Rotary electric machine and method of manufacturing the same

Abstract

In a rotary electric machine including a stator and a rotor, the stator includes: a connected core (1) composed of a plurality of cores in which a first core (1b) and a second core (1c) are paired to connect in a belt shape to be rounded into a substantially cylindrical shape by being folded at a core connecting portion (1d) so as to surround the rotor; a plurality of coils in which a first coil (3f) and a second coil (3g) are paired; and a crossover wire (3c) which connects the winding end (3b) of the first coil (3f) to the winding start (3d) of the second coil (3g). The crossover wire (3c) are arranged on the inner diameter side than the core connecting portion (1d).

Claims

1. A method of manufacturing a rotary electric machine including a stator and a rotor arranged in face-to-face relation to said stator via an air gap, said stator including a connected core, a plurality of coils, and a crossover wire, the method of manufacturing the rotary electric machine comprising: forming said connected core from a plurality of cores in which a first core and a second core adjacent to said first core are paired to connect in a belt shape to be rounded into a substantially cylindrical shape by being folded at a core connecting portion so as to surround said rotor; forming said plurality of coils in which a first coil whose coil wire is wound around said first core via a coil bobbin and a second coil whose coil wire is wound around said second core via a coil bobbin; forming said crossover wire from a coil wire which connects the winding end of said first coil to the winding start of said second coil; forming said first coil, said second coil, and said crossover wire from a single continuous coil wire; and arranging said crossover wire to cross between the first core and the second core on the inner diameter side of the core connecting portion serving as the folding center of said plurality of cores, wherein said coil wire is wound using a hook pin having a hook portion at an end thereof and having a taper shape having a smaller diameter toward an outer end of the hook pin; and when said coil wire is completed, said hook pin is made to rotate centering on its axis to remove said core after coil winding from a winding machine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a plan view of a relevant part of a stator of a rotary electric machine according to Embodiment 1;

(2) FIG. 2 is a front view of a relevant part of the stator of the rotary electric machine according to Embodiment 1;

(3) FIG. 3 is a sectional view of a relevant part of the stator of the rotary electric machine according to Embodiment 1;

(4) FIG. 4 is a plan view of a relevant part of the case where a hook pin is rotated in order to remove cores;

(5) FIG. 5 is a front view of a relevant part of the case where the hook pin is rotated in order to remove cores;

(6) FIG. 6 is a sectional view of a relevant part of the case where the hook pin is rotated in order to remove cores;

(7) FIG. 7 is a plan view showing a relevant part of a connected core after winding;

(8) FIG. 8 is a front view showing the relevant part of the connected core after winding;

(9) FIG. 9 is a sectional view showing the relevant part of the connected core after winding;

(10) FIG. 10 is a plan view showing an entire stator after rounding;

(11) FIG. 11 is a plan view of a relevant part showing a state in the middle of hooking a coil by the hook pin;

(12) FIG. 12 is a front view of the relevant part showing a state in the middle of hooking the coil by the hook pin;

(13) FIG. 13 is a perspective view showing a connected core in a state fixed to a core fixing jig;

(14) FIG. 14 is a perspective view showing the connected core in a state unfixed to the core fixing jig;

(15) FIG. 15 is a sectional view of the stator of the rotary electric machine according to Embodiment 1;

(16) FIG. 16 is a connection diagram at the time when coils are connected in delta in the stator according to Embodiment 1;

(17) FIG. 17 is a connection diagram at the time when the coils are connected in star in the stator according to Embodiment 1;

(18) FIG. 18 is a sectional view of a stator of a rotary electric machine according to Embodiment 2;

(19) FIG. 19 is a plan view of a relevant part showing a conventional winding method in which coils are continuously wound using a connecting component;

(20) FIG. 20 is a plan view of a relevant part showing a conventional winding method in which coils are continuously wound using hook pins provided on a core fixing jig, the hook pins each being parallel to the direction of core stacking thickness;

(21) FIG. 21 is a plan view of a relevant part showing a conventional winding method in which coils are continuously wound using convex portions each provided on a coil bobbin; and

(22) FIG. 22 is a plan view of a relevant part showing a conventional winding method in which coils are continuously wound using protrusions each provided on a coil bobbin.

DESCRIPTION OF REFERENCE NUMERALS

(23) 1 Connected stator core 1a Tooth portion 1b First core 1c Second core 1d Core connecting portion 1e Cutout portion 2 Coil bobbin 2a Convex portion 2b Protrusion 3 Stator coil 3a Winding start of first coil 3b Winding end of first coil 3c Crossover wire 3d Winding start of second coil 3e Winding end of second coil 3f First coil 3g Second coil 4 Hook pin 4a Hook portion 5 Core fixing jig 6 Rotor 7 Magnet 8 Entire stator 9 Slot 10 Different connecting component 11 Pin 12 Winding nozzle

MODE FOR CARRYING OUT THE INVENTION

(24) Hereinafter, an embodiment example according to the present invention will be described with reference to drawings.

(25) Incidentally, the same reference numerals as those in the respective drawings represent the same or corresponding elements.

Embodiment 1

(26) FIG. 1 is a plan view of a relevant part of a stator of a rotary electric machine according to Embodiment 1 of the present invention.

(27) Furthermore, FIG. 2 is a front view of a relevant part of the stator of the rotary electric machine according to Embodiment 1; and FIG. 3 is a sectional view of a relevant part of the stator of the rotary electric machine according to Embodiment 1.

(28) Incidentally, FIG. 1 to FIG. 3 show a state during coil winding.

(29) In FIG. 1 to FIG. 3, reference numeral 1 denotes a connected core (connected stator core); 1a denotes a tooth portion of the connected core; 1b denotes a first core; 1c denotes a second core; 1e denotes a cutout portion provided on an outer periphery portion of each connected core; 2 denotes a coil bobbin; 3 denotes a coil; 3a denotes the winding start of a first coil; 3b denotes the winding end of the first coil; 3c denotes a crossover wire; 3d denotes the winding start of a second coil; 3e denotes the winding end of the second coil; 3f denotes the first coil; 3g denotes the second coil; 4 denotes a hook pin provided on a fixing jig that fixes the core during coil winding; and 4a denotes a hook portion provided on an end portion of the hook pin.

(30) Incidentally, in the drawings, the coil 3 includes the winding start 3a of the first coil, the winding end 3b of the second coil, the first coil 3f, the crossover wire 3c, the winding start 3d of the second coil, the winding end 3e of the second coil, and the second coil 3g.

(31) Furthermore, FIG. 1 shows the connected core 1 in which two cores of the first core 1b and the second core 1c are paired to connect at a core connecting portion 1d; however, in fact, a plurality of two or more cores (for example, 12 cores) are continuously connected in a belt shape (flat shape).

(32) A method of continuously winding a coil around a connected core according to the present embodiment will be described.

(33) The first coil 3f is wound clockwise around the first core 1b when seen from the core inner diameter direction; next, the crossover wire 3c of the coil is hooked on the hook pin 4 having the hook portion 4a at the end provided on the core fixing jig side; and the second coil 3g is wound counterclockwise when seen from the core inner diameter direction, around the second core 1c that is arranged on the left side of the first core 1b when seen from the core inner diameter direction.

(34) In the present embodiment, the crossover wire 3c of the coil is hooked on the hook pin 4 having the hook portion 4a at the end provided on the core fixing jig side to wind the coil around the core, which is to be described later; and accordingly, the hook portion does not need to be formed on the coil bobbin 2 as in the known art and thus the shape of the coil bobbin can be more simplified.

(35) Furthermore, in this embodiment, the hook pin 4 can be made of a material higher in rigidity than the coil bobbin 2; and therefore, the hook pin 4 can be formed thinner and thus the length of the crossover wire 3c can be shortened.

(36) The length of the crossover wire 3c can be shortened; and accordingly, the crossover wire can be placed well inside the stator, an increase in resistance value of the coil wire can be suppressed, and the rotary electric machine can also be improved in performance.

(37) Next, FIG. 4 is a plan view of a relevant part of the case where the hook pin is rotated in order to remove cores; FIG. 5 is a front view of the relevant part of the case where the hook pin is rotated in order to remove cores; and FIG. 6 is a sectional view of the relevant part of the case where the hook pin is rotated in order to remove cores.

(38) Incidentally, as in FIG. 1, FIG. 4 shows the connected core 1 in which two cores of the first core 1b and the second core 1c are paired to connect at the core connecting portion 1d; however, in fact, a plurality of two or more cores are continuously connected in a belt shape.

(39) When continuous winding work of the coil wire around each core of the belt shaped connected core 1 is completed, the belt-shaped connected core 1 around which the coil wire is wound is removed from the core fixing jig (not shown in the drawing) and the removed belt-shaped connected core needs to be rounded into a round shape in the outer periphery thereof in order to be used as the stator of the rotary electric machine.

(40) In the present embodiment, as shown in FIG. 4 and FIG. 5, the hook pin 4 has a structure in which the hook portion 4a at the end is rotatable centering on the axis of the hook pin 4. Further, as shown in FIG. 6, the hook pin 4 has a taper shape that is smaller in diameter as approaching to the end.

(41) The hook pin 4 has such structure; and accordingly, when continuous winding of the coil is completed, the hook portion 4a can be easily removed without getting stuck with the wound coil by rotating the hook portion 4a.

(42) That is, according to the present embodiment, the belt-shaped connected core around which the coil is wound can be easily removed from the core fixing jig; and therefore, coil winding work can be efficiently performed.

(43) FIG. 7 is a plan view showing a relevant part of the connected core after coil winding; FIG. 8 is a front view showing a relevant part of the connected core after coil winding; and FIG. 9 is a sectional view showing a relevant part of the connected core after coil winding.

(44) Incidentally, as in FIG. 1 and FIG. 4, FIG. 7 shows the connected core 1 in which two cores of the first core 1b and the second core 1c are paired to connect at the core connecting portion 1d; however, in fact, a plurality of two or more cores are continuously connected in a belt shape.

(45) The winding start 3d of the second coil of the connected core removed from the core fixing jig after coil winding is fixed by winding a coil wire (for example, the winding end 3e of the second coil) on the upper layer of the second coil 3g as shown in FIG. 7; and therefore, the crossover wire 3c does not loosen.

(46) Incidentally, FIG. 7 shows a state before folding the belt-shaped connected core at the core connecting portion 1d to be rounded; and a letter A denotes a space portion between the first core 1b and the second core 1c.

(47) When the belt-shaped connected core 1 is folded at the core connecting portion 1d to be rounded, the belt-shaped connected core 1 becomes a substantially cylindrical shape to eliminate the space portion A and the outer periphery of the connected core 1 becomes a round shape.

(48) FIG. 10 is a plan view conceptually showing an entire stator after being rounded by folding the connected core at the core connecting portion 1d.

(49) The rounded connected core after removing from the core fixing jig is a substantially cylindrical shape and the central axis of the cylindrical shape substantially conforms to the rotational center axis of the rotor arranged in face-to-face relation to the stator.

(50) As shown in FIG. 10, the stator according to the present embodiment includes: the connected core 1 composed of a plurality of cores (1b, 1c, 1b, 1c, . . . ) in which the first core 1b and the second core 1c adjacent to the first core 1b are paired to connect in a belt shape to be rounded into a cylindrical shape by being folded at the core connecting portion 1d so as to surround the rotor 6; a plurality of coils in which the first coil 3f whose coil wire is wound around the first core 1b via the coil bobbin 2 and the second coil 3g whose coil wire is wound around the second core 1c via the coil bobbin 2 of the connected core 1; and the crossover wire 3c which connects the winding end 3b of the first coil to the winding start 3d of the second coil.

(51) Then, the first coil 3f, the second coil 3g, and the crossover wire 3c are formed of a single continuous coil wire in each of the plurality of coils; and the plurality of crossover wires 3c are arranged on the inner diameter side than the core connecting portion 1d serving as the folding center of the plurality of cores.

(52) The crossover wire 3c is arranged on the inner diameter side than the core connecting portion 1d serving as the folding center of the connected core; and therefore, when the belt-shaped connected core is rounded as shown in FIG. 10, the crossover wire 3c is bent in a direction being small in curvature, tension is applied in a direction in which the winding end 3b of the first coil is pressed to the first core 1b, and the winding end 3b of the first coil does not loosen.

(53) In this case, even when the arrangement of the first core 1b and the second core 1c and the winding direction of the first coil 3f and the second coil 3g are interchanged and, more specifically, even when the second core is arranged on the right side of the first core when seen from the core inner diameter direction and the first coil is wound counterclockwise and the second coil is wound clockwise when seen from the core inner diameter direction, similar effects can be obtained.

(54) Incidentally, FIG. 10 shows a state where the winding start 3a of the first coil wound around the first core 1b of the paired cores and the winding end 3e of the second coil wound around the second core 1c of the paired cores adjacent on the right side are not connected; however, the coil may be wound around each paired core by a single coil wire, alternatively the coil may be wound around all connected cores by a single coil wire.

(55) FIG. 11 is a plan view of a relevant part showing a state in the middle of hooking a coil by a hook pin; and FIG. 12 is a front view of a relevant part showing a state in the middle of hooking the coil by the hook pin.

(56) In FIG. 11 and FIG. 12, a coil wire to be served as the coil is discharged from a winding nozzle 12 of a winding machine (not shown in the drawing), the discharged coil wire is first wound around the first core 1b via the coil bobbin 2 to be the first coil 3f; and then, the first coil 3f is wound around the second core 1c via the coil bobbin 2 to be the second coil 3g. In this case, the coil bobbin 2 is attached to the first core 1b and the second core 1c, respectively.

(57) Incidentally, as described before, the winding end 3b of the first coil and the winding start 3d of the second coil are connected by the crossover wire 3c; and the first coil 3f, the crossover wire 3c, and the second coil 3g are configured by a single continuous coil wire. In this regard, however, the second coil 3g is before winding and therefore the second coil 3g is not shown in FIG. 11 and FIG. 12.

(58) FIG. 11 and FIG. 12 show a state where a portion of the crossover wire 3c is hooked by the hook portion 4a of the hook pin 4.

(59) FIG. 13 is a perspective view showing a connected core in a state fixed to a core fixing jig; and FIG. 14 is a perspective view showing the connected core in a state unfixed to the core fixing jig.

(60) FIG. 13 shows a state where the connected core in which a plurality of cores arranged in line in a belt shape are fixed to the core fixing jig 5 provided with rotatable hook pins 4.

(61) In this state, a coil wire is continuously wound around the plurality of cores by a winding machine (not shown in the drawing).

(62) Incidentally, when the connected core is fixed to the core fixing jig 5, the cutout portion 1e of the core shown in FIG. 1, FIG. 4, FIG. 7, and the like is used.

(63) FIG. 14 is the perspective view showing the connected core in the state unfixed to the core fixing jig. FIG. 14 shows a state where the connected core around which the coil is wound is removed from the core fixing jig 5 provided with the hook pin 4.

(64) FIG. 14 shows the state where the hook portion 4a of the hook pin 4 is rotated so as to easily remove the connected core around which the coil is wound.

(65) The hook portion 4a does not get stuck with the coil wire wound around the core by rotating the hook portion 4a of the hook pin 4; and therefore, the connected core around which the coil is wound can be easily removed from the core fixing jig 5.

(66) FIG. 15 is a sectional view of a stator of the rotary electric machine according to Embodiment 1.

(67) As shown in FIG. 15, the number of poles of a magnet 7 of the rotor 6 of the rotary electric machine according to the present embodiment is 10, and the number of slots 9 of an entire stator 8 is 12. Then, three phase coils are arranged in the order of U+, U, V, V+, W+, W, U, U+, V+, V, W, and W+. (+ and represent that winding directions are different.)

(68) Incidentally, in FIG. 15, hatched portions show coils and the slots 9 are provided in the core to place the coils.

(69) FIG. 16 is a connection diagram at the time when coils are connected in delta in the stator according to Embodiment 1.

(70) As shown in FIG. 16, a configuration is such that the coils are connected in delta and in two parallel groups of two coils in series each and the two coils in series are different in winding direction with each other.

(71) Furthermore, the two coils in series mean that two coils which are different in winding direction with each other and are connected in series (for example, U+, U).

(72) This configuration is made by a system of 10 poles and 12 slots, and the winding method of the present embodiment is applied to the two coils in series. For example, U+ corresponds to the first coil 3f and U corresponds to the second coil 3g.

(73) In addition, FIG. 17 is a connection diagram at the time when coils are connected in star in the stator according to Embodiment 1.

(74) As shown in FIG. 17, the coils may be connected in star and in two parallel groups of two coils in series each.

(75) In this case, the reason why the combination of the number of poles and the number of slots is 10 poles and 12 slots is that the winding factor with respect to a fundamental wave is large and the winding factor with respect to harmonics is small.

(76) That is, this shows that a torque ripple can be small while generating a large torque by the small number of magnets; and this leads to be able to supply a high-performance rotary electric machine inexpensively.

(77) As described above, the rotary electric machine according to the present embodiment is the rotary electric machine including the stator and the rotor 6 arranged in face-to-face relation to the stator via an air gap.

(78) The stator includes: the connected core 1 composed of a plurality of cores (1b, 1c, 1b, 1c, . . . ) in which the first core 1b and the second core 1c adjacent to the first core 1b are paired to connect in a belt shape to be rounded into a substantially cylindrical shape by being folded at the core connecting portion 1d so as to surround the rotor 6; a plurality of coils in which the first coil 3f whose coil wire is wound around the first core 1b via the coil bobbin 2 and the second coil 3g whose coil wire is wound around the second core 1c via the coil bobbin 2 of the connected core 1; and the crossover wire 3c which connects the winding end 3b of the first coil to the winding start 3d of the second coil.

(79) The first coil 3f, the second coil 3g, and the crossover wire 3c are formed of a single continuous coil wire in each of the plurality of coils.

(80) The plurality of crossover wires 3c are arranged on the inner diameter side than the core connecting portion 1d serving as the folding center of the plurality of cores.

(81) According to the present embodiment, when the belt-shaped connected core is rounded into the cylindrical shape, the crossover wire 3c is arranged on the inner diameter side than the core connecting portion 1d serving as the folding center of the connected core 1; and therefore, the crossover wire 3c is bent in a direction being small in curvature, tension is applied in a direction in which the winding end 3b of the first coil is pressed to the first core 1b, and the winding end 3b of the first coil does not loosen.

(82) Therefore, the winding end 3d of the first coil is wound to the winding start 3d of the second coil using the hook pin 4 and winding of the coil does not loosen even when the connected core around which the coil is wound is removed from the core fixing jig; and therefore, the rotary electric machine that is inexpensive and excellent in workability can be obtained.

(83) Furthermore, the plurality of coils of the rotary electric machine according to the present embodiment are formed of the single continuous coil wire. Therefore, connection work of the plurality of coils is not needed and workability of the coil winding work can be considerably improved.

(84) Further, the crossover wire 3c of the rotary electric machine according to the present embodiment is arranged on the outer diameter side of the plurality of coils rounded into a round shape and on the inner diameter side than the outer diameter of the plurality of coil bobbins rounded into a round shape.

(85) In addition, the crossover wire 3c of the rotary electric machine according to the present embodiment is bent in the direction being small in curvature. Therefore, the tension is applied in the direction where the winding end of the first coil is pressed to the first core; and thus, even when the core around which the coil is wound is removed from the core fixing jig, the coil winding does not loosen.

(86) Besides, in the rotary electric machine according to the present embodiment, the winding direction of the first coil 3f wound around the first core 1b is different from that of the second coil 3g wound around the second core 1c.

(87) Furthermore, in the rotary electric machine according to the present embodiment, the second coil 3g is arranged on the left side of the first coil 3f when seen from the core inner diameter direction; the winding direction of the first coil 3f is clockwise when seen from the core inner diameter direction; and the winding direction of the second coil 3g is counterclockwise when seen from the inner diameter direction.

(88) Further, in the rotary electric machine according to the present embodiment, the second coil 3g is arranged on the right side of the first coil 3f when seen from the core inner diameter direction; the winding direction of the first coil 3f is counterclockwise when seen from the core inner diameter direction; and the winding direction of the second coil 3g is clockwise when seen from the inner diameter direction.

(89) In addition, in the rotary electric machine according to the present embodiment, the number of poles of the magnet of the rotor 6 is 10 and the number of slots provided on the stator is 12.

(90) Besides, in the rotary electric machine according to the present embodiment, the plurality of coils are connected such that windings of the same phase are connected in two parallel groups of two coils in series each and respective phases are connected in delta or in star.

(91) According to the present embodiment, the following specific effects are exhibited. The coils can be continuously wound around the connected core in which a plurality of cores are connected. The coils are continuously wound; and therefore, the connecting component can be reduced. The coils are continuously wound; and therefore, connection process can be reduced. The coil wire is hooked by the hook pin on the core fixing jig side; and therefore, the shape of the coil bobbin can be simplified. A thin shaped hook pin can be used; and therefore, the length of the crossover wire can be shortened and the amount of coils to be used can be reduced. After winding, even when the belt shaped connected core is rounded, the crossover wire does not protrude on the outer side than the outer diameter of the coil bobbin. After winding, even when the core is rounded, the coil does not loosen. A posture of the core does not need to be changed during winding and during hooking; and therefore, the total time of winding can be shortened.

Embodiment 2

(92) In a rotary electric machine of Embodiment 2, as shown in FIG. 18, the number of poles of a magnet 7 of a rotor 6 is 14; the number of slots 9 of a stator core 8 is 12; and three phase coils are arranged in the order of U+, U, V, V+, W+, W, U, U+, V+, V, W, and W+. (+ and represent that winding directions are different.)

(93) The continuously arranged coils of the same phase are connected in series as in Embodiment 1 and are connected in two parallel groups of two coils in series each.

(94) A configuration is also similar that the two coils in series are different in winding direction with each other. The configuration of other portions is similar to Embodiment 1.

(95) In this case, the reason why the combination of the number of poles and the number of slots is 14 poles and 12 slots is that the winding factor with respect to a fundamental wave is large and the winding factor with respect to harmonics is small.

(96) The winding factor with respect to a fundamental wave is large and the winding factor with respect to harmonics is small shows that a torque ripple can be small while generating a large torque by the small number of magnets; and this leads to be able to supply a high-performance rotary electric machine inexpensively.

(97) As described above, in the rotary electric machine according to the present embodiment, the number of poles of the magnet of the rotor 6 is 14 and the number of slots provided on the stator is 12.

(98) Furthermore, in the rotary electric machine according to the present embodiment, a plurality of coils are connected such that windings of the same phase are connected in two parallel groups of two coils in series each and respective phases are connected in delta or in star.

INDUSTRIAL APPLICABILITY

(99) The present invention is useful for achieving a rotary electric machine that is inexpensive and excellent in workability, which is capable of continuously winding a coil around a belt-shaped connected core and is capable of reducing a space that places a crossover wire between coils.