Stator coil including sequentially connected segment conductors preferably applicable to an electric rotary machine

• US 20050253466A1
• Filed: 05/11/2005
• Published: 11/17/2005
• Est. Priority Date: 05/14/2004
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Seguchi, Masahiro, Kouda, Shinji
• Granted Patent: US 7,135,793 B2
• Time in Patent Office: Days
• US Class Current: 310/71
• CPC Class Codes: H02K 2203/09 Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 3/50 Fastening of winding heads, equalising connectors, or connections thereto

Abstract

A stator coil includes a coil portion wound around a stator core and a terminal board serving as a bus bar array board. The coil portion is arranged by sequentially connected segment conductors. The terminal board is a molded ring plate member disposed adjacently to a head coil end of the coil portion in the axial direction and elongated in the radial direction. The turn number of the stator coil is easily adjustable by selecting an optimum one of a plurality of terminal boards.

Claims

1. A stator coil including sequentially connected segment conductors, wherein

each segment conductor includes a pair of leg portions individually inserted into two slots of a stator core spaced at substantially one magnetic pole pitch and one head portion continuously formed with said pair of leg portions and disposed at a head coil end,

the leg portions of said segment conductors are sequentially connected at a tail coil end to form a coil group occupying a coil group layer of said slot which has even conductor insertion positions neighboring with each other,

said coil group includes plural partial coils being mutually connected for each phase,

said stator coil includes a bus bar array board including plural inter-group crossover bus bars and an electric insulating member,

said inter-group crossover bus bars are disposed in a circumferential direction or a radial direction to connect end portions of said partial coils, and

said inter-group crossover bus bars are integrally supported in said electric insulating member.

2. The stator coil including sequentially connected segment conductors in accordance with claim 1, wherein partial coil connecting bus bars, used for connecting said partial coils, are integrally molded with said insulating member.

3. The stator coil including sequentially connected segment conductors in accordance with claim 2, wherein said bus bar array board has inter-group crossover bus bars connecting end portions of plural partial coils respectively belonging to said plural coil groups individually occupying mutually different coil group layers of said slot.

4. The stator coil including sequentially connected segment conductors in accordance with claim 2, wherein said bus bar array board has a terminal bus bar serving as an external connecting terminal which is connected to one end of a phase coil arranged by partial coils of the same phase, and said terminal bus bar protrudes from said insulating member.

5. The stator coil including sequentially connected segment conductors in accordance with claim 3, wherein said bus bar array board has a neutral bus bar connecting other ends of the phase coils of respective phases, and said neutral bus bar extends in the circumferential direction.

6. The stator coil including sequentially connected segment conductors in accordance with claim 5, wherein said neutral bus bar is disposed at a position substantially identical with a core back of said stator core in the radial direction.

7. The stator coil including sequentially connected segment conductors in accordance with claim 2, wherein said partial coil connecting bus bar is exposed in a window portion of said insulating member, and is connected to the end portion of the partial coil inserted in said window portion.

8. The stator coil including sequentially connected segment conductors in accordance with claim 1, wherein said bus bar array board is disposed adjacently to the head coil end in the axial direction and elongated in the radial direction.

9. The stator coil including sequentially connected segment conductors in accordance with claim 1, wherein a semiconductor switching element is fixed to said bus bar array board and is connected to one end of a phase coil arranged by partial coils of the same phase.

10. The stator coil including sequentially connected segment conductors in accordance with claim 1, wherein said bus bar array board is selectable from a plurality of array boards mutually differentiated in a bus bar arrangement, and a serial turn number of one phase is adjustable by changing a connecting pattern of said partial coils.