Rotating electric machine

Abstract

The rotating electrical machine (1) provides a multi-phase winding by a plurality of magnetic poles (21, 22, 23) arranged in the circumferential direction. A lap line (54) extends between two single coils (51) providing magnetic poles of the same phase. The lapping wire (54) includes inter-pole lapping wires (58, 59) extending between one end (20a) and the other end (20b) in the axial direction in a pole gap (PG) between two magnetic poles adjacent in the circumferential direction. The lapping wire (54) includes an end lapping wire (57) extending in the circumferential direction at the other end (20b). Since the inter-electrode lapping wires (58, 59) provide a part of the lapping wire (54), the length of the end lapping wire (57) can be suppressed. As a result, it is possible to suppress the overlap of the out-of-phase end lapping wires (57), thereby providing a small-sized rotating electrical machine (1).

Description

[0001] This is a divisional application of the patent application for an invention entitled "Rotating Electric Machine" with International Application No. PCT / JP2020 / 022630 filed on June 9, 2020, which entered the National Phase in China as Application No. 202080101913.6. TECHNICAL FIELD

[0002] The disclosure in this specification relates to a rotating electric machine. BACKGROUND

[0003] Patent Literature 1 discloses the configuration of a lap wire of a stator coil. The lap wire is configured in a stack along an insulator of a stator. The content described in the prior art document is cited by reference as a description of technical elements in this specification.

[0004] PRIOR ART DOCUMENT PATENT LITERATURE Patent Literature 1: Japanese Patent Application Publication No. 2007-236181 SUMMARY

[0005] Sometimes, a rotating electric machine with a short length in the axial direction is required. In the above-mentioned point of view, or in other points of view not mentioned, further improvement of the rotating electric machine is required.

[0006] One object of the disclosure is to provide a small rotating electric machine.

[0007] Another object of the disclosure is to provide a rotating electric machine that is easy to manufacture.

[0008] Still another object of the disclosure is to provide a rotating electric machine with a short length in the axial direction.

[0009] The rotating electric machine provides a multi-phase winding by a plurality of magnetic poles configured in the circumferential direction. The lap wire extending between two single coils of the same phase of the rotating electric machine includes at least an inter-pole lap wire extending between one end and the other end in an inter-pole gap between two magnetic poles adjacent in the circumferential direction and an end lap wire extending in the circumferential direction at the other end.

[0010] According to the disclosed rotating electric machine, the inter-pole lap wire is included in a part of the lap wire extending between two single coils of the same phase. The inter-pole lap wire extends between one end and the other end in an inter-pole gap between two magnetic poles adjacent in the circumferential direction. Since the inter-pole lap wire provides a part 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 different phases can be suppressed, thereby providing a small rotating electric machine.

[0011] The modes disclosed in the present specification achieve respective objects by different technical means. The technical solutions and the symbols in parentheses described in the technical solutions exemplarily represent the correspondence with the parts of the embodiments described later, and are not intended to limit the technical scope. The objects, features, and effects disclosed in the present specification can be more apparent from the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0012] Figure 1 is a plan view of a rotary electric machine of the first embodiment.

[0013] Figure 2 is a sectional view at II-II line of Figure 1

[0014] Figure 3 is a sectional view of a connecting portion of the electrically conductive member.

[0015] Figure 4 is a winding diagram of the stator.

[0016] Figure 5 is a plan view of a rotary electric machine of the second embodiment.

[0017] Figure 6 is a perspective view of the rotary electric machine.

[0018] Figure 7 is a sectional view at VII-VII line of Figure 5

[0019] Figure 8 is a perspective view of the stator.

[0020] Figure 9 is a plan view of the stator except for the terminal block.

[0021] Figure 10 is a side view of arrow X of Figure 9

[0022] Figure 11 is a side view of arrow XI of Figure 9

[0023] Figure 12 is a sectional view at XII-XII line of Figure 9

[0024] Figure 13 is a winding diagram of the stator.

[0025] Figure 14 is a winding diagram of the stator of the third embodiment.

[0026] Figure 15 is a winding diagram of the stator of the fourth embodiment.​​​​​

[0027] Figure 16 is an exploded perspective view of the stator of the fifth embodiment.

[0028] Figure 17 is a winding diagram of the stator of the fifth embodiment.

[0029] Figure 18 is an exploded perspective view of the stator of the sixth embodiment.

[0030] Figure 19 is a winding diagram of the stator of the sixth embodiment.

[0031] Figure 20 is a plan view of the stator of the seventh embodiment.

[0032] Figure 21 is a partial enlarged plan view of the stator.

[0033] Figure 22 is an exploded perspective view of the stator.

[0034] Figure 23 is a partial enlarged perspective view of the stator.

[0035] Figure 24 is a sectional view of the stator.

[0036] Figure 25 is a partial enlarged sectional view of the stator.

[0037] Figure 26 is a partial enlarged sectional view of the stator.

[0038] Figure 27 is a partial enlarged plan view of the stator.

[0039] Figure 28 is a partial enlarged perspective view of the stator.

[0040] Figure 29 is a partial enlarged sectional view of the stator.

[0041] Figure 30 is a partial enlarged plan view of the stator of the eighth embodiment.

[0042] Figure 31 is a partial enlarged perspective view of the stator.

[0043] Figure 32 is a partial enlarged sectional view of the stator.

[0044] Figure 33 is a partial enlarged plan view of the stator.

[0045] Figure 34 is a partial enlarged perspective view of the stator.

[0046] Figure 35 is a partial enlarged sectional view of the stator.

[0047] Figure 36 is a partial enlarged plan view of the stator of the ninth embodiment.

[0048] Figure 37 is a partial enlarged perspective view of the stator.

[0049] Figure 38 is a partial enlarged sectional view of the stator.

[0050] Figure 39 is a partial enlarged plan view of the stator.

[0051] Figure 40 is a partial enlarged perspective view of the stator.

[0052] Figure 41 is a partial enlarged sectional view of the stator.

[0053] Figure 42 is a partial enlarged plan view of the stator of the tenth embodiment.

[0054] Figure 43 is a partial enlarged perspective view of the stator.

[0055] Figure 44 is a partial enlarged sectional view of the stator.

[0056] Figure 45 is a partial enlarged plan view of the stator of the eleventh embodiment.

[0057] Figure 46 is a partial enlarged perspective view of the stator.

[0058] Figure 47 is a partial enlarged sectional view of the stator.

[0059] Figure 48 is a partial enlarged plan view of the stator of the twelfth embodiment.

[0060] Figure 49 is a partial enlarged perspective view of the stator.

[0061] Figure 50 is a partial enlarged sectional view of the stator.

[0062] Figure 51 is a plan view showing a rotary electric machine of the thirteenth embodiment. DETAILED DESCRIPTION

[0063] Hereinafter, a plurality of embodiments will be described with reference to the drawings. In the plurality of embodiments, the same reference signs are sometimes attached to functionally and / or structurally corresponding portions and / or associated portions, or reference signs differing by more than one digit are attached. For the corresponding portions and / or associated portions, the description of the other embodiments can be referred to.

[0064] First Embodiment Figure 1 and Figure 2 A rotary electric machine 1 is shown. In Figure 1 and Figure 2 The rotary electric machine 1 is slightly exaggerated in the radial direction. Dotted lines indicate omitted or hidden lines. The rotary electric machine 1 is configured to rotate around a rotational axis AX. In the following description, the direction in which the rotational axis AX extends is referred to as the axial direction, the surrounding of the rotational axis AX is referred to as the circumferential direction, and the radial direction from the rotational axis AX is referred to as the radial direction.

[0065] In Figure 1 The rotary electric machine 1 is coupled to a rotating body 2. The rotating body 2 is configured to rotate around the rotational axis AX. The rotating body 2 is a rotational shaft or an input / output of a transmission. The rotary electric machine 1 is housed in a housing 3. The housing 3 provides a fixing portion for the rotary electric machine 1.

[0066] The rotary electric machine 1 has a rotor 10 and a stator 20. The rotary electric machine 1 is of an inner rotor type. The rotor 10 and the stator 20 are arranged so as to have an air gap AG therebetween. The rotor 10 is arranged on the radially outer side of the rotating body 2. The stator 20 is arranged at a position more radially outward than the rotor 10.

[0067] The rotor 10 has a rotor core 11 and a plurality of rotor magnetic poles 12. The rotor core 11 is a ring-shaped magnetic body. The rotor core 11 is coupled to the rotating body 2 in the rotational direction. The plurality of rotor magnetic poles 12 are provided by permanent magnets. The plurality of rotor magnetic poles 12 are arranged at equal intervals on the outer circumferential surface of the rotor core 11. As a result, the rotor 10 provides a permanent magnet rotor.

[0068] The stator 20 has a stator core 30, an insulator 40 mounted to the stator core 30, and a coil 50 mounted to the insulator 40. The stator 20 provides a plurality of stator magnetic poles. In the present embodiment, the stator 20 provides eighteen stator magnetic poles. The stator magnetic poles 21, 22, 23 are exemplified in the drawing. The above three stator magnetic poles 21, 22, 23 each include a corresponding phase winding. One stator magnetic pole has one pole tooth 31, one bobbin 41, and one single coil 51.

[0069] The plurality of stator magnetic poles divide the inter-pole gap PG between two stator magnetic poles adjacent in the circumferential direction. The inter-pole gap PG is also referred to as a circumferential gap and as a coil-to-coil gap. The plurality of inter-pole gaps PG have a prescribed width equal to each other in the circumferential direction. The plurality of inter-pole gaps PG are arranged equidistantly in the circumferential direction. The inter-pole gap PG has a size that allows the connection portion described later to be arranged. The inter-pole gap PG has a size that allows a manufacturing operation for forming and arranging the connection portion to be performed. The size of the inter-pole gap PG can ensure electrical insulation required for the rotary electric machine 1 between the connection portion described later and the coil 50.

[0070] The stator core 30 is, for example, a laminate of electromagnetic steel sheets. The stator core 30 has a plurality of pole teeth 31. The stator core 30 has a yoke portion 32. The yoke portion 32 is a ring-shaped magnetic body. The yoke portion 32 magnetically and mechanically links the plurality of pole teeth 31. The plurality of pole teeth 31 are arranged equidistantly on an inner circumferential surface of the yoke portion 32. The plurality of pole teeth 31 and the ring-shaped yoke portion 32 are a continuous body.

[0071] The insulator 40 is electrically insulating and is made of resin. The insulator 40 is a resin molded body. The insulator 40 has a plurality of divided bodies divided in the axial direction. The plurality of divided bodies are mounted to the stator core 30, thereby providing the insulator 40. The insulator 40 provides a plurality of bobbins 41 for the plurality of pole teeth 31. One bobbin 41 is formed on one pole tooth 31. The bobbin 41 provides a reel for the coil 50. One bobbin 41 has a cylindrical portion 42 located radially outward of one pole tooth 31. One bobbin 41 provides a base end flange 43 at a base end of the pole tooth 31 and a front end flange 44 at a 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 one bobbin 41.

[0072] The coil 50 provides a stator winding. The coil 50 provides a multi-phase winding. In the present embodiment, the coil 50 provides a three-phase winding. The insulator 40 is arranged between the coil 50 and the stator core 30. The coil 50 is arranged radially outward of the plurality of pole teeth 31. The coil 50 includes a plurality of single coils 51. One single coil 51 is arranged radially outward of one pole tooth 31. The plurality of single coils 51 are formed by winding a wire around the bobbin 41. The wire is a single wire made of copper or a copper alloy. The wire has flexibility that allows a winding operation to be performed.

[0073] The stator magnetic pole 21 provides one phase winding, for example, a U-phase winding, of the three-phase winding. The stator magnetic pole 22 provides another phase winding, for example, a V-phase winding, of the three-phase winding. The stator magnetic pole 23 provides a remaining one phase winding, for example, a W-phase winding, of the three-phase winding.

[0074] The stator 20 includes at least one electrically conductive member 60. The stator 20 has a plurality of electrically conductive members 60. The electrically conductive member 60 is also referred to as a bus bar. The electrically conductive member 60 has a different cross-sectional shape from the wire used to form the coil 50. The wire is a circular cross-section, and the electrically conductive member 60 is a rectangular cross-section that is oblong or square. The electrically conductive member 60 has flexibility. The flexibility of the electrically conductive member 60 is lower than the flexibility of the wire. The electrically conductive member 60 is harder and less deformable than the wire. Thus, the electrically conductive member 60 is an electrically conductive member for electrically leading out the wire used for the coil 50 from the single coil 51.

[0075] The plurality of electrically conductive members 60 includes power terminal members 61, 62, 63 and a neutral point member 64. The power terminal members 61, 62, 63 provide output terminals or input terminals as a three-phase winding. In the case where the rotary electric machine 1 functions as a generator, the power terminal members 61, 62, 63 provide output terminals. In the case where the rotary electric machine 1 functions as a motor, the power terminal members 61, 62, 63 provide input terminals. In the present embodiment, the power terminal members 61, 62, 63 provide terminals of an electric connector. The neutral point member 64 provides a neutral point connection as a three-phase winding.

[0076] One electrically conductive member 60 has at least one connection portion 65, 66, 67, 68, 69. The electrically conductive member 60 is electrically and mechanically connected to at least one coil end 52 in the connection portion 65, 66, 67, 68, 69. The coil end 52 is an end portion 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 has, for example, six coil ends 52.

[0077] The plurality of power terminal members 61, 62, 63 respectively have a plurality of connection portions 65, 66, 67, which are respectively arranged in three inter-pole gaps PG adjacent to each other. The power terminal member 61 has the connection portion 65 arranged in the first inter-pole gap PG. The power terminal member 62 has the connection portion 66 arranged in the second inter-pole gap PG. The power terminal member 63 has the connection portion 67 arranged in the third inter-pole gap PG. The first inter-pole gap PG to the third inter-pole gap PG are arranged adjacent to each other. The plurality of connection portions 65, 66, 67 are respectively connected to the number of coil ends 52 in the smallest unit. The smallest unit is the number of parallel connections in the coil 50. In the present embodiment, the smallest unit is 1. In the case where the coil 50 is provided by two parallel coils, the smallest unit is 2.

[0078] The neutral point member 64 has a plurality of connection portions 68, 69 disposed in a plurality of inter-pole gaps PG adjacent to each other, respectively. In the illustrated example, the neutral point member 64 has two connection portions 68, 69 disposed in two inter-pole gaps PG adjacent to each other, respectively. The connection portion 68 is connected to the coil end 52 of the number of the minimum unit. The connection portion 69 is connected to the coil end 52 of 2 times the number of the minimum unit.

[0079] The plurality of connection portions 65, 66, 67, 68, 69 are dispersedly disposed in the plurality of inter-pole gaps PG adjacent to each other. The plurality of connection portions 65, 66, 67, 68, 69 are disposed in the plurality of inter-pole gaps PG adjacent to each other in a 1-to-1 relationship. In the present embodiment, one connection portion is disposed in one inter-pole gap PG. As a result, five connection portions 65, 66, 67, 68, 69 are disposed in five inter-pole gaps PG adjacent to each other.

[0080] The connection portions 65, 66, 67, 68, 69 are located in the inter-pole gap PG. The connection portions 65, 66, 67, 68, 69 are located in the inter-pole gap PG in the axial direction. There is a case where a part of the conductive member 60 extends from the inter-pole gap PG in the axial direction. However, the entire connection portions 65, 66, 67, 68, 69 are disposed in the inter-pole gap PG. The connection portions 65, 66, 67, 68, 69 are located in the inter-pole gap PG in the radial direction. There is a case where a part of the conductive member 60 extends from the inter-pole gap PG in the radial direction. However, the entire connection portions 65, 66, 67, 68, 69 are disposed in the inter-pole gap PG.

[0081] The plurality of magnetic poles protrude in the radial direction from the yoke portion 32 extending in the circumferential direction. The plurality of conductive members 60 have a circumferential extension portion 60a and a radial extension portion 60b. The circumferential extension portion 60a extends in the circumferential direction along the yoke portion 32. The radial extension portion 60b extends in the radial direction from the circumferential extension portion, and the front end reaches the inter-pole gap PG. The connection portions 65, 66, 67, 68, 69 are formed at the front end of this radial extension portion 60b. For example, the power terminal members 61, 63 have the circumferential extension portion 60a and the radial extension portion 60b. The power terminal member 62 is constituted only by the radial extension portion 60b. The power terminal members 61, 62, 63 have the radial extension portion for the connection portion extending toward the inter-pole gap PG and the radial extension portion for external connection extending for connection with the external circuit. The neutral point member 64 has the circumferential extension portion 60a and two radial extension portions 60b.

[0082] 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.

[0083] Figure 2 It shows Figure 1 The 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.

[0084] 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.

[0085] 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 a plurality of stator poles of the same phase by means of continuous wire. In the case of a three-phase winding, for example, a plurality of individual coils 51 belonging to the same phase, such as coils 1-4-7, are connected. 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.

[0086] The power terminal member 61 extends in the radial direction in the connector portion 82 for external connection. The power terminal member 61 extends in the circumferential direction on the radially outer side of the base end flange 43. The power terminal member 61 has a corner portion on the radially outer side of the first inter-pole gap PG. The power terminal member 61 extends in the radial direction across the base end flange 43 on the radially outer side of the first inter-pole gap PG. The power terminal member 61 extends in the axial direction in the first inter-pole gap PG. The connecting portion 65 is located in the first inter-pole gap PG. The connecting portion 65 is located substantially in the center of the inter-pole gap PG in the axial direction. The connecting portion 65 is located substantially in the center of the inter-pole gap PG in the radial direction.

[0087] The terminal table 80 is located on the radially outer side than the base end flange 43. The terminal table 80 is provided only at one of the axial ends of the rotary electric machine 1. The connector portion 82 is located on the radially outer side than the base end flange 43. The connector portion 82 is exposed to the outside of the housing 3. The connector portion 82 is open toward the radially outer side on the outside of the housing 3. The connector portion 82 forms an electrical connection via the power terminal member 61 by accepting a connector of an external circuit operated in the radial direction from the radially outer side.

[0088] Figure 3 is Figure 2 An enlarged view of the connecting portion in the is shown. The plurality of conductive members 60, i.e., the plurality of power terminal members 61, 62, 63, and the neutral point member 64 have similar shapes in the connecting portions 65, 66, 67, 68, 69 that they provide. The conductive member 60 has a bent portion 60c and a joint portion 60d in the radially extending portion 60b. The bent portion 60c has a crank shape that extends from the axial end surface of the stator 20 along the surface of the insulator 40 and further extends out to the inter-pole gap PG. The connection of the conductive member 60 and the coil end 52 is achieved by welding. The joint portion 60d that provides the connection achieved by welding is provided by the conductive member 60 that is bent in a manner that wraps the coil end 52. The conductive member 60 and the coil end 52 are electrically and mechanically connected by the welding process.

[0089] Figure 4is a winding diagram showing a circuit of the coil 50 in the rotary electric machine 1. The rotary electric machine 1 provides a multi-phase winding by a plurality of magnetic poles arranged in the circumferential direction. The coil 50 is illustrated in a state observed from the inner side of the stator 20. In the drawing, the range of the repeating slot S7-S15 is omitted. The coil 50 has a plurality of phase windings. The coil 50 has a U-phase winding 50u, a V-phase winding 50v, and a W-phase winding 50w. The coil 50 is wound in a manner that alternately forms a single coil 51 of the U-phase winding 50u, a single coil 51 of the V-phase winding 50v, and a single coil 51 of the W-phase winding 50w. In the present embodiment, eighteen magnetic poles are formed, and eighteen slots S1-S18 are formed between the plurality of magnetic poles. The slots S1-S18 correspond to the pole gap PG. The stator 20 has one end 20a and the other end 20b in the axial direction. The one end 20a is an end portion in which the electrically conductive member 60 is arranged. The other end 20b is an end portion in which the end lap wire 57 is arranged.

[0090] The coil 50 is wound from a prescribed initial magnetic pole. The coil 50 is transferred to the next magnetic pole of the same phase via the lap wire 54 after winding of the single coil 51 in the initial magnetic pole is completed, and is wound to the magnetic pole. Accordingly, the lap wire 54 extends between two single coils 51 of the magnetic poles of the same phase. The lap wire 54 is also referred to as a jumper. The coil 50 is sequentially wound with respect to the plurality of magnetic poles. In the following description, the initial magnetic pole is referred to as No. 1. Due to the winding process, the winding start portion 55 and the winding end portion 56 in one single coil 51 of one 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.

[0091] The end lap wire 57 is arranged at the other end 20b of the rotary electric machine 1, that is, the stator 20. In other words, the end lap wire 57 is arranged at the end portion (the other end 20b) on the side opposite to the end portion (the one end 20a) in which the electrically conductive member 60 is arranged. The end lap wire 57 extends in the circumferential direction at the other end 20b. The end lap wire 57 extends in the circumferential direction over the length range of at least two single coils 51 and one slot.

[0092] The inter-pole lap wire 58 is arranged between the winding end portion 56 and the end lap wire 57. Since the inter-pole lap wire 58 is located in front of the end lap wire 57 in the winding process, it is also referred to as a front lap wire. The inter-pole lap wire 58 connects the pole gap PG between two single coils 51 of different phases which are separated in the circumferential direction between the one end 20a and the other end 20b in the axial direction. The inter-pole lap wire 58 extends in the pole gap PG between two magnetic poles adjacent in the circumferential direction between the one end 20a and the other end 20b in the axial direction.

[0093] The inter-pole lap wire 59 is arranged between the end lap wire 57 and the winding start 55. Since the inter-pole lap wire 59 is located behind the end lap wire 57 in the winding process, it is also called a rear lap wire. The inter-pole lap wire 59 links the inter-pole gap PG between two single coils 51 of different phases separated in the circumferential direction between the one end 20a and the other end 20b in the axial direction. The inter-pole lap wire 59 extends in the inter-pole gap PG between two magnetic poles adjacent in the circumferential direction between the one end 20a and the other end 20b in the axial direction.

[0094] In the illustration and explanation, the end lap wire 57, the winding start 55, the winding end 56, the inter-pole lap wire 58, and the inter-pole lap wire 59 are labeled with identification symbols such as a, b,... to be identified. The identification symbols such as a, b,... correspond to the repetition of the winding process. For example, the U-phase winding 50u is wound from the initial winding start 55a and ends at the final winding end 56f. Hereinafter, the U-phase winding 50u is described in detail. The V-phase winding 50v and the W-phase winding 50w have the same shape.

[0095] The U-phase winding 50u starts winding from the No. 1 magnetic pole from the winding start 55a and exits from the No. 1 magnetic pole at the winding end 56a. In the present embodiment, the single coil 51 is wound in the clockwise direction. Alternatively, the single coil 51 can be wound in the counterclockwise direction. In the present embodiment, the winding process advances in the right direction from the No. 1 magnetic pole. Alternatively, the winding process can advance in the left direction from the No. 1 magnetic pole.

[0096] The single coil 51 has a wire material that is stacked in several layers in the radial direction in the magnetic pole. The number of layers of the single coil 51 is 2 or more and 10 or less. In a preferred embodiment, the single coil 51 is 2 or more and 7 or less. In the present embodiment, the single coil 51 is 2 or more and 5 or less. Specifically, the single coil 51 is 3 layers. This number of layers defines the height of the base end flange 43 and the front end flange 44. As a result, the number of layers defines the height TH40 of the insulator 40, which defines the height of the rotary electric machine 1. The number of layers of the single coil 51 is 2 or more in both the regular winding and the random winding. The winding diagram schematically shows the single coil 51, omitting the number of turns and the number of layers. The single coil 51 is arranged on the inner side of the stator 20, that is, the inner peripheral surface.

[0097] The U-phase winding 50u reaches the end lap wire 57a from the winding end 56a via the inter-pole lap wire 58a. The winding start 55a is arranged at the one end 20a. The end lap wire 57a is arranged at the other end 20b, that is, the end opposite to the electrically conductive member 60. A plurality of electrically conductive members 60 are concentratedly arranged at the one end 20a in the axial direction of the stator 20, and a plurality of end lap wires 57 are concentratedly arranged at the other end 20b in the axial direction of the stator 20. Thereby, the both ends of the stator 20 can be effectively utilized.

[0098] The U-phase winding 50u is continued by shifting from the winding end portion 56a to the inter-pole connection line 58a. The inter-pole connection line 58a extends from the one end 20a toward the other end 20b. The inter-pole connection line 58a extends in the axial direction within the cut slot S2. The inter-pole connection line 58a extends in the circumferential direction within the cut slot S2. Thus, the inter-pole connection line 58a extends obliquely within the cut slot S2. The inter-pole connection line 58a is disposed on the inner side of the stator 20. The inter-pole connection line 58a is disposed within the inter-pole gap PG. The inter-pole connection line 58a incompletely functions as a part of the single coil 51 in the No. 1 magnetic pole.

[0099] The U-phase winding 50u is continued by shifting from the inter-pole connection line 58a to the end connection line 57a. The end connection line 57a extends in the circumferential direction. The end connection line 57a is disposed so as to extend in the circumferential direction of the stator 20. The end connection line 57a is disposed along the base end flange 43. The end connection line 57a is disposed on the outer side of the stator 20. At this time, the base end flange 43 functions as a stopper that holds the end connection line 57a. Meanwhile, the circumferential end portion of the base end flange 43 defines the boundary of the inter-pole connection line 58a and the end connection line 57a.

[0100] The U-phase winding 50u is continued by shifting from the end connection line 57a to the inter-pole connection line 59a. The inter-pole connection line 59a extends from the other end 20b toward the one end 20a. The inter-pole connection line 59a extends in the axial direction within the cut slot S4. The inter-pole connection line 59a extends in the circumferential direction within the cut slot S4. Thus, the inter-pole connection line 59a extends obliquely within the cut slot S4. The inter-pole connection line 59a is disposed on the inner side of the stator 20. The inter-pole connection line 59a incompletely functions as a part of the single coil 51 in the No. 4 magnetic pole.

[0101] The U-phase winding 50u is continued by shifting from the inter-pole connection line 59a to the winding start portion 55b. The U-phase winding 50u repeatedly performs the basic cycle of sequentially passing through the winding start portion 55, the single coil 51, the winding end portion 56, the inter-pole connection line 58, the end connection line 57, and the inter-pole connection line 59, and reaches the last single coil. In the last single coil, the U-phase winding 50u is continued by shifting from the inter-pole connection line 59e to the winding start portion 55f. The U-phase winding 50u is wound around the No. 16 magnetic pole, and ends at the winding end portion 56f. The winding end portion 56f is connected to the neutral point member 64.

[0102] The U-phase winding 50u provides magnetic poles of Nos. 1, 4, 7, 10, 13, and 16. The V-phase winding 50v and the W-phase winding 50w have the same shape as the U-phase winding 50u. Therefore, the V-phase winding 50v provides magnetic poles of Nos. 2, 5, 8, 11, 14, and 17. The W-phase winding 50w provides magnetic poles of Nos. 3, 6, 9, 12, 15, and 18.

[0103] The plurality of phase windings 50u, 50v, 50w provide a plurality of two kinds of inter-pole links 58, 59. The above-mentioned inter-pole links 58, 59 are configured in (1) only one of them extends obliquely in the slot, (2) both of them cross in the slot, or (3) neither of them in the slot.

[0104] (1) In the slot S2, only the inter-pole link 58 of the U-phase winding 50u is provided. In the slot S3, only the inter-pole link 58 of the V-phase winding 50v is provided. In the slot S17, only the inter-pole link 59 of the V-phase winding 50v is provided. In the slot S18, only the inter-pole link 59 of the W-phase winding 50w is provided. In the four slots of the start and end of the winding, only one of the inter-pole link 58 or the inter-pole link 59 is provided obliquely. The above-mentioned slots S2, S3, S17, S18 are also called end slots, and one of the inter-pole link 58 or the inter-pole link 59 is provided.

[0105] (2) In the slot S4, the inter-pole link 58 of the W-phase winding 50w and the inter-pole link 59 of the U-phase winding 50u are provided. Both of the inter-pole links 58, 59 cross in the slot S4, that is, in the inter-pole gap PG. In the slot S5, the inter-pole link 58 of the U-phase winding 50u and the inter-pole link 59 of the V-phase winding 50v are provided. Both of the inter-pole links 58, 59 cross in the slot S5, that is, in the inter-pole gap PG. In the slot S6, the inter-pole link 58 of the V-phase winding 50v and the inter-pole link 59 of the W-phase winding 50w are provided. Both of the inter-pole links 58, 59 cross in the slot S6, that is, in the inter-pole gap PG. The above-mentioned cross configuration observed in the slots S4, S5, S6 is also observed in the slots S7, S8, S9, S10, S11, S12, S13, S14, S15, S16 provided with two inter-pole links 58, 59 of different phase windings by the repeated process of the winding process. Both of the inter-pole links 58, 59 cross at the center in the axial direction of the inter-pole gap PG. Both of the inter-pole links 58, 59 cross at the center in the circumferential direction of the inter-pole gap PG. The above-mentioned slots S4-S16 are also called intermediate slots, and both of the inter-pole link 58 and the inter-pole link 59 are provided in a cross manner.

[0106] (3) Neither the inter-pole overlap line 58 nor the inter-pole overlap line 59 is arranged in the slot S1. The slot S1 is also referred to as a boundary slot, and no inter-pole overlap line is arranged.

[0107] The end overlap line 57 is arranged at the other end 20b. The end overlap line 57 is arranged along the base end flange 43. The end overlap line 57 is arranged radially outward of the base end flange 43. The end overlap lines 57 are arranged so as to overlap each other in the radial and axial directions. In the present embodiment, the end overlap lines 57 of different phases are stacked in the axial direction at the other end 20b. The end overlap line 57 arranged at the other end 20b is two or less in number at all positions in the circumferential direction. In the drawings, symbols *1, *2 indicate the number of end overlap lines 57 at the positions. At the axial end (the other end 20b) of the stator 20, the plurality of end overlap lines 57 are arranged so as to (1) extend by one only, (2) extend by two overlapping each other, or (3) become zero.

[0108] (1) One end overlap line 57 is positioned along the base end flange 43 of the No. 2 magnetic pole. One end overlap line 57 is positioned along the base end flange 43 of the No. 17 magnetic pole. One end overlap line 57 is positioned axially of the slot S3. This is because the inter-pole overlap line 58 of the V-phase winding 50v is arranged within the slot S3. One end overlap line 57 is positioned axially of the slot S4. This is because two inter-pole overlap lines 58, 59 are arranged within the slot S4. One end overlap line 57 is positioned axially of the slot S5. This is because two inter-pole overlap lines 58, 59 are arranged within the slot S5. The presence of one end overlap line 57 observed at the end of the slots S3, S4, S5 is repeated in the slots S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, S16, S17.

[0109] (2) Two end overlap lines 57 are positioned along the base end flange 43 of the No. 3 magnetic pole. Two end overlap lines 57 are positioned along the base end flange 43 of the No. 4 magnetic pole. Two end overlap lines 57 are positioned along the base end flange 43 of the No. 5 magnetic pole. The presence of the plurality of end overlap lines 57 observed at the base end flanges 43 of the No. 3, No. 4, No. 5 magnetic poles is repeated in the base end flanges 43 of the No. 6, No. 7, No. 8, No. 9, No. 10, No. 11, No. 12, No. 13, No. 14, No. 15, No. 16 magnetic poles.

[0110] (3) There is no (0) end lap wire 57 located in the axial direction of the cut slot S1. There is no end lap wire 57 located along the base end flange 43 of the No. 1 magnetic pole. There is no end lap wire 57 located along the base end flange 43 of the No. 18 magnetic pole. This is because the boundary cut slot S1 and the other end 20b of the magnetic pole at the both ends do not require a lap wire. There is no end lap wire 57 located in the axial direction of the cut slot S2. This is because the inter-pole lap wire 58 functioning as a lap wire is disposed within the cut slot S2. There is no end lap wire 57 located in the axial direction of the cut slot S18. This is because the inter-pole lap wire 59 functioning as a lap wire is disposed within the cut slot S18.

[0111] In the present embodiment, the lap wire 54 includes one inter-pole lap wire 58, one inter-pole lap wire 59, and one end lap wire 57. One inter-pole lap wire 58 extends from the winding end portion 56 of one single coil 51 of the two single coils 51 of the same phase. One inter-pole lap wire 59 extends from the winding start portion 55 of the other single coil 51 of the two single coils 51 of the same phase. The lap wire 54 successively has one inter-pole lap wire 58, an end lap wire 57, and one inter-pole lap wire 59. The plurality of phase windings 50u, 50v, 50w forming the multiphase winding each have the inter-pole lap wires 58, 59. As a result, in the plurality of inter-pole gaps PG, the inter-pole lap wires 58, 59 of different phases cross. The plurality of cut slots S1-S18 formed between the plurality of magnetic poles includes one cut slot S1 having no inter-pole lap wires 58, 59. The plurality of cut slots S1-S18 includes a plurality of cut slots S2, S3, S17, S18 in which one inter-pole lap wire 58 or one inter-pole lap wire 59 is disposed. The plurality of cut slots S1-S18 includes a plurality of cut slots S4, S5, S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, S16 in which two inter-pole lap wires 58, 59 are disposed in cross. The end lap wire 57 is disposed on a surface opposite to the surface on which the single coil 51 is disposed, in the inner and outer surfaces in the radial direction of the stator 20. In other words, the magnetic pole includes the base end flange 43, and the end lap wire 57 and the inter-pole lap wires 58, 59 are disposed on both sides of the base end flange 43 in the radial direction of the rotary electric machine 1.

[0112] The manufacturing method of the rotary electric machine includes a process of assembling the rotor 10 and a process of assembling the stator 20. The process of assembling the stator 20 includes a process of assembling the stator core 30, a process of mounting the insulator 40 to the stator core 30, a process of winding the coil 50, and a process of forming the plurality of connection portions 65, 66, 67, 68, 69. In the process of winding the coil 50, the wire is wound to the stator core 30 with the insulator 40 by using a winding machine to form the coil 50. This process can be performed successively by one winding nozzle or in parallel by a plurality of winding nozzles.

[0113] The procedure of winding the coil 50 is to start winding from the one end 20a and to wind the first single coil 51. This procedure is performed while arranging the end lap wire 57 at the other end 20b. In the repeated procedure, the single coil 51 is wound from the other end 20b, and the single coils 51 are successively wound. Also, in this procedure, the single coils 51 are successively wound while arranging both the inter-pole lap wire 58 and the inter-pole lap wire 59 in the cut slot. This procedure ends the winding of the last single coil 51 at the one end 20a.

[0114] In the procedure of forming the plurality of connection portions 65, 66, 67, 68, 69, the plurality of coil ends 52 are connected with the plurality of conductive members 60. In this procedure, the conductive members 60 and the coil ends 52 are electrically connected. This procedure can be performed by arranging the coil ends 52 in contact with the conductive members 60 after arranging the conductive members 60 at the inter-pole gap PG, and bending, welding the joint portion 60d in a manner to wrap the coil ends 52. Alternatively, this procedure can be performed by arranging the coil ends 52 in contact with the conductive members 60 outside the inter-pole gap PG, and bending, welding the joint portion 60d in a manner to wrap the coil ends 52, and then arranging the conductive members 60 at the inter-pole gap PG.

[0115] Further, the manufacturing method of the rotary electric machine includes a procedure of fixing the plurality of conductive members 60. This procedure can be performed before or after the procedure of forming the plurality of connection portions. In the present embodiment, the plurality of power supply end members 61, 62, 63 are positioned and fixed to the prescribed positions of the stator 20 by the terminal table 80.

[0116] According to the above-described embodiment, by including at least one of the inter-pole lap wire 58 or the inter-pole lap wire 59, it is possible to suppress the number of the end lap wires 57 at the axial end portion of the cut slot (inter-pole gap PG) where the inter-pole lap wire 58 or the inter-pole lap wire 59 is arranged. This is because the end lap wire 57 that should be arranged at the axial end portion of the cut slot (inter-pole gap PG) is provided by the inter-pole lap wire 58, 59. In particular, by crossing the inter-pole lap wire 58 and the inter-pole lap wire 59 of two different phase windings in the cut slot (inter-pole gap PG), it is possible to suppress the number of the end lap wires 57 at the axial end portion of the cut slot (inter-pole gap PG) where the inter-pole lap wire 58 and the inter-pole lap wire 59 are arranged to the number of phases - 2. In the case of a three-phase winding, it is possible to suppress the number of the end lap wires 57 at the axial end portion of the cut slot (inter-pole gap PG) where the inter-pole lap wire 58 and the inter-pole lap wire 59 are crossed to one. As a result, it is possible to provide a small rotary electric machine 1.

[0117] According to the above-described embodiment, the connection portions 65, 66, 67, 68, 69 for the plurality of coil ends 52 can be arranged in the interpole gap PG. Thus, the axial downsizing of the connection portions 65, 66, 67, 68, 69 for the coil ends 52 can be achieved. According to the present embodiment, the connection portions 65, 66, 67, 68, 69 can be easily manufactured. According to the present embodiment, a rotary electric machine having a short axial length can be provided.

[0118] Second Embodiment The present embodiment is a modification of the previous embodiment. In the above-described embodiment, the rotary electric machine 1 includes the neutral point member 64 and the arc-shaped terminal table 80. Instead, in the present embodiment, the rotary electric machine 1 includes a multi-terminal type neutral point member 264 and a circular ring-shaped terminal table 280. In the present embodiment, the same symbols are attached to elements corresponding to those of the above-described embodiment. The description of the elements denoted by the same symbols can be referred to the description of the above-described embodiment. In the present embodiment, the rotary electric machine 1 includes a 20-pole rotor 10 and a 15-pole stator 20.

[0119] As Figures 5 to 12 , in particular Figure 9 indicated, the neutral point member 264 has three connection portions 68, 69, 270. The neutral point member 264 provides three terminals for the three-phase winding. The connection portion 68 provides electrical connection of the coil end of the winding of the first phase of the three-phase winding to the neutral point member 264. The connection portion 69 provides electrical connection of the coil end of the winding of the second phase of the three-phase winding to the neutral point member 264. The connection portion 270 provides electrical connection of the coil end of the winding of the third phase of the three-phase winding to the neutral point member 264.

[0120] The plurality of connection portions 65, 66, 67, 68, 69, 270 are arranged in the plurality of interpole gaps PG adjacent to each other in a dispersed manner. The plurality of connection portions 65, 66, 67, 68, 69, 270 are arranged in the plurality of interpole gaps PG adjacent to each other in a 1-to-1 relationship. In the present embodiment, one connection portion is arranged in one interpole gap PG. As a result, six connection portions 65, 66, 67, 68, 69, 270 are arranged in the six interpole gaps PG adjacent to each other. The neutral point member 264 is a shape called a comb-tooth type or a fork type. The neutral point member 264 has an arc-shaped portion extending in the circumferential direction along the yoke portion 32 of the stator core 30 and a radial portion extending from the arc-shaped portion as a connection portion to the radially inner side. The radial portions are arranged at equal intervals in the circumferential direction.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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.

[0125] 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.

[0126] 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.

[0127] Third Implementation Method 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.

[0128] 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.

[0129] 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.

[0130] Fourth Implementation Method 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.

[0131] 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.

[0132] 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.

[0133] Fifth Embodiment This embodiment is a modification of the previous embodiment. In the above embodiment, the end lap wire 57 is provided outside the radial direction of the base flange 43. In this embodiment, the base flange 43 provides a plurality of communication portions 548, 549 for providing the end lap wire 57. In this embodiment, the stator 20 provides fifteen magnetic poles.

[0134] In Figure 16 the stator 20 has a stator core 30, an insulator 40, and a coil 50. The end lap wire 57, the inter-pole lap wire 58, and the inter-pole lap wire 59 of the stator 20 are shown in the figure. In addition, the coil 50 is schematized and partially illustrated with hidden lines (dotted lines) in order to help understanding and avoid the figure becoming complex. The insulator 40 has a base flange 43 and a front flange 44. The base flange 43 and the front flange 44 define the range of the single coil 51. In addition, the base flange 43 has a plurality of communication portions for defining the position of the wire of the coil 50. The plurality of communication portions provide slit-like opening portions in the radial direction. The plurality of communication portions can provide the wire. The plurality of communication portions are located at both ends of the end lap wire 57 and define the circumferential range of the end lap wire 57. The coil 50 has a plurality of phase windings 50u, 50v, 50w. The coil 50 is wound from three magnetic poles shown in the central portion of the figure.

[0135] The base flange 43 is provided at one end 20a for each magnetic pole. The base flange 43 has a first flange piece 546 and a second flange piece 547 for providing the plurality of communication portions at the other end 20b. The first flange piece 546 is located outside the radial direction of the magnetic pole and protrudes in the axial direction. The first flange piece 546 is also referred to as a magnetic pole flange. The second flange piece 547 is located outside the radial direction of the slot S1-S15 and protrudes in the axial direction. The second flange piece 547 has a protrusion 245. The second flange piece 547 is also referred to as a slot flange. The first flange piece 546 and the second flange piece 547 are alternately provided in the circumferential direction. The first communication portion 548 and the second communication portion 549 are alternately divided between the first flange piece 546 and the second flange piece 547. In the proceeding direction of the wire winding process, the first communication portion 548 is located on the front side of the first flange piece 546, and the second communication portion 549 is located on the rear side of the first flange piece 546. In other words, the second communication portion 549 is located on the front side of the second flange piece 547, and the first communication portion 548 is located on the rear side of the second flange piece 547.

[0136] The first communication portion 548 and the second communication portion 549 are respectively located at both ends of the end portion lap wire 57. The first communication portion 548 is located between the inter-pole lap wire 58 and the end portion lap wire 57 and defines a boundary therebetween. The first communication portion 548 is located at a terminal end of the inter-pole lap wire 58. The first communication portion 548 is located at a start end of the end portion lap wire 57. The first communication portion 548 is also an exit communication portion that leads the wire out from the inner side to the outer side of the stator 20. The second communication portion 549 is located between the end portion lap wire 57 and the inter-pole lap wire 59 and defines a boundary therebetween. The second communication portion 549 is located at a start end of the inter-pole lap wire 59. The second communication portion 549 is located at a terminal end of the end portion lap wire 57. The second communication portion 549 is also an entrance communication portion that leads the wire in from the outer side to the inner side of the stator 20. In the present embodiment, two inter-pole lap wires 58, 59 are arranged in the cut slot. The second communication portion 549 located on the front side of the second flange piece 547 that is the cut slot flange provides an entrance that leads the wire in from the outer side to the inner side of the stator 20. The first communication portion 548 located on the rear side of the second flange piece 547 that is the cut slot flange provides an exit that leads the wire out from the inner side to the outer side of the stator 20. In the case where the rotary electric machine 1 includes both the inter-pole lap wire 58 and the inter-pole lap wire 59, both the first communication portion 548 and the second communication portion 549 are utilized. In the case where the rotary electric machine 1 includes the inter-pole lap wire 58 or the inter-pole lap wire 59, only the first communication portion 548 or the second communication portion 549 is utilized. For example, in the case where the rotary electric machine 1 includes only the inter-pole lap wire 58, only the first communication portion 548 is used as an entrance and an exit. For example, in the case where the rotary electric machine 1 includes only the inter-pole lap wire 59, only the second communication portion 549 is used as an entrance and an exit.

[0137] The U-phase winding 50u will be described as a representative example. The U-phase winding 50u is wound on the initial magnetic pole from the winding start portion 55a and is continuous by being transferred from the winding end portion 56a to the inter-pole overlap line 58a. The inter-pole overlap line 58a is led out to the radially outer side of the base end flange 43 from the first communication portion 548 and is continuous by being transferred to the end overlap line 57a. The end overlap line 57a is led in to the radially inner side of the base end flange 43 from the second communication portion 549 and is continuous by being transferred to the inter-pole overlap line 59a. The shapes of the plurality of phase windings 50u, 50v, 50w are similar. Therefore, in several slot segments, the inter-pole overlap line 58 of one phase winding and the inter-pole overlap line 59 of the other phase winding cross. For example, in the slot segment S4, the inter-pole overlap line 58 of the W-phase winding 50w and the inter-pole overlap line 59 of the U-phase winding 50u cross. In the present embodiment, since fifteen magnetic poles are provided, the coil 50 includes elements indicated by identifiers of a, b, c, d, e. For example, the inter-pole overlap line 58c, the end overlap line 57c, and the inter-pole overlap line 59c are arranged between the 7th magnetic pole and the 10th magnetic pole. The end overlap line 57c extends from the first communication portion 548 as an exit to the second communication portion 549 as an entrance.

[0138] In the Figure 17 , a single coil 51 of one phase winding is located on both sides of the inter-pole overlap line 58, the end overlap line 57, and the inter-pole overlap line 59. The coil 50 is illustrated in a state observed from the inside of the stator 20. Therefore, in one slot segment, the inter-pole overlap line 58 of a different two phase windings and the inter-pole overlap line 59 cross. As a result, it is possible to suppress the number of end overlap lines 57 at the outer side of the base end flange 43, thereby providing a small-sized rotary electric machine 1.

[0139] Sixth Embodiment The present embodiment is a modification example of the previous embodiments. In the above-described embodiments, the rotary electric machine 1 includes both the inter-pole overlap line 58 and the inter-pole overlap line 59. In addition thereto, in the present embodiment, the rotary electric machine 1 includes only the inter-pole overlap line 58.

[0140] In the Figure 18 , the stator 20 includes the insulator 40 and the coil 350 described in the fifth embodiment. The coil 350 includes only the inter-pole overlap line 58. In the present embodiment, only the first communication portion 548 is used as an entrance and an exit. For example, the U-phase winding 50u is led out from one first communication portion 548 and is led in from another first communication portion 548. In this structure, since the coil 350 is formed only by the inter-pole overlap line 58, the end overlap line 57 is slightly longer. For example, the end overlap line 57c extends to the first communication portion 548 before the 10th magnetic pole.

[0141] In the Figure 19In the present embodiment, the coil 350 includes only the inter-pole overlap line 58. Alternatively, a coil 450 having only the inter-pole overlap line 59 can be included instead of the coil 350. In the present embodiment, a small rotary electric machine 1 can be provided.

[0142] Seventh Embodiment The present embodiment is a modification of the previous embodiment. In the previous embodiment, at least one of the inter-pole overlap line 58 and the inter-pole overlap line 59 is obliquely arranged in the cutout. Alternatively, the inter-pole overlap line 58 or the inter-pole overlap line 59 can be provided by various arrangements.

[0143] In the following description, the rotary electric machine 1 is represented by an axial direction AD, a radial direction RD, and a circumferential direction CD. Sometimes, elements belonging to one phase of the multi-phase winding are described with the identifiers g, h, i. Sometimes, elements belonging to another phase of the multi-phase winding are described with the identifiers j, k, L, m. Sometimes, elements belonging to yet another phase of the multi-phase winding are described with the identifiers p, q, r, s. The stator 20 includes the single coils 51g, 51q, 51k, 51h, 51r, 51L, 51i, 51s, 51m in this order. Likewise, the inter-pole overlap line 58 is representatively described by the inter-pole overlap line 58g or the inter-pole overlap line 58k. Likewise, the inter-pole overlap line 59 is representatively described by the inter-pole overlap line 59p or the inter-pole overlap line 59g.

[0144] In the present embodiment, each of the plurality of overlap lines 54 also has the end overlap line 57, the inter-pole overlap line 58, and the inter-pole overlap line 59. In the present embodiment, between the end overlap line 57 and the inter-pole overlap lines 58, 59, a transition portion (second portion 758g2, 759p2, first portion 758gl, 759pl) of the end overlap line 57 and the inter-pole overlap lines 58, 59 is provided by a portion of the inter-pole overlap lines 58, 59.

[0145] In Figure 20 and Figure 22In the embodiment, the stator 20 includes a plurality of pseudo-poles 725. The pseudo-poles 725 are located between two magnetic poles that are circumferentially adjacent. The pseudo-poles 725 provide positioning members for defining the positions of the inter-pole straps 58 or 59. The stator 20 includes three pseudo-poles 725. The pseudo-poles 725 are located between two adjacent pole teeth 31. The three pseudo-poles 725 are separated from each other by 72° in mechanical angle. The three pseudo-poles 725 are separated from each other by 720° (360° x integer) in electrical angle. The pseudo-poles 725 can adjust the torque variation observed in the rotor 10 to a desired waveform. The stator 20 includes a plurality of first cut slots Sa having the pseudo-poles 725 and a plurality of second cut slots Sb not having the pseudo-poles 725. The circumferential width of the axially front end face of the pseudo-poles 725 is 1 / 3 or less of the circumferential width of the first cut slots Sa. The inter-pole straps 58 and 59 are arranged in the first cut slots Sa around the pseudo-poles 725.

[0146] Figure 21 is an enlarged view of the portion of the arrow XXI of Figure 20 Figure 23 is an enlarged view of the portion of the arrow XXIII of Figure 22 The pseudo-poles 725 include a magnetic material. The pseudo-poles 725 are mainly provided by a magnetic core portion provided by a material continuous from the stator core 30. The pseudo-poles 725 include an insulator 740a. The insulator 740a is provided by a material continuous from the insulator 40. Thus, the insulator 740a provides electrical insulation at the pseudo-poles 725. The inter-pole straps 58, 59 are arranged hooked to the pseudo-poles 725. The pseudo-poles 725 provide positioning members for defining the positions of the inter-pole straps 58, 59.

[0147] In the first cut slot Sa, the inter-pole strap 58g is provided by the inter-pole strap 758 located in the first cut slot Sa. The single coil 51g has a winding end portion 56g. The winding end portion 56g is arranged at a front end portion of the single coil 51g, i.e., a radially inner portion. The inter-pole strap 58g is arranged to obliquely cross the cut slot space between the single coil 51g and the pseudo-pole 725 from the winding end portion 56g of the single coil 51g. The inter-pole strap 58g extends circumferentially, radially and axially from the winding end portion 56g. The inter-pole strap 58g passes in the air. The inter-pole strap 58g is arranged to straddle the axially end face of the pseudo-pole 725. Also, the inter-pole strap 58g is arranged to reach a radially end portion of the base end flange 43q, i.e., a radially outer portion, via the axially end face of the stator core 30. As a result, the inter-pole strap 58g is connected to the end strap 57g.

[0148] ​The inter-pole lap wire 58g has a first portion 758g1 and a second portion 758g2. The first portion 758g1 is obliquely disposed in the partial slot Sa1 between the single coil 51g and the pseudo pole tooth 725. The second portion 758g2 is disposed on the axially outer side of the partial slot Sa2 between the pseudo pole tooth 725 and the single coil 51q. The axial displacement amount and the radial displacement amount of the first portion 758g1 are larger than those of the second portion 758g2. Since the second portion 758g2 is located at the axial end surface of the stator 20, it can also be classified as a part of the end lap wire 57g. In this case, the inter-pole lap wire 58g is provided only by the first portion 758g1. The second portion 758g2 is also referred to as a transition portion between the end lap wire 57g and the first portion 758g1 as the inter-pole lap wire 58g.

[0149] In the first slot Sa, the inter-pole lap wire 59p is provided by the inter-pole lap wire 759 located in the first slot Sa. The end lap wire 57p is disposed on the axially outer side, that is, the axially outer side of the base flange 43g. The inter-pole lap wire 59p is disposed so as to pass the axial end surface of the pseudo pole tooth 725 from the end lap wire 57p. Further, the inter-pole lap wire 59p is disposed so as to obliquely cross the space within the first slot Sa from the axial end surface of the pseudo 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, that is, the radially outer portion of the single coil 51q. The inter-pole lap wire 59p extends in the circumferential and axial directions from the axial end surface of the pseudo pole tooth 725 toward the winding start portion 55q. The inter-pole lap wire 59p passes the air. The inter-pole lap wire 59p is disposed so as to reach the winding start portion 55q from the axial end surface of the pseudo pole tooth 725. As a result, the inter-pole lap wire 59p is connected to the winding start portion 55q of the single coil 51q.

[0150] The inter-pole lap wire 58g and the inter-pole lap wire 59p cross over the pseudo-pole tooth 725. The inter-pole lap wire 58g extending from the single coil 51g of one of the two circumferentially adjacent single coils 51g, 51q crosses the inter-pole lap wire 59p extending from the single coil 51q of the other in the inter-pole gap PG. The inter-pole lap wire 59p has a first portion 759pl and a second portion 759p2. The first portion 759pl is disposed axially outward of the partial slot Sa1 between the single coil 51g and the pseudo-pole tooth 725. The second portion 759p2 is obliquely disposed in the partial slot Sa2 between the pseudo-pole tooth 725 and the single coil 51q. The second portion 759p2 has an amount of axial displacement greater than that of the first portion 759pl. Since the first portion 759pl is located at the axial end face of the stator 20, it can also be classified as a portion of the end lap wire 57p. In this case, the inter-pole lap wire 59p is provided only by the second portion 759p2. The first portion 759pl is also referred to as a transition portion between the end lap wire 57p and the second portion 759p2 which is the inter-pole lap wire 59p.

[0151] Figure 24 A cross section at the line XXIV-XXIV of Figure 20 is shown. Figure 25 is an enlarged view of the arrow XXV portion of Figure 24 In Figure 25 insulators 740a, 740b are respectively disposed over the two axial end faces of the pseudo-pole tooth 725. The end lap wire 57j for one phase, the inter-pole lap wire 58g for another phase, and the inter-pole lap wire 59p for yet another phase are positioned over the two axial end faces of the pseudo-pole tooth 725. The inter-pole lap wire 58g and the inter-pole lap wire 59p are disposed more radially offset than the end lap wire 57j. Over the pseudo-pole tooth 725, the end lap wire 57j, the inter-pole lap wire 58g, and the inter-pole lap wire 59p are positioned in a radial arrangement. Axially of the pseudo-pole tooth 725, the end lap wire 57j, the inter-pole lap wire 58g, and the inter-pole lap wire 59p are disposed within the range of the coil edge end height axially of the single coil 51g.

[0152] Figure 26 is an enlarged view of the arrow XXVI portion of Figure 24 In Figure 26In the middle, a cross section of the single coil 51m is shown. The end lap wire 57i and the end lap wire 57s are arranged radially outward of the base end flange 43m for the single coil 51m. The end lap wire 57i connects the single coil 51i and a not-shown single coil of the same phase. The end lap wire 57s connects the single coil 51s and a not-shown single coil of the same phase. The base end flange 43m provides a holding member for holding the two end lap wires 57i, 57s. Even radially outward of the magnetic pole, i.e. radially outward of the base end flange 43m, the end lap wire 57i and the end lap wire 57s are arranged within the coil edge end height in the axial direction of the single coil 51g.

[0153] The first portion 758g1 of the inter-pole lap wire 58g extends in the axial direction of the stator 20 between the one end 20a and the other end 20b in the inter-pole gap PG. The first portion 758g1 extends at least circumferentially and obliquely in the axial direction. Thereby, the number of lap wires 54 stacked in the axial or radial direction at the radially outer side of the insulator 40 can be suppressed. The second portion 759p2 of the inter-pole lap wire 59p extends in the axial direction of the stator 20 between the one end 20a and the other end 20b in the inter-pole gap PG. The second portion 759p2 extends at least circumferentially and obliquely in the axial direction. Thereby, the number of lap wires 54 stacked in the axial or radial direction at the radially outer side of the insulator 40 can be suppressed. The inter-pole lap wire 58g and the inter-pole lap wire 59p cross in the inter-pole gap PG radially inward of the base end flanges 43g, 43q. Thus, in the angular range of the first cut slot Sa, the lap wires 54 are radially dispersed. Thereby, the number of lap wires 54 stacked in the axial or radial direction at the radially outer side of the insulator 40 can be suppressed. The number of lap wires 54 stacked in the axial or radial direction at the radially outer side of the insulator 40 is suppressed to two.

[0154] Figure 27 is an enlarged view of the arrow XXVII portion of Figure 20 Figure 28 is an enlarged view of the arrow XXVIII portion of Figure 22 In the second cut slot Sb, the inter-pole lap wire 58k is provided by the inter-pole lap wire 758 located at the second cut slot Sb. Figure 27 and Figure 28 The inter-pole lap wire 58k, the first portion 758k1, the second portion 758k2 shown in Figure 21 and Figure 23 have the same shape as the inter-pole lap wire 58g, the first portion 758g1, the second portion 758g2 shown in Figure 27 and Figure 28 The inter-pole lap wire 59g, the first portion 759g1, the second portion 759g2 shown in​Figure 21 and Figure 23 The same shape as the inter-pole lap wire 59p, the first portion 759pl, and the second portion 759p2. The inter-pole lap wire 58k and the inter-pole lap wire 59g cross in the space (inter-pole gap PG) of the axial end portion of the second slot Sb. The inter-pole lap wire 58k and the inter-pole lap wire 59g are meanderingly arranged in such a manner that the pseudo-pole tooth 725 is virtually present therein.

[0155] Figure 29 is Figure 27 an enlarged view of the arrow XXIX portion. Figure 29 A cross section at the second slot Sb without the pseudo-pole tooth 725 is shown. In the second slot Sb, the end lap wire 57q for one phase, the inter-pole lap wire 58k for another phase, and the inter-pole lap wire 59g for yet another phase are positioned. The inter-pole lap wire 58k and the inter-pole lap wire 59g are arranged more radially offset than the end lap wire 57q. The end lap wire 57q, the inter-pole lap wire 58k, and the inter-pole lap wire 59g are positioned in a radial alignment. In the circumferential middle portion of the second slot Sb, the end lap wire 57q, the inter-pole lap wire 58k, and the inter-pole lap wire 59g are arranged within the coil edge end height of the single coil 51k.

[0156] Returning to Figure 28 , the first portion 758kl of the inter-pole lap wire 58k extends in the inter-pole gap PG between the one end 20a and the other end 20b of the stator 20 in the axial direction. The first portion 758kl extends at least circumferentially and obliquely in the axial direction. Thereby, the number of the lap wires 54 stacked in the axial or radial direction at the radially outer side of the insulator 40 can be suppressed. The second portion 759g2 of the inter-pole lap wire 59g extends in the inter-pole gap PG between the 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. Thereby, the number of the lap wires 54 stacked in the axial or radial direction at the radially outer side of the insulator 40 can be suppressed. The inter-pole lap wire 58k and the inter-pole lap wire 59g cross in the inter-pole gap PG more radially inward than the base end flange 43k, 43h. Therefore, in the angular range of the first slot Sa, the lap wires 54 are dispersed in the radial direction. Thereby, the number of the lap wires 54 stacked in the axial or radial direction at the radially outer side of the insulator 40 can be suppressed. The number of the lap wires 54 stacked in the axial or radial direction at the radially outer side of the insulator 40 is suppressed to two.

[0157] In the present embodiment, by including the inter-pole lap wires, it is also possible to suppress the volume for disposing the lap wires. In the illustrated example, it is possible to suppress the number of layers of the lap wires in the circumferential angle range of the cut slots Sa, Sb. In the case where the lap wires are layered in the radial direction of the stator 20, it is possible to suppress the radial dimension of the stator 20. In the case where the lap wires are layered in the axial direction of the stator 20, it is possible to suppress the axial dimension of the stator 20. Further, the lap wires are located in the range of the coil edge end portions of the plurality of single coils, that is, in the range of the axial height of the single coils. Thereby, it is possible to suppress the axial height of the stator 20.

[0158] Eighth Embodiment The present embodiment is a modification of the previous embodiments. In the previous embodiments, the inter-pole lap wires 58, 59 are disposed on one side in the axial direction of the stator 20. In other words, the inter-pole lap wires 58, 59 are disposed on one side in the axial direction of the pseudo-pole teeth 725. Instead, in the present embodiment, the inter-pole lap wires 58, 59 are disposed on both sides in the axial direction of the stator 20.

[0159] Figure 30 Figure 31 Figure 32 are equivalent to Figure 21 Figure 23 Figure 25 are equivalent toIn these drawings, the inter-pole lap wire 58g and the inter-pole lap wire 59p are configured to include portions extending along both sides in the axial direction of the stator 20. The inter-pole lap wire 58g and the inter-pole lap wire 59p are disposed at both ends in the axial direction of the pseudo-pole teeth 725. In the first cut slot Sa, the inter-pole lap wire 58g is provided by the inter-pole lap wire 858 located in the first cut slot Sa. The inter-pole lap wire 759 is disposed at one end of the pseudo-pole tooth 725, and the inter-pole lap wire 858 is disposed at the opposite side, that is, the other end of the pseudo-pole tooth 725. The inter-pole lap wire 58g has a first portion 858g1 disposed on the other end side of the pseudo-pole tooth 725. The first portion 858g1 is obliquely disposed on the end surface of the stator 20 in the partial cut slot Sa1 between the single coil 51g and the pseudo-pole tooth 725. The first portion 858g1 provides a transition portion. The inter-pole lap wire 58g has a second portion 858g2 obliquely extending between the pseudo-pole tooth 725 and the single coil 51q. The second portion 858g2 of the inter-pole lap wire 58g extending from the single coil 51g on one side intersects with the second portion 759p2 of the inter-pole lap wire 59p extending from the single coil 51q on the other side in the partial cut slot Sa2. The second portion 858g2 provides an intersection portion.

[0160] ​​​The second portion 858g2 of the inter-pole strap 58g extends in the inter-pole gap PG between the one end 20a and the other end 20b of the stator 20 in the axial direction. The second portion 858g2 extends at least circumferentially and obliquely in the axial direction. Thereby, it is possible to suppress the number of the straps 54 stacked in the axial or radial direction at the radially outer side of the insulator 40. The second portion 759p2 of the inter-pole strap 59p extends in the inter-pole gap PG between the one end 20a and the other end 20b of the stator 20 in the axial direction. The second portion 759p2 extends at least circumferentially and obliquely in the axial direction. Thereby, it is possible to suppress the number of the straps 54 stacked in the axial or radial direction at the radially outer side of the insulator 40. The inter-pole strap 58g and the inter-pole strap 59p cross in the inter-pole gap PG more radially inward than the base end flange 43g, 43q. In the present embodiment, the inter-pole strap 58g and the inter-pole strap 59p cross in the partial slot Sa2. Therefore, in the angular range of the first slot Sa, the straps 54 are dispersed in the radial direction. Thereby, it is possible to suppress the number of the straps 54 stacked in the axial or radial direction at the radially outer side of the insulator 40. The number of the straps 54 stacked in the axial or radial direction at the radially outer side of the insulator 40 is suppressed to two.

[0161] Figure 33 , Figure 34 , Figure 35 are drawings corresponding to Figure 27 , Figure 28 , Figure 29 . In these drawings, the inter-pole strap 58k and the inter-pole strap 59g are disposed at both ends in the axial direction of the stator 20 without the dummy pole teeth 725. The inter-pole strap 58k and the inter-pole strap 59g are disposed in the second slot Sb in a meandering manner in space. In other words, the inter-pole strap 58k and the inter-pole strap 59g are not disposed in the shortest path of a straight line. It can also be said that the inter-pole strap 58k and the inter-pole strap 59g are disposed in a crank shape.

[0162] Returning to Figure 34The second portion 858k2 of the inter-pole strap 58k extends in the inter-pole gap PG between the one end 20a and the other end 20b of the stator 20 in the axial direction. The second portion 858k2 extends at least in the circumferential direction and obliquely in the axial direction. Thereby, it is possible to suppress the number of the straps 54 stacked in the axial or radial direction at the radially outer side of the insulator 40. The second portion 759g2 of the inter-pole strap 59g extends in the inter-pole gap PG between the one end 20a and the other end 20b of the stator 20 in the axial direction. The second portion 759g2 extends at least in the circumferential direction and obliquely in the axial direction. Thereby, it is possible to suppress the number of the straps 54 stacked in the axial or radial direction at the radially outer side of the insulator 40. The inter-pole strap 58k and the inter-pole strap 59g cross in the inter-pole gap PG at a radially inner side than the base end flange 43k, 43h. Therefore, in the angular range of the second cut slot Sb, the straps 54 are dispersed in the radial direction. Thereby, it is possible to suppress the number of the straps 54 stacked in the axial or radial direction at the radially outer side of the insulator 40. The number of the straps 54 stacked in the axial or radial direction at the radially outer side of the insulator 40 is suppressed to two.

[0163] In the present embodiment, the inter-pole strap 58g and the inter-pole strap 59p cross in the partial cut slot Sa2. Alternatively, the inter-pole strap 58g and the inter-pole strap 59p can cross in the partial cut slot Sa1.

[0164] According to the present embodiment, the inter-pole straps 58, 59 are dispersedly arranged on both axial sides of the pseudo-pole teeth 725. Thereby, it is possible to obtain advantageous effects achieved by the dispersion of the plurality of straps. For example, it is possible to suppress the physical interaction between the plurality of straps. For example, it is possible to suppress the capacitance component and the inductance component at times. In addition, it is possible to promote the heat dissipation at times. In the present embodiment, it is also possible to obtain the same action effects as the previous embodiments.

[0165] Ninth Embodiment The present embodiment is a modification example of the previous embodiments. In the previous embodiments, particularly the seventh embodiment, the winding end portion 56 of the single coil 51 is arranged at the leading end portion of the single coil 51, that is, the radially inner side portion. Alternatively, in the present embodiment, the winding end portion 56 is arranged at the base end portion of the single coil 51, that is, the radially outer side portion.

[0166] Figure 36 , Figure 37 , Figure 38 are respectively equivalent to Figure 21 , Figure 23 , Figure 25Fig. 6 is a view corresponding to Fig. 5. In these figures, the winding end portions 56g, 56q of the single coils 51g, 51q are disposed at the base end portions of the single coils 51g, 51q. In the first cutaway groove Sa, the inter-pole lap wire 58g is provided by the inter-pole lap wire 958 located in the first cutaway groove Sa. The first portion 958gl of the inter-pole lap wire 58g is disposed obliquely in the partial cutaway groove Sail. The first portion 958gl is disposed along the inner surface of the yoke portion 32. The second portion 958g2 is also a transition portion. The inter-pole lap wire 58g and the inter-pole lap wire 59p are axially laminated and cross in the axial direction of the pseudo-pole tooth 725.

[0167] Figure 39 , Figure 40 , Figure 41 are views corresponding to Figure 27 , Figure 28 , Figure 29 Fig. 6 is a view corresponding to Fig. 5. In these figures, the winding end portions 56g, 56q of the single coils 51g, 51q are disposed at the base end portions of the single coils 51g, 51q. In the first cutaway groove Sa, the inter-pole lap wire 58g is provided by the inter-pole lap wire 958 located in the first cutaway groove Sa. The first portion 958gl of the inter-pole lap wire 58g is disposed obliquely in the partial cutaway groove Sail. The first portion 958gl is disposed along the inner surface of the yoke portion 32. The second portion 958g2 is also a transition portion. The inter-pole lap wire 58g and the inter-pole lap wire 59p are axially laminated and cross in the axial direction of the pseudo-pole tooth 725.

[0168] According to the present embodiment, the inter-pole lap wire 58 can be disposed without being limited by the position of the winding end portion 56. Likewise, the inter-pole lap wire 59 can also be disposed without being limited by the position of the winding start portion 55. In the present embodiment, the same advantageous effects as in the previous embodiments can also be obtained.

[0169] Tenth Embodiment The present embodiment is a modification of the previous embodiments. In the previous embodiments, the inter-pole lap wires 58, 59 are disposed in a manner that bypasses the pseudo-pole tooth 725 or makes the pseudo-pole tooth 725 virtually exist therein. Instead, the present embodiment includes a member that replaces the pseudo-pole tooth 725.

[0170] Figure 42 , Figure 43 , Figure 44 are views corresponding to Figure 27 , Figure 28 , Figure 29 Fig. 6 is a view corresponding to Fig. 5. In these figures, the winding end portions 56g, 56q of the single coils 51g, 51q are disposed at the base end portions of the single coils 51g, 51q. In the first cutaway groove Sa, the inter-pole lap wire 58g is provided by the inter-pole lap wire 958 located in the first cutaway groove Sa. The first portion 958gl of the inter-pole lap wire 58g is disposed obliquely in the partial cutaway groove Sail. The first portion 958gl is disposed along the inner surface of the yoke portion 32. The second portion 958g2 is also a transition portion. The inter-pole lap wire 58g and the inter-pole lap wire 59p are axially laminated and cross in the axial direction of the pseudo-pole tooth 725. Figure 44 Fig. 6 is a view corresponding to Fig. 5. In these figures, the winding end portions 56g, 56q of the single coils 51g, 51q are disposed at the base end portions of the single coils 51g, 51q. In the first cutaway groove Sa, the inter-pole lap wire 58g is provided by the inter-pole lap wire 958 located in the first cutaway groove Sa. The first portion 958gl of the inter-pole lap wire 58g is disposed obliquely in the partial cutaway groove Sail. The first portion 958gl is disposed along the inner surface of the yoke portion 32. The second portion 958g2 is also a transition portion. The inter-pole lap wire 58g and the inter-pole lap wire 59p are axially laminated and cross in the axial direction of the pseudo-pole tooth 725. Figure 42the cross section at XLIV-XLIV line. In these drawings, the insulator 40 has a protrusion A46 in the second cut groove Sb. The protrusion A46 contains a resin material. The protrusion A46 is also a positioning member that positions the inter-pole overlap lines 58, 59 instead of the dummy pole teeth 725. The circumferential width of the protrusion A46 is smaller than the circumferential width of the second cut groove Sb. The partial cut grooves Sb1, Sb2 are formed on both circumferential sides of the protrusion A46. The radial length of the protrusion A46 is lower than the pole face of the stator 20. The protrusion A46 is disposed at the intermediate portion of the circumferential direction of the second cut groove Sb. The protrusion A46 can also be disposed close to either of the circumferential direction of the second cut groove Sb. The axial height of the protrusion A46 is about 1 / 3 of the axial dimension of the insulator 40. Alternatively, the axial height of the protrusion A46 is sometimes equal to the axial dimension of the insulator 40. The axial height of the protrusion A46 can be set to obtain the strength for positioning the inter-pole overlap lines 58, 59.

[0171] The inter-pole overlap line 58k is provided by the inter-pole overlap line 758. The inter-pole overlap line 59g is provided by the inter-pole overlap line 759. The inter-pole overlap lines 58k, 59g are bent into the illustrated shape by hooking on the protrusion A46. The inter-pole overlap lines 58k, 59g are guided by the protrusion A46 instead of the dummy pole teeth 725. From this viewpoint, the dummy pole teeth 725 and the protrusion A46 provide a guide member that guides the inter-pole overlap lines 58, 59 to the prescribed disposition position. As a result, the same inter-pole overlap lines as the previous embodiment are provided.

[0172] Eleventh Embodiment This embodiment is a modification of the previous embodiment. In the previous embodiment, the dummy pole teeth 725 and the protrusion A46 provide a positioning member for the inter-pole overlap lines 58, 59 to hook on. Instead, this embodiment includes a groove for more reliably holding the inter-pole overlap lines 58, 59.

[0173] Figure 45 、 Figure 46 、 Figure 47 are drawings corresponding to Figure 27 、 Figure 28 、 Figure 29 . Figure 47 shows Figure 45the cross section at lines XLVII-XLVII of FIG. 45. In these drawings, the insulator 40 has a protrusion B46 in the second cut groove Sb. The protrusion B46 has the same degree of size as the protrusion A46 of the previous embodiment. The protrusion B46 has a groove B47 that receives the inter-electrode connecting line 59g. The protrusion B46 has a groove B48 that receives the inter-electrode connecting line 58k. The groove B47 is disposed at one end surface in the axial direction of the protrusion B46. The groove B48 is disposed at the other end surface in the axial direction of the protrusion B46. The groove B47 and the groove B48 are disposed at opposite surfaces of the protrusion B46. The grooves B47, B48 hold the inter-electrode connecting lines 59g, 58k.

[0174] The groove B47 at least restricts the inter-electrode connecting line 59g in the radial direction. The groove B47 is a relatively small groove that receives the inter-electrode connecting line 59g while restricting the inter-electrode connecting line 59g. The inter-electrode connecting line 59g is pressed in the axial direction toward the groove B47. The groove B47 has a long side direction in the circumferential or tangential direction. The groove B47 is also called a snap-fit groove that restricts the inter-electrode connecting line 59g using the elasticity of the protrusion B46. As a result, the groove B47 also restricts the inter-electrode connecting line 59g in the circumferential or tangential direction. The axial depth of the groove B47 is equal to or more than the radius of the inter-electrode connecting line 59g. The groove B47 can also be provided by a relatively large groove that loosely receives the inter-electrode connecting line 59g in a state that allows the inter-electrode connecting line 59g to float. The axial depth of the groove B47 can also be less than the radius of the inter-electrode connecting line 59g.

[0175] The groove B48 at least restricts the inter-electrode connecting line 58k in the radial direction. The groove B48 is a relatively small groove that receives the inter-electrode connecting line 58k while restricting the inter-electrode connecting line 58k. The inter-electrode connecting line 58k is pressed in the axial direction toward the groove B48. The groove B48 has a long side direction in the circumferential or tangential direction. The groove B48 is also called a snap-fit groove that restricts the inter-electrode connecting line 58k using the elasticity of the protrusion B46. As a result, the groove B48 also restricts the inter-electrode connecting line 58k in the circumferential or tangential direction. The axial depth of the groove B48 is equal to or more than the radius of the inter-electrode connecting line 58k. The groove B48 can also be provided by a relatively large groove that loosely receives the inter-electrode connecting line 58k in a state that allows the inter-electrode connecting line 58k to float. The axial depth of the groove B48 can also be less than the radius of the inter-electrode connecting line 58k.

[0176] In the manufacturing method of the stator, by restraining and holding the inter-pole lap wire arranged therein, the shape stability of the inter-pole lap wire in the winding process is improved. In the winding process, after winding one single coil 51k, the inter-pole lap wire 58k is housed and held in the slot B48. Thereby, the case that the winding of the single coil 51 is slowly loosened can be suppressed. In the winding process, after the end lap wire 57g is arranged, the inter-pole lap wire 59g is housed and held in the slot B47. Thereby, the case that the end lap wire 57 is slowly loosened can be suppressed. As a result, the slots B47 and B48 improve the shape stability of the coil 50. In addition, the slots B47 and B48 promote the progress of the winding process.

[0177] The inter-pole lap wire 58k is provided by the inter-pole lap wire B58. The middle portion of the inter-pole lap wire B58 is restrained by the protrusion B46. Thereby, the inter-pole lap wire B58 is arranged in a meandering manner in Z or S shape. The inter-pole lap wire 59g is provided by the inter-pole lap wire B59. The middle portion of the inter-pole lap wire B59 is restrained by the protrusion B46. Thereby, the inter-pole lap wire B59 is arranged in a meandering manner in Z or S shape.

[0178] In the present embodiment, the stator 20 includes both the slot B47 and the slot B48. Alternatively, the stator 20 can include only either one of the slot B47 and the slot B48. In the present embodiment, the slot B47 or the slot B48 is arranged in the protrusion B46 made of resin which extends from the insulator 40. Alternatively, the slot B47 or the slot B48 can be provided in the insulator 740a, 740b at the pseudo-pole tooth 725. In the present embodiment, the same effect as the previous embodiment can be obtained.

[0179] Twelfth Embodiment The present embodiment is a modification example of 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 be variously changed.

[0180] Figure 48 、 Figure 49 、 Figure 50 are drawings corresponding to Figure 27 、 Figure 28 、 Figure 29 , respectively. Figure 50 shows a cross section at the L-L line of Figure 48 . In these drawings, the winding end portion 56k of the single coil 51k is located at a radially outer portion. The inter-pole lap wire 58k is provided by the inter-pole lap wire C58. The inter-pole lap wire C58 is arranged along the inner surface of the stator core 30. In the present embodiment, the same effect as the previous embodiment can be obtained.

[0181] Thirteenth Implementation Method 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.

[0182] 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. The distances G2 and G3 are not equal (G2 ≠ G3). The 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.

[0183] Other implementation methods 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.

[0184] 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.

[0185] In the above-described embodiments, the rotary electric machine 1 is of an inner rotor type. Alternatively, the rotary electric machine 1 can be of an outer rotor type. In the above-described embodiments, the rotary electric machine 1 provides a motor. Alternatively, the rotary electric machine 1 can provide a generator or a motor-generator. In addition, the rotary electric machine 1 can be used for various purposes called a servo motor, a step motor, and the like.

[0186] In the above-described embodiments, the stator core 30 is provided by a steel sheet in which a plurality of the pole teeth 31 and the yoke portion 32 are continuous. Alternatively, the stator core 30 can be provided by a so-called multi-partition core. In this case, the stator core 30 is provided by a plurality of joint bodies of partial cores. One partial core is provided by, for example, one partial annular yoke portion and a continuous body of one pole tooth.

[0187] In the above-described embodiments, the plurality of electrically conductive members 60 are insert-molded in the terminal platform 80, 280. Alternatively, the plurality of electrically conductive members 60 can be press-fitted to the terminal platform 80, 280. In addition, the plurality of electrically conductive members 60 can be supported or fixed by the insulator 40 without the terminal platform 80, 280. For example, the plurality of electrically conductive members 60 can be directly fixed to the insulator 40 by a snap fit. In this structure, since the connection portions 65, 66, 67, 68, 69, 270 are disposed in the inter-pole gap PG, the size of the coil end 52 of the rotary electric machine 1 can be reduced. In the above-described embodiments, the connector portion 82 is opened toward the radially outer side outside the housing 3. Alternatively, the connector portion 82 can be opened toward the axial direction outside the housing 3. In this case, the connector portion 82 forms an electrical connection by receiving a connector of an external circuit operated in the axial direction from either direction in the axial direction.

[0188] In the above-described embodiments, the coil 50 is of a star connection. Alternatively, the coil 50 can be of a delta connection. In this case, the connection portion of one electrically conductive member 60 and at least two coil ends 52 is disposed in the inter-pole gap PG. Further, in the above-described embodiments, one phase winding is provided by one wire. Alternatively, one phase winding can be provided as a parallel circuit of a plurality of wires. In this case, one single coil 51 is provided by the parallel circuit of a plurality of wires. For example, in a case where one single coil 51 is provided by two wires, in a star connection, the connection portion of one electrically conductive member 60 providing one power terminal and two coil ends 52 is disposed in the inter-pole gap PG. For example, in a case where one single coil 51 is provided by two wires, in a delta connection, the connection portion of one electrically conductive member 60 providing one power terminal and four coil ends 52 is disposed in the inter-pole gap PG.

[0189] In the above-described embodiment, the electrically conductive member 60 is a bus bar. Alternatively, the electrically conductive member 60 can also be an electrode for a terminal, a wire, a conductor foil on a substrate. In these cases, by disposing the connecting portion in the inter-pole gap PG, miniaturization can also be achieved. In the above-described embodiment, the coil 50 is made of copper or a copper alloy. Alternatively, the coil 50 can also be made of aluminum or an aluminum alloy. In the above-described embodiment, the connection of the electrically conductive member to the coil end 52 is provided by fusion. Alternatively, the connection of the electrically conductive member to the coil end 52 can also be provided by hot riveting, welding, soldering, or the like.

[0190] In the above-described embodiment, the electrically conductive member 60 has a connector terminal extending radially as a power terminal. Alternatively, the electrically conductive member 60 can also extend in the axial direction. In this case, by disposing the connecting portion in the inter-pole gap PG, axial miniaturization can also be achieved. In the above-described embodiment, the plurality of power terminal members 61, 62, 63 provide the connector terminal. Alternatively, the power terminal members 61, 62, 63 can also provide crimp terminals, solder terminals, or the like.

[0191] In the above-described embodiment, the inter-pole gap PG is a hollow. Alternatively, the inter-pole gap PG can also be filled in after the electrically conductive member 60 is disposed by a resin member. In addition, the electrically conductive member 60 disposed in the inter-pole gap PG can also be coated with a thin resin material. In either structure, by disposing the connecting portion, which is a part of the electrically conductive member 60, in the inter-pole gap PG, a small-sized rotary electric machine 1 can be provided.

[0192] In the above-described embodiment, the plurality of coil ends at which winding starts are used as power terminals, and the plurality of coil ends at which winding ends are used as neutral points. Alternatively, the plurality of coil ends at which winding ends can also be used as power terminals, and the plurality of coil ends at which winding starts can be used as neutral points. Furthermore, the coil ends can also be used as power terminals or neutral points without using the electrically conductive member 60. For example, the plurality of coil ends at which winding starts or ends can also be drawn out longer and used as power terminals. For example, the plurality of coil ends at which winding starts or ends can also be directly joined to each other and used as neutral points.

Claims

1. A rotary electric machine that provides a multiphase winding by a plurality of magnetic poles arranged in a circumferential direction, The overlap line extending between the two single coils of the magnetic poles providing the in-phase comprises at least: an inter-pole overlap line extending between one end and the other end in an axial direction in an inter-pole gap between two of the magnetic poles that are circumferentially adjacent to each other; and an end overlap line extending in the circumferential direction at the other end, the end overlap lines that are out of phase being stacked in the axial direction at the other end, the end overlap lines that are stacked in the axial direction being two or fewer at all positions in the circumferential direction.

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