Patent Application
20200358327
The present invention relates to a stator, a motor, a compressor, and an air conditioner.
In the technical field of motors, an increase in output and reduction in size of motors are recently demanded. When the output of the motor is increased, a current flowing through a coil increases. Furthermore, when the size of the motor is reduced, the current required to obtain the same output increases. Thus, dissipation of heat generated in the coil is an issue to be solved.
In a motor used in a compressor, a coil of a stator is hardly in contact with refrigerant and lubricating oil inside the compressor. Thus, heat generated in the coil needs to be dissipated from the stator core. Heat generation in the coil is due to an electrical resistance of the coil, and thus it is desirable that the electrical resistance of the coil is low in order to suppress the heat generation in the coil.
The use of an aluminum wire coil in combination with a conventional copper wire coil is recently proposed in order to reduce the cost and weight of a motor (see, for example, Patent Reference 1).
International Publication WO2014/188466 (see
However, the aluminum wire coil has a higher electrical resistivity than the copper wire coil, and therefore a large amount of heat is generated when a current flows through the aluminum wire coil. Thus, it is demanded to enhance the heat dissipation effect while using different types of coils.
The present invention is intended to solve the above-described problems, and an object of the present invention is to enhance the heat dissipation effect while using different types of coils.
A stator of the present invention includes a stator core having an inner circumference extending in a circumferential direction about an axis, and a slot formed on an outer side of the inner circumference in a radial direction about the axis, and a first coil and a second coil disposed in the slot and connected in series with each other. The first coil has a conductor formed of a first metal. The second coil has a conductor formed of a second metal that has a lower electrical resistivity than that of the first metal. The slot includes a slot opening opened to the inner circumference of the stator core, a slot bottom portion having a curved shape and disposed on an outer side of the slot opening in the radial direction, and a first side portion and a second side portion disposed between the slot opening and the slot bottom portion and facing each other in the circumferential direction. In a plane perpendicular to the axis, a first straight line is defined as a straight line connecting a border between the slot bottom portion and the first side portion and a border between the slot bottom portion and the second side portion. A first region is defined as a region surrounded by the first straight line and the slot bottom portion. A second region is defined as a region in the slot on an outer side of the slot opening in the radial direction and on an inner side of the first straight line in the radial direction. An area S1 of the first region, a total cross-sectional area A1 of the first coil in the first region, an area S2 of the second region, and a total cross-sectional area A2 of the first coil in the second region satisfy (A1/S1)>(A2/S2).
According to the present invention, of the first and second coils, the first coil which has the higher electrical resistivity is densely disposed in the first region which is closer to the outer circumference of the stator core than the second region. Thus, the heat generated in the first coil can be efficiently transferred to the stator core. Thus, the heat generated in the first coil can be efficiently dissipated, and an increase in the temperature of the first and second coils can be suppressed.
Hereinafter, a direction of an axis C, which is a center of rotation of the rotor 5, is referred to as an “axial direction”. A circumferential direction (indicated by an arrow R1 in
The rotor core 50 is obtained by stacking electromagnetic steel sheets each having a thickness of, for example, 0.1 to 0.7 mm in the axial direction and integrating the sheets together by crimping or the like. A circular shaft hole 54 is formed at a center of the rotor core 50 in the radial direction. The shaft 55 is fixed to the shaft hole 54 by press-fitting. A center axis of the shaft 55 is the axis C serving as the center of the rotation of the rotor 5.
The rotor core 50 is formed in an annular shape about the axis C. The plurality of slots 51 (also referred to as rotor slots) are formed at equal intervals in the circumferential direction along an outer circumference 53 of the rotor core 50. The number of slots 51 is 34 in this example, but is not limited to 34. Each slot 51 is a groove extending in the radial direction, and passes through the rotor core 50 in the axial direction. Teeth 52 (also referred to as rotor teeth) are each formed between two of the slots 51 adjacent to each other in the circumferential direction.
As shown in
The squirrel-cage secondary conductor 60 is formed of a non-magnetic material with electrical conductivity such as, for example, aluminum. The end rings 61 and 62 and the bars 60 of the squirrel-cage secondary conductor 6 are formed by casting aluminum at both ends of the rotor core 50 and in the slots 51. Copper may be used in place of aluminum.
The bar 60 extends to be inclined so that one end of the bar in the longitudinal direction is displaced in the circumferential direction with respect to the other end of the bar 60. In
The stator core 10 is obtained by stacking electromagnetic steel sheets each having a thickness of, for example, 0.1 to 0.7 mm in the axial direction, and integrating the sheets together by crimping or the like. The stator core 10 has an inner circumference 10b extending in the circumferential direction about the axis C and an outer circumference 10a disposed on an outer side of the inner circumference 10b in the radial direction. In the stator core 10, the plurality of slots 13 opened to the inner circumference 10b are formed at equal intervals in the circumferential direction. The coil 3 is accommodated in the slot 13. The number of slots 13 is 30 in this example, but is not limited to 30.
The stator core 10 includes an annular yoke (also referred to as a core back) 11 and a plurality of teeth 12 protruding inward in the radial direction from the yoke 11. The teeth 12 are arranged at equal intervals in the circumferential direction. The above-described slot 13 is formed between two teeth 12 adjacent to each other in the circumferential direction. The number of teeth 12 is the same as the number of slots 13 (in this example, 30). The coil 3 is wound around the tooth 12.
The tooth 12 has a tooth tip portion 12a at its tip end on the inner side in the radial direction. The tooth tip portion 12a has a width (i.e., a dimension in the circumferential direction) wider than the width of other portions of the tooth 12. An end of the tooth tip portion 12a has an arc shape and forms the above-described inner circumference 10b of the stator core 10.
An electrical resistance of the conductor 31a of the aluminum wire coil 31 is expressed as RA1, and an electrical resistivity of the conductor 31a is expressed as ρA1. A diameter (also referred to as a wire diameter) of the aluminum wire coil 31 is expressed as DA1. A thickness of the film 31b is thinner as compared with the diameter of the conductor 31a, and thus the diameter DA1 can be considered to be equivalent to the diameter of the conductor 31a.
The second coil 32 has a conductor 32a formed of copper as a second metal that has a lower electrical resistivity than that of the first metal. A circumference of the conductor 32a is covered with an insulating coating 32b. The second metal forming the conductor 32a is copper in this example, but is not limited to copper.
An electrical resistance of the conductor 32a of the copper wire coil 32 is expressed as RCu, and an electrical resistivity thereof is expressed as ρCu. A diameter of the copper wire coil 32 is expressed as DCu. Since a thickness of the coating 32b is thinner as compared with the diameter of the conductor 32a, the diameter DCu can be considered to be equivalent to the diameter of the conductor 32a.
The slot opening 14 is formed between tooth tip portions 12a adjacent to each other in the circumferential direction. The slot opening 14 serves as an inlet through which the coil 3 passes when the coil 3 is wound around the tooth 12, i.e., when the coil 3 is disposed in the slot 13.
The slot bottom portion 13a has a curved shape (more specifically, an arc shape) such that a center of the slot bottom portion 13a in the circumferential direction protrudes outward in the radial direction with respect to both ends of the slot bottom portion 13a in the circumferential direction. The length of the slot bottom portion 13a in the circumferential direction is longer than the length of the slot opening 14 in the circumferential direction.
The side portions 13b and 13c extend from the slot opening 14 toward the slot bottom portion 13a. The side portions 13b and 13c extend such that an interval between these side portions in the circumferential direction increases outward in the radial direction.
The first side portion 13b has a curved portion 131 at a part leading to the slot opening 14. The curved portion 131 is curved so that a part thereof located closer to the slot opening 14 is displaced inward in the circumferential direction in the slot 13. The second side portion 13c has a curved portion 132 at a part leading to the slot opening 14. The curved portion 132 is curved so that a part thereof located closer to the slot opening 14 is displaced inward in the circumferential direction in the slot 13.
An insulating portion 2 is provided on an inner surface of each slot 13. The insulating portion 2 is formed of, for example, a resin such as polyethylene terephthalate (PET). The insulating portion 2 electrically insulates the coil 3 in the slot 13 from the stator core 10. The insulating portion 2 includes a first part 21 covering the slot bottom portion 13a, a second part 22 covering the first side portion 13b, and a third part 23 covering the second side portion 13c.
An interior of the slot 13 may be filled with a resin having a high thermal conductivity so that the resin surrounds the coil 3 (i.e., the aluminum wire coil 31 and the copper wire coil 32). For example, polybutylene terephthalate (PBT) or the like can be used as the resin.
In this example, the interior of the slot 13 is divided into a first region 101 and a second region 102. This will be described below.
In a plane perpendicular to the axis C, a first point P1 is defined as a border between the slot bottom portion 13a of the slot 13 and the first side portion 13b. A second point P2 is defined as a border between the slot bottom portion 13a of the slot 13 and the second side portion 13c. These points P1 and P2 correspond to both ends of the slot bottom portion 13a of the slot 13 in the circumferential direction. A first straight line L1 is defined as a straight line connecting the first point P1 and the second point P2. The first region 101 is defined as a region surrounded by the first straight line L1 and the slot bottom portion 13a.
In the plane perpendicular to the axis C, a third point P3 is defined as a point disposed at an outer end of the slot opening 14 in the radial direction and on the first side portion 13b side. A fourth point P4 is defined as a point disposed at the outer end of the slot opening 14 in the radial direction and on the second side portion 13c side. A second straight line L2 is defined as a straight line connecting the third point P3 and the fourth point P4. The second region 102 is defined as a region surrounded by the second straight line L2 and the first straight line L1. In other words, the second region 102 is the region on the outer side of the slot opening 14 in the radial direction and on the inner side of the first straight line L1 in the radial direction in the slot 13.
Since the insulating portion 2 is provided on the inner side of the slot 13, the points P1 to P4 may be defined on an inner surface of the insulating portion 2. That is, the first point P1 may be defined as a border between an inner surface of the first part 21 and an inner surface of the second part 22 of the insulating portion 2, while the second point P2 may be defined as a border between the inner surface of the first part 21 and an inner surface of the third part 23 of the insulating portion 2. The point P3 may be defined as a point closest to the slot opening 14 on the inner surface of the second part 22 of the insulating portion 2. The point P4 may be defined as a point closest to the slot opening 14 on the inner surface of the third part 23 of the insulating portion 2.
An area of the first region 101 is expressed as S1, while an area of the second region 102 is expressed as S2. A total cross-sectional area of the aluminum wire coil 31 disposed in the first region 101 is expressed as A1, while a total cross-sectional area of the aluminum wire coil 31 disposed in the second region 102 is expressed as A2. A total cross-sectional area of the copper wire coil 32 disposed in the first region 101 is expressed as C1, while a total cross-sectional area of the copper wire coil 32 disposed in the second region 102 is expressed as C2.
In this regard, the “total cross-sectional area of the coil” means a sum of cross-sectional areas of coil elements disposed in a given region. In other words, the “total cross-sectional area of the coil” means a product of a cross-sectional area of each coil element of the coil and the number of the coil elements disposed in the given region.
The area S1 of the first region 101, the total cross-sectional area A1 of the aluminum wire coil 31 in the first region 101, the area S2 of the second region 102, and the total cross-sectional area A2 of the aluminum wire coil 31 in the second region 102 satisfy (A1/S1)>(A2/S2).
That is, the aluminum wire coil 31 is arranged so that an occupancy density thereof in the first region 101 is higher than an occupancy density thereof in the second region 102. In other words, the aluminum wire coil 31 is disposed more densely in the first region 101 than in the second region 102.
The area S1 of the first region 101, the total cross-sectional area A1 of the aluminum wire coil 31 in the first region 101, and the total cross-sectional area C1 of the copper wire coil 32 in the first region 101 satisfy (A1/S1)>(C1/S1).
That is, in the first region 101, the occupancy density of the aluminum wire coil 31 is higher than the occupancy density of the copper wire coil 32. In other words, in the first region 101, the aluminum wire coil 31 is disposed more densely than the copper wire coil 32.
The total cross-sectional area A1 of the aluminum wire coil 31 and the total cross-sectional area C1 of the copper wire coil 32 in the first region, and the total cross-sectional area A2 of the aluminum wire coil 31 and the total cross-sectional area C2 of the copper wire coil 32 in the second region 102 satisfy (A1/C1)>(A2/C2). That is, a ratio of the total cross-sectional area of the aluminum wire coil 31 to the total cross-sectional area of the copper wire coil 32 is higher in the first region 101 than in the second region 102.
Next, a function of the motor in the first embodiment will be described. When the output of the motor 100 increases, a current flowing through the coil 3 increases, and thus the amount of heat generated in the coil 3 increases. An area where the coil 3 disposed in the slot 13 is in contact with the refrigerant, the lubricating oil, and the air is small, and thus heat of the coil 3 is dissipated through the stator core 10. In order to suppress an increase in the temperature of the coil 3, it is necessary to effectively dissipate the heat of the coil 3 through the stator core 10.
Among the heat dissipation paths, the tooth 12 has a small area, and heat is transferred to one tooth 12 from the slots 13 on both sides of the tooth 12. Thus, the heat tends to be accumulated in the tooth 12. In contrast, the yoke 11 has a large area and its outer circumference 10a (
The electrical resistivity of the aluminum wire coil 31 is higher than that of the copper wire coil 32, and thus the amount of heat generated in the aluminum wire coil 31 is larger than the amount of heat generated in the copper wire coil 32. Further, the thermal conductivity of the aluminum wire coil 31 is lower than that of the copper wire coil 32, and therefore the temperature of the aluminum wire coil 31 is easily raised.
Thus, in the first embodiment, the aluminum wire coil 31 is disposed more densely in the first region 101 than in the second region 102. That is, (A1/S1)>(A2/S2) is satisfied. The aluminum wire coil 31, whose temperature is easily raised, is disposed more densely in the first region 101 than in the second region 102, and therefore the heat of the aluminum wire coil 31 can be efficiently dissipated through the yoke 11.
In addition, since the contact area between coil elements of the aluminum wire coil 31 and the contact area between the aluminum wire coil 31 and the copper wire coil 32 increase, and the distance between the aluminum wire coil 31 and the stator core 10 is shortened, the heat of the aluminum wire coil 31 is easily transferred to the stator core 10. Thus, an increase in the temperature of the aluminum wire coil 31 can be suppressed.
In the first region 101, the occupancy density of the aluminum wire coil 31 is higher than the occupancy density of the copper wire coil 32. That is, (A1/S1)>(C1/S1) is satisfied. In the first region 101, the aluminum wire coil 31 is disposed more densely than the copper wire coil 32, and thus the heat of the aluminum wire coil 31 can be easily dissipated through the yoke 11. Thus, the heat dissipation effect can be further enhanced.
The ratio of the total cross-sectional area of the aluminum wire coil 31 to the total cross-sectional area of the copper wire coil 32 is higher in the first region 101 than in the second region 102. That is, (A1/C1)>(A2/C2) is satisfied. Since the ratio of the total cross-sectional area of the aluminum wire coil 31 to that of the copper wire coil 32 is higher in the first region 101, the heat of the aluminum wire coil 31 can be easily dissipated through the yoke 11. Thus, the heat dissipation effect can be further enhanced.
An aluminum wire coil 231 and a copper wire coil 232 are disposed in the slot 213. Unlike the coils 31 and 32 of the first embodiment, the aluminum wire coil 231 is disposed on one side of the slot 213 in the circumferential direction (on the right side in
Thus, in the stator 201 of the comparison example, most of the heat from the aluminum wire coil 231 is dissipated through the teeth 212. Since the heat dissipation efficiency of the teeth 212 is low as compared to that of the yoke 211 as described above, the effect of suppressing an increase in the temperature of the aluminum wire coil 231 is not high.
In contrast, in the first embodiment, as shown in
Next, a relationship between the diameters of the coils 31 and 32 will be described. Since the aluminum wire coil 31 and the copper wire coil 32 are connected in series with each other, the currents flowing through both coils 31 and 32 are equal. Therefore, a loss generated in the aluminum wire coil 31 having the higher electrical resistivity is higher than a loss generated in the copper wire coil 32. Thus, it is desirable to concentrate as many coil elements of the aluminum wire coil 31 as possible in the first region 101 where the heat dissipation efficiency is high.
As described above, the electrical resistivity of the aluminum wire coil 31 is expressed as ρA1[Ω·m], and the diameter of the aluminum wire coil 31 is expressed as DA1 [mm]. The electrical resistivity of the copper wire coil 32 is expressed as ρCu[Ω·m], and the diameter of the copper wire coil 32 is expressed as DCu [mm]. An electrical resistance of a coil is a value (i.e., ρ×L/S) obtained by multiplying an electrical resistivity ρ by a length L of the coil and dividing the multiplied value by a cross-sectional area S of the coil. That is, when the length L of the coil is constant, the electrical resistance of the coil increases as the electrical resistivity of the coil increases, and the electrical resistance of the coil decreases as the cross-sectional area of the coil decreases.
A wire cross-sectional area of the aluminum wire coil 31 is expressed as SA1, while a wire cross-sectional area of the copper wire coil 32 is expressed as SCu. In the case where the aluminum wire coil 31 and the copper wire coil 32 have the equal length L and the current flowing through the coils 31 and 32 is 1 [A], a loss [W] generated in the aluminum wire coil 31, i.e., the product of the square of the current and the electrical resistance is expressed as ρA1×(L/SA1), while a loss [W] generated in the copper wire coil 32 is expressed as ρCu×(L/SCu).
When the loss generated in the aluminum wire coil 31 is equal to the loss generated in the copper wire coil 32, ρA1×(L/SA1)=ρCu×(L/SCu) is satisfied. When this equation is solved for SA1, SA1=(ρA1/ρCu)×SCu is obtained. That is, the cross-sectional area SA1 of the aluminum wire coil 31 is (ρA1/ρCu) times as large as the cross-sectional area SCu of the copper wire coil 32.
The cross-sectional area of a coil is proportional to the square of the diameter of the coil. Thus, when the loss generated in the aluminum wire coil 31 is equal to the loss generated in the copper wire coil 32, the diameter DA1 [mm] of the aluminum wire coil 31 is √(ρA1/ρCu) times the diameter DCu [mm] of the copper wire coil 32.
Thus, in order to make the loss generated in the aluminum wire coil 31 equal to or more than the loss generated in the copper wire coil 32, it is sufficient that the diameter DA1 of the aluminum wire coil 31 is √(ρA1/ρCu) times or less the diameter DCu [mm] of the copper wire coil 32. In other words, it is sufficient that the diameter DA1 of the aluminum wire coil 31 is less than or equal to √(ρA1/ρCu)×DCu.
For this reason, it is most desirable that the electrical resistivity ρA1 [Q·m ] and the diameter DA1 of the aluminum wire coil 31 and the electrical resistivity ρCu [Ω·m] and the diameter DCu [mm] of the copper wire coil 32 satisfy the following equation (1).
When the diameter DA1 of the aluminum wire coil 31 is less than or equal to √(ρA1/ρCu)×DCu, the electrical resistance of the aluminum wire coil 31 is greater than or equal to the electrical resistance of the copper wire coil 32, and therefore the loss generated in the aluminum wire coil 31 is greater than or equal to the loss generated in the copper wire coil 32. That is, a large loss (i.e., heat) is generated in the aluminum wire coil 31 concentrated in the first region 101, and its heat is dissipated through the yoke 11 of the stator core 10. Thus, especially high heat dissipation effect can be obtained.
For example, when the electrical resistivity ρA1 of the aluminum wire coil 31 is 2.82×10−8 [Ω·m] and the electrical resistivity ρCu, of the copper wire coil 32 is 1.68×10−8 [Ω·m], the upper limit of the diameter DA1 [mm] of the aluminum wire coil 31 is 1.296 times the diameter DCu [mm] of the copper wire coil 32. When the diameter DA1 of the aluminum wire coil 31 is smaller than 1.296×DCu, especially high heat dissipation effect is obtained.
In the equation (1), the lower limit of the diameter DA1 of the aluminum wire coil 31 is equal to the diameter DCu of the copper wire coil 32. This is because, as mechanical strength of the aluminum wire coil 31 per unit cross-sectional area is lower than that of the copper wire coil 32, the diameter DA1 of the aluminum wire coil 31 is desirably greater than or equal to the diameter DCu of the copper wire coil 32 (i.e., DCu≤DA1) in order to obtain sufficient strength of the aluminum wire coil 31 in a winding process.
When the electrical resistivity ρA1 and the diameter DA1 of the aluminum wire coil 31 and the electrical resistivity ρCu and the diameter DCu of the copper wire coil 32 satisfy the equation (1), a large loss is generated in the aluminum wire coil 31 concentrated in the first region 101, and its heat can be efficiently dissipated through the yoke 11. Further, sufficient strength of the aluminum wire coil 31 in the winding process can be obtained.
Although the current flowing through the coils 31 and 32 is assumed to be 1 [A] when the equation (1) is derived, the current is not limited to 1 [A]. This is because of the following reason. If a current flowing through the coils 31 and 32 is expressed as I [A], and the loss generated in the aluminum wire coil 31 is equal to the loss generated in the copper wire coil 32, ρA1×(L/SA1)×I2=ρCu×(L/SCu)×I2 is satisfied. From this equation, the above-described SA1=(ρA1/ρCu)×SCu is obtained, from which the equation (1) is derived.
The relationship between the electrical resistivity ρA1 and the diameter DA1 of the aluminum wire coil 31 and the electrical resistivity ρCu and the diameter DCu of the copper wire coil 32 is not limited to the above-described equation (1). The following equation (2) may be satisfied.
The upper limit of the diameter DA1 of the aluminum wire coil 31 in equation (2) is the same as that in equation (1). The reason for this is as described above. In contrast, the lower limit of the diameter DA1 of the aluminum wire coil 31 in equation (2) is 0.5×DCu, i.e., ½ of the diameter DCu of the coil 32.
In a process of winding the coil 3 composed of the aluminum wire coil 31 and the copper wire coil 32 connected in series around the tooth 12 of the stator core 10, it is desirable to use a common winding machine in order to avoid complicating the process. When the aluminum wire coil 31 and the copper wire coil 32 have different diameters, it is necessary to adjust a nozzle diameter of a winding nozzle of the winding machine to the diameter of the thicker coil.
If the diameter DA1 of the aluminum wire coil 31 is less than ½ of the diameter DCu of the copper wire coil 32, the aluminum wire coil 31 may be inserted in two rows into the winding nozzle and may be damaged thereby. The winding machine winds the aluminum wire coil 31 and the copper wire coil 32 by applying the same tension, and thus disconnection of the aluminum wire coil 31 may occur if the aluminum wire coil 31 is extremely thin.
For the reasons described above, in equation (2), the diameter DA1 [mm] of the aluminum wire coil 31 is set to be greater than or equal to 0.5×DCu [mm]. Thus, a large loss is generated in the aluminum wire coil 31 concentrated in the first region 101, and its heat is effectively dissipated through the yoke 11, while the damage and disconnection of the aluminum wire coil 31 in the winding process can be prevented.
The ratio of the wire cross-sectional area SA1 of the aluminum wire coil 31 to the wire cross-sectional area SCu of the copper wire coil 32, i.e., SA1/SCu is referred to as a cross-sectional area ratio k. Since the cross-sectional area SA1 is π×(DA1/2)2 and the cross-sectional area SCu is π×(DCu/2)2, the cross-sectional area ratio k can be expressed as k=(DA1/DCu)2. When the cross-sectional area ratio k is used, DCu≤DA1 of equation (1) is expressed as 1≤k. Further, 0.5×DCu≤DA1 of equation (2) is expressed as k≤0.25.
As described above, the aluminum wire coil 31 and the copper wire coil 32 are connected in series, and the loss generated in the aluminum wire coil 31 with the higher electrical resistivity is higher than the loss generated in the copper wire coil 32. In the first region 101 of the slot 13, the aluminum wire coil 31 in which a large loss is generated is disposed more densely, and thus the heat of the aluminum wire coil 31 is dissipated through the yoke 11.
A loss density will be described herein. The loss density [W/mm2] is a value obtained by dividing the loss generated in the coil by the wire cross-sectional area of the coil. Here, consideration will be given to a range of the loss density of the aluminum wire coil 31 with respect to the loss density of the copper wire coil 32 with which the heat dissipation effect is enhanced.
The wire cross-sectional area SA1 [mm2] of the aluminum wire coil 31 and the wire cross-sectional area SCu [mm2] of the copper wire coil 32 have the relationship of SA1=k×SCu using the definition (k=SA1/SCu) of the cross-sectional area ratio k. When the current flowing through the coil 3 is 1 [A], the loss [W] generated in the aluminum wire coil 31 is RA1 while the loss [W] generated in the copper wire coil 32 is RCu.
Therefore, the loss density [W/m2] of the aluminum wire coil 31 is RA1/SA1, and is expressed as RA1/(k×SCu) using the cross-sectional area ratio k. The loss density [W/m2] of the copper wire coil 32 is RCu/SCu.
A loss density ratio is defined as a ratio of the loss density of the aluminum wire coil 31 to the loss density of the copper wire coil 32. The loss density ratio is {RA1/(k×SCu)}/{RCu/SCu}, and thus is expressed as RA1/(k×RCu).
When the loss density ratio is 1 or more, that is, when the loss density of the aluminum wire coil 31 is greater than or equal to the loss density of the copper wire coil 32, a large loss can be generated in the aluminum wire coil 31 disposed in the first region 101, and the heat can be efficiently dissipated through the yoke 11. Thus, 1≤RA1/(k×RCu) is desirable.
As the mechanical strength of the aluminum wire coil 31 per unit cross-sectional area is lower than that of the copper wire coil 32, it is desirable that the diameter DA1 of the aluminum wire coil 31 is greater than or equal to the diameter DCu of the copper wire coil 32, in order to obtain sufficient strength for the winding process using the common winding machine. Thus, 1≤k is desirable.
From the above, the cross-sectional area ratio k, the electrical resistance RA1 [Ω] of the aluminum wire coil 31, and the electrical resistance RCu [Ω] of the copper wire coil 32 satisfy the following equations (3) and (4). Thus, a large loss can be generated in the aluminum wire coil 31 concentrated in the first region 101 and its heat can be efficiently dissipated through the yoke 11, while the sufficient strength of the aluminum wire coil 31 in the winding process can be obtained.
Here, the upper limit of the loss density ratio RA1/(k×RCu) is RA1/RCu which is obtained by substituting 1 into k. For example, when the diameter DCu of the copper wire coil 32 is 0.9 [mm], the electrical resistance RCu of the copper wire coil 32 is 27.1 [Ω], the diameter DA1 of the aluminum wire coil 31 is 0.9 [mm], and the electrical resistance RA1 of the aluminum wire coil 31 is 73.72 [Ω], the upper limit of RA1/(k×RCu) is RA1/RCu=1.679. Thus, a desirable range of the loss density ratio RA1/(k×RCu) is expressed as 1≤RA1/(k×RCu)≤1.679.
In addition, the cross-sectional area ratio k, the electrical resistance RA1 [Ω] of the aluminum wire coil 31, and the electrical resistance RCu [Ω] of the copper wire coil 32 may satisfy the following equations (5) and (6). Equation (5) is the same as the equation (3) described above.
As described above, when the aluminum wire coil 31 and the copper wire coil 32 are wound using the common winding machine, the nozzle diameter of the winding nozzle of the winding machine needs to be adjusted to the diameter of the thicker coil. If the diameter DA1 of the aluminum wire coil 31 is less than or equal to ½ of the diameter DCu of the copper wire coil 32, the aluminum wire coil 31 may be inserted in two rows into the winding nozzle and may be damaged thereby. The winding machine winds the aluminum wire coil 31 and the copper wire coil 32 by applying the same tension, and thus disconnection of the aluminum wire coil 31 may occur if the aluminum wire coil 31 is extremely thin.
Thus, the lower limit of diameter DA1 [mm] of the aluminum wire coil 31 is desirably 0.5×DCu [mm]. This condition is expressed as 0.25≤k using the cross-sectional area ratio k.
As described above, the cross-sectional area ratio k, the electrical resistance RA1 [Ω] of the aluminum wire coil 31, and the electrical resistance RCu [Ω] of the copper wire coil 32 satisfy equations (5) and (6). Thus, a large loss can be generated in the aluminum wire coil 31 concentrated in the first region 101 of the slot 13 and its heat can be efficiently dissipated through the yoke 11, while the damage and disconnection of the aluminum wire coil 31 in the winding process can be sufficiently prevented.
Here, the upper limit of loss density ratio RA1/(k×RCu) is RA1/(0.25×RCu) which is obtained by substituting 0.25 into k. For example, when the diameter DCu of the copper wire coil 32 is 0.9 [mm], the electrical resistance Rm of the copper wire coil 32 is 27.1 [Ω], the diameter DA1 of the aluminum wire coil 31 is 0.45 [mm], and the electrical resistance RA1 of the aluminum wire coil 31 is 174.9 [Ω], the upper limit of RA1/(k×RCu) is RA1/(0.25×RCu)=25.815. In this case, a desirable range of the loss density ratio RA1/(k×RCu) is expressed as 1≤RA1(k×RCu)≤25.815.
The motor 100 of the first embodiment is an induction motor as described above. That is, a rotating magnetic field is generated by the current in the coil 3 of the stator 1, and generates an induced current in the squirrel-cage secondary conductor 6 of the rotor 5, so that torque is produced by the action of the induced current and the rotating magnetic field.
The induction motor is generally driven without using an inverter. That is, a controller of the motor 100 generally drives the motor 100 by supplying a constant voltage to the coil 3. Thus, the fluctuation in load applied to the motor 100 or voltage supplied to the motor 100 may cause significant increase in the current flowing through the coil 3, and may cause rise in temperature of the coil 3.
Since the motor 100 of the first embodiment has the high heat dissipation effect as described above and thus can suppress the increase in the temperature of the coil 3, especially high effect can be obtained when the motor 100 is applied to the induction motor where the current largely fluctuates. Although the motor 100 of the first embodiment is the induction motor, the high heat dissipation effect can be obtained even when the motor 100 is a synchronous motor.
As described above, in the first embodiment of the present invention, the area S1 of the first region 101 of the slot 13, the total cross-sectional area A1 of the aluminum wire coil 31 (i.e., the first coil) in the first region 101, the area S2 of the second region 102, and the total cross-sectional area A2 of the aluminum wire coil 31 in the second region 102 satisfy (A1/S1)>(A2/S2). In this way, the aluminum wire coil 31 with the higher electrical resistivity are densely disposed in the first region 101 on the outer side of the slot 13 in the radial direction, and thus the heat of the aluminum wire coil 31 can be efficiently dissipated through the yoke 11 of the stator core 10, and thus an increase in the temperature can be suppressed. Furthermore, the heat dissipation effect of the motor 100 makes it possible to flow a large amount of current through the coil 3, and thus an output of the motor 100 can be increased.
The total cross-sectional area A1 of the aluminum wire coil 31 in the first region 101, the total cross-sectional area C1 of the copper wire coil 32 (i.e., the second coil) in the first region 101, and the area S1 of the first region 101 satisfy (A1/S1)>(C1/S1). In this way, the occupancy density of the aluminum wire coil 31 is higher than the occupancy density of the copper wire coil 32 in the first region 101, and thus the heat of the aluminum wire coil 31 can be efficiently dissipated through the yoke 11 of the stator core 10. Therefore, the heat dissipation effect can be further enhanced.
The total cross-sectional area A1 of the aluminum wire coil 31 in the first region 101, the total cross-sectional area C1 of the copper wire coil 32 in the first region 101, the total cross-sectional area A2 of the aluminum wire coil 31 in the second region 102, and the total cross-sectional area C2 of the copper wire coil 32 in the second region 102 satisfy (A1/C1)>(A2/C2). In this way, the ratio of the total cross-sectional area of the aluminum wire coil 31 to that of the copper wire coil 32 is higher in the first region 101 than in the second region 102, and thus the heat of the aluminum wire coil 31 can be efficiently dissipated through the yoke 11 of the stator core 10, so that the heat dissipation effect can be further enhanced.
The electrical resistivity ρA1 [Ω·m] and the diameter DA1 [mm] of the aluminum wire coil 31 and the electrical resistivity ρCu [Ω·m] and the diameter DCu [mm] of the copper wire coil 32 satisfy the above-described equation (1). Thus, a large loss (i.e., heat) is generated in the aluminum wire coil 31 concentrated in the first region 101, and its heat is dissipated through the yoke 11 of the stator core 10, so that the heat dissipation effect can be further enhanced. Moreover, by making the diameter DA1 of the aluminum wire coil 31 greater than or equal to the diameter DCu of the copper wire coil 32, sufficient strength of the aluminum wire coil 31 in the winding process can be obtained.
The electrical resistivity ρA1 [Ω·m] and the diameter DA1 [mm] of the aluminum wire coil 31 and the electrical resistivity ρCu [Ω·m] and the diameter DCu [mm] of the copper wire coil 32 satisfy the above-described equation (2), and thus the heat dissipation effect can be enhanced. Further, by making the diameter DA1 of the aluminum wire coil 31 greater than or equal to ½ of the diameter DCu of the copper wire coil 32, the damage and disconnection of the aluminum wire coil 31 in the winding process can be prevented.
In addition, the electrical resistance RA1 of the aluminum wire coil 31, the electrical resistance RCu of the copper wire coil 32, and the cross-sectional area ratio k, which is the ratio of the cross-sectional area of the aluminum wire coil 31 to the cross-sectional area of the copper wire coil 32, satisfy the above-described equation (3). Thus, the loss density of the aluminum wire coil 31 is greater than or equal to the loss density of the copper wire coil 32. Therefore, a large loss can be generated in the aluminum wire coil 31, and its heat can be efficiently dissipated through the yoke 11, so that the heat dissipation effect can be further enhanced.
When the cross-sectional area ratio k is greater than or equal to 1, sufficient strength of the aluminum wire coil 31 can be obtained in the winding process using the common winding machine. When the cross-sectional area ratio k is greater than or equal to 0.25, the damage or disconnection of the aluminum wire coil 31 can be prevented in the winding process using the common winding machine.
The motor 100 of the first embodiment exhibits especially high effect when the motor 100 is applied to the induction motor which is generally driven without using the inverter.
Although the aluminum wire coil 31 as the first coil and the copper wire coil 32 as the second coil are used in the first embodiment, the coils are not limited to a combination of the aluminum wire coil 31 and the copper wire coil 32. For example, two types of coils may be selected from coils made of gold, silver, copper, aluminum, and the like. In this case, one of the selected coils that has a higher electrical resistivity may be used as the first coil, while the other of the selected coils that has a lower electrical resistivity may be used as the second coil.
In contrast, in the modification, only the aluminum wire coil 31 is disposed in the first region 101 of the slot 13. In the second region 102, the aluminum wire coil 31 and the copper wire coil 32 are disposed. The other configuration of the modification is the same as described in the first embodiment.
In the modification, only the aluminum wire coil 31 is disposed in the first region 101 where the heat dissipation efficiency is high. Thus, the heat of the aluminum wire coil 31 can be more effectively transferred to the stator core 10 and dissipated therethrough.
Next, a scroll compressor 300 as the compressor to which the motor 100 described in the first embodiment and the modification is applicable will be described.
The compression mechanism 305 includes a fixed scroll 301 having a spiral portion, an swing scroll 302 having a spiral portion that forms a compression chamber between itself and the spiral portion of the fixed scroll 301, a compliance frame 303 that holds an upper end of the shaft 55, and a guide frame 304 that is fixed to the closed container 307 and holds the compliance frame 303.
A suction pipe 310 penetrating the closed container 307 is press-fitted into the fixed scroll 301. The closed container 307 is provided with a discharge pipe 311 that allows high-pressure refrigerant gas discharged from the fixed scroll 301 to be discharged to the outside. The discharge pipe 311 is connected to a not shown opening provided between the motor 100 and the compression mechanism 305 in the closed container 307.
The motor 100 is fixed to the closed container 307 by fitting the stator 1 into the closed container 307. The configuration of the motor 100 is as described above. A glass terminal 309 for supplying electric power to the motor 100 is fixed to the closed container 307 by welding.
When the motor 100 rotates, the rotation of the motor 100 is transmitted to the swing scroll 302, and the swing scroll 302 swings. When the swing scroll 302 swings, a volume of the compression chamber formed between the spiral portion of the swing scroll 302 and the spiral portion of the fixed scroll 301 changes. Refrigerant gas is sucked therein through the suction pipe 310, compressed, and discharged through the discharged pipe 311.
During rotation of the motor 100, the current flows through the coil 3, and heat is generated. The heat generated in the coil 3 is transferred to the stator core 10 via the insulating portion (
Although the scroll compressor 300 is described as an example of the compressor, the motor described in each of the first embodiment and modification may also be applied to compressors other than the scroll compressor 300.
Next, an air conditioner to which the motor of each of the above-described first embodiment and modification is applicable will be described.
The compressor 401, the condenser 402, and the throttle device 403 are provided in an outdoor unit 410. The compressor 401 is constituted by the scroll compressor 300 shown in
An operation of the air conditioner 400 is as follows. The compressor 401 compresses sucked refrigerant, and sends out the compressed refrigerant. The condenser 402 exchanges heat between the refrigerant flowing from the compressor 401 and outdoor air to condense and liquefy the refrigerant and sends out the liquefied refrigerant to the refrigerant pipe 407. The outdoor fan 405 supplies outdoor air to the condenser 402. The throttle device 403 adjusts the pressure or the like of the refrigerant flowing through the refrigerant pipe 407 by changing its opening degree.
The evaporator 404 exchanges heat between the refrigerant brought into a low-pressure state by the throttle device 403 and the indoor air to cause the refrigerant to take heat from the indoor air and evaporate (vaporize), and then sends out the evaporated refrigerant to the refrigerant pipe 407. The indoor fan 406 supplies indoor air to the evaporator 404. Thus, cooled air deprived of heat at the evaporator 404 is supplied into the room.
As described above, the motor 100 of each of the first embodiment and the modification has the high heat dissipation effect and thus can suppress an increase in the temperature inside the compressor 401. Thus, a stable operation of the air conditioner 400 is enabled. With the increase in output of the compressor 401 due to the increase in output of the motor 100, the output of the air conditioner 400 can also be increased.
Although the desirable embodiment of the present invention has been described, the present invention is not limited to the above-described embodiment, and various modifications and changes can be made without departing from the scope of the present invention.
This application is a U.S. national stage application of International Patent Application No. PCT/JP2018/006204 filed on Feb. 21, 2018, the disclosure of which is incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2018/006204 | 2/21/2018 | WO | 00 |
