Rotating Electrical Machine and Method for Manufacturing the Same

• US 20090085421A1
• Filed: 08/22/2008
• Published: 04/02/2009
• Est. Priority Date: 09/19/2007
• Status: Active Grant

• Current Assignee: Hitachi, Ltd.
• Original Assignee: Hitachi, Ltd.
• Inventors: Toba, Akira, Mita, Toru, Ishigami, Takashi, Nakayama, Kenichi, SAITO, Yasuyuki
• Granted Patent: US 8,330,318 B2
• Time in Patent Office: Days
• US Class Current: 310/214
• 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 3/345 between conductor and core, e.g. slot insulation
• CPC Class Codes: H02K 3/487 Slot-closing devices
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine

Abstract

A rotating electrical machine includes: a stator that has a stator core and a stator coil; and a rotor disposed rotatably on an inner circumferential side of the stator core. The stator core includes a plurality of slots opening on the inner circumferential side and the slots are each formed as an open slot with a width of an inner circumferential-side opening thereof ranging along a circumferential direction set substantially equal to or greater than a width of a bottom side measured along the circumferential direction. The stator further includes a slot insulator disposed between inner wall of each of the slots at the stator core and the stator coil and a holding member constituted with a nonmagnetic material and inserted in each of the slots at the stator core so as to hold the slot insulator between two side surfaces present along the circumferential direction at the slot. The stator is formed by winding the stator coil through the plurality of slots.

Claims

1. A rotating electrical machine, comprising:

a stator that comprises a stator core and a stator coil; and

a rotor disposed rotatably on an inner circumferential side of the stator core, wherein;

the stator core comprises a plurality of slots opening on the inner circumferential side and the slots are each formed as an open slot with a width of an inner circumferential-side opening thereof ranging along a circumferential direction set substantially equal to or greater than a width of a bottom side measured along the circumferential direction;

the stator further comprises a slot insulator disposed between inner wall of each of the slots at the stator core and the stator coil and a holding member constituted with a nonmagnetic material and inserted in each of the slots at the stator core so as to hold the slot insulator between two side surfaces present along the circumferential direction at the slot; and

the stator is formed by winding the stator coil through the plurality of slots.

2. A rotating electrical machine according to claim 1, wherein:

holding grooves are formed at the two side surfaces present along the circumferential direction at each of the slots; and

the holding member is inserted at the holding grooves via the slot insulator.

3. A rotating electrical machine according to claim 2, wherein:

inner circumferential side surfaces of the holding grooves incline toward the inner circumferential side of the holding grooves.

4. A rotating electrical machine according to claim 2, wherein:

the holding member is formed in a substantially U-shape.

5. A rotating electrical machine according to claim 1, wherein:

at least one end of the holding member along an axial direction is formed in a tapered shape.

6. A rotating electrical machine according to claim 1, wherein:

the holding member is constituted with a non-conductive material.

7. A rotating electrical machine according to claim 1, wherein:

the stator coil is wound through lap winding, at least a winding portion where the stator coil is lap-wound is constituted with a continuous wire and the stator coil is wound so as to range across the inner circumferential side and an outer circumferential side of the slots on two sides of the stator core along an axial direction.

8. A rotating electrical machine according to claim 7, wherein:

the stator coil has a substantially rectangular section.

9. A rotating electrical machine, comprising:

a stator that comprises a stator core and a stator coil; and

a rotor disposed rotatably on an inner circumferential side of the stator core, wherein;

the stator core comprises a plurality of slots opening on the inner circumferential side and the slots are each formed as an open slot with a width of an inner circumferential-side opening thereof ranging along a circumferential direction set substantially equal to or greater than a width of a bottom side measured along the circumferential direction; and

the stator is formed by mounting an insulator constituted with an insulator sheet at the stator coil as an integrated part thereof and winding the stator coil through the plurality of slots.

10. A rotating electrical machine according to claim 9, wherein:

the stator coil is constituted with a continuous wire wound so as to range across through the plurality of slots at least at one end of the stator core along an axial direction; and

a side of the insulator bent as the wire is laid across the plurality of slots, assumes a greater length than a length of the slots measured along the axial direction.

11. A rotating electrical machine according to claim 10, wherein:

a length of the insulator is greater than the length of the slots measured along the axial direction.

12. A rotating electrical machine according to claim 9, wherein:

the insulator is constituted with a resin material molded as an integrated part of the stator coil.

13. A rotating electrical machine according to claim 9, wherein:

the insulator sheet is bonded to the stator coil.

14. A rotating electrical machine according to claim 9, wherein:

the stator coil is wound through lap winding, at least a winding portion where the stator coil is lap-wound is constituted with a continuous wire and the stator coil is wound so as to range across the inner circumferential side and an outer circumferential side of the slots on two sides of the stator core along an axial direction.

15. A rotating electrical machine according to claim 14, wherein:

the stator coil has a substantially rectangular section.

16. A rotating electrical machine manufacturing method for manufacturing a rotating electrical machine that comprises a stator comprising a stator core with a plurality of slots each having an insertion portion on an inner circumferential side formed therein along a circumferential direction, and a stator coil wound through the slots, and a rotor with a plurality of magnetic poles formed along the circumferential direction which rotates relative to the stator, comprising:

a preliminary forming step in which a preliminary forming process is executed by winding a plurality of times a continuous stator coil in a spiral pattern that includes a pair of linear portions facing opposite each other;

a disposing step in which a plurality of winding portions are disposed along the circumferential direction so that the linear portions at the stator coil having undergone the preliminary forming process in the preliminary forming step are positioned on an inner circumferential side and an outer circumferential side;

a temporary forming step in which the linear portions set on the inner circumferential side and the outer circumferential side at the plurality of winding portions at the stator coil, disposed along the circumferential direction in the disposing step, are rotated relative to each other;

an insulation step in which a slot insulator constituted with an insulator sheet is inserted at each of the plurality of slots so as to form an opening on the inner circumferential side;

an insertion step in which the stator coil is inserted into each of the plurality of slots through the opening formed at the insulator, so that the linear portion set on the outer circumferential side at the stator coil having undergone the temporary forming process in the temporary forming step, is positioned on a bottom side of the plurality of slots and that the linear portion, set on the inner circumferential side is positioned toward the stator coil insertion portion;

a holding step in which a holding member constituted of a nonmagnetic material is inserted along an axial direction into each of the slots so as to hold therein the slot insulator;

a connecting step in which terminal portions of the stator coil having been inserted in the plurality of slots through the insertion step are electrically connected; and

a mounting step in which the rotor is mounted inside the stator via a bearing so that the rotor is allowed to rotate relative to the stator.

17. A rotating electrical machine manufacturing method for manufacturing a rotating electrical machine that comprises a stator comprising a stator core with a plurality of slots each having an insertion portion on an inner circumferential side formed therein along a circumferential direction, and a stator coil wound through the slots, and a rotor with a plurality of magnetic poles formed along the circumferential direction which rotates relative to the stator, comprising:

a preliminary forming step in which a preliminary forming process is executed by winding a plurality of times a continuous stator coil in a spiral pattern that includes a pair of linear portions facing opposite each other;

an insulation step in which insulators are mounted at the pair of linear portions at the stator coil having undergone the preliminary forming process in the preliminary forming step;

a disposing step in which a plurality of winding portions are disposed along the circumferential direction so that the linear portions at the stator coil, with the insulators mounted thereat through the insulation step, are positioned on an inner circumferential side and an outer circumferential side;

a temporary forming step in which the linear portions set on the inner circumferential side and the outer circumferential side at the plurality of winding portions at the stator coil, disposed along the circumferential direction in the disposing step, are rotated relative to each other;

an insertion step in which the stator coil is inserted into each of the plurality of slots, so that the linear portion, set on the outer circumferential side at the stator coil having undergone the temporary forming process in the temporary forming step, is positioned on a bottom side of the plurality of slots and that the linear portion, set on the inner circumferential side, is positioned toward the stator coil insertion portion; and

a mounting step in which the rotor is mounted inside the stator via a bearing so that the rotor is allowed to rotate relative to the stator.

18. A rotating electrical machine manufacturing method according to claim 17, wherein:

resin is molded over the linear portions of the stator coil in the insulation step.

19. A rotating electrical machine manufacturing method according to claim 17, wherein:

insulators constituted with an insulator sheet are wound over the linear portions of the stator coil and then the insulators are fixed onto the stator coil via an adhesive during the insulation step.