Stator for rotary electric machine and rotary electric machine using same

• US 8,008,830 B2
• Filed: 03/04/2008
• Issued: 08/30/2011
• Est. Priority Date: 03/05/2007
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Takada, Masahiro, Kajiura, Hiroaki, Kouda, Shinji
• Primary Examiner(s): Nguyen; Tran N
• Application Number:
  US12/529,651
• Publication Number:
  US 20100141078A1
• Time in Patent Office: 1,274 Days
• Field of Search: 310/180, 310/184, 310/201, 310/203, 310/206, 310/207
• US Class Current: 310/201
• CPC Class Codes: H02K 15/064 Windings consisting of separate segments, e.g. hairpin windings H02K15/063 takes precedence
• 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 3/50 Fastening of winding heads, equalising connectors, or connections thereto

Abstract

The wire 30 forming the stator winding 20 includes the in-slot portions 40 to be disposed in the slots 14 and 15 of the stator core 12 and the turned portions 42 connecting the in-slot portions 40 disposed in the circumferentially different slots 14 and 15. The turned portions 42 formed on axial opposite end sides of the stator core 12. The crank portion 44 which does not twist is formed at substantially the center of the turned portion 42. Steps are formed at sections of the turned portion 42 which protrude outside the stator core 12 from the slots 14 and 15. Further, the turned portion 42 of the wire 30 also has two steps 48 formed between the substantially central crank portion 44 and each of the steps 46 formed at the protruding sections of the turned portion 42.

Claims

1. A stator for a rotary electric machine equipped with a stator core having a plurality of slots in a circumferential direction and stator windings that are made of wire and disposed in the slots, wherein said stator windings include in-slot portions disposed in the slots different in the circumferential direction and turned portions connecting said in-slot portions outside the slots, and steps that extend along an end surface of said stator core are formed at sections of the turned portions protruding from said slots.

2. A stator for a rotary electric machine as set forth in claim 1, wherein the steps that extend along the end surface of said stator core are formed at all the sections of said turned portion protruding from said slots.

3. A stator for a rotary electric machine as set forth in claim 1, wherein a length of the protruding sections of said turned portions along the end surface of the stator core is smaller than or equal to an interval between the slots adjacent in the circumferential direction.

4. A stator for a rotary electric machine as set forth in claim 1, wherein said turned portions are shaped stepwise to have the steps that are parallel to the end surface of said stator core, in an axial direction of said stator core.

5. A stator for a rotary electric machine as set forth in claim 4, wherein a length of all said steps parallel to the end surface of said stator core is smaller than or equal to an interval between the slots adjacent in the circumferential direction.

6. A stator for a rotary electric machine as set forth in claim 4, wherein if the number of phases of said stator windings is k, and the number of said slots for each phase per pole of a rotor having a plurality of magnetic poles different alternately in the circumferential direction is n, the number of said steps formed at the turned portion is k×

n.

7. A stator for a rotary electric machine as set forth in claim 1, wherein the turned portions have a crank-shaped crank portion formed at a location farthest away from said stator core.

8. A stator for a rotary electric machine as set forth in claim 7, wherein the crank portion is formed in parallel to the end surface of said stator core.

9. A stator for a rotary electric machine as set forth in claim 7, wherein said crank portion is shifted in a radial direction of said stator core by a width of said wire.

10. A stator for a rotary electric machine as set forth in claim 7, wherein each of said turned portions is laid to overlap a circumferentially adjacent one of said turned portions in an axial direction.

11. A stator for a rotary electric machine as set forth in claim 7, wherein said turned portion is shaped stepwise to have a plurality of steps in an axial direction of said stator core, said steps are in parallel to the end surface of said stator core, and an axial distance between the crank portion and an uppermost step that is one of said steps defining a stepwise shape that is farthest from said stator core in the axial direction is longer than an axial distance between said steps.

12. A stator for a rotary electric machine as set forth in claim 11, wherein said crank portion is laid to axially overlap said uppermost step of a circumferentially adjacent one of said turned portions.

13. A stator for a rotary electric machine as set forth in claim 11, wherein distances between said steps of said turned portion is equivalent to a height of said wire.

14. A stator for a rotary electric machine as set forth in claim 1, wherein said wire has a rectangular section.

15. A stator for a rotary electric machine as set forth in claim 1, wherein said wire is formed to continue over an entire circumference of said stator core.

16. A stator for a rotary electric machine as set forth in claim 1, wherein said wire has a conductor and an insulating film wrapped about the conductor, the insulating film having a thickness of 100 to 200 μ

m.

17. A stator for a rotary electric machine as set forth in claim 16, wherein said insulating film has an inner layer and an outer layer covering said inner layer, said outer layer being lower in glass-transition temperature than said inner layer.

18. A stator for a rotary electric machine as set forth in claim 16, wherein said wire has a fusing material covering an outer periphery of said insulating film.

19. A stator for a rotary electric machine as set forth in claim 1, wherein said wire has an conductor made of aluminum.

20. A rotary electric machine, wherein it includes the stator as set forth in claim 1 and a rotor forming magnetic poles different alternately in the circumferential direction.

21. A stator for a rotary electric machine equipped with a stator core having a plurality of slots in a circumferential direction and a stator windings that is made of wire and disposed in the slots, wherein said Stator windings include in-slot portions disposed in the slots different in the circumferential direction and turned portions connecting said in-slot portions outside the slots, and all the turned portions have steps parallel to an end surface of said stator core.