Sequentially joined-segment coil for rotary electrical machine

• US 20060033394A1
• Filed: 09/29/2005
• Published: 02/16/2006
• Est. Priority Date: 06/12/2002
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Fukushima, Akira, Ogawa, Shinichi
• Granted Patent: US 7,242,124 B2
• Time in Patent Office: Days
• US Class Current: 310/179
• CPC Class Codes: H02K 19/22 having windings each turn of which co-operates alternately with poles of opposite polarity, e.g. heteropolar generators
• 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 3/505 for large machine windings, e.g. bar windings H02K3/51 takes precedence

Abstract

A polyphase sequentially joined-segment coil of a rotary electric machine and a production method thereof are provided. The coil is made up of a plurality of conductor segments joined in series. Each of the conductor segments a head projecting from a stator core, a pair of legs, and a pair of ends projecting from the stator core. The heads are of two types: a large-sized head and a small-sized head extending inside the large-sized head. This structure permits the length of the conductor segments in an axial direction of the core to be decreased and improves cooling capability of the machine and coil losses.

Claims

1. A sequentially joined-segment stator coil of a rotary electric machine comprising:

a stator core having opposed ends and slots formed at given intervals in a circumferential direction of the stator core; and

a plurality of conductor segments each including a head portion, a pair of slot-inserted portions, and a pair of end portions, each of the head portions having one of substantially U- and V-shapes, extending in a circumferential direction of said stator core at one of the ends of said stator core, the head portions of the conductor segments defining a segment head-side coil end of the stator coil, the slot-inserted conductor portions of each pair continuing from ends of one of the head portions, inserted into two of the slots formed in said stator core, six of the slot-inserted conductor portions being arrayed in line in a radius direction of said stator core within each of the slots of said stator core, the end portions projecting from the slot-inserted conductor portions outside the other end of said stator core in the axial direction thereof, extending substantially in the circumferential direction of said stator core, the end portions defining a segment end-side coil end of the stator coil,

wherein said conductor segments are connected at least through joints each provided between two of tips of the end portions, and

wherein said segment head-side coil end includes the head portions which lead to the first and fourth slot-inserted conductor portions as counted from a radial inside of said stator core and have a larger size, the head portions which lead to the second and third slot-inserted conductor portions and have a smaller size, and the head portions which lead to the fifth and sixth slot-inserted conductor portions and have a smaller size.

2. A sequentially joined-segment stator coil as set forth in claim 1, wherein said segment end-side coil end of the stator coil is made up of the end portions which are joined together and lead to the first and second slot-inserted conductor portions as counted from a radial inside of said stator core, the end portions which are joined together and lead to the third and fourth slot-inserted conductor portions, and the end portions which are joined together and lead to the fifth and sixth slot-inserted conductor portions.

3. A sequentially joined-segment stator coil as set forth in claim 1, wherein the head portions of the smaller size which are not surrounded by the head portions of the larger size each have a length, as projecting from the end of the stator core, shorter than that of the head portions of the larger size.

1-1. A rotary electrical machine for a high-voltage vehicle comprising:

a stator core having opposed ends and slots formed at given intervals in a circumferential direction of said stator core; and

a three-phase sequentially joined-segment stator coil which includes three phase coils joined together through one of star connection and delta connection, each of the phase coils including a plurality of conductor segments each of which includes a head portion, a pair of slot-inserted portions, and a pair of end portions, each of the head portions having one of substantially U- and V-shapes, extending in a circumferential direction of said stator core at one of the ends of the stator core, the slot-inserted conductor portions of each pair continuing from ends of one of the head portions, inserted into two of the slots of the stator core which are spaced at given slot pitches, a given number of the slot-inserted conductor portions being disposed in each of the slots in alignment in a radius direction of said stator core, the end portions projecting from the slot-inserted conductor portions outside the other end of the stator core in the axial direction thereof, extending substantially in the circumferential direction of the stator core,

wherein said conductor segments are connected in series through joints each provided between two of tips of the end portions to complete each of said phase coils, and

wherein each of the phase coils is made up of different types of the conductor segments joined in series, one of the types being different from another in slot pitch between the slots within which the slot-inserted portions of each of the conductor segments are disposed.

2-2. A rotary electrical machine as set forth in claim 1, wherein six of the slot-inserted conductor portions are arrayed in each of the slots in line in a radius direction of said stator core.

3-3. A rotary electrical machine as set forth in claim 2, wherein each of the slot-inserted conductor portions of each of the conductor segments forming each of said phase coils is disposed within one of adjacent three of the slots, the adjacent three having disposed therein the slot-inserted conductor portions through which electrical currents flow in the same direction, and wherein each of said phase coils is made up of a first, a second, and a third type of the conductor segments, the slot-inserted conductor portions of each of the conductor segments of the first type being spaced from each other at eight slot pitches, the slot-inserted conductor portions of each of the conductor segments of the second type being spaced from each other at nine slot pitches, the slot-inserted conductor portions of each of the conductor segments of the third type being spaced from each other at eleven slot pitches.

4. A sequentially joined-segment stator coil of a rotary electric machine comprising:

a stator core having opposed ends and slots formed at given intervals in a circumferential direction of said stator core; and

a plurality of conductor segments each including a head portion, a pair of slot-inserted portions, and a pair of end portions, each of the head portions having one of substantially U- and V-shapes, extending in a circumferential direction of said stator core at one of the ends of the stator core in an axial direction thereof, the head portions of the conductor segments defining a segment head-side coil end of the stator coil, the slot-inserted conductor portions of each pair continuing from ends of one of the head portions, inserted into two of the slots formed in the stator core, six of the slot-inserted conductor portions being arrayed in line in a radius direction of said stator core within each of the slots of said stator core, the end portions projecting from the slot-inserted conductor portions outside the other end of the stator core in the axial direction thereof, extending substantially in the circumferential direction of the stator core, the end portions defining a segment end-side coil end of the stator coil,

wherein said conductor segments are connected at least through joints each provided between two of tips of the end portions, and

wherein said segment head-side coil end includes the head portions which lead to the sixth and third slot-inserted conductor portions as counted from a radial inside of said stator core and have a larger size, the head portions which lead to the fifth and fourth slot-inserted conductor portions and have a smaller size, and the head portions which lead to the second and first slot-inserted conductor portions and have a smaller size.

5. A sequentially joined-segment stator coil as set forth in claim 4, wherein said segment end-side coil end of the stator coil is made up of the end portions which are joined together and lead to the first and second slot-inserted conductor portions as counted from a radial inside of said stator core, the end portions which are joined together and lead to the third and fourth slot-inserted conductor portions, and the end portions which are joined together and lead to the fifth and sixth slot-inserted conductor portions.

6. A sequentially joined-segment stator coil as set forth in claim 4, wherein the head portions of the smaller size which are not surrounded by the head portions of the larger size each have a length, as projecting from the end of the stator core, shorter than that of the head portions of the larger size.

7. A rotary electrical machine for a high-voltage vehicle comprising:

a stator core having opposed ends and slots formed at given intervals in a circumferential direction of said stator core; and

a three-phase sequentially joined-segment stator coil which includes three phase coils joined together through one of star connection and delta connection, each of the phase coils including a plurality of conductor segments each of which includes a head portion, a pair of slot-inserted portions, and a pair of end portions, each of the head portions having one of substantially U- and V-shapes, extending in a circumferential direction of said stator core at one of the ends of the stator core, the slot-inserted conductor portions of each pair continuing from ends of one of the head portions, inserted into two of the slots of the stator core which are spaced at given slot pitches, a given number of the slot-inserted conductor portions being disposed in each of the slots in alignment in a radius direction of said stator core, the end portions projecting from the slot-inserted conductor portions outside the other end of the stator core in the axial direction thereof, extending substantially in the circumferential direction of the stator core,

wherein said conductor segments are connected in series through joints each provided between two of tips of the end portions to complete each of said phase coils, and

wherein each of the phase coils is made up of different types of the conductor segments joined in series, one of the types being different from another in slot pitch between the slots within which the slot-inserted portions of each of the conductor segments are disposed.

4-4. A sequentially joined-segment stator coil equipped rotary electrical machine comprising:

a rotor having a plurality of pairs of magnetic poles;

a stator core having opposed ends, said stator core having formed therein a plurality of slots arrayed at a given pitch in a circumferential direction of said stator core, each of the slots defining therein a sequence of at least first to sixth conductor-inserted positions aligned in a radius direction of said stator core; and

a polyphase stator coil made up of a given number of phase windings each including a plurality of substantially U-shaped conductor segments joined in series, each of the U-shaped conductor segments having a pair of legs which are disposed at different two of the conductor-inserted positions in two of the slots, respectively, and which are oriented within the slots toward the same end of said stator core, the legs of the U-shaped conductor segments being joined in pair to complete each of the phase windings,

wherein the U-shaped conductor segments include lap winding segments in which end portions of the legs projecting from the slots extend so as to approach each other in the circumferential direction of said stator core and wave-segments in which end portions of the legs projecting from the slots extend away from each other in the circumferential direction of said stator core,

wherein said stator core has k(=natural number more than or equal to two) of the slots defining each of sets of same phase slots for each magnetic pole, the k slots being located adjacent each other in the circumferential direction of said stator core and having one of the phase windings extend therethrough, the k slots having slot series numbers which are defined in series in the circumferential direction of said stator core, and

wherein each of the phase windings includes a lap winding coil, a wave winding coil, and a connecting line connecting the lap winding coil and the wave winding coil, the lap winding coil being made up of a total of 2 k single-lap winding coils connected in series each of which includes the wave-segment having the legs inserted into the first and fourth conductor-inserted positions in ones of the same phase slots of the same slot serial number in two of the sets of the same phase slots and the lap winding segment having the legs inserted into the second and third conductor-inserted positions in the same ones of the same phase slots as those of the wave-segment, the wave winding coil being made up of a total of 2 k single-turn wave winding coils connected in series each of which includes the wave-segments connected in series each of which has the legs inserted into the fifth and sixth conductor-inserted positions in ones of the same phase slots of the same slot serial number in two of the sets of the same phase slots.

5-5. A sequentially joined-segment stator coil equipped rotary electrical machine as set forth in claim 4, wherein the lap winding coil is made up of a first sequence of series-connected k of the single-lap winding coils and a second sequence of series-connected k of the single-lap winding coils, the first and second sequences extending in opposite directions.

6-6. A sequentially joined-segment stator coil equipped rotary electrical machine as set forth in claim 4, wherein the wave winding coil is made up of a first sequence of series-connected k of the single-turn wave winding coils and a second sequence of series-connected k of the single-turn wave winding coils, the first and second sequences extending in opposite directions.

7-7. A sequentially joined-segment stator coil equipped rotary electrical machine as set forth in claim 6, further comprising a directional turning connecting line establishing a joint between the first and second sequences of the single-turn wave winding coils, and wherein said directional turning connecting line and ends of each of the phase windings lie within a range of two magnetic pole pitches.

8. A rotary electrical machine as set forth in claim 7, wherein six of the slot-inserted conductor portions are arrayed in each of the slots in line in a radius direction of said stator core.

9. A rotary electrical machine as set forth in claim 8, wherein each of the slot-inserted conductor portions of each of the conductor segments forming each of said phase coils is disposed within one of adjacent three of the slots, the adjacent three having disposed therein the slot-inserted conductor portions through which electrical currents flow in the same direction, and wherein each of said phase coils is made up of a first, a second, and a third type of the conductor segments, the slot-inserted conductor portions of each of the conductor segments of the first type being spaced from each other at eight slot pitches, the slot-inserted conductor portions of each of the conductor segments of the second type being spaced from each other at nine slot pitches, the slot-inserted conductor portions of each of the conductor segments of the third type being spaced from each other at eleven slot pitches.

10. A sequentially joined-segment stator coil equipped rotary electrical machine comprising:

a rotor having a plurality of pairs of magnetic poles;

a stator core having opposed ends, said stator core having formed therein a plurality of slots arrayed at a given pitch in a circumferential direction of said stator core, each of the slots defining therein a sequence of at least first to sixth conductor-inserted positions aligned in a radius direction of said stator core; and

a polyphase stator coil made up of a given number of phase windings each including a plurality of substantially U-shaped conductor segments joined in series, each of the U-shaped conductor segments having a pair of legs which are disposed at different two of the conductor-inserted positions in two of the slots, respectively, and which are oriented within the slots toward the same end of said stator core, the legs of the U-shaped conductor segments being joined in pair to complete each of the phase windings,

wherein the U-shaped conductor segments include lap winding segments in which end portions of the legs projecting from the slots extend so as to approach each other in the circumferential direction of said stator core and wave-segments in which end portions of the legs projecting from the slots extend away from each other in the circumferential direction of said stator core,

wherein said stator core has k(=natural number more than or equal to two) of the slots defining each of sets of same phase slots for each magnetic pole, the k slots being located adjacent each other in the circumferential direction of said stator core and having one of the phase windings extend therethrough, the k slots having slot series numbers which are defined in series in the circumferential direction of said stator core, and

wherein each of the phase windings includes a lap winding coil, a wave winding coil, and a connecting line connecting the lap winding coil and the wave winding coil, the lap winding coil being made up of a total of 2 k single-lap winding coils connected in series each of which includes the wave-segment having the legs inserted into the first and fourth conductor-inserted positions in ones of the same phase slots of the same slot serial number in two of the sets of the same phase slots and the lap winding segment having the legs inserted into the second and third conductor-inserted positions in the same ones of the same phase slots as those of the wave-segment, the wave winding coil being made up of a total of 2 k single-turn wave winding coils connected in series each of which includes the wave-segments connected in series each of which has the legs inserted into the fifth and sixth conductor-inserted positions in ones of the same phase slots of the same slot serial number in two of the sets of the same phase slots.

11. A sequentially joined-segment stator coil equipped rotary electrical machine as set forth in claim 10, wherein the lap winding coil is made up of a first sequence of series-connected k of the single-lap winding coils and a second sequence of series-connected k of the single-lap winding coils, the first and second sequences extending in opposite directions.

12. A sequentially joined-segment stator coil equipped rotary electrical machine as set forth in claim 10, wherein the wave winding coil is made up of a first sequence of series-connected k of the single-turn wave winding coils and a second sequence of series-connected k of the single-turn wave winding coils, the first and second sequences extending in opposite directions.

13. A sequentially joined-segment stator coil equipped rotary electrical machine as set forth in claim 12, further comprising a directional turning connecting line establishing a joint between the first and second sequences of the single-turn wave winding coils, and wherein said directional turning connecting line and ends of each of the phase windings lie within a range of two magnetic pole pitches.

8-8. A segment-joined coil for a rotary electrical machine comprising:

a core having opposed ends, said core having formed therein a plurality of slots arrayed at a given pitch in a circumferential direction of said core; and

a polyphase stator coil made up of a given number of phase windings each including a first coil and a second coil connected in series with each other, the first coil including a plurality of first conductor segments each having a substantially U-shaped head and a first and a second leg extending form ends of the head, the first and second legs passing through two of the slots, respectively, tips of the first and second legs being joined in series in pair to complete the first coil, the second coil including a plurality of second conductor segments each having a head and a first and a second leg extending form ends of the head, the first and second legs passing through two of the slots, respectively, tips of the first and second legs being joined in series in pair to complete the second coil,

wherein the first leg of each of the first conductor segments of the first coil and the first leg of each of the second conductor segments of the second coil are disposed within a first one of the slots and arrayed adjacent to each other so that the first leg of the first conductor segment is located inside the first leg of the second conductor segment in a radius direction of said core,

wherein the second leg of each of the first conductor segments is disposed within a second one of the slots which is spaced from said first slot at substantially one magnetic pole pitch in the circumferential direction and located inside the first leg of the first conductor segment in the radius direction of said core, and

wherein the second leg of each of the second conductor segments is disposed within a third one of the slots which is spaced from said first slot at substantially one magnetic pole pitch in the circumferential direction and located inside the first leg of the second conductor segment in the radius direction of said core.

9-9. A method of producing a segment-joined coil for a rotary electrical machine as set forth in claim 8, comprising:

preparing a large ring having grooves or holes formed therein at a given pitch in a circumferential direction thereof, a middle ring having grooves or holes formed therein at the same pitch as that of the large ring, and a small ring having groove or holes formed therein at the same pitch as that of the middle ring, the middle ring being arranged inside the large ring, the small ring being arranged inside the middle ring;

preparing first and second conductor members for forming the first and second conductor segments, respectively, each of the first and second conductor members including a substantially U-shaped head and a first and a second leg extending form ends of the head;

fitting the first legs of the first and second conductor members within the grooves or holes of said middle ring;

fitting the second legs of the first conductor members within the grooves or holes of said small ring;

fitting the second legs of the second conductor members within the grooves or holes of said large ring; and

rotating said large and small rings in the same circumferential direction thereof relative to said middle ring through approximately one magnetic pole pitch to spread the heads of the first and second conductor members in the circumferential direction.

10-10. A method as set forth in claim 9, further comprising:

inserting the first and second legs of the spread first and second conductor members into the slots of the core from one of the ends of the core;

preparing a second large ring having grooves or holes formed therein at a given pitch in a circumferential direction thereof, a second middle ring having grooves or holes formed therein at the same pitch as that of the second large ring, and a second small ring having groove or holes formed therein at the same pitch as that of the second middle ring, the second middle ring being arranged inside the large ring, the second small ring being arranged inside the second middle ring;

fitting end portions of the first legs of the spread first and second conductor members projecting from said core within the grooves or holes of said second middle ring;

fitting end portions of the second legs of the spread first conductor members projecting from said core within the grooves or holes of said small ring;

fitting end portions the second legs of the second conductor members projecting from said core within the grooves or holes of said large ring; and

rotating said second large ring and the second small ring in the same circumferential direction thereof relative to said second middle ring through approximately one magnetic pole pitch to spread the end portions of the spread first and second conductor members in the circumferential direction to complete the first and second conductor segments, respectively.

14. A segment-joined coil for a rotary electrical machine comprising:

a core having opposed ends, said core having formed therein a plurality of slots arrayed at a given pitch in a circumferential direction of said core; and

a polyphase stator coil made up of a given number of phase windings each including a first coil and a second coil connected in series with each other, the first coil including a plurality of first conductor segments each having a substantially U-shaped head and a first and a second leg extending form ends of the head, the first and second legs passing through two of the slots, respectively, tips of the first and second legs being joined in series in pair to complete the first coil, the second coil including a plurality of second conductor segments each having a head and a first and a second leg extending form ends of the head, the first and second legs passing through two of the slots, respectively, tips of the first and second legs being joined in series in pair to complete the second coil,

wherein the first leg of each of the first conductor segments of the first coil and the first leg of each of the second conductor segments of the second coil are disposed within a first one of the slots and arrayed adjacent to each other so that the first leg of the first conductor segment is located inside the first leg of the second conductor segment in a radius direction of said core,

wherein the second leg of each of the first conductor segments is disposed within a second one of the slots which is spaced from said first slot at substantially one magnetic pole pitch in the circumferential direction and located inside the first leg of the first conductor segment in the radius direction of said core, and

wherein the second leg of each of the second conductor segments is disposed within a third one of the slots which is spaced from said first slot at substantially one magnetic pole pitch in the circumferential direction and located inside the first leg of the second conductor segment in the radius direction of said core.

15. A method of producing a segment-joined coil for a rotary electrical machine as set forth in claim 14, comprising:

preparing a large ring having grooves or holes formed therein at a given pitch in a circumferential direction thereof, a middle ring having grooves or holes formed therein at the same pitch as that of the large ring, and a small ring having groove or holes formed therein at the same pitch as that of the middle ring, the middle ring being arranged inside the large ring, the small ring being arranged inside the middle ring;

preparing first and second conductor members for forming the first and second conductor segments, respectively, each of the first and second conductor members including a substantially U-shaped head and a first and a second leg extending form ends of the head;

fitting the first legs of the first and second conductor members within the grooves or holes of said middle ring;

fitting the second legs of the first conductor members within the grooves or holes of said small ring;

fitting the second legs of the second conductor members within the grooves or holes of said large ring; and

rotating said large and small rings in the same circumferential direction thereof relative to said middle ring through approximately one magnetic pole pitch to spread the heads of the first and second conductor members in the circumferential direction.

16. A method as set forth in claim 15, further comprising:

inserting the first and second legs of the spread first and second conductor members into the slots of the core from one of the ends of the core;

preparing a second large ring having grooves or holes formed therein at a given pitch in a circumferential direction thereof, a second middle ring having grooves or holes formed therein at the same pitch as that of the second large ring, and a second small ring having groove or holes formed therein at the same pitch as that of the second middle ring, the second middle ring being arranged inside the large ring, the second small ring being arranged inside the second middle ring;

fitting end portions of the first legs of the spread first and second conductor members projecting from said core within the grooves or holes of said second middle ring;

fitting end portions of the second legs of the spread first conductor members projecting from said core within the grooves or holes of said small ring;

fitting end portions the second legs of the second conductor members projecting from said core within the grooves or holes of said large ring; and

rotating said second large ring and the second small ring in the same circumferential direction thereof relative to said second middle ring through approximately one magnetic pole pitch to spread the end portions of the spread first and second conductor members in the circumferential direction to complete the first and second conductor segments, respectively.