Rotating electric machine and method for manufacturing the same

Abstract

The present invention provides a rotating electric machine, which includes a stator 31, and a connecting portion 50 between a coil end 33a and a terminal 71 is provided on the stator 31. The stator 31 has a wall member 62, which provides a wall body surrounding the coil end 33a and the terminal 71. The coil end 33a and the terminal 71 are wrapped by a protective resin in the wall member 62. In other embodiments, the coil end of the rotating electric machine is pressed into a narrow positioning portion from a wider entrance portion. Since the guide portion allows the coil end to move, the sliding of the coil end on the terminal is suppressed.

Description

[0001] This application is a divisional application with application date of February 14, 2017, application number 201780085630.5, and invention name “rotating electric machine and manufacturing method thereof”. Technical Field

[0002] The disclosure in this specification relates to a rotating electrical machine and a method for manufacturing the same. Background Art

[0003] Patent documents 1 to 5 disclose a rotating electric machine. And, Patent documents 4 and 5 disclose in detail a connection portion for a rotating electric machine. The rotating electric machine disclosed in Patent document 4 includes a resin that wraps a joint between an aluminum wire and a metal terminal. However, it is difficult to cure the applied resin into a desired shape. The rotating electric machine disclosed in Patent document 5 includes a lower dam (112B) that prevents the resin surrounding the joint from flowing out.

[0004] Patent documents 1-5 disclose a rotating electric machine and a manufacturing method thereof. In this technology, a guide groove (112C) for guiding a coil end is provided at an insulator (bobbin) provided on a stator. The coil end is arranged in the guide groove. The guide groove positions the coil end near a terminal.

[0005] The disclosed contents in the prior art documents listed as background art are incorporated into this application by reference as the explanatory contents of the technical elements in this specification.

[0006] Prior art literature

[0007] Patent Literature

[0008] Patent Document 1: Japanese Patent Application Publication No. 2013-233030

[0009] Patent Document 2: Japanese Patent Application Publication No. 2013-27252

[0010] Patent Document 3: Patent No. 5064279

[0011] Patent Document 4: Japanese Patent Application Publication No. 2013-188048

[0012] Patent Document 5: Japanese Patent Application Publication No. 2015-130785 Summary of the invention

[0013] In the technology of Patent Document 5, the resin sometimes goes over the dam. In this case, the joint may not be fully wrapped. In addition, the resin that flows out may adhere to an undesired part.

[0014] One view is that, in the structure of Patent Document 4, it is difficult to accommodate the coil end in the guide groove and bend the coil end so that it contacts the terminal. Therefore, the coil end may sometimes fall out of the guide groove during the operation. In addition, it is difficult to stably bend the coil end into a desired shape.

[0015] Another view is that Patent Document 4 does not disclose any information about the fit strength between the guide groove and the coil end. However, a too loose fit may sometimes allow the coil end to move undesirably and unstably during the process of connecting the coil end to the terminal, thereby preventing the desired connection state from being formed. On the other hand, a too tight fit may prevent the coil end from moving as desired to accommodate the terminal during the process of connecting the coil end to the terminal, thereby preventing the desired connection state from being formed.

[0016] In the above viewpoints and other viewpoints not mentioned, further improvements are required in rotating electrical machines and methods of manufacturing the same.

[0017] An object of the present disclosure is to provide a rotating electrical machine that can reliably protect terminals and a method for manufacturing the same.

[0018] Another object of the present disclosure is to provide a rotating electric machine that holds a resin for protecting a terminal around the terminal and a method of manufacturing the same.

[0019] Still another object of the present disclosure is to provide a rotating electrical machine suitable for forming a desired connection state and a method for manufacturing the same.

[0020] Another object of the present disclosure is to provide a rotating electric machine and a method for manufacturing the same, wherein the rotating electric machine can provide a guide for the coil end suitable for forming a desired connection state.

[0021] The various methods disclosed in this specification use different technical means to achieve their respective purposes. The reference numerals in brackets in the scope of protection and the claims are only for indicating the corresponding relationship with the relevant parts of the following embodiments, and do not limit the scope of protection.

[0022] The rotary electric machine disclosed in the present specification has a connection portion (50) for connecting a coil end (33a) to a terminal (71). The rotary electric machine includes: a wall member (62) forming a surrounding wall surrounding the coil end and the terminal; and a protective resin (61) stored in a storage tank defined by the surrounding wall and surrounding the coil end and the terminal.

[0023] According to the rotating electrical machine, the surrounding wall is provided by the wall member. Moreover, the surrounding wall defines a storage tank. Since the protective resin is arranged in the storage tank, the protective resin can be stored in the storage tank. Thus, the coil end and the terminal are reliably protected by the protective resin. In addition, the wall member can suppress the outflow of the protective resin.

[0024] In this specification, a method for manufacturing a rotating electric machine (10) is disclosed, wherein the rotating electric machine (10) has a connecting portion (50) for connecting a coil end (33a) to a terminal (71). The manufacturing method includes a step of connecting the coil end to the terminal. The manufacturing method includes a step of configuring a wall member (62) to form a surrounding wall surrounding the coil end and the terminal after the coil end and the terminal are connected. The manufacturing method includes a step of injecting a protective resin (61) into a storage tank defined by the surrounding wall, thereby wrapping the coil end and the terminal with the protective resin.

[0025] According to the manufacturing method of the rotating electric machine, the wall member is arranged after the coil end is connected to the terminal. Therefore, the connection operation is not hindered by the wall member. Since the protective resin is injected into the storage tank, the outflow of the protective resin is suppressed by the wall member. Since the protective resin can be stored thickly in the storage tank, the coil end and the terminal are reliably protected by the protective resin.

[0026] According to one aspect of the present invention, a rotating electric machine is disclosed. The rotating electric machine includes: a coil end (33a) which is an end of a stator coil (33); a terminal (71) which is connected to the coil end; and a guide portion (35c) which defines a groove (43) which guides the coil end toward the terminal by accommodating the coil end. The guide portion includes: a positioning portion (47) which is arranged at a specified position of the coil end in the groove and deformed by contacting the coil end; and an entrance portion (46, B46, C46, ​​D46) which is arranged at the entrance of the groove and has a width (WW) which is larger than the diameter (DC) of the coil end and larger than the width (WN) of the positioning portion.

[0027] The rotating electric machine has a positioning portion and an entrance portion in a groove for guiding the coil end toward the terminal. The positioning portion is deformed by contacting the coil end. The positioning portion can position the coil end so that the coil end and the terminal are in a desired connection state. Further, the guide portion has an entrance portion arranged at the entrance of the groove. The width of the entrance portion is greater than the diameter of the coil end and greater than the width of the positioning portion. The entrance portion can position the coil end more loosely than the positioning portion. The coil end is operated toward the positioning portion via the entrance portion. When the coil end is placed in the groove, the coil end is operated toward the positioning portion after being loosely positioned at the entrance portion. Therefore, the coil end can be easily operated toward the positioning portion.

[0028] According to one aspect of the present invention, a method for manufacturing a rotating electric machine is disclosed. The rotating electric machine includes: a coil end (33a) which is an end of a stator coil (33); a terminal (71) connected to the coil end; and a guide portion (35c) defining a groove (43) for guiding the coil end toward the terminal by accommodating the coil end. The method for manufacturing the rotating electric machine includes the following steps: loosely positioning the coil end at an entrance portion (46, B46, C46, ​​D46) provided at an entrance of the groove and having a width (WW) greater than a diameter (DC) of the coil end; moving the coil end toward a positioning portion (47) provided at a specified position of the coil end in the groove via the entrance portion; deforming the guide portion by bringing the coil end into contact with the guide portion at the positioning portion, thereby firmly positioning the coil end; and connecting the coil end to the terminal in a state where the coil end is positioned by the positioning portion.

[0029] The rotating electric machine has a positioning portion and an entrance portion in a groove for guiding the coil end toward the terminal. The coil end is loosely positioned in the entrance portion and then tightly positioned in the positioning portion. At this time, the guide portion is deformed. The positioning portion can position the coil end so that the coil end and the terminal are in a desired connection state. The entrance portion positions the coil end more loosely than the positioning portion. The coil end is operated toward the positioning portion via the entrance portion. When the coil end is placed in the groove, the coil end is loosely positioned in the entrance portion and then operated toward the positioning portion. Therefore, the coil end can be easily operated toward the positioning portion.

[0030] According to one aspect of the present invention, a method for manufacturing a rotating electric machine is disclosed. The rotating electric machine includes: a coil end (33a) which is an end of a stator coil (33); a terminal (71) which is connected to the coil end; and a guide portion (35c) which defines a groove (43) for guiding the coil end toward the terminal by accommodating the coil end. The method for manufacturing the rotating electric machine includes the following steps: inserting the coil end into the groove so that the coil end contacts the guide portion and deforms the guide portion, thereby firmly positioning the coil end; clamping the coil end and the terminal with welding electrodes (81, 82) in a state where the coil end is positioned by the groove, and welding the coil end and the terminal; and when the coil end and the terminal are clamped by the welding electrodes, the guide portion is further deformed as the coil end moves, thereby allowing the coil end to move.

[0031] In a method for manufacturing a rotating electrical machine, a coil end is firmly positioned before welding. During welding, the coil end is pushed by a welding electrode. When the coil end moves with it, the guide portion is further deformed. Thus, the guide portion allows the coil end to move. Therefore, when the coil end and the terminal are clamped by the welding electrode, the sliding of the coil end on the terminal is suppressed. Thus, a desired weld can be formed.

[0032] According to one aspect of the present invention, a method for manufacturing a rotating electric machine is disclosed. The rotating electric machine includes: a coil end (33a) which is an end of a stator coil (33); a terminal (71) which is connected to the coil end; and a guide portion (35c) which defines a groove (43) for guiding the coil end toward the terminal by accommodating the coil end. The method for manufacturing the rotating electric machine includes the following steps: inserting the coil end into the groove so that the coil end contacts the guide portion and deforms the guide portion, thereby firmly positioning the coil end; bending the coil end so that the coil end is arranged above the terminal so that the coil end is farther away from the terminal as it moves toward the front end of the coil end; and, in a state where the coil end is positioned by the groove, clamping the coil end and the terminal with welding electrodes (81, 82) to weld the coil end to the terminal.

[0033] In a method for manufacturing a rotating electrical machine, a coil end is firmly positioned before welding. During welding, the coil end is pushed by a welding electrode. The coil end is above a terminal and is arranged to be farther away from the terminal toward the front end of the coil end. Therefore, the welding electrode and the coil end first come into contact at the front end of the coil end. Compared with a case where a suspension portion of the coil end, which is mounted between a guide portion and a terminal, is pushed, sliding of the coil end on the terminal is suppressed. Thus, a desired weld portion can be formed.

[0034] According to one aspect of the present invention, a method for manufacturing a rotating electric machine is disclosed. The rotating electric machine includes: a coil end (33a) which is an end of a stator coil (33); a terminal (71) connected to the coil end; and a guide portion (35c) defining a groove (43) for guiding the coil end toward the terminal by accommodating the coil end. The method for manufacturing the rotating electric machine includes the following steps: inserting the coil end into the groove so that the coil end contacts the guide portion and deforms the guide portion, thereby firmly positioning the coil end; bending the coil end so that a sag is formed in a suspension portion of the coil end that is arranged between the guide portion and the terminal; clamping the coil end and the terminal with welding electrodes (81, 82) in a state where the coil end is positioned by the groove, and welding the coil end to the terminal; and deforming the sag when the coil end rotates along the terminal.

[0035] In a method for manufacturing a rotating electric machine, a coil end is firmly positioned before welding. A slack portion is formed at a suspension portion of the coil end that is mounted between a guide portion and a terminal. During welding, the coil end is pushed by a welding electrode. Therefore, the coil end rotates along the terminal. At this time, the slack portion is deformed. Since the slack portion is deformed, the sliding of the coil end on the terminal is suppressed. Thus, a desired weld portion can be formed. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 is a cross-sectional view of the rotating electrical machine provided in the first embodiment.

[0037] Figure 2 It is a plan view of the stator in the first embodiment.

[0038] Figure 3 It is a perspective view of the stator in the first embodiment.

[0039] Figure 4 It is a modeled cross-sectional view of the stator in the first embodiment.

[0040] Figure 5 This is a plan view of the stator in the first embodiment without protective resin.

[0041] Figure 6 This is a perspective view of the stator in the first embodiment without protective resin.

[0042] Figure 7 It is an exploded perspective view of the stator in the first embodiment.

[0043] Figure 8 It is a perspective view showing the wall member in the first embodiment.

[0044] Fig. 9 is along Figure 8 Stereoscopic image when observed from the middle arrow IX.

[0045] Fig.10 is along Figure 8 The top view when viewed from the center arrow X.

[0046] Fig.11 is along Figure 8 Bottom view when observing from the middle arrow XI.

[0047] Fig.12 yes Fig.11 An enlarged stereoscopic image of the portion indicated by arrow XII.

[0048] Fig.13 yes Figure 7 An enlarged stereoscopic image of the portion indicated by arrow XIII.

[0049] Fig.14 It is a perspective view of the stator in the second embodiment.

[0050] Fig.15 is a modeled cross-sectional view of the stator in the second embodiment.

[0051] Fig.16 It is an exploded perspective view of the stator in the second embodiment.

[0052] Fig.17 It is a perspective view showing a wall member in the second embodiment.

[0053] Fig.18It is a plan view showing a wall member in the second embodiment.

[0054] Fig.19 It is a perspective view showing a wall member in the third embodiment.

[0055] Fig. 20 It is a plan view showing a wall member in the third embodiment.

[0056] Fig.21 It is a perspective view showing a wall member in the fourth embodiment.

[0057] Fig. 22 It is a perspective view showing a wall member in the fifth embodiment.

[0058] Fig.23 It is a perspective view showing a wall member in the sixth embodiment.

[0059] Fig.24 It is a perspective view showing a wall member in the seventh embodiment.

[0060] Fig.25 It is a plan view of a stator in the eighth embodiment.

[0061] Fig.26 It is a partial enlarged view of the stator in the eighth embodiment.

[0062] Fig. 27 It is a partial enlarged view of the stator in the eighth embodiment.

[0063] Fig.28 It is a partial enlarged view of the stator in the eighth embodiment.

[0064] Fig.29 It is a partial enlarged view of the stator in the eighth embodiment.

[0065] Fig.30 It is a partial enlarged view of the stator in the eighth embodiment.

[0066] Fig.31 It is a partial enlarged view of the stator in the eighth embodiment.

[0067] Fig.32 It is a partial perspective view of a stator in the ninth embodiment.

[0068] Fig.33 It is a partial perspective view of a stator in the ninth embodiment.

[0069] Fig.34 It is a partial enlarged view of the stator in the ninth embodiment.

[0070] Fig.35 It is a partial enlarged view of the stator in the ninth embodiment.

[0071] Fig.36 It is a partial enlarged view of the stator in the ninth embodiment.

[0072] Fig.37 It is a partial enlarged view of the stator in the tenth embodiment.

[0073] Fig.38 It is a partial enlarged view of the stator in the tenth embodiment.

[0074] Fig.39 It is a partial enlarged view of the stator in the eleventh embodiment.

[0075] Fig.40 It is a partial enlarged view of the stator in the twelfth embodiment.

[0076] Fig.41 It is a partial enlarged view of the stator in the thirteenth embodiment.

[0077] Fig.42 It is a modeled cross-sectional view of the stator in the fourteenth embodiment.

[0078] Fig.43 It is a modeled cross-sectional view of the stator in the fifteenth embodiment. DETAILED DESCRIPTION

[0079] The following describes various embodiments in conjunction with the drawings of the specification. In multiple embodiments, functionally and / or structurally corresponding parts and / or associated parts are sometimes marked with the same reference numerals, or with reference numerals that differ only in the digits above the hundredth place. For corresponding parts and / or associated parts, reference can be made to the relevant descriptions in other embodiments.

[0080] (First Embodiment)

[0081] exist Figure 1 In the present invention, the rotating electric machine for internal combustion engine (hereinafter referred to as rotating electric machine 10) is also called a generator motor or an AC starter generator (AC Generator Starter). The rotating electric machine 10 is electrically connected to a circuit 11 including an inverter (INV) and a control device (ECU). The circuit 11 provides a three-phase power conversion circuit. An example of the use of the rotating electric machine 10 is a generator motor connected to an internal combustion engine 12 for a vehicle. The rotating electric machine 10 can be used, for example, in a two-wheeled vehicle.

[0082] When the rotating electric machine 10 operates as a generator, the circuit 11 provides a rectifier circuit that rectifies the output AC power and supplies power to an electric load including a battery. The circuit 11 provides a signal processing circuit that receives a reference position signal for ignition control provided by the rotating electric machine 10. The circuit 11 may also provide an ignition controller that performs ignition control. The circuit 11 provides a drive circuit that operates the rotating electric machine 10 as a motor. The circuit 11 receives a rotation position signal from the rotating electric machine 10, and the rotation position signal is used to operate the rotating electric machine 10 as a motor. The circuit 11 controls the energization of the rotating electric machine 10 based on the detected rotation position, thereby operating the rotating electric machine 10 as a motor.

[0083] The rotating electric machine 10 is assembled to the internal combustion engine 12. The internal combustion engine 12 includes: a body 13 and a rotating shaft 14, which is rotatably supported by the body 13 and rotates in conjunction with the internal combustion engine 12. The rotating electric machine 10 is assembled to the body 13 and the rotating shaft 14. The body 13 is a structural body such as a crankcase and a gearbox of the internal combustion engine 12. The rotating shaft 14 is a crankshaft of the internal combustion engine 12 or a rotating shaft that is in conjunction with the crankshaft.

[0084] The rotating electric machine 10 is an outer rotor type rotating electric machine. The rotating electric machine 10 includes a rotor 21, a stator 31, and a sensor unit 41. In the following description, the term "axial direction" refers to the direction along the central axis when the rotor 21, the stator 31, or the stator core 32 is regarded as a cylinder. The term "radial direction" refers to the diameter direction when the rotor 21, the stator 31, or the stator core 32 is regarded as a cylinder.

[0085] The rotor 21 is an excitation element. The stator 31 is an armature. The rotor 21 is cup-shaped as a whole. The rotor 21 is connected to the end of the rotating shaft 14. The rotor 21 rotates together with the rotating shaft 14. The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 provides a yoke for the permanent magnet 23 described later. The rotor core 22 is made of magnetic metal. The rotor 21 has a permanent magnet 23 arranged on the inner surface of the rotor core 22. The rotor 21 provides a magnetic field through the permanent magnet 23. In addition, the permanent magnet 23 provides a portion of special magnetic poles, which is used to provide a reference position signal required for ignition control.

[0086] The stator 31 is an annular component. The stator 31 is configured to be opposite to the rotor 21. The stator 31 has a stator core 32. The stator core 32 is fixed to the body 13 of the internal combustion engine 12. The stator 31 includes a stator coil 33 wound on the stator core 32. The stator coil 33 provides an armature winding. The stator coil 33 is a single-phase winding or a multi-phase winding. The stator coil 33 can selectively use the rotor 21 and the stator 31 as a generator or a motor. The coil wire forming the stator coil 33 is formed by a single-wire conductor covered with an insulating coating. The coil wire is made of an aluminum-based metal such as aluminum or an aluminum alloy.

[0087] The rotating electric machine 10 includes a wiring harness 15 that provides an electrical connection between the rotating electric machine 10 and the circuit 11. The wiring harness 15 includes a plurality of electric wires. The wiring harness 15 includes a signal line for external connection that connects the sensor unit 41 to the circuit 11. The wiring harness 15 also includes a plurality of power lines that connect the stator coil 33 to the circuit 11. The circuit 11 is an external circuit connected to the power lines. When the rotating electric machine 10 is used as a generator, the power lines supply the electric circuit 11 with the power induced by the stator coil 33. When the rotating electric machine 10 is used as a motor, the power lines are used to supply the power that excites the stator coil 33 from the circuit 11 to the stator coil 33.

[0088] exist Figure 2 and Figure 3 In the figure, the stator 31 is an outer salient pole stator. The stator core 32 has a plurality of magnetic poles 32a. An insulator 35 is arranged between the stator core 32 and the stator coil 33. The insulator 35 is made of an electrically insulating resin. The insulator 35 is arranged on the stator core 32. The insulator 35 is also called a bobbin. A portion of the insulator 35 is positioned adjacent to the magnetic pole 32a, thereby providing a flange portion of the bobbin. A portion of the insulator 35 is arranged on both axial sides of the magnetic pole 32a. In the following description, insulator 35 in most cases refers to: an inner flange portion that is arranged in the central annular portion of the stator core 32 and is annular, and an electrode support portion that extends to cover a portion of the axial surface of the central annular portion.

[0089] The sensor unit 41 provides a rotation position detection device for an internal combustion engine. The sensor unit 41 is fixed to one end surface of the stator core 32. The sensor unit 41 is arranged between the stator core 32 and the body 13. The sensor unit 41 detects the rotation position of the rotor 21 by detecting the magnetic flux supplied by the permanent magnet 23, and outputs an electrical signal indicating the rotation position. The sensor unit 41 has a plurality of rotation position sensors. The rotation position sensor is provided by a Hall sensor, an MRE sensor, etc. The sensor unit 41 includes one sensor for ignition control and three sensors for motor control. For details of the permanent magnet 23 used for ignition control and motor control, and details related to the sensor unit 41, the contents described in Japanese Patent Publication No. 2013-233030, Japanese Patent Publication No. 2013-27252, or Japanese Patent Publication No. 5064279 listed as patent documents can be cited.

[0090] The stator 31 has a connection portion 50 for connecting the coil end 33a, which is the end of the stator coil 33, to form a circuit. The connection portion 50 connects the coil end 33a and the terminal 71. The connection portion 50 is used to connect the stator coil 33 to a predetermined multi-phase winding or to connect the stator coil 33 to a power line. In the example shown in the figure, the stator 31 has two connection portions 51 and 52. The connection portion 51 is used for neutral point connection of the star connection. The connection portion 52 is used to connect the stator coil 33 to the power line.

[0091] The stator core 32 has a plurality of bolt holes for fixing the stator core 32 to the body 13. The connection portion 51 is disposed between two bolt holes adjacent to each other in the circumferential direction. The connection portion 52 is disposed between another two bolt holes.

[0092] The connecting portion 50 has a protective resin 61 that surrounds the coil end 33a and the terminal connected to the coil end 33a. The protective resin 61 is an electrically insulating resin. The protective resin 61 is tightly attached to the coil end 33a and the surface of the coil end 33a. The protective resin 61 is applied or dripped in an uncured state and cured. The protective resin 61 is also called a potting resin or a sealing resin.

[0093] The connecting portion 50 has a wall member 62 that surrounds the connecting portion 50 on the end face of the stator 31. The wall member 62 is made of an electrically insulating resin. The wall member 62 forms a surrounding wall that surrounds the coil end 33a and the terminal 71. The surrounding wall is formed by the wall member 62 and the insulator 35. A storage tank for storing the protective resin 61 is defined by the surrounding wall. The wall member 62 is configured to surround the coil end 33a and the terminal 71 on the insulator 35. The wall member 62 defines a storage tank on the end face of the stator 31. Specifically, the wall member 62 defines a storage tank on the insulator 35.

[0094] The wall member 62 is used to limit the application range of the protective resin 61. The wall member 62 is used to maintain a predetermined thickness of the protective resin 61. The wall member 62 is formed to engage with the components of the stator 31 to suppress the outflow of the protective resin 61. The wall member 62 is connected to the insulator 35 to suppress the outflow of the protective resin 61. The wall member 62 receives the coil end 33a to suppress the outflow of the protective resin 61.

[0095] Figure 4A modeled cross section of the stator 31 is shown. At the connection portion 50, a terminal 71 connected to the coil end 33a is arranged. The terminal 71 has a shape suitable for welding. For example, the terminal 71 has a convex portion having a ridgeline intersecting with the coil end 33a. The terminal 71 is made of a metal suitable for welding with the coil end 33a made of aluminum metal. The terminal 71 is also called a welding terminal. The terminal 71 is supported by an insulator 35. The terminal 71 is supported to extend along the axial direction of the stator 31. The terminal 71 is plate-shaped. The terminal 71 is arranged so that its surface intersects with the radial direction. In other words, the terminal 71 is arranged so as to be sandwiched between a pair of welding electrodes for welding, which can be opened and closed in the radial direction. The terminal 71 is welded to the coil end 33a by resistance welding or spot welding, and is electrically and mechanically connected. Therefore, the terminal 71 and the coil end 33a arranged in the connection portion 50 have a surface where the metal is exposed.

[0096] In the connection part 51, a plurality of terminals 71 are arranged. A coil end 33a is connected to each terminal 71. The plurality of terminals 71 arranged in the connection part 51 are formed in a common electrode 72. The electrode 72 is insert-molded in the insulator 35, or inserted therein so as to be supported by the insulator 35. The electrode 72 is also called a busbar. The electrode 72 provides a neutral point connection for the stator coil 33. The electrode 72 is also called a multi-head electrode or a neutral point electrode. The electrode 72 is arranged on one end face of the stator 31. The electrode 72 does not penetrate the stator core 32. The electrode 72 is also called a non-penetrating electrode.

[0097] In the connection part 52, a plurality of terminals 71 are arranged. A coil end 33a is connected to each terminal 71. The plurality of terminals 71 arranged in the connection part 52 are electrically insulated from each other. One terminal 71 is formed on an electrode 73. The electrode 73 is insert-molded in the insulator 35, or inserted therein so as to be supported by the insulator 35. The electrode 73 is also called a busbar. The electrode 73 is arranged to protrude from both end surfaces of the stator 31. The electrode 73 is arranged to penetrate the stator core 32. The electrode 73 is also called a through electrode.

[0098] The electrode 73 has a terminal 71 at one end and a terminal 74 at the other end. The terminal 74 is used to connect the power line. The electrode 73 provides a connection between the output end of the stator coil 33 and the power line of the wiring harness 15. The terminal 74 has a shape suitable for connection with the power line. In the example shown in the figure, the terminal 74 has a wrist portion that covers a multi-core electric wire. The terminal 74 has a shape suitable for soldering.

[0099] Figure 5 and Figure 6The stator 31 before the protective resin 61 is applied is shown. In the connection portion 50, the wall member 62 is configured to surround the plurality of terminals 71. The wall member 62 defines a cylindrical portion extending axially from the end surface of the stator 31. The cylindrical portion serves as a storage tank. The wall member 62 extends higher in the axial direction than the terminal 71. As a result, the terminal 71 and the coil end 33a are completely accommodated in the storage tank defined by the wall member 62 in the axial direction.

[0100] Three terminals 71 are positioned on the connection portion 51. The three coil ends 33a are pulled into the connection portion 51. The three terminals 71 and the three coil ends 33a are arranged in the circumferential direction. Three terminals 71 are positioned on the connection portion 52. The three coil ends 33a are pulled into the connection portion 52. The three terminals 71 and the three coil ends 33a are arranged in the circumferential direction.

[0101] Figure 7 The state where the wall member 62 is separated from the insulator 35 is shown. The insulator 35 has a step portion 36. The step portion 36 is formed to provide a fit between the wall member 62 and the insulator 35. The step portion 36 is used as a mark to show the specified position of the wall member 62. The step portion 36 is used as a guide portion for guiding the wall member 62 to the specified position. The step portion 36 is used as a fixing portion to suppress the movement of the wall member 62. Further, in the manufacturing method of the rotating electric machine, the step portion 36 provides a connection portion for pre-connecting the insulator 35 and the wall member 62. The step portion 36 and the wall member 62 are connected to each other by the elasticity of the resin so that they are not easily detached during the process of the manufacturing method. The step portion 36 provides a temporary fixation of the wall member 62 in the process before the protective resin 61 is applied. The step portion 36 extends around the connection portion 50.

[0102] Figure 8 , Fig. 9 , Fig.10 and Fig.11 A wall member 62 is shown. One wall member 62 is provided by a cylindrical member 63. The cylindrical member 63 is formed around a plurality of terminals 71. The cylindrical member 63 has a shape that can be called an arc or a fan. The cylindrical member 63 has an outer wall 64, which is arranged on the radial outside of the stator 31. The outer wall 64 is an arc-shaped wall. The outer wall 64 is arranged on the radial inside of the stator coil 33. The cylindrical member 63 has an inner wall 65 arranged on the radial inside of the outer wall 64. The storage tank is defined by the outer wall 64 and the inner wall 65.

[0103] The outer wall 64 is provided with a notch 66. The notch 66 is formed by extending in the axial direction from the edge of the insulator 35 side. The notch 66 is used to configure the coil end 33a to pass through the cylindrical member 63. Through the notch 66, the coil end 33a is pulled from the outside of the cylindrical member 63 to the inside. In the present embodiment, one cylindrical member 63 has three notches 66.

[0104] return Figure 7 The insulator 35 has a positioning portion 37. The positioning portion 37 is used to position the coil end 33a at a specified position. The positioning portion 37 is formed as a pair of protrusions extending along the axial direction from the insulator 35. The positioning portion 37 positions the coil end 33a at a specified position in the circumferential direction by receiving the coil end 33a between the pair of protrusions. In addition, the positioning portion 37 can also be used as a part for holding or fixing the coil end 33a. In the example shown in the figure, 6 positioning portions 37 are provided.

[0105] Fig.12 It is a perspective view of the cutout portion 66 as viewed from the bottom. Fig.13 The fitting part between the notch 66 and the insulator 35 is shown. The notch 66 is formed to be fitted with the positioning part 37. The notch 66 is formed to be covered by the positioning part 37 by receiving the positioning part 37. By fitting the notch 66 and the positioning part 37 with each other, the outflow of the protective resin 61 can be suppressed. The notch 66 has a receiving groove 66a that receives the positioning part 37 along the axial direction. The notch 66 has a rib 66b that fixes the positioning part 37 using the elasticity of the resin. Through the rib 66b, the notch 66 is firmly fitted with the positioning part 37. The notch 66 has a convex part 66c that covers the slit 38 by being inserted into the slit 38 between the two convex parts of the positioning part 37. The convex part 66c reduces the gap around the coil end 33a. The convex part 66c can be formed to contact the coil end 33a.

[0106] return Fig.11 , a step portion 67 is provided on the end surface of the cylindrical member 63 on the side of the insulator 35. The step portion 67 is provided on the end surface of the cylindrical member 63 except the notch portion 66. The step portion 67 is formed to provide a fit between the wall member 62 and the insulator 35. The step portion 67 is used as a guide portion for guiding the wall member 62 to a predetermined position on the insulator 35. The step portion 67 is used as a fixing portion for suppressing the movement of the wall member 62. Further, in the manufacturing method of the rotating electric machine, the step portion 67 provides a connection portion for pre-connecting the insulator 35 with the wall member 62. The step portion 67 and the insulator 35 are connected to each other in a manner that is not easily detached during the process of the manufacturing method by utilizing the elasticity of the resin. The step portion 67 provides a temporary fixation of the wall member 62 in the process before applying the protective resin 61. The step portion 67 extends around the connection portion 50.

[0107] The step portion 36 is a step that is concave in the axial direction toward the stator core 32 in the connection portion 50. The step portion 67 is a step that is convex in the axial direction from the stator core 32 in the connection portion 50. The step portion 67 is formed to be engageable with the step portion 36. The wall member 62 and the insulator 35 are opposed to each other on a plane perpendicular to the axial direction. Furthermore, by providing the step portion 36 and the step portion 67, the wall member 62 and the insulator 35 are extended in the axial direction and are also opposed to each other on a slender surface extending along the edge of the cylindrical member 63. The insulator 35 and the wall member 62 are connected by the mutual engagement of the step portion 36 and the step portion 67. The outflow of the protective resin 61 is suppressed by the mutual engagement of the step portion 36 and the step portion 67.

[0108] In this embodiment, the wall member 62 and the insulator 35 have a plurality of connection portions that connect the wall member 62 and the insulator 35. One of the connection portions is provided by the step portion 36 and the step portion 67. The other connection portion is provided by the positioning portion 37 and the notch portion 66.

[0109] The method of manufacturing the rotating electrical machine 10 includes: a step of manufacturing the rotor 21 ; a step of manufacturing the stator 31 ; and a step of mounting the rotor 21 and the stator 31 on the internal combustion engine 12 .

[0110] The process of manufacturing the stator 31 includes a first process of assembling the stator 31 so that the coil end 33a and the terminal 71 are arranged in a normal position. In this process, the insulator 35 and the stator coil 33 are mounted on the stator core 32. In this process, the electrodes 72 and 73 are fixed to the stator 31. In this process, the coil end 33a and the terminal 71 are arranged in a normal position. The normal position refers to the position before the coil end 33a is welded to the terminal 71.

[0111] The process of manufacturing the stator 31 includes a process of electrically connecting the coil end 33a and the terminal 71. This process includes: a process of clamping the coil end 33a and the terminal 71 with a pair of welding electrodes; a process of welding the coil end 33a and the terminal 71 by energizing the welding electrodes; and a process of removing the welding electrodes. This process may also include a process of inspecting the welding state between the coil end 33a and the terminal 71.

[0112] The process of manufacturing the stator 31 includes a process of installing the wall member 62 after the welding process. The wall member 62 is configured to form a surrounding wall surrounding the coil end 33a and the terminal 71 after the coil end 33a is connected to the terminal 71. Figure 7 As shown, the wall member 62 is mounted on the insulator 35 along the axial direction of the stator 31. The wall member 62 is mounted to be connected to the insulator 35. At this time, the step portion 36 and the step portion 67 position the wall member 62 at a prescribed position.

[0113] The process of manufacturing the stator 31 includes a process of applying the protective resin 61 after installing the wall member 62. The protective resin 61 is injected into the storage tank defined by the surrounding wall. The coil end 33a and the terminal 71 are wrapped with the protective resin 61. The protective resin 61 is injected to completely cover the exposed metal surfaces of the coil end 33a and the terminal 71 arranged in the connecting portion 50. The protective resin 61 covers at least the metal surface of the coil end 33a exposed due to the removal of the protective film, and the exposed metal surface of the terminal 71. The protective resin 61 is injected into the wall member 62 in an uncured state. Thereafter, the protective resin 61 is cured. The step portion 36 and the step portion 67 can suppress the outflow of the protective resin 61. Moreover, the positioning portion 37 and the notch portion 66 can also suppress the outflow of the protective resin 61.

[0114] The protective resin 61 provides insulation protection for electrically insulating the coil end 33a and the terminal 71 from other components. The protective resin 61 also provides corrosion protection for suppressing corrosion of the coil end 33a and the terminal 71. Due to the corrosion protection, the aluminum-based metal coil end 33a can be used. Furthermore, due to the corrosion protection, the aluminum-based metal coil end 33a and the iron-based metal terminal 71 can be welded.

[0115] The protective resin 61 prevents direct contact between the coil end 33a and the terminal 71 and other components. When the rotating electric machine 10 is air-cooled, the protective resin 61 protects the coil end 33a and the terminal 71 from foreign matter such as liquid and mud. When the rotating electric machine 10 is arranged in the lubricating oil storage space of the internal combustion engine 12, the protective resin 61 protects the coil end 33a and the terminal 71 from metal powder in the lubricating oil.

[0116] The protective resin 61 helps maintain the connection between the coil end 33a and the terminal 71 in the face of vibration. The protective resin 61 not only contacts the coil end 33a and the terminal 71, but also contacts the insulator 35. The protective resin 61 fills the space between the coil end 33a, the terminal 71 and the insulator 35. As a result, the movement and deformation of the coil end 33a, the terminal 71 and the insulator 35 can be suppressed. In this embodiment, the coil end 33a, which is easier to move, is connected to the terminal 71, which is more strongly fixed, and the protective resin 61 helps maintain the connection between them. Moreover, even if the coil end 33a and the terminal 71 are deformed due to connection processes such as welding, it helps to reinforce and maintain their connection.

[0117] The process of manufacturing the stator 31 includes a process of connecting the terminal 74 to the power line. The terminal 74 is connected to the power line in any process after the electrode 73 is fixed to the stator 31.

[0118] According to the above embodiment, the surrounding wall is provided by the insulator 35 and the wall member 62. Moreover, the surrounding wall defines a storage tank. The protective resin can be stored in the storage tank. Thus, the coil end 33a and the terminal 71 are reliably protected by the protective resin 61. Moreover, the wall member 62 can suppress the outflow of the protective resin 61.

[0119] The coil end 33a and the terminal 71 arranged in the connection portion 50 are reliably protected. The wall member 62 is installed after the coil end 33a and the terminal 71 are welded. Therefore, the wall member 62 does not hinder the welding operation. The protective resin 61 is kept in the connection portion 50, that is, around the coil end 33a and the terminal 71. Thus, the adhesion of the protective resin 61 to an undesirable part can be suppressed. Further, since the outflow of the protective resin 61 is suppressed by the wall member 62, the protective resin 61 whose viscosity is suitable for wrapping the coil end 33a and the terminal 71 can be used. Thus, the formation of the cavity in the protective resin 61 can be reduced.

[0120] The wall member 62 is axially higher than the coil end 33a and the terminal 71 to be protected. Since the wall member 62 protects the coil end 33a and the terminal 71, the electrical connection is maintained. In addition, the surface of the protective resin 61 is lower than the axial front end surface of the wall member 62. Since the wall member 62 protects the protective resin 61, the damage and destruction of the protective resin 61 can be reduced.

[0121] (Second Embodiment)

[0122] This embodiment is a modification of the previous embodiment. In the previous embodiment, a common electrode 72 and a through-type electrode 73 are used. In addition, a cylindrical member 63 surrounding a plurality of terminals 71 is used. Instead, in this embodiment, an independent electrode 272 and a non-through-type electrode 273 are used. In addition, in this embodiment, a wall member 62 forming a plurality of storage tanks is used.

[0123] like Fig.14 and Fig.15 As shown, two connection parts 50 are also provided in this embodiment. The connection part 51 provides a neutral point connection. The connection part 51 has a plurality of electrodes 272 and a common electrode 276. The plurality of electrodes 272 are arranged on the insulator 35 so as to be electrically insulated from each other. Each electrode 272 has a terminal 71 connected to the coil end 33a, and a terminal 275 connected to the electrode 276. The electrode 272 has a fixing part corresponding to the insulator 35 at one end, and a terminal 275 at the other end. The terminal 71 is arranged in the central part in the longitudinal direction of the electrode 272. The electrode 272 is an I-shaped plate body. The plurality of electrodes 272 are configured so that their surfaces extend substantially in the radial direction. The plurality of electrodes 272 are configured so as to be clamped by a welding electrode that can be opened and closed along the circumferential direction of the stator 31.

[0124] Electrode 276 is a common electrode connected to the plurality of electrodes 272. Electrode 276 may be provided by a conductor sheet or a wire. Electrode 272 and electrode 276 are electrically and mechanically connected by soldering.

[0125] The connection portion 52 provides a connection between the stator coil 33 and the power line. The connection portion 52 has a plurality of electrodes 273. The plurality of electrodes 273 are arranged on the insulator 35 so as to be electrically insulated from each other. Each electrode 273 has a terminal 71 connected to the coil end 33a and a terminal 274 connected to the power line. The electrode 273 has a fixing portion corresponding to the insulator 35 at one end and a terminal 274 at the other end. The electrode 273 is an L-shaped plate. The plurality of electrodes 273 are configured so that their surfaces extend substantially in the radial direction. The plurality of electrodes 273 are configured so as to be clamped by welding electrodes that can be opened and closed along the circumferential direction of the stator 31.

[0126] exist Fig.14 In order to show the terminal 275, the electrode 276 is not shown. Fig.15 As shown in FIG. 1 , the protective resin 61 wraps the coil end 33 a and the terminal 71 . However, the protective resin 61 does not wrap the terminal 275 and the electrode 276 .

[0127] The wall member 62 for the connection portion 51 defines a plurality of storage grooves corresponding to each of the plurality of electrodes 272. The wall member 62 for the connection portion 52 defines a plurality of storage grooves corresponding to each of the plurality of electrodes 273. The storage grooves defining the wall member 62 and the insulator 35 are filled with the protective resin 61. The height of the wall member 62 in the axial direction is at least higher than the height of the coil end 33a and the terminal 71. Thus, the protective resin 61 can wrap the coil end 33a and the terminal 71.

[0128] like Fig.16 As shown, one wall member 62 includes three semi-cylindrical members 263. These multiple semi-cylindrical members 263 are connected to each other. Multiple semi-cylindrical members 263 are integrally molded from a resin material. The insulator 35 has a cylindrical wall body 35a along the radial inner edge of the stator coil 33. The wall body 35a extends out along the axial direction of the stator 31. The wall body 35a is located radially further outward than the fixing parts of the multiple electrodes 272 and 273 corresponding to the insulator 35. The insulator 35 has a step portion 36 corresponding to the shape of the wall member 62.

[0129] like Fig.17 and Fig.18As shown, the semi-cylindrical member 263 has an arm portion 264 located on the radially outer side and a U-shaped inner wall 265 located on the radially inner side. The semi-cylindrical member 263 has a notch portion 266 arranged on the radially outer side. The semi-cylindrical member 263 has a connecting portion 268 connecting two semi-cylindrical members 263 adjacent in the circumferential direction. The wall member 62 has three semi-cylindrical members 263 connected in a row.

[0130] The semi-cylindrical member 263 is mounted on the stator 31 so that its notch 266 is blocked by the wall 35a. The semi-cylindrical member 263 is positioned at a predetermined position by the step portion 36. The wrist 264 extends circumferentially from the edge of the inner wall 265 to the circumferential center of the notch 266, and further extends axially. The wrist 264 has a convex portion 266c extending and contacting the coil end 33a at its front end. The convex portion 266c extends and covers the slit formed on the wall 35a so that the coil end 33a passes. As a result, the wall 35a and the semi-cylindrical member 263 define a cylindrical storage tank.

[0131] According to the present embodiment, the coil end 33a and the terminal 71 can be protected by the protective resin 61 and the wall member 62. Furthermore, the plurality of semi-cylindrical members 263 contribute to reducing the amount of the protective resin 61 used.

[0132] (Third Embodiment)

[0133] This embodiment is a modification of the previous embodiment. In the previous embodiment, a plurality of U-shaped semi-cylindrical members 263 are used to form a plurality of storage tanks. Instead, in this embodiment, a plurality of cylindrical members 363 are used to form a plurality of storage tanks.

[0134] like Fig.19 and Fig. 20 As shown, the wall member 62 includes a plurality of cylindrical members 363. The cylindrical member 363 has an inner wall 364, an outer wall 365, a notch 366 and a connecting portion 368. Furthermore, the cylindrical member 363 also has a convex portion 366c. This embodiment can also obtain the same effects as the previous embodiment.

[0135] (Fourth Embodiment)

[0136] This embodiment is a modification of the previous embodiment. In the previous embodiment, the wall member 62 has a notch 66, 266, 366 for the coil end 33a to pass through. Instead, in this embodiment, the coil end 33a is introduced into the inner cavity of the wall member 62 from the bottom opening of the wall member 62.

[0137] exist Fig.21In the embodiment, the coil end 33a is pulled into the cavity in the wall member 62 via the groove formed in the insulator 35. The wall member 62 is provided by a cylindrical member 463 without a notch. According to this embodiment, the same effect as the previous embodiment can be obtained. Moreover, according to this embodiment, the gap between the insulator 35 and the wall member 62 is suppressed. Therefore, the outflow of the protective resin 61 can be suppressed. The structure used for laying the coil end 33a in this embodiment can also be applied to the previous embodiment.

[0138] (Fifth Embodiment)

[0139] This embodiment is a modification of the previous embodiment. In the previous embodiment, the wall member 62 provides a wall body extending in the axial direction. Instead, in this embodiment, the wall member 62 provides a wall body having a step in the axial direction.

[0140] exist Fig. 22 In the embodiment, the wall member 62 has a cylindrical member 563. The cylindrical member 563 has a small inner diameter portion on the insulator 35 side. The cylindrical member 563 has a large inner diameter portion on the axially outer side. As a result, a step portion 569 is formed on the inner wall of the cylindrical member 563. The cylindrical member 563 is filled with a protective resin 61. The protective resin 61 can be engaged with the complex shapes of the coil end 33a and the terminal 71. The step portion 569 provides a connection between the protective resin 61 and the cylindrical member 563. As a result, the axial fall-off of the cylindrical member 563 is suppressed. The step portion 569 can also be provided by a concave portion provided on the inner surface of the cylindrical member 563. According to this embodiment, the same effect as the previous embodiment can also be obtained. Further, according to this embodiment, the fall-off of the wall member 62 can be suppressed. The step portion 569 in this embodiment can also be applied to the previous embodiment.

[0141] This embodiment is a modification of the previous embodiment. In the previous embodiment, the coil end 33a is positioned at a predetermined position by the insulator 35. Alternatively, the wall member 62 may have a positioning portion that positions the coil end 33a at a predetermined position.

[0142] exist Fig.23In the embodiment, the cylindrical member 663 has a slit-shaped notch portion 666. The notch portion 666 is formed by extending axially from the contact surface with the insulator 35. The notch portion 666 has a narrow width equivalent to the diameter of the coil end 33a. The notch portion 666 can suppress the outflow of the protective resin 61 and at the same time receive the coil end 33a inside the wall member 62. The notch portion 666 is formed to elastically deform when receiving the coil end 33a, and the width becomes narrower again after receiving the coil end 33a. In addition, a convex portion that blocks the notch portion 666 can be provided on the insulator 35. According to this embodiment, the same effect as the previous embodiment can also be obtained.

[0143] (Seventh Embodiment)

[0144] This embodiment is a modification of the previous embodiment. In some previous embodiments, a wall member 62 is provided to connect a plurality of cylindrical members. Alternatively, a plurality of independent cylindrical members may be used.

[0145] exist Fig.24 In the embodiment, the wall member 62 is provided by an independent cylindrical member 763. On a stator 31, a plurality of wall members 62, i.e., a plurality of cylindrical members 763, are installed. The cylindrical member 763 includes an inner wall 764, an outer wall 765, and a notch 766. The cylindrical member 763 has a convex portion 766c. In addition, the cylindrical member 763 also has a step portion 769. According to this embodiment, the same effect as the previous embodiment can also be obtained. Further, according to this embodiment, the configuration freedom of the terminal 71 on the stator 31 can be improved.

[0146] (Eighth Embodiment)

[0147] This embodiment is a modification of the previous embodiment. The rotating electric machine 10 is a generator. The rotating electric machine 10 is electrically connected to a circuit 11 including a rectifier circuit (AC / DC). The circuit 11 provides a single-phase power conversion circuit.

[0148] exist Fig.25 In FIG. 1 , the stator 31 is an outer salient pole stator. The magnetic poles 32a are also called teeth.

[0149] In the illustrated example, the stator 31 has two connection portions 50. One connection portion 50 provides a connection between a coil conductor and an electrode on one end surface of the stator 31. One electrode is connected to a power line on the other end surface of the stator 31. The other electrode is connected to a coil end of another coil conductor on the other end surface of the stator 31. In the present embodiment, the electrode provides separate connection portions on one end surface and the other end surface of the stator 31.

[0150] The stator core 32 has a plurality of bolt holes for fixing the stator core 32 to the body 13. A set of two connection portions 50 is disposed between two bolt holes adjacent to each other in the circumferential direction.

[0151] The connection portion 50 includes a protective resin 61 that wraps the coil end 33a and the terminal 71 connected to the coil end 33a. In the figure, in order to illustrate the coil end 33a and the terminal 71, the range covered by the protective resin 61 is indicated by a dotted line.

[0152] Fig.26 This is an enlarged view showing a part of the stator 31, in particular, the connection portion 50. The figure shows the state after the coil end 33a is connected to the terminal 71. In order to show the coil end 33a and the terminal 71, the protective resin 61 is not shown in the figure. The application range of the protective resin 61 is indicated by a dotted line.

[0153] The insulator 35 has a wall 35a for suppressing the outflow of the protective resin 61. Due to the wall 35a, the range of the flow and expansion of the protective resin 61 is limited. The axial height of the wall 35a is lower than the axial height of the terminal 71. Due to the wall 35a, the protective resin 61 can be applied thicker around the coil end 33a and the terminal 71. The insulator 35 has a winding tube portion 35b. The winding tube portion 35b is arranged between the magnetic pole 32a and the stator coil 33. The winding tube portion 35b is in the shape of a tube surrounding the magnetic pole 32a. In the figure, the stator coil 33 is not shown.

[0154] The insulator 35 has a guide portion 35c. The guide portion 35c is used to configure the coil end 33a for the connection portion 50 into a predetermined shape. Furthermore, the guide portion 35c is used to hold the coil end 33a at a predetermined position. The guide portion 35c is formed as a protrusion extending in the axial direction on the end surface of the stator 31. The guide portion 35c and the wall body 35a are arranged around the connection portion 50. The axial height of the wall body 35a is lower than the axial height of the guide portion 35c.

[0155] The coil end 33a is configured to extend from the radially outer side to the inner side. The coil end 33a is configured to be adjacent to the terminal 71 from the stator coil 33 via the guide portion 35c. The coil end 33a is slightly bent. The coil end 33a is bent along the surface of the terminal 71. Therefore, the coil end 33a has: a portion extending along the axial direction of the stator 31, a portion bent along the radial direction of the stator 31, and a portion extending along the surface of the terminal 71.

[0156] The guide portion 35c defines a groove 43 that guides the coil end 33a toward the terminal 71 by accommodating the coil end 33a. The guide portion 35c has a first protrusion 841 and a second protrusion 842. The first protrusion 841 and the second protrusion 842 define a groove 43 that can receive the coil end 33a therebetween. The first protrusion 841 and the second protrusion 842 can be provided by a wall body that extends elongated along the circumferential direction of the stator 31.

[0157] The first protrusion 841 is located at the bend of the coil end 33a, i.e., the inner side of the bend 33b. The first protrusion 841 can limit the movement of the bend shape of the coil end 33a to the inner side. The first protrusion 841 defines the bend shape of the coil end 33a. The first protrusion 841 is also referred to as the inner side protrusion. The first protrusion 841 provides a wall surface 41a opposite to the coil end 33a. The wall surface 41a has a curved surface that defines the bend shape of the coil end 33a.

[0158] The second protrusion 842 is located at the bend of the coil end 33a, that is, the outside of the bend 33b. The second protrusion 842 can limit the movement of the bend shape of the coil end 33a to the outside. The second protrusion 842 is also called the outer protrusion. The second protrusion 842 has a thin plate portion 44 opposite to the coil end 33a and in contact with the coil end 33a. The thin plate portion 44 is formed in a plate shape thinner than other parts of the second protrusion 842. The thin plate portion 44 is only formed on the second protrusion 842. The second protrusion 842 is only arranged in the axial depth of the groove 43, rather than at the entrance of the groove 43. The thin plate portion 44 holds the coil end 33a by contacting the coil end 33a from the outside of the bend shape of the coil end 33a.

[0159] A deformation portion 45 is formed at the front end of the thin plate portion 44, that is, on the contact portion with the coil end 33a. The deformation portion 45 is arranged on the second protrusion 842. The deformation portion 45 is arranged on the positioning portion 47 described later. The deformation portion 45 is formed by the resin material being deformed by contact with the coil end 33a. The deformation portion 45 is formed by elastic deformation and / or plastic deformation of the resin material. The deformation portion 45 allows the coil end 33a to move while preventing excessive movement of the coil end 33a. For example, the thin plate portion 44 is formed to deform with the movement of the coil end 33a in the usual manufacturing method. In contrast, another part of the second protrusion 842 is formed so as not to be greatly deformed by the movement of the coil end 33a in the usual manufacturing method. Therefore, the thin plate portion 44 is formed to be thinner or narrower than other parts of the second protrusion 842. The size of the deformation portion 45 changes due to factors such as errors in the shapes of various parts and offsets in the configuration position. Sometimes, the deformation portion 45 may not be formed.

[0160] A gap 48 is formed between the wall surface 41a and the coil end 33a. The width of the gap 48 corresponds to the deformation amount of the deformation portion 45. The width of the gap 48 varies due to factors such as errors in the shapes of various parts and deviations in the arrangement positions. The gap 48 may not be formed in some cases.

[0161] The terminal 71 is plate-shaped. The terminal 71 is configured so that its surface extends radially. In other words, the terminal 71 is configured so that it can be clamped between a pair of welding electrodes used for welding, and the pair of welding electrodes can be opened and closed in the circumferential direction. The terminal 71 is provided on a portion of the plate-shaped electrode 72. In the illustrated example, the electrode 72 has two ends protruding on both end surfaces of the stator 31. The terminal 71 is formed on the end of the electrode 72. The electrode 72 is insert-molded in the insulator 35, or inserted therein so as to be supported by the insulator 35. The electrode 72 is also called a busbar. The other end of the electrode 72 is connected to other coil ends or power lines.

[0162] The terminal 71 has a shape suitable for welding. For example, the terminal 71 has a protrusion 77 having a ridgeline intersecting with the coil end 33a. The protrusion 77 is a protrusion extending in the axial direction. The terminal 71 is made of a metal suitable for welding with the coil end 33a made of aluminum-based metal. The terminal 71 is also called a welding terminal. The terminal 71 is supported by the insulator 35. The terminal 71 is supported to extend along the axial direction of the stator 31.

[0163] The coil end 33a and the terminal 71 are welded by resistance welding or spot welding, and are electrically and mechanically connected. A welding portion 55 is formed between the coil end 33a and the terminal 71, and the welding portion 55 is formed by melting the metal of both of them and then solidifying. The welding portion 55 is also called a welding mark. The terminal 71 and the coil end 33a arranged in the connecting portion 50 have a metal exposed surface.

[0164] The cross-sectional shape of the coil end 33a before welding is circular. The cross-sectional shape of the coil end 33a after welding is slightly flat. In the welding process, the coil end 33a and the terminal 71 are clamped by the electrodes used for welding. The coil end 33a and the terminal 71 are slightly deformed due to the compression during welding and the melting accompanying welding. The coil end 33a sometimes has a flat portion that serves as a contact mark with the welding electrode. The coil end 33a is deformed along the protrusion 77 at the contact portion between the coil end 33a and the terminal 71. The protrusion 77 is also deformed. The cross-sectional shape of the coil end 33a is an ellipse or an oblong shape having a major axis in the axial direction of the stator 31. The coil end 33a is positioned along the plate-shaped surface of the terminal 71. The coil end 33a is configured so that its length direction intersects with the length direction of the protrusion 77. The coil end 33a is configured so that its surface contacts the top of the protrusion 77, the two inclined surfaces of the protrusion 77, and the flat portion of the terminal 71. As a result, the coil end 33 a and the terminal 71 are firmly joined together.

[0165] Fig. 27 The guide portion 35c is shown. In the figure, the dotted line and the one-dot chain line represent the coil end 33a. The arrow of the thick solid line represents the movement path of the coil end 33a in the manufacturing method.

[0166] The groove 43 provides various functions. In the manufacturing method, the groove 43 provides a guide groove that guides the coil end 33a to a predetermined position. The groove 43 provides a retaining groove that holds the coil end 33a at a predetermined position before the coil end 33a and the terminal 71 are welded in the manufacturing method. In the manufacturing method, the groove 43 positions the coil end 33a within a predetermined position range and also provides a welding auxiliary portion that allows the coil end 33a to move slightly to achieve the desired welding between the coil end 33a and the terminal 71. The function of the welding auxiliary portion is provided by the deformation of the shape of the groove 43, that is, the deformation of the first protrusion 841 and the second protrusion 842 that define the groove 43. More specifically, the function of the welding auxiliary portion is provided by the deformation of the thin plate portion 44. After the rotary electric machine 10 is manufactured, the groove 43 can also provide a movement suppression portion that suppresses excessive movement of the coil end 33a. The manufacturing method of the rotary electric machine 10 may sometimes include a step of bonding and fixing the stator coil 33 and the coil end 33a by an adhesive, that is, a resin. In this case, the groove 43 can also play the effect of storing adhesive and the effect of stopping the excessive diffusion of adhesive as the part of blocking adhesive. In this case, the loose maintenance constituted by the groove 43 and the thin plate portion 44 and the deformed portion 45 therein becomes firmly fixed by cooperating with the adhesive.

[0167] The groove 43 has an entrance portion 46 for receiving the coil end 33a into the groove 43. The entrance portion 46 has a width WW that can receive the coil end 33a. The width WW of the entrance portion 46 is greater than the diameter DC of the coil end 33a. The entrance portion 46 has a depth greater than or equal to the diameter DC of the coil end 33a along the axial direction of the stator 31. In order to loosely hold the coil end 33a therein, the entrance portion 46 preferably has a depth exceeding DC / 2. The entrance portion 46 guides the coil end 33a, which is operated along the axial direction of the stator 31, toward the bottom of the groove 43. In the manufacturing method, the entrance portion 46 is used to temporarily position the coil end 33a. The entrance portion 46 is also called an opening portion or a wide width portion.

[0168] The groove 43 has a positioning portion 47. The positioning portion 47 is arranged at the bottom of the groove 43. The positioning portion 47 is arranged at a specified position in the axial direction of the stator 31 where the coil end 33a is finally positioned. The positioning portion 47 has a depth greater than or equal to the diameter DC of the coil end 33a along the axial direction of the stator 31. In order to stably hold the coil end 33a therein, the positioning portion 47 preferably has a depth exceeding DC / 2. At least a portion of the positioning portion 47 is defined and formed by the thin plate portion 44. An inclined surface is provided between the entrance portion 46 and the positioning portion 47. The inclined surface is smoothly connected to the entrance portion 46 and the positioning portion 47. The inclined surface can press the smooth coil end 33a in.

[0169] The positioning portion 47 has a width WN capable of receiving the coil end 33a by deformation of the first protrusion 841 and the second protrusion 842. The width WN of the positioning portion 47 is smaller than the diameter DC of the coil end 33a. The width WN of the positioning portion 47 can also be set to be less than the diameter DC of the coil end 33a. The width WN of the positioning portion 47 is smaller than the width WW of the entrance portion 46. The positioning portion 47 receives the coil end 33a operated in the axial direction of the stator 31 while the first protrusion 841 and the second protrusion 842 are deformed. The positioning portion 47 is deformed by contact with the coil end 33a. It can also be said that the coil end 33a is pressed into the positioning portion 47. The deformation is mainly the deformation of the thin plate portion 44. The positioning portion 47 is also called a bottom or a narrow width portion.

[0170] The positioning portion 47 is deformed when the coil end 33a is operated from the position PS1 shown by the dotted line to the position PS2. This deformation is provided by elastic deformation or plastic deformation. At this time, the positioning portion 47 firmly holds the coil end 33a. The positioning portion 47 sometimes further deforms as the coil end 33a moves during the welding process. This deformation is provided by the deformation of the thin plate portion 44. Through this deformation, a deformed portion 45 can be formed in the thin plate portion 44. When the deformed portion 45 is formed, the positioning portion 47 changes the holding of the coil end 33a from firmly holding to loose holding. At this time, the positioning portion 47 has a portion that is deformed by contacting with the coil end 33a at the position where the coil end 33a is positioned, thereby providing a width greater than or equal to the diameter DC of the coil end 33a. In addition, the positioning portion 47 has a portion of width WN that is smaller than the diameter DC of the coil end 33a.

[0171] The coil end 33a is positioned at the position PS2 in the groove 43. In addition, the coil end 33a is operated from the position PS3 shown by the single-dot chain line to the position PS4 at the part in contact with the terminal 71, and is positioned at the position PS4. In addition, the position of the coil end 33a before welding is shown in the figure.

[0172] The method for manufacturing the rotating electrical machine 10 includes the steps in the previous embodiment. Fig. 27 , Fig.28 and Fig.29 As shown, the coil end 33a is inserted into the groove 43 and bent to contact the terminal 71. The operation of the coil end 33a is provided by manual operation of an operator or by the action of a mechanized tool of an assembly machine.

[0173] like Fig. 27 As shown by the arrow P1, the coil end 33a is operated to move in the axial direction in the groove 43. The coil end 33a is inserted into the groove 43 from the outside of the groove 43. Thus, a process of loosely positioning the coil end 33a at the entrance portion 46 is provided. Here, the coil end 33a can move in the radial direction of the coil end 33a within the range limited by the entrance portion 46 in the entrance portion 46. The coil end 33a can move slightly in the axial direction of the coil end 33a.

[0174] Furthermore, the coil end 33a is pushed from the position PS1 shown by the dotted line to the position PS2. Thus, a process is provided for moving the coil end 33a toward the positioning portion 47 via the entrance portion 46. At this time, at least the thin plate portion 44 is elastically deformed. In the present embodiment, a portion of the thin plate portion 44 is plastically deformed. As a result, the coil end 33a is firmly held in the groove 43 by means of the elasticity of the resin material. Firm holding is also strong fastening. Thus, a process is provided for firmly positioning the coil end 33a by contacting the coil end 33a with the guide portion 35c at the positioning portion 47, thereby deforming the guide portion 35c. However, the thin plate portion 44 is formed to be thinner in the direction in which the coil end 33a extends, that is, in the radial direction. Therefore, the thin plate portion 44 is more easily deformed than other parts of the first protrusion 841 and the second protrusion 842. Furthermore, since the contact area between the coil end 33 a and the thin plate portion 44 is small, the friction force provided by the thin plate portion 44 is adjusted to be smaller than the friction force caused by the thickness of the second protrusion 842 .

[0175] like Fig. 27 As shown by arrows P2 and P3 in FIG. 4 , the coil end 33a is operated to move from above the terminal 71 to above the surface of the terminal 71 outside the groove 43. The front end of the coil end 33a extends out of the groove 43, and its front end is positioned at the position PS3 shown by the single-point chain line. The coil end 33a is operated to contact the upper part of the protrusion 77 via the upper part of the terminal 71. At this time, the coil end 33a is bent.

[0176] exist Fig.28 , a state after the coil end 33a is arranged in the groove 43 by the operation indicated by the arrow P1 is shown by a solid line. The coil end 33a is arranged in the groove 43 from above the groove 43 as indicated by the arrow P1.

[0177] The portion of the coil end 33a extending from the groove 43 is subjected to an operation as indicated by the arrow P2. That is, the coil end 33a passes over the terminal 71 and is bent. At this time, the coil end 33a can be bent using the first protrusion 841 as an inner mold. Alternatively, the coil end 33a can also be bent using a member different from the first protrusion 841 as an inner mold. The coil end 33a is bent as indicated by the dotted line. A bending portion 33b is formed on the coil end 33a. The bending portion 33b allows the coil end 33a to bend along the terminal 71.

[0178] Next, as shown by the tail of the arrow P3, the coil end 33a is operated to be pushed in along the axial direction of the stator 31 so that it contacts the top of the protrusion 77 in the protruding direction of the protrusion 77. Thus, the coil end 33a is positioned on the surface of the terminal 71, that is, positioned beside the protrusion 77 with respect to the axial direction of the stator 31.

[0179] The operations indicated by the arrows P1, P2 and P3 may also be performed simultaneously and in parallel. Furthermore, the operations may also be performed in the order of the arrows P1, P2 and P3. For example, while the coil end 33a is gradually pushed into the groove 43 according to the operation of the arrow P1, the operations of the arrows P2 and P3 are performed in sequence.

[0180] Fig.29 The state where the coil end 33a is in the normal position is shown. This state is the state before welding. The coil end 33a is firmly held between the first protrusion 841 and the thin plate portion 44. The coil end 33a extends straight from the bent portion 33b. The outer peripheral surface of the coil end 33a contacts the upper part of the protrusion 77. The coil end 33a is held in a specified position by the holding effect of the guide portion 35c and the elasticity of the coil end 33a itself.

[0181] The manufacturing process of the stator 31 is a process of connecting the coil end 33a to the terminal 71 while the coil end 33a is positioned by the positioning portion 47. This process is also a process of welding the coil end 33a and the terminal 71 by sandwiching the coil end 33a and the terminal 71 with the welding electrodes 81 and 82. This process is also called a joining process or a welding process.

[0182] Fig.30 The figure shows the initial stage in which the coil end 33a and the terminal 71 are clamped by the welding electrodes 81 and 82. The welding electrode 81 is operated as indicated by the arrow P5 to contact the terminal 71. The welding electrode 82 is operated as indicated by the arrow P6 to contact the coil end 33a. At this time, due to the inclination of the coil end 33a and the like, the coil end 33a and the welding electrode 82 are sometimes not in parallel contact.

[0183] For example, as shown in the figure, the corner of the welding electrode 82 contacts the suspension portion of the coil end 33a arranged between the guide portion 35c and the protrusion 77. In the present embodiment, the shape of the guide portion 35c and the bending process of the coil end 33a are both set to provide the shape of the coil end 33a shown in the figure. The coil end 33a is bent so that its suspension portion will not cross the virtual plane PP and be positioned on the terminal 71 side. The virtual plane PP is a plane parallel to the surface of the terminal 71 and tangent to the top in the protruding direction of the protrusion 77. This virtual plane PP is also parallel to the surfaces of the welding electrodes 81, 82 that will clamp the terminal 71.

[0184] The guide portion 35c is formed so that the coil end 33a can be configured into the shape shown in the figure. That is, the edges 41c and 42c of the groove 43 on the radial inner side of the stator 31 are both positioned on the side opposite to the terminal 71 with respect to the virtual plane PP. In other words, of the edges 41c and 42c on the radial inner side of the groove 43, the edge 42c located on the outer side of the bend of the coil end 33a is positioned to be tangent to the virtual plane PP or to be positioned closer to the welding electrode 82 side than the virtual plane PP. Here, the edge 41c is provided by the first protrusion 841. And the edge 42c is provided by the second protrusion 842. As a result, the coil end 33a extends from the edges 41c and 42c toward the terminal 71 and the virtual plane PP, thereby reaching the terminal 71. In the bending process of the coil end 33a, the coil end 33a is bent so that it extends straight from the edges 41c and 42c toward the terminal 71.

[0185] When welding electrode 82 is operated along arrow P6, welding electrode 82 first contacts coil end 33a at contact portion 33c and pushes contact portion 33c. As a result, coil end 33a is not only pushed toward terminal 71 in parallel, but also rotates along terminal 71.

[0186] At this time, the coil end 33a may sometimes move in a manner that is not desirable for forming an ideal welded portion. For example, since one end of the suspension portion of the coil end 33a is held by the guide portion 35c, the coil end 33a may slide on the protrusion 77. Such movement may cause the molten portion to move during the welding process, thereby preventing the proper amount of melting. In addition, the molten portion may exceed the appropriate position.

[0187] Fig.31 The movement of the coil end 33a by the welding electrode 82 is shown. The welding electrode 82 is operated as shown by the arrow P6. The coil end 33a and the terminal 71 sandwiched between the pair of welding electrodes 81 and 82 form a welded portion 55 as welding proceeds.

[0188] During this process, the coil end 33a is pulled in the direction of arrow P7 to contact the terminal 71. At this time, since the thin plate portion 44 holds the coil end 33a with a small friction force, the coil end 33a is allowed to be pulled in the direction of arrow P7.

[0189] Furthermore, the component force along the force indicated by the arrow P7 deforms the thin plate portion 44 to form a deformed portion 45. Since the deformed portion 45 is formed at the contact portion between the thin plate portion 44 and the coil end 33a, the thin plate portion 44 continues to hold the coil end 33a in the axial direction. As a result, the coil end 33a is separated from the first protrusion 841 and a gap 48 is formed. This deformation of the thin plate portion 44 also allows the coil end 33a to move. This process is a process in which when the coil end 33a and the terminal 71 are clamped by the welding electrodes 81 and 82, the guide portion 35c is further deformed as the coil end 33a moves, thereby allowing the coil end 33a to move.

[0190] Even after the coil end 33a is pulled in along the arrow P7, the first protrusion 841 and the second protrusion 842 can suppress excessive movement of the coil end 33a in the circumferential and axial directions of the stator 31. Even after the thin plate portion 44 is deformed, the first protrusion 841 and the second protrusion 842 can suppress excessive movement of the coil end 33a in the circumferential and axial directions of the stator 31.

[0191] Thus, the guide portion 35c, particularly the thin plate portion 44, firmly holds the coil end 33a until the initial stage of the welding process. During the welding process, the thin plate portion 44 allows the movement of the coil end 33a. As a result, the coil end 33a can enter the welding state shown in the figure without moving over the terminal 71 as if being pulled. The coil end 33a can be welded to the terminal 71 on the protrusion 77 without being offset in the length direction of the coil end 33a.

[0192] The manufacturing process of the stator 31 includes a process of applying the protective resin 61. The coil end 33a and the terminal 71 are wrapped with the protective resin 61. The protective resin 61 is applied to completely cover the exposed metal surfaces of the coil end 33a and the terminal 71 arranged in the connection portion 50. The protective resin 61 covers at least the metal surface of the coil end 33a exposed due to the removal of the protective film, and the exposed metal surface of the terminal 71. The protective resin 61 is applied in an uncured state. Thereafter, the protective resin 61 is cured.

[0193] The manufacturing process of the stator 31 also includes other connection processes. This process may include a process of connecting the electrode 72 to the power line or a process of connecting the electrode 72 to other coil ends.

[0194] According to the above embodiment, the inlet portion 46 and the positioning portion 47 are provided in the groove 43. As a result, the coil end 33a can be inserted into the positioning portion 47 using the inlet portion 46. Thus, the positioning portion 47 can be formed to provide guidance of the coil end 33a suitable for forming a desired connection state.

[0195] The positioning portion 47 allows the coil end 33a to move during the welding process. Therefore, it is possible to suppress the coil end 33a from sliding on the terminal 71. As a result, a desired connection state can be formed between the coil end 33a and the terminal 71.

[0196] In the welding process, the positioning portion 47 holds the coil end 33a at the deformed deformation portion 45. Thus, the positioning portion 47 firmly holds the coil end 33a before the deformation portion 45 is formed, and loosely holds the coil end 33a after the deformation portion 45 is formed. Thus, in the process of clamping the coil end 33a and the terminal 71 and welding them, the positioning portion 47 can allow the coil end 33a to move.

[0197] (Ninth Embodiment)

[0198] This embodiment is a modification of the previous embodiment. In the above embodiment, the positioning portion 47 can be deformed to loosely hold the coil end 33a. Instead, in this embodiment, the guide portion 35c of the positioning portion 47 is provided to continue to firmly hold the coil end 33a.

[0199] Fig.32 and Fig.33 It is a perspective view showing the guide portion 35c in this embodiment. Fig.34 , Fig.35 and Fig.36 The following is a diagram showing a process for electrically connecting the coil end 33 a and the terminal 71 in the present embodiment.

[0200] In this embodiment, the guide portion 35c also has a first protrusion 841 and a second protrusion 942. The second protrusion 942 is not provided in the thin plate portion 44 and the deformed portion 45 in the previous embodiment. The second protrusion 942 contacts the coil end 33a with almost the entire thickness of its radial direction. In this embodiment, the first protrusion 841 and the second protrusion 942 also define a groove 43. The groove 43 has an entrance portion 46 and a positioning portion 47. The positioning portion 47 holds the coil end 33a with almost the entire thickness of the second protrusion 942.

[0201] exist Fig.34 The initial stage of the welding process is shown in FIG. In the present embodiment, the coil end 33a is firmly held in the groove 43. Furthermore, the coil end 33a is firmly held in the groove 43 both before and after the joining process.

[0202] The welding electrodes 81 and 82 are respectively operated to contact the coil end 33a and the terminal 71. At this time, in the present embodiment, the free end portion of the coil end 33a protruding radially inward from the protrusion 77 contacts the welding electrode 82. The welding electrode 82 first contacts the contact portion 933c. The contact portion 933c is located at the protruding free end portion of the coil end 33a.

[0203] In this embodiment, the coil end 33a is bent so that the contact portion 933c is located at the free end portion. Another view is that the shape of the guide portion 35c and the position of the protrusion 77 are set so that the contact portion 933c is located at the free end portion. The coil end 33a is arranged above the terminal 71 so that it is farther away from the terminal 71 toward the front end of the coil end 33a.

[0204] In this embodiment, the shape of the guide portion 35c and the bending process of the coil end 33a are both set to provide the shape of the coil end 33a shown in the figure. The coil end 33a is bent so that a part of its hanging portion is positioned on the terminal 71 side beyond the virtual plane PP.

[0205] The guide portion 35c is formed so that the coil end 33a can be configured into the shape shown in the figure. That is, the edge 42c is positioned on the terminal 71 side relative to the virtual plane PP. In other words, of the radially inner edges 41c and 42c of the groove 43, the curved, outer edge 42c of the coil end 33a is positioned closer to the terminal 71 side than the virtual plane PP. As a result, the coil end 33a extends from the edges 41c and 42c, crosses the virtual plane PP and passes through the terminal 71 side, and then extends back to the top of the protrusion 77. In the bending process of the coil end 33a, the coil end 33a is bent from the edges 41c and 42c to cross the virtual plane PP and pass through the terminal 71 side.

[0206] In the present embodiment, a bending process of the coil end 33a is adopted to provide this configuration. This configuration of the coil end 33a can form the contact portion 933c at the free end portion.

[0207] exist Fig.35 , the welding electrode 82 is gradually pushed. The coil end 33a is gradually deformed along the terminal 71. The coil end 33a is gradually deformed from its free end portion, that is, from the front end. Thus, the coil end 33a gradually contacts the terminal 71 while maintaining its contact with the protrusion 77 at a certain portion.

[0208] exist Fig.36 The final stage of the welding process is shown in FIG. 8 . The welding electrode 82 is pushed to a predetermined final position. The coil end 33 a is welded to the terminal 71 .

[0209] According to the present embodiment, the coil end 33a can be inserted into the positioning portion 47 using the inlet portion 46. Thus, the positioning portion 47 can be formed so as to provide guidance of the coil end 33a suitable for forming a desired connection state.

[0210] The guide portion 35c firmly holds the coil end 33a. Furthermore, the coil end 33a and the welding electrode 82 are configured so that the welding electrode 82 contacts the free end portion of the coil end 33a. The welding electrode 82 first contacts the coil end 33a at a portion close to the front end of the coil end 33a. In other words, it is possible to avoid forming the contact portion 33c on the suspension portion of the coil end 33a. Thus, the sliding movement of the coil end 33a on the terminal 71, particularly at the receiving portion of the protrusion 77, is suppressed. Compared to the case where the suspension portion is pushed, the sliding of the coil end 33a on the terminal 71 is suppressed. Thus, a desired connection state can be formed between the coil end 33a and the terminal 71.

[0211] (Tenth Embodiment)

[0212] This embodiment is a modification of the previous embodiment. In this embodiment, the movement of the coil end 33a on the terminal 71 is suppressed by the bent portion 33b of the coil end 33a.

[0213] Fig.37 and Fig.38 The electrical connection process between the coil end 33a and the terminal 71 in this embodiment is shown. In this embodiment, the coil end 33a is also guided and held by the guide portion 35c. The coil end 33a is pressed and firmly held between the first protrusion 841 and the second protrusion A42. The second protrusion A42 is formed in the manufacturing process so as not to be deformed by the force acting on the coil end 33a. In this embodiment, a groove 43 is also formed between the first protrusion 841 and the second protrusion A42. The groove 43 has an entrance portion 46 and a positioning portion 47.

[0214] The coil end 33a is provided with an S-shaped bent portion A33d including the bent portion 33b in the portion extending from the guide portion 35c to the terminal 71. Here, the term S-shape is defined as including an inverse S-shape. The bent portion A33d causes the coil end 33a to slightly detour in the direction approaching the terminal 71. The bent portion A33d can be configured so that the coil end 33a forms a desired positional relationship relative to the terminal 71. The coil end 33a is configured above the terminal 71 so as to be farther away from the terminal 71 toward the front end of the coil end 33a. This configuration with an open front end is provided by the bent portion A33d. Similar to the second embodiment, the configuration with an open front end can position the contact portion 933c at the free end portion of the coil end 33a.

[0215] Another view is that the bend A33d is formed as a portion of the coil end 33a that is easy to bend. Compared with the case where only the bend 33b is formed on the suspension portion of the coil end 33a between the guide portion 35c and the protrusion 77, the bend A33d is formed as a portion for making the coil end 33a easy to bend. The bend A33d allows the coil end 33a that is closer to the bend A33d to rotate along the terminal 71 through the deformation of the bend A33d itself. In other words, the bend A33d can prevent the coil end 33a from sliding on the protrusion 77 through its own deformation.

[0216] The bent portion A33d may also be referred to as a sag formed by sag the coil end 33a between the guide portion 35c and the protrusion 77. In the present embodiment, the coil end 33a bending process is adopted to form a sag at the hanging portion of the coil end 33a between the guide portion 35c and the terminal 71.

[0217] In this embodiment, the shape of the guide portion 35c and the bending process of the coil end 33a are both set to provide the shape of the coil end 33a shown in the figure. The coil end 33a is bent so that a part of its suspension part, that is, a part of the bent portion A33d, passes over the virtual plane PP and is positioned on the terminal 71 side.

[0218] The guide portion 35c is formed so that the coil end 33a can be configured into the shape shown in the figure. The edge 42c is positioned on the welding electrode 82 side relative to the virtual plane PP, that is, on the protruding direction side of the protrusion 77 relative to the virtual plane PP. In other words, the radially inner edges 41c and 42c of the groove 43 are both positioned on the opposite side of the terminal 71 relative to the virtual plane PP. Further, the guide portion 35c is formed to be away from the terminal 71 on the radial outer side of the stator 31 so as to provide a space required for forming the bent portion A33d between the guide portion 35c and the terminal 71. In the bending process of the coil end 33a, the coil end 33a is bent from the edges 41c and 42c so as to cross the virtual plane PP and pass the terminal 71 side. In other words, the coil end 33a is bent in a serpentine manner from the edges 41c and 42c.

[0219] In the present embodiment, the welding electrode 82 first contacts the contact portion 933c of the free end portion. The welding electrode 82 presses the coil end 33a toward the terminal 71. As a result, the coil end 33a is deformed along the terminal 71. At this time, the bend A33d allows the coil end 33a on the front end side of the bend A33d to rotate along the terminal 71. The bend A33d acts as a hinge in the coil end 33a. In the present embodiment, the welding electrode 82 not only contacts the suspension portion of the coil end 33a arranged between the protrusion 77 and the guide portion 35c. Compared with the case where the suspension portion of the coil end 33a arranged between the guide portion 35c and the terminal 71 is pressed, the sliding of the coil end 33a on the terminal 71 is suppressed. As a result, the desired welding portion can be formed.

[0220] According to the present embodiment, the coil end 33a is firmly positioned before welding. A sag is formed in the suspension portion of the coil end, which is arranged between the guide portion 35c and the terminal 71. During the welding process, the coil end 33a is pushed by the welding electrode. Thus, the coil end 33a can rotate along the terminal 71. At this time, the sag is deformed. Due to the deformation of the sag, the sliding of the coil end 33a on the terminal 71 is suppressed. Thus, the desired welding portion can be formed.

[0221] (Eleventh Embodiment)

[0222] This embodiment is a modification of the previous embodiment as a basic form, and various shapes of the groove 43 can be used instead of the previous embodiment. Fig.39 The groove 43 of this embodiment is shown. The groove 43 has a quadrangular inlet portion B46 defined by a pair of edges parallel to the axial direction of the stator 31. In this embodiment, the coil end 33a can also be guided through the inlet portion B46.

[0223] (Twelfth Embodiment)

[0224] This embodiment is a modification of the previous embodiment as a basic form. Fig.40 The groove 43 of this embodiment is shown. The groove 43 has an inlet portion C46 which can be called a triangle or a trapezoid, and the inlet portion C46 is defined by a pair of edges inclined with respect to the axial direction of the stator 31. In this embodiment, the coil end 33a can also be guided through the inlet portion C46.

[0225] (Thirteenth embodiment)

[0226] This embodiment is a modification of the previous embodiment as a basic form. Fig.41The groove 43 of this embodiment is shown. The groove 43 has an inlet portion D46 defined by one edge parallel to the axial direction and one edge inclined with respect to the axial direction. In this embodiment, the coil end 33a can also be guided through the inlet portion D46.

[0227] (Fourteenth Embodiment)

[0228] This embodiment is a modification of the previous embodiment. In the previous embodiment, the electrode 73 used for a single-phase coil is exemplified. Instead, the structure of the guide portion 35c adopted in the previous embodiment can be applied to electrodes for various purposes.

[0229] Fig.42 : is a cross-sectional view modeling the stator 31 of this embodiment. In this embodiment, electrodes 72 and 73 for three-phase coils are shown. The plurality of electrodes 72 and 73 are arranged so that their surfaces extend substantially in the circumferential direction. The plurality of electrodes 72 and 73 are arranged so as to be clamped by welding electrodes that can be opened and closed in the radial direction of the stator 31.

[0230] The electrode 73 connects the coil end 33a to the electric power line of the harness 15. The electrode 73 has a terminal 71 and a terminal 74. The electrode 73 is a through electrode that penetrates the stator 31 in the axial direction. The electrode 73 has terminals 71 and 74 that are spaced apart from each other on both surfaces of the stator 31.

[0231] The electrode 72 provides a neutral point connection for the three-phase coil. The electrode 72 has a plurality of terminals 71. The electrode 72 is an E-shaped multi-head electrode. In this embodiment, the guide portion 35c can also adopt the same structure as the previous embodiment.

[0232] (Fifteenth embodiment)

[0233] This embodiment is a modification of the previous embodiment as a basic form. In this embodiment, other electrodes 272 and 273 are exemplified.

[0234] Fig.43 This is a cross-sectional view of a model of the stator 31 of this embodiment. In this embodiment, electrodes 272 and 273 for three-phase coils are shown. The plurality of electrodes 272 and 273 are arranged so that their surfaces extend substantially in the radial direction. The plurality of electrodes 272 and 273 are arranged so as to be clamped by welding electrodes that can be opened and closed along the circumferential direction of the stator 31.

[0235] The electrode 272 connects the coil end 33a to the power line of the wiring harness 15. The electrode 273 is an L-shaped plate. The electrode 273 has a terminal 71 and a terminal 274. The electrode 273 is a non-penetrating electrode that does not penetrate the stator 31. The electrode 273 has a fixing portion corresponding to the insulator 35 at one end thereof. The electrode 273 has a terminal 274 connected to the power line at the other end thereof. The electrode 273 has a terminal 71 between the terminal 274 and the fixing portion.

[0236] The plurality of electrodes 272 provide neutral point connection for the three-phase coils. In this embodiment, the guide portion 35c may also adopt the same structure as in the previous embodiment.

[0237] (Other embodiments)

[0238] The content of the invention of this specification is not limited to the enumerated embodiments. The content of the invention includes the enumerated embodiments and the modified embodiments obtained by those skilled in the art based on them. For example, the content of the invention is not limited to the combination of components and / or elements disclosed in the embodiments. The present invention can be implemented through a variety of combinations. The present invention may also include additional parts that can be added to the embodiments. The present invention includes embodiments in which components and / or elements in the embodiments are omitted. The present invention includes the replacement or combination of components and / or elements between one embodiment and other embodiments. The disclosed technical scope is not limited to the description of the embodiments. The disclosed technical protection scope is determined by the description of the claims, and should also be understood to include all changes within the same meaning and scope as the description of the claims.

[0239] In the above embodiment, the height of the wall body provided by the wall member 62 is set to be higher than the height of the coil end 33a and the terminal 71 arranged in the connection portion 50 in the axial direction. Alternatively, the height of the wall body provided by the wall member 62 may be set to be slightly lower than the height of the coil end 33a and the terminal 71 arranged in the connection portion 50, or to be the same as the height of the coil end 33a and the terminal 71 arranged in the connection portion 50. Even in this case, the coil end 33a and the terminal 71 arranged in the connection portion 50 can be completely wrapped by virtue of the viscosity and surface tension of the protective resin 61.

[0240] In the above embodiment, the coil end 33a and the terminal 71 are welded by resistance welding or spot welding. Alternatively, the coil end 33a and the terminal 71 may be joined by soldering or riveting by mechanically deforming the members.

[0241] In the above embodiment, the guide portion 35c is integrally molded from the resin material of the insulator 35. Alternatively, the guide portion 35c may be formed from a resin material separate from the insulator 35. In this case, the guide portion 35c is connected via a connection mechanism such as insertion into the stator core 32 or the insulator 35.

[0242] Description of reference numerals:

[0243] 10 Rotating electric machine, 11 Circuit, 12 Internal combustion engine, 13 Airframe,

[0244] 14 rotating shaft, 15 wiring harness, 21 rotor,

[0245] 22 rotor core, 23 permanent magnet, 31 stator,

[0246] 32 stator core, 32 magnetic poles, 33 stator coils,

[0247] 33a coil end, 33b, 233b, A33b bending part,

[0248] 33c, 933c contact part, A33d bending part,

[0249] 35 insulator, 35a wall, 35b bobbin, 35c guide portion,

[0250] 36 step portion, 37 positioning portion, 38 slit,

[0251] 41 sensor units,

[0252] 841 first protrusion, 842, 942, A42 second protrusion, 43 groove,

[0253] 44 thin plate part, 45 deformation part, 46, B46, C46, ​​D46 entrance part,

[0254] 47 positioning portion, 48 gap,

[0255] 50, 51, 52 connecting parts, 55 welding part,

[0256] 61 protective resin, 62 wall member,

[0257] 63, 363, 463, 563, 663, 763 cylindrical members,

[0258] 263 semi-cylindrical member, 64 outer wall, 65 inner wall,

[0259] 66, 266, 366, 666, 766 notch part, 67 step part,

[0260] 569 step section, 769 step section,

[0261] 71 terminal, 72, 272 electrode, 73, 273 electrode,

[0262] 74, 274 terminal, 275 terminal, 276 electrode, 77 protrusion,

[0263] 81, 82 welding electrodes.

Claims

1. A rotating electrical machine, comprising: A coil end (33a), which is an end of the stator coil (33); A terminal (71) connected to the coil end; as well as A guide portion (35c) defines a groove (43) for guiding the coil end toward the terminal by accommodating the coil end; wherein, The guide portion has: a positioning portion (47) disposed at a predetermined position of the coil end in the groove and deformed by contact with the coil end; as well as An entrance portion (46, B46, C46, ​​D46) is disposed at the entrance of the groove, has a width (WW) greater than the diameter (DC) of the coil end and greater than the width (WN) of the positioning portion, and is not significantly deformed, The guide portion has a thin plate portion (44) formed in a thin plate shape and deformed by contact with the coil end. The thin plate portion is provided only at the deep part of the groove, that is, the positioning portion, and is not provided at the entrance portion.

2. A rotating electrical machine, comprising: A coil end (33a), which is an end of the stator coil (33); A terminal (71) connected to the coil end; as well as A guide portion (35c) defines a groove (43) for guiding the coil end toward the terminal by accommodating the coil end; wherein, The guide portion has: a positioning portion (47) disposed at a predetermined position of the coil end in the groove and deformed by contact with the coil end; as well as an entrance portion (46, B46, C46, ​​D46) disposed at the entrance of the groove, having a width (WW) greater than the diameter (DC) of the coil end and greater than the width (WN) of the positioning portion, and a depth greater than 1 / 2 the diameter (DC) of the coil end, The guide portion has a thin plate portion (44) formed in a thin plate shape and deformed by contact with the coil end. The thin plate portion is provided only at the deep part of the groove, that is, the positioning portion, and is not provided at the entrance portion.

3. The rotating electrical machine according to claim 2, wherein: The inlet portion has a depth greater than or equal to a diameter (DC) of the coil end.

4. The rotating electrical machine according to claim 2, wherein: The positioning portion has a depth greater than 1 / 2 of a diameter (DC) of the coil end, or a depth greater than or equal to the diameter of the coil end.

5. A rotating electrical machine, comprising: A coil end (33a), which is an end of the stator coil (33); A terminal (71) connected to the coil end; as well as A guide portion (35c) defines a groove (43) for guiding the coil end toward the terminal by accommodating the coil end; wherein, The guide portion has: a positioning portion (47) disposed at a predetermined position of the coil end in the groove and deformed by contact with the coil end; as well as an entrance portion (46, B46, C46, ​​D46) disposed at the entrance of the groove and having a width (WW) greater than the diameter (DC) of the coil end and greater than the width (WN) of the positioning portion; The guide portion has a thin plate portion (44) formed in a thin plate shape and deformed by contact with the coil end. The thin plate portion is provided only at the deep part of the groove, that is, the positioning portion, and is not provided at the entrance portion.

6. The rotating electrical machine according to claim 5, comprising: a rotor (21) connected to a rotating shaft (14) of an internal combustion engine; a stator (31), which is arranged opposite to the rotor; and An electrically insulating insulator (35) is arranged on the stator; wherein: The stator coil is arranged on the stator; The terminal is supported by the insulator to extend along the axial direction of the stator; The guide portion is disposed on the insulator and has a first protrusion (841) and a second protrusion (842, 942, A42) defining the groove.

7. The rotating electrical machine according to claim 6, wherein: The coil end is a portion protruding from the guide portion and has a bent portion (33b, A33d) bent along the terminal; The first protrusion is located on the inner side of the curved portion; The second protrusion is located outside the curved portion; The second protrusion has a deformation portion (45) provided on the positioning portion and deformed by contacting the coil end.

8. The rotating electrical machine according to claim 7, wherein: The second protrusion has a thin plate portion (44) which is formed in a thin plate shape and forms the deformation portion by contacting the coil end.

9. The rotating electrical machine according to any one of claims 5 to 8, wherein: The positioning portion has: deformed by contact with the coil end at a portion where the coil end is located to provide a portion having a width greater than or equal to a diameter (DC) of the coil end; as well as A portion whose width (WN) is smaller than the diameter (DC) of the coil end.

10. A method for manufacturing a rotating electrical machine, wherein: The rotating electrical machine comprises: A coil end (33a), which is an end of the stator coil (33); A terminal (71) connected to the coil end; and a guide portion (35c) defining a groove (43) for guiding the coil end toward the terminal by accommodating the coil end, the guide portion having a thin plate portion (44) formed in a thin plate shape and deformed by contact with the coil end, the thin plate portion being provided only at a deep portion of the groove, i.e., a positioning portion, and not at an entrance portion; The manufacturing method of the rotating electrical machine comprises: Loosely positioning the coil end in an entrance portion (46, B46, C46, ​​D46) disposed at the entrance of the groove and having a width (WW) greater than a diameter (DC) of the coil end; Moving the coil end to a positioning portion (47) provided in the groove at a predetermined position of the coil end via the inlet portion formed so as not to be greatly deformed during the movement of the coil end; The guide portion is deformed by bringing the coil end into contact with the guide portion at the positioning portion to firmly position the coil end; and The coil end is connected to the terminal in a state where the coil end is positioned by the positioning portion.

11. The method for manufacturing a rotating electrical machine according to claim 10, comprising: The connection is provided by welding the coil end and the terminal by clamping the coil end and the terminal with welding electrodes (81, 82) in a state where the coil end is positioned by the positioning portion; Also includes, When the coil end and the terminal are clamped by the electrodes, the guide portion is further deformed as the coil end moves, thereby allowing the movement of the coil end.

12. The method for manufacturing a rotating electrical machine according to claim 11, further comprising: The coil end is bent before the welding so that the coil end is arranged on the terminal so as to be farther away from the terminal toward the front end of the coil end.

13. The method for manufacturing a rotating electrical machine according to claim 11, further comprising: The coil end is bent before the welding to form a sag at the coil end between the lead portion and the terminal.

14. The method for manufacturing a rotating electrical machine according to claim 12, wherein: The coil ends are bent into an S shape.

15. The method for manufacturing a rotating electrical machine according to any one of claims 10 to 14, wherein: The inlet portion has a depth greater than 1 / 2 of the diameter (DC) of the coil end, or a depth greater than or equal to the diameter of the coil end, so that the coil end is loosely positioned at the inlet portion; After the coil end is loosely positioned at the inlet portion, the coil end is firmly positioned at the positioning portion by deforming the thin plate portion.

16. A method for manufacturing a rotating electrical machine, wherein: The rotating electrical machine comprises: A coil end (33a), which is an end of the stator coil (33); A terminal (71) connected to the coil end; and a guide portion (35c) defining a groove (43) for guiding the coil end toward the terminal by accommodating the coil end, the guide portion having a thin plate portion (44) formed in a thin plate shape and deformed by contact with the coil end, the thin plate portion being provided only at a deep portion of the groove, i.e., a positioning portion, and not at an entrance portion; The manufacturing method of the rotating electrical machine comprises: inserting the coil end in the groove so that the coil end contacts the guide portion and deforms the guide portion, thereby firmly positioning the coil end; In a state where the coil end is positioned by the groove, the coil end and the terminal are clamped by welding electrodes (81, 82) to weld the coil end to the terminal; and When the coil end and the terminal are clamped by the electrodes, the guide portion is further deformed as the coil end moves, thereby allowing the movement of the coil end.

17. A method for manufacturing a rotating electrical machine, wherein: The rotating electrical machine comprises: A coil end (33a), which is an end of the stator coil (33); A terminal (71) connected to the coil end; and a guide portion (35c) defining a groove (43) for guiding the coil end toward the terminal by accommodating the coil end, the guide portion having a thin plate portion (44) formed in a thin plate shape and deformed by contact with the coil end, the thin plate portion being provided only at a deep portion of the groove, i.e., a positioning portion, and not at an entrance portion; The manufacturing method of the rotating electrical machine comprises: inserting the coil end in the groove so that the coil end contacts the guide portion and deforms the guide portion, thereby firmly positioning the coil end; bending the coil end so that the coil end is disposed above the terminal and is further away from the terminal toward the front end of the coil end; and With the coil end positioned by the groove, the coil end and the terminal are clamped by welding electrodes (81, 82) to weld the coil end to the terminal.

18. A method for manufacturing a rotating electrical machine, wherein: The rotating electrical machine comprises: A coil end (33a), which is an end of the stator coil (33); A terminal (71) connected to the coil end; and a guide portion (35c) defining a groove (43) for guiding the coil end toward the terminal by accommodating the coil end, the guide portion having a thin plate portion (44) formed in a thin plate shape and deformed by contact with the coil end, the thin plate portion being provided only at a deep portion of the groove, i.e., a positioning portion, and not at an entrance portion; The manufacturing method of the rotating electrical machine comprises the following steps: inserting the coil end in the groove so that the coil end contacts the guide portion and deforms the guide portion, thereby firmly positioning the coil end; The coil end is bent so that a sag is formed at a hanging portion of the coil end that is spanned between the guide portion and the terminal; In a state where the coil end is positioned by the groove, the coil end and the terminal are clamped by welding electrodes (81, 82) to weld the coil end to the terminal; and When the coil end rotates along the terminal, the flap is deformed.

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