COIL, STATOR, AND METHOD FOR MANUFACTURING COIL

• US 20120200191A1
• Filed: 02/07/2012
• Published: 08/09/2012
• Est. Priority Date: 02/09/2011
• Status: Active Grant

• Current Assignee: Kabushiki Kaisha Toyota Jidoshokki
• Original Assignee: Kabushiki Kaisha Toyota Jidoshokki
• Inventors: BABA, Satoru, SATAKE, Yasuyuki
• Granted Patent: US 9,130,416 B2
• Time in Patent Office: Days
• US Class Current: 310/201
• CPC Class Codes: H02K 15/0464 Lap windings when on diagonally wound hollow coils H02K15/0492
• CPC Class Codes: H02K 3/04 Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine

Abstract

A coil including a first winding portion and a second winding portion arranged on a stator of a rotary electrical machine. The first winding portion is formed by edgewise-winding a conductive rectangular wire. The second winding portion is formed by edgewise-winding a conductive rectangular wire, which is connected to the first winding portion. Coil end parts of the first and second winding portions each include a crank-shaped section. The first and second winding portions are formed so that when slot insertion parts of the first and second windings are arranged in slots of the stator, a long side of a cross-section of the rectangular wire extends in the circumferential direction of the stator and a short side of the cross-section of the rectangular wire extends in a radial direction of the stator.

Claims

1. A coil arranged in a stator of a rotary electrical machine, wherein the stator includes a plurality of slots arranged in a circumferential direction, the coil comprising:

a first winding portion formed by edgewise-winding a conductive rectangular wire, wherein the first winding portion includes two first slot insertion parts, which are respectively arranged in two first slots spaced apart from each other in the circumferential direction, and two first coil end parts, which connect the two first slot insertion parts, and wherein the first slots are included in the plurality of slots of the stator; and

a second winding portion formed by edgewise-winding a conductive rectangular wire that is connected to the first winding portion, wherein the second winding portion includes two second slot insertion parts, which are respectively arranged in two second slots spaced apart from each other in the circumferential direction, and two second coil end parts, which connect the two second slot insertion parts, and wherein the two second slots are included in the plurality of slots of the stator;

wherein each of the first and second coil end parts includes a crank-shaped section, and the first and second winding portions are formed so that when the first and second slot insertion parts are arranged in the corresponding slots, a long side of a cross-section of the rectangular wire extends in the circumferential direction of the stator and a short side of the cross-section of the rectangular wire extends in a radial direction of the stator.

2. The coil according to claim 1, further comprising a connecting portion connecting the first winding portion and the second winding portion, wherein the connecting portion extends between the crank-shaped section of the first winding portion and the crank-shaped section of the second winding portion.

3. The coil according to claim 1, further comprising a connecting portion connecting the first winding portion and the second winding portion,

wherein one of the two first slot insertion parts is arranged in the coil outward in the circumferential direction of the stator from the second winding portion, and one of the second slot insertion parts is arranged in the coil outward in the circumferential direction of the stator from the first winding portion, and

the connecting portion extends to connect the one of the first slot insertion part and the one of the second slot insertion part that are outwardly arranged.

4. The coil according to claim 1, further comprising a plurality of coil elements that are separated from each other and arranged in a radial direction of the stator, each of the coil elements is formed to include one or more turnings of the conductive wire in the same slot.

5. The coil according to claim 4, wherein

each of the coil elements includes a drawn out portion connected to an adjacent one of the coil elements in the radial direction of the stator, and

the drawn out portions of adjacent coil elements in the radial direction of the stator are arranged at overlapping positions in the circumferential direction of the stator and directly joined with each other.

6. The coil according to claim 5, wherein

the drawn out portion of each of the coil elements includes an inner drawn out portion arranged inward in the radial direction of the stator and an outer drawn out portion arranged outward in the radial direction of the stator, and

the inner drawn out portion of an innermost one of the coil elements in the radial direction is an offset drawn out portion arranged at a position offset in the circumferential direction from the drawn out portions of the other coil elements.

7. The coil according to claim 6, wherein

the coil is one of a plurality of coils that have the same phase and are adjacent to each other in the circumferential direction of the stator,

the offset drawn out portions of the coils of the same phase are connected with each other by a connecting wire of the same phase,

the drawn out portions extend in an axial direction of the stator, and

the connecting wire of the same phase is arranged outward in the radial direction from an inner circumferential surface of the stator on an axial end surface of the stator and extends between the drawn out portions.

8. The coil according to claim 7, wherein

the connecting wire of the same phase is provided with each of a plurality of phases,

the connecting wires corresponding to the plurality of phases extend obliquely relative to a plane orthogonal to the axial direction of the stator in a state in which the connecting wires are overlapped with one another in the axial direction of the stator.

9. The coil according to claim 4, wherein among the coil elements that are adjacent to each other in the radial direction of the stator, the coil element located inward in the radial direction of the state has a number of windings of the conductive wire that is the same8 or smaller than that of the coil element located outward in the radial direction of the stator.

10. The coil according to claim 1, wherein one of the two first slot insertion parts and one of the two second slot insertion parts are arranged in different slots, and the other one of the two first slot insertion parts and the other one of the two second slot insertion parts are arranged in different slots.

11. The coil according to claim 1, wherein one of the two first slot insertion parts and one of the two second slot insertion parts are arranged in the same slot, and the other one of the two first slot insertion parts and the other one of the two second slot insertion parts are arranged in the same slot.

12. A stator comprising:

a cylindrical stator core including an inner circumferential surface and slots, which open in the inner circumferential surface of the stator core and which are arranged in a circumferential direction; and

the coil according to claim 1 inserted into the slots of the stator core.

13. A method for manufacturing a coil including a first winding portion, which includes two slot insertion parts and two coil end parts, and a second winding portion, which includes two slot insertion parts and two coil end parts, the method comprising:

edgewise-winding a single conductive rectangular wire to form the first winding portion and the second winding portion that are connected by a connecting portion;

forming a crank-shaped section in each of the coil end parts of the first winding portion and the second winding portion; and

shaping the connecting portion and aligning the two slot insertion parts of each of the first winding portion and the second winding portion with two of a plurality of slots of the stator core arranged in a circumferential direction.