Stator for electric rotating machine

• US 8,193,675 B2
• Filed: 12/15/2009
• Issued: 06/05/2012
• Est. Priority Date: 12/15/2008
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Ishizuka, Atsuo, Umeda, Atsushi
• Primary Examiner(s): NGUYEN, HANH N
• Application Number:
  US12/638,122
• Publication Number:
  US 20100148621A1
• Time in Patent Office: 903 Days
• Field of Search: 310/201, 310/207, 310/180, 310/205, 310/206, 310/208
• US Class Current: 310/201
• CPC Class Codes: H02K 15/0037 Shaping or compacting winding heads H02K15/005, H02K15/0087 and H02K15/0428 take precedence
• CPC Class Codes: H02K 15/0485 manufactured by shaping an annular winding
• 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

Abstract

A stator includes a hollow cylindrical stator core and a stator coil made up of wave-shaped electric wires. Each of the electric wires has in-slot portions, which are received in slots of the stator core, and turn portions that are located outside of the slots to connect the in-slot portions. The stator coil includes first crank-shaped portions and second crank-shaped portions. Each of the first and second crank-shaped portions is provided, in one of the electric wires, at the center of an apex part of one of the turn portions and is radially bent to shift the radial position of the electric wire. The amount of radial position shift made by each of the second crank-shaped portions is less than that made by each of the first crank-shaped portions. The second crank-shaped portions are located at a plurality of places in the circumferential direction of the stator core.

Claims

1. A stator for an electric rotating machine, the stator comprising:

a hollow cylindrical stator core having a plurality of slots that are formed in a radially inner surface of the stator core and spaced at predetermined intervals in a circumferential direction of the stator core; and

a stator coil made up of a plurality of wave-shaped electric wires mounted on the stator core, each of the electric wires having a plurality of in-slot portions, each of which is received in one of the slots of the stator core, and a plurality of turn portions each of which is located outside of the slots of the stator core to connect one adjacent pair of the in-slot portions of the electric wire, each of the turn portions including an apex part that is located axially furthest in the turn portion from the stator core,

wherein

the stator coil includes a plurality of first crank-shaped portions and a plurality of second crank-shaped portions,

each of the first and second crank-shaped portions is provided, in one of the electric wires, at the center of the apex part of one of the turn portions of the electric wire and at least the first crank-shaped portions are radially bent to shift the radial position of the electric wire,

any amount of radial position shift made by each of the second crank-shaped portions is less than that made by each of the first crank-shaped portions, and

the second crank-shaped portions are located at a plurality of places in the circumferential direction of the stator core.

2. The stator as set forth in claim 1, wherein the plurality of electric wires comprise first-type electric wires and second-type electric wires,

each of the first-type electric wires includes only at least one of the first crank-shaped portions, and each of the second-type electric wires includes both at least one of the first crank-shaped portions and at least one of the second crank-shaped portions.

3. The stator as set forth in claim 2, wherein one of the second-type electric wires includes a plurality of crank-shaped portion groups each of which consists of m of the first crank-shaped portions and n of the second crank-shaped portions, where m and n each represent an integer greater than zero, and

the plurality of crank-shaped portion groups are cyclically arranged in a longitudinal direction of the second-type electric wire.

4. The stator as set forth in claim 2, wherein one of the second-type electric wires includes j of the first crank-shaped portions on one longitudinal end side and k of the second crank-shaped portions on the other longitudinal end side of the second-type electric wire, where j and k each represent an integer greater than zero, and the sum of j and k is equal to the number of the apex parts of the turn portions in the second-type electric wire.

5. The stator as set forth in claim 2, wherein the number of the electric wires making up the stator coil is h, where h is an integer greater than 1,

the stator coil is a hollow cylindrical electric wire assembly that is formed by rolling a flat band-shaped electric wire assembly by a predetermined number of turns, and the flat band-shaped electric wire assembly is formed by sequentially stacking the h electric wires, and

the second to (h−

1)th electric wires in the sequential stacking of the h electric wires are the first-type electric wires.

6. The stator as set forth in claim 1, wherein each of the turn portions of the electric wires is stepped to include a plurality of shoulder parts that extend parallel to an axial end face of the stator core from which the turn portion protrudes.

7. The stator as set forth in claim 1, wherein each of the electric wires is made up of an electric conductor having a rectangular cross section and an insulating coat covering the surface of the electric conductor.

8. A stator for an electric rotating machine, the stator comprising:

a hollow cylindrical stator core having a plurality of slots that are formed in a radially inner surface of the stator core and spaced at predetermined intervals in a circumferential direction of the stator core; and

a stator coil made up of a plurality of wave-shaped electric wires mounted on the stator core, each of the electric wires having a plurality of in-slot portions, each of which is received in one of the slots of the stator core, and a plurality of turn portions each of which is located outside of the slots of the stator core to connect one adjacent pair of the in-slot portions of the electric wire, each of the turn portions including an apex part that is located axially furthest in the turn portion from the stator core,

wherein

the stator coil includes a plurality of crank-shaped portions and a plurality of straight portions,

each of the crank-shaped portions is provided, in one of the electric wires, at the center of the apex part of one of the turn portions of the electric wire and is radially bent to shift the radial position of the electric wire,

each of the straight portions is provided, in one of the electric wires, at the center of the apex part of one of the turn portions of the electric wire and extends in the circumferential direction of the stator core without being radially bent, and

the straight portions are located at a plurality of places in the circumferential direction of the stator core.

9. The stator as set forth in claim 8, wherein the plurality of electric wires comprise first-type electric wires and second-type electric wires,

each of the first-type electric wires includes only at least one of the crank-shaped portions, and each of the second-type electric wires includes both at least one of the crank-shaped portions and at least one of the straight portions.

10. The stator as set forth in claim 9, wherein one of the second-type electric wires includes a plurality of crank-shaped portion groups each of which consists of m of the crank-shaped portions and n of the straight portions, where m and n each represent an integer greater than zero, and

the plurality of crank-shaped portion groups are cyclically arranged in a longitudinal direction of the second-type electric wire.

11. The stator as set forth in claim 9, wherein one of the second-type electric wires includes j of the crank-shaped portions on one longitudinal end side and k of the straight portions on the other longitudinal end side of the second-type electric wire, where j and k each represent an integer greater than zero, and the sum of j and k is equal to the number of the apex parts of the turn portions in the second-type electric wire.

12. The stator as set forth in claim 9, wherein the number of the electric wires making up the stator coil is h, where h is an integer greater than 1,

the stator coil is a hollow cylindrical electric wire assembly that is formed by rolling a flat band-shaped electric wire assembly by a predetermined number of turns, and the flat band-shaped electric wire assembly is formed by sequentially stacking the h electric wires, and

the second to (h−

1)th electric wires in the sequential stacking of the h electric wires are the first-type electric wires.

13. The stator as set forth in claim 8, wherein each of the turn portions of the electric wires is stepped to include a plurality of shoulder parts that extend parallel to an axial end face of the stator core from which the turn portion protrudes.

14. The stator as set forth in claim 8, wherein each of the electric wires is made up of an electric conductor having a rectangular cross section and an insulating coat covering the surface of the electric conductor.