Sequentially joined-segment coil for rotary electrical machine

• US 7,242,124 B2
• Filed: 09/29/2005
• Issued: 07/10/2007
• Est. Priority Date: 06/12/2002
• Status: Expired due to Fees

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Ogawa, Shinichi, Fukushima, Akira
• Primary Examiner(s): TAMAI, KARL I
• Application Number:
  US11/237,654
• Publication Number:
  US 20060033394A1
• Time in Patent Office: 649 Days
• Field of Search: 310/201, 310/206, 310/207, 310/179, 310/180, 310/184, 310/208, 310/205, 310/198
• US Class Current: 310/180
• 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 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 a star connection and a 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, and 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 of the types in slot pitch between the slots within which the slot-inserted portions of each of the conductor segments are disposed,

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, and

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 type, a second type, 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.