Rotating electric machine

Patent metadata

Field	Value
Publication number	US-11594930-B2
Application number	US-202117235337-A
Country	US
Kind code	B2
Filing date	Apr 20, 2021
Priority date	Apr 20, 2020
Publication date	Feb 28, 2023
Grant date	Feb 28, 2023

Abstract

A rotating electric machine includes a multi-phase armature coil wound on an armature core. The armature coil is formed of electrical conductor groups each being a bundle of electrical conductor segments and having a pair of leg portions and a connecting portion that connects the leg portions. The connecting portion is bent radially with respect to a circumferential direction. The electrical conductor groups are paired such that each pair of the electrical conductor groups consists of a first electrical conductor group and a second electrical conductor group both belonging to a same phase of the armature coil. The circumferential pitch between the leg portions of the first electrical conductor group is greater than that between the leg portions of the second electrical conductor group. In each pair of the electrical conductor groups, the connecting portions of the first and second electrical conductor groups are arranged to axially overlap each other.

First claim

What is claimed is:

1. A rotating electric machine comprising an armature, the armature including an annular armature core and a multi-phase armature coil wound on the armature core,
wherein:
the armature core has a plurality of slots arranged in a circumferential direction thereof;
the armature coil is formed of a plurality of electrical conductor groups connected with one another, each of the plurality of electrical conductor groups being constituted of a bundle of a plurality of electrical conductor segments;
each of the plurality of electrical conductor groups is substantially U-shaped to have a pair of leg portions and a connecting portion, the pair of leg portions being respectively received in a corresponding pair of the slots of the armature core and located at different radial positions in the corresponding slots, the connecting portion extending on one axial side of the armature core to connect the pair of leg portions, the connecting portion having a bent part that is bent radially with respect to the circumferential direction;
the plurality of electrical conductor groups are paired such that each pair of the electrical conductor groups consists of a first electrical conductor group and a second electrical conductor group that both belong to a same phase of the armature coil;
a circumferential pitch between the pair of leg portions of the first electrical conductor group is greater than a circumferential pitch between the pair of leg portions of the second electrical conductor group; and
in each pair of the electrical conductor groups, the connecting portions of the first and second electrical conductor groups are arranged to axially overlap each other.

2. The rotating electric machine as set forth in claim 1 , wherein:
for each of the electrical conductor groups, the electrical conductor segments constituting the electrical conductor group are arranged, at the pair of leg portions of the electrical conductor group, in a predetermined arrangement sequence in a radial direction so as to be radially aligned with each other in the corresponding slots of the armature core; and
at the connecting portion of the electrical conductor group, the electrical conductor segments constituting the electrical conductor group are arranged parallel to each other keeping the arrangement sequence of the electrical conductor segments at the pair of leg portions of the electrical conductor group in the corresponding slots.

3. The rotating electric machine as set forth in claim 1 , wherein:
the bent parts of the connecting portions of the first electrical conductor groups are arranged in alignment with each other in the circumferential direction;
a circumferential pitch between the bent parts of the connecting portions of the first electrical conductor groups is greater than or equal to a circumferential pitch between the slots of the armature core and less than or equal to twice the circumferential pitch between the slots;
the bent parts of the connecting portions of the second electrical conductor groups are also arranged in alignment with each other in the circumferential direction; and
a circumferential pitch between the bent parts of the connecting portions of the second electrical conductor groups is also greater than or equal to the circumferential pitch between the slots of the armature core and less than or equal to twice the circumferential pitch between the slots.

4. The rotating electric machine as set forth in claim 1 , wherein:
for each of the electrical conductor groups, one of the pair of leg portions of the electrical conductor group is received in a radially outer part of one corresponding slot of the armature core and the other of the pair of leg portions is received in a radially inner part of another corresponding slot of the armature core;
for each of the electrical conductor groups, there is formed, in the bent part of the connecting portion of the electrical conductor group, a radially-extending part which extends along a radial direction and in which the electrical conductor segments constituting the electrical conductor group are arranged in alignment with each other in the circumferential direction;
the radially-extending parts of the connecting portions of the first electrical conductor groups are arranged in alignment with each other in the circumferential direction, and the radially-extending parts of the connecting portions of the second electrical conductor groups are arranged in alignment with each other in the circumferential direction; and
the following relationship is satisfied:
Rc× 2×π/ S≤N×Hc≤Rc× 2×π/( S/ 2)

where Rc is a distance from a central axis of the armature core to a radial center of each of the slots, S is the number of the slots formed in the armature core, N is the number of the electrical conductor segments included in each of the electrical conductor groups, and Hc is a radial thickness of each of the electrical conductor segments in the corresponding slots of the armature core.

5. The rotating electric machine as set forth in claim 1 , wherein:
a clearance is provided between each circumferentially-adjacent pair of the bent parts of the connecting portions of the electrical conductor groups.

6. The rotating electric machine as set forth in claim 1 , wherein:
for each of the electrical conductor groups, one of the pair of leg portions of the electrical conductor group is received in a radially outer part of one corresponding slot of the armature core and the other of the pair of leg portions is received in a radially inner part of another corresponding slot of the armature core; and
the following relationship is satisfied:
Wc× 2< Hc×N,

where Wc is a circumferential width of each of the electrical conductor segments in the corresponding slots of the armature core, Hc is a radial thickness of each of the electrical conductor segments in the corresponding slots of the armature core, and N is the number of the electrical conductor segments included in each of the electrical conductor groups.

7. The rotating electric machine as set forth in claim 1 , wherein:
the armature coil is a three-phase coil having three phase windings star-connected to define a neutral point therebetween;
the first and second electrical conductor groups forming a same one of the phase windings of the armature coil are connected in series with each other; and
the first electrical conductor groups are connected closer to the neutral point than the second electrical conductor groups are.

8. The rotating electric machine as set forth in claim 1 , wherein:
at the connecting portions of each pair of the electrical conductor groups, an axially-inner side surface of the first electrical conductor group and an axially-outer side surface of the second electrical conductor group are arranged in surface contact with each other.

9. The rotating electric machine as set forth in claim 1 , wherein:
each of the electrical conductor segments includes a main body formed of an electrically-conductive material and an insulating coat covering a surface of the main body; and
the insulating coat is formed of an electrically-insulative material with voids formed therein.

10. The rotating electric machine as set forth in claim 1 , wherein:
at the connecting portions of each pair of the electrical conductor groups, the electrical conductor segments constituting the first electrical conductor group are respectively axially opposed to and spaced at a substantially constant interval from the electrical conductor segments constituting the second electrical conductor group.

11. The rotating electric machine as set forth in claim 1 , wherein:
each of the

Assignees

• Denso Corp

Inventors

• Endo Hiroshi
• Tamura Akito

Classifications

• H02K2213/03

  Machines characterised by numerical values, ranges, mathematical expressions or similar information · CPC title

• H02K3/34

  between conductors or between conductor and core, e.g. slot insulation · CPC title

• H02K3/28 Primary

  Layout of windings or of connections between windings (windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32) · CPC title

• H02K11/33

  Drive circuits, e.g. power electronics (H02K11/38 takes precedence) · CPC title

• H02K3/505

  for large machine windings, e.g. bar windings (H02K3/51 takes precedence) · CPC title