This application is related to Japanese Patent Application No. 2007-305118 filed on Nov. 26, 2007, the contents of which are hereby incorporated by reference.
1. Field of the Invention
The present invention relates to a stator of an electric rotating machine and an electric rotating machine including the stator.
2. Description of Related Art
Recently, there is a growing need for high-output and compact electric rotating machine usable as an electric motor or an alternator mounted on a vehicle.
The reason is that the space in the engine compartment of a vehicle assigned to mount electric rotating machines is becoming smaller and smaller, while the output power required of each of them is becoming higher and higher.
As shown, for example, in Japanese Patent Application Laid-open No. 2004-88993, there is known an electric rotating machine in which a coil of its stator is constituted by phase windings which are successively joined so as to form a three-phase stator winding.
In this conventional electric rotating machine, the three-phase stator winding is constituted by 12 wires, and the stator has such a configuration that 24 wire ends of the 12 wires project axially from the stator. Accordingly, this conventional electric rotating machine has a problem in that since a space for electrical connection of the 24 wire ends is needed in the axial direction of the stator, the stator becomes large in size in the axial direction.
The present invention provides a stator of an electric rotating machine comprising:
a stator core having slots formed therein along a circumference direction thereof; and
a stator coil constituted by a plurality of phase windings wave-wound around said stator core along said circumferential direction;
each of said plurality of said phase windings being constituted by a first winding portion and a second winding wound in opposite directions, each of said first and second winding portions including in-slot portions accommodated in said slots, turn portions each connecting an adjacent two of said in-slot portions, and a foldback portion defined by one of said in-slot portions at which said first and second winding portions are joined to each other,
said in-slot portions of said first and second winding portions being accommodated together in every one of a predetermined number of said slots adjacent in said circumferential direction such that said first winding portion and said second winding portion alternate in a depth direction of said slots along said circumferential direction,
a first one of said slots which accommodates said foldback portion, and a second one of said slots which is adjacent to said first one of said slots and does not accommodate one of said in-slot portions which is adjacent to said foldback portion having a depth deeper than a height of a pile of a predetermined number of said slots to be accommodated in each of said slots.
The present invention also provides a stator of an electric rotating machine comprising:
a stator core having slots formed therein along a circumference direction thereof; and
a stator coil constituted by a plurality of phase windings wave-wound around said stator core along said circumferential direction;
each of said plurality of said phase windings being constituted by a first winding portion and a second winding wound in opposite directions, each of said first and second winding portions including in-slot portions accommodated in said slots, turn portions each connecting adjacent two of said in-slot portions, and a foldback portion defined by one of said in-slot portions at which said first and second winding portions are joined to each other,
said in-slot portions of said first and second winding portions being accommodated together in every one of a predetermined number of said slots adjacent in said circumferential direction such that said first winding portion and said second winding portion alternate in a depth direction of said slots along said circumferential direction,
a first one of said slots circumferentially adjacent to a second one of said slots which accommodates said foldback portion being empty at a radial position at which said foldback portion is located,
a radial width of each of said phase windings being smaller at said turn portion connected to said foldback portion than at other portions thereof.
The present invention also provides an electric rotating machine comprising the stator as described above, and a rotor having a plurality of N-poles and S-poles alternately located along a circumferential direction thereof, said rotor being located inside or outside of said stator.
According to the present invention, it is possible to provide an electric rotating machine which is high-output and compact in size can be obtained.
Other advantages and features of the invention will become apparent from the following description including the drawings and claims.
In the accompanying drawings:
The rotor 2 includes a plurality of N-poles and S-poles made of permanent magnets and alternately located along its circumferential direction on its outer peripheral side facing the inner peripheral side of the stator 3. The number of poles of the rotor 2 is set as required. In this embodiment, the rotor 2 includes eight poles (four N-poles and four S-poles).
As shown in
The stator core 30 is formed in an annular ring formed with a plurality of slots 31 at its inner periphery. Each of the slots 31 is formed such that its depth direction coincides with the radial direction of the stator core 30. In this embodiment, two slots 31 are formed for each pole of the rotor 2 for each phase of the coil 4. Accordingly, the stator core 30 is formed with 48 (=8×3×2) slots 31 in total.
The stator core 30 is constituted by a plurality of segment cores arranged in the circumferential direction of the stator 3. In this embodiment, the stator core 30 is constituted by 24 segment cores. Each segment core includes a teeth portion extending radially inwardly and a back core portion in which the teeth portion is formed. Each segment core defines one slot 31 by itself, and another one slot 31 with a circumferentially adjacent segment core.
The segment core is formed by laminating 410 electromagnetic steel plates having a thickness of 0.3 mm. Between each adjacent two of the electromagnetic steel plates, an insulating thin film is interposed. Alternatively, the stator core 30 may be formed of thin metal plates and the insulating films.
The coil 4 is formed by winding a plurality of windings 40 in accordance with a predetermined method described later. As shown in
The outer layer 421 is formed of insulating material such as Nylon. The inner layer 420 is formed of insulating material such as polyamideimide or thermoplastic resin having a glass transition temperature higher than that of the material of the outer layer 421. Accordingly, since the outer layer 421 softens earlier than the inner layer 420 due to heat generated in the electric rotating machine, the windings 40 accommodated in the same slot 31 are heat-adhered to one other at their outer layers 421. As a result, since the windings 40 accommodated in the same slot 31 become integrated together to be a rigid body, the mechanical strength of the windings 40 increases. In addition, if excessive vibration occurs, since the adhered portion between the inner layer 420 and the outer layer 421 peels off earlier than the adhered portion between the inner layer 420 and the conductor 41, the adhesion between the inner layer 420 and the conductor 41 can be maintained to thereby ensure the insulation.
As shown in
As shown in
The coil 4 is formed by winding a plurality of the windings 40 in a predetermined shape. The windings 40 constituting the coil 4 are wave-wound in the circumferential direction on the inner periphery of the stator core 30. Each winding 40 includes linear in-slot portions 44 accommodated in the slots 31 formed in the stator core 30, and turn portions 45 each of which connects adjacent two in-slot portions 44. The in-slot portions 44 of each of the six phase windings U1, U2, V1, V2, W1 and W2 are accommodated in one of every six slots 31. The turn portions 45 are formed axially projecting from the end surfaces of the stator core 30.
That is, the coil 4 is formed by wave-winding the windings 40 in the circumferential direction in a state that one ends of windings 40 project from one of the end surfaces of the stator core 30. Each phase winding of the coil 4 is constituted by two winding portions 40a and 40b which are wave-wound differently, and connected to each other at a foldback portion 46 at which the winding direction is reversed. That is, the winding 40 is constituted including the first winding portion 40 and the second winding portion connected in series to each other. The winding portions 40a and 40b are accommodated in the same slots 31 at their in-slot portions 44 such that they alternate in depth of the slots 31 along the circumferential direction.
In this embodiment, two sets of an assembly of the winding portions 40a and 40b constitute one of three phases. In other words, in this embodiment, six sets of the assembly of the winding portions 40a and 40b constitute the coil 4 including 6 (=2×3) phase windings U1, U2, V1 V2, W1 and W2. That is, the coil 4 is constituted by 12 windings 40.
In this embodiment, the assemblies of the winding portions 40a and 40b are wound four times around the stator core 30 along the circumferential direction. That is, the coil 4 has such a configuration that the assemblies of the winding portions 40a and 40b are piled in four layers in the radial direction. Accordingly, each slot 31 accommodates 8 (=4×2) in-slot portions. The coil 4 having the above configuration is wound such that the ends of the windings 40 are located on the side of the outermost layer, and the foldback portions 46 of the windings 40 are located on the side of the innermost layer.
The turn portions 45 of the coil 4 are located on both axial end sides of the stator core 30. Each turn portion 45 is formed to have a crank-like shape with no twist in the circumferential direction at around its center. The height of the crank-like shape is about the same as the width of the winding 40, so that the turn portions 45 of the radially adjacent windings 40 do not interfere with each other to enable densely winding the turn portions 45. As a result, since the radial width of each of the coil ends of the coil 4 projecting from the end surface of the stator core 30 is reduced, it is possible to prevent the windings 40 from overhanging radially.
Furthermore, the turn portion 45 has a configuration projecting stepwise from the end surface of the stator core 30, so that the turn portion 45 does not interfere with the winding 40 projecting from the circumferentially adjacent slot 31. This makes it unnecessary to increase the height of the coil end from the end surface of the stator core 30, or to increase the radial width of the coil end for the purpose of preventing the windings 40 projecting from the circumferentially adjacent slots 31 from interfering with each other. Accordingly, this makes it possible to reduce the height of the coil end, and accordingly to prevent the coil 4 from overhanging radially.
The turn portion 45 is formed to have a shape of 4-step stairs, and the height of one step is about the same as the width (height) of the winding 40. This makes it possible to densely wind the turn portions 45, because the turn portions 45 having the same axial position can be overlapped with no gap therebetween.
The highest portion of the turn portion 45 having the stairs-like shape forms the crank-like portion. Therefore, more specifically, the turn portion 45 of the winding 40 has such a shape that two stairs-like portions are located at both sides of the crank-like portion.
The end portions of the assemblies of the winding portions 40a and 40b constituting the windings 40 project radially outwardly within the confines of the height of the coil end of the stator core 30. In more detail, the end portions the assemblies on the side of the neutral point project radially outwardly more than the end portions of the assemblies on the other side.
Next, the wound state of the windings 40 constituting the coil 4 is explained in detail with reference to
Here, the method to wind the U1-phase winding is explained with reference to
In
Since the rotor 2 is an eight-pole rotor, the windings 40 constituting the U1-phase winding are accommodated in eight of the slots 31 (the eight slots 31a to 31h) formed in the stator core 30. Of these eight slots, the slots 31a and 31b have a depth nearly equal to the height of nine piled in-slot portions 44. The other slots 31c to 31h have a depth nearly equal to the height of eight piled in-slot portions 44. The assembly is formed in a state of 8 in-slot portions being piled in the depth direction in each slot. In each slot, addresses having a larger value indicate a deeper position from the slot opening. In the slots 31a and 31b, the deepest accommodating space is indicated by an address of 0.
The assembly constituting the U1-phase winding is constituted by the winding portions 40a and 40b joined to each other. The end portion of the winding portion 40a is connected to the neutral point of the stator 3, and the end portion of the winding portion 4b is connected to the U1-phase terminal.
As shown in
Likewise, the winding portion 40b is accommodated in the address 0 of the slot 31b at its in-slot portion 44 closest to the phase terminal, and then accommodated in the address 1 of the slot 31c, in the address 2 of the slot 31d, and in the address 1 of the slot 31e at its in-slot portions 44, respectively. Thereafter, it is accommodated in the address 2 and the address 1 in an alternate manner. When the winding portion 40b makes a round in the stator core 30, it is accommodated in the address 2 of the slot 31h at its in-slot portion 44.
The depth positions in the slots 31 of the in-slot portions 44 of the winding portions 40a and 40b change places with each other as they go from the slot 31c to 31h.
The winding portion 40a accommodated in the address 1 of the slot 31h at its in-slot portion 44 is then accommodated in the address 2 of the slot 31a, in the address 3 of the slot 31b, in the address 4 of the slot 31c, and in the address 3 of the slot 31d at its in-slot portions 44, respectively. Thereafter, it is accommodated in the address 4 and the address 3 in an alternate manner. When the winding portion 40a makes another round in the stator core 30, it is accommodated in the address 3 of the slot 31h at its in-slot portion 44.
The winding portion 40b accommodated in the address 2 of the slot 31h at its in-slot portion 44 is then accommodated in the address 1 of the slot 31a, in the address 2 of the slot 31b, in the address 3 of the slot 31c, and in the address 4 of the slot 31d at its in-slot portions 44, respectively. Thereafter, it is accommodated in the address 3 and the address 4 in an alternate manner. When the winding portion 40b makes another round in the stator core 30, it is accommodated in the address 4 of the slot 31h at its in-slot portion 44.
The winding portion 40a accommodated in the address 3 of the slot 31h at its in-slot portion 44 is then accommodated in the address 4 of the slot 31a, in the address 5 of the slot 31b, in the address 6 of the slot 31c, and in the address 5 of the slot 31d at its in-slot portions 44, respectively. Thereafter, it is accommodated in the address 6 and the address 5 in an alternate manner. When the winding portion 40a makes another round in the stator core 30, it is accommodated in the address 5 of the slot 31h at its in-slot portion 44.
The winding portion 40b accommodated in the address 4 of the slot 31h at its in-slot portion 44 is then accommodated in the address 3 of the slot 31a, in the address 4 of the slot 31b, in the address 5 of the slot 31c, and in the address 6 of the slot 31d at its in-slot portions 44, respectively. Thereafter, it is accommodated in the address 5 and the address 6 in an alternate manner. When the winding portion 40b makes another round in the stator core 30, it is accommodated in the address 6 of the slot 31h at its in-slot portion 44.
The winding portion 40a accommodated in the address 5 of the slot 31h at its in-slot portion 44 is then accommodated in the address 6 of the slot 31a, in the address 7 of the slot 31b, in the address 8 of the slot 31c, and in the address 7 of the slot 31d at its in-slot portions 44, respectively. Thereafter, it is accommodated in the address 8 and the address 7 in an alternate manner. When the winding portion 40a makes another round in the stator core 30, it is accommodated in the address 7 of the slot 31h at its in-slot portion 44.
The winding portion 40b accommodated in the address 6 of the slot 31h at its in-slot portion 44 is then accommodated in the address 5 of the slot 31a, in the address 6 of the slot 31b, in the address 7 of the slot 31c, and in the address 8 of the slot 31d at its in-slot portions 44, respectively. Thereafter, it is accommodated in the address 7 and the address 8 in an alternate manner. When the winding portion 40b makes another round in the stator core 30, it is accommodated in the address 8 of the slot 31h at its in-slot portion 44.
The winding portion 40a accommodated in the address 7 of the slot 31h at its in-slot portion 44, is then accommodated in the address 8 of the slot 31a at its next in-slot portion 44. The winding portion 40b accommodated in the address 8 of the slot 31h at its in-slot portion 44, is then accommodated in the address 8 of the slot 31a at its next in-slot portion 44.
That is, the in-slot portion 44 accommodated in the address 8 of the slot 31a forms the foldback portion 46.
The address 7 of the slot 31a and the address 8 of the slot 31b are empty.
In the stator 3 of the electric rotating machine of this embodiment, the empty space in the address 7 of the slot 31a makes handling and arranging of the turn portion 45 connected to the foldback portion 46 easy. This makes it possible to prevent the coil end of the stator 3 from projecting radially inwardly.
In addition, the first embodiment provides the following advantages.
Since each phase winding is constituted by the assembly of the winding portions 40a and 40b wound in opposite directions and joined to each other at the foldback portion 46, and accordingly, the number of the end portions of each phase winding is reduced by half, the cost for carrying out electrical connection of these end portions can be significantly reduced. In addition, since the end portions of each phase winding are located radially outwardly of the coil 4 across from the rotor 2, connection work between the end portions and external terminals is easy.
Each of the phase windings is made of the metal conductor having a rectangular cross-section, and the insulating resin film covering the metal conductor. This makes it possible to reduce the cost of manufacturing the phase windings.
In a second embodiment of the invention, all the slots 31a to 31h have a depth sufficient to accommodate nine in-slot portions. The others are the same as the first embodiment.
In the second embodiment, the innermost accommodating space is an empty space to handle the turn portions 45. The second embodiment makes it possible to prevent the coil end from protruding radially inwardly as well as the first embodiment. In addition, since all of the slots have a sufficiently large depth, the phase windings can be wound with a high degree of flexibility.
In the foregoing first and second embodiments, the slots are made sufficiently deep to form the space to handle the turn portions 45. However, if the number of the assemblies of the winding portions 40a and 40b is reduced, the number of the in-slot portions 44 to be accommodated in the slot 31 can be reduced for the same depth of the slot 31. Accordingly, also by reducing the number of the assemblies of the winding portions 40a and 40b, it is possible to prevent the coil end from protruding radially inwardly as well as the first and second embodiments.
Although not shown in
In each of theses phases, the windings 40 are wound in the same way as in U1-phase described above. Accordingly, when the connection of the in-slot portions between the slot 31h and the slot 31a of U1-phase are made by the turn portion 45, this turn portion 45 interferes with equivalent turn portions 45 of other phases.
To solve this problem, in this embodiment, the number of turns of the winding 40 of U2-phase is set smaller than that of U1-phase. In more detail, as shown in
Furthermore, in this embodiment, the turn portion 45 extending between the slots 31h and 31a of U1-phase is formed to have a crank-like shape, and to have one-half the axial thickness of the in-slot portions 45.
By forming the turn portions 45 in a crank-like shape, it is possible to prevent them from interfering with equivalent turn portions 45 of other phases.
Although the turn portion 45 connected to the foldback portion 46 is made shorter in its axial width in this embodiment, there occurs no deterioration in electrical characteristic in this turn portion, because its radial width is set to such a value that its cross sectional area is the same as that of the in-slot portions.
Accordingly, also this embodiment makes it possible to prevent the coil end from protruding radially inwardly. In addition, since this embodiment makes it possible that all the slots have the same depth, the manufacturing cost of the stator core can be reduced.
In the foregoing embodiments, each phase winding of the coil 4 is constituted by the assemblies of the winding portions 40a and 40b joined to each other. In the comparison example 1, the coil 4 is differently constituted without using such an assembly.
Since the coil 4 is constituted by a number of the windings 40, and accordingly, it takes much time and a lot of labor to handle the winding-finish ends of the windings 40, the manufacturing cost increases.
In addition, since the winding-finish ends of the windings 40 have to be located axially outside the coil end, the coil 4 becomes bulky.
In contrast, in the foregoing embodiments of the invention, since the coil 4 is constituted by the assemblies of the winding portion 40a and the winding portion 40b joined through the foldback portion 46, the ends of the assemblies of the winding portion 40a and the winding portion 40b do not project from the coil end. This makes it possible to make the stator 3 compact in size.
In the comparison example 2, no space to handle the turn portions 45 connected to the foldback portions 46 is provided.
In contrast, in the foregoing embodiments of the invention, since the windings 40 do not project radially inwardly toward the rotor 2, there is no possibility that the coil 4 interferes with the rotor 2.
As clear from the above description, according to the invention, the stator 3 can be made compact in size, to thereby provide a high-output and compact electric rotating machine.
The above explained preferred embodiments are exemplary of the invention of the present application which is described solely by the claims appended below. It should be understood that modifications of the preferred embodiments may be made as would occur to one of skill in the art.
Number | Date | Country | Kind |
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2007-305118 | Nov 2007 | JP | national |