reduce the detection accuracy of the rotation position detector. In order to solve this problem, it is possible to dispose the rotation position detector away from the front-side coil end portions. However, this increases the size of the rotating electrical machine accordingly as the rotation position detector is located away from the front-side coil end portions.
The present invention has been developed in view of the above problem of the related art, and it is an object of the present invention to provide a rotating electrical machine whose size can be reduced while being capable of accurately detecting the rotation position of a rotor.
A rotating electrical machine according to a first aspect of the present invention includes a stator formed by disposing coils of a plurality of phases in a plurality of slots formed along an axial direction of a stator core, and a rotor rotatably provided on an inner peripheral side of the stator, and is characterized in that the coils of the plurality of phases are disposed so that, in the slots of the same phase, a plurality of coil conductors of the same phase are arranged adjacent to each other in a radial direction of the stator core, in one end-side coil end portion that protrudes from one axial end face of the stator core, the plurality of coil conductors of the same phase are arranged on a radially outer peripheral side of an inner peripheral end face of the stator core, and in the other end-side coil end portion that protrudes from the other axial end face of the stator core, the plurality of coil conductors of the same phase are arranged on a radially inner peripheral side of the inner peripheral end face of the stator core. Further, the rotating electrical machine according to the first aspect is also characterized in that a rotation position detector for detecting a rotation position of the rotor is disposed on the one axial end side of the stator core.
In the rotor in the rotating electrical machine according to the first aspect of the present invention, the rotation position detector for detecting the rotation position of the rotor is disposed on the one axial end side of the stator core. In the case where the rotation position detector is disposed on the other axial end side of the rotor, the other end-side coil end portion and the rotation position detector are located close to each other. Thus, noise is superimposed on the rotation position detector, thereby reducing the detection accuracy. In this case, if the rotation position detector is disposed so as to avoid interference with the other end-side coil end portion, the axial dimension of the rotating electrical machine is increased.
On the other hand, by disposing the rotation position detector on the one axial end side of the rotor, the one end-side coil end portion and the rotation position detector can be disposed away from each other. This can suppress reduction in detection accuracy of the rotation position by the rotation position detector, and can prevent increase in axial dimension of the rotating electrical machine.
Thus, by disposing the rotation position detector on the one axial end side of the stator core, the axial dimension of the rotating electrical machine can be maintained at a small value while accurately detecting the rotation position of the rotor.
A preferred embodiment of the present invention described above will be described below.
In the present invention, the rotating electrical machine can be used as a motor, a generator, and a motor-generator.
Moreover, the coils of the plurality of phases can be formed by using rectangular conductors having a substantially quadrangular cross section, rectangular conductors having a flat cross section, and the like. Moreover, the coils of the plurality of phases can be formed by rectangular conductors that are produced by forming an insulating coating, made of an insulating resin or the like, on the entire periphery of a conductor portion made of copper or the like.
Moreover, it is preferable that the rotation position detector be disposed on an inner peripheral side of the one end-side coil end portion so as to axially overlap the one end-side coil end portion.
In this case, the rotation position detector can be disposed inside the space located on the inner peripheral side of the one end-side coil end portion, whereby the axial dimension of the rotating electrical machine can further be reduced.
Moreover, it is preferable that the rotation position detector be a resolver that is formed by a resolver rotor connected to the rotor, and a resolver stator disposed so as to face an outer peripheral side of the resolver rotor.
In this case, the resolver as the rotation position detector can be easily disposed while maintaining the reduced size of the rotating electrical machine.
An embodiment of a rotating electrical machine of the present invention will be described below in detail with reference to the accompanying drawings.
As shown in
As shown in
The rotating electrical machine 1 of the present embodiment will be described below with reference to
As shown in
Moreover, the three-phase coils 3U, 3V, and 3W are structured by using rectangular conductors 301 which are produced by forming an insulating coating, such as an insulating resin, on the entire periphery of a conductor portion (a conductor base material) made of copper or the like. The rectangular conductors 301 have a substantially quadrangular cross section.
As shown in
As shown in
The circumferential conductor portions 322 are formed in a circular arc shape along the circumferential direction C of the stator core 2 in the one end-side coil end portion 30A and the other end-side coil end portion 30B. Moreover, the circumferential conductor portions 322 may be formed in a linear shape in the other end-side coil end portion 30B.
As shown in
As shown in
The three-phase coils 3U, 3V, and 3W of the present embodiment use sets of two coil conductors 4 which are arranged adjacent to each other in the radial direction R in the same slot 21, where every two sets of two coil conductors 4 are arranged adjacent to each other in the same slot 21 in the radial direction R of the stator core 2. Thus, in each slot 21, the four coil conductors 4 of the same phase are arranged adjacent to each other in the radial direction R. Similarly, four coil conductors 4 are arranged adjacent to each other in the radial direction R in each of the slots 21 of the same phase which are adjacent to each other.
As shown in
In the three-phase coils 3U, 3V, and 3W, sets of two coil conductors 4 of the same phase are arranged adjacent to each other in the radial direction R of the stator core 2 in each of adjacent slots 21 of the same phase. Moreover, in each of adjacent slots 21 of the same phase, another set of two coil conductors 4 of the same phase are arranged adjacent to each other on the radially inner peripheral side R1 of a set of two coil conductors 4 of the same phase.
Moreover, in the one end-side coil end portion 30A in the three-phase coils 3U, 3V, and 3W, sets of two coil conductors 4 of the same phase, which are disposed in each slot 21 of the same phase, are arranged adjacent to each other in the axial direction L of the stator core 2. Moreover, sets of two coil conductors 4 of the same phase, which are disposed in adjacent slots 21 of the same phase, are arranged in four lines in the axial direction L of the stator core 2.
Note that the sets of two coil conductors 4 of the same phase, which are disposed in adjacent slots 21 of the same phase, may be formed integrally by winding one continuous rectangular conductor 301 around the circumferential direction C of the stator core 2 four times.
Moreover, as shown in
Moreover, in the other end-side coil end portion 30B, of two coil conductors 4 of the same phase which are disposed adjacent to each other in the radial direction R of the stator core 2 in each slot 21 of the same phase, one coil conductor 4A is bent toward the radially inner peripheral side R1 of the stator core 2 in a state perpendicular to the axial direction L of the stator core 2. The other coil conductor 4B is bent toward the radially inner peripheral side R1 of the stator core 2, and is offset with respect to the axial direction L of the stator core 2 so that the other coil conductor 4B is arranged adjacent to the one coil conductor 4A in the radial direction R of the stator core 2.
As shown in
In each radial conductor portion 323 between the bent corner conductor portion 321 and the circumferential conductor portion 322, arrangement of the coil conductors 4 changes from the state where the two coil conductors 4 are arranged adjacent to each other in the axial direction L of the stator core 2 in the bent corner conductor portion 321, to the state where the two coil conductors 4 are arranged adjacent to each other in the radial direction R.
The coil conductors 4 of the three-phase coils 3U, 3V, and 3W are arranged so as to extend from two adjacent slots 21 of the same phase (the first slot set S1) to two slots 21 of the same phase which are adjacent to the two slots 21 of the same phase in the circumferential direction C (the second slot set S2).
As shown in
Moreover, as shown in
Before assembly in the stator core 2, in the three-phase coils 3U, 3V, and 3W of the present embodiment, similar to the one end-side coil end portion 30A, the coil conductors 4 are formed in parallel to the axial direction L, shaped in a wave winding shape around the circumferential direction C, and then, bent to the inner peripheral side of the radial direction R so as to form the other end-side coil end portion 30B.
Moreover, as shown in
As shown in
As shown in
The stator core 2 and the rotor core 62 are formed by stacking a multiplicity of electromagnetic steel plates in the axial direction. Moreover, end plates 63 for maintaining the stacked state of the multiplicity of electromagnetic steel plates are provided on both axial end faces of the rotor core 62. An outer peripheral portion in the circumferential direction of the end plate 63 located on the other axial end side has a cut-out shape for preventing interference with the coil conductors 4 of the other end-side coil end portion 30B.
Moreover, as shown in
Advantageous effects of the rotating electrical machine 1 of the present embodiment will next be described.
The rotating electrical machine 1 of the present embodiment facilitates disposition of the three-phase coils 3U, 3V, and 3W in the stator core 2 by devising the shape of the other end-side coil end portion 30B, and also, eliminates the need to further form the three-phase coils 3U, 3V, and 3W after disposed in the stator coil 2.
More specifically, in the stator 10 of the present embodiment, the one end-side coil end portion 30A is bent to the radially outer peripheral side R2 of the stator core 2 in advance before disposed in the stator core 2, as in the related art. Thus, the one end-side coil end portion 30A can be shaped so as to be entirely located on the radially outer peripheral side R2 of the inner peripheral end face 221 in teeth 22 (portions located between the slots 21). Note that the coil end conductor portions 32 located in the one end-side coil end portion 30A can be formed so as to be bent toward the radially outer peripheral side R2. Thus, as shown in
Moreover, the other end-side coil end portion 30B is bent to the radially inner peripheral side R1 of the stator core 2 in advance before disposed in the stator core 2. Thus, the other end-side coil end portion 30B is shaped so as to be entirely located on the radially inner peripheral side R1 of an outer peripheral end face 211 in the slots 21. Therefore, as shown in
Moreover, in the three-phase coils 3U, 3V, and 3W, a plurality of coil conductors 4 of the same phase are arranged adjacent to each other in the radial direction R of the stator core 2, in the other end-side coil end portion 30B. Thus, the amount by which the other end-side coil end portion 30B protrudes from the other axial end face 201B of the stator core 2 can be reduced on the other end side in the axial direction L of the stator 10.
Thus, the coil end portion 30B located on the other axial end face 201B side in the stator 10 can be reduced in size in the axial direction L.
Moreover, in the stator 10 of the present embodiment, the one end-side coil end portion 30A and the other end-side coil end portion 30B can be formed in an assembled shape in advance before disposed in the stator core 2. Both coil end potions 30A and 30B after assembled in the stator core 2 can be used as a product almost in the shape as they are disposed in the stator core 2, without performing any forming processes such as a bending forming process and a compression forming process. Thus, the insulating coatings formed on the surfaces of the coil conductors 4 of coils 3 are hardly destroyed or degraded. Therefore, quality of the stator can be improved according to the stator 10 of the present embodiment.
Moreover, as shown in
Moreover, in the rotor 6 in the rotating electrical machine 1 of the present embodiment, the rotation position detector 7 for detecting the rotation position of the rotor 6 is disposed on the rotor shaft 61 at a position on the inner peripheral side of the one end-side coil end portion 30A, as described above.
In the case where the rotation position detector 7 is disposed on the other axial end side of the rotor shaft 61, the other end-side coil end portion 30B and the rotation position detector 7 are located close to each other. Thus, noise is superimposed on the rotation position detector 7, thereby reducing the detection accuracy. In this case, if the rotation position detector 7 is disposed so as to avoid interference with the other end-side coil end portion 30B, the axial dimension of the rotating electrical machine 1 is increased.
On the other hand, by disposing the rotation position detector 7 on the one axial end side of the rotor shaft 61, the one end-side coil end portion 30A and the rotation position detector 7 can be disposed away from each other. This can suppress reduction in detection accuracy of the rotation position by the rotation position detector 7, and can prevent increase in axial dimension of the rotating electrical machine 1.
Thus, by disposing the rotation position detector 7 on the one axial end side of the stator core 2, the axial dimension of the rotating electrical machine 1 can be maintained at a small value while accurately detecting the rotation position of the rotor 6.
Thus, according to the present embodiment, the three-phase coils 3U, 3V, and 3W can be easily disposed in the stator core 2, high quality of the three-phase coils 3U, 3V, and 3W can be maintained, and the size of the rotating electrical machine 1 can be reduced while accurately detecting the rotation position of the rotor 6.
Number | Date | Country | Kind |
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2008-273106 | Oct 2008 | JP | national |