Stator of segmented conductor type electric rotary machine and fabrication method thereof

Patent metadata

Field	Value
Publication number	US-9257875-B2
Application number	US-201414273635-A
Country	US
Kind code	B2
Filing date	May 9, 2014
Priority date	May 16, 2013
Publication date	Feb 9, 2016
Grant date	Feb 9, 2016

Abstract

One embodiment provides a stator of a segmented conductor type electric rotary machine including an annular stator core and coil. On at least one axial end portion of the stator core, the coils are disposed to form a coil end so that plural spanning portions of the coils are arranged continuously in a circumferential direction and so that circumferentially adjacent ones of the spanning portions partially overlap each other as seen in an axial direction. An apex portion of the spanning portion is twisted so that an intersecting state is formed as seen in a radial direction within a range where the spanning portion is exposed as seen in the axial direction.

First claim

The invention claimed is:

1. A stator of a segmented conductor type electric rotary machine comprising:
an annular stator core which includes plural slots; and
plural coil segments which are inserted into the slots,
wherein, on at least one axial end portion of the stator core, the plural coil segments are disposed to form a coil end so that plural spanning portions of the plural coil segments are arranged continuously in a circumferential direction and so that circumferentially adjacent ones of the spanning portions partially overlap each other as seen in an axial direction of the stator core, each spanning portion spanning from a radially inner portion of one of the plural slots to a radially outer portion of another one of the plural slots, and
wherein the spanning portion comprises:
a first sloping portion, where a central portion of the plural coil segments extends axially outwards in the axial direction along a first sloping line as the central portion goes from the one of the plural slots to the another one of the plural slots, as seen in a radial direction;
a second sloping portion, where the central portion of the plural coil segments extends axially outwards in the axial direction along a second sloping line as the central portion goes from the another one of the plural slots to the one of the plural slots, as seen in the radial direction;
a first bent portion, where the plural coil segments are disposed in parallel and curve in such a way as to go in the radial direction from the first sloping portion; and
a second bent portion, where the plural coil segments are disposed in parallel and curve in such a way as to go in the radial direction from the second sloping portion, wherein
at a most radially inner coil segment of the plural coil segments in the first bent portion, a corner portion positioned at a side of the another one of the plural slots and at an outside in the axial direction as seen in the radial direction is located more axially outwards in the axial direction than an extension line of the first sloping line,
at a most radially outer coil segment of the plural coil segments in the second bent portion, a corner portion positioned at a side of the one of the plural slots and at the outside in the axial direction as seen in the radial direction is located more axially outwards in the axial direction than an extension line of the second sloping line.

2. The stator of claim 1 ,
wherein the second bent portion expands radially outwards as seen in the axial direction.

3. The stator of claim 1 ,
wherein the first bent portion expands radially inwards as seen in the axial direction.

4. The stator of claim 1 ,
wherein the spanning portion is made up of the plural coil segments which are aligned together side by side into a bundle, and
wherein an apex portion of the spanning portion is twisted so that adjacent ones of the coil segments are attached closely to each other.

5. A fabrication method of a stator of a segmented conductor type electric rotary machine which comprises an annular stator core which includes plural slots, and plural coil segments which are inserted into the slots, the method comprising:
forming spanning portions of the plural coil segments, on at least one axial end portion of the stator core, each spanning portion spanning from a radially inner portion of one of the plural slots to a radially outer portion of another one of the plural slots; and
disposing the plural coil segments in the plural slots in the stator core so that the plural spanning portions are arranged continuously in a circumferential direction and so that circumferentially adjacent ones of the spanning portions partially overlap each other as seen in an axial direction,
wherein the spanning portion comprises:
a first sloping portion, where a central portion of the plural coil segments extends axially outwards in the axial direction along a first sloping line as the central portion goes from the one of the plural slots to the another one of the plural slots, as seen in a radial direction;
a second sloping portion, where the central portion of the plural coil segments extends axially outwards in the axial direction along a second sloping line as the central portion goes from the another one of the plural slots to the one of the plural slots, as seen in the radial direction;
a first bent portion, where the plural coil segments are disposed in parallel and curve in such a way as to go in the radial direction from the first sloping portion; and
a second bent portion, where the plural coil segments are disposed in parallel and curve in such a way as to go in the radial direction from the second sloping portion, wherein
at a most radially inner coil segment of the plural coil segments in the first bent portion, a corner portion positioned at a side of the another one of the plural slots and at an outside in the axial direction as seen in the radial direction is located more axially outwards in the axial direction than an extension line of the first sloping line,
at a most radially outer coil segment of the plural coil segments in the second bent portion, a corner portion positioned at a side of the one of the plural slots and at the outside in the axial direction as seen in the radial direction is located more axially outwards in the axial direction than an extension line of the second sloping line.

6. The method of claim 5 , further comprising:
expanding the second bent portion radially outwards as seen in the axial direction.

7. The method of claim 5 , further comprising:
expanding the first bent portion radially inwards as seen in the axial direction.

8. The method of claim 5 ,
wherein, in the step of forming the spanning portions, an apex portion of the spanning portion is formed by twisting altogether plural coil segments which are aligned together side by side into a bundle so that adjacent ones of the plural coil segments are attached closely to each other.

9. The stator of claim 1 ,
wherein a cross state is formed between the plural coil segments that constitute the first bent portion and the plural coil segments that constitute the second bent portion, as seen in the radial direction.

10. The method of claim 5 ,
wherein a cross state is formed between the plural coil segments that constitute the first bent portion and the plural coil segments that constitute the second bent portion, as seen in the radial direction.

11. The stator of claim 1 ,
wherein the most radially inner coil segment of the plural coil segments in the first bent portion is located more axially outwards in the axial direction than other coil segment of the plural coil segments.

12. The method of claim 5 ,
wherein the most radially inner coil segment of the plural coil segments in the first bent portion is located more axially outwards in the axial direction than other coil segment of the plural coil segments.

Assignees

• Honda Motor Co Ltd

Inventors

• Matsuoka Yoshihisa

Classifications

• H02K3/12 Primary

  arranged in slots · CPC title

• H02K3/50

  Fastening of winding heads, equalising connectors, or connections thereto · CPC title

• H02K3/48

  in slots · CPC title

• H02K15/02

  of stator or rotor bodies · CPC title

• H02K3/28

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