Toyota Jidosha Kabushiki Kaisha

Masayoshi Haga

Atsushi Watanabe

Yusuke Fukushima

Kevin K Hunter

Hideo Karikomi

Akira Yamaguchi

Tetsuro Hakamada

Manabu Kitamura

Fujio Ando

Shingo Hashimoto

To provide a motor in which a cage coil formed of a wave winding conductor wire wound in plural turns and with bent portions is inserted in an integral type stator core. The motor including a stator provided with a wave winding coil using a flat conductor and a stator core, and a rotor provided with a rotor shaft is configured such that the wave winding coil includes the cage coil formed of a first wave winding wire assembly wound in plural turns, this assembly being formed of a plurality of bent-end wave winding conductor wires formed in a meandering pattern and overlapped in sequence with displacements from each other, a coil end part of the cage coil at one end is bent toward the rotor with respect to in-slot portions of the stator core, and the coil end part at the one end is positioned closer to an axis of the rotor than an inner peripheral surface of the stator core is.

Motor having a cage wave stator winding

A stator includes a stator core and a distributed winding type multi-phase coil. This coil includes unit coils made by winding a flat conductor wire in plural turns. The unit coils are mounted in slots of the stator core and connected with each other. Each unit coil includes an outer-layer coil and an inner-layer coil each being concentrically wound. Those two layer coils are made of a single continuous flat conductor wire. A winding start portion of the outer-layer coil and a winding end portion of the inner-layer coil form first and second connection end portions of the unit coil respectively. The first and second connection end portions are located separately on both edges of the unit coil above an upper end face of the stator core. The first connection end portion is placed close to an inner circumference of the stator core and the second connection end portion is placed close to an outer circumference of the stator core. The first connection end portions of the adjacent unit coils constituting the same phase are connected with each other. The second connection end portions of the adjacent unit coils constituting the same phase are connected with each other.

Stator and method of manufacturing unit coil to be used therein

To provide a stator capable of achieving downsizing and high output power and a stator manufacturing method, a stator comprises a split stator core and slots formed between the teeth, and protrusion-formed coils each being made of a flat rectangular conductor and placed in the slots. Each protrusion-formed coil has a shape including, in a coil end portion, a lead-side protrusion or a non-lead-side protrusion formed to protrude upward in an axial direction of the stator core from a first oblique side portion, a second oblique side portion, a third oblique side portion, and a fourth oblique side portion, and a first oblique side portion, a second oblique side portion, a third oblique side portion, and a fourth oblique side portion. The lead-side protrusion or the non-lead-side protrusion is designed with a height to avoid interference between the protrusion-formed coils placed in the stator core.

Stator

Truck

Growing community of inventors

Nagoya, Japan

Masayoshi Haga