Stator and electric motor with cancel coil for reducing unbalanced magnetic flux
10511200 ยท 2019-12-17
Assignee
Inventors
- Hirofumi Kinjo (Nagoya, JP)
- Masahito Shirahase (Nishio, JP)
- Toru Wakimoto (Chiryu, JP)
- Takeshi Tomonaga (Toyota, JP)
- Hiroyuki Hattori (Okazaki, JP)
Cpc classification
H02K1/146
ELECTRICITY
H02K5/1732
ELECTRICITY
H02K7/083
ELECTRICITY
International classification
Abstract
A stator for a electric motor, the stator including: a stator core including a yoke having an annular shape, and a plurality of teeth protruding from an inner circumferential surface of the yoke in a stator radial direction; a stator coil wound around the teeth, the stator coil being configured to generate a rotating magnetic field as a current is applied thereto; and a cancel coil extending in a stator axial direction at positions on the inner circumferential side and the outer circumferential side relative to the yoke, the cancel coil being wound around the stator core so as to extend in the stator radial direction and traverse the yoke at positions outside the stator core in the stator axial direction, and constituting one or more closed circuits.
Claims
1. A stator for an electric motor, the stator comprising: a stator core comprising: a yoke having an annular shape, and a plurality of teeth protruding from an inner circumferential side of the yoke in a stator radial direction; a stator coil wound around the teeth, the stator coil being configured to generate a rotating magnetic field as a current is applied to the stator coil; and a cancel coil extending in a stator axial direction at positions on the inner circumferential side and an outer circumferential side relative to the yoke, the cancel coil being wound around the stator core such that the cancel coil extends in the stator radial direction at positions outside the stator core in the stator axial direction and traverses the yoke, wherein the stator coil comprises phase coils including a U-phase coil, a V-phase coil, and a W-phase coil, wherein the U-phase coil, the V-phase coil, and the W-phase coil are connected to one another, wherein the cancel coil has a plurality of first element coils corresponding to the U-phase coil and wound at different locations, a plurality of second element coils corresponding to the V-phase coil and wound at different locations, and a plurality of third element coils corresponding to the W-phase coil and wound at different locations, and wherein the cancel coil has a plurality of closed circuits in each of which one first element coil, one second element coil, and one third element coil are connected in series.
2. The stator according to claim 1, wherein a magnetomotive force of the first element coil, a magnetomotive force of the second element coil, and a magnetomotive force of the third element coil are equal to one another.
3. The stator according to claim 1, wherein grooves penetrating in the stator axial direction are provided at locations facing to the teeth in an outer circumferential surface of the yoke, and the cancel coil is partially housed in the grooves.
4. The stator according to claim 1, wherein the cancel coil is arranged to pass through a slot that is a gap between the teeth, and the cancel coil is arranged to be wound such that the cancel coil traverses the yoke at positions outside the stator core in the stator axial direction.
5. The stator according to claim 1, wherein the cancel coil is arranged to pass through positions on the inner circumferential side relative to the stator coil, and the cancel coil is arranged to be wound such that the cancel coil traverses the stator coil and the yoke at positions outside the stator core in the stator axial direction.
6. The stator according to claim 1, wherein the cancel coil is arranged to pass through positions on the inner circumferential side relative to the teeth, and the cancel coil is arranged to be wound such that the cancel coil traverses the teeth and the yoke at positions outside the stator core in the stator axial direction.
7. The stator according to claim 1, wherein the stator coil is comprised of a U-phase coil, a V-phase coil, and a W-phase coil in star connection, and the cancel coil is not connected to the stator coil.
8. The stator according to claim 1, wherein the stator coil is comprised of a U-phase coil, a V-phase coil, and a W-phase coil in delta connection, and the cancel coil is connected in series to the stator coil.
9. The stator according to claim 1, wherein a portion of the cancel coil on the inner circumferential side of the yoke extends along the stator axial direction, and is arranged between two of the phase coils along a circumferential direction of the yoke.
10. An electric motor comprising: a rotor; a rotating shaft configured to be rotatably mounted on a housing through bearings and rotate with the rotor; and a stator disposed on an outer periphery of the rotor, the stator comprising: a stator core comprising: a yoke having an annular shape, and a plurality of teeth protruding from an inner circumferential side of the yoke in a stator radial direction, a stator coil wound around the teeth, the stator coil being configured to generate a rotating magnetic field as a current is applied to the stator coil, and a cancel coil extending in a stator axial direction at positions on the inner circumferential side and an outer circumferential side relative to the yoke, the cancel coil being wound around the stator core such that the cancel coil extends in the stator radial direction at positions outside the stator core in the stator axial direction and traverses the yoke, wherein the stator coil comprises phase coils including a U-phase coil, a V-phase coil, and a W-phase coil, wherein the U-phase coil, the V-phase coil, and the W-phase coil are connected to one another, wherein the cancel coil has a plurality of first element coils each corresponding to the U-phase coil and wound at different locations, a plurality of second element coils corresponding to the V-phase coil and wound at different locations, and a plurality of third element coils corresponding to the W-phase coil and wound at different locations, and wherein the cancel coil has a plurality of closed circuits in each of which one first element coil, one second element coil, and one third element coil are connected in series.
11. The electric motor according to claim 10, wherein a portion of the cancel coil on the inner circumferential side of the yoke extends along the stator axial direction, and is arranged between two of the phase coils along a circumferential direction of the yoke.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Features, advantages, and technical and industrial significance of exemplary embodiments will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
DETAILED DESCRIPTION OF EMBODIMENTS
(20) An embodiment will be described below with reference to the drawings.
(21) The electric motor 10 is mainly divided into a rotor 12, the stator 14, a rotating shaft 16, and a housing 18. The rotor 12 includes a rotor core 20 and permanent magnets embedded in the rotor core 20. The rotor core 20 is a columnar member composed of a stack of electromagnetic steel sheets. The rotating shaft 16 is inserted and fixed at the center of the rotor core 20. The rotating shaft 16 is mounted at both ends on the housing 18 through bearings 19, and the rotating shaft 16 and the rotor core 20 fixed to the rotating shaft 16 are rotatable relative to the housing 18.
(22) The bearing 19 has a plurality of rolling elements 19b (spherical bodies) disposed between an outer ring 19a and an inner ring 19c, with a lubricating oil film interposed between the outer ring 19a and the rolling elements 19b and between the inner ring 19c and the rolling elements 19b. This lubricating oil film functions both as a lubricant that allows smooth motion of the rolling elements 19b and as an insulation member that insulates the outer ring 19a and the inner ring 19c from each other. With the lubricating oil film thus interposed, the rotating shaft 16 and the housing 18 are electrically insulated from each other.
(23) The stator 14 has a stator core 24, a stator coil 30, and the cancel coil 32. The stator core 24 is a roughly cylindrical member that is disposed concentrically with the rotor 12, and includes an annular yoke 26 and a plurality of teeth 28 protruding in the radial direction from an inner circumferential surface of the yoke 26. The plurality of teeth 28 are arranged at predetermined intervals in the circumferential direction, and a slot that is a space into which the stator coil 30 is inserted is formed between each two adjacent teeth 28.
(24) Such a stator core 24 is composed of a plurality of electromagnetic steel sheets (e.g., silicon steel sheets) stacked in the axial direction. The plurality of electromagnetic steel sheets are positioned relative to one another and joined together to constitute the stator core 24. Many methods for positioning and joining electromagnetic steel sheets have been hitherto proposed. One example is a method in which a protrusion and a recess for crimping are formed in each electromagnetic steel sheet, and the protrusion of one electromagnetic steel sheet is fitted into the recess of another electromagnetic steel sheet to thereby position relative to one another and couple together the plurality of electromagnetic steel sheets and constitute the stator core 24.
(25) The stator coil 30 is composed of windings wound around the teeth 28 in concentrated arrangement. The stator coil 30 has three-phase phase coils, namely, a U-phase coil PU, a V-phase coil PV, and a W-phase coil PW. Where no distinction is made among the U-phase, the V-phase, and the W-phase in the following description, the phase coils will be referred to simply as phase coils P by omitting the alphabets U, V, W. One end of each phase coil P is connected to an input terminal (not shown). The other end of each phase coil P is connected to another phase coil P to constitute a neutral point (as shown in
(26) The cancel coil 32 is a coil wound around the yoke 26. The cancel coil 32 is not connected to the stator coil 30 but provided completely independent of the stator coil 30. The cancel coil 32 includes four first element coils CU corresponding to the U-phase coil PU, four second element coils CV corresponding to the V-phase coil PV, and four third element coils CW corresponding to the W-phase coil PW. Where no distinction is made among the first to third element coils, the element coils will be referred to simply as element coils C by omitting the alphabets U, V, W. Each element coil C extends in the axial direction at positions on the inner circumferential side and the outer circumferential side relative to the yoke 26, and is wound around the yoke 26 so as to extend in the radial direction and traverse the yoke 26 at positions outside the stator core 24 in the axial direction. As will be described in detail later, two types of magnetic fluxes flow through the yoke 26 in the circumferential direction, and the element coils C are wound so as to surround the periphery of the magnetic fluxes flowing in the circumferential direction.
(27) Here, the expression corresponding to the U-phase coil PU means having a certain magnetic relation with the U-phase coil PU. For example, in this embodiment, the element coil disposed next to the U-phase coil PU on the left side (between the U-phase coil PU and the V-phase coil PV) is the first element coil CU corresponding to the U-phase coil PU. Although the four first element coils CU are wound at different locations as is clear from
(28) Similarly, the coil disposed next to the V-phase coil PV on the left side (between the V-phase coil PV and the W-phase coil PW) is the second element coil CV corresponding to the V-phase coil PV, and the coil disposed next to the W-phase coil PW on the left side (between the W-phase coil PW and the U-phase coil PU) is the third element coil CW corresponding to the W-phase coil PW. Each of the first to third element coils CU, CV, CW has a certain positional relation with the corresponding phase coil P, and is subjected to a certain magnetic influence of a magnetic flux (so-called effective magnetic flux) generated as a current is applied to the corresponding phase coil P.
(29) Such first to third element coils CU, CV, CW are connected to one another so as to constitute one or more closed circuits. While various forms of connection are conceivable, in this embodiment, the four first element coils CU, the four second element coils CV, and the four third element coils CW composing the cancel coil 32 are connected in series to constitute a single closed circuit as shown in
(30) Next, reasons why the cancel coil 32 is provided will be described.
(31) To solve such a problem, some proposals have been made to separately provide a conductive member that connects the rotating shaft 16 and the housing 18 to each other. Such a configuration can suppress electrical corrosion of the bearings 19 by causing the induced current 52 to flow dominantly to the conductive member that has lower impedance than the bearings 19. However, employing such a conductive member leads to structural restrictions, which raises other problems such as that the design flexibility decreases and that the electric motor 10 as a whole increases in size, weight, and cost.
(32) This embodiment is provided with the cancel coil 32 to suppress electrical corrosion of the bearings 19 without requiring a conductive member that couples together the rotating shaft 16 and the housing 18. As described already, the cancel coil 32 is wound around the yoke 26, and mainly two types of magnetic fluxes flow through the yoke 26.
(33) One is the unbalanced magnetic flux 50 resulting from a magnetic unbalance in the electric motor 10. The unbalanced magnetic flux 50 flows through the yoke 26 in the circumferential direction. The unbalanced magnetic flux 50 is a tertiary magnetic flux that changes at a frequency three times higher than the fundamental frequency.
(34) The other is a magnetic flux that generates rotating torque. Hereinafter this magnetic flux will be referred to as an effective magnetic flux. The effective magnetic flux flows outward in the radial direction from a tip of one tooth 28, and moves through the yoke 26 in the circumferential direction, and then flows inward in the radial direction through another tooth 28 into the rotor 12. This effective magnetic flux is a primary magnetic flux that changes at the same frequency as the fundamental frequency.
(35) The element coils C composing the cancel coil 32 are wound around the yoke 26 so as to surround the periphery of the unbalanced magnetic flux 50 and the effective magnetic flux flowing through the yoke 26 in the circumferential direction. In other words, the unbalanced magnetic flux 50 and the effective magnetic flux penetrate the inside of the cancel coil 32. As a result, a voltage is induced in the cancel coil 32 according to the temporal change of the unbalanced magnetic flux 50 and the effective magnetic flux, and a current in the direction of blocking these magnetic fluxes flows through the cancel coil 32.
(36) Hereinafter a voltage induced according to the temporal change of the effective magnetic flux and a voltage induced according to the temporal change of the unbalanced magnetic flux 50 will be referred to as a primary induced voltage and a tertiary induced voltage, respectively.
(37)
(38)
(39) The form of connection of the element coils C shown in
(40) Yet another example may be a configuration in which two first element coils CU, two second element coils CV, and two third element coils CW are connected in series to constitute one closed circuit, and the cancel coil 32 as a whole includes two closed circuits. In any case, it is desirable that one closed circuit include the same numbers of the first element coils CU, the second element coils CV, and the third element coils CW. Such a configuration can reduce the sum A_V1 of the primary induced voltages in one closed circuit close to zero. In this case, it is also desirable that the first to third element coils CU, CV, CW are equal to one another in magnetomotive force, i.e., in material, shape, number of winding, etc. of the winding constituting the element coil C. Such a configuration can reduce the sum A_V1 of the primary induced voltages in one closed circuit to nearly zero. As a result, the influence of the cancel coil 32 on the rotating torque can be reduced more reliably.
(41) This embodiment is provided with the first to third element coils CU, CV, CW in one closed circuit to minimize the influence on the rotating torque. However, if suppression of electrical corrosion of the bearings 19 is the only purpose, the first to third element coils CU, CV, CW do not have to be connected in series. For example, one closed circuit may be composed of the first element coils CU alone, the second element coils CV alone, or the third element coils CW alone. This configuration can also reduce the unbalanced magnetic flux 50, and thus can suppress electrical corrosion of the bearings 19.
(42) Next, variations in arrangement of the element coils C will be described. In
(43) For example, the element coils C may be disposed only partially in the circumferential direction as shown in
(44) In the foregoing examples, the element coils C extend through the slots (pass through the slots) in the axial direction and are wound so as to traverse the yoke 26 on the outside of the stator core 24 in the axial direction. However, the positions of the element coils C may be changed as appropriate. For example, as shown in
(45) In the foregoing examples, grooves in which the element coils C are partially housed are provided in an inner circumferential surface of the housing 18 to avoid interference between the element coils C and the housing 18. Alternatively, as shown in
(46) In this case, the part of the element coil C located on the inner circumferential side relative to the yoke 26 may pass through the slot, or may pass through a position on the inner circumferential side relative to the phase coil P as shown in
(47) A coil end that is a part of the stator coil 30, a connecting wire that connects the coils P of the same phase to each other, and the like are present at the ends of the stator 14 in the axial direction. The element coils C may pass through the outside in the axial direction or the inside in the axial direction relative to these coil ends, connecting wire, etc. (hereinafter referred to collectively as the coil end etc.). Specifically, as shown in
(48) Alternatively, the ends of the element coil C in the axial direction may pass through the gap between the axial end face of the stator core 24 and the coil end etc. as shown in
(49) In the foregoing description, the case of star connection in which one ends of the three-phase phase coils PU, PV, PW are connected to one another at the neutral point is taken as an example. However, the technique of the present application is also applicable to the case of delta connection in which the three-phase phase coils PU, PV, PW are connected to one another in the direction of application of a phase voltage to constitute a closed circuit.