ROTARY ELECTRIC MACHINE AND MANUFACTURING METHOD THEREFOR

• US 20150162787A1
• Filed: 02/25/2013
• Published: 06/11/2015
• Est. Priority Date: 07/06/2012
• Status: Active Grant

• Current Assignee: Mitsubishi Electric Corporation
• Original Assignee: Mitsubishi Electric Corporation
• Inventors: Sakaue, Atsushi, Akita, Hiroyuki, Tsuiki, Hironori, Inoue, Masaya
• Granted Patent: US 10,461,591 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 1/16 Stator cores with slots for windings
• CPC Class Codes: H02K 15/04 of windings, prior to mounting into machines insulating windings H02K15/10, H02K15/12
• CPC Class Codes: H02K 15/045 Form wound coils
• CPC Class Codes: H02K 15/085 by laying conductors into slotted stators
• 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: Y10T 29/49009 Dynamoelectric machine

Abstract

A stator winding is formed by mounting winding bodies individually into pairs of slots of a stator core separated by a predetermined number of slots, the winding bodies each being formed by winding a jointless, continuous conductor wire coated with insulation for m turns into a helical shape such that end portions of rectilinear portions are linked by coil ends, where m is a natural number that is greater than or equal to two, and the coil ends include a top portion that displaces by a predetermined amount in a radial direction at an approximately central portion between the linked rectilinear portions, the radial displacement at the top portions is approximately a×d, where a is a natural number that is greater than or equal to 1 and less than or equal to (m−1), and d is a radial thickness of the rectilinear portions.

Claims

1-18. -18. (canceled)

19. A rotary electric machine comprising an armature that is formed by mounting an armature core to an annular armature winding, wherein:

said armature winding is formed by mounting winding bodies individually into pairs of slots of said armature core that are separated by a predetermined number of slots, said winding bodies each being formed by winding a jointless, continuous conductor wire that is coated with insulation for m turns into a helical shape such that end portions of rectilinear portions are linked by coil ends, where m is a natural number that is greater than or equal to two;

said coil ends include a top portion that displaces by a predetermined amount in a radial direction at an approximately central portion between said linked rectilinear portions;

said radial displacement at said top portion is approximately a×

d, where a is a natural number that is greater than or equal to 1 and less than or equal to (m−

1), and d is a radial thickness of said rectilinear portions that are housed inside said slots;

2m of said conductor wires of different pairs of said winding bodies are housed inside said slots so as to be stacked in a radial direction; and

said armature core includes core blocks that are divided circumferentially, each of said core blocks comprising;

a circular arc-shaped core back portion; and

a tooth that is disposed so as to extend radially from said core back portion.

20. The rotary electric machine according to claim 19, wherein a is a natural number that is greater than or equal to two.

21. The rotary electric machine according to claim 19, wherein a is a factor of m.

22. The rotary electric machine according to claim 19, wherein a number of slots per phase per pole is greater than or equal to two, and greater than or equal to two and less than or equal to said number of slots per phase per pole of said winding bodies that are arranged consecutively in a circumferential direction are each produced using a single conductor wire.

23. The rotary electric machine according to claim 19, wherein a cross section of said conductor wire is rectangular.

24. The rotary electric machine according to claim 23, wherein said cross section of said conductor wire is an oblong rectangle, and said conductor wire is housed inside said slots so as to line up radially such that a long side of said oblong rectangular cross section is oriented in a circumferential direction.

25. The rotary electric machine according to claim 19, wherein heights of said top portions of said coil ends of said winding bodies from an axial end surface of said armature core reduce gradually toward a radially inner side.

26. The rotary electric machine according to claim 19, wherein said coil ends of said winding bodies are positioned nearer to bottom portions of said slots of said armature core than to opening ends of said slots.

27. The rotary electric machine according to claim 19, wherein said coil ends of said winding bodies are positioned nearer to openings of said slots of said armature core than to bottom portions of said slots.

28. A rotary electric machine comprising an armature that is formed by mounting an armature core to an annular armature winding, wherein:

said armature winding is formed by mounting winding bodies individually into pairs of slots of said armature core that are separated by a predetermined number of slots, said winding bodies each being formed by winding a jointless, continuous conductor wire that is coated with insulation for m turns into a helical shape such that end portions of rectilinear portions are linked by coil ends, where m is a natural number that is greater than or equal to two; and

rectilinear portions of two of said winding bodies are housed so as to line up radially in each of said slots of said armature core such that greater than or equal to one and less than or equal to (m−

1) rectilinear portions of a first winding body enter between rectilinear portions of a second winding body.

29. The rotary electric machine according to claim 28, wherein a number of slots per phase per pole is greater than or equal to two, and greater than or equal to two and less than or equal to said number of slots per phase per pole of said winding bodies that are arranged consecutively in a circumferential direction are each produced using a single conductor wire.

30. The rotary electric machine according to claim 28, wherein a cross section of said conductor wire is rectangular.

31. The rotary electric machine according to claim 30, wherein said cross section of said conductor wire is an oblong rectangle, and said conductor wire is housed inside said slots so as to line up radially such that a long side of said oblong rectangular cross section is oriented in a circumferential direction.

32. The rotary electric machine according to claim 28, wherein heights of said top portions of said coil ends of said winding bodies from an axial end surface of said armature core reduce gradually toward a radially inner side.

33. The rotary electric machine according to claim 28, wherein said coil ends of said winding bodies are positioned nearer to bottom portions of said slots of said armature core than to opening ends of said slots.

34. The rotary electric machine according to claim 28, wherein said coil ends of said winding bodies are positioned nearer to openings of said slots of said armature core than to bottom portions of said slots.

35. A rotary electric machine manufacturing method comprising steps of:

producing winding bodies that are each formed by winding a jointless, continuous conductor wire for m turns into a helical shape such that end portions of rectilinear portions are linked by coil ends, where m is a natural number that is greater than or equal to two, said coil ends including a top portion that displaces by a predetermined amount in a direction of lamination of said conductor wire that is wound into said helical shape at an approximately central portion between said linked rectilinear portions, and said displacement at said top portion in said direction of lamination of said conductor wire being approximately a×

d, where a is a natural number that is greater than or equal to 1 and less than or equal to (m−

1), and d is a thickness of said rectilinear portions in said direction of lamination of said conductor wire;

assembling a winding assembly by lining up said winding bodies in a circumferential direction such that said coil ends overlap with each other in a radial direction; and

lining up a plurality of core blocks in an annular shape around an outer circumference of said winding assembly and inserting said plurality of core blocks radially into said winding assembly, said core blocks comprising;

a circular arc-shaped core back portion; and

a tooth that is disposed so as to extend radially inward from an inner circumferential portion of said core back portion.

36. The rotary electric machine manufacturing method according to claim 35, wherein, in said step of assembling said winding assembly, said winding assembly is assembled by moving said winding bodies individually in a circumferential direction.

37. The rotary electric machine manufacturing method according to claim 36, wherein, in said step of assembling said winding assembly, said winding assembly is assembled into an annular shape by assembling a C-shaped assemblage until a single winding body of said winding bodies that constitute said winding assembly remains, widening an opening of said assemblage such that an opening width of said C shape of said assemblage becomes wider than a circumferential width of said winding body, assembling said remaining single winding body on a first circumferential end of said assemblage through said opening of said assemblage, and subsequently assembling said winding bodies at ends of said opening by closing said opening of said assemblage.

38. The rotary electric machine manufacturing method according to claim 35, wherein, in said step of assembling said winding assembly, sub-assemblies are assembled by moving a plurality of said winding bodies individually in a circumferential direction, and said winding assembly is assembled by moving said sub-assemblies individually in a circumferential direction.

39. The rotary electric machine manufacturing method according to claim 38, wherein, in said step of assembling said winding assembly, said winding assembly is assembled into an annular shape by assembling a C-shaped assemblage until a single sub-assembly of said sub-assemblies that constitute said winding assembly remains, widening an opening of said assemblage such that an opening width of said C shape of said assemblage becomes wider than a circumferential width of said sub-assembly, assembling said remaining single sub-assembly on a first circumferential end of said assemblage through said opening of said assemblage, and subsequently assembling said sub-assemblies at ends of said opening by closing said opening of said assemblage.

40. The rotary electric machine manufacturing method according to claim 35, wherein, in said step of mounting said winding assembly into said armature core, core blocks that are formed by dividing said armature core circumferentially by a number equal to a total number of slots, and that include:

a circular arc-shaped core back portion; and

a single tooth that is disposed so as to extend radially inward from an inner circumferential portion of said core back portion, are arranged in an annular shape on an outer circumferential side of said winding assembly such that tip ends of said tooth are directed between respective adjacent columns of said rectilinear portions, and said core blocks that are arranged in said annular shape are moved radially inward such that said tip portions of said teeth are inserted between each of said columns of said rectilinear portions simultaneously.

41. The rotary electric machine manufacturing method according to claim 40, wherein said winding assembly before said teeth of said core blocks are inserted is formed so as to have a diameter that is larger than a final diameter of said winding assembly that is mounted into said armature core.

42. The rotary electric machine manufacturing method according to claim 35, wherein, in said step of mounting said winding assembly into said armature core, core blocks that are formed by dividing said armature core equally in a direction of arrangement of said slots by a number that is half a total number of slots, and that include:

a circular arc-shaped core back portion; and

two teeth that are disposed so as to extend radially inward from an inner circumferential portion of said core back portion so as to be separated circumferentially, are arranged in an annular shape on an outer circumferential side of said winding assembly such that tip ends of said tooth are directed between respective adjacent columns of said rectilinear portions, and said core blocks that are arranged in said annular shape are moved radially inward such that said tip portions of said teeth are inserted between each of said columns of said rectilinear portions simultaneously.

43. The rotary electric machine manufacturing method according to claim 42, wherein said winding assembly before said teeth of said core blocks are inserted is formed so as to have a diameter that is larger than a final diameter of said winding assembly that is mounted into said armature core.