JP6696387B2 - Cassette coil for rotating electric machine - Google Patents

Description

  The present disclosure relates to a cassette coil for a rotary electric machine, and particularly to a cassette coil for a rotary electric machine that is concentratedly wound by two layers.

  As a method of winding around a plurality of teeth of a stator of a rotary electric machine, there are concentrated winding as well as distributed winding. In concentrated winding, one phase winding is wound around one tooth with a predetermined number of turns, and it is wound in advance as a cassette coil, assembled in sequence to each tooth, and each coil is connected with a crossover wire. To obtain a predetermined stator winding.

  Patent Document 1 describes that each tooth of a stator core of a rotating electric machine is covered with an insulator, and then a coil formed as a winding is fitted into each tooth from above the insulator. A snap fit is formed on the upper and lower end surfaces of the insulator, with a protrusion formed on the tip of the leaf spring.The snap fit returns when the inner end of the coil passes over while pushing the snap fit, and the protrusion on the tip causes the inner end surface of the coil to move. Hold.

  As a technique related to the present disclosure, when two-layer winding coils for concentrated winding are sequentially assembled to each tooth, when the last coil is assembled, the coils are already assembled on the teeth on both sides of the tooth. , It becomes difficult to assemble the last coil. At this time, the last coil is assembled to the tooth by utilizing the elastic deformability of the shape. However, in Patent Document 2, in the winding method of the two-layer winding coil, the outer first layer coil and the inner first layer coil are used. There is disclosed a configuration in which an appropriate gap is provided between the two-layer coil and the elastic deformability at the time of assembly is enhanced.

JP2012-222944A JP, 2013-223288, A

  Since the concentrated winding coil continuously winds one conductor wire concentrically, it can be easily expanded and contracted in the axial direction like a coil spring. When this concentrated winding cassette coil is assembled to the tooth, it expands and contracts in the axial direction, so unless the winding on the innermost diameter side is held down, it may collapse to the inner diameter side. When the winding on the innermost diameter side falls to the inner diameter side, an extra load is applied to the joint between the lead drawn from the winding on the innermost diameter side and the crossover wire, etc. There is a possibility that the insulation performance may deteriorate due to the inclusion of foreign matter between the phases. In order to prevent the inner diameter from collapsing, all the windings may be fixed to each other with an adhesive or the like, but then, the entire cassette coil is integrated, and when the last cassette coil is assembled to the tooth. Elastic deformation becomes difficult. Therefore, there is a demand for a cassette coil for a rotary electric machine that can prevent the winding of the winding on the inner diameter side from falling toward the inner diameter side while ensuring the elastic deformability at the time of assembling to the teeth.

  A cassette coil for a rotary electric machine according to the present disclosure has a two-layer winding in which a first-layer coil is stacked on a second-layer coil on the teeth side, and has a predetermined radial direction from the root side to the tip side of the teeth. In a cassette coil for a rotary electric machine, which is concentratedly wound in a plurality of winding stages, and winding is performed on one of the four outer peripheral sides of the tooth, the height arrangement from the tooth end face is regular along the radial direction. This is a winding of a hierarchical displacement structure having repeated steps, and only the two-layer winding of the winding stage on the radially innermost side of the plurality of winding stages is the first of the sides other than the side taking the hierarchical displacement structure. The two-layer coil and the first-layer coil are bonded and fixed by a fixing layer made of an insulating material.

  According to the above configuration, since the second layer coil and the first layer coil are not bonded and fixed except for the winding stage on the innermost diameter side, elastic deformability at the time of assembling to the tooth can be secured. In addition, in the two-layer winding of the winding stage on the innermost diameter side, the second layer coil and the first layer coil are adhesively fixed, so the inner diameter of the winding on the innermost diameter side is greater than when there is no adhesive fixing. Can prevent falling to the side.

  According to the cassette coil for a rotary electric machine having the above structure, it is possible to prevent the winding of the inner diameter side from collapsing to the inner diameter side while ensuring the elastic deformability when assembled to the tooth.

It is a perspective view which shows the relationship between the cassette coil for rotary electric machines which concerns on embodiment, and the teeth of the stator with which this is assembled. It is a figure which shows an example of the winding of the double layer winding in FIG. It is a flow chart which shows the procedure of the manufacturing method of the cassette coil for rotary electric machines concerning an embodiment. It is a figure which shows the coil winding process process in FIG. FIG. 4A is a front view, and FIG. 4B is a sectional view taken along the line BB of FIG. It is a figure which shows the fixing process process of the two-layer winding of the innermost diameter side in FIG. FIG. 5A is a diagram showing a state in which the winding coil is set on the fixing jig, and FIG. 5B is a diagram showing a pressure heating process for fixing. It is a figure corresponding to FIG. 3 and showing the cassette coil for rotary electric machines after the fixing process process of FIG. FIG. 6A is a front view, and FIG. 6B is a sectional view taken along line BB of FIG. It is a trihedral view of the cassette coil for rotary electric machines after the assembly process in FIG. It is a figure which shows the elastic deformation process process at the time of assembling the last cassette coil for rotary electric machines in FIG. It is a figure which shows the comparative example of the effect of embodiment. FIG. 9A is a diagram showing the winding of the winding on the inner diameter side when the two-layer winding on the innermost diameter side is not fixed, and FIG. 9B is a concentrated winding of the two-layer winding of the conventional technique. It is a figure which shows the insulator for.

  Embodiments according to the present invention will be described in detail below with reference to the drawings. In the following, a cassette coil used in a stator of a rotary electric machine mounted on a vehicle will be described. However, this is an example for explanation, and a stator of a rotary electric machine using a coil wound in a concentrated manner is not mounted on the vehicle. May be used. Hereinafter, as the concentratedly wound coil, a coil wound in two layers using a rectangular wire will be described, but this is an example for description. It suffices that the first layer coil and the second layer coil of the two-layer winding can be fixed to each other with an insulating material, and a conductor wire having an elliptical cross section other than a rectangular wire, or a conductor wire having a circular cross section may be used.

  The shape, the number of teeth, the number of winding stages, the total number of windings, the material, and the like described below are examples for description, and can be appropriately changed according to the specifications of the cassette coil for a rotary electric machine. In the following, similar elements are denoted by the same reference symbols in all the drawings, and redundant description will be omitted.

  FIG. 1 is a diagram showing a configuration of a rotary electric machine cassette coil 30 used in a stator 10 of a rotary electric machine mounted on a vehicle. Hereinafter, the stator 10 of the rotating electric machine will be referred to as the stator 10 and the cassette coil 30 for the rotating electric machine will be referred to as the cassette coil 30, unless otherwise specified.

  The rotating electrical machine in which the stator 10 is used is a motor-generator that functions as an electric motor when the vehicle is running under control of a drive circuit and as a generator when the vehicle is braking, and is a three-phase synchronous rotating electrical machine. Is. The rotating electric machine includes a stator 10 shown in FIG. 1 and a rotor that is an annular rotor arranged on the inner peripheral side of the stator 10 with a predetermined gap. The illustration of the rotor is omitted in FIG.

  The stator 10 includes a stator core 12, an insulator 20 mounted on the stator core 12, and a cassette coil 30 assembled to the stator core 12 via the insulator 20.

  The stator core 12 is an annular magnetic component, and includes an annular stator yoke 14 and a plurality of teeth 16 protruding from the stator yoke 14 toward the inner diameter side. The teeth 16 are magnetic poles in the stator 10, and in the case of a three-phase synchronous rotating electric machine, the teeth 16 that are multiples of 3 are arranged along the circumferential direction of the stator core 12. Here, 15 teeth 16 are arranged, but one of them is shown in FIG. 1. The teeth 16 have the same height dimension in the vertical direction as the stator yoke 14, and the width along the circumferential direction has a taper shape in which the root side on the stator yoke 14 side is large and the width decreases along the inner diameter side. The space between the adjacent teeth 16 is a slot 18.

  The stator core 12 is formed by laminating a plurality of annular magnetic thin plates 19 each having a stator yoke 14 and teeth 16 and formed into a predetermined shape so that the slots 18 are formed. Both sides of the magnetic thin plate 19 are electrically insulated. As a material for the magnetic thin plate 19, an electromagnetic steel plate is used. Instead of the laminated body of the magnetic thin plates 19, magnetic powder integrally molded into a predetermined shape may be used.

  FIG. 1 shows the circumferential direction, the vertical direction, and the radial direction of the stator core 12, respectively. The circumferential direction is the direction along the circumferential direction of the stator core 12, and the vertical direction is the direction of the rotation axis of the rotating electric machine, but here, the direction is perpendicular to the end surface of the stator core 12. The crossover side of the vertical direction is the direction of the lead side from which the winding start lead 32 and the winding end lead 34 of the winding of the cassette coil 30 are drawn out, and the plurality of cassette coils 30 in the stator 10 are connected to each other in a predetermined connection relationship. This is the side where the crossover is placed when it is connected. The opposite crossover side is the opposite direction to the crossover side. The radial direction is the direction in which the teeth 16 project from the stator yoke 14 in the stator core 12, and is the direction in which the cassette coil 30 is assembled to the teeth 16. The inner diameter side is the tapered shape side of the tooth 16, and the outer diameter side is the stator yoke 14 side. The cassette coil 30 is assembled so as to fit from the inner diameter side of the tooth 16 to the outer diameter side. Details of the assembly will be described later.

  The insulator 20 is an insulator having a tubular shape held between the inner peripheral side surface of the second layer coil, which is the inner winding of the two-layer winding of the cassette coil 30, and the outer peripheral side surface of the stator core 12 facing the inner peripheral side surface. is there. The insulator 20 is fixed to the stator core 12 by a fixing means such as adhesion. The claws 22 and 24 are respectively provided on the crossover side surface of the insulator 20 and the opposite crossover side surface of the insulator 20, and the second layer coil on the innermost diameter side of the concentrated winding of the cassette coil 30 is on the inner diameter side. It is a coil presser that can be pressed so that it does not pop out.

  As the insulator 20, a sheet having an electrically insulating property formed into a predetermined shape can be used. As the electrically insulating sheet, a plastic film can be used in addition to paper. The insulator 20 may be omitted when the insulating film of the cassette coil 30 has sufficient electric insulation. At that time, the cassette coil 30 is arranged so as to directly face the outer peripheral surface of the tooth 16 and is fixed by means such as adhesion. Below, the insulator 20 shall be provided.

  The cassette coil 30 is a coil that is concentratedly wound, and is a two-layer winding coil in which one tooth is wound around one tooth 16 by a predetermined number of turns. The concentratedly wound coil is a coil in which one conductor with an insulating film is continuously wound around four sides forming a rectangular cross section perpendicular to the radial direction of the tooth 16. A copper wire, a copper-tin alloy wire, a silver-plated copper-tin alloy wire, or the like is used as the element wire of the conductor with an insulating film. A rectangular wire having a substantially rectangular cross section is used as the strand. A polyamide-imide enamel film is used as the insulating film. Instead of this, polyester imide, polyimide, polyester, formal or the like can be used. As the enamel coating, a coating having a self-bonding layer that melts by heating under pressure and fuses adjacent conductive wires to each other is used. As the self-bonding layer, butyral resin, nylon resin, or epoxy resin is used.

  The concentratedly wound two-layer winding coil is arranged by being wound in a predetermined plurality of winding stages along the radial direction of the tooth 16, and each winding stage is configured by a two-layer winding. In other words, the cassette coil 30, which is a two-layer winding coil, is formed by winding a conductor wire with an insulating film in a predetermined number of winding stages in a two-layer winding to form a predetermined total number of windings. The number of turns is (number of winding stages × two layers). In FIG. 1, the winding stages 40a, 40b, 40c, 40d, and 40e are shown from the outer diameter side toward the inner diameter side as the winding stage 40 with the number of winding stages = 6. The total number of turns is 12. The winding start lead 32 is provided in the winding stage 40a on the outermost diameter side, and the winding end lead 34 is provided in the winding stage 40f on the innermost diameter side.

  Here, the two-layer windings constituting one two-layer winding coil wound around one tooth 16 are distinguished from each other and are referred to as a first layer coil 36 and a second layer coil 38. When the two-layer winding coils are stacked in a two-layer structure, the winding wound on the outside is the first layer coil 36, and the winding wound on the tooth 16 side inside the first layer coil 36 is the second layer coil 38. is there.

  For the "double-layer winding coil", several winding methods are known in the prior art. In the first example, the inner layer coil is wound from the root side of the tooth 16 and wound toward the tip side of the tooth 16 by a predetermined number of turns. When reaching the tip side of the tooth 16, the inner layer coil is moved to the outside of the inner layer coil. The outer side coil is a winding method that returns from the tip side of the tooth to the root side. According to the first example, the outer layer coil is stacked outside the inner layer coil on all four sides of the outer circumference of the tooth 16, but the winding start lead 32 and the winding end lead 34 are both formed on the tooth 16. It is on the root side.

  The second example is the winding method known as multi-layer winding. In this winding method, when the outer layer coil reaches the root side of the tooth 16 in the above-described two-layer winding, it is moved further outside the outer layer coil there, and as the third layer coil, from the root side to the tip side of the tooth. Return and repeat this to get the total number of turns required. In the second example, if three-layer winding is adopted, three layers of coils are wound in the same stacking order on all four sides of the outer periphery of the tooth 16, and the winding start lead 32 is on the root side of the tooth 16. The end-of-winding lead 34 is on the tip side of the tooth 16.

  Unlike any of the above winding methods, the cassette coil 30 of FIG. 1 is a two-layer winding, but the winding start lead 32 is provided on the outermost diameter winding stage 40a on the root side of the tooth 16 and the winding end lead is formed. 34 is provided on the innermost diameter side winding stage 40f on the tip side of the teeth 16. This winding method is also known from the prior art, and for example, the winding method is disclosed in Patent Document 2.

  Several winding methods known in the prior art of "two-layer winding coil" or "multi-layer winding coil" each have advantages, and the optimum winding method is selected according to the object to which it is applied. In the winding method of the cassette coil 30 of FIG. 1, since the winding start lead 32 and the winding end lead 34 are divided into the root side and the tip end side of the tooth 16, respectively, a crossover wire is provided for the plurality of cassette coils 30 in the stator 10. It is convenient to use and connect by a predetermined winding method. Moreover, since it is a two-layer winding, the total number of windings can be efficiently increased within the limited space of the slot 18. In the above-described first example, the winding start lead 32 and the winding end lead 34 cannot be separately arranged on the root side and the tip side of the tooth 16, respectively. In the above-mentioned second example, the winding start lead 32 and the winding end lead 34 are arranged in three layers to be separately arranged on the root side and the tip side of the tooth 16, respectively. It may occur that the slot cannot be stored within the space.

  In FIG. 2, although it is a two-layer winding, the winding start lead 32 is provided on the outermost diameter side winding step 40a on the root side of the tooth 16, and the winding end lead 34 is the innermost diameter side on the tip side of the tooth 16. The basic structure of the winding method provided in the winding stage 40f is shown. This winding method is repeated in units of two winding stages. In the example of FIG. 1, since the number of winding stages = 6, this is repeated three times based on the winding method of the two winding stages in FIG.

  In FIG. 2, the outline of the four outer peripheral sides of the tooth 16 is shown in (a) by a shaded frame A. The side 21 is the side on the crossover side of the four outer sides. The frame A is used to show that the conductive wire is wound around the four outer peripheral sides of the tooth 16, and the height position of the side 21 along the vertical direction is the height of the winding wound on the side 21. Used as a position reference. The conductor wire is wound around the tooth 16 via the insulator 20, but the thickness of the insulator 20 is omitted in FIG. 2.

  FIG. 2B shows the winding stage on the outer diameter side of the two winding stages serving as the winding unit, and FIG. 2C shows the winding stage on the inner diameter side. In the actual cassette coil 30, (b) and (c) are closely adjacent to each other, but in FIG. 2, the transition from the outer diameter side winding stage to the inner diameter side winding stage is shown, so they should be appropriately separated. Show. The shaded frame A in each of (b) and (c) is the contour of the outer four sides of the tooth 16 shown in (a). The contours of the four outer peripheral sides of the tooth 16 have a larger width along the circumferential direction toward the inner diameter side, but are shown with the same width in FIG. 2.

  In the winding stage on the outer diameter side in (b), the winding 43 starting from the winding 42 is first wound by one turn, then moved to the inside thereof and the winding 45 is wound by about 3/4 turns. The winding 45 becomes a winding 46 that moves to the winding stage on the inner diameter side along the side 21. The direction of winding order is indicated by an arrow.

  When this is applied to the cassette coil 30 of FIG. 1, the winding start lead 32 is used as the winding 42 of (b), and the winding start lead 32 is wound around the outer circumference of the tooth 16 in the winding stage 40a on the outermost diameter side. After being wound by the number of turns, it moves to the inside and the winding 43 is wound by about 3/4 turns. The winding wire 43 becomes a winding wire 46 that moves along the side 21 to the winding stage 40b on the inner diameter side.

  In the winding stage on the inner diameter side of (c), the winding 46 transferred from (b) is wound around the frame A with diagonal lines related to the teeth 16 by one turn, and then moved to the outside thereof and the winding 44 is moved. Is wound in about 3/4 volume. The winding 44 moves to the next winding stage on the inner diameter side. Since the next winding stage on the inner diameter side is the same as that in (b), the winding 44 is the winding 42 in the winding stage on the next inner diameter side. This is repeated to form the cassette coil 30 having the winding stages 40 in multiples of two.

  When this is applied to the cassette coil 30 of FIG. 1, the winding end lead 34 is used as the winding 44 of (c), and one winding 47 is wound inside the winding 44 in the winding stage 40f on the innermost diameter side. After being wound, it moves to the outside and the winding is wound in about 3/4 turns. When it is pulled out from there, it becomes a lead 34 at the end of winding. In a state where the winding end lead 34 is extended to the crossover side, the winding stage 40f on the innermost diameter side is stacked on the outside of the winding having a height position in contact with the shaded frame A on the side 21. There is a winding at the designated height.

  Regarding (b) and (c), the height positions of the windings wound around the side 21 are indicated as h1, h2, and h3. The origin of h1, h2, and h3 is the height position of the side 21 along the vertical direction. In (b), the winding 42 has the highest height h1, the height position of the winding 43 is h2 lower than h1, and the winding 46 has a lower height h3. h3 corresponds to the height position of the side 21. As for (c), the winding 44 has the highest height h1, the height position of the winding 47 is h2 lower than h1, and the winding 46 has a lower height h3. h3 corresponds to the height position of the side 21.

  As described above, in the two-layer winding of the cassette coil 30, in order to arrange the winding start lead 32 and the winding end lead 34 on the outermost diameter side and the innermost diameter side of the tooth 16, after winding the outer layer coil, Wrap the inner layer coil inside. Following this, the coil of the inner layer is wound, and then the coil of the outer layer is wound on the outer side thereof. When this is repeated, the transition from the outer layer to the inner layer and the transition from the inner layer to the outer layer are performed on the side 21 on the crossover side. For this reason, in the winding on both sides in the circumferential direction of the four outer peripheral sides of the tooth 16 and the side on the opposite crossover side in the vertical direction, the first layer coil 36 and the second layer coil 38 are simply stacked. However, the winding on the side 21 on the crossover side is different from these. That is, in the winding around the crossover side 21 of the four outer circumferences of the tooth 16, the height positions h1, h2, and h3 from the tooth end surface have regular repeated steps along the radial direction. This structure is called a hierarchical displacement structure 50. In both the first example and the second example of the prior art, a plurality of layers of coils are wound in the same stacking order on all four sides of the outer circumference of the tooth 16, and the hierarchical displacement structure 50 is provided. Absent.

  Returning to FIG. 1, the insulator 20 is provided with a pawl 22 on the side 21 side of the tooth 16 and a pawl 24 on the side opposite to the crossover line. The claws 22 and 24 are coil retainers that prevent the winding of the second layer coil 38 on the innermost diameter side of the concentrated winding of the cassette coil 30 from protruding to the inner diameter side. In the winding of the hierarchical displacement structure 50, in the winding stage 40f on the innermost diameter side, with respect to the side 21, the winding 46 having the height position h3 in contact with the shaded frame A and the height position h2 stacked outside thereof are stacked. Winding 47. Since the winding having the height position h3 corresponds to the second layer coil 38, the winding 46 corresponding to the second layer coil 38 is firmly fixed by the claw 22 and does not protrude to the inner diameter side. On the other hand, since the winding wire 47 has the height position h2, it is not fixed by the claw 22 and is in a free state. Therefore, when the cassette coil 30 is assembled to the tooth 16 via the insulator 20, the winding wire 47 is placed on the inner diameter side. There is a risk of falling (see FIG. 9A described later).

  In the structure of the insulator 20, it may be possible to provide a claw for preventing the winding 47 from popping out. However, in the hierarchical displacement structure 50, since the three height positions h1, h2, and h3 have regular repeated steps along the radial direction, it is difficult to provide a claw for fixing the winding wire 47 at the intermediate height position h2. .. In the first example and the second example of the prior art, the coils of a plurality of layers are wound in the same stacking order on all four sides of the outer periphery of the tooth 16, so that all the height positions It is easy to provide a fixing claw for the coil.

  The fixed layer 60 in the cassette coil 30 of FIG. 1 is an insulating layer in which the first layer coil 36 and the second layer coil 38 are bonded and fixed with an insulating material in the winding stage 40f on the innermost diameter side. The fixed layer 60 is provided only on the winding stage 40f on the innermost diameter side. This is because when the concentrated winding cassette coil 30 is assembled to the teeth 16 of the stator core 12 via the insulator 20, the final fifteenth cassette coil 30 utilizes the elastic deformability of the winding (described later). Therefore, the winding stage 40 on the outer diameter side cannot be fixed. The fixed layer 60 is provided between the first layer coil 36 and the second layer coil 38 on both sides in the circumferential direction of the winding stage 40f on the innermost diameter side. When distinguishing the fixed layers 60 on both sides, the left side along the circumferential direction when viewed from the inner diameter side is called the fixed layer 62, and the right side is called the fixed layer 64. Since the first layer coil 36 and the second layer coil 38 on the crossover side are not a simple stacked structure but a part of the hierarchical displacement structure 50, the fixed layer 60 is not provided. An additional fixing layer may be provided between the first layer coil 36 and the second layer coil 38 on the side of the crossover.

  By providing the fixing layers 62 and 64, the winding wire 47 having the height position h2 is fixed to the winding wire 46 having the height position h3, and the rigidity is increased. Further, since the winding 46 is fixed to the tooth 16 by the claws 22 and 24, when the cassette coil 30 is assembled to the tooth 16 via the insulator 20, the winding 47 having the height position h2 is located on the inner diameter side. It is possible to prevent falling.

  A method of manufacturing the cassette coil 30 having the above configuration and a method of assembling the cassette coil 30 to the stator core 12 via the insulator 20 will be described in detail with reference to FIGS. 3 to 8. FIG. 3 is a flowchart showing a procedure of manufacturing the cassette coil 30 and assembling the manufactured cassette coil 30 to the stator core 12 via the insulator 20.

  First, a coil winding process step is performed (S10). In this treatment step, a wire with an insulating film having a self-bonding layer is wound around a predetermined winding form frame, the first layer coil 36 is laid over the inner second layer coil 38, and a predetermined plurality of windings are performed. It is done by winding in a line. The method of winding the first layer coil 36 and the second layer coil 38 is the method described in FIG. FIG. 4 is a diagram showing the winding coil 29 after the coil winding process. FIG. 4A is a front view seen from the inner diameter side, and FIG. 4B is a sectional view taken along the line BB of FIG. In the winding coil 29, the self-bonding layer is not melted, and the fixing layers 62 and 64 are not formed yet. Therefore, the total number of windings = 12 including the winding stage 40f on the innermost diameter side is one coil spring shape and can be elastically extended in the radial direction.

  Returning to FIG. 3, next, a fixing treatment process between the first layer coil 36 and the second layer coil 38 on the innermost diameter side is performed (S12). A predetermined fixing jig 70 is used for the fixing process. As shown in FIG. 5A, the fixing jig 70 is configured to include a pedestal 72 and a holding plate 74 having a heater 73 built therein. FIG. 5A is a diagram in which the winding coil 29 obtained in S10 is arranged between the pedestal 72 and the heater 73. Here, the winding step 40a on the outermost diameter side is arranged on the pedestal 72 side, and the winding step 40f on the innermost diameter side is arranged on the holding plate 74 side in which the heater 73 is incorporated.

  FIG. 5B is a diagram for performing a pressure heating process in which pressure P is applied to the holding plate 74 with respect to the pedestal 72, and the heater 73 of the holding plate 74 is energized. The winding coil 29 is shaped by applying the pressure P. By applying the pressure P and energizing the heater 73, only the self-bonding layer of the winding stage 40f on the innermost diameter side is melted, and the self-bonding of the other winding stages 40e, 40d, 40c, 40b, 40a. The layer is set so as not to melt. In FIG. 5B, a broken line frame indicated by θ indicates a range in which the self-bonding layer melts. The arrangement of the heater 73 on the holding plate 74 is set so that the broken line frame indicated by θ does not extend to the hierarchical displacement structure 50 and the crossover line side described in FIG. The setting conditions for applying the pressure P and energizing the heater 73 such that the broken line frame indicated by θ stays in the winding stage 40f on the innermost diameter side are obtained in advance by experiments or the like.

  In the above description, the conductor with the insulating coating having the self-fusion layer is used for the cassette coil 30, but the conductor with the insulating coating having no self-fusing layer is used, and the predetermined position of the winding stage 40f on the innermost diameter side is used. A thermosetting insulating resin may be disposed in the. An epoxy resin can be used as the thermosetting insulating resin. In this case, in order to prevent the thermosetting insulating resin provided at a predetermined position of the innermost winding stage 40f by coating or the like from flowing to the other winding stages 40e, 40d, 40c, 40b, 40a, The structure of the fixing jig 70 is reversed from that of FIG. That is, it is preferable that the pedestal 72 has the heater 73 built-in, the winding step 40f on the innermost diameter side is arranged on the pedestal 72 side, and the winding step 40a on the outermost diameter side is arranged on the holding plate 74 side.

  FIG. 6 is a view corresponding to FIG. 4, and is a view showing the cassette coil 30 after the fixing processing step (S12) of FIG. FIG. 6A is a front view, and FIG. 6B is a sectional view taken along line BB of FIG. Here, the fixed layers 62 and 64 are formed between the first layer coil 36 and the second layer coil 38 of the winding stage 40f on the innermost diameter side. Others are the same as the contents described in FIG. 4, and thus detailed description will be omitted.

  Returning to FIG. 3, when the cassette coil 30 after the fixing process (S12) of FIG. 5 is obtained, the process of assembling the cassette coil 30 to the tooth 16 is then performed (S14). Since the stator core 12 has fifteen teeth 16, up to fourteen cassette coils 30 can be easily attached to the teeth 16 if the teeth 16 adjacent to at least one side of the teeth 16 have not yet been assembled. Can be attached to. With reference to FIG. 1, the teeth 16 on which the insulator 20 has already been arranged are assembled by fitting the cassette coil 30 from the tip side on the inner diameter side. At that time, since the claws 22 and 24 have elasticity, the cassette coil 30 pushes the claws 22 and 24 to the outer diameter side while bending the claws 22 and 24 toward the outer diameter side, so that the winding step 40f on the innermost diameter side is claws 22 and 24. When it goes over, the pawls 22 and 24 return to their original shapes and fix the cassette coil 30.

  FIG. 7 is a three-sided view showing the relationship between the cassette coil 30 and the stator core 12 and the insulator 20 after the assembly processing step of S14. FIG. 7A is a front view seen from the inner diameter side, FIG. 7B is a side view thereof, and FIG. 7C is a top view. As shown in FIG. 7, fixed layers 62 and 64 are provided between the first layer coil 36 and the second layer coil 38 in the winding stage 40f on the innermost diameter side. The second-layer coil 38 on the crossover side (corresponding to the winding wire 47 in FIG. 2) is fixed to the tooth 16 by the claw 22, and the second-layer coil 38 on the opposite crossover side is fixed by the claw 24.

  Returning to FIG. 3, of the 15 teeth 16 in the stator core 12, up to the 14th, the cassette coils 30 are sequentially assembled (S16). The state after assembling of each is the content described in FIG. 7. The assembly of the final 15th cassette coil 30 is performed by an elastic assembly process utilizing the elastic deformability of the cassette coil 30 (S18).

  FIG. 8 is a diagram showing the elastic assembly process of S18. FIG. 8 is a top view of the stator 10. The 15 teeth 16 are distinguished and numbered N = 1 to N = 15 clockwise in the top view. FIG. 8 shows a state where the 14 cassette coils 30 of the cassette coil 30 (N = 1) to the cassette coil 30 (N = 14) are assembled to the teeth 16 of N = 1 to N = 14, respectively. An insulator 20 (N = 15) is already covered on the teeth 16 of N = 15, and a cassette coil 30 (N = 15) is placed on the inner diameter side of the stator core 12 for assembly. The cassette coil 30 (N = 1) and the cassette coil 30 (N = 14) are already present on the teeth (N = 1) and the teeth (N = 14) adjacent to each other on both sides in the circumferential direction of the teeth (N = 15). It has been assembled.

  The teeth 16 are tapered on the inner diameter side. Therefore, the distance L0 between the cassette coil 30 (N = 1) and the cassette coil 30 (N = 14) on the tip side of the tooth (N = 15) is the same as that of the cassette coil 30 (which is formed in FIG. 6). N = 15), which is smaller than the dimension L1 along the circumferential direction on the outermost diameter side. If the cassette coil 30 (N = 15) is directly attached to the tooth 16 (N = 15), the cassette coil 30 (N = 1) and the cassette coil 30 (N = 14) interfere with each other.

  Therefore, the shape of the coil spring is deformed by utilizing the elastic deformability of the cassette coil 30 (N = 15). The deformation is performed by widening or narrowing the gap between the first layer coil 36 and the second layer coil 38. In the winding stage 40f on the innermost diameter side, the first layer coil 36 and the second layer coil 38 are fixed to each other by the fixing layers 62, 64, but the winding stages 40e, 40d, 40c, 40b, 40a other than that are Since the first layer coil 36 and the second layer coil 38 are not fixed to each other, there is a degree of freedom of deformation. FIG. 8 shows an arrangement state of each winding in the winding coil 31 (N = 15) after elastic deformation. Due to this elastic deformability, the final cassette coil 30 (N = 15) is attached to the insulator (N = 15), and is fixed to the tooth 16 (N = 15) by the claws 22 and 24. In this way, the assembly of the cassette coil 30 to the stator core 12 is performed.

  FIG. 9 is a diagram showing two comparative examples showing the operational effects of the cassette coil 30 according to the present embodiment. FIG. 9A is a diagram showing the collapse Δ of the winding toward the inner diameter side when the fixing process to the winding stage 40f on the innermost diameter side is not performed. When the fixing process is not performed, the second layer coil 38 is fixed to the stator core 12 by the claws 22 and 24. Even at that time, since the winding end lead 34 provided on the innermost diameter side is pulled out from the first layer coil 36, it is not fixed to the stator core 12 by the claws 22 and 24 and is a free end. Therefore, when the cassette coil 30 is assembled to the tooth 16 and the operator does not press it with a finger or the like, the winding end lead 34 tilts Δ toward the inner diameter side. In the cassette coil 30 according to the present embodiment, the winding layers 40f on the innermost diameter side are fixed by the fixing layers 62 and 64 between the first layer coil 36 and the second layer coil 38. The second layer coil 38 is fixed to the stator core 12 by the claws 22 and 24, and the first layer coil 36 is fixed to the second layer coil 38 by the fixing layers 62 and 64. Therefore, the first layer coil 36 is fixed to the teeth 16. To be done. This prevents the end-of-winding lead 34 from falling toward the inner diameter side.

  FIG. 9B is a diagram showing an example of a conventional double-layer wound concentrated winding insulator 80. The insulator 80 has three claws 82, 84, 86. The claws 82 and 84 are for fixing the second layer coil 38, and have the same function as the claws 22 and 24 of the present embodiment. The claw 86 serves to fix the first layer coil 36 on the side opposite to the crossover line of the cassette coil 30. As a result, it is possible to reduce the inclination Δ of the winding end lead 34 toward the inner diameter side. In the cassette coil 30 of the present embodiment, since the first layer coil 36 and the second layer coil 38 are fixed by the fixing layers 62 and 64 in the winding stage 40f on the innermost diameter side, the first layer coil 36 is fixed. It is not necessary to use the claw 86 for. That is, the insulator 20 for the cassette coil 30 of the present embodiment has a simpler structure as compared with the insulator 80 of the related art, the cost can be reduced, and the size of the stator 10 can be reduced.

  The rotary electric machine cassette coil 30 according to the present embodiment has a two-layer winding in which the first-layer coil 36 is superposed on the second-layer coil 38 on the tooth 16 side, and has a diameter from the root side of the tooth 16 toward the tip side. The cassette coil 30 is concentratedly wound along a direction by a plurality of predetermined winding stages 40. Here, the winding of one of the four outer peripheral sides of the tooth 16 is a winding of the hierarchical displacement structure 50 in which the height arrangement from the end surface of the tooth 16 has regular repeated steps along the radial direction. Times. Then, among the plurality of winding stages 40, only the two-layer winding of the winding stage 40f on the radially innermost side of the plurality of winding stages 40 includes the second layer coil 38 and the first layer coil 36 on the sides other than the side having the hierarchical displacement structure 50. The space between them is adhered and fixed by fixing layers 62 and 64 made of an insulating material.

  According to the above configuration, the second layer coil 38 and the first layer coil 36 are not adhesively fixed by the fixing layers 62 and 64 except the winding stage 40f having the innermost diameter, so that the elastic deformation at the time of assembling to the tooth 16 is performed. You can secure the sex. Further, in the two-layer winding of the winding step 40f having the innermost diameter, the second layer coil 38 and the first layer coil 36 are bonded and fixed by the fixing layers 62 and 64. It is possible to prevent the winding on the inner diameter side from falling toward the inner diameter side.

  10 stators, 12 stator cores, 14 stator yokes, 16 teeth, 18 slots, 19 magnetic thin plates, 20,80 insulators, 21 sides, 22, 24, 82, 84, 86 claws, 29 winding coils, 30 (for rotating electrical machines ) Cassette coil, 31 (elastically deformed) winding coil, 32 winding start lead, 34 winding end lead, 36 first layer coil, 38 second layer coil, 40 (predetermined plural) winding stages, 40a, 40b , 40c, 40d, 40e winding stage, 40f (innermost diameter side) winding stage, 42, 43, 44, 45, 46, 47 winding, 50 layer displacement structure, 60, 62, 64 fixing layer, 70 fixing jig , 72 pedestal, 73 heater, 74 holding plate.

Claims (1)

For a rotating electric machine in which a two-layer winding, in which the first-layer coil is stacked on the second-layer coil on the tooth side, is concentratedly wound in a plurality of predetermined winding stages along the radial direction from the root side to the tip side of the tooth. A cassette coil,
The winding around one of the four outer peripheral sides of the tooth is a winding of a hierarchical displacement structure in which the height arrangement from the tooth end face has regular repeated steps along the radial direction,
Insulation material is fixed between the second layer coil and the first layer coil on the side other than the side having the hierarchical displacement structure only for the two-layer winding of the innermost diameter side winding stage among the plurality of winding stages A cassette coil for a rotating electric machine that is adhesively fixed in layers.

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