Rotating electrical machine

Abstract

A rotary electric machine (1) provides a multi-phase winding by a plurality of magnetic poles (21, 22, 23) arranged in a circumferential direction. A lap wire (54) extends between two single coils (51) that provide magnetic poles of the same phase. The lap wire (54) includes pole gap lap wires (58, 59) that extend between one end (20a) and the other end (20b) in an axial direction in a pole gap (PG) between circumferentially adjacent magnetic poles. The lap wire (54) includes an end lap wire (57) that extends in the circumferential direction at the other end (20b). Since the pole gap lap wires (58, 59) provide a portion of the lap wire (54), the length of the end lap wire (57) can be suppressed. As a result, the overlap of the end lap wire (57) of the different phase can be suppressed, thereby providing a compact rotary electric machine (1).

Description

Technical Field

[0001] The disclosure in this specification relates to a rotary electric motor. Background Technology

[0002] Patent Document 1 discloses the arrangement of the contact wires for the stator coils. The contact wires are arranged in a manner that overlaps the insulator layers of the stator. The contents of prior art documents are incorporated herein by reference as an explanation of the technical elements herein.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2007-236181 Summary of the Invention

[0006] Sometimes a shorter axial length is required for rotary motors. Further improvements to rotary motors are demanded from the perspectives mentioned above, or from other perspectives not mentioned.

[0007] One objective of this disclosure is to provide a small rotary motor.

[0008] Another objective of the disclosure is to provide a rotary motor that is easy to manufacture.

[0009] Another objective disclosed is to provide a rotary motor with a shorter axial length.

[0010] Rotating electric machines provide multiphase windings via multiple magnetic poles arranged circumferentially. The lap joint extending between two single coils providing the same phase magnetic poles of the rotating electric machine includes at least an inter-pole lap joint extending axially between one end and the other in the inter-pole gap between two circumferentially adjacent magnetic poles, and an end lap joint extending circumferentially at the other end.

[0011] According to the disclosed rotary electric motor, a portion of the lap wire extending between two single coils of the same phase includes an inter-pole lap wire. The inter-pole lap wire extends axially between one end and the other in the inter-pole gap between two circumferentially adjacent magnetic poles. Because the inter-pole lap wire provides a portion of the lap wire, the length of the end lap wire can be suppressed. As a result, the overlap of the end lap wires of out-of-phase motors can be suppressed, thereby providing a compact rotary electric motor.

[0012] This specification discloses multiple methods that employ different technical means to achieve various objectives. The technical solutions and the symbols enclosed in parentheses within them illustratively indicate their correspondence with portions of the embodiments described later, and are not intended to limit the scope of the technology. The objectives, features, and effects disclosed in this specification will become clearer with reference to the following detailed description and accompanying drawings. Attached Figure Description

[0013] Figure 1 This is a top view showing the rotary electric motor of the first embodiment.

[0014] Figure 2 yes Figure 1 A cross-sectional view at line II-II.

[0015] Figure 3 It is a cross-sectional view showing the connection part of the conductive component.

[0016] Figure 4 This is the stator winding diagram.

[0017] Figure 5 This is a top view showing the rotary electric motor of the second embodiment.

[0018] Figure 6 It is a three-dimensional diagram representing a rotating electric motor.

[0019] Figure 7 yes Figure 5 A sectional view at line VII-VII.

[0020] Figure 8 It is a three-dimensional diagram representing the stator.

[0021] Figure 9 This is a top view of the stator excluding the terminal block.

[0022] Figure 10 yes Figure 9 The side view of the arrow X.

[0023] Figure 11 yes Figure 9 Side view of arrow XI.

[0024] Figure 12 yes Figure 9 A sectional view at line XII-XII.

[0025] Figure 13 This is the stator winding diagram.

[0026] Figure 14 This is the winding diagram of the stator in the third embodiment.

[0027] Figure 15 This is the winding diagram of the stator in the fourth embodiment.

[0028] Figure 16 This is a perspective view of the stator according to the fifth embodiment.

[0029] Figure 17 This is the winding diagram of the stator in the fifth embodiment.

[0030] Figure 18This is a perspective view of the stator according to the sixth embodiment.

[0031] Figure 19 This is the winding diagram of the stator in the sixth embodiment.

[0032] Figure 20 This is a top view of the stator in the seventh embodiment.

[0033] Figure 21 This is a magnified top view of a portion of the stator.

[0034] Figure 22 This is a 3D diagram of the stator.

[0035] Figure 23 This is a magnified 3D view of a portion of the stator.

[0036] Figure 24 This is a sectional view of the stator.

[0037] Figure 25 This is a partially enlarged sectional view of the stator.

[0038] Figure 26 This is a partially enlarged sectional view of the stator.

[0039] Figure 27 This is a magnified top view of a portion of the stator.

[0040] Figure 28 This is a magnified 3D view of a portion of the stator.

[0041] Figure 29 This is a partially enlarged sectional view of the stator.

[0042] Figure 30 This is a partially enlarged top view of the stator in the eighth embodiment.

[0043] Figure 31 This is a magnified 3D view of a portion of the stator.

[0044] Figure 32 This is a partially enlarged sectional view of the stator.

[0045] Figure 33 This is a magnified top view of a portion of the stator.

[0046] Figure 34 This is a magnified 3D view of a portion of the stator.

[0047] Figure 35 This is a partially enlarged sectional view of the stator.

[0048] Figure 36 This is a partially enlarged top view of the stator in the ninth embodiment.

[0049] Figure 37 This is a magnified 3D view of a portion of the stator.

[0050] Figure 38 This is a partially enlarged sectional view of the stator.

[0051] Figure 39 This is a magnified top view of a portion of the stator.

[0052] Figure 40 This is a magnified 3D view of a portion of the stator.

[0053] Figure 41 This is a partially enlarged sectional view of the stator.

[0054] Figure 42 This is a partially enlarged top view of the stator according to the tenth embodiment.

[0055] Figure 43 This is a magnified 3D view of a portion of the stator.

[0056] Figure 44 This is a partially enlarged sectional view of the stator.

[0057] Figure 45 This is a partially enlarged top view of the stator in the eleventh embodiment.

[0058] Figure 46 This is a magnified 3D view of a portion of the stator.

[0059] Figure 47 This is a partially enlarged sectional view of the stator.

[0060] Figure 48 This is a partially enlarged top view of the stator in the twelfth embodiment.

[0061] Figure 49 This is a magnified 3D view of a portion of the stator.

[0062] Figure 50 This is a partially enlarged sectional view of the stator.

[0063] Figure 51 This is a top view showing the rotary electric motor according to the thirteenth embodiment. Detailed Implementation

[0064] Hereinafter, several embodiments will be described with reference to the accompanying drawings. In several embodiments, sometimes functionally and / or structurally corresponding and / or related parts are labeled with the same reference numeral, or reference numerals differing by more than one hundred positions. For corresponding and / or related parts, the description of other embodiments can be referred to.

[0065] First Implementation Method

[0066] Figure 1 and Figure 2 A rotary motor 1 is shown. In Figure 1 and Figure 2 In the diagram, the rotary motor 1 is shown with a slightly exaggerated radial orientation. Dashed lines indicate omitted or hidden lines. The rotary motor 1 is configured to rotate about the rotation axis AX. In the following description, the direction in which the rotation axis AX extends is called the axial direction, the circumference of the rotation axis AX is called the circumferential direction, and the radial direction centered on the rotation axis AX is called the radial direction.

[0067] exist Figure 1 In this configuration, a rotary motor 1 is connected to a rotating body 2. The rotating body 2 is configured to rotate about a rotation axis AX. The rotating body 2 serves as the input / output end of a rotating shaft or a transmission. The rotary motor 1 is housed within a housing 3. The housing 3 provides a mounting portion for the rotary motor 1.

[0068] The rotary electric machine 1 has a rotor 10 and a stator 20. The rotary electric machine 1 is an internal rotor type. The rotor 10 and the stator 20 are configured to form an air gap AG between them. The rotor 10 is located radially outward of the rotating body 2. The stator 20 is located radially outward of the rotor 10.

[0069] The rotor 10 has a rotor core 11 and a plurality of rotor poles 12. The rotor core 11 is a ring-shaped magnetic body. The rotor core 11 is connected to the rotating body 2 in the direction of rotation. The plurality of rotor poles 12 are provided by permanent magnets. The plurality of rotor poles 12 are arranged at equal intervals on the outer peripheral surface of the rotor core 11. As a result, the rotor 10 provides a permanent magnet rotor.

[0070] The stator 20 has a stator core 30, an insulator 40 mounted on the stator core 30, and a coil 50 mounted on the insulator 40. The stator 20 provides a plurality of stator poles. In this embodiment, the stator 20 provides eighteen stator poles. Stator poles 21, 22, and 23 are illustrated in the figure. The three stator poles 21, 22, and 23 each include a corresponding phase winding. Each stator pole has a pole tooth 31, a winding tube 41, and a single coil 51.

[0071] These multiple stator poles are divided into inter-pole gaps PG between two adjacent stator poles along the circumferential direction. The inter-pole gaps PG are referred to as both circumferential gaps and coil gaps. The multiple inter-pole gaps PG have a predetermined width that is equal to each other in the circumferential direction. The multiple inter-pole gaps PG are arranged at equal intervals along the circumferential direction. The inter-pole gaps PG have a size that allows for the configuration of the connection portion described later. The inter-pole gaps PG have a size that allows for the manufacturing operations for forming and configuring the connection portion. The size of the inter-pole gaps PG ensures the electrical insulation required for a rotating electric motor 1 between the connection portion described later and the coil 50.

[0072] The stator core 30 is, for example, a laminate of electromagnetic steel sheets. The stator core 30 has multiple pole teeth 31. The stator core 30 has a yoke 32. The yoke 32 is a ring-shaped magnetic body. The yoke 32 magnetically and mechanically connects the multiple pole teeth 31. The multiple pole teeth 31 are arranged at equal intervals on the inner circumferential surface of the yoke 32. The multiple pole teeth 31 and the ring-shaped yoke 32 are a continuous body.

[0073] The insulator 40 is made of electrically insulating resin. The insulator 40 is a molded resin body. The insulator 40 has multiple segments divided along its axial direction. The multiple segments are mounted on the stator core 30, thereby providing the insulator 40. The insulator 40 provides multiple winding tubes 41 for multiple pole teeth 31. One winding tube 41 is formed on one pole tooth 31. The winding tube 41 provides a spool for the coil 50. One winding tube 41 has a cylindrical portion 42 located radially outward of one pole tooth 31. One winding tube 41 provides a base end flange 43 at the base end of the pole tooth 31 and a front end flange 44 at the front end of the pole tooth 31. In other words, the cylindrical portion 42, the base end flange 43, and the front end flange 44 provide a winding tube 41.

[0074] Coil 50 provides a stator winding. Coil 50 provides a multiphase winding. In this embodiment, coil 50 provides a three-phase winding. An insulator 40 is disposed between coil 50 and stator core 30. Coil 50 is disposed radially outside a plurality of pole teeth 31. Coil 50 includes a plurality of single coils 51. A single coil 51 is disposed radially outside a pole tooth 31. The plurality of single coils 51 are formed by winding wire into a winding tube 41. The wire is a single wire made of copper or a copper alloy. The wire has flexibility to perform winding operations.

[0075] Stator pole 21 provides one phase winding of the three-phase winding, such as the U-phase winding. Stator pole 22 provides another phase winding of the three-phase winding, such as the V-phase winding. Stator pole 23 provides the remaining phase winding of the three-phase winding, such as the W-phase winding.

[0076] The stator 20 includes at least one conductive member 60. The stator 20 has multiple conductive members 60. The conductive members 60 are also referred to as busbars. The conductive members 60 have a different cross-sectional shape than the wire used to form the coil 50. The wire has a circular cross-section, while the conductive member 60 has a rectangular cross-section, either rectangular or square. The conductive member 60 is flexible. The flexibility of the conductive member 60 is lower than that of the wire. The conductive member 60 is stiffer and less prone to deformation than the wire. Therefore, the conductive member 60 is a conductive member used to electrically draw the wire used for the coil 50 from the single coil 51.

[0077] The plurality of conductive components 60 include power terminal components 61, 62, and 63 and a neutral point component 64. Power terminal components 61, 62, and 63 provide output or input terminals as three-phase windings. When the rotating electric machine 1 functions as a generator, power terminal components 61, 62, and 63 provide output terminals. When the rotating electric machine 1 functions as a motor, power terminal components 61, 62, and 63 provide input terminals. In this embodiment, power terminal components 61, 62, and 63 provide terminals for an electrical connector. The neutral point component 64 provides a neutral point connection as a three-phase winding.

[0078] A conductive member 60 has at least one connecting portion 65, 66, 67, 68, 69. The conductive member 60 is electrically and mechanically connected to at least one coil end 52 in one of the connecting portions 65, 66, 67, 68, 69. The coil end 52 is the end of the coil 50. The stator 20 has a plurality of coil ends 52. In the case where the coil 50 provides a three-phase winding, the stator 20, for example, has six coil ends 52.

[0079] Multiple power terminal components 61, 62, and 63 each have multiple connecting portions 65, 66, and 67, which are respectively disposed in three adjacent inter-pole gaps PG. Power terminal component 61 has a connecting portion 65 disposed in the first inter-pole gap PG. Power terminal component 62 has a connecting portion 66 disposed in the second inter-pole gap PG. Power terminal component 63 has a connecting portion 67 disposed in the third inter-pole gap PG. The first inter-pole gaps PG to the third inter-pole gaps PG are disposed adjacent to each other. The multiple connecting portions 65, 66, and 67 are respectively connected to a minimum number of coil terminals 52. The minimum unit is the number of parallel connections in the coil 50. In this embodiment, the minimum unit is 1. When the coil 50 is provided by two parallel coils, the minimum unit is 2.

[0080] The neutral point member 64 has multiple connecting portions 68 and 69 respectively disposed in a plurality of adjacent inter-electrode gaps PG. In the illustrated example, the neutral point member 64 has two connecting portions 68 and 69 respectively disposed in two adjacent inter-electrode gaps PG. The connecting portion 68 is connected to the minimum number of coil ends 52. The connecting portion 69 is connected to twice the number of coil ends 52 of the minimum number.

[0081] Multiple connecting portions 65, 66, 67, 68, and 69 are distributed in multiple adjacent inter-pole gaps PG. The multiple connecting portions 65, 66, 67, 68, and 69 are arranged in a one-to-one relationship in the multiple adjacent inter-pole gaps PG. In this embodiment, one connecting portion is arranged in one inter-pole gap PG. As a result, five connecting portions 65, 66, 67, 68, and 69 are arranged in five adjacent inter-pole gaps PG.

[0082] Connecting portions 65, 66, 67, 68, and 69 are located within the inter-electrode gap PG. Connecting portions 65, 66, 67, 68, and 69 are axially located within the inter-electrode gap PG. In some cases, a portion of the conductive member 60 extends axially from the inter-electrode gap PG. However, the entirety of connecting portions 65, 66, 67, 68, and 69 is disposed within the inter-electrode gap PG. Connecting portions 65, 66, 67, 68, and 69 are radially located within the inter-electrode gap PG. In some cases, a portion of the conductive member 60 extends radially from the inter-electrode gap PG. However, the entirety of connecting portions 65, 66, 67, 68, and 69 is disposed within the inter-electrode gap PG.

[0083] Multiple magnetic poles protrude radially from a circumferentially extending yoke 32. Multiple conductive members 60 have circumferential extensions 60a and radial extensions 60b. The circumferential extension 60a extends circumferentially along the yoke 32. The radial extension 60b extends radially from the circumferential extension, with its front end reaching the inter-pole gap PG. Connecting portions 65, 66, 67, 68, and 69 are formed at the front end of the radial extension 60b. For example, power terminal members 61 and 63 have circumferential extensions 60a and radial extensions 60b. Power terminal member 62 consists only of the radial extension 60b. Power terminal members 61, 62, and 63 have radial extensions extending toward the inter-pole gap PG for connecting portions and radial extensions extending for external connection to an external circuit. Neutral point member 64 has a circumferential extension 60a and two radial extensions 60b.

[0084] The stator 20 includes a terminal block 80. The terminal block 80 is made of electrically insulating resin. The terminal block 80 supports a plurality of conductive members 60. The terminal block 80 supports a plurality of power terminal members 61, 62, and 63. The plurality of power terminal members 61, 62, and 63 are embedded in the terminal block 80. The terminal block 80 has a body portion 81 and a connector portion 82. The body portion 81 extends arcuately along the stator 20. The connector portion 82 is located radially outward from the body portion 81 and extends radially outward. The connector portion 82 connects to a connector of an external circuit. The connector portion 82 provides connection between the power terminal members 61, 62, and 63 and the external circuit. The external circuit provides control circuitry for the rotating motor 1. The terminal block 80 is fixed to the stator 20. Specifically, the terminal block 80 is fixed to an insulator 40. The neutral point member 64 is supported by the insulator 40.

[0085] Figure 2 It shows Figure 1The cross-section at line II-II. The position of the power terminal member 61 among the multiple conductive members 60 is illustrated in the figure by way of their relative positional relationship with the multiple stator poles. The multiple conductive members 60 are arranged in the same manner as the one shown in the figure. A tie wire 54 is illustrated in the figure. Furthermore, the arrangement and number of tie wires 54 are merely illustrative. The arrangement and number of the multiple tie wires 54 are represented by the winding diagram described later.

[0086] Multiple magnetic poles 21, 22, and 23 include an insulator 40 serving as a winding tube 41. The axial height TH40 of the insulator 40 of the rotary motor 1 defines the height of the stator 20. In other words, the height TH40 of the insulator 40 defines the height of the rotary motor 1. Multiple conductive members 60 are disposed within the axial height TH40 of the insulator 40.

[0087] Coil 50 has a connecting wire 54 extending between a plurality of individual coils 51. The connecting wire 54 connects the plurality of individual coils 51 belonging to one phase winding by means of continuous wire. In other words, the connecting wire 54 connects the plurality of stator poles of the same phase by means of continuous wire. In the case of a three-phase winding, for example, there are a plurality of individual coils 51 belonging to the same phase such as 1-4-7... The connecting wire 54 is laid along the insulator 40. The connecting wire 54 passes at least partially radially outward of the base flange 43. The connecting wire 54 passes at least partially axially opposite to the axial end where the terminal block 80 is disposed.

[0088] The power terminal member 61 extends radially within the connector portion 82 for external connection. The power terminal member 61 extends circumferentially outward from the radially outer side of the base flange 43. The power terminal member 61 has a corner portion outward from the radially outer side of the first inter-electrode gap PG. The power terminal member 61 extends radially across the base flange 43 outward from the radially outer side of the first inter-electrode gap PG. The power terminal member 61 extends axially within the first inter-electrode gap PG. The connecting portion 65 is located within the first inter-electrode gap PG. The connecting portion 65 is axially located approximately at the center of the inter-electrode gap PG. The connecting portion 65 is radially located approximately at the center of the inter-electrode gap PG.

[0089] Terminal block 80 is located radially outward from the base flange 43. Terminal block 80 is disposed only at one of the axial ends of the rotary motor 1. Connector portion 82 is located radially outward from the base flange 43. Connector portion 82 protrudes to the outside of housing 3. Connector portion 82 opens radially outward from the outside of housing 3. Connector portion 82 forms an electrical connection via power terminal member 61 by accepting a connector for radially operating external circuitry from the radially outward.

[0090] Figure 3 yes Figure 2Enlarged view of the connection portion. Multiple conductive members 60, namely multiple power terminal members 61, 62, 63 and neutral point member 64, have similar shapes in the connection portions 65, 66, 67, 68, and 69 they provide. The conductive member 60 has a bent portion 60c and a joint portion 60d within its radial extension 60b. The bent portion 60c is crank-shaped, extending from the axial end face of the stator 20 along the surface of the insulator 40 and further towards the inter-electrode gap PG. The connection between the conductive member 60 and the coil end 52 is achieved by welding. The joint portion 60d, providing the connection achieved by welding, is provided by the conductive member 60 bent in a manner that wraps around the coil end 52. The conductive member 60 and the coil end 52 are electrically and mechanically connected by the welding process.

[0091] Figure 4 This is a winding diagram showing the circuit of coil 50 in rotary electric machine 1. Rotary electric machine 1 provides multiphase windings through multiple magnetic poles arranged circumferentially. Coil 50 is illustrated in the state viewed from the inside of stator 20. In the figure, the range of repeated slots S7-S15 is omitted. Coil 50 has multiple phase windings. Coil 50 has a U-phase winding 50u, a V-phase winding 50v, and a W-phase winding 50w. Coil 50 is wound in such a way that single coils 51 of U-phase winding 50u, single coils 51 of V-phase winding 50v, and single coils 51 of W-phase winding 50w are formed alternately. In this embodiment, eighteen magnetic poles are formed, and eighteen slots S1-S18 are formed between these multiple magnetic poles. Slots S1-S18 correspond to the inter-pole gap PG. Stator 20 has one end 20a and another end 20b in the axial direction. One end 20a is the end where a conductive member 60 is disposed. The other end 20b is the end used to configure the end connection wire 57.

[0092] The coil 50 is wound starting from a predetermined initial magnetic pole. After winding the single coil 51 of the initial magnetic pole, the coil 50 is transferred to the next magnetic pole of the same phase via the lap wire 54 and wound around that magnetic pole. Therefore, the lap wire 54 extends between the two single coils 51 providing the magnetic pole of the same phase. The lap wire 54 is also called a jumper wire. The coil 50 is wound sequentially with respect to multiple magnetic poles. In the following description, the initial magnetic pole is referred to as No. 1. Due to this winding process, the winding start portion 55 and winding end portion 56 of a single coil 51 of a magnetic pole can be determined. The lap wire 54 has an end lap wire 57, an inter-pole lap wire 58, and an inter-pole lap wire 59.

[0093] An end lap wire 57 is disposed at the other end 20b of the rotary motor 1, i.e., the stator 20. In other words, the end lap wire 57 is disposed at the end (the other end 20b) opposite to the end (one end 20a) where the conductive member 60 is disposed. The end lap wire 57 extends circumferentially at the other end 20b. The end lap wire 57 extends circumferentially over a length covering at least two single coils 51 and a slot.

[0094] An inter-pole bonding wire 58 is disposed between the winding end portion 56 and the end bonding wire 57. Since the inter-pole bonding wire 58 is located in front of the end bonding wire 57 during the winding process, it is also called the front bonding wire. The inter-pole bonding wire 58 connects the inter-pole gap PG between two single coils 51 of different phases separated in the circumferential direction between one end 20a and the other end 20b in the axial direction of the inter-pole gap PG between two adjacent magnetic poles in the circumferential direction.

[0095] Interpole connection wire 59 is disposed between end connection wire 57 and winding start portion 55. Since interpole connection wire 59 is located behind end connection wire 57 during the winding process, it is also called rear connection wire. Interpole connection wire 59 connects the interpole gap PG between two single coils 51 of different phases separated in the circumferential direction between one end 20a and the other end 20b in the axial direction. Interpole connection wire 59 extends between one end 20a and the other end 20b in the interpole gap PG between two adjacent magnetic poles in the circumferential direction.

[0096] In the illustrations and descriptions, the end overlap line 57, winding start section 55, winding end section 56, inter-pole overlap line 58, and inter-pole overlap line 59 are marked with identification symbols such as a, b, etc., for identification purposes. These identification symbols correspond to the repetition of the winding process. For example, the U-phase winding 50u is wound from the initial winding start section 55a and ends at the final winding end section 56f. The U-phase winding 50u will be described in detail below. The V-phase winding 50v and the W-phase winding 50w have the same shape.

[0097] The U-phase winding 50u begins winding around the first magnetic pole at the winding start point 55a and exits from the first magnetic pole at the winding end point 56a. In this embodiment, the single coil 51 is wound clockwise. Alternatively, the single coil 51 may be wound counterclockwise. In this embodiment, the winding process proceeds to the right from the first magnetic pole. Alternatively, the winding process may proceed to the left from the first magnetic pole.

[0098] The single coil 51 has several layers of wire radially stacked in the magnetic poles. The number of layers in the single coil 51 is 2 or more and 10 or less. In a preferred embodiment, the single coil 51 has 2 or more and 7 or less. In this embodiment, the single coil 51 has 2 or more and 5 or less. Specifically, the single coil 51 has 3 layers. This number of layers defines the height of the base flange 43 and the front flange 44. As a result, the number of layers defines the height TH40 of the insulator 40, which in turn defines the height of the rotary motor 1. The number of layers in the single coil 51 is 2 or more in both regular and random winding. The winding diagram schematically shows the single coil 51, omitting the number of turns and layers. The single coil 51 is disposed on the inner side of the stator 20, i.e., the inner circumferential surface.

[0099] The U-phase winding 50u extends from the winding end portion 56a to the end connection portion 57a ​​via the inter-pole connection 58a. The winding start portion 55a is located at one end 20a. The end connection portion 57a ​​is located at the other end 20b, opposite to the conductive member 60. Multiple conductive members 60 are concentrated at one end 20a along the axial direction of the stator 20, and multiple end connection portions 57 are concentrated at the other end 20b along the axial direction of the stator 20. This allows for efficient utilization of both ends of the stator 20.

[0100] The U-phase winding 50u is continuous by transferring from the winding end portion 56a to the inter-pole connection 58a. The inter-pole connection 58a extends from one end 20a to the other end 20b. The inter-pole connection 58a extends axially within the slot S2. The inter-pole connection 58a extends circumferentially within the slot S2. Therefore, the inter-pole connection 58a extends obliquely within the slot S2. The inter-pole connection 58a is disposed inside the stator 20. The inter-pole connection 58a is disposed within the inter-pole gap PG. The inter-pole connection 58a does not function completely as part of the single coil 51 in the first magnetic pole.

[0101] The U-phase winding 50u is continuous by transitioning from the inter-pole connection 58a to the end connection 57a. The end connection 57a ​​extends circumferentially. The end connection 57a ​​is configured to extend circumferentially along the stator 20. The end connection 57a ​​is positioned along the base flange 43. The end connection 57a ​​is located on the outside of the stator 20. At this time, the base flange 43 functions as a stop to hold the end connection 57a. Simultaneously, the circumferential end of the base flange 43 defines the boundary between the inter-pole connection 58a and the end connection 57a.

[0102] The U-phase winding 50u is continuous by transferring from the end connection 57a ​​to the inter-pole connection 59a. The inter-pole connection 59a extends from one end 20b to the other end 20a. The inter-pole connection 59a extends axially within the slot S4. The inter-pole connection 59a extends circumferentially within the slot S4. Therefore, the inter-pole connection 59a extends obliquely within the slot S4. The inter-pole connection 59a is disposed inside the stator 20. The inter-pole connection 59a does not function completely as part of the single coil 51 in the fourth magnetic pole.

[0103] The U-phase winding 50u is continuous by transferring from the inter-pole contact line 59a to the winding start section 55b. The U-phase winding 50u repeatedly follows a basic cycle sequentially through the winding start section 55, single coil 51, winding end section 56, inter-pole contact line 58, end contact line 57, and inter-pole contact line 59, reaching the final single coil. In the final single coil, the U-phase winding 50u is continuous by transferring from the inter-pole contact line 59e to the winding start section 55f. The U-phase winding 50u is wound around the 16th magnetic pole and ends at the winding end section 56f. The winding end section 56f is connected to the neutral point member 64.

[0104] The U-phase winding 50u provides magnetic poles 1, 4, 7, 10, 13, and 16. The V-phase winding 50v and W-phase winding 50w have the same shape as the U-phase winding 50u. Therefore, the V-phase winding 50v provides magnetic poles 2, 5, 8, 11, 14, and 17. The W-phase winding 50w provides magnetic poles 3, 6, 9, 12, 15, and 18.

[0105] Multiple phase windings 50u, 50v, and 50w provide multiple inter-pole connection wires 58 and 59 of two types. The above inter-pole connection wires 58 and 59 are configured such that (1) only one of them extends obliquely in the slot, (2) the two cross in the slot, or (3) neither of them is in the slot.

[0106] (1) In slot S2, only the inter-pole connection wire 58 of the U-phase winding 50u is provided. In slot S3, only the inter-pole connection wire 58 of the V-phase winding 50v is provided. In slot S17, only the inter-pole connection wire 59 of the V-phase winding 50v is provided. In slot S18, only the inter-pole connection wire 59 of the W-phase winding 50w is provided. In the above four slots at the beginning and end of winding, only one of the inter-pole connection wires 58 or 59 is provided in an oblique direction. The above slots S2, S3, S17, and S18 are also called two-end slots, and each is provided with one of the inter-pole connection wires 58 or 59.

[0107] (2) In slot S4, an inter-pole connection wire 58 for the W-phase winding 50w and an inter-pole connection wire 59 for the U-phase winding 50u are arranged. The two inter-pole connection wires 58 and 59 cross within slot S4, i.e., within the inter-pole gap PG. In slot S5, an inter-pole connection wire 58 for the U-phase winding 50u and an inter-pole connection wire 59 for the V-phase winding 50v are arranged. The two inter-pole connection wires 58 and 59 cross within slot S5, i.e., within the inter-pole gap PG. In slot S6, an inter-pole connection wire 58 for the V-phase winding 50v and an inter-pole connection wire 59 for the W-phase winding 50w are arranged. The two inter-pole connection wires 58 and 59 cross within slot S6, i.e., within the inter-pole gap PG. The cross configuration observed in the aforementioned slots S4, S5, and S6 can also be observed in slots S7, S8, S9, S10, S11, S12, S13, S14, S15, and S16, which contain two inter-pole bonding wires 58 and 59 with different phase windings, through repeated winding processes. The two inter-pole bonding wires 58 and 59 cross at the center of the inter-pole gap PG in the axial direction. The two inter-pole bonding wires 58 and 59 cross at the center of the inter-pole gap PG in the circumferential direction. These slots S4-S16 are also referred to as intermediate slots, and the inter-pole bonding wires 58 and 59 are configured in a cross configuration.

[0108] (3) Neither the inter-pole connection wire 58 nor the inter-pole connection wire 59 is configured in the groove S1. The groove S1 is also called the boundary groove, and no inter-pole connection wire is configured.

[0109] End overlap wires 57 are disposed at the other end 20b. End overlap wires 57 are disposed along the base flange 43. End overlap wires 57 are disposed radially outside the base flange 43. End overlap wires 57 are disposed overlapping each other radially and axially. In this embodiment, the out-of-phase end overlap wires 57 are stacked axially at the other end 20b. There are two or fewer end overlap wires 57 disposed at the other end 20b at all positions in the circumferential direction. In the figure, the symbols *1 and *2 indicate the number of end overlap wires 57 at that position. At the axial end of the stator 20 (the other end 20b), the plurality of end overlap wires 57 are configured to (1) extend only one, (2) extend two overlappingly, or (3) become zero.

[0110] (1) There is one end-connecting wire 57 positioned along the base flange 43 of magnetic pole No. 2. There is one end-connecting wire 57 positioned along the base flange 43 of magnetic pole No. 17. There is one end-connecting wire 57 located axially in slot S3. This is because the inter-pole connecting wire 58 of the V-phase winding 50V is arranged in slot S3. There is one end-connecting wire 57 located axially in slot S4. This is because two inter-pole connecting wires 58 and 59 are arranged in slot S4. There is one end-connecting wire 57 located axially in slot S5. This is because two inter-pole connecting wires 58 and 59 are arranged in slot S5. The presence of one end-connecting wire 57 observed at the end of slots S3, S4, and S5 is also repeated in slots S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, S16, and S17.

[0111] (2) There are two end-connecting wires 57 located along the base flange 43 of magnetic pole 3. There are two end-connecting wires 57 located along the base flange 43 of magnetic pole 4. There are two end-connecting wires 57 located along the base flange 43 of magnetic pole 5. The presence of multiple end-connecting wires 57 observed in the base flanges 43 of magnetic poles 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, and 16 is also repeated.

[0112] (3) There are no (0) end lap wires 57 located axially in the groove S1. There are no end lap wires 57 positioned along the base flange 43 of pole 1. There are no end lap wires 57 positioned along the base flange 43 of pole 18. This is because the boundary groove S1 and the other ends 20b of the poles at both ends do not require lap wires. There are no end lap wires 57 located axially in the groove S2. This is because the inter-pole lap wire 58, which functions as a lap wire, is disposed within the groove S2. There are no end lap wires 57 located axially in the groove S18. This is because the inter-pole lap wire 59, which functions as a lap wire, is disposed within the groove S18.

[0113] In this embodiment, the inter-pole ... The plurality of slots S1-S18 include multiple slots S2, S3, S17, and S18 configured with one inter-pole contact wire 58 or one inter-pole contact wire 59. The plurality of slots S1-S18 also include multiple slots S4, S5, S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, and S16 with two inter-pole contact wires 58 and 59 arranged alternately. The end contact wire 57 is disposed on the radial inner or outer surface of the stator 20, opposite to the surface where the single coil 51 is disposed. In other words, the magnetic pole includes a base flange 43, and the end contact wire 57 and the inter-pole contact wires 58 and 59 are arranged radially on both sides of the base flange 43 of the rotary motor 1.

[0114] The manufacturing method of the rotating electric machine includes the steps of assembling the rotor 10 and assembling the stator 20. The step of assembling the stator 20 includes the steps of assembling the stator core 30, installing the insulator 40 onto the stator core 30, winding the coil 50, and forming a plurality of connecting parts 65, 66, 67, 68, and 69. In the step of winding the coil 50, wire is wound onto the stator core 30 with the insulator 40 using a winding machine to form the coil 50. This step can be performed sequentially by a single winding nozzle or in parallel by multiple winding nozzles.

[0115] The winding process of coil 50 begins with winding the initial single coil 51 from one end 20a. This process is performed simultaneously with placing the end lap wire 57 at the other end 20b. In a repeated process, single coils 51 are wound starting from the other end 20b and continuing to be wound. Furthermore, in this process, single coils 51 are wound continuously while placing both the inter-pole lap wire 58 and the inter-pole lap wire 59 within the grooves. This process concludes with the winding of the final single coil 51 at one end 20a.

[0116] In the process of forming multiple connecting portions 65, 66, 67, 68, and 69, multiple coil ends 52 are connected to multiple conductive members 60. In this process, the conductive members 60 and the coil ends 52 are electrically connected. This process can be performed by placing the conductive members 60 in the inter-electrode gap PG, then placing the coil ends 52 in contact with the conductive members 60, and bending and welding the joint portion 60d to wrap around the coil ends 52. Alternatively, this process can be performed by placing the coil ends 52 outside the inter-electrode gap PG in contact with the conductive members 60, bending and welding the joint portion 60d to wrap around the coil ends 52, and then placing the conductive members 60 in the inter-electrode gap PG.

[0117] Furthermore, the manufacturing method of the rotary electric motor includes a step of fixing multiple conductive components 60. This step can be performed before or after the step of forming multiple connections. In this embodiment, multiple power terminal components 61, 62, and 63 are positioned and fixed at predetermined positions on the stator 20 by means of a terminal block 80.

[0118] According to the embodiments described above, by including at least one inter-pole connection wire 58 or inter-pole connection wire 59, the number of end connection wires 57 at the axial end of the slot (inter-pole gap PG) where the inter-pole connection wires 58 or 59 are disposed can be suppressed. This is because the end connection wires 57 to be disposed at the axial end of the slot (inter-pole gap PG) are provided by the inter-pole connection wires 58 and 59. In particular, by making the inter-pole connection wires 58 and 59 of two different phase windings cross within the slot (inter-pole gap PG), the number of end connection wires 57 at the axial end of the slot (inter-pole gap PG) where the inter-pole connection wires 58 and 59 are disposed can be suppressed to phase number - 2. In the case of a three-phase winding, the number of end connection wires 57 at the axial end of the slot (inter-pole gap PG) where the inter-pole connection wires 58 and 59 are cross-distributed can be suppressed to 1. As a result, a small rotary motor 1 can be provided.

[0119] According to the embodiments described above, the connecting portions 65, 66, 67, 68, and 69 for multiple coil ends 52 can be arranged in the inter-pole gap PG. Therefore, axial miniaturization of the connecting portions 65, 66, 67, 68, and 69 for the coil ends 52 can be achieved. According to this embodiment, the connecting portions 65, 66, 67, 68, and 69 can be easily manufactured. According to this embodiment, a rotary motor with a shorter axial length can be provided.

[0120] Second Implementation Method

[0121] This embodiment is a variation based on the previous embodiment. In the above embodiment, the rotary motor 1 includes a neutral point member 64 and an arc-shaped terminal block 80. Alternatively, in this embodiment, the rotary motor 1 includes a multi-terminal neutral point member 264 and an annular terminal block 280. In this embodiment, components corresponding to those in the above embodiment are labeled with the same symbols. The description of components indicated by the same symbols can be found in the description of the above embodiment. In this embodiment, the rotary motor 1 includes a 20-pole rotor 10 and a 15-pole stator 20.

[0122] like Figures 5 to 12 ,in particular Figure 9 As shown, the neutral point member 264 has three connection portions 68, 69, and 270. The neutral point member 264 provides three terminals for the three-phase winding. Connection portion 68 provides an electrical connection between the coil end of the first phase winding of the three-phase winding and the neutral point member 264. Connection portion 69 provides an electrical connection between the coil end of the second phase winding of the three-phase winding and the neutral point member 264. Connection portion 270 provides an electrical connection between the coil end of the third phase winding of the three-phase winding and the neutral point member 264.

[0123] Multiple connecting portions 65, 66, 67, 68, 69, and 270 are distributed in multiple adjacent inter-pole gaps PG. The multiple connecting portions 65, 66, 67, 68, 69, and 270 are arranged in a one-to-one relationship in the multiple adjacent inter-pole gaps PG. In this embodiment, one connecting portion is arranged in one inter-pole gap PG. As a result, six connecting portions 65, 66, 67, 68, 69, and 270 are arranged in six adjacent inter-pole gaps PG. The neutral point member 264 has a shape referred to as a comb-type or fork-type. The neutral point member 264 has an arc-shaped portion extending circumferentially along the yoke 32 of the stator core 30 and a radial portion extending radially inward from the arc-shaped portion as a connecting portion. The radial portions are arranged at equal intervals circumferentially.

[0124] In this embodiment, the plurality of conductive members 60 also have circumferential extensions 60a and radial extensions 60b. For example, power terminal members 61 and 63 have circumferential extensions 60a and radial extensions 60b. Power terminal member 62 is composed only of radial extensions 60b. Neutral point member 264 has a circumferential extension 60a and three radial extensions 60b.

[0125] In the above embodiment, terminal block 80 supports only the plurality of power terminal components 61, 62, and 63. Terminal block 80 does not support the neutral point component 64. Alternatively, terminal block 280 supports all of the plurality of conductive components 60. Terminal block 280 supports both the plurality of power terminal components 61, 62, and 63 and the neutral point component 264. These plurality of conductive components 60 are embedded in terminal block 280.

[0126] like Figures 5 to 12 ,in particular Figure 5 , Figure 6 , Figure 7 , Figure 8 As shown, the terminal block 280 is annular. The terminal block 280 extends circumferentially along the yoke 32. The terminal block 280 is positioned radially outward from the base flange 43. In this embodiment, the terminal block 280 also provides a body portion 281 and a connector portion 82. The body portion 281 is annular. The connector portion 82 is located as a portion of the annular body portion 281.

[0127] like Figure 10 , Figure 11 As shown, the insulator 40 has protrusions 245. The insulator 40 has multiple protrusions 245. The protrusions 245 further protrude radially outward from the radially outer side of the axial front end portion of the base end flange 43. The protrusions 245 serve as stops for positioning and holding multiple lap joints 54 along the base end flange 43. The arrangement and number of the multiple lap joints 54 are shown in the winding diagram described later.

[0128] exist Figure 13 In this configuration, the neutral point component 264 connects multiple phase windings 50u, 50v, and 50w. The coil 50 is the same as in the embodiment described above.

[0129] In this embodiment, the number of end taps 57 at the axial ends of the slots (inter-pole gap PG) where inter-pole taps 58 and inter-pole taps 59 are cross-arranged can also be reduced. As a result, a compact rotary motor 1 can be provided. In this embodiment, the connecting portions 65, 66, 67, 68, 69, and 270 for multiple coil ends 52 can also be arranged in the inter-pole gap PG. Therefore, axial miniaturization of the connecting portions 65, 66, 67, 68, 69, and 270 for multiple coil ends 52 can be achieved. According to this embodiment, the connecting portions 65, 66, 67, 68, 69, and 270 can be easily manufactured. According to this embodiment, a rotary motor with a shorter axial length can be provided.

[0130] Third Implementation Method

[0131] This embodiment is a variation based on the previous embodiment. In the above embodiment, the rotary motor 1 includes both the inter-pole connection wire 58 and the inter-pole connection wire 59. Alternatively, in this embodiment, the rotary motor 1 includes only the inter-pole connection wire 58.

[0132] exist Figure 14 In this embodiment, the rotary motor 1 includes a coil 350. The coil 350 has only inter-pole bonding wires 58 in multiple slots. As a result, the number of end bonding wires 57 at the axial ends of the slots where the inter-pole bonding wires 58 are arranged can be suppressed. The number of end bonding wires 57 is suppressed to two or less.

[0133] In this embodiment, the contact wire 54 consists only of an inter-pole contact wire 58 and an end contact wire 57 extending from the winding end portion 56 of one of the two single coils 51 of the same phase. In this embodiment, a small rotary motor 1 can also be provided.

[0134] Fourth Implementation Method

[0135] This embodiment is a variation based on the previous embodiment. In the above embodiment, the rotary motor 1 includes at least an inter-pole connection wire 58. Alternatively, in this embodiment, the rotary motor 1 includes only an inter-pole connection wire 59.

[0136] exist Figure 15 In this embodiment, the rotary motor 1 includes a coil 450. The coil 450 has only inter-pole bonding wires 59 in multiple slots. As a result, the number of end bonding wires 57 at the axial ends of the slots where the inter-pole bonding wires 59 are arranged can be suppressed. The number of end bonding wires 57 is suppressed to two or less.

[0137] In this embodiment, the contact wire 54 consists only of an inter-pole contact wire 59 and an end contact wire 57 extending from the winding start portion 55 of the other single coil 51 of the two single coils 51 in the same phase. In this embodiment, a small rotary motor 1 can also be provided.

[0138] Fifth Implementation Method

[0139] This embodiment is a variation based on the previous embodiment. In the above embodiment, the rotary motor 1 has an end connection wire 57 disposed radially outside the base flange 43. Furthermore, in this embodiment, the base flange 43 is provided with a plurality of connecting portions 548, 549 for distributing the end connection wire 57. In this embodiment, the stator 20 is provided with fifteen magnetic poles.

[0140] exist Figure 16In the figure, stator 20 has stator core 30, insulator 40, and coil 50. The figure shows end contact wire 57, inter-pole contact wire 58, and inter-pole contact wire 59 of stator 20. Additionally, to aid understanding and avoid overcomplicating the figure, coil 50 is schematically shown only partially with hidden lines (dashed lines). Insulator 40 has base flange 43 and front flange 44. Base flange 43 and front flange 44 define the extent of a single coil 51. Furthermore, base flange 43 has multiple connecting portions for defining the position of the wire in coil 50. The multiple connecting portions provide slit-like openings in the radial direction. The multiple connecting portions allow for the placement of wire. The multiple connecting portions are located at both ends of end contact wire 57 and define the circumferential extent of end contact wire 57. Coil 50 has multiple phase windings 50u, 50v, and 50w. Coil 50 is wound from three magnetic poles shown in the center of the figure.

[0141] A base flange 43 is provided at one end 20a for each magnetic pole. At the other end 20b, the base flange 43 has a first flange piece 546 and a second flange piece 547 for providing multiple connecting portions. The first flange piece 546 is located radially outside the magnetic pole and protrudes axially. The first flange piece 546 is also referred to as the magnetic pole flange. The second flange piece 547 is located radially outside the grooves S1-S15 and protrudes axially. The second flange piece 547 has a protrusion 245. The second flange piece 547 is also referred to as the groove flange. The first flange piece 546 and the second flange piece 547 are arranged alternately circumferentially. A first connecting portion 548 and a second connecting portion 549 are alternately formed between the first flange piece 546 and the second flange piece 547. In the winding process direction, the first connecting portion 548 is located in front of the first flange piece 546, and the second connecting portion 549 is located behind the first flange piece 546. In other words, the second connecting portion 549 is located on the front side of the second flange piece 547, and the first connecting portion 548 is located on the rear side of the second flange piece 547.

[0142] The first connecting portion 548 and the second connecting portion 549 are located at both ends of the end connection wire 57, respectively. The first connecting portion 548 is located between the inter-electrode connection wire 58 and the end connection wire 57 and defines their boundaries. The first connecting portion 548 is located at the end of the inter-electrode connection wire 58. The first connecting portion 548 is located at the beginning of the end connection wire 57. The first connecting portion 548 is also an outlet connecting portion for leading the wire from the inside to the outside of the stator 20. The second connecting portion 549 is located between the end connection wire 57 and the inter-electrode connection wire 59 and defines their boundaries. The second connecting portion 549 is located at the beginning of the inter-electrode connection wire 59. The second connecting portion 549 is located at the end of the end connection wire 57. The second connecting portion 549 is also an inlet connecting portion for introducing the wire from the outside to the inside of the stator 20. In this embodiment, two inter-electrode connection wires 58 and 59 are arranged in the slot. A second connecting portion 549, located on the front side of the second flange piece 547 which serves as a slotting flange, provides an inlet for introducing wire from the outside to the inside of the stator 20. A first connecting portion 548, located on the rear side of the second flange piece 547 which serves as a slotting flange, provides an outlet for leading wire from the inside to the outside of the stator 20. When the rotary motor 1 includes both inter-pole bonding wire 58 and inter-pole bonding wire 59, both the first connecting portion 548 and the second connecting portion 549 are utilized. When the rotary motor 1 includes either inter-pole bonding wire 58 or inter-pole bonding wire 59, only the first connecting portion 548 or the second connecting portion 549 is utilized. For example, when the rotary motor 1 includes only inter-pole bonding wire 58, only the first connecting portion 548 is used as both the inlet and the outlet. For example, when the rotary motor 1 includes only inter-pole bonding wire 59, only the second connecting portion 549 is used as both the inlet and the outlet.

[0143] The U-phase winding 50u is used as an example for explanation. The U-phase winding 50u begins winding around the initial magnetic pole from the winding start portion 55a and continues by transitioning from the winding end portion 56a to the inter-pole contact line 58a. The inter-pole contact line 58a extends radially outward from the first connecting portion 548 towards the base flange 43 and continues by transitioning to the end contact line 57a. The end contact line 57a is introduced radially inward from the second connecting portion 549 towards the base flange 43 and continues by transitioning to the inter-pole contact line 59a. The multiple phase windings 50u, 50v, and 50w have similar shapes. Therefore, in several slots, the inter-pole contact line 58 of one phase winding crosses the inter-pole contact lines 59 of other phase windings. For example, in slot S4, the inter-pole contact line 58 of the W-phase winding 50w crosses the inter-pole contact line 59 of the U-phase winding 50u. In this embodiment, since fifteen magnetic poles are provided, the coil 50 includes elements represented by the identifiers a, b, c, d, and e. For example, an inter-pole connection wire 58c, an end connection wire 57c, and an inter-pole connection wire 59c are arranged between magnetic poles 7 and 10. The end connection wire 57c extends from a first connecting portion 548, which serves as an outlet, to a second connecting portion 549, which serves as an inlet.

[0144] exist Figure 17 In this configuration, a single coil 51 of one phase winding is located on both sides of the inter-pole connection 58, end connection 57, and inter-pole connection 59. The coil 50 is illustrated in its state as viewed from the inside of the stator 20. Therefore, within a single slot, the inter-pole connections 58 and 59 of the two different phase windings intersect. As a result, the number of end connections 57 at the outer side of the base flange 43 can be reduced, thereby providing a compact rotary motor 1.

[0145] Sixth Implementation Method

[0146] This embodiment is a variation based on the previous embodiment. In the above embodiment, the rotary motor 1 includes both inter-pole connection wire 58 and inter-pole connection wire 59. However, in this embodiment, the rotary motor 1 includes only inter-pole connection wire 58.

[0147] exist Figure 18 In this embodiment, the stator 20 includes an insulator 40 and a coil 350 as described in the fifth embodiment. The coil 350 includes only inter-pole contact wires 58. In this embodiment, only the first connecting portion 548 is used as an inlet and outlet. For example, the U-phase winding 50u is led out from one first connecting portion 548 and introduced from another first connecting portion 548. In this structure, since the coil 350 is formed only by inter-pole contact wires 58, the end contact wires 57 are slightly longer. For example, the end contact wires 57c extend to the first connecting portion 548 before the 10th magnetic pole.

[0148] exist Figure 19 In this embodiment, coil 350 includes only the inter-pole bonding wire 58. Alternatively, coil 450, which only has the inter-pole bonding wire 59, may be included instead of coil 350. In this embodiment, a small rotary motor 1 can also be provided.

[0149] Seventh Implementation Method

[0150] This embodiment is a variation based on the previous embodiment. In the previous embodiment, at least one of the inter-electrode connection wires 58 and 59 is disposed obliquely within the groove. Alternatively, the inter-electrode connection wires 58 and 59 can be provided in various configurations.

[0151] In the following description, the rotating electric machine 1 is represented by axial AD, radial RD, and circumferential CD. Sometimes, elements belonging to one phase of the multiphase winding are designated with the identifiers g, h, i. Sometimes, elements belonging to another phase of the multiphase winding are designated with the identifiers j, k, L, m. Sometimes, elements belonging to yet another phase of the multiphase winding are designated with the identifiers p, q, r, s. The stator 20 sequentially includes single coils 51g, 51q, 51k, 51h, 51r, 51L, 51i, 51s, and 51m. Similarly, the inter-pole connection wire 58 is typically represented by inter-pole connection wire 58g or inter-pole connection wire 58k. Similarly, the inter-pole connection wire 59 is typically represented by inter-pole connection wire 59p or inter-pole connection wire 59g.

[0152] In this embodiment, each of the plurality of bonding wires 54 also has an end bonding wire 57, an inter-electrode bonding wire 58, and an inter-electrode bonding wire 59. In this embodiment, between the end bonding wire 57 and the inter-electrode bonding wires 58, 59, a transition portion (second portion 758g2, 759p2, first portion 758g1, 759p1) is provided by a portion of the inter-electrode bonding wires 58, 59.

[0153] exist Figure 20 and Figure 22In the stator 20, a plurality of pseudo-pole teeth 725 are included. Pseudo-pole teeth 725 are located between two circumferentially adjacent magnetic poles. Pseudo-pole teeth 725 provide positioning members for defining the position of inter-pole contact lines 58 or 59. The stator 20 includes three pseudo-pole teeth 725. Pseudo-pole teeth 725 are located between two adjacent pole teeth 31. The three pseudo-pole teeth 725 are mechanically separated by 72°. The three pseudo-pole teeth 725 are electrically separated by 720° (360° × integer multiples) from each other. The pseudo-pole teeth 725 are capable of regulating torque variations observed in the rotor 10 to a desired waveform. The stator 20 includes a plurality of first slots Sa with pseudo-pole teeth 725 and a plurality of second slots Sb without pseudo-pole teeth 725. The circumferential width of the axial leading edge face of the pseudo-pole teeth 725 is less than one-third of the circumferential width of the first slots Sa. Inter-pole connection wires 58 and 59 are configured to bypass the pseudo-pole tooth 725 in the first slot Sa.

[0154] Figure 21 yes Figure 20 An enlarged view of the arrow XXI section. Figure 23 yes Figure 22 An enlarged view of the section indicated by arrow XXIII. The dummy pole tooth 725 comprises a magnetic material. The dummy pole tooth 725 is primarily provided by a magnetic core portion, which is provided by a material continuously supplied from the stator core 30. The dummy pole tooth 725 includes an insulator 740a. The insulator 740a is provided by a material continuously supplied from the insulator 40. Therefore, the insulator 740a provides electrical insulation at the dummy pole tooth 725. Inter-pole contact lines 58 and 59 are hooked onto the dummy pole tooth 725 and configured accordingly. The dummy pole tooth 725 is provided with positioning members for defining the position of the inter-pole contact lines 58 and 59.

[0155] In the first slot Sa, the inter-pole bridging wire 58g is provided by the inter-pole bridging wire 758 located in the first slot Sa. The single coil 51g has a winding end portion 56g. The winding end portion 56g is disposed at the front end portion of the single coil 51g, i.e., the radially inner portion. The inter-pole bridging wire 58g is configured to obliquely traverse the slot space between the single coil 51g and the dummy pole tooth 725 from the winding end portion 56g. The inter-pole bridging wire 58g extends circumferentially, radially, and axially from the winding end portion 56g. The inter-pole bridging wire 58g passes through the air. The inter-pole bridging wire 58g is configured to span the axial end face of the dummy pole tooth 725. Furthermore, the inter-pole bridging wire 58g is configured to reach the radial end of the base end flange 43q, i.e., the radially outer portion, via the axial end face of the stator core 30. As a result, the inter-pole bridging wire 58g is connected to the end bridging wire 57g.

[0156] The inter-pole lap joint 58g has a first portion 758g1 and a second portion 758g2. The first portion 758g1 is obliquely disposed in a partial groove Sa1 between the single coil 51g and the dummy pole tooth 725. The second portion 758g2 is disposed axially outside the partial groove Sa2 between the dummy pole tooth 725 and the single coil 51g. The axial and radial displacements of the first portion 758g1 are greater than those of the second portion 758g2. Since the second portion 758g2 is located on the axial end face of the stator 20, it can also be classified as part of the end lap joint 57g. In this case, the inter-pole lap joint 58g is provided only by the first portion 758g1. The second portion 758g2 is also referred to as the transition portion located between the end lap joint 57g and the first portion 758g1, which is the inter-pole lap joint 58g.

[0157] In the first groove Sa, the inter-pole connection 59p is provided by the inter-pole connection 759 located in the first groove Sa. An end connection 57p is disposed at the axial end of the base flange 43g, i.e., axially outer. The inter-pole connection 59p is configured to pass from the end connection 57p through the axial end face of the dummy pole tooth 725. Furthermore, the inter-pole connection 59p is configured to obliquely traverse the space within the first groove Sa from the axial end face of the dummy pole tooth 725. The single coil 51q has a winding start portion 55q. The winding start portion 55q is disposed at the base end portion of the single coil 51q, i.e., the radially outer portion. The inter-pole connection 59p extends circumferentially and axially from the axial end face of the dummy pole tooth 725 toward the winding start portion 55q. The inter-pole connection 59p passes through the air. The inter-pole connection 59p is configured to reach the winding start portion 55q from the axial end face of the dummy pole tooth 725. As a result, the inter-pole connection 59p is connected to the winding start portion 55q of the single coil 51q.

[0158] Interpole connection wires 58g and 59p intersect on the pseudo-pole tooth 725. Interpole connection wire 58g, extending from one of the two circumferentially adjacent single coils 51g and 51q, intersects with interpole connection wire 59p, extending from the other single coil 51q, in the interpole gap PG. Interpole connection wire 59p has a first portion 759p1 and a second portion 759p2. The first portion 759p1 is disposed axially outside the partial groove Sa1 between the single coil 51g and the pseudo-pole tooth 725. The second portion 759p2 is obliquely disposed within the partial groove Sa2 between the pseudo-pole tooth 725 and the single coil 51q. The axial displacement of the second portion 759p2 is greater than the axial displacement of the first portion 759p1. Since the first portion 759p1 is located on the axial end face of the stator 20, it can also be classified as part of the end connection wire 57p. In this case, the interpole connection wire 59p is provided only by the second portion 759p2. The first part 759p1 is also called the transition part located between the end lap joint 57p and the second part 759p2, which is the inter-pole lap joint 59p.

[0159] Figure 24 It shows Figure 20 The cross section at the XXI V-XXIV line. Figure 25 yes Figure 24 A magnified view of the XXV portion of the arrow. Figure 25 In the dummy pole tooth 725, insulators 740a and 740b are respectively disposed on the two axial end faces. An end contact wire 57j for one phase, an inter-pole contact wire 58g for another phase, and an inter-pole contact wire 59p for yet another phase are positioned on the two axial end faces of the dummy pole tooth 725. The inter-pole contact wires 58g and 59p are configured to be offset radially more than the end contact wire 57j. On the dummy pole tooth 725, the end contact wires 57j, 58g, and 59p are positioned radially aligned. Axially, the end contact wires 57j, 58g, and 59p are positioned within the height of the coil edge end of the single coil 51g.

[0160] Figure 26 yes Figure 24 A magnified view of the XXV I section of the arrow. Figure 26The cross-section of a single coil 51m is shown. End lap wires 57i and 57s are arranged radially outside the base flange 43m for the single coil 51m. End lap wire 57i connects the single coil 51i and a single coil of the same phase (not shown). End lap wire 57s connects the single coil 51s and a single coil of the same phase (not shown). The base flange 43m provides a retaining member for holding the two end lap wires 57i and 57s. Even radially outside the magnetic pole, i.e., radially outside the base flange 43m, the end lap wires 57i and 57s are arranged within the height of the coil edge end in the axial direction of the single coil 51g.

[0161] The first portion 758g1 of the inter-electrode lap wire 58g extends in the inter-electrode gap PG between one end 20a and the other end 20b of the stator 20 in the axial direction. The first portion 758g1 extends obliquely in the axial direction, at least circumferentially. This suppresses the number of lap wires 54 stacked axially or radially on the radially outer side of the insulator 40. The second portion 759p2 of the inter-electrode lap wire 59p extends in the inter-electrode gap PG between one end 20a and the other end 20b of the stator 20 in the axial direction. The second portion 759p2 extends obliquely in the axial direction, at least circumferentially. This suppresses the number of lap wires 54 stacked axially or radially on the radially outer side of the insulator 40. The inter-electrode lap wires 58g and 59p cross in the inter-electrode gap PG further radially inward than the base end flanges 43g and 43q. Therefore, within the angular range of the first groove Sa, the lap wires 54 are radially dispersed. Therefore, the number of overlapping wires 54 stacked axially or radially on the radially outer side of the insulator 40 can be suppressed to two.

[0162] Figure 27 yes Figure 20 An enlarged view of the XXVII section of the arrow. Figure 28 yes Figure 22 Enlarged view of the XXVIII section of the arrow. In the second groove Sb, the inter-electrode connection 58k is provided by the inter-electrode connection 758 located in the second groove Sb. Figure 27 and Figure 28 The inter-electrode connection wires 58k, the first part 758k1, and the second part 758k2 shown have respectively with Figure 21 and Figure 23 The inter-electrode connection wire 58g, the first part 758g1, and the second part 758g2 shown have the same shape. In the second groove Sb, the inter-electrode connection wire 59g is provided by the inter-electrode connection wire 759 located in the second groove Sb. Figure 27 and Figure 28 The inter-electrode bonding wire 59g, the first part 759g1, and the second part 759g2 shown have the same characteristics as... Figure 21 and Figure 23 The interpole connection wires 59p, the first portion 759p1, and the second portion 759p2 shown have the same shape. The interpole connection wires 58k and 59g intersect in the space (interpole gap PG) at the axial ends of the second groove Sb. The interpole connection wires 58k and 59g are arranged in a meandering manner so that the pseudo-pole tooth 725 virtually exists therein.

[0163] Figure 29 yes Figure 27 A magnified view of the XXIX section of the arrow. Figure 29 A cross-section is shown at the second groove Sb without the pseudo-pole tooth 725. An end-connector 57q for one phase, an inter-pole connection 58k for another phase, and an inter-pole connection 59g for yet another phase are positioned in the second groove Sb. The inter-pole connections 58k and 59g are configured to be offset radially more than the end-connector 57q. The end-connector 57q, inter-pole connection 58k, and inter-pole connection 59g are positioned radially aligned. In the circumferential middle portion of the second groove Sb, the end-connector 57q, inter-pole connection 58k, and inter-pole connection 59g are positioned within the height of the coil edge end of the single coil 51k.

[0164] Return to Figure 28 The first portion 758k1 of the inter-electrode lap wire 58k extends in the inter-electrode gap PG between one end 20a and the other end 20b of the stator 20 in the axial direction. The first portion 758k1 extends at least circumferentially and obliquely in the axial direction. This suppresses the number of lap wires 54 stacked axially or radially on the radially outer side of the insulator 40. The second portion 759g2 of the inter-electrode lap wire 59g extends in the inter-electrode gap PG between one end 20a and the other end 20b of the stator 20 in the axial direction. The second portion 759g2 extends at least circumferentially and obliquely in the axial direction. This suppresses the number of lap wires 54 stacked axially or radially on the radially outer side of the insulator 40. The inter-electrode lap wires 58k and 59g cross in the inter-electrode gap PG further radially inward than the base flanges 43k and 43h. Therefore, within the angular range of the first groove Sa, the lap wires 54 are radially dispersed. Therefore, the number of overlapping wires 54 stacked axially or radially on the radially outer side of the insulator 40 can be suppressed to two.

[0165] In this embodiment, by including inter-pole lap joints, the volume required for aligning the lap joints can also be suppressed. In the illustrated example, the number of lap joint stacks can be suppressed within the circumferential angle range of the slots Sa and Sb. When the lap joints are stacked radially along the stator 20, the radial dimension of the stator 20 can be suppressed. When the lap joints are stacked axially along the stator 20, the axial dimension of the stator 20 can be suppressed. Furthermore, the lap joints are located within the range of the coil edge ends of the plurality of individual coils, i.e., within the range of the axial height of the individual coils. Thus, the axial height of the stator 20 can be suppressed.

[0166] Eighth Implementation Method

[0167] This embodiment is a variation based on the previous embodiment. In the previous embodiment, inter-pole bonding lines 58 and 59 were arranged on one side of the stator 20 along the axial direction. In other words, the inter-pole bonding lines 58 and 59 were arranged on one side of the axial direction passing through the pseudo-pole teeth 725. Instead, in this embodiment, the inter-pole bonding lines 58 and 59 are distributed on both sides of the stator 20 along the axial direction.

[0168] Figure 30 , Figure 31 , Figure 32 They are equivalent to Figure 21 , Figure 23 , Figure 25 The figures show that the inter-pole connection wires 58g and 59p are configured to include portions extending on both sides of the stator 20 along the axial direction. The inter-pole connection wires 58g and 59p are disposed at both ends of the dummy pole tooth 725 in the axial direction. In the first groove Sa, the inter-pole connection wire 58g is provided by the inter-pole connection wire 858 located in the first groove Sa. The inter-pole connection wire 759 is disposed at one end of the dummy pole tooth 725, and the inter-pole connection wire 858 is disposed on the opposite side, i.e., the other end, of the dummy pole tooth 725. The inter-pole connection wire 58g has a first portion 858g1 disposed on the other end side of the dummy pole tooth 725. The first portion 858g1 is obliquely disposed on the end face of the stator 20 in a portion of the groove Sa1 between the single coil 51g and the dummy pole tooth 725. The first portion 858g1 provides a transition portion. The inter-pole connection wire 58g has a second portion 858g2 that extends obliquely between the pseudo-pole tooth 725 and the single coil 51q. The second portion 858g2 of the inter-pole connection wire 58g extending from one single coil 51g intersects the second portion 759p2 of the inter-pole connection wire 59p extending from the other single coil 51q in a partial groove Sa2. The second portion 858g2 provides the crossing portion.

[0169] The second portion 858g2 of the inter-electrode lap wire 58g extends in the inter-electrode gap PG between one end 20a and the other end 20b of the stator 20 in the axial direction. The second portion 858g2 extends obliquely in the axial direction at least circumferentially. This suppresses the number of lap wires 54 stacked axially or radially on the radially outer side of the insulator 40. The second portion 759p2 of the inter-electrode lap wire 59p extends in the inter-electrode gap PG between one end 20a and the other end 20b of the stator 20 in the axial direction. The second portion 759p2 extends obliquely in the axial direction at least circumferentially. This suppresses the number of lap wires 54 stacked axially or radially on the radially outer side of the insulator 40. The inter-electrode lap wires 58g and 59p cross in the inter-electrode gap PG further radially inward than the base end flanges 43g and 43q. In this embodiment, the inter-electrode lap wires 58g and 59p cross in a partial groove Sa2. Therefore, within the angular range of the first notch Sa, the overlap lines 54 are radially dispersed. This suppresses the number of overlap lines 54 stacked axially or radially on the radially outer side of the insulator 40. The number of overlap lines 54 stacked axially or radially on the radially outer side of the insulator 40 is suppressed to two.

[0170] Figure 33 , Figure 34 , Figure 35 They are equivalent to Figure 27 , Figure 28 , Figure 29 The diagrams show that the inter-pole connection wires 58k and 59g are arranged at both ends of the stator 20 in the axial direction without the dummy pole teeth 725. The inter-pole connection wires 58k and 59g are arranged in a meandering manner in the second slot Sb. In other words, the inter-pole connection wires 58k and 59g are not arranged along the shortest straight path. Alternatively, they can be described as being configured in a crank-like shape.

[0171] Return to Figure 34The second portion 858k2 of the inter-electrode lap wire 58k extends in the inter-electrode gap PG between one end 20a and the other end 20b of the stator 20 in the axial direction. The second portion 858k2 extends obliquely in the axial direction, at least circumferentially. This suppresses the number of lap wires 54 stacked axially or radially on the radially outer side of the insulator 40. The second portion 759g2 of the inter-electrode lap wire 59g extends in the inter-electrode gap PG between one end 20a and the other end 20b of the stator 20 in the axial direction. The second portion 759g2 extends obliquely in the axial direction, at least circumferentially. This suppresses the number of lap wires 54 stacked axially or radially on the radially outer side of the insulator 40. The inter-electrode lap wires 58k and 59g cross in the inter-electrode gap PG further radially inward than the base flanges 43k and 43h. Therefore, within the angular range of the second groove Sb, the lap wires 54 are radially dispersed. Therefore, the number of overlapping wires 54 stacked axially or radially on the radially outer side of the insulator 40 can be suppressed to two.

[0172] In this embodiment, the inter-electrode bonding wire 58g and the inter-electrode bonding wire 59p cross in a portion of the groove Sa2. Alternatively, the inter-electrode bonding wire 58g and the inter-electrode bonding wire 59p may also cross in a portion of the groove Sa1.

[0173] According to this embodiment, inter-pole bonding lines 58 and 59 are dispersed on both sides of the phasing pole tooth 725. This provides an advantageous effect achieved by the dispersion of multiple bonding lines. For example, physical interactions between the multiple bonding lines can be suppressed. For example, capacitive and inductive components can sometimes be suppressed. Additionally, heat dissipation can sometimes be promoted. In this embodiment, the same effects as in the previous embodiment can also be obtained.

[0174] Ninth Implementation Method

[0175] This embodiment is a variation based on the previous embodiment. In the previous embodiment, particularly the seventh embodiment, the winding end portion 56 of the single coil 51 is disposed at the front end portion of the single coil 51, that is, the radially inner portion. Instead, in this embodiment, the winding end portion 56 is disposed at the base end portion of the single coil 51, that is, the radially outer portion.

[0176] Figure 36 , Figure 37 , Figure 38 They are equivalent to Figure 21 , Figure 23 , Figure 25The figures show that the winding ends 56g and 56q of the single coils 51g and 51q are located at the base ends of the single coils 51g and 51q. In the first slot Sa, the inter-pole bonding wire 58g is provided by the inter-pole bonding wire 958 located in the first slot Sa. The first portion 958g1 of the inter-pole bonding wire 58g is obliquely arranged in the partial slot Sa1. The first portion 958g1 is arranged along the inner surface of the yoke 32. The second portion 958g2 is also a transition portion. The inter-pole bonding wires 58g and 59p are axially stacked and intersecting in the axial direction of the pseudo-pole tooth 725.

[0177] Figure 39 , Figure 40 , Figure 41 They are equivalent to Figure 27 , Figure 28 , Figure 29 The figures show that the inter-electrode bonding wires 58k and 59g are arranged in the second groove Sb without the dummy pole tooth 725. The inter-electrode bonding wires 58k and 59g are axially stacked and intersecting at the middle of the inter-electrode gap PG.

[0178] According to this embodiment, the inter-electrode bonding line 58 can be configured without being restricted by the position of the winding end portion 56. Similarly, the inter-electrode bonding line 59 can be configured without being restricted by the position of the winding start portion 55. In this embodiment, the same effects as in the previous embodiment can also be obtained.

[0179] Tenth Implementation Method

[0180] This embodiment is a variation based on a previous embodiment. In the previous embodiment, the inter-pole bonding wires 58 and 59 were configured to bypass the dummy pole tooth 725, or to make the dummy pole tooth 725 virtually exist therein. Alternatively, this embodiment includes a component that replaces the dummy pole tooth 725.

[0181] Figure 42 , Figure 43 , Figure 44 They are equivalent to Figure 27 , Figure 28 , Figure 29 The image. Figure 44 It shows Figure 42The cross-section at the XLIV-XLIV line. In these figures, the insulator 40 has a protrusion A46 within the second groove Sb. The protrusion A46 comprises resin material. The protrusion A46 also serves as a positioning member for positioning the inter-pole contact lines 58 and 59 in place of the pseudo-pole teeth 725. The circumferential width of the protrusion A46 is smaller than the circumferential width of the second groove Sb. Partial grooves Sb1 and Sb2 are formed on both circumferential sides of the protrusion A46. The radial length of the protrusion A46 is lower than the magnetic pole face of the stator 20. The protrusion A46 is positioned at the middle of the circumferential direction of the second groove Sb. The protrusion A46 may also be located near either side of the circumferential direction of the second groove Sb. The axial height of the protrusion A46 is approximately 1 / 3 of the axial dimension of the insulator 40. Alternatively, the axial height of the protrusion A46 may sometimes be equal to the axial dimension of the insulator 40. The axial height of protrusion A46 can be set to obtain the strength required for positioning inter-pole bonding wires 58 and 59.

[0182] Inter-pole connection wire 58k is provided by inter-pole connection wire 758. Inter-pole connection wire 59g is provided by inter-pole connection wire 759. Inter-pole connection wires 58k and 59g are bent into the illustrated shape by hooking onto protrusion A46. Inter-pole connection wires 58k and 59g are guided by protrusion A46, which replaces the dummy pole tooth 725. From this point of view, the dummy pole tooth 725 and protrusion A46 provide guide members for guiding inter-pole connection wires 58 and 59 to a predetermined configuration position. As a result, the same inter-pole connection wires as in the previous embodiment are provided.

[0183] Eleventh Implementation Method

[0184] This embodiment is a variation based on a previous embodiment. In the previous embodiment, the dummy pole teeth 725 and the protrusion A46 provided positioning members for hooking the inter-pole contact wires 58 and 59 only. Instead, this embodiment includes grooves for more reliably retaining the inter-pole contact wires 58 and 59.

[0185] Figure 45 , Figure 46 , Figure 47 They are equivalent to Figure 27 , Figure 28 , Figure 29 The image. Figure 47 It shows Figure 45The cross-section at the XLVII-XLVII line. In these figures, the insulator 40 has a protrusion B46 within the second groove Sb. The protrusion B46 has the same dimensions as the protrusion A46 in the previous embodiment. The protrusion B46 has a groove B47 for receiving the inter-electrode bonding wire 59g. The protrusion B46 has a groove B48 for receiving the inter-electrode bonding wire 58k. The groove B47 is disposed on one end face of the protrusion B46 in the axial direction. The groove B48 is disposed on the other end face of the protrusion B46 in the axial direction. The grooves B47 and B48 are disposed on opposite sides of the protrusion B46. The grooves B47 and B48 hold the inter-electrode bonding wires 59g and 58k.

[0186] The groove B47 constrains the inter-pole lap joint 59g at least radially. The groove B47 is a relatively small groove that receives the inter-pole lap joint 59g while constraining it. The inter-pole lap joint 59g is pressed axially into the groove B47. The groove B47 has a long side direction in the circumferential or tangential direction. The groove B47 is also referred to as a snap-fit ​​groove that constrains the inter-pole lap joint 59g using the elasticity of the protrusion B46. As a result, the groove B47 also constrains the inter-pole lap joint 59g in the circumferential or tangential direction. The axial depth of the groove B47 is greater than the radius of the inter-pole lap joint 59g. The groove B47 can also be provided by a relatively large groove that loosely receives the inter-pole lap joint 59g in a state that allows it to float. The axial depth of the groove B47 can also be less than the radius of the inter-pole lap joint 59g.

[0187] The slot B48 constrains the inter-pole lap joint 58k at least radially. The slot B48 is a relatively small slot that receives the inter-pole lap joint 58k while constraining it. The inter-pole lap joint 58k is pressed axially into the slot B48. The slot B48 has a long side direction in the circumferential or tangential direction. The slot B48 is also referred to as a snap-fit ​​slot that constrains the inter-pole lap joint 58k using the elasticity of the protrusion B46. As a result, the slot B48 also constrains the inter-pole lap joint 58k in the circumferential or tangential direction. The axial depth of the slot B48 is greater than the radius of the inter-pole lap joint 58k. The slot B48 can also be provided by a relatively large slot that loosely receives the inter-pole lap joint 58k in a state that allows it to float. The axial depth of the slot B48 can also be less than the radius of the inter-pole lap joint 58k.

[0188] In the stator manufacturing method, constraining and holding the inter-pole lap wires disposed therein contributes to improving the shape stability of the inter-pole lap wires during the winding process. In the winding process, after winding a single coil 51k, the inter-pole lap wire 58k is received and held in slot B48. This prevents the single coil 51 from slowly unwinding. In the winding process, after placing the end lap wire 57g, the inter-pole lap wire 59g is received and held in slot B47. This prevents the end lap wire 57 from slowly unwinding. As a result, slots B47 and B48 improve the shape stability of the coil 50. Furthermore, slots B47 and B48 facilitate the winding process.

[0189] Inter-electrode connector 58k is provided by inter-electrode connector B58. The middle portion of inter-electrode connector B58 is constrained by protrusion B46. Therefore, inter-electrode connector B58 is configured in a Z-shaped or S-shaped meandering manner. Inter-electrode connector 59g is provided by inter-electrode connector B59. The middle portion of inter-electrode connector B59 is constrained by protrusion B46. Therefore, inter-electrode connector B59 is configured in a Z-shaped or S-shaped meandering manner.

[0190] In this embodiment, the stator 20 includes both slot B47 and slot B48. Alternatively, the stator 20 may include only either slot B47 or slot B48. In this embodiment, slot B47 or slot B48 is disposed in a resin protrusion B46 extending from the insulator 40. Alternatively, slot B47 or slot B48 may be provided in the insulators 740a and 740b at the dummy pole teeth 725. In this embodiment, the same effects as in the previous embodiment can be obtained.

[0191] Twelfth Implementation Method

[0192] This embodiment is a variation based on the previous embodiment. As shown in the previous embodiment, in the eleventh embodiment, the position of the winding end portion 56 of the single coil 51 can also be changed in various ways.

[0193] Figure 48 , Figure 49 , Figure 50 They are equivalent to Figure 27 , Figure 28 , Figure 29 The image. Figure 50 It shows Figure 48 The cross-section at the LL line. In these figures, the winding end 56k of the single coil 51k is located on the radially outer side. The inter-pole connection wire 58k is provided by the inter-pole connection wire C58. The inter-pole connection wire C58 is arranged along the inner surface of the stator core 30. In this embodiment, the same effects as in the previous embodiment can also be obtained.

[0194] Thirteenth Implementation Method

[0195] This embodiment is a variation based on a previous embodiment. In the previous embodiment, the plurality of rotor poles 12 are arranged at equal intervals. Alternatively, some of the poles included in the plurality of rotor poles 12 may be arranged at slightly offset positions from the equal intervals. The rotor 10 disclosed in this embodiment can be used as the rotor of the previous embodiment.

[0196] exist Figure 51 In this rotor, most of the multiple rotor poles 12 are arranged at equal intervals. For example, three adjacent poles 12a, 12b, and 12c are separated from each other by a distance G1 (G1 = G1). The multiple rotor poles 12 include one or more rotor poles 12 arranged circumferentially offset. Rotor poles 12 arranged circumferentially offset are also called offset poles. For example, two adjacent poles 12d and 12e are separated by a distance G2. Two adjacent poles 12e and 12f are separated by a distance G3. Distances G2 and G3 are not equal (G2 ≠ G3). Distances G2 and G3 are either G2 < G3 or G2 > G3. Thus, pole 12e is offset in the advance angle direction or the retardation angle direction. Pole 12e provides the offset pole. The offset amount is a minute quantity that is difficult to illustrate. The rotor 10 can include one or more offset poles. For example, the rotor 10 sometimes includes three offset poles. The offset magnetic poles can adjust the torque variation observed in the rotor 10 to the desired waveform.

[0197] Other implementation methods

[0198] The disclosure in this specification and accompanying drawings is not limited to the illustrated embodiments. This disclosure includes illustrated embodiments and modifications made by those skilled in the art based thereon. For example, this disclosure is not limited to combinations of components and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. This disclosure may have additional portions that can be added to the embodiments. This disclosure includes embodiments in which components and / or elements of the embodiments are omitted. This disclosure includes substitutions or combinations of components and / or elements between one embodiment and another. The scope of the disclosed technology is not limited to the description of the embodiments. Several technical scopes of the disclosure should be understood to be expressed by the description of the claims, and also include all modifications within the meaning and scope of equivalence to the description of the claims.

[0199] The disclosures in the specification and drawings are not limited by the claims. The disclosures in the specification and drawings include the technical ideas described in the claims, and involve more diverse and broader technical ideas than those described in the claims. Therefore, it is possible to extract various technical ideas from the disclosures in the specification and drawings without being limited by the claims.

[0200] In the above embodiment, the rotary motor 1 is an internal rotor type. Alternatively, the rotary motor 1 can also be an external rotor type. In the above embodiment, the rotary motor 1 provides an electric motor. Alternatively, the rotary motor 1 can also provide a generator or a generator-motor. Furthermore, the rotary motor 1 can be used for various applications, such as servo motors, stepper motors, etc.

[0201] In the above embodiment, the stator core 30 is provided by a continuous steel plate consisting of a plurality of pole teeth 31 and a yoke 32. Alternatively, the stator core 30 may also be provided by a so-called multi-segment core. In this case, the stator core 30 is provided by a connecting body of a plurality of segmented cores. A segmented core may be provided, for example, by a partially annular partial yoke and a continuous body of pole teeth.

[0202] In the above embodiment, a plurality of conductive members 60 are embedded in terminal blocks 80, 280. Alternatively, the plurality of conductive members 60 may also be press-fitted to terminal blocks 80, 280. Furthermore, the plurality of conductive members 60 may be supported or fixed by the insulator 40 without terminal blocks 80, 280. For example, the plurality of conductive members 60 may also be directly fixed to the insulator 40 by fasteners. In this structure, since the connecting portions 65, 66, 67, 68, 69, 270 are arranged in the inter-pole gap PG, the size of the coil end 52 of the rotary motor 1 is miniaturized. In the above embodiment, the connector portion 82 opens radially outward on the outside of the housing 3. Alternatively, the connector portion 82 may also open axially on the outside of the housing 3. In this case, the connector portion 82 forms an electrical connection by accepting a connector for an external circuit operating axially from either axial direction.

[0203] In the above embodiment, coil 50 is star-connected. Alternatively, coil 50 can also be delta-connected. In this case, the connection between a conductive member 60 and at least two coil ends 52 is disposed in the inter-pole gap PG. Furthermore, in the above embodiment, a phase winding is provided by a single wire. Alternatively, a phase winding can also be provided as a parallel circuit of multiple wires. In this case, a single coil 51 is provided by a parallel circuit of multiple wires. For example, in the case where a single coil 51 is provided by two wires, in the star connection, the conductive member 60 providing a power terminal and the connection between two coil ends 52 are disposed in the inter-pole gap PG. For example, in the case where a single coil 51 is provided by two wires, in the delta connection, the conductive member 60 providing a power terminal and the connection between four coil ends 52 are disposed in the inter-pole gap PG.

[0204] In the above embodiment, the conductive member 60 is a busbar. Alternatively, the conductive member 60 may also be an electrode for a terminal, a wire, or a conductor foil on a substrate. In these cases, miniaturization can also be achieved by arranging the connection portion in the inter-electrode gap PG. In the above embodiment, the coil 50 is made of copper or a copper alloy. Alternatively, the coil 50 may also be made of aluminum or an aluminum alloy. In the above embodiment, the connection between the conductive member and the coil end 52 is provided by welding. Alternatively, the connection between the conductive member and the coil end 52 may also be provided by hot riveting, welding, soldering, etc.

[0205] In the above embodiment, the conductive member 60 has a connector terminal extending radially as a power terminal. Alternatively, the conductive member 60 may also extend axially. In this case, axial miniaturization can also be achieved by arranging the connection portion in the inter-electrode gap PG. In the above embodiment, multiple power terminal members 61, 62, and 63 are provided with connector terminals. Alternatively, the power terminal members 61, 62, and 63 may also be provided with crimp terminals, solder terminals, etc.

[0206] In the above embodiment, the inter-electrode gap PG is a void. Alternatively, the inter-electrode gap PG may be filled with a resin component after the conductive member 60 is disposed. Furthermore, the conductive member 60 disposed in the inter-electrode gap PG may also be coated with a thin resin material. In any configuration, by disposing a connecting portion, which is part of the conductive member 60, in the inter-electrode gap PG, a small rotary motor 1 can be provided.

[0207] In the above embodiment, the multiple coil ends at the start of winding are used as power terminals, and the multiple coil ends at the end of winding are used as neutral points. Alternatively, the multiple coil ends at the end of winding may be used as power terminals, and the multiple coil ends at the start of winding may be used as neutral points. Furthermore, the coil ends may be used as power terminals or neutral points without using the conductive member 60. For example, the multiple coil ends at the start or end of winding may be extended and used as power terminals. For example, the multiple coil ends at the start or end of winding may be directly joined to each other and used as neutral points.

Claims

1. A rotary electric motor that provides multiphase windings via a plurality of magnetic poles projecting radially from an annular yoke and arranged circumferentially. The lap joint extending between the two single coils providing in-phase magnetic poles includes at least: An inter-pole lap joint extending axially between one end and the other end in the inter-pole gap between two circumferentially adjacent magnetic poles; and the end overlap line extending circumferentially at the other end, A positioning member is disposed between two circumferentially adjacent magnetic poles, the positioning member being positioned in a radially projecting manner similar to that of the magnetic poles. The inter-electrode connection line is configured to bypass the positioning member in the inter-electrode gap.

2. The rotary motor as described in claim 1, characterized in that, The positioning component is a pseudo-pole tooth made of magnetic material.

3. The rotary motor as described in claim 1, characterized in that, The positioning member is a protrusion made of resin material.

4. The rotary motor as described in claim 1, characterized in that, The positioning component includes a groove for retaining the inter-pole bonding line.

5. The rotary electric motor as described in any one of claims 1 to 4, characterized in that, The stator of the rotary electric motor includes: A plurality of first inter-electrode gaps, the plurality of first inter-electrode gaps having the positioning member; and Multiple second-electrode gaps, wherein the multiple second-electrode gaps do not have the positioning member. The inter-electrode connection line It is configured in the first interpole gap in a manner that bypasses the positioning member. The positioning member is configured in the second interpole gap in such a way that it virtually exists therein.

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