Patent Application
20240128808
The present application is based on and claims priority from Japanese Patent Application No. 2022-165785 filed on Oct. 14, 2022, Japanese Patent Application No. 2023-090354 filed on May 31, 2023, and Japanese Patent Application No. 2023-173141 filed on Oct. 4, 2023. The entire contents of these applications are incorporated by reference into the present application.
The present disclosure relates to stators for rotating electric machines.
Conventionally, stators for rotating electric machines have been known which include a stator core formed of a straight core. Specifically, the straight core is formed by laminating a plurality of core sheets. Each of the core sheets has a band-shaped back yoke extending straight, a plurality of teeth each protruding from a long side portion of the back yoke, and a plurality of V-shaped notches each of which is formed in the long side portion of the back yoke so as to be located between an adjacent pair of the teeth. Further, the straight core is bent, at the notches, into a ring shape, thereby forming the stator core.
According to the present disclosure, there is provided a first stator for a rotating electric machine. The first stator includes a stator core and a stator coil. The stator core is formed of a band-shaped steel sheet that is helically bent and laminated. The stator core has a plurality of slots each opening at an inner periphery of the stator core and spaced from one another in a circumferential direction. The stator coil is formed of a plurality of electrical conductor segments. The electrical conductor segments have respective leg portions inserted in the slots of the stator core and connected with one another. In the band-shaped steel sheet, for each of at least some of the slots, there is formed at least one slit, at a position corresponding to the slot, to be open to the slot. At one or more locations in the first stator, a pair of the leg portions of the electrical conductor segments are connected with each other across at least one of those slots for each of which the at least one slit is formed to be open to the slot.
According to the present disclosure, there is also provided a second stator for a rotating electric machine. The second stator includes a stator core and a stator coil. The stator core is formed of a band-shaped steel sheet that is helically bent and laminated. The stator core has a plurality of slots each opening at an inner periphery of the stator core and spaced from one another in a circumferential direction. The stator coil is formed of a plurality of electrical conductor segments that are inserted in the slots of the stator core and connected with one another. Moreover, the band-shaped steel sheet has a plurality of slits each of which is formed, at a position corresponding to one of the slots, to be open to the corresponding slot. Each of the electrical conductor segments is substantially U-shaped and has a pair of leg portions respectively inserted in corresponding two of the slots of the stator core; the corresponding two slots are circumferentially apart from each other by two or more slot-pitches.
In the above-described conventional stators (see, for example, Japanese Patent No. JP3681487B2), due to springback of the straight core, side surfaces (or mating surfaces) of each of the notches which face each other may become separated from each other, thereby lowering magnetic properties of the stator core. Here, springback of the straight core denotes the tendency of the straight core, which has been bent at the notches into a ring shape, to revert to its original straight shape.
The present disclosure has been accomplished in view of the above problem with the conventional stators.
With the configuration of the above-described first stator according to the present disclosure, when the band-shaped steel sheet is helically bent and laminated to form the stator core, the band-shaped steel sheet can be easily deformed such that a pair of side surfaces (or slit mating surfaces) of each of the at least one slit, which face each other, become closer to each other. However, after the formation of the stator core, the slit mating surfaces may be separated from each other due to springback of the band-shaped steel sheet, thereby lowering magnetic properties of the stator core. Here, springback of the band-shaped steel sheet denotes the tendency of the band-shaped steel sheet, which has been helically bent and laminated to form the stator core, to revert to its original straight shape.
In this regard, at one or more locations in the first stator according to the present disclosure, a pair of the leg portions of the electrical conductor segments are connected with each other across at least one of those slots for each of which the at least one slit is formed to be open to the slot. In general, in the state of being respectively inserted in a pair of the slots of the stator core, the pair of leg portions apply to the stator core forces in the directions of urging the pair of leg portions to approach each other. Consequently, for the at least one slit corresponding to the at least one slot across which the pair of the leg portions of the electrical conductor segments are connected with each other, forces are applied by the pair of the leg portions to urge the slit mating surfaces of each of the at least one slit to become closer to each other. As a result, the slit mating surfaces are suppressed from being separated from each other due to springback of the band-shaped steel sheet.
With the configuration of the above-described second stator according to the present disclosure, when the band-shaped steel sheet is helically bent and laminated to form the stator core, the band-shaped steel sheet can be easily deformed such that a pair of side surfaces (or slit mating surfaces) of each of the slits, which face each other, become closer to each other. However, after the formation of the stator core, the slit mating surfaces may be separated from each other due to springback of the band-shaped steel sheet, thereby lowering magnetic properties of the stator core. Here, springback of the band-shaped steel sheet denotes the tendency of the band-shaped steel sheet, which has been helically bent and laminated to form the stator core, to revert to its original straight shape.
In this regard, in the second stator according to the present disclosure, each of the electrical conductor segments is substantially U-shaped and has the pair of leg portions respectively inserted in the corresponding two slots of the stator core which are circumferentially apart from each other by two or more slot-pitches. In general, in the state of being respectively inserted in the corresponding two slots of the stator core, the pair of leg portions apply to the stator core forces in the directions of urging the pair of leg portions to approach each other. Moreover, each corresponding pair of the leg portions, which respectively belong to two different electrical conductor segments, are joined to each other. In the state of being jointed to each other, each corresponding pair of the leg portions also apply to the stator core forces in the directions of urging the corresponding pair of the leg portions to approach each other. Consequently, for the one or more slits corresponding to the one or more slots sandwiched between a connected or joined pair of the leg portions of the electrical conductor segments, forces are applied by the connected or joined pair of the leg portions to urge the slit mating surfaces of each of the one or more slits to become closer to each other. As a result, the slit mating surfaces are suppressed from being separated from each other due to springback of the band-shaped steel sheet.
In addition, with the above configuration of the second stator according to the present disclosure, between the pair of leg portions of each of the electrical conductor segments, there are interposed one or more slots. Moreover, for each of the slots, there is formed a corresponding one of the slits. Consequently, each of the electrical conductor segments can exert the effect of suppressing separation of the slit mating surfaces for one or more slits.
In further implementations of the first and second stators according to the present disclosure, for each of the slits, a recess may be formed in one of the pair of side surfaces of the slit; and a protrusion may be formed on the other of the pair of side surfaces and press-fitted in the recess. In this case, with engagement between the recess and the protrusion, it will become possible to more effectively suppress separation of the slit mating surfaces (i.e., the pair of side surfaces) from each other.
Simultaneously or alternatively, for each of the slits, a first engagement portion may be formed in one of the pair of side surfaces of the slit; and a second engagement portion may be formed in the other of the pair of side surfaces and engaged with the first engagement portion. In this case, with engagement between the first engagement portion and the second engagement portion, it will become possible to more effectively suppress separation of the slit mating surfaces (i.e., the pair of side surfaces) from each other.
For each of the slits, there may be formed an indentation in an outer edge portion of the band-shaped steel sheet at a position corresponding to an end of the slit on an opposite side to the corresponding slot. In this case, it will become possible to reduce that portion (i.e., outer edge portion) of the band-shaped steel sheet where tensile stress remains; the tensile stress is generated when the band-shaped steel sheet is helically bent and laminated to form the stator core. Consequently, it will become possible to reduce the amount of springback of the band-shaped steel sheet.
Further, the stator core may have a back yoke extending in the circumferential direction and a plurality of teeth extending radially inward from the back yoke and spaced from one another in the circumferential direction. Each of the slots may be formed between a circumferentially-adjacent pair of the teeth. For each of the slits, the end of the slit on the opposite side to the corresponding slot may be located radially outside and in radial alignment with a corresponding one of the teeth. In this case, when magnetic flux flowing through the back yoke in the circumferential direction is blocked by the indentation formed in the outer edge portion of the band-shaped steel sheet, the magnetic flux can be bypassed to that part of the back yoke which is radially interposed between the end of the slit on the opposite side to the corresponding slot and the corresponding tooth, thereby being allowed to continue flowing in the circumferential direction. Consequently, it will become possible to suppress the magnetic properties of the stator core from being lowered due to magnetic saturation.
Each of the number of the slots and the number of the slits may be set to be greater than or equal to 48. In this case, it will become possible to reduce the amount of deformation of the band-shaped steel sheet at the positions corresponding to the slits when the band-shaped steel sheet is helically bent and laminated to form the stator core. Consequently, it will become possible to reduce the force of springback of the band-shaped steel sheet while suppressing the magnetic properties of the stator core from being lowered. Moreover, it will become easy to increase the number of the slots interposed between the pair of leg portions of each of the electrical conductor segments; thus, it will become possible to suppress separation of the slit mating surfaces of each of the slits using more than one electrical conductor segment.
For each of the slits, each of the pair of side surfaces of the slit may be arc-shaped. In this case, when the band-shaped steel sheet is helically bent and laminated to form the stator core, the difference in shape between the slit mating surfaces (i.e., the pair of side surfaces) due to manufacturing tolerances can be easily absorbed by the slit mating surfaces being deformed to change the curvatures thereof. Consequently, the entire slit mating surfaces can be easily brought into intimate contact with each other, thereby improving the magnetic properties of the stator core.
Further, for each of the slits, the pair of side surfaces of the slit may consist of a first side surface and a second side surface that is deformed later than the first side surface when the band-shaped steel sheet is helically bent and laminated to form the stator core. The radius of curvature of the second side surface may be set to be greater than the radius of curvature of the first side surface. In this case, when the band-shaped steel sheet is helically bent and laminated to form the stator core, the second side surface can be deformed in such as manner as to conform to the first side surface. Consequently, the entire slit mating surfaces can be more easily brought into intimate contact with each other, thereby improving the magnetic properties of the stator core.
The stator core may have a polygonal prism shape. A case may be fitted under pressure on an outer periphery of the stator core. In this case, the corner portions of the polygonal prism-shaped stator core will be compressed by the case, thereby reducing the residual tensile stress in the stator core which is caused by the tensile deformation (i.e., bending deformation) of the band-shaped steel sheet. As a result, it will become possible to improve the magnetic properties of the stator core.
The radial positions of outer circumferential surfaces of a plurality of layers of the helically-laminated band-shaped steel sheet may be set to vary in the lamination direction of the band-shaped steel sheet. In this case, it will become possible to increase the area of the radially outer surface of the entire stator core, thereby improving the heat dissipation performance of the stator core.
For each of the slits, there may be formed an indentation in an outer edge portion of the band-shaped steel sheet at a position circumferentially offset from an imaginary line that extends radially outward from the end of the slit on the opposite side to the corresponding slot. In this case, it will become possible to reduce that portion (i.e., outer edge portion) of the band-shaped steel sheet where tensile stress remains; the tensile stress is generated when the band-shaped steel sheet is helically bent and laminated to form the stator core. Consequently, it will become possible to reduce the amount of springback of the band-shaped steel sheet. Moreover, compared to the case of the indentation being formed at a position on the imaginary line, it will become difficult for the band-shaped steel sheet to be broken due to cracks generated at the indentation and reaching the slit.
Simultaneously or alternatively, for each of the slits, there may be formed a protrusion that protrudes radially outward from an outer edge portion of the band-shaped steel sheet at a position corresponding to the end of the slit on the opposite side to the corresponding slot. In this case, it will become possible to increase the radial width of an outer peripheral portion of the back yoke, thereby relaxing stress concentration on the outer peripheral portion due to the bending of the band-shaped steel sheet. Consequently, it will become possible to prevent the outer peripheral portion from being broken due to stress concentration on the outer peripheral portion. Moreover, it will also become possible to suppress reduction in the radial width of the outer peripheral portion of the back yoke when the outer peripheral portion is stretched in the circumferential direction. Here, the outer peripheral portion denotes a portion of the back yoke which extends between the ends of the slits on the opposite side to the corresponding slots and a radially outer edge of the back yoke.
Simultaneously or alternatively, for each of the slits, there may be formed a circumferential slit that extends, from the end of the slit on the opposite side to the corresponding slot, to both sides in the circumferential direction. In this case, it will become possible to expand the area where stress concentration occurs due to the bending of the band-shaped steel sheet to the area where the circumferential slit is formed. Consequently, it will become possible to reduce the average stress in the area where stress concentration occurs due to the bending of the band-shaped steel sheet. As a result, it will become possible to prevent the outer peripheral portion of the back yoke from being broken due to stress concentration on the outer peripheral portion.
Simultaneously or alternatively, for each of the slits, there may be formed a first circular hole at the end of the slit on the opposite side to the corresponding slot. Further, at least one second circular hole may be formed so as to be connected with a portion of the first circular hole which is away from an end of the first circular hole on an opposite side to the slit; the at least one second circular hole is smaller than the first circular hole. In this case, it will become possible to expand the area where stress concentration occurs due to the bending of the band-shaped steel sheet to the area(s) where the at least one second circular hole is formed. Consequently, it will become possible to reduce the average stress in the area where stress concentration occurs due to the bending of the band-shaped steel sheet. As a result, it will become possible to prevent the outer peripheral portion of the back yoke from being broken due to stress concentration on the outer peripheral portion.
Hereinafter, an exemplary embodiment, in which a stator according to the present disclosure is embodied as a stator of a rotating electric machine installed in a vehicle (e.g., a hybrid vehicle or an electric vehicle), will be described with reference to the drawings. In addition, in the following embodiment and modifications, identical or equivalent parts will be designated by the same reference signs in the drawings; and explanation thereof will not be repeated.
The rotating electric machine may be, for example, an electric motor, an electric generator or a motor-generator that selectively functions either as an electric motor or as an electric generator. More particularly, the rotating electric machine may be configured as a permanent magnet synchronous motor, a field coil synchronous motor or an induction motor.
In the present embodiment, the rotating electric machine includes a substantially cylindrical stator 10 as shown in
Hereinafter, the axial direction of the stator 10, which coincides with the direction of the rotation axis of the rotor, will be simply referred to as the axial direction; the radial directions of the stator 10, which coincide with the directions of extending radially from the rotation axis of the rotor, will be simply referred to as the radial directions; and the circumferential direction of the stator 10, which coincides with the direction of extending along a circle whose center is on the rotation axis of the rotor, will be simply referred to as the circumferential direction.
As shown in
The stator coil 12 is a three-phase coil which includes a U-phase winding, a V-phase winding and a W-phase winding. The U-phase, V-phase and W-phase windings are Y-connected (i.e., star-connected) to define a neutral point therebetween.
Moreover, the stator 10 also includes three electric power input/output busbars 13 and a neutral busbar 14. Each of the U-phase, V-phase and W-phase windings of the stator coil 12 has a first end connected with a corresponding one of the three electric power input/output busbars 13 and a second end connected with the neutral busbar 14.
Although not shown in the drawings, the stator coil 12 is supplied with three-phase AC power from an inverter that converts DC power from a power supply into the three-phase AC power. With supply of the three-phase AC power to the stator coil 12, magnetic flux is generated by the stator 10.
In addition, as shown in
A case 15 is shrink-fitted (or fitted under pressure) on a radially outer periphery of the stator core 11. Specifically, the case 15 is formed of a metal into a cylindrical shape. The stator core 11 has an outer diameter slightly greater than an inner diameter of the case 15. In assembling the case 15 to the stator core 11, the case 15 is first heated and thereby expanded. Then, the stator core 11 is fitted into the case 15. Thereafter, the case 15 is cooled so that the stator core 11 and the case 15 are fixed together. In addition, in the case 15, there are formed grooves through which the electric power input/output busbars 13 extend. Alternatively, the electric power input/output busbars 13 may be arranged at locations where they do not interfere with the case 15.
As shown in
The stator core 11 has a substantially annular back yoke 21, a plurality of teeth 22 and a plurality of slots 23. The teeth 22 each protrude radially inward from the back yoke 21, and are arranged at predetermined intervals in the circumferential direction. Each of the slots 23 is formed between a circumferentially-adjacent pair of the teeth 22. Specifically, each of the slots 23 extends with its longitudinal direction coinciding with the radial direction and has an opening at a radially inner periphery of the stator core 11. Moreover, the slots 23 are formed in the stator core 11 at equal intervals in the circumferential direction. The number of the slots 23 is set to be not less than 48, more particularly set to 48 in the present embodiment. The stator coil 12 is wound on the stator core 11 so as to be received in the slots 23. In the 48-gonal prism-shaped stator core 11, for each of the slots 23, there is formed a corresponding slit 25 (more specifically, a corresponding set of axially-overlapping slits 25 of the layers of the helically-laminated band-shaped steel sheet 20). That is, in the 48-gonal prism-shaped stator core 11, there are formed a total of 48 slits 25 at equal intervals in the circumferential direction.
In the band-shaped steel sheet 20, each of the slits 25 is formed, at a position corresponding to (more specifically, in radial alignment with) one of the slots 23, to be open to the corresponding slot 23. As shown in
Referring to
In addition, if the slit mating surfaces 25a are separated from each other due to springback of the band-shaped steel sheet 20, magnetic properties of the stator core 11 will be lowered. Here, springback of the band-shaped steel sheet 20 denotes the tendency of the band-shaped steel sheet 20, which has been helically bent and laminated to form the stator core 11, to revert to its original straight shape.
The stator coil 12 is formed by connecting the electrical conductor segments 30 in a predetermined pattern. Hereinafter, the segment structure of the stator coil 12 will be described in detail.
In the present embodiment, the electrical conductor segments 30 are obtained by cutting and plastically deforming an electric wire that includes an electrical conductor and an insulating coat. The electrical conductor is formed of an electrically conductive material (e.g., copper) and has a substantially rectangular cross section. The insulating coat is formed of an electrically insulative resin and provided to cover the outer surface of the electrical conductor. Moreover, as shown in
In addition, the shape of the electrical conductor segments 30 is not limited to the substantially U-shape. For example, as an alternative, each of the electrical conductor segments 30 may have a wave shape that has a plurality of substantially U-shaped sections connected with one another; that is, each of the electrical conductor segments 30 may have two or more pairs of leg portions 31. As another alternative, each of the electrical conductor segments 30 may have a substantially I-shape; that is, each of the electrical conductor segments 30 may have only a single leg portion 31. Moreover, the electrical conductor segments 30 may be joined to one another by welding or the like, or be formed continuously (or seamlessly) with one another.
In each of the slots 23 of the stator core 11, the electrical conductor segments 30 are inserted so as to be radially aligned in a row. More particularly, in the present embodiment, in each of the slots 23, the leg portions 31 of the electrical conductor segments 30 are radially stacked in four layers.
Moreover, for each of the electrical conductor segments 30, the pair of leg portions 31 of the electrical conductor segment 30 are respectively received in the corresponding two slots 23 of the stator core 11 which are circumferentially apart from each other by two or more slot-pitches (or by a predetermined coil pitch). It should be noted that the term “two slots 23 that are circumferentially apart from each other by two or more slot-pitches” does not denote two circumferentially-adjacent slots 23, but denotes two slots 23 that are circumferentially apart from each other with one or more other slots 23 interposed therebetween. For example, for each of the electrical conductor segments 30, the corresponding two slots 23 of the stator core 11, in which the pair of leg portions 31 of the electrical conductor segment 30 are respectively received, may be circumferentially apart from each other by three to six slot-pitches (i.e., circumferentially apart from each other with two to five other slots 23 interposed therebetween).
Those parts of the leg portions 31 of the electrical conductor segments 30 which are received in the corresponding slots 23 of the stator core 11 together constitute the coil main part CS of the stator coil 12. Furthermore, in each of the slots 23, there is provided an insulating sheet 24 (see
In the present embodiment, for each of the electrical conductor segments 30, the pair of leg portions 31 of the electrical conductor segment 30 are respectively received in the corresponding two slots 23 of the stator core 11 so as to be offset in radial position from each other by one layer. For example, one of the pair of leg portions 31 is located at the nth layer counting from the radially outer side (i.e., from the back yoke 21 side) while the other of the pair of leg portions 31 is located at the (n+1)th layer counting from the radially outer side.
In assembling the electrical conductor segments 30 (i.e., the stator coil 12) to the stator core 11, the leg portions 31 of the electrical conductor segments 30 are inserted into the corresponding slots 23 of the stator core 11 from a first axial side (i.e., the lower side in
Next, the connection between the electrical conductor segments 30 at the second coil end part CE2 of the stator coil 12 will be described in more detail.
At the second coil end part CE2 of the stator coil 12, each of those anti-turn-portion-side parts of the leg portions 31 of the electrical conductor segments 30 which extend to one side in the circumferential direction is joined to a corresponding one of those anti-turn-portion-side parts of the leg portions 31 of the electrical conductor segments 30 which extend to the other side in the circumferential direction. Consequently, at the second coil end part CE2, the stator coil 12 has the leg portions 31 of the electrical conductor segments 30 extending obliquely with respect to the axial direction and turned back at predetermined top positions. Moreover, each joined-pair of the leg portions 31 of the electrical conductor segments 30 apply to the stator core 11 forces in the directions of urging the joined-pair of the leg portions 31 to approach each other. In addition, the anti-turn-portion-side parts of the leg portions 31 of the electrical conductor segments 30 include both those anti-turn-portion-side parts which are bent to the same side as the corresponding turn portions 32 in the circumferential direction and those anti-turn-portion-side parts which are bent to the opposite side to the corresponding turn portions 32 in the circumferential direction.
In the above manner, for each of the U-phase, V-phase and W-phase windings of the stator coil 12, all the electrical conductor segments 30 that together constitute the phase winding are joined and thus electrically connected to one another at the exposed portions 33 thereof, that one of the exposed portions 33 of the electrical conductor segments 30 which is located at the first end of the phase winding is joined and thus electrically connected to the corresponding electric power input/output busbar 13; and that one of the exposed portions 33 of the electrical conductor segments 30 which is located at the second end of the phase winding is joined and thus electrically connected to the neutral busbar 14.
According to the present embodiment described in detail above, it is possible to achieve the following advantageous effects.
In the present embodiment, the stator core 11 is formed by helically bending and laminating the band-shaped steel sheet 20. In other words, the stator core 11 is formed of the band-shaped steel sheet 20 that is helically bent and laminated. The stator core 11 has the slots 23 each opening at the radially inner periphery of the stator core 11 and spaced at predetermined intervals (more particularly, at equal intervals in the present embodiment) in the circumferential direction. The stator coil 12 is formed of the electrical conductor segments 30 that are inserted in the slots 23 of the stator core 11 and connected with one another.
Moreover, in the present embodiment, the band-shaped steel sheet 20 has the slits 25 each of which is formed, at a position corresponding to (more specifically, in radial alignment with) one of the slots 23, to be open to the corresponding slot 23. Therefore, when the band-shaped steel sheet 20 is helically bent and laminated to form the stator core 11, the band-shaped steel sheet 20 can be easily deformed such that the side surfaces 25a (i.e., the slit mating surfaces 25a) of each of the slits 25, which face each other, become closer to each other.
Furthermore, in the present embodiment, each of the electrical conductor segments 30 is substantially U-shaped and has the pair of leg portions 31 respectively inserted in the corresponding two slots 23 of the stator core 11 which are circumferentially apart from each other by two or more slot-pitches. In the state of being respectively inserted in the corresponding two slots 23 of the stator core 11, the pair of leg portions 31 apply to the stator core 11 forces in the directions of urging the pair of leg portions 31 to approach each other. Moreover, each corresponding pair of the leg portions 31, which respectively belong to two different electrical conductor segments 30, are joined to each other. In the state of being jointed to each other, each corresponding pair of the leg portions 31 also apply to the stator core 11 forces in the directions of urging the corresponding pair of the leg portions 31 to approach each other. Consequently, for the one or more slits 25 corresponding to the one or more slots 23 sandwiched between a connected or joined pair of the leg portions 31 of the electrical conductor segments 30, forces are applied by the connected or joined pair of the leg portions 31 to urge the slit mating surfaces 25a of each of the one or more slits 25 to become closer to each other. As a result, the slit mating surfaces 25a are suppressed from being separated from each other due to springback of the band-shaped steel sheet 20.
It should be noted that the above advantageous effects can be achieved regardless of the shape of the electrical conductor segments 30 and regardless of the manner of connecting the electrical conductor segments 30.
In addition, in the present embodiment, between the pair of leg portions 31 of each of the electrical conductor segments 30, there are interposed one or more slots 23. Moreover, for each of the slots 23, there is formed a corresponding one of the slits 25. Consequently, each of the electrical conductor segments 30 can exert the effect of suppressing separation of the slit mating surfaces 25a for one or more slits 25.
In the present embodiment, the number of the slots 23 formed in the stator core 11 is set to 48; and the number of the slits 25 formed in the stator core 11 is also set to 48. Consequently, it becomes possible to reduce the amount of deformation of the band-shaped steel sheet 20 at the positions corresponding to the slits 25 when the band-shaped steel sheet 20 is helically bent and laminated to form the stator core 11. As a result, it becomes possible to reduce the force of springback of the band-shaped steel sheet 20 while suppressing the magnetic properties of the stator core 11 from being lowered. Moreover, it becomes easy to increase the number of the slots 23 interposed between the pair of leg portions 31 of each of the electrical conductor segments 30; thus, it becomes possible to suppress separation of the slit mating surfaces 25a of each of the slits 25 using more than one electrical conductor segment 30.
In the present embodiment, the stator core 11 has a 48-gonal prism shape; and the case 15 is shrink-fitted (or fitted under pressure) on the radially outer periphery of the stator core 11. Consequently, the corner portions of the 48-gonal prism-shaped stator core 11 are compressed by the case 15, thereby reducing the residual tensile stress in the stator core 11 which is caused by the tensile deformation (i.e., bending deformation) of the band-shaped steel sheet 20. As a result, it becomes possible to improve the magnetic properties of the stator core 11.
The above-described embodiment can be modified as follows. Moreover, the above-described embodiment and the following modifications can also be implemented in combination with each other to the extent that there is no technical contradiction between them.
In the band-shaped steel sheet 20 according to this modification, as shown in
Moreover, as shown in
Consequently, with engagement between the recess 25c and the protrusion 25d, it becomes possible to more effectively suppress separation of the slit mating surfaces 25a from each other.
In the band-shaped steel sheet 20 according to this modification, as shown in
Moreover, as shown in
With the above configuration, the contact area and thus the friction force between the slit mating surfaces 25a can be increased, thereby more effectively suppressing separation of the slit mating surfaces 25a from each other.
In the above-described second modification, each of the recesses 25c and the protrusions 25d has a triangular shape.
Alternatively, each of the recesses 25c and the protrusions 25d may have other shapes such as an arc shape (or round shape) as shown in
In the above-described second modification, all the recesses 25c are identical in shape to each other; and all the protrusions 25d respectively fitted in the recesses 25c are also identical in shape to each other.
In contrast, in this modification, as shown in
In the band-shaped steel sheet 20 according to this modification, as shown in
Moreover, as shown in
With the above configuration, the contact area and thus the friction force between the slit mating surfaces 25a can be increased, thereby more effectively suppressing separation of the slit mating surfaces 25a from each other.
Furthermore, in this modification, in each of the slit mating surfaces 25a of the slits 25, the recesses 25c and the protrusions 25d are continuously formed without being spaced from one another. Consequently, as shown in
The band-shaped steel sheet 20 according to this modification differs from the band-shaped steel sheet 20 according to the fifth modification only in that in this modification, each of the protrusions 25d formed on the slit mating surfaces 25a of the slits 25 has a hole 25da formed therein.
Consequently, with the holes 25da formed in the protrusions 25d, it becomes possible to facilitate elastic deformation of the protrusions 25d, thereby facilitating insertion of the protrusions 25d into the respective recesses 25c.
In the band-shaped steel sheet 20 according to this modification, as shown in
Moreover, as shown in
Consequently, with engagement between the indentation 25e and the protrusion 25f, it becomes possible to more effectively suppress separation of the slit mating surfaces 25a from each other.
In the band-shaped steel sheet 20 according to this modification, as shown in
Moreover, as shown in
Consequently, with engagement between the indentation 25e and the protrusion 25f, it becomes possible to more effectively suppress separation of the slit mating surfaces 25a from each other.
In the band-shaped steel sheet 20 according to this modification, as shown in
Moreover, as shown in
Consequently, with engagement between the indentation 25e and the protrusion 25f, it becomes possible to more effectively suppress separation of the slit mating surfaces 25a from each other.
In this modification, as shown in
With the above configuration, when the indentation 25e and the protrusion 25f are brought into engagement with each other during the bending of the band-shaped steel sheet 20, the R portion 25fa of the protrusion 25f can slide against the tapered opening portion 25ea of the indentation 25e, thereby facilitating insertion of the protrusion 25f into the indentation 25e.
The indentation 25e (i.e., the first engagement portion) and the protrusion 25f (i.e., the second engagement portion) described in the tenth modification (see
In this modification, as shown in
With the above configuration, after the indentation 25e and the protrusion 25f are brought into engagement with each other, it is difficult for the protrusion 25f to be displaced out of the indentation 25e. Consequently, it becomes possible to more effectively suppress separation of the slit mating surfaces 25a from each other.
In this modification, as shown in
With the above configuration, when the indentation 25e and the protrusion 25f are brought into engagement with each other during the bending of the band-shaped steel sheet 20, the protrusion 25f can be easily elastically deformed due to the hole 25fc formed therein; thus, the protrusion 25f can be easily inserted into the indentation 25e.
Moreover, as shown in
In this modification, as shown in
Moreover, as shown in
In the band-shaped steel sheet 20 according to this modification, for each of the slits 25, there is formed an indentation 27 in an outer edge portion 20a of the band-shaped steel sheet 20 at a position corresponding to (more specifically, in radial alignment with) the end (or the circular hole 25b) of the slit 25 on the opposite side to the corresponding slot 23. In addition, the indentation 27 may have, for example, a V-shape or a U-shape.
With the above configuration, it becomes possible to reduce the volume of that portion (i.e., outer edge portion 20a) of the band-shaped steel sheet 20 where tensile stress remains; the tensile stress is generated when the band-shaped steel sheet 20 is helically bent and laminated to form the stator core 11. Consequently, it becomes possible to reduce the amount of springback of the band-shaped steel sheet 20.
In the band-shaped steel sheet 20 according to this modification, for each of the slits 25, the end (or the circular hole 25b) of the slit 25 on the opposite side to the corresponding slot 23 is located radially outside and in radial alignment with a corresponding one of the teeth 22, as indicated by dashed-line arrows in
In addition, in this modification, for each of the slits 25, there is formed an indentation 27 in an outer edge portion 20a of the band-shaped steel sheet 20 at a position corresponding to (more specifically, in radial alignment with) the end (or the circular hole 25b) of the slit 25 on the opposite side to the corresponding slot 23, as in the fifteenth modification.
With the configuration of the band-shaped steel sheet 20 according to this modification, when magnetic flux flowing through the back yoke 21 in the circumferential direction is blocked by the indentation 27 formed in the outer edge portion 20a of the band-shaped steel sheet 20 and the circular hole 25b, the magnetic flux can be bypassed to that part of the back yoke 21 which is radially interposed between the circular hole 25b and the corresponding tooth 22, thereby being allowed to continue flowing in the circumferential direction. Consequently, it becomes possible to suppress the magnetic properties of the stator core 11 from being lowered due to magnetic saturation.
In the band-shaped steel sheet 20 according to this modification, for each of the slits 25, the side surfaces 25a (i.e., the slit mating surfaces 25a) of the slit 25 which face each other are arc-shaped. Moreover, the radii of curvature of the side surfaces 25a are set to be equal to each other.
With the above configuration, when the band-shaped steel sheet 20 is helically bent and laminated to form the stator core 11, the difference in shape between the slit mating surfaces 25a due to manufacturing tolerances can be easily absorbed by the slit mating surfaces 25a being deformed to change the curvatures thereof. Consequently, the entire slit mating surfaces 25a can be easily brought into intimate contact with each other, thereby improving the magnetic properties of the stator core 11.
Hereinafter, for the sake of convenience of explanation, the pair of side surfaces 25a (i.e., the pair of slit mating surfaces 25a) of each of the slits 25 will be respectively referred to as the first side surface 25al and the second side surface 25a2; the second side surface 25a2 is deformed later than the first side surface 25al when the band-shaped steel sheet 20 is helically bent and laminated to form the stator core 11.
The band-shaped steel sheet 20 according to this modification differs from the band-shaped steel sheet 20 according to the seventeenth modification only in that in this modification, for each of the slits 25, the radius of curvature of the second side surface 25a2 of the slit 25 is set to be greater than the radius of curvature of the first side surface 25al of the slit 25.
With the above configuration, when the band-shaped steel sheet 20 is helically bent and laminated to form the stator core 11, the second side surface 25a2 can be deformed in such as manner as to conform to the first side surface 25a1. Consequently, the entire slit mating surfaces 25al and 25a2 can be more easily brought into intimate contact with each other, thereby improving the magnetic properties of the stator core 11.
In this modification, the positions of outer circumferential surfaces S1, S2 and S3 of layers of the helically-laminated band-shaped steel sheet 20 in the radial direction D1 vary in the lamination direction D2 (i.e., the axial direction).
With the above configuration, it becomes possible to increase the area of the radially outer surface of the entire stator core 11, thereby improving the heat dissipation performance of the stator core 11.
In addition, in this modification, the stator core 11 may be placed in the case 15 (see
In the band-shaped steel sheet 20 according to this modification, for each of the slits 25, there is formed an indentation 28 in an outer edge portion 20b of the band-shaped steel sheet 20 at a position circumferentially offset from an imaginary line that extends radially outward from the end (or the circular hole 25b) of the slit 25 on the opposite side to the corresponding slot 23. In addition, the indentation 28 may have, for example, a V-shape, a U-shape, a trapezoidal shape or a rectangular shape.
With the above configuration, it becomes possible to reduce the volume of that portion (i.e., outer edge portion 20b) of the band-shaped steel sheet 20 where tensile stress remains; the tensile stress is generated when the band-shaped steel sheet 20 is helically bent and laminated to form the stator core 11. Consequently, it becomes possible to reduce the amount of springback of the band-shaped steel sheet 20.
Moreover, with the above configuration, the indentation 28 is formed at the position circumferentially offset from the imaginary line that extends from the end of the slit 25 in the radially outward direction, i.e., in the longitudinal direction of the slit 25. Consequently, compared to the configuration where the indentation 27 is formed at a position on the imaginary line extending in the longitudinal direction of the slit 25 (see
In the band-shaped steel sheet 20 according to this modification, for each of the slits 25, there is formed a protrusion 29 that protrudes radially outward from an outer edge portion 20a of the band-shaped steel sheet 20 at a position corresponding to (more specifically, in radial alignment with) the end (or the circular hole 25b) of the slit 25 on the opposite side to the corresponding slot 23. In addition, the protrusion 29 may have, for example, a semi-elliptical shape or a rectangular shape.
With the above configuration, it becomes possible to increase the radial width of the outer peripheral portion 26 of the back yoke 21, thereby relaxing stress concentration on the outer peripheral portion 26 due to the bending of the band-shaped steel sheet 20. Consequently, it becomes possible to prevent the outer peripheral portion 26 from being broken due to stress concentration on the outer peripheral portion 26.
Moreover, with the above configuration, it becomes possible to suppress reduction in the radial width of the outer peripheral portion 26 of the back yoke 21 when the outer peripheral portion 26 is stretched in the circumferential direction.
In addition, the outer peripheral portion 26 denotes a portion of the back yoke 21 which extends between the ends (or the circular holes 25b) of the slits 25 on the opposite side to the corresponding slots 23 and the radially outer edge of the back yoke 21.
In the band-shaped steel sheet 20 according to this modification, for each of the slits 25, there is formed a circumferential slit 40 that extends, from the end of the slit 25 on the opposite side to the corresponding slot 23, to both sides in the circumferential direction. In addition, the circumferential slit 40 may have, for example, a flat oval shape, an elliptical shape, a rectangular shape, or an inverted triangular shape.
With the above configuration, it becomes possible to expand the area where stress concentration occurs due to the bending of the band-shaped steel sheet 20 to the area where the circumferential slit 40 is formed. Consequently, it becomes possible to reduce the average stress in the area where stress concentration occurs due to the bending of the band-shaped steel sheet 20. As a result, it becomes possible to prevent the outer peripheral portion 26 of the back yoke 21 from being broken due to stress concentration on the outer peripheral portion 26.
In a band-shaped steel sheet 20 according to this modification, as shown in
With the above configuration, it becomes possible to expand the area where stress concentration occurs due to the bending of the band-shaped steel sheet 20 to those areas where the small circular holes 25ba are formed. Consequently, it becomes possible to reduce the average stress in the area where stress concentration occurs due to the bending of the band-shaped steel sheet 20. As a result, it becomes possible to prevent the outer peripheral portion 26 of the back yoke 21 from being broken due to stress concentration on the outer peripheral portion 26.
In addition, the number of the small circular holes 25ba is not limited to two, but may alternatively be one, or three or more. Moreover, the small circular holes 25ba may have any size smaller than that of the circular hole 25b. Furthermore, the small circular holes 25ba may have the same size or different sizes from each other.
The band-shaped steel sheet 20 according to this modification is a combination of the band-shaped steel sheet 20 according to the twentieth modification (see
That is, in the band-shaped steel sheet 20 according to this modification, for each of the slits 25, there are formed both an indentation 28 as described in the twentieth modification and a protrusion 29 as described in the twenty-first modification.
Consequently, it becomes possible to achieve both the advantageous effects achievable with the indentation 28 and the advantageous effects achievable with the protrusion 29.
The band-shaped steel sheet 20 according to this modification is a combination of the band-shaped steel sheet 20 according to the twentieth modification (see
That is, in the band-shaped steel sheet 20 according to this modification, for each of the slits 25, there are formed both an indentation 28 as described in the twentieth modification and a circumferential slit 40 as described in the twenty-second modification.
Consequently, it becomes possible to achieve both the advantageous effects achievable with the indentation 28 and the advantageous effects achievable with the circumferential slit 40.
The band-shaped steel sheet 20 according to this modification is a combination of the band-shaped steel sheet 20 according to the twenty-first modification (see
That is, in the band-shaped steel sheet 20 according to this modification, for each of the slits 25, there are formed both a protrusion 29 as described in the twenty-first modification and a circumferential slit 40 as described in the twenty-second modification.
Consequently, it becomes possible to achieve both the advantageous effects achievable with the protrusion 29 and the advantageous effects achievable with the circumferential slit 40.
The band-shaped steel sheet 20 according to this modification is a combination of the band-shaped steel sheet 20 according to the twentieth modification (see
That is, in the band-shaped steel sheet 20 according to this modification, for each of the slits 25, there are formed an indentation 28 as described in the twentieth modification, a protrusion 29 as described in the twenty-first modification and a circumferential slit 40 as described in the twenty-second modification.
Consequently, it becomes possible to achieve all of the advantageous effects achievable with the indentation 28, the advantageous effects achievable with the protrusion 29 and the advantageous effects achievable with the circumferential slit 40.
In the band-shaped steel sheet 20 according to this modification, for each of the slots 23, there are formed, at positions corresponding to (more specifically, in radial alignment with) the slot 23, two slits 25 that are open to the slot 23.
With the above configuration, for each of the slots 23, forces are applied by the connected or joined pair of the leg portions 31 of the electrical conductor segments 30, between which the slot 23 is interposed, to urge the slit mating surfaces 25a of each of the two slits 25 corresponding to the slot 23 to become closer to each other. As a result, the slit mating surfaces 25a are suppressed from being separated from each other due to springback of the band-shaped steel sheet 20.
In the band-shaped steel sheet 20 according to this modification, for each of only some of the slots 23, there is formed, at a position corresponding to (more specifically, in radial alignment with) the slot 23, a slit 25 that is open to the slot 23.
With the above configuration, for each of the some of the slots 23, forces are applied by the connected or joined pair of the leg portions 31 of the electrical conductor segments 30, between which the slot 23 is interposed, to urge the slit mating surfaces 25a of the slit 25 corresponding to the slot 23 to become closer to each other. As a result, the slit mating surfaces 25a are suppressed from being separated from each other due to springback of the band-shaped steel sheet 20.
The band-shaped steel sheet 20 according to this modification is a combination of the band-shaped steel sheet 20 according to the twenty-eighth modification (see
That is, in the band-shaped steel sheet 20 according to this modification, for each of only some of the slots 23, there are formed, at positions corresponding to (more specifically, in radial alignment with) the slot 23, two slits 25 that are open to the slot 23.
With the above configuration, for each of the some of the slots 23, forces are applied by the connected or joined pair of the leg portions 31 of the electrical conductor segments 30, between which the slot 23 is interposed, to urge the slit mating surfaces 25a of each of the two slits 25 corresponding to the slot 23 to become closer to each other. As a result, the slit mating surfaces 25a are suppressed from being separated from each other due to springback of the band-shaped steel sheet 20.
While the above particular embodiment and modifications have been shown and described, it will be understood by those skilled in the art that various further modifications, changes, and improvements may be made without departing from the spirit of the present disclosure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2022-165785 | Oct 2022 | JP | national |
| 2023-090354 | May 2023 | JP | national |
| 2023-173141 | Oct 2023 | JP | national |
