Stator of a rotating electrical machine, rotating electrical machine, method for manufacturing the stator of a rotating electrical machine, and method for manufacturing a rotating electrical machine

Abstract

The first outer flange (51a) includes: a first introduction groove portion (51in) formed along the axial direction for introducing the coil wire of the wound coil (7); a first lead-out groove portion (51out) formed along the axial direction for leading out the coil wire (70) after the wound coil (7) to the radially outer side of the stator core (11); and a plurality of guides (G1 to G4) forming a plurality of groove portions (M1 to M3) for respectively holding a plurality of jumper wires (70J) connecting the coils (7) of different tooth portions (11b), extending in the circumferential direction and arranged in the axial direction.

Description

Technical Field

[0001] The present application relates to a stator of a rotating electric machine, a rotating electric machine, a method for manufacturing a stator of a rotating electric machine, and a method for manufacturing a rotating electric machine. Background Art

[0002] Conventionally, a stator for a rotating electric machine such as a motor or a generator is composed of a stator core and coils, and the coils are housed and installed in slots formed between teeth of the stator core. The coil wires forming the coils are insulated and coated, and the coils are electrically insulated from the stator core. However, in the stator of a rotating electric machine, in order to ensure sufficient insulation between the coils and the stator core, an insulating portion is further provided at a portion where the stator core and the coils are in contact with each other.

[0003] As a conventional stator, a technique of simultaneously winding coil wires around three consecutive teeth has been proposed (for example, refer to Patent Document 1).

[0004] Prior Art Documents

[0005] Patent Documents

[0006] Patent Document 1: Japanese Patent Laid-Open No. 9-191588 Summary of the Invention

[0007] Problems to be Solved by the Invention

[0008] Generally, in the manufacture of a stator of a rotating electric machine, in order to ensure the quality of the product, it is important to prevent interference between jumper wires between coils and to equalize the coils.

[0009] In the stator described in Patent Document 1, three winding nozzles are used to simultaneously wind the coil wires around every three teeth of a stator core having six teeth. First, coils for three teeth are simultaneously formed, and jumper wires are formed between the teeth separated by sandwiching two teeth therebetween. Then, the coil wires are continuously wound around the next three teeth simultaneously.

[0010] In this document, in order to prevent interference caused by the crossing of the start wire of winding and the jumper wire, for example, when the start wire of winding is set on the upper side in the axial direction of the stator, the jumper wire is implemented via an insulating member on the lower side. When performing this continuous winding in a stator having nine teeth, two lead-out processes of the jumper wire are required. In order to arrange the start wire of winding and the end wire of winding on the upper side, the three teeth wound in the third time are wound with a number of turns of the coil being half a turn more or less than the normal number of turns, and there are problems such as generation of electrical problems such as pulsation or vibration of the rotating electric machine.

[0011] The present application discloses a technology for solving the above problems, and an object thereof is to provide a stator of a rotating electric machine, a rotating electric machine, a method for manufacturing a stator of a rotating electric machine, and a method for manufacturing a rotating electric machine, which can prevent interference of jumper wires of the stator and can reduce electrical problems such as pulsation or vibration.

[0012] Means for solving the problems

[0013] The stator of the rotating electric machine disclosed in the present application includes:

[0014] A stator core formed by combining a plurality of core portions into a ring shape, the core portion having a yoke portion and a tooth portion formed to protrude radially inward from a circumferential central portion of an inner circumferential surface of the yoke portion;

[0015] Coils formed by winding coil wires around the plurality of tooth portions respectively; and

[0016] An insulating portion disposed between the core portion and the coil, and insulating the stator core and the coil,

[0017] As the first bobbin of the insulating portion, it includes: a first tooth end face covering portion that covers an axial end face of a portion of the tooth portion where the coil is wound and installed; and a first outer flange that is connected to a radially outer end portion of the first tooth end face covering portion, covers an axial end face of the yoke portion, and protrudes upward in the axial direction.

[0018] The first outer flange includes: a first introduction groove portion formed along the axial direction and introducing the coil wire wound around the coil; a first export groove portion formed along the axial direction and exporting the coil wire after winding the coil to the radially outer side of the stator core; and a plurality of guides forming a plurality of groove portions respectively holding a plurality of jumper wires, extending in the circumferential direction and arranged in the axial direction, the plurality of jumper wires connecting coils of different tooth portions to each other.

[0019] In addition, the rotating electric machine disclosed in the present application includes:

[0020] The stator of the rotating electric machine; and

[0021] A rotor disposed opposite to the inside of the stator with a gap therebetween.

[0022] In addition, the method for manufacturing a stator of a rotating electric machine disclosed in the present application includes:

[0023] A winding process, in which the yoke portions of the plurality of core portions are deformed into a straight line shape during the winding process, and three coil wires are formed into coils on three consecutive tooth portions respectively using three winding nozzles; and

[0024] A nozzle moving process, in which the three winding nozzles are simultaneously moved by an amount corresponding to three teeth, so that the three jumper wires are held in the slot portions at different heights.

[0025] In addition, in the manufacturing method of the rotating electric machine disclosed in the present application, the rotor is disposed facing the inside of the stator manufactured by the manufacturing method of the stator of the rotating electric machine with a gap therebetween.

[0026] Advantages of the Invention

[0027] According to the stator of the rotating electric machine, the rotating electric machine, the manufacturing method of the stator of the rotating electric machine, and the manufacturing method of the rotating electric machine disclosed in the present application, it is possible to provide a stator of a rotating electric machine, a rotating electric machine, a manufacturing method of the stator of a rotating electric machine, and a manufacturing method of a rotating electric machine that can prevent interference of the jumper wires of the stator and reduce electrical problems such as pulsation or vibration. Description of the Drawings

[0028] Figure 1 is a cross-sectional view perpendicular to the axial direction of the rotating electric machine according to Embodiment 1.

[0029] Figure 2 is a cross-sectional view of the rotating electric machine according to Embodiment 1 taken along a plane passing through the axis of the rotating shaft.

[0030] Figure 3 is a rear view showing a state in which the stator of the rotating electric machine according to Embodiment 1 is cut and rotated into a straight line shape.

[0031] Figure 4 is Figure 3 a perspective view of the stator shown, and is a view capable of seeing Figure 3 the back side, that is, the inside of the stator.

[0032] Figure 5 is a view showing Figure 3 the structure of two kinds of iron core chip sets of the stator core constituting the stator shown.

[0033] Figure 6 is a perspective view showing the structure of the stator core according to Embodiment 1.

[0034] Figure 7 is a top view of the core portion according to Embodiment 1.

[0035] Figure 8 is a perspective view showing the structure of the first winding frame according to Embodiment 1.

[0036] Figure 9 It is a perspective view showing the structure of the fourth bobbin in Embodiment 1.

[0037] Figure 10 It is a perspective view showing a state where the first bobbin and the fourth bobbin are mounted on the iron core portion in Embodiment 1.

[0038] Figure 11 It is a view along Figure 10 the first iron core portion observed in the direction of arrow A.

[0039] Figure 12 It is a view along Figure 10 the first iron core portion observed in the direction of arrow B.

[0040] Figure 13A It is a view along Figure 10 the first iron core portion observed in the direction of arrow C.

[0041] Figure 13B It is a view along Figure 10 the first iron core portion observed in the direction of arrow D.

[0042] Figure 14 It is a perspective view of the second bobbin in Embodiment 1.

[0043] Figure 15 It is a view of the second iron core portion on which the second bobbin and the fourth bobbin are mounted in Embodiment 1, observed from the outside X1 in the radial direction X.

[0044] Figure 16 It is a perspective view of the third bobbin in Embodiment 1.

[0045] Figure 17 It is a view of the third iron core portion on which the third bobbin and the fourth bobbin are mounted in Embodiment 1, observed from the outside X1 in the radial direction X.

[0046] Figure 18 It is a flowchart showing the manufacturing process of the rotating electric machine in Embodiment 1.

[0047] Figure 19 It is a flowchart showing the manufacturing process of the coil in Embodiment 1.

[0048] Figure 20 It is a developed view of the stator in the coil forming process in Embodiment 1.

[0049] Figure 21 It is a view showing the operation of the winding nozzle of the winding machine in Embodiment 1.

[0050] Figure 22 It is a view showing the operations of the nozzles N1, N2, and N3 after the coils of the first iron core portion, the second iron core portion, and the third iron core portion in Embodiment 1 are formed.

[0051] Figure 23 It is a conceptual diagram showing another winding method of Embodiment 1.

[0052] Figure 24 It is a perspective view showing a state in which a first winding frame, a second winding frame, a third winding frame, a fourth winding frame 254, and a film portion are mounted on the stator core of Embodiment 2.

[0053] Figure 25 It is Figure 24 a perspective view of the disassembled components of

[0054] Figure 26 It is a perspective view showing the structure of the film portion of Embodiment 2.

[0055] Figure 27A It is a perspective view showing the structure of the first winding frame of Embodiment 2.

[0056] Figure 27B It is a perspective view of the first winding frame shown Figure 27A from the opposite side of the axial direction Y.

[0057] Figure 28 It is a perspective view showing the structure of the fourth winding frame of Embodiment 2.

[0058] Figure 29 It is a perspective view of the stator core of Embodiment 3.

[0059] Figure 30 It is an enlarged top view of the main part of the stator core of Embodiment 3.

[0060] Figure 31 It is a perspective view of the iron core portion of Embodiment 4.

[0061] Figure 32 It is a perspective view showing the state after winding of the stator of Embodiment 4. Detailed Embodiments

[0062] Embodiment 1.

[0063] Hereinafter, the stator of the rotating electric machine, the rotating electric machine, the manufacturing method of the stator of the rotating electric machine, and the manufacturing method of the rotating electric machine according to Embodiment 1 will be described with reference to the drawings.

[0064] Figure 1 It is a cross-sectional view of the rotating electric machine 100 perpendicular to the axial direction.

[0065] Figure 2 It is a cross-sectional view of the rotor 20 of the rotating electric machine 100 cut along a plane passing through the axis of the rotating shaft 21.

[0066] The rotating electric machine 100 includes: a cylindrical frame 101; brackets 103 that close the opening portions at both axial ends of the frame 101; a stator 10 fitted inside the frame 101; and a rotor 20 rotatably supported at the center of each of the two brackets 103 via a bearing (not shown), and disposed with its outer peripheral surface facing the inner peripheral surface of the stator 10. A gap 107 exists between the outer peripheral surface of the rotor 20 and the inner peripheral surface of the stator 10.

[0067] In addition, permanent magnets 105 are buried in a V shape in the rotor core 22 fixed to the outer periphery of the rotating shaft 21, but the permanent magnets may also be arranged in a linear shape or other shapes. In addition, the permanent magnets may not be buried but arranged in a manner of being pasted on the outer peripheral surface of the rotor core 22 and facing the inner peripheral surface of the stator 10.

[0068] In the following description, the directions of the stator 10 of the rotating electric machine 100 are respectively represented as the circumferential direction Z, the axial direction Y, the radial direction X, the outer side X1 of the radial direction X, and the inner side X2 of the radial direction X, based on the state where the yoke portions 11a of the plurality of core portions 60 are arranged in a ring shape and combined. Therefore, with respect to the stator 10, even when the yoke portions 11a of the respective core portions 60 of the stator 10 are rotated and deformed into a linear shape, or even when rotated and deformed into a reverse warped shape where the protruding directions of the respective tooth portions 11b are opposite, that is, the inner and outer sides of the ring-shaped stator 10 are reversed, the directions are shown and described in each figure based on the state where the yoke portions 11a of the stator 10 are arranged in a ring shape as the product state.

[0069] In addition, when not specifically stated as "up" or "down", the side of the plane perpendicular to the axial direction Y of the stator 10 and passing through the center of the stator 10 is set as "down", and the opposite side of the plane is set as "up". In addition, when comparing the height, the comparison is made based on the distance from the plane perpendicular to the axial direction Y of the stator 10 and passing through the center of the stator 10.

[0070] The stator 10 includes: a stator core 11A formed by combining a plurality of core portions 60 into a ring shape, the core portion 60 having a yoke portion 11a and a tooth portion 11b formed to protrude from the central portion in the circumferential direction Z of the inner peripheral surface of the yoke portion 11a toward the inner side X2 in the radial direction X; a coil 7 formed by winding coil wires around the plurality of tooth portions 11b; and an insulating portion disposed between each core portion 60 and the coil 7 to insulate the core portion 60 and the coil 7. The structure in which nine core portions 60 are connected and combined is the stator core 11A.

[0071] Figure 3This is a rear view showing the state in which the stator 10 of the originally ring-shaped rotating electric machine 100 is cut and deformed into a linear shape, and is a view of the stator 10 observed from the outer peripheral side.

[0072] In the following description, reference numerals 61 to 69 are assigned to the respective core portions 60, and the first core portion 61 to the ninth core portion 69 will be described.

[0073] Figure 4 Is Figure 3 A perspective view of the stator 10 shown, and is a view that can see Figure 3 The back side, that is, the inner side of the stator 10.

[0074] Figure 5 Is a view showing the constitution of Figure 3 A perspective view of the structure of the two types of iron core chip groups 11k1 and 11k2 that make up the stator core 11A of the stator 10 shown.

[0075] Figure 6 Is a view showing Figure 5 A perspective view of the structure of the stator core 11A formed by alternately laminating multiple sets of the two types of iron core chip groups 11k1 and 11k2 in the axial direction Y.

[0076] Figure 7 Is a top view of the core portion 60.

[0077] As Figure 3 , Figure 4 Shown, the stator 10 includes a stator core 11A composed of a plurality of core portions 60, a coil 7, a first winding frame 51, a second winding frame 52, a third winding frame 53 on the upper side of the paper surface as an insulating portion for insulating the stator core 11A from the coil 7, and a fourth winding frame 54 on the lower side of the paper surface. As Figure 6 Shown, the core portions 60 arranged in the circumferential direction Z are set as the first core portion 61, the second core portion 62, the third core portion 63, the fourth core portion 64, the fifth core portion 65, the sixth core portion 66, the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69 starting from the winding start side of the first coil wire 71. The first winding frame 51 is used for the first core portion 61, the fourth core portion 64, and the seventh core portion 67, that is, for the core portions 60 constituting the U phase. The second winding frame 52 is used for the second core portion 62, the fifth core portion 65, and the eighth core portion 68, that is, for the core portions 60 constituting the V phase. The third winding frame 53 is used for the third core portion 63, the sixth core portion 66, and the ninth core portion 69, that is, for the core portions 60 constituting the W phase, and different details will be described later.

[0078] The stator core 11A is formed by alternately laminating multiple sets Figure 6 Shown in the axial direction Y Figure 5It is formed by a plurality of iron chip groups 11k1 and 11k2 shown, and the plurality of iron chip groups 11k1 and 11k2 are formed by blanking a thin-walled magnetic steel plate in a die (not shown). Thus, each yoke portion 11a of the first core portion 61 to the ninth core portion 69 of the stator core 11A is formed by being connected by a connecting portion 111 provided at an end portion arranged in the circumferential direction Z. In Figure 6 the stator core 11A is composed of nine core portions, namely, the first core portion 61 to the ninth core portion 69, which are connected in a straight line by a connecting portion 111.

[0079] In this connecting portion 111, the yoke portions 11a of adjacent core portions 60 can rotate freely. Thus, the stator core 11A can be rotated into a straight shape or an anti-warped shape in which the directions in which the tooth portions 11b protrude in the radial direction X are opposite.

[0080] The stator coil is composed of three phases, namely, the U phase, the V phase, and the W phase, and has a star connection wiring structure in which different phases are arranged for each core portion 60 connected in the circumferential direction Z. And, the first core portion 61 winds the coil 7 of the U phase (U1), the second core portion 62 winds the coil 7 of the V phase (V1), the third core portion 63 winds the coil 7 of the W phase (W1), the fourth core portion 64 winds the coil 7 of the U phase (U2), the fifth core portion 65 winds the coil 7 of the V phase (V2), the sixth core portion 66 winds the coil 7 of the W phase (W2), the seventh core portion 67 winds the coil 7 of the U phase (U3), the eighth core portion 68 winds the coil 7 of the V phase (V3), and the ninth core portion 69 winds the coil 7 of the W phase (W3).

[0081] In addition, when the description of this order is not required, the first core portion 61 to the ninth core portion 69 are collectively referred to as the core portion 60 as described above. Further, a coil 7 and first winding frames 51, second winding frames 52, third winding frames 53, and fourth winding frames 54 on the upper side as insulating portions are respectively provided in each core portion 60. However, whether in the state where the coil 7, the first winding frames 51, second winding frames 52, third winding frames 53 on the upper side of the paper surface in Figure 4 and the fourth winding frame 54 on the lower side of the paper surface in Figure 4 or in the state where the coil 7, the first winding frames 51, second winding frames 52, third winding frames 53 on the upper side of the paper surface in Figure 4 and the fourth winding frame 54 on the lower side of the paper surface in Figure 4 are not provided in each core portion 60, the first core portion 61 to the ninth core portion 69 are all described as such.

[0082] Next, based on Figure 7The structure of each part of the iron core portion 60 will be described. The surface along the axial direction Y on the outer side X1 of the radial direction X of the yoke portion 11a is defined as the yoke outer peripheral surface 113. On the yoke outer peripheral surface 113, a first concave portion 114 extending along the axial direction Y is formed at the central portion in the circumferential direction Z. The first concave portion 114 is used for positioning when the stator core 11A is installed on the winding machine for forming the coil 7. In addition, the tooth portion 11b is provided with shoe portions 11c protruding respectively in the circumferential direction Z from the tip at the inner side X2 of the radial direction X. The surface along the axial direction Y on the inner side X2 of the radial direction X of the yoke portion 11a is defined as the yoke inner peripheral surface 112.

[0083] The two surfaces along the axial direction Y at both ends in the circumferential direction Z of the tooth portion 11b are defined as the tooth portion side surfaces 121, and the surface along the axial direction Y at the tip at the inner side X2 of the radial direction X of the tooth portion 11b is defined as the tooth portion inner peripheral surface 122. The surface along the axial direction Y on the outer side X1 of the radial direction X of the shoe portion 11c is defined as the shoe portion outer peripheral surface 131. And the region surrounded by the yoke inner peripheral surface 112, the tooth portion side surfaces 121, and the shoe portion outer peripheral surface 131 becomes the slot 14 for winding the coil wire 70 to form the coil 7.

[0084] Next, the first bobbin 51, the second bobbin 52, the third bobbin 53 on the upper side of the paper surface and Figure 4 the fourth bobbin 54 on the lower side of the paper surface in Figure 4 which are the insulating portions will be described.

[0085] The first bobbin 51 is a bobbin installed on the first iron core portion 61, the fourth iron core portion 64, and the seventh iron core portion 67. The first bobbin 51 is installed on the tooth portion 11b and the yoke portion 11a.

[0086] The second bobbin 52 is a bobbin installed on the second iron core portion 62, the fifth iron core portion 65, and the eighth iron core portion 68. The second bobbin 52 is installed on the tooth portion 11b and the yoke portion 11a.

[0087] The third bobbin 53 is a bobbin installed on the third iron core portion 63, the sixth iron core portion 66, and the ninth iron core portion 69. The third bobbin 53 is installed on the tooth portion 11b and the yoke portion 11a.

[0088] Figure 8 is a perspective view showing the structure of the first bobbin 51 for the Figure 3 , 4 stator 10 shown.

[0089] The first bobbin 51 includes a tooth end face covering portion 51c (first tooth end face covering portion), an outer flange 51a (first outer flange), an inner flange 51b (first inner flange), and a slot side face covering portion 51d (first slot side face covering portion), which are formed integrally.

[0090] The end face of the axial direction Y of the portion of the winding installation coil 7 covered by the tooth end face covering portion 51c covers one end face of the tooth portion 11b. The outer flange 51a is connected to the end portion of the outer side X1 in the radial direction X of the tooth end face covering portion 51c, covers one end face of the yoke portion 11a in the axial direction Y, and protrudes upward in the axial direction Y.

[0091] The inner flange 51b is connected to the end portion of the inner side X2 in the radial direction X of the tooth end face covering portion 51c, covers the inner top end portion of one end face of the tooth portion 11b in the axial direction Y and one end face of the tile portion 11c in the axial direction Y, and protrudes upward in the axial direction Y.

[0092] The groove side face covering portion 51d covers the tooth side face 121 of the tooth portion 11b, the inner yoke surface 112 of the yoke portion 11a, and the outer tile surface 131 of the tile portion 11c. The groove side face covering portion 51d protrudes downward from the tooth end face covering portion 51c, the outer flange 51a, and the inner flange 51b. Actually, the groove side face covering portion 51d covers half of the axial direction Y of each face constituting the groove 14.

[0093] Figure 9 It is a perspective view showing the structure of the fourth winding bobbin 54 for the Figure 3 , Figure 4 stator 10 shown. The fourth winding bobbin 54 is an insulating member on the lower side of the paper surface of the stator 10 shown. Figure 3 shown.

[0094] The fourth winding bobbin 54 includes a tooth end face covering portion 54c (second tooth end face covering portion), an outer flange 54a (second outer flange), an inner flange 54b (second inner flange), and a groove side face covering portion 54d (second groove end face covering portion), which are formed integrally.

[0095] The tooth end face covering portion 54c covers the other end face of the axial direction Y of the portion of the winding installation coil 7 covered by the tooth portion 11b. The outer flange 54a is connected to the end portion of the outer side X1 in the radial direction X of the tooth end face covering portion 54c, covers the other end face of the yoke portion 11a in the axial direction Y, and protrudes upward in the axial direction Y.

[0096] The inner flange 54b is connected to the end portion of the inner side X2 in the radial direction X of the tooth end face covering portion 54c, covers the inner top end portion of the other end face of the tooth portion 11b in the axial direction Y and the other end face of the tile portion 11c in the axial direction Y, and protrudes upward in the axial direction Y.

[0097] The slot side covering portion 54d covers the tooth side surface 121 of the tooth portion 11b, the inner yoke peripheral surface 112 of the yoke portion 11a, and the outer tile peripheral surface 131 of the tile portion 11c. The slot side covering portion 54d protrudes downward from the tooth end covering portion 54c, the outer flange 54a, and the inner flange 54b. In fact, the slot side covering portion 54d covers half of the axial direction Y of each surface constituting the slot 14. Therefore, the slot side covering portion 51d of the first bobbin 51 and the slot side covering portion 54d of the fourth bobbin 54 can cover the entire surface of each side surface constituting the slot 14.

[0098] The first bobbin 51 and the fourth bobbin 54 are mounted on each core portion 60 so as to be fitted into the inner peripheral surface of the slot 14 from both axial sides. Also, the first bobbin 51 and the fourth bobbin 54 electrically insulate the coil 7 from each core portion 60. The first bobbin 51 and the fourth bobbin 54 are formed, for example, by injection molding of an insulating resin.

[0099] In addition, in the present Embodiment 1, an example is shown in which the axial lengths in the Y direction of the slot side covering portion 51d of the first bobbin 51 and the slot side covering portion 54d of the fourth bobbin 54 are formed to be substantially the same length, but it is not limited thereto, and the axial lengths in the Y direction of each can be appropriately changed as long as all side surfaces constituting the slot 14 can be covered.

[0100] Next, the structure of the rightmost first core portion 61 among the core portions 60 will be described with reference to the drawings. Figure 3 In the first core portion 61, the first bobbin 51 is mounted on the upper side of the paper surface, and the fourth bobbin 54 is mounted on the lower side of the paper surface.

[0101] Figure 10 is a perspective view showing a state in which the first bobbin 51 and the fourth bobbin 54 are mounted on the first core portion 61.

[0102] Figure 11 is a view of the first core portion 61 on which the first bobbin 51 and the fourth bobbin 54 are mounted as viewed from the outside X1 in the radial direction X, that is, a view of the first core portion 61 as viewed along the Figure 10 arrow A direction of Figure 10 .

[0103] Figure 12 is a view of the first core portion 61 on which the first bobbin 51 and the fourth bobbin 54 are mounted as viewed from the inside X2 in the radial direction X, that is, a view of the first core portion 61 as viewed along the Figure 10 arrow B direction of Figure 10 .

[0104] Figure 13A is a view of Figure 10The figure of the first iron core portion 61 equipped with the first winding frame 51 and the fourth winding frame 54 shown, that is, is the figure of observing the first iron core portion 61 along the Figure 10 arrow C direction of Figure 10 .

[0105] Figure 13B It is observed from the axial direction Y of Figure 10 the figure of the first iron core portion 61 equipped with the first winding frame 51 and the fourth winding frame 54 shown, that is, is the figure of observing the first iron core portion 61 along the Figure 10 arrow D direction of Figure 10 .

[0106] As Figure 10 , Figure 11 , Figure 13A shown, on the outer peripheral surface of the outer flange 51a at the outside X1 in the radial direction X, groove portions M extending in the circumferential direction Z are formed in multiple stages in the axial direction Y. Here, the groove portions M are formed in three stages of the first groove portion M1, the second groove portion M2, and the third groove portion M3 starting from the upper side far from the iron core portion 60 in the axial direction Y. That is, the first groove portion M1, the second groove portion M2, and the third groove portion M3 are formed in parallel with the circumferential direction Z and arranged in the axial direction Y with different heights. The first groove portion M1 is formed on the outer peripheral surface of the outer flange 51a between the first guide member G1 and the second guide member G2 provided along the circumferential direction Z. Similarly, the second groove portion M2 is formed on the outer peripheral surface of the outer flange 51a between the second guide member G2 and the third guide member G3 provided along the circumferential direction Z. The third groove portion M3 is formed on the outer peripheral surface of the outer flange 51a between the third guide member G3 and the fourth guide member G4 provided along the circumferential direction Z. Therefore, the first guide member G1 to the fourth guide member G4 are also formed in parallel with the circumferential direction Z and arranged in the axial direction Y with different heights. As Figure 11 shown, actually, the first guide member G1 is only provided near both sides in the circumferential direction Z of the later-described lead-out groove portion 51out (first lead-out groove portion) and one edge in the circumferential direction Z of the later-described lead-in groove portion 51in (first lead-in groove portion). Therefore, the portions where the first groove portion M1 is formed are only near both sides in the circumferential direction Z of the lead-out groove portion 51out and one edge in the circumferential direction Z of the lead-in groove portion 51in. The second groove portion M2 and the third groove portion M3 extend intermittently in the circumferential direction Z.

[0107] The first groove portion M1, the second groove portion M2, and the third groove portion M3 are used to hold a plurality of jumper wires 70J in parallel with the circumferential direction, and the plurality of jumper wires 70J connect the coils 7 of different tooth portions 11b to each other. The jumper wire 70J is a continuous wire between the coils 7. In the outer flange 51a, the lead-in groove portion 51in formed in the axial direction Y is an entrance for leading the coil wire 70 from the outside X1 in the radial direction X of the stator core 11A to the inside X2 in the radial direction X for winding the coil 7 around the tooth portion 11b.

[0108] In the outer flange 51a, the lead-out groove portion 51out formed along the axial direction Y is an outlet for leading out the coil wire 70 after forming the coil 7 by winding around the tooth portion 11b from the inner side X2 in the radial direction X of the stator core 11A to the outer side X1 in the radial direction X. The lead-out groove portion 51out is inclined such that the lower end portion of the side surface on the bridging direction side of the jumper wire 70J is located on the side of the bridging direction of the jumper wire 70J closer than the upper end portion.

[0109] And, as Figure 11 shown, the lead-out groove portion 51out formed in the outer flange 51a of the first bobbin 51 is set such that the height of the lower portion of the lead-out groove portion 51out is the same as the height of the upper surface of the second guide member G2 constituting the lower surface of the first groove portion M1 in a manner that the lower portion is connected to the first groove portion M1 provided on the left side in the circumferential direction Z of the lead-out groove portion 51out. That is, the lower portion of the lead-out groove portion 51out is connected flush with the upper surface of the second guide member G2.

[0110] Figure 14 is a perspective view of the second bobbin 52.

[0111] Figure 15 is a view of the second iron core portion 62 to which the second bobbin 52 and the fourth bobbin 54 are mounted as viewed from the outer side X1 in the radial direction X.

[0112] The basic structure of the second bobbin 52 is the same as that of the first bobbin 51, so only the different parts will be described.

[0113] First, on the outer flange 52a of the second bobbin 52, the second guide member G2 intermittently provided on the outer flange 51a of the first bobbin 51 is provided only at the central portion in the circumferential direction Z of the outer flange 52a and is not provided at both end portions in the circumferential direction Z. Therefore, there is no second guide member G2 on both sides in the circumferential direction Z of the lead-out groove portion 52out (second lead-out groove portion), and the first groove portion M1 and the second groove portion M2 of the first bobbin 51 are integrated. The same applies to the outer side in the circumferential direction Z of the lead-in groove portion 52in (second lead-in groove portion). Therefore, the groove portions capable of axially fixing the jumper wire 70J are the third groove portion M3 and the second groove portion M2 at the central portion in the circumferential direction Z.

[0114] And, as Figure 15 shown, the lead-out groove portion 52out formed in the outer flange 52a of the second bobbin 52 is set to have the same height as the upper surface of the third guide member G3. That is, the lower portion of the lead-out groove portion 52out is connected flush with the upper surface of the third guide member G3.

[0115] Figure 16 is a perspective view of the third bobbin 53.

[0116] Figure 17This is a view of the third iron core portion 63 equipped with the third winding frame 53 and the fourth winding frame 54 as observed from the outside X1 in the radial direction X.

[0117] The basic structure of the third winding frame 53 is the same as that of the first winding frame 51, so only the different parts will be described.

[0118] First, on the outer flange 53a of the third winding frame 53, the second guide member G2 and the third guide member G3 that are intermittently provided in the circumferential direction Z on the outer flange 51a of the first winding frame 51 are only provided at the central portion in the circumferential direction Z of the outer flange 52a, and these guide members are not provided at both end portions in the circumferential direction Z. Therefore, the second groove portion M2 and the third groove portion M3 do not exist on both sides in the circumferential direction Z of the lead-out groove portion 53out (the third lead-out groove portion), and the first groove portion M1, the second groove portion M2, and the third groove portion M3 of the first winding frame 51 are integrated. The same applies to the outside in the circumferential direction Z of the lead-in groove portion 53in (the third lead-in groove portion).

[0119] And, as Figure 17 shown, the lower part of the lead-out groove portion 53out formed on the outer flange 53a of the third winding frame 53 is set to be at the same height as the upper surface of the fourth guide member G4. That is, the lower part of the lead-out groove portion 53out is connected flush with the upper surface of the fourth guide member G4.

[0120] Next, Figure 3 and Figure 4 the coil wire 70 will be described. The coil wire 70 is the wire used to form the coil 7. Here, three coil wires 70, namely the first coil wire 71, the second coil wire 72, and the third coil wire 73, are used. Among the first coil wire 71, the second coil wire 72, and the third coil wire 73, the parts where the winding of the coil 7 starts are the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731.

[0121] When the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731 are moved from the outside X1 to the inside X2 in the radial direction X of the stator core 11A and used as power supply wires, their respective parts become the first power supply wire 713, the second power supply wire 723, and the third power supply wire 733.

[0122] Among the first coil wire 71, the second coil wire 72, and the third coil wire 73, the parts where the winding of the coil 7 ends and are led out are the first winding end wire 712, the second winding end wire 722, and the third winding end wire 732. The first winding end wire 712, the second winding end wire 722, and the third winding end wire 732 are wired to form the neutral point 700. In addition, when it is not necessary to describe using the names of the respective parts of the coil wire 70, they are collectively referred to as the coil wire 70 for description.

[0123] Next, use Figure 3 The jumper wire 70J will be described. The jumper wire 70J is formed as a part of the coil wire 70. The jumper wire 70J has a first jumper wire 70J1, a second jumper wire 70J2, a third jumper wire 70J3, a fourth jumper wire 70J4, a fifth jumper wire 70J5, and a sixth jumper wire 70J6. The first jumper wire 70J1 connects the coil 7 of the first iron core portion 61 to the coil 7 of the fourth iron core portion 64 that is separated by three iron core portions in the circumferential direction Z. The second jumper wire 70J2 connects the coil 7 of the second iron core portion 62 to the coil 7 of the fifth iron core portion 65 that is separated by three iron core portions in the circumferential direction Z. The third jumper wire 70J3 connects the coil 7 of the third iron core portion 63 to the coil 7 of the sixth iron core portion 66 that is separated by three iron core portions in the circumferential direction Z.

[0124] The fourth jumper wire 70J4 connects the coil 7 of the fourth iron core portion 64 to the coil 7 of the seventh iron core portion 67 that is separated by three iron core portions in the circumferential direction Z. The fifth jumper wire 70J5 connects the coil 7 of the fifth iron core portion 65 to the coil 7 of the eighth iron core portion 68 that is separated by three iron core portions in the circumferential direction Z. The sixth jumper wire 70J6 connects the coil 7 of the sixth iron core portion 66 to the coil 7 of the ninth iron core portion 69 that is separated by three iron core portions in the circumferential direction Z.

[0125] In addition, when it is not necessary to distinguish between the first jumper wire 70J1 to the sixth jumper wire 70J6 for description, they are collectively referred to as the jumper wire 70J for description.

[0126] Next, the manufacturing process of the rotating electrical machine 100 will be described.

[0127] Figure 18 is a flowchart showing the manufacturing process of the rotating electrical machine 100.

[0128] Figure 19 is a flowchart showing the manufacturing process of the coil 7.

[0129] Figure 20 is a developed view of the stator 10 in the coil forming process. It is a rear view showing the state where the stator 10 is rotated (deformed) into a linear shape, and is a view of the stator 10 observed from the outer peripheral side.

[0130] Figure 21 is a view showing the operation of the winding nozzle of the winding machine.

[0131] First, while alternately blanking out two types of iron core chip groups 11k1 and 11k2 from the magnetic steel sheet, a plurality of groups are stacked in the axial direction Y respectively, and adjacent iron core portions 60 are connected by the connecting portion 111 of the yoke portion 11a to form the stator core 11A (ST1: stator core manufacturing process).

[0132] Next, in the slots 14 on both circumferential Z sides of the first iron core portion 61, the fourth iron core portion 64, and the seventh iron core portion 67, the groove side covering portion 51d of the first bobbin 51 is inserted and installed from one end side in the axial direction Y, and the groove side covering portion 54d of the fourth bobbin 54 is inserted and installed from the other end side. Similarly, the second bobbin 52 and the fourth bobbin 54 are installed on the second iron core portion 62, the fifth iron core portion 65, and the eighth iron core portion 68, and the third bobbin 53 and the fourth bobbin 54 are installed on the third iron core portion 63, the sixth iron core portion 66, and the ninth iron core portion 69 (ST2: Bobbin installation process). In this way, three types of bobbins are installed on one end side of the nine iron core portions 60, and the same fourth bobbin 54 is installed on the other end side.

[0133] Next, the coil forming process (ST3) for forming the coil 7 is described using Figure 19 , Figure 20 , Figure 21 , Figure 11 , Figure 15 and Figure 17 .

[0134] First, the first coil wire 71 is introduced from the outer side X1 to the inner side X2 in the radial direction X using the introduction groove portion 51in of the first iron core portion 61. At this time, simultaneously, the second coil wire 72 and the third coil wire 73 are also introduced from the outer side X1 to the inner side X2 in the radial direction X using the introduction groove portions 52in and 53in of the second iron core portion 62 and the third iron core portion 63 respectively ( Figure 19 , ST31: Introduction process).

[0135] And, as Figure 21 shows, using three first winding nozzles N1, second winding nozzles N2, and third winding nozzles N3 of a winding machine (details not shown), the first coil wire 71, the second coil wire 72, and the third coil wire 73 are simultaneously wound around the tooth portions 11b of the first iron core portion 61, the second iron core portion 62, and the third iron core portion 63 as indicated by the arrows N11, N21, and N31 ( Figure 19 , ST32: Winding process).

[0136] Figure 22 is a diagram showing the operations of the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 after the formation of the coil 7 in the first iron core portion 61, the second iron core portion 62, and the third iron core portion 63.

[0137] As described above, after coils 7 are formed on the tooth portions 11b of the first iron core portion 61, the second iron core portion 62, and the third iron core portion 63 respectively, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are held in the respective lead-out groove portions 51out, 52out, 53out of the first iron core portion 61, the second iron core portion 62, and the third iron core portion 63 in a manner that prevents slack, and are led out from the inner side X2 to the outer side X1 in the radial direction X (refer to Figure 20 ). And, in order to perform the next winding process (step ST33 - No), while the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 respectively discharge the first coil wire 71, the second coil wire 72, and the third coil wire 73 in the direction of arrow E, the first winding nozzle N1 is moved by the amount of 3 teeth to the position of the fourth iron core portion 64, the second winding nozzle N2 is moved by the amount of 3 teeth to the position of the fifth iron core portion 65, and the third winding nozzle N3 is moved by the amount of 3 teeth to the position of the sixth iron core portion 66 ( Figure 19 , ST34: Nozzle movement process).

[0138] At this time, the first jumper wire 70J1 that connects the coil 7 of the first iron core portion 61 and the coil 7 of the fourth iron core portion 64 is held at the bottom of the lead-out groove portion 51out that is inclined in such a manner that the lower end portion on the side of the jumper direction is located on the jumper direction side of the upper end portion, and is held in the Figure 11 , Figure 20 first groove portion M1 provided on the left side in the circumferential direction of the lead-out groove portion 51out of the first iron core portion 61, and then is held in the first groove portion M1 of the second iron core portion 62 connected in the circumferential direction Z, and then is wound along the upper surface of the second guide member G2 and the lower surface of the first guide member G1 of the third iron core portion 63 connected in the circumferential direction Z, and then is held in the Figure 11 and Figure 20 first groove portion M1 provided on the right side in the circumferential direction of the lead-in groove portion 51in of the fourth iron core portion 64, and is introduced from the outer side X1 to the inner side X2 in the radial direction X of the fourth iron core portion 64 through the lead-in groove portion 51in.

[0139] In addition, the second jumper wire 70J2 that connects the coil 7 of the second iron core portion 62 and the coil 7 of the fifth iron core portion 65 is led along the bottom of the lead-out groove portion 52out that is inclined in such a manner that the lower end portion on the side of the jumper direction is located on the jumper direction side of the upper end portion Figure 15The upper surface of the third guide member G3 of the second iron core portion 62 shown is held in the second groove portion M2 of the third iron core portion 63 connected in the circumferential direction Z, and further held in the second groove portion M2 of the fourth iron core portion 64 connected in the circumferential direction Z. Then, it is along the upper surface of the third guide member G3 of the fifth iron core portion 65 connected in the circumferential direction Z, and is introduced from the outer side X1 to the inner side X2 in the radial direction X of the fifth iron core portion 65 through the introduction groove portion 52in.

[0140] Similarly, the third jumper wire 70J3 connecting the coil 7 of the third iron core portion 63 and the coil 7 of the sixth iron core portion 66 is from the bottom of the lead-out groove portion 53out inclined in such a manner that the lower end portion on the side of the jumper direction is located at a position closer to the jumper direction side than the upper end portion, along Figure 17 the upper surface of the fourth guide member G4 of the third iron core portion 63 shown, held in the third groove portion M3 of the fourth iron core portion 64 connected in the circumferential direction Z, and further held in the third groove portion M3 of the fifth iron core portion 65 connected in the circumferential direction Z. Then, it is along the upper surface of the fourth guide member G4 of the sixth iron core portion 66 connected in the circumferential direction Z, and is introduced from the outer side X1 to the inner side X2 in the radial direction X of the sixth iron core portion 66 through the introduction groove portion 53in.

[0141] And, similarly to the first iron core portion 61 to the third iron core portion 63, using the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are simultaneously wound around the tooth portions 11b of the fourth iron core portion 64, the fifth iron core portion 65, and the sixth iron core portion 66 as shown by the arrows N11, N21, and N31.

[0142] In this way, after the coils 7 are formed on the tooth portions 11b of the fourth iron core portion 64, the fifth iron core portion 65, and the sixth iron core portion 66 respectively, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are held in the lead-out groove portions 51out of the fourth iron core portion 64, the fifth iron core portion 65, and the sixth iron core portion 66 in a manner to prevent slack, and are led out from the inner side X2 to the outer side X1 in the radial direction X (refer to Figure 20 ). And, in order to perform the next winding process, while the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 respectively release the first coil wire 71, the second coil wire 72, and the third coil wire 73 in the direction of the arrow E, the first winding nozzle N1 is moved to the position of the seventh iron core portion 67, the second winding nozzle N2 is moved to the position of the eighth iron core portion 68, and the third winding nozzle N3 is moved to the position of the ninth iron core portion 69.

[0143] At this time, the fourth jumper wire 70J4 that connects the coil 7 of the fourth iron core portion 64 and the coil 7 of the seventh iron core portion 67 is held at the fourth iron core portion 64 from the bottom of the lead-out groove portion 51out that is inclined such that the lower end portion of the side surface on the jumper direction side is located on the jumper direction side of the upper end portion. Figure 11 , Figure 20 in the first groove portion M1 provided on the left side in the circumferential direction of the lead-out groove portion 51out, and then held in the first groove portion M1 of the fifth iron core portion 65 connected in the circumferential direction Z. Then, it is wound along the upper surface of the second guide member G2 and the lower surface of the first guide member G1 of the sixth iron core portion 66 connected in the circumferential direction Z, and then held at the seventh iron core portion 67 connected in the circumferential direction Z. Figure 11 and Figure 20 in the first groove portion M1 provided on the right side in the circumferential direction of the lead-in groove portion 51in, and is introduced from the outer side X1 to the inner side X2 in the radial direction X of the seventh iron core portion 67 through the lead-in groove portion 51in.

[0144] In addition, the fifth jumper wire 70J5 that connects the coil 7 of the fifth iron core portion 65 and the coil 7 of the eighth iron core portion 68 is along the bottom of the lead-out groove portion 52out that is inclined such that the lower end portion of the side surface on the jumper direction side is located on the jumper direction side of the upper end portion. Figure 15 as shown in the upper surface of the third guide member G3 of the fifth iron core portion 65, held in the second groove portion M2 of the sixth iron core portion 66 connected in the circumferential direction Z, then held in the second groove portion M2 of the seventh iron core portion 67 connected in the circumferential direction Z, and then along the upper surface of the third guide member G3 of the eighth iron core portion 68 connected in the circumferential direction Z, and is introduced from the outer side X1 to the inner side X2 in the radial direction X of the eighth iron core portion 68 through the lead-in groove portion 52in.

[0145] Similarly, the sixth jumper wire 70J6 that connects the coil 7 of the sixth iron core portion 66 and the coil 7 of the ninth iron core portion 69 is along the bottom of the lead-out groove portion 53out that is inclined such that the lower end portion of the side surface on the jumper direction side is located on the jumper direction side of the upper end portion. Figure 17 as shown in the upper surface of the fourth guide member G4 of the sixth iron core portion 66, held in the third groove portion M3 of the seventh iron core portion 67 connected in the circumferential direction Z, then held in the third groove portion M3 of the eighth iron core portion 68 connected in the circumferential direction Z, and then along the upper surface of the fourth guide member G4 of the ninth iron core portion 69 connected in the circumferential direction Z, and is introduced from the outer side X1 to the inner side X2 in the radial direction X of the ninth iron core portion 69 through the lead-in groove portion 53in.

[0146] Also, in the same manner as the fourth core portion 64 to the sixth core portion 66, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are simultaneously wound around the tooth portions 11b of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69, respectively, as indicated by arrows N11, N21, and N31, using the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3.

[0147] Also, after coils 7 are formed on the tooth portions 11b of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69, respectively, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are cut to form a first winding end wire 712, a second winding end wire 722, and a third winding end wire 732. Then, the first winding end wire 712, the second winding end wire 722, and the third winding end wire 732 are gathered and riveted to form a neutral point 700 of a star connection (see Figure 3 ). As a method of gathering, wiring processes such as riveting, brazing, or soldering based on terminals can also be used ( Figure 19 , ST33 - Yes, ST35: Wiring, Wiring Process).

[0148] In this way, the lower part of the lead - out groove portion 51out of the first winding frame 51 is connected flush with the upper surface of the second guide member G2, the lower part of the lead - out groove portion 52out of the second winding frame 52 is connected flush with the upper surface of the third guide member G3, and the lower part of the lead - out groove portion 53out of the third winding frame 53 is connected flush with the upper surface of the fourth guide member G4. Moreover, the respective side surfaces of the lead - out groove portions 51out, 52out, 53out on the side of the bridging direction of the jumper wire 70J are inclined such that the lower end portion is located on the side of the bridging direction of the jumper wire 70J closer than the upper end portion. Therefore, in fact, only by moving the nozzle, each jumper wire 70J is fixed to the lower part of the lead - out groove portions 51out to 53out, and at the same time, the jumper wires 70J constituting each phase are held in the first groove portion M1 to the third groove portion M3 located at different heights in the axial direction.

[0149] As Figure 3As shown, the first coil wire 71 formed in this way is a continuous wire without being cut midway, and becomes the first winding start wire 711, the coil 7 of the first iron core portion 61, the first jumper wire 70J1, the coil 7 of the fourth iron core portion 64, the fourth jumper wire 70J4, the coil 7 of the seventh iron core portion 67, and the first winding end wire 712. Similarly, the second coil wire 72 is a continuous wire without being cut midway, and becomes the second winding start wire 721, the coil 7 of the second iron core portion 62, the second jumper wire 70J2, the coil 7 of the fifth iron core portion 65, the fifth jumper wire 70J5, the coil 7 of the eighth iron core portion 68, and the second winding end wire 722. Similarly, the third coil wire 73 is a continuous wire without being cut midway, and becomes the third winding start wire 731, the coil 7 of the third iron core portion 63, the third jumper wire 70J3, the coil 7 of the sixth iron core portion 66, the sixth jumper wire 70J6, the coil 7 of the ninth iron core portion 69, and the third winding end wire 732.

[0150] Next, a process of using the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731 as power supply wires is performed. These three first winding start wires 711, second winding start wires 721, and third winding start wires 731 need to be arranged inside X2 in the radial direction X of the stator 10 when forming the stator 10 into a circular ring shape. However, in the state where the winding of the coil 7 is completed, as Figure 3 shown by the solid line, the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731 are located on the outer side X1 in the radial direction X of the stator 10.

[0151] In addition, even when all the coils 7 are formed, the second slot portion M2 and the third slot portion M3 of the first iron core portion 61 and the third slot portion M3 of the second iron core portion 62 are not used for holding the jumper wire 70J.

[0152] Therefore, as Figure 1 shown by the dashed line, as Figure 3 shown by the dashed line, the first winding start wire 711, the second winding start wire 721, and the third winding start wire 731 are folded back, passed through the unused second slot portion M2 and third slot portion M3, and then through the notch K continuously opened in the circumferential direction Z of the introduction slot portion 51in of the first iron core portion 61 and arranged inside X2 in the radial direction X of the stator 10. The first power supply wire 713, the second power supply wire 723, and the third power supply wire 733 are covered with an insulating tube inside X2 in the radial direction X to maintain insulation and perform wiring processing ( Figure 19 , ST35: Wiring, wiring process).

[0153] Next, each iron core portion 60 is rotated and deformed into a circular ring shape, and the ends of the stator iron core 11A are fixed to each other by welding or the like to form the stator 10 ( Figure 18, ST4: Stator forming process). Next, the outer peripheral surface of the stator 10 is fixed to the inner peripheral surface of the frame 101 ( Figure 18 , ST5: Stator fixing process).

[0154] Next, the rotor 20 is rotatably supported by the bracket 103 through a bearing (not shown), and the rotor 20 is disposed opposite to the stator 10 with a gap therebetween ( Figure 18 , ST6: Rotor arranging process). The rotating electrical machine 100 is formed through these processes.

[0155] In the previous description, a method of forming the coil 7 by rotating a plurality of yoke portions 11a of the stator core 11A into a straight line and winding the coil wire 70 around the tooth portions 11b has been shown, but it is not limited thereto. As another method, a method of forming a coil in which a plurality of yoke portions 11a of the stator core 11A are rotated by a connecting portion into a reverse warped shape in which the direction in which the tooth portions protrude in the radial direction X is opposite to the product state will be described.

[0156] Figure 23 is a conceptual diagram showing another winding method. Only the winding machine is different, and the manufactured stator 10 is the same. The winding machine 400 has a hexagonal chuck mechanism 40. And the chuck mechanism 40 has chucks 41, 42, 43, 44, 45, 46.

[0157] At Figure 23 positions facing the chucks 41, 42, 43, first winding nozzles NB1, second winding nozzles NB2, and third winding nozzles NB3 for winding the coil wire 70 are provided. The first winding nozzles NB1, second winding nozzles NB2, and third winding nozzles NB3 rotate around the rotation axes RB1, rotation axis RB2, and rotation axis RB3, and wind the coil wire 70 around the respective tooth portions 11b. However, Figure 23 different from the case of Figure 3 , the axial direction Y is reversed and shown. That is, Figure 23 is a view showing a state of the fourth winding frame 54 in which each iron core portion 60 can be seen. In addition, since the chuck mechanism 40 rotates in the direction of arrow R, the positions of the chucks 41 to 46 change.

[0158] First, as Figure 23 shown, a first iron core portion 61, a second iron core portion 62, and a third iron core portion 63 are respectively fixed to the chuck 41, the chuck 42, and the chuck 43. Then, the first winding nozzles NB1, second winding nozzles NB2, and third winding nozzles NB3 are rotated around the rotation axes RB1, RB2, RB3, and the coil wire 70 is wound around the respective tooth portions 11b to form the coil 7.

[0159] Then, after the winding process of the first coil is completed, by moving the first winding nozzle NB1, the second winding nozzle NB2, and the third winding nozzle NB3 back and forth and up and down, and rotating the chuck mechanism 40, the jumper wire 70 is bridged between the predetermined core portions 60 in the same manner as described above.

[0160] At this time, the chuck mechanism 40 rotates three times at 60° intervals. That is, the rotation at 60° intervals is repeated three times until Figure 23 the fourth core portion 64 shown comes to the position where the first core portion 61 was fixed in the first coil winding process (moving the amount of three core portions 60). At this time, all the other core portions 60 also move simultaneously (core portion moving process instead of nozzle moving process). In addition, since the core portions 60 are discharged in sequence from the position of the chuck 46 shown in Figure 23 , the stator core 11A is not fixed to the chuck mechanism 40 at the position of the chuck 45 shown in Figure 23 .

[0161] According to this method, it is possible to ensure a relatively wide space between the tooth portions 11b adjacent to each other in the circumferential direction Z, and wind the coil wire 70 around the tooth portions 11b to form the coil 7. That is, as shown in Figure 23 , it is possible to always wind the first winding nozzle NB1, the second winding nozzle NB2, and the third winding nozzle NB3 with their rotation axes facing the tooth portion 11b side. Therefore, the coil wire 70 can be wound around the tooth portion 11b at high speed, and the cycle time for winding the coil wire 70 can be shortened.

[0162] In addition, the method for manufacturing the stator of the rotating electric machine shown in the first embodiment can also be carried out in the same manner in the following embodiments, so its description is appropriately omitted.

[0163] In addition, in the first embodiment, three types of winding frames, namely the first winding frame 51, the second winding frame 52, and the third winding frame 53, are used on one end side of each core portion 60, but only the first winding frame 51 may be used.

[0164] In addition, in the first embodiment, an example in which the insulating portion is composed of a plurality of members is shown, but the insulating portion may also be integrally formed with each core portion 60. For example, an insulating portion in the shape of combining the first winding frame 51 and the fourth winding frame 54 may be integrally resin-molded on each core portion 60.

[0165] In addition, even if a stator core without the rib portion 11c is used, as long as there is a winding frame on which the coil 7 can be formed by an insulator.

[0166] The stator of the rotating electric machine according to the first embodiment configured as described above includes:

[0167] A stator core, which is formed by combining a plurality of core portions into a ring shape. Each core portion has a yoke portion and a tooth portion formed to project radially inward from a circumferential central portion of an inner circumferential surface of the yoke portion;

[0168] A coil, which is formed by winding coil wires around a plurality of the tooth portions respectively; and

[0169] An insulating portion, which is disposed between the core portion and the coil and insulates the stator core from the coil,

[0170] As the first bobbin of the insulating portion, it includes: a first tooth end face covering portion, which covers an axial end face of a portion of the tooth portion where the coil is wound and installed; and a first outer flange, which is connected to a radially outer end portion of the first tooth end face covering portion, covers an axial end face of the yoke portion and projects upward in the axial direction,

[0171] The first outer flange includes: a first introduction groove portion, which is formed in the axial direction and introduces the coil wire wound around the coil; a first export groove portion, which is formed in the axial direction and exports the coil wire after winding the coil to the radially outer side of the stator core; and a plurality of guide members, which form a plurality of groove portions respectively holding a plurality of jumper wires, extend in the circumferential direction and are arranged in the axial direction, and the plurality of jumper wires connect the coils of different tooth portions to each other,

[0172] Therefore, interference of the jumper wires of the stator can be prevented, the number of turns of the coils of the teeth can be made the same, and the directions of the winding start wire and the winding end wire can be made the same, and a stator of a rotating electric machine that can reduce electrical problems such as pulsation or vibration can be provided. In addition, the wiring members can be reduced, and the manufacturing time can be shortened to improve productivity.

[0173] In addition, since the plurality of groove portions are formed parallel to the circumferential direction, interference of the plurality of jumper wires extending in the circumferential direction and arranged in the axial direction can be prevented.

[0174] In addition, since it includes: the first bobbin installed on the tooth portion and the yoke portion of the core portion constituting the U phase;

[0175] The second bobbin as the insulating portion installed on the tooth portion and the yoke portion of the core portion constituting the V phase; and

[0176] The third bobbin as the insulating portion installed on the tooth portion and the yoke portion of the core portion constituting the W phase,

[0177] The second winding bobbin includes: a second inlet groove portion that is formed axially and guides the coil wire around which the coil is wound; a second outlet groove portion that is formed axially and guides the coil wire after the coil is wound to the radially outer side of the stator core; and a plurality of guides that form a plurality of groove portions that respectively hold a plurality of jumper wires, extend circumferentially, and are arranged axially, and the plurality of jumper wires connect the coils of different tooth portions to each other.

[0178] The third winding bobbin includes: a third inlet groove portion that is formed axially and guides the coil wire around which the coil is wound; a third outlet groove portion that is formed axially and guides the coil wire after the coil is formed to the radially outer side of the stator core; and a plurality of guides that form a plurality of groove portions that respectively hold a plurality of jumper wires, extend circumferentially, and are arranged axially, and the plurality of jumper wires connect the coils of different tooth portions to each other.

[0179] The axial heights of the lower portions of the first outlet groove portion, the second outlet groove portion, and the third outlet groove portion are all different.

[0180] The axial positions of the lower portions of the first outlet groove portion, the second outlet groove portion, and the third outlet groove portion increase in the order of the third outlet groove portion, the second outlet groove portion, and the first outlet groove portion.

[0181] The lower portions of the first outlet groove portion, the second outlet groove portion, and the third outlet groove portion are connected flush with the upper surface of any one of the guides.

[0182] Therefore, it is possible to smoothly guide, hold, and wind the three-phase jumper wires to groove portions having different heights axially. In addition, for all the first winding bobbin, the second winding bobbin, and the third winding bobbin, the U-phase jumper wire is held in the first groove portion, the V-phase jumper wire is held in the second groove portion, and the W-phase jumper wire is held in the third groove portion, so the jumper wires of each phase do not interfere with each other.

[0183] In addition, since the respective side surfaces of the first outlet groove portion, the second outlet groove portion, and the third outlet groove portion on the side of the cross-connection direction of the jumper wire are inclined such that the lower end portion is located on the side of the cross-connection direction of the jumper wire closer than the upper end portion, it is possible to guide the coil wire along the side surface of the inclined inlet groove portion to the lower portion of the inlet groove portion and further guide and hold it on the upper surface of a predetermined guide that is connected flush with the inlet groove portion only by moving the winding nozzle circumferentially.

[0184] In addition, since the lower positions in the axial directions of the first lead-in groove portion, the second lead-in groove portion, and the third lead-in groove portion are lower than the upper surface position of the guide member at the lowest position, interference between the winding start line and the jumper wire can be prevented.

[0185] In addition, since the yoke portions of the iron core portions are formed such that the yoke portions of the respective iron core portions can be deformed into a straight shape, a manufacturing method of a stator of a rotating electric machine having a winding process and a nozzle moving process can be used to wind coil wires around three continuously circumferential tooth portions simultaneously to form coils, and then lead the jumper wires of the respective phases without interference. In the winding process, the yoke portions of the stator core are deformed into a straight shape, and three coil wires are used to form coils at three continuously circumferential tooth portions by three winding nozzles. In the nozzle moving process, the three winding nozzles are simultaneously moved by an amount corresponding to three teeth so that the three jumper wires are held in the groove portions at different heights. As a result, the number of wiring members can be reduced, and the product cost can be suppressed.

[0186] In addition, since the yoke portions are formed such that they can be deformed into an anti-warped shape in which the radially protruding directions of the plurality of tooth portions are opposite, a manufacturing method of a stator of a rotating electric machine having a winding process and a nozzle moving process can be used to wind coil wires around three continuously circumferential tooth portions simultaneously to form coils, and then lead the jumper wires of the respective phases without interference. In the winding process, the yoke portions of the stator core are deformed into an anti-warped shape, and three coil wires are used to form coils at three continuously circumferential tooth portions by three winding nozzles. In the nozzle moving process, the iron core portions are moved by an amount corresponding to three iron core portions so that the three jumper wires are held in the groove portions at different heights. As a result, the number of wiring members can be reduced, and the product cost can be suppressed.

[0187] Embodiment 2.

[0188] Hereinafter, with reference to the drawings, the stator of the rotating electric machine, the rotating electric machine, the manufacturing method of the stator of the rotating electric machine, and the manufacturing method of the rotating electric machine according to Embodiment 2 will be described, centering on the parts different from those of Embodiment 1.

[0189] Figure 24 It is a perspective view showing a state in which a first winding frame 251, a second winding frame 252, a third winding frame 253, a fourth winding frame 254, and a film portion 230 are mounted on each iron core portion 60. It shows a state in which the yoke portions 11a of the respective iron core portions 60 are deformed into a straight shape and the first winding frame 251, the second winding frame 252, the third winding frame 253 on the upper side of the paper surface as an insulating portion, the fourth winding frame 254 on the lower side of the paper surface, and the film portion 230 are mounted in each groove 14.

[0190] Figure 25 It is to Figure 24Exploded perspective view of each component.

[0191] Figure 26 shows Figure 24 Perspective view showing the structure of the film portion 230 shown.

[0192] Figure 27A shows Figure 25 Perspective view showing the structure of the first bobbin 251 shown.

[0193] Figure 27B is viewed from the opposite side of the axial direction Y Figure 27A Perspective view of the first bobbin 251 shown.

[0194] Figure 28 Perspective view showing the structure of the fourth bobbin 254.

[0195] As shown in the respective figures, in the stator 10 of Embodiment 2, the structures of the first bobbin 251, the second bobbin 252, the third bobbin 253, and the fourth bobbin 254, which are insulating portions that insulate the plurality of core portions 60 from the coil 7, are different from those of the respective bobbins of Embodiment 1. In the present Embodiment 2, in order to insulate the plurality of core portions 60 from the coil 7, the insulating portion is composed of the above four types of bobbins and the film portion 230 that covers the wall surface of the slot.

[0196] The first bobbin 251, the second bobbin 252, the third bobbin 253, and the fourth bobbin 254 do not have the slot side covering portions that the respective bobbins in Embodiment 1 have. That is, as Figure 27A shown, the first bobbin 251 includes a tooth end covering portion 251c, an outer flange 251a, and an inner flange 251b, which are formed integrally. The tooth end covering portion 251c covers one end surface in the axial direction Y of the portion of the tooth portion 11b where the coil 7 is wound and mounted. The outer flange 251a is connected to the end portion on the outer side X1 in the radial direction X of the tooth end covering portion 251c, covers one end surface in the axial direction Y of the yoke portion 11a, and protrudes upward in the axial direction Y.

[0197] The inner flange 251b is connected to the end portion on the inner side X2 in the radial direction X of the tooth end covering portion 251c, covers the inner top end portion of one end surface of the tooth portion 11b and one end surface of the tile portion 11c, and protrudes upward in the axial direction Y.

[0198] Regarding the structure of the bobbin described below, the first bobbin 251, the second bobbin 252, and the third bobbin 253 are all the same, and therefore the first bobbin 251 will be used for the description.

[0199] The first winding bobbin 251 is provided with claw portions bt1, bt2, and at1 for fixing the film portion 230 described later. Among the three claw portions, the claw portions bt1 and bt2 are provided on the outer sides X1 in the radial direction X at both ends in the circumferential direction Z of the inner flange 251b. The remaining claw portion at1 is provided on the side surface in the circumferential direction Z at the end portion on the outer flange 251a side of the tooth end face covering portion 251c, that is, on the side where the lead-out groove portion 251out is present. Each of the claw portions bt1, bt2, and at1 protrudes downward in the axial direction Y. In addition, no claw portion is provided in the portion on the side opposite to the side where the claw portion at1 is provided in the circumferential direction Z. Since the lead-in groove portion 251in for the coil wire 70 is provided on the outer side X1 in the radial direction X of this portion, interference with the lead-in wire is avoided.

[0200] As Figure 28 shown, the fourth winding bobbin 254 is provided with four claw portions bt3, bb4, at3, and at4. For the fourth winding bobbin 254, since interference with the lead-in wire will not occur, the claw portion at4 is provided in the portion corresponding to the portion omitted in the first winding bobbin 251.

[0201] In addition, as Figure 27B shown, a convex portion 251e protruding downward in the axial direction Y is provided on the lower surface of the first winding bobbin 251. In addition, as Figure 28 shown, a convex portion 254e protruding downward in the axial direction Y is provided on the lower surface of the fourth winding bobbin 254. The convex portion 251e and the convex portion 254e are used to position the respective first winding bobbin 251 and fourth winding bobbin 254 on the end faces of the iron core portion 60. The convex portion 251e is fitted into the second concave portion 11r provided on one end face of the iron core portion 60, and the convex portion 254e is fitted into the second concave portion 11r provided on the other end face of the iron core portion 60.

[0202] The film portion 230 is formed of a thin-walled and insulating film material. For example, a film material with a thickness of 0.125 mm can be considered. And a plurality of creases are imparted to this film material to form Figure 26a shape as shown. Through this crease, the film portion 230 is formed to cover the first yoke inner peripheral surface covering portion 231 on one side in the axial direction Y of the inner side X2 in the radial direction X of the yoke portion 11a of the first iron core portion 61, the first side surface covering portion 232 covering one side surface in the circumferential direction Z of the tooth portion 11b and the outer peripheral surface of one tile portion 11c, the continuous portion 233 that is wound around the inner side X2 in the radial direction X of the tooth portion 11b of the first iron core portion 61 and is continuous with the second side surface covering portion 232b covering the outer peripheral surface of the other tile portion 11c and the side surface of the other tooth portion 11b, the second side surface covering portion 232b, and the second yoke inner peripheral surface covering portion 231b that continuously covers the other yoke inner peripheral surface 112 of the first iron core portion 61 and one yoke inner peripheral surface 112 of the second iron core portion 62, and they are repeated to cover up to the ninth iron core portion 69.

[0203] In addition, since the film portion 230 is sandwiched and installed between each iron core portion 60 and the claw portions bt1, bt2, at1, bt1 - bt4 provided on the first bobbin 251, the second bobbin 252, the third bobbin 253, and the fourth bobbin 254, each iron core portion 60 and the coil 7 can be completely insulated. Further, the continuous portion 233 and the second yoke inner peripheral surface covering portion are cut off after the coil 7 is wound.

[0204] Other structures of the stator and the winding method of the stator of the rotating electric machine are the same as those in Embodiment 1.

[0205] According to the stator of the rotating electric machine, the rotating electric machine, the manufacturing method of the stator of the rotating electric machine, and the manufacturing method of the rotating electric machine according to Embodiment 2, the stator of the rotating electric machine includes:

[0206] A stator core formed by combining a plurality of iron core portions into a ring shape, and the iron core portion has a yoke portion and a tooth portion formed to protrude radially inward from the central portion in the circumferential direction of the inner peripheral surface of the yoke portion;

[0207] A coil formed by winding coil wires around the plurality of tooth portions respectively; and

[0208] An insulating portion disposed between the iron core portion and the coil to insulate the stator core and the coil,

[0209] The first bobbin as the insulating portion includes: a first tooth end surface covering portion that covers one end surface in the axial direction of the portion where the coil is wound and installed on the tooth portion; and a first outer flange connected to the radially outer end of the first tooth end surface covering portion, covering one end surface in the axial direction of the yoke portion and protruding upward in the axial direction.

[0210] The first outer flange includes: a first introduction groove portion that is formed axially and introduces the coil wire that winds the coil; a first lead-out groove portion that is formed axially and leads out the coil wire after winding the coil to the radially outer side of the stator core; and a plurality of guides that form a plurality of groove portions that respectively hold a plurality of jumper wires, extend circumferentially, and are arranged axially, and the plurality of jumper wires connect the coils of different tooth portions to each other.

[0211] Therefore, interference of the jumper wires of the stator can be prevented, the number of turns of the coils of the teeth can be made the same, and the directions of the winding start wire and the winding end wire can be made the same, and a stator of a rotating electric machine that can reduce electrical problems such as pulsation or vibration can be provided. In addition, the wiring members can be reduced, and the manufacturing time can be shortened to improve productivity.

[0212] In addition, since the plurality of groove portions are formed parallel to the circumferential direction, interference of the plurality of jumper wires that extend circumferentially and are arranged axially can be prevented.

[0213] In addition, since it includes: a first winding bobbin that is mounted on the tooth portion and the yoke portion of the iron core portion that constitutes the U phase;

[0214] a second winding bobbin as an insulating portion that is mounted on the tooth portion and the yoke portion of the iron core portion that constitutes the V phase; and

[0215] a third winding bobbin as an insulating portion that is mounted on the tooth portion and the yoke portion of the iron core portion that constitutes the W phase,

[0216] The second winding bobbin includes: a second introduction groove portion that is formed axially and introduces the coil wire that winds the coil; a second lead-out groove portion that is formed axially and leads out the coil wire after forming the coil to the radially outer side of the stator core; and a plurality of guides that form a plurality of groove portions that respectively hold a plurality of jumper wires, extend circumferentially, and are arranged axially, and the plurality of jumper wires connect the coils of different tooth portions to each other.

[0217] The third winding bobbin includes: a third introduction groove portion that is formed axially and introduces the coil wire that winds the coil; a third lead-out groove portion that is formed axially and leads out the coil wire after forming the coil to the radially outer side of the stator core; and a plurality of guides that form a plurality of groove portions that respectively hold a plurality of jumper wires, extend circumferentially, and are arranged axially, and the plurality of jumper wires connect the coils of different tooth portions to each other.

[0218] The axial heights of the lower parts of the first lead-out groove part, the second lead-out groove part, and the third lead-out groove part are all different.

[0219] The axial positions of the lower parts of the first lead-out groove part, the second lead-out groove part, and the third lead-out groove part become higher in the order of the third lead-out groove part, the second lead-out groove part, and the first lead-out groove part.

[0220] The lower parts of the first lead-out groove part, the second lead-out groove part, and the third lead-out groove part are connected flush with the upper surface of any one of the guide members.

[0221] Therefore, it is possible to smoothly guide, hold, and wind the three-phase jumper wires to the groove parts with different axial heights. In addition, for all the first winding frames, second winding frames, and third winding frames, the U-phase jumper wire is held in the first groove part, the V-phase jumper wire is held in the second groove part, and the W-phase jumper wire is held in the third groove part. Therefore, the jumper wires of each phase do not interfere with each other.

[0222] In addition, since the respective side surfaces on the jumper direction side of the jumper wires of the first lead-out groove part, the second lead-out groove part, and the third lead-out groove part are inclined such that the lower end portions are located on the jumper direction side of the jumper wires closer to the upper end portions, it is possible to guide the coil wires along the side surfaces of the inclined lead-in groove parts to the lower parts of the lead-in groove parts respectively only by moving the winding nozzle in the circumferential direction, and further guide and hold them in the predetermined groove parts from the upper surface of the predetermined guide member connected flush with the lead-in groove part.

[0223] In addition, since the axial lower positions of the first lead-in groove part, the second lead-in groove part, and the third lead-in groove part are lower than the position of the upper surface of the guide member located at the lowest position, it is possible to prevent the winding start wire from interfering with the jumper wire.

[0224] In addition, since the yoke parts of the iron core parts are formed such that the yoke parts of the respective iron core parts can be deformed into a straight shape, it is possible to use a manufacturing method of a stator of a rotating electric machine having a winding process and a nozzle moving process to wind the coil wires on three continuously circumferential tooth parts at the same time to form a coil, and then wind the jumper wires of each phase without interference. In the winding process, the yoke parts of the stator core are deformed into a straight shape, and three coil wires are formed into coils on three continuous tooth parts using three winding nozzles. In the nozzle moving process, the three winding nozzles are simultaneously moved by an amount corresponding to three teeth to hold the three jumper wires in the groove parts with different heights. Thereby, it is possible to reduce the wiring members and suppress the product cost.

[0225] In addition, since the yoke portion is formed to be deformable into a reverse warped shape in which the radially protruding directions of the plurality of tooth portions are opposite to each other, it is possible to use a manufacturing method of a stator of a rotating electric machine having a winding process and a nozzle moving process to wind coil wires around three circumferentially continuous tooth portions at the same time to form coils, and then lead out the jumper wires of each phase without interference. In the winding process, the yoke portion of the stator core is deformed into a reverse warped shape, and three coil wires are used to form coils on three continuous tooth portions respectively by three winding nozzles. In the nozzle moving process, the core portion is moved by the amount of three core portions so that the three jumper wires are held in the slot portions having different heights. Thereby, the wiring members can be reduced, and the product cost can be suppressed.

[0226] Embodiment 3.

[0227] Hereinafter, with reference to the drawings, the stator of the rotating electric machine, the rotating electric machine, the manufacturing method of the stator of the rotating electric machine, and the manufacturing method of the rotating electric machine according to Embodiment 3 will be described centering on the parts different from Embodiment 1.

[0228] The stator of the present embodiment is the same as the stator 10 of Embodiment 1 except for the structure of the stator core 311A for the stator.

[0229] Figure 29 It is a perspective view of the stator core 311A.

[0230] Figure 30 It is an enlarged top view of the main part of the stator core 311A.

[0231] The difference between the stator core 11A of Embodiment 1 and the stator core 311A of Embodiment 3 of the present invention is that adjacent core portions 60 constituting the stator core 11A of Embodiment 1 are connected to each other by a connecting portion 111 formed at the end of the circumferential direction Z of the yoke portion 11a and capable of rotating. In contrast, adjacent core portions 360 constituting the stator core 311A of Embodiment 3 of the present invention are connected to each other by a connecting portion 111B formed at the end of the circumferential direction Z of the yoke portion 311a and capable of bending.

[0232] The stator core 11A of Embodiment 1 is formed by alternately laminating two types of iron core chip groups 11k1 and 11k2 formed by punching thin magnetic steel sheets in the axial direction Y to form the connecting portion 111. However, in Embodiment 3 of the present invention, a plurality of one type of core plate 311k formed by punching thin magnetic steel sheets are laminated in the axial direction Y.

[0233] The iron core plates 311k are stacked such that the portions forming the yoke 311a are arranged linearly, i.e., the portions forming the teeth 311b are arranged in parallel, and the portions of adjacent yokes are not physically separated but are connected by thin walls. Therefore, by stacking multiple pieces of the same type of iron core plate 311k in the axial direction Y, a thin-walled connecting portion 111B can be formed between adjacent iron core portions 360.

[0234] In a state where multiple iron core plates 311k are stacked in the axial direction Y, the yokes 311a of the respective iron core portions 360 are maintained in a linearly arranged state. The stator of the present Embodiment 3 also includes the same insulating member as the insulating member used in Embodiment 1 or Embodiment 2.

[0235] After winding is completed around each tooth portion 311b, the connecting portion 111B is plastically deformed to bend such that the yokes 311a are arranged in a circular shape. At this time, the positional relationship between each yoke 311a and each tooth portion 311b is the same as the positional relationship between each yoke 11a and each tooth portion 11b in Embodiment 1.

[0236] The structure of the stator of the present embodiment other than the connecting portion of the stator core is also the same as the structure of the stator in Embodiment 1, and includes:

[0237] A stator core formed by combining a plurality of iron core portions into a ring shape, the iron core portion having a yoke and teeth formed to protrude radially inward from the circumferential center portion of the inner circumferential surface of the yoke;

[0238] A coil formed by winding coil wires around the plurality of teeth respectively; and

[0239] An insulating portion disposed between the iron core portion and the coil and insulating the stator core from the coil,

[0240] The first winding bobbin serving as the insulating portion includes: a first tooth end covering portion that covers an axial end surface of a portion of the tooth portion where the coil is wound and mounted; and a first outer flange that is connected to an end portion on the radially outer side of the first tooth end covering portion, covers an axial end surface of the yoke, and protrudes upward in the axial direction.

[0241] The first outer flange includes: a first lead-in groove portion formed in the axial direction and guiding the coil wire wound around the coil; a first lead-out groove portion formed in the axial direction and leading the coil wire after winding the coil to the radially outer side of the stator core; and a plurality of guides forming a plurality of groove portions respectively holding a plurality of jumper wires, extending in the circumferential direction and arranged in the axial direction, the plurality of jumper wires connecting the coils of different tooth portions to each other.

[0242] Therefore, it is possible to prevent interference of the jumper wires of the stator, make the number of turns of the coils of the teeth the same, and make the directions of the winding start wire and the winding end wire the same, and it is possible to provide a stator of a rotating electrical machine that can reduce electrical problems such as pulsation or vibration. In addition, it is possible to reduce the wiring members and shorten the manufacturing time to improve productivity.

[0243] In addition, since the plurality of slot portions are formed parallel to the circumferential direction, it is possible to prevent interference of the plurality of jumper wires extending in the circumferential direction and arranged in the axial direction.

[0244] In addition, since it includes: the first winding frame mounted on the tooth portion and the yoke portion of the iron core portion constituting the U phase;

[0245] the second winding frame as the insulating portion mounted on the tooth portion and the yoke portion of the iron core portion constituting the V phase; and

[0246] the third winding frame as the insulating portion mounted on the tooth portion and the yoke portion of the iron core portion constituting the W phase,

[0247] The second winding frame includes: a second lead-in groove portion formed in the axial direction and guiding the coil wire for winding the coil; a second lead-out groove portion formed in the axial direction and leading out the coil wire after winding the coil to the radially outer side of the stator core; and a plurality of guide members forming a plurality of slot portions respectively holding a plurality of jumper wires, extending in the circumferential direction and arranged in the axial direction, the plurality of jumper wires connecting the coils of different tooth portions to each other,

[0248] The third winding frame includes: a third lead-in groove portion formed in the axial direction and guiding the coil wire for winding the coil; a third lead-out groove portion formed in the axial direction and leading out the coil wire after forming the coil to the radially outer side of the stator core; and a plurality of guide members forming a plurality of slot portions respectively holding a plurality of jumper wires, extending in the circumferential direction and arranged in the axial direction, the plurality of jumper wires connecting the coils of different tooth portions to each other,

[0249] The axial heights of the lower portions of the first lead-out groove portion, the lower portion of the second lead-out groove portion, and the lower portion of the third lead-out groove portion are all different,

[0250] The axial positions of the lower portions of the first lead-out groove portion, the second lead-out groove portion, and the third lead-out groove portion become higher in the order of the third lead-out groove portion, the second lead-out groove portion, and the first lead-out groove portion,

[0251] The lower parts of the first lead-out groove part, the second lead-out groove part, and the third lead-out groove part are connected flush with the upper surface of any one of the guide members.

[0252] Therefore, it is possible to smoothly guide, hold, and wind the three-phase jumper wires to the groove parts with different axial heights. In addition, for all the first winding frames, the second winding frames, and the third winding frames, the U-phase jumper wire is held in the first groove part, the V-phase jumper wire is held in the second groove part, and the W-phase jumper wire is held in the third groove part. Therefore, the jumper wires of each phase do not interfere with each other.

[0253] In addition, since the respective side surfaces on the jumper direction side of the jumper wires in the first lead-out groove part, the second lead-out groove part, and the third lead-out groove part are inclined such that the lower ends are located on the jumper direction side of the jumper wires relative to the upper ends, by simply moving the winding nozzle in the circumferential direction, the coil wire can be guided along the side surfaces of the inclined lead-in groove parts to the lower parts of the lead-in groove parts respectively, and further guided and held in the predetermined groove parts from the upper surface of the predetermined guide member connected flush with the lead-in groove parts.

[0254] In addition, since the axial lower positions of the first lead-in groove part, the second lead-in groove part, and the third lead-in groove part are lower than the upper surface position of the guide member located at the lowest position, it is possible to prevent the winding start wire from interfering with the jumper wire.

[0255] In addition, since the yoke parts of the iron core part are formed so as to be able to hold the yoke parts of the respective iron core parts in a straight line, it is possible to use a manufacturing method of a stator of a rotating electric machine having a winding process, a nozzle moving process, and a process of deforming the thin-walled connecting parts of the stator core to form the yoke parts into a circular ring shape. The coil wire is wound around three continuously circumferential tooth parts at the same time to form a coil, and then the jumper wires of each phase are wound without interference. In the winding process, three coil wires are formed into coils on three continuously circumferential tooth parts using three winding nozzles. In the nozzle moving process, the three winding nozzles are simultaneously moved by the amount of three teeth so that the three jumper wires are held in the groove parts with different heights. Thus, the wiring members can be reduced, and the product cost can be suppressed. In addition, since each yoke part is held in a straight line by the rigidity of the thin-walled connecting part without using a jig, the fixing jig during winding can be simplified.

[0256] Embodiment 4.

[0257] Hereinafter, with reference to the drawings, the stator of the rotating electric machine, the rotating electric machine, the manufacturing method of the stator of the rotating electric machine, and the manufacturing method of the rotating electric machine according to Embodiment 4 will be described centering on the parts different from Embodiment 1.

[0258] The stator of this embodiment is the same as the stator 10 of Embodiment 1 except for the structure of the stator core used for the stator.

[0259] Figure 31 It is a perspective view of the core portion 460.

[0260] The core portion 460 has the same yoke portion 411a and tooth portion 411b as the core portion 60 of Embodiment 1.

[0261] Figure 32 It is a perspective view showing the state after winding of the stator 410.

[0262] The difference between the stator core 11A of Embodiment 1 and the stator core 411A of this Embodiment 4 is that adjacent core portions 60 constituting the stator core 11A of Embodiment 1 are connected to each other by a connecting portion 111 formed at the end of the circumferential direction Z of the yoke portion 11a and capable of rotating. In contrast, adjacent core portions 460 constituting the stator core 411A of this Embodiment 4 do not have a connecting portion and are independent of each other.

[0263] The core portion 460 is also formed by laminating a plurality of iron core sheets 411k formed by punching a thin magnetic steel sheet in the axial direction Y.

[0264] The stator core 11A of Embodiment 1 forms the connecting portion 111 by alternately laminating two types of iron core sheet groups 11k1 and 11k2 formed by punching a thin magnetic steel sheet in the axial direction Y. However, in this Embodiment 4, the core portion 460 laminates a plurality of pieces of one type of iron core sheet 411k formed by punching a thin magnetic steel sheet in the axial direction Y. In this way, the stator 410 of this Embodiment 4 is composed of 9 independent core portions 460. The stator 410 of this Embodiment 4 also has the same insulating member as the insulating member used in Embodiment 1 or Embodiment 2.

[0265] In order to wind each core portion 460, the core portion fixing jig 80 is arranged and holds all the core portions 460 in such a way that the yoke portions 411a are arranged in a straight line, and the same winding as in Embodiment 1 is continuously performed. After that, the core portion fixing jig 80 is removed, and the core portions 460 are combined in such a way that the yoke portions 411a of each core portion 460 form a circular ring, and adjacent core portions 460 are fixed to each other, thereby forming the stator 410. The fixing method is welding, hot press fitting, etc.

[0266] The structure of the stator of this embodiment except that the stator core does not have a connecting portion is also the same as the structure of the stator of Embodiment 1, and includes:

[0267] A stator core, which is formed by combining a plurality of core portions into a ring shape. Each core portion has a yoke portion and a tooth portion formed to protrude radially inward from the circumferential central portion of the inner circumferential surface of the yoke portion;

[0268] A coil, which is formed by winding coil wires around the plurality of tooth portions respectively; and

[0269] An insulating portion, which is disposed between the core portion and the coil and insulates the stator core from the coil,

[0270] As the first winding frame of the insulating portion, it includes: a first tooth end face covering portion, which covers the axial end face of the portion of the tooth portion where the coil is wound and installed; and a first outer flange, which is connected to the radially outer end of the first tooth end face covering portion, covers the axial end face of the yoke portion and protrudes upward in the axial direction,

[0271] The first outer flange includes: a first guiding groove portion, which is formed along the axial direction and guides the coil wire wound around the coil; a first guiding-out groove portion, which is formed along the axial direction and guides the coil wire after winding the coil to the radially outer side of the stator core; and a plurality of guiding members, which form a plurality of groove portions respectively holding a plurality of jumper wires, extend in the circumferential direction and are arranged in the axial direction. The plurality of jumper wires connect the coils of different tooth portions to each other,

[0272] Therefore, interference of the jumper wires of the stator can be prevented, the number of turns of the coils of the teeth can be made the same, and the directions of the winding start wire and the winding end wire can be made the same, and a stator of a rotating electric machine capable of reducing electrical problems such as pulsation or vibration can be provided. In addition, the wiring members can be reduced, and the manufacturing time can be shortened to improve productivity.

[0273] In addition, since the plurality of groove portions are formed parallel to the circumferential direction, interference of the plurality of jumper wires extending in the circumferential direction and arranged in the axial direction can be prevented.

[0274] In addition, since it includes: the first winding frame installed on the tooth portion and the yoke portion of the core portion constituting the U phase;

[0275] The second winding frame as the insulating portion installed on the tooth portion and the yoke portion of the core portion constituting the V phase; and

[0276] The third winding frame as the insulating portion installed on the tooth portion and the yoke portion of the core portion constituting the W phase,

[0277] The second winding bobbin includes: a second lead-in groove portion that is formed axially and leads in the coil wire around which the coil is wound; a second lead-out groove portion that is formed axially and leads out the coil wire after the coil is wound to the radially outer side of the stator core; and a plurality of guides that form a plurality of groove portions for respectively holding a plurality of jumper wires, extending in the circumferential direction and arranged axially, the plurality of jumper wires connecting the coils of different tooth portions to each other.

[0278] The third winding bobbin includes: a third lead-in groove portion that is formed axially and leads in the coil wire around which the coil is wound; a third lead-out groove portion that is formed axially and leads out the coil wire after the coil is formed to the radially outer side of the stator core; and a plurality of guides that form a plurality of groove portions for respectively holding a plurality of jumper wires, extending in the circumferential direction and arranged axially, the plurality of jumper wires connecting the coils of different tooth portions to each other.

[0279] The axial heights of the lower portions of the first lead-out groove portion, the lower portion of the second lead-out groove portion, and the lower portion of the third lead-out groove portion are all different.

[0280] The axial positions of the lower portions of the first lead-out groove portion, the second lead-out groove portion, and the third lead-out groove portion increase in the order of the third lead-out groove portion, the second lead-out groove portion, and the first lead-out groove portion.

[0281] The lower portions of the first lead-out groove portion, the second lead-out groove portion, and the third lead-out groove portion are connected flush with the upper surface of any one of the guides.

[0282] Therefore, the three-phase jumper wires can be smoothly guided, held, and led around to groove portions with different axial heights. In addition, for all the first winding bobbin, the second winding bobbin, and the third winding bobbin, the U-phase jumper wire is held in the first groove portion, the V-phase jumper wire is held in the second groove portion, and the W-phase jumper wire is held in the third groove portion, so the jumper wires of each phase do not interfere with each other.

[0283] In addition, since the respective side surfaces on the jumper connection direction side of the first lead-out groove portion, the second lead-out groove portion, and the third lead-out groove portion are inclined such that the lower end portion is located on the jumper connection direction side of the upper end portion, only by moving the winding nozzle in the circumferential direction, the coil wire can be guided along the side surface of the inclined lead-in groove portion to the lower portion of the lead-in groove portion respectively, and further guided and held in a predetermined groove portion from the upper surface of the predetermined guide that is connected flush with the lead-in groove portion.

[0284] In addition, since the lower positions of the axial directions of the first introduction groove portion, the second introduction groove portion, and the third introduction groove portion are lower than the upper surface position of the guide member located at the lowest position, interference between the winding start line and the jumper wire can be prevented.

[0285] In addition, since the yoke portions of the iron core portions can hold the yoke portions of the respective iron core portions in a straight line, a manufacturing method of a stator of a rotating electric machine having a winding process and a nozzle moving process can be used to form coils by simultaneously winding coil wires around three circumferentially continuous tooth portions, and then lead the jumper wires of each phase without interference. In the winding process, three coil wires are used to form coils on three continuous tooth portions respectively by using three winding nozzles, and in the nozzle moving process, the three winding nozzles are simultaneously moved by an amount corresponding to three teeth to hold the three jumper wires in groove portions having different heights. Thereby, the wiring members can be reduced, and the product cost can be suppressed. In addition, since there is no connecting portion in the iron core portion, the mold of the iron core laminations constituting the iron core portion can be miniaturized.

[0286] In addition, the number of magnetic poles generated by the permanent magnet of the rotor is not limited to six poles, and may also be a number corresponding to the number of tooth portions of the stators 10 and 410. For example, in this case (UVWUVW···) where a jumper wire is required for a tooth portion straddling two teeth, when the number of tooth portions is set to 3·N (N is an integer of 2 or more), the number of magnetic poles may also be ((3±1)·N). In addition, in the winding method (UU’UVV’VWW’W…) where winding is performed continuously on three adjacent teeth, when winding the second tooth, winding in the reverse rotation direction from the first and third teeth is required. When the number of tooth portions is set to 9·N (N is an integer of 1 or more), the number of magnetic poles may also be ((9±1)·N). In addition, in the winding method (UU’VV’WW’···) where winding is performed continuously on two adjacent teeth, when the number of tooth portions is set to 6·N (N is an integer of 1 or more), the number of magnetic poles may also be ((6±1)·N).

[0287] When the number of magnetic poles is ((9±1)·N), when N is 2 or more, after winding continuously on three teeth, winding needs to be performed on the next tooth portion separated by six teeth, so a lead-out operation of a jumper wire separated by six teeth is required. When the number of magnetic poles is ((6±1)·N), when N is 2 or more, after winding continuously on two teeth, winding needs to be performed on the next tooth portion separated by four teeth, so a lead-out operation of a jumper wire separated by four teeth is required.

[0288] This application describes various exemplary embodiments and examples. However, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment and can be applied alone or in various combinations to the embodiments.

[0289] Therefore, countless variations that are not illustrated can be envisioned within the scope of the technology disclosed in this application. For example, this includes cases where at least one component is modified, added, or omitted, as well as cases where at least one component is extracted and combined with components of other embodiments.

[0290] Description of Reference Numerals

[0291] 100 Rotating electric machine, 10, 410 Stator, 11A, 311A, 411A Stator core, 11a, 311a, 411a Yoke portion, 11b, 311b, 411b Tooth portion, 11c Segment portion, 11k1, 11k2 Stack of iron core sheets, 311k Core plate, 411k Iron core sheet, 11r Second recess, 14 Slot, 20 Rotor, 21 Rotating shaft, 22 Rotor core, 51, 251 First winding frame, 51a, 52a, 53a, 54a, 251a Outer flange, 51b, 54b, 251b Inner flange, 51c, 54c, 251c Tooth end face covering portion, 51d, 54d Slot side face covering portion, 51in, 52in, 53in, 251in Lead-in slot portion, 51out, 52out, 53out, 251out Lead-out slot portion, 52, 252 Second winding frame, 53, 253 Third winding frame, 54, 254 Fourth winding frame, 60, 360, 460 Core portion, 61 First core portion, 62 Second core portion, 63 Third core portion, 64 Fourth core portion, 65 Fifth core portion, 66 Sixth core portion, 67 Seventh core portion, 68 Eighth core portion, 69 Ninth core portion, 70 Coil wire, 71 First coil wire, 72 Second coil wire, 73 Third coil wire, 70J Jumper wire, 70J1 First jumper wire, 70J2 Second jumper wire, 70J3 Third jumper wire, 70J4 Fourth jumper wire, 70J5 Fifth jumper wire, 70J6 Sixth jumper wire, G1 First guide, G2 Second guide, G3 Third guide, G4 Fourth guide, M1 First slot portion, M2 Second slot portion, M3 Third slot portion, N1 First winding nozzle, N2 Second winding nozzle, N3 Third winding nozzle, 80 Core portion fixing jig, 101 Frame, 103 Bracket, 105 Permanent magnet, 107 Air gap, 111, 111B Connecting portion, 112 Inner peripheral surface of yoke, 113 Outer peripheral surface of yoke, 114 First recess, 121 Side face of tooth portion, 122 Inner peripheral surface of tooth portion, 131 Outer peripheral surface of segment portion, 230 Film portion, 231 First inner peripheral surface covering portion of yoke, 231b Second inner peripheral surface covering portion of yoke, 232 First side face covering portion, 232b Second side face covering portion, 233 Continuous portion, 251e, 254e Protrusion, 400 Winding machine, 40 Chuck mechanism, 41~46 Chucks, 700 Neutral point, 711 First winding start line, 712 First winding end line, 713 First power supply line, 721 Second winding start line, 722 Second winding end line, 723 Second power supply line, 731 Third winding start line, 732 Third winding end line, 733 Third power supply line, NB1 First winding nozzle, NB2 Second winding nozzle, NB3 Third winding nozzle, RB1, RB2, RB3 Rotating shaft, at1, at4, bt1, bt3 Claw portions.

Claims

1. A stator of a rotating electric machine, the stator of the rotating electric machine comprising: A stator core formed by combining a plurality of core portions into a ring shape, the core portion having a yoke portion and a tooth portion formed to project radially inward from a circumferential central portion of an inner circumferential surface of the yoke portion; A coil formed by winding coil wires around the plurality of tooth portions respectively; And An insulating portion disposed between the core portion and the coil and insulating the stator core from the coil, wherein A first bobbin as the insulating portion includes: a first tooth end covering portion that covers an axial end surface of a portion of the tooth portion where the coil is wound and mounted; and a first flange that is connected to a radially outer end portion of the first tooth end covering portion, covers an axial end surface of the yoke portion, and projects upward in the axial direction, The first flange includes: a first lead-in groove portion formed in the axial direction and guiding the coil wire wound around the coil; a first lead-out groove portion formed in the axial direction and leading the coil wire after winding the coil to the radially outer side of the stator core; and a plurality of guides that form a plurality of groove portions respectively holding a plurality of jumper wires, extending in the circumferential direction and arranged in the axial direction, the plurality of jumper wires connecting the coils of different tooth portions to each other, On the opposite side of the first lead-in groove portion in the jumper direction, a first groove portion is formed as the groove portion holding the uppermost jumper wire, A notch is formed on the jumper direction side of the first lead-in groove portion, the notch being continuous in the circumferential direction of the first lead-in groove portion and opened from a position axially above the axial position of the first groove portion.

2. The stator of the rotating electric machine according to claim 1, Wherein The first groove portion does not exist on the jumper direction side of the first lead-in groove portion.

3. The stator of the rotating electric machine according to claim 1 or 2, Wherein The plurality of groove portions are formed parallel to the circumferential direction.

4. The stator of the rotating electric machine according to claim 1 or 2, Wherein The stator of the rotating electric machine further includes: The first bobbin mounted on the tooth portion and the yoke portion of the core portion constituting the U phase; A second bobbin as the insulating portion mounted on the tooth portion and the yoke portion of the core portion constituting the V phase; and A third bobbin as the insulating portion mounted on the tooth portion and the yoke portion of the core portion constituting the W phase, The second bobbin includes: a second lead-in groove portion formed in the axial direction and guiding the coil wire wound around the coil; a second lead-out groove portion formed in the axial direction and leading the coil wire after forming the coil to the radially outer side of the stator core; and a plurality of guides that form a plurality of groove portions respectively holding a plurality of jumper wires, extending in the circumferential direction and arranged in the axial direction, the plurality of jumper wires connecting the coils of different tooth portions to each other, The third winding bobbin includes: a third lead-in groove portion that is formed in the axial direction and leads in the coil wire around which the coil is wound; a third lead-out groove portion that is formed in the axial direction and leads out the coil wire after the coil is formed to the radially outer side of the stator core; and a plurality of guides that form a plurality of groove portions for respectively holding a plurality of jumper wires, extend in the circumferential direction, and are arranged in the axial direction, and the plurality of jumper wires connect the coils of different tooth portions to each other. The axial heights of the lower portions of the first lead-out groove portion, the lower portion of the second lead-out groove portion, and the lower portion of the third lead-out groove portion are all different. The axial positions of the lower portions of the first lead-out groove portion, the second lead-out groove portion, and the third lead-out groove portion increase in the order of the third lead-out groove portion, the second lead-out groove portion, and the first lead-out groove portion. The lower portions of the first lead-out groove portion, the second lead-out groove portion, and the third lead-out groove portion are connected flush with the upper surface of any one of the guides.

5. The stator of the rotating electric machine according to claim 4, wherein, The respective side surfaces of the circumferential ends on the jumper direction side of the first lead-out groove portion, the second lead-out groove portion, and the third lead-out groove portion are inclined with respect to the circumferential direction such that the axially lower end portion is located on the jumper direction side of the axially upper end portion when viewed radially. The coil wire is led out to the radially outer side of the stator core from the axially lower end portions of the respective side surfaces of the first lead-out groove portion, the second lead-out groove portion, and the third lead-out groove portion.

6. The stator of the rotating electric machine according to claim 4, wherein, One of the plurality of guides is located at a position higher than the axial lower portion of the first lead-out groove portion.

7. The stator of the rotating electric machine according to claim 4, wherein, The cutout of the first winding bobbin allows one end portion of the coil wire led into the first lead-in groove portion, the second lead-in groove portion, and the third lead-in groove portion to lead from the radially outer side to the radially inner side.

8. The stator of the rotating electric machine according to claim 4, wherein, The axial lower portions of the first lead-in groove portion, the second lead-in groove portion, and the third lead-in groove portion are located lower than the upper surface of the guide located at the lowest position.

9. The stator of the rotating electric machine according to claim 1 or 2, wherein, The yoke portion of the iron core portion has a connecting portion that can rotate the yoke portions of the plurality of iron core portions into a straight shape or into an anti-warped shape in which the radially protruding directions of the plurality of tooth portions are opposite.

10. The stator of the rotating electric machine according to claim 1 or 2, wherein, In the yoke portion, the circumferential ends of adjacent yoke portions are connected to each other by a thin wall.

11. A rotating electric machine, wherein, The rotating electric machine includes: The stator of the rotating electric machine according to any one of claims 1 to 10; and A rotor that is disposed opposite to the inside of the stator with a gap therebetween.

12. A manufacturing method of a stator of a rotating electrical machine, the manufacturing method of the stator of the rotating electrical machine being the manufacturing method of the stator of the rotating electrical machine according to claim 9 or 10, wherein, the manufacturing method of the stator of the rotating electrical machine has: a winding process, in which the yoke portions of the plurality of core portions are deformed into a straight shape in the winding process, and three coil wires are formed into coils at three consecutive tooth portions using three winding nozzles; and a nozzle moving process, in which the three winding nozzles are simultaneously moved by an amount corresponding to three teeth in the nozzle moving process so that the three jumper wires are held in the slot portions having different heights.

13. A manufacturing method of a stator of a rotating electrical machine, the manufacturing method of the stator of the rotating electrical machine being the manufacturing method of the stator of the rotating electrical machine according to claim 9 or 10, wherein, the manufacturing method of the stator of the rotating electrical machine has: a winding process, in which the yoke portions of the plurality of core portions are deformed into an anti-warped shape in the winding process, and three coil wires are formed into coils at three consecutive tooth portions using three winding nozzles; and a nozzle moving process, in which the core portions are moved by an amount corresponding to three core portions in the nozzle moving process so that the three jumper wires are held in the slot portions having different heights.

14. A manufacturing method of a rotating electrical machine, wherein, a rotor is disposed opposite to the inside of a stator manufactured by the manufacturing method of the stator of the rotating electrical machine according to claim 12 or 13 with a gap therebetween.

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