Rotary electric machine

Abstract

To provide a rotary electric machine that eliminates the need for a welding process when joining a front end and achieves improvement in productivity SOLUTION: A rotary electric machine comprising: a stator coil in which a first flat wire and a second flat wire are fitted to each other, wherein the first flat wire has a convex portion and the second flat wire has a concave portion, the convex portion and the concave portion are configured to be inserted and fitted to each other, the convex portion has a protrusion and the concave portion has a groove on a surface along an extending direction of the first flat wire and the second flat wire among surfaces constituting the convex portion and the concave portion, and the protrusion and the groove respectively have a pair of protrusions and a pair of grooves.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] The present invention relates to a rotating electric machine. [Background technology]

[0002] Rotating electric machines are so-called motors and are widely used in industry. Therefore, mass production is required, and a structure that contributes to improving the production process is desired.

[0003] Patent Document 1 discloses a structure of a first tip portion and a second tip portion that are joined to each other. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2022-162929 Summary of the Invention [Problem to be solved by the invention]

[0005] The tip structure disclosed in Patent Document 1 is a structure that requires welding. However, the welding process takes time and requires welding equipment. Therefore, the more points to be welded and the more units to be welded, the more expensive the manufacturing process becomes. Furthermore, in principle, a temperature rise around the welded parts is unavoidable, which poses a risk of deformation of non-welded parts.

[0006] Therefore, the present application provides a rotating electric machine that does not require a welding process when joining the tip portion, thereby improving productivity. [Means for solving the problem]

[0007] The stator coil has a first rectangular wire and a second rectangular wire fitted together, The first flat wire has a convex portion, and the second flat wire has a concave portion, and the convex portion and the concave portion are configured to be inserted and fitted into each other, Among the surfaces constituting the convex portion and the concave portion, on the surface along the extension direction of the first flat wire and the second flat wire, the convex portion has a protrusion portion, and the concave portion has a groove portion, The rotary electric machine has a pair of protrusions and a pair of grooves as the protrusions and the grooves, respectively. [Effects of the Invention]

[0008] According to the rotating electric machine of the present invention, the welding process is not required when joining the tip portion, and productivity can be improved.

[0009] Furthermore, when the welding process is not required, a structure that is easy to manufacture and does not easily come loose can be realized.

[0010] Further means and effects of the present invention will become apparent throughout the entire specification below. [Brief explanation of the drawings]

[0011] [Figure 1A] FIG. 10 is an explanatory diagram of an embodiment before mating. [Figure 1B] FIG. 10 is an explanatory diagram of the embodiment after mating. [Figure 2A] FIG. 2 is a perspective view showing the internal structure of a stator in one embodiment. [Figure 2B] FIG. 10 is an explanatory diagram of the fitting relationship of the hairpin coil in one embodiment. [Figure 3A] FIG. 2 is an explanatory diagram of a stator core according to an embodiment. [Figure 3B] FIG. 2 is an explanatory diagram of a resin bobbin according to an embodiment. [Figure 3C] FIG. 2 is an explanatory diagram of the positional relationship of teeth cores in a stator according to an embodiment. [Figure 3D] FIG. 4 is an explanatory diagram of the positional relationship of a resin bobbin in a stator according to an embodiment. [Figure 4A] FIG. 2 is a top view illustrating a stator according to an embodiment. [Figure 4B] FIG. 2 is a perspective view of a stator according to an embodiment. [Figure 4C]FIG. 2 is an explanatory diagram of a coil end 10 according to an embodiment. [Figure 4D] FIG. 2 is an explanatory diagram of a coil end 50 according to an embodiment. [Figure 4E] FIG. 2 is an explanatory diagram of a coil end 30 according to an embodiment. [Figure 5A] FIG. 2 is an explanatory diagram of a stator and coils according to an embodiment. [Figure 5B] FIG. 2 is an explanatory diagram of a stator and coils according to an embodiment. [Figure 6A] FIG. 10 is an explanatory diagram of a compression test in a comparative example. [Figure 6B] 10 shows the results of a compression test in a comparative example. [Figure 6C] FIG. 10 is an explanatory diagram of a tensile test in a comparative example. [Figure 6D] 10 shows the results of a tensile test in a comparative example. [Figure 7A] FIG. 1 is an explanatory diagram of a compression test in one embodiment. [Figure 7B] 1 shows the results of a compression test in one embodiment. [Figure 7C] FIG. 1 is an explanatory diagram of a tensile test in one example. [Figure 7D] 1 shows the results of a tensile test in one example. [Figure 8A] FIG. 2 is a three-dimensional perspective view of an insulating resin bobbin according to an embodiment. [Figure 8B] 10A and 10B are explanatory diagrams showing an example of the relationship between a convex-side member and a concave-side member in one embodiment. [Figure 8C] FIG. 10 is an explanatory diagram showing a convex-side member in one embodiment. [Figure 8D] FIG. 10 is an explanatory diagram showing a concave-side member in one embodiment. [Figure 9A] 5A to 5C are schematic explanatory views illustrating a fitting process in one embodiment. [Figure 9B] 10A and 10B are schematic explanatory views illustrating a fitting process in a comparative example. [Figure 9C] 10A and 10B are schematic explanatory views illustrating a fitting process in a comparative example. [Figure 9D] 10A and 10B are schematic explanatory views illustrating a fitting process in a comparative example. [Figure 10A]10A and 10B are explanatory diagrams illustrating an example of the relationship between fitting members in another embodiment. [Figure 10B] 10A and 10B are explanatory diagrams of the relationship between fitting members in another embodiment. [Figure 10C] 10A and 10B are explanatory diagrams illustrating an example of the relationship between fitting members in another embodiment. [Figure 11A] FIG. 4 is an explanatory diagram of an example of a concave-side member. [Figure 11B] FIG. 10 is an explanatory diagram of an example of a convex side member. [Figure 12A] FIG. 4 is an explanatory diagram of a plating layer of a concave-side member. [Figure 12B] FIG. 4 is an explanatory diagram of a plating layer of a convex member. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, embodiments of the present invention will be described with reference to the drawings as needed. For convenience of explanation, the same reference numeral may be used for a coil end portion and a coil having the coil end portion.

[0013] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. [Example]

[0014] Figure 1A shows the shape of the rectangular conductor before the concave-convex mating portions are mated, and Figure 1B shows the shape of the rectangular conductor after the concave-convex mating portions are mated. This rectangular conductor can be used in a variety of applications, including the stators of rotating electrical machines. While not limited to specific types of rotating electrical machines, one example is a radial gap rotating electrical machine.

[0015] The rectangular conductor is an enameled conductor coated with enamel, and is formed by punching out the concave and convex portions using a press die, for example. The punched cross section has a concave portion 12 shown on the left side of Fig. 1A and a convex portion 22 shown on the right side.

[0016] In Fig. 1A, for example, 11 is a concave coil, 12 is a recess, and 13 is a groove. In Fig. 1B, 21 is a convex coil, 22 is a convex, and 23 is a protrusion.

[0017] The concave coil 11 and the convex coil 21 approach each other from the left and right in the figure and are inserted into each other, thereby reaching the fitted state shown in FIG. 1B.

[0018] 1B, the concave coil 11 and the convex coil 21 are fixed together by inserting the convex portion 22 into the concave portion 12 and fitting the protrusion portion 23 into the groove portion 13. In this way, the first and second flat wires are fitted and fixed together without using a welding process.

[0019] The projections 23 are fixed in place by fitting into the grooves 13, preventing the assembly from coming loose after being fixed. In this way, the assembly is easy and the assembly is difficult to remove.

[0020] To achieve this effect, both the concave coil 11 and the convex coil 21 must be flat conductors. If they were round wires, it would be difficult to deform them when they were fitted together, making assembly itself difficult.

[0021] 2A shows an example of a rotating electric machine, with a 48-slot stator and an 8-pole motor rotor, showing the coil shape (three phases per pole) that achieves concentric winding of rectangular conductors and the connection of axial coils. In the figure, the stator 5 is composed of a lead-side stator 5a and a non-lead-side stator 5b.

[0022] In FIG. 2A, a concentrically wound coil is formed by combining a coil 20 having a structure that connects the slots of the lead-side stator 5a in the circumferential direction at the same diameter as the radial position of the slots, and a coil 10 having a structure that connects the slots of the anti-lead-side stator 5b in the circumferential direction at the same diameter as the radial position of the slots.

[0023] 1 is a teeth core, 2 is a core-back core, 10 is a concave coil end, 30 is a concave outer coil end, 50 is a concave inner coil end, 20 is a convex coil end, 40 is a convex outer coil end, 60 is a convex inner coil end, 70 is an outlet coil, and 72 is a convex portion. A concentrically wound coil is formed by combining a coil 60 having a shape in which the slots of the outlet side stator 5a are connected by arranging the coil ends radially inward of the conductors entering the slots, and a coil 30 having a structure in which the slots of the counter-lead side stator 5b are connected on the outer diameter side of the radial position of the conductors.

[0024] Furthermore, a concentrically wound coil is formed by combining a coil 40 having a shape in which the slots of the lead-side stator 5a are connected by arranging the coil ends on the outer diameter side of the radial direction in which the conductors enter the slots, and a coil 50 having a structure in which the slots of the counter-lead-side stator 5b are connected on the inner diameter side of the radial position of the conductors.

[0025] By configuring in this way, it is possible to prevent a difference in resistance value from occurring because the coil end passing through the inner periphery is shorter than the coil end passing through the outer periphery.

[0026] As shown in Figure 2B, these coils form a loop coil, starting from the lead coil 70 with a protruding portion 72, via the concave coil 11 with a recessed portion 12, and then connecting the other recessed portion 12 of the concave coil 11 with the protruding portion 22 of the convex coil 21. The other protruding portion 22 of the convex coil 21 fits into the recessed portion 12 of the next concave coil 11, and this process is repeated to form successive loops. The rest of the process is repeated in the same way to form a concentric coil with four turns per slot.

[0027] In FIG. 2B, the concave coil 11 and the convex coil 21 are depicted as central coils, but they can also be applied to the inner coils and outer coils, or to all coils.

[0028] In addition, 21 alone or a combination of 20 and 21 can be called the first rectangular wire, and 11 alone or a combination of 10 and 11 can be called the second rectangular wire.

[0029] FIG. 3A is a schematic diagram of a stator 4. 2 is a core-back core. FIG. 3B is a schematic external view of a resin bobbin 3. As shown in the schematic cross-sectional explanatory diagram of FIG. 3C, the stator 5 has teeth cores 1 inside the core-back core 2. Then, as shown in FIG. 3D, the resin bobbin 3 is arranged between adjacent teeth cores 1 so as to be close to the core-back core 2.

[0030] As an example, the stator teeth are made of laminated amorphous metal foil strips cut into trapezoidal shapes. In motors that rotate at high speeds, the high frequency increases the iron loss in the teeth, so it is desirable to use low-loss magnetic materials for the teeth. In addition to amorphous, the teeth can also be made of Finemet, a nanocrystalline alloy material, or nanocrystalline alloys with high saturation magnetization. In the case of electrical steel, using a low-iron-loss material, such as thin steel sheet containing 6.5% Si, is another way to improve characteristics.

[0031] As shown in Figure 3C, the core-back core 2, which holds the trapezoidal teeth together, is made of electromagnetic steel sheet. The core-back portion has a relatively low magnetic flux density compared to the teeth portion, and is less affected by harmonics, so it is sufficient to use a material with relatively low loss.

[0032] The shape of the core-back core 2 is designed in part because it is difficult to punch out amorphous material into complex shapes, and so the core-back core 2 is made into a trapezoidal shape that can be formed simply by cutting.

[0033] A resin bobbin for insulation is assembled to fit the combined core shape. Resin bobbin 3 has the shape shown in Figure 3B. As shown as the rectangular portion at the top of Figure 3B, it has slot holes into which rectangular conductors are inserted. Each slot hole has a wall (partition) so that each inserted rectangular conductor can be insulated.

[0034] The resin bobbins 3 are assembled from the inner diameter of the stator core, and when all the resin bobbins are assembled, they form a structure that restrains the stator teeth in both the circumferential and axial directions.

[0035] Fig. 4A is a partial configuration diagram for explaining the configuration of the axial direction (opposite side of the lead wire) of a stator core for configuring the stator shown in Fig. 3A. It is also a diagram of the coil on the opposite side of the lead wire projected in the axial direction.

[0036] FIG. 4B is a schematic internal perspective view for explaining the shape of each coil.

[0037] Coil 10 (referred to as the central coil, for example) has coil ends arranged at the same diameter as the conductor insertion position of the slot, and is configured, as an example, as shown in the figure, with four coils connected radially from insertion hole 1 inside the slot to insertion hole 1 spanning five slots.

[0038] 4C is a perspective view of the shape of the central coil, which is bent slightly outward to ensure an inner area due to the overall arrangement space of the stator coils.

[0039] The tip has a recess. The inner part is punched out, and the cut cross section is plated with a plating layer, for example, about 10 micrometers thick, using electrolytic tin plating, for example.

[0040] The inner coils are placed inside the central coil, and the side coils are placed outside, so the bending radius of the coils needs to be relatively small so as not to interfere with the other coils. As an example, as shown in Figure 4B, all four central coils have the same coil height (height from the end of the stator core).

[0041] Next, the shape of the inner coil will be explained with reference to Figure 4D. The coils rising from the straight section are bent radially inward so as not to interfere with the central coil and not to protrude toward the inner diameter of the stator. As shown in Figure 4B, the inner coils rising from the inside of the slot insertion holes are configured with the shortest coil height. Furthermore, among the inner coils, the coils inserted at the rear are positioned higher than the coils inserted at the front insertion opening of the resin bobbin 3. The coils at the rear are positioned higher than the coils at the front, ensuring a coil height equivalent to the wire thickness and a slight gap. The same applies to the following coils.

[0042] Like the central coil, the inner coil also has recesses at the coil ends and is, for example, tin-plated.

[0043] For convenience of illustration, FIG. 4B does not show the resin bobbin of the slot into which the inner coil 50 is inserted.

[0044] The coil with the recess is designed to be shorter than the length of the stator core, and the fitting portion is located at a predetermined distance from the end of the core. For example, the ends of the other coils are also located at the same axial position.

[0045] Next, the shape of the outer coil will be explained with reference to Figure 4E. The coil that rises from the straight section is bent radially outward to form a shape that does not interfere with the central coil. Since the outer coil often has room in the core back section, it can be configured with a large bend outward. As an example, the bending angle can be set to a large angle of about 45 degrees.

[0046] As shown in Figure 4B, the outer coil is configured with the coil rising from the inside of the slot insertion hole as the tallest coil. The next outer coil is then positioned below the coil in front, with the coil height set lower to allow for the wire thickness and a slight gap. The same applies to the coils below.

[0047] Like the central coil, the outer coil also has recesses at the coil ends and is, for example, tin-plated.

[0048] Fig. 5A is a perspective view illustrating the assembled state of the coils of the flat rectangular conductor. Stators 5a and 5b are arranged in the axial direction. Fig. 5A shows the state in which all concave coils are inserted into the stator core. Fig. 5B shows the state in which one convex coil 20 is inserted in this state.

[0049] 5B shows the state in which the next convex coil 20 is about to be inserted. In this state, if the connector does not have an appropriate fitting structure, touching the first inserted coil may cause the coil to come loose. For this reason, it is necessary to insert the coil without touching it, or to insert the subsequent coil while checking to see if the previous coil has come loose. Inserting all the coils while making such checks and checking the contact resistance of the coils makes assembly extremely difficult.

[0050] The present invention can eliminate such concerns and provide a fitting structure that is easy to assemble and difficult to come loose, and a rotating electric machine having the same.

[0051] The specific experimental results will be explained with reference to FIGS. 6 and 7.

[0052] Fig. 6A is an explanatory diagram of a compression test of a rectangular conductor having recesses 12 and protrusions 22, which is a comparative example.

[0053] As shown in Figure 6A, a compression test was conducted on a rectangular test piece in which the recess 12 had no grooves and the protrusion 22 had no protrusions. Figure 6B shows the results of the changes in the amount of movement and insertion force of two test pieces (sample 1 and sample 2) during the compression test. The insertion force gradually increased as the contact surface increased from the point where the straight recessed and protruding mating parts interlocked, and it was found that the insertion force reached approximately 100 N at the specified insertion dimension of 5 mm.

[0054] As shown in Figure 6C, a tensile test was conducted on a rectangular test piece in which the recessed portion 12 had no grooves and the protruding portion 22 had no protrusions. Figure 6D shows the results of the movement amount and tensile load changes for three test pieces (samples 1 to 3) during the tensile test. All test pieces came out with a force of about 30 N, and after coming out once, they could be removed with a small pulling force, almost equivalent to friction.

[0055] Fig. 7A shows the compression test of the rectangular conductor having the recessed portion 12 and the protruding portion 22.

[0056] As shown in Figure 7A, a compression test was conducted on a rectangular test piece in which the recess 12 had a groove and the protrusion 22 had a protrusion. Figure 7B shows the results of the movement and insertion force changes for two test pieces (Sample 1 and Sample 2) during the compression test. The insertion force initially increased as the contact area increased, and an insertion history was confirmed in which the insertion force temporarily increased where the protrusion deformed the recess, and then decreased when the protrusion removed that part. It was also found that when the protrusion and groove engaged, an insertion peak was observed, indicated by 90 in the figure.

[0057] The existence of this insertion peak has a secondary significant effect. That is, when fitting and assembling a rectangular conductor with a convex portion and a rectangular conductor with a concave portion, the insertion force must rise and fall above the peak, which, when assembled by a human, serves as feedback to let the worker know that the fitting has been completed successfully. If we were to express this in words, it would be a clicking sensation, a feeling of completion of insertion, a feeling of the work being completed, or a feeling that it has clicked into place. This kind of tactile feedback can be obtained, making it possible to avoid operational errors by the worker.

[0058] In particular, when the mating portion is located inside a resin bobbin, the mating portion cannot be seen from the outside, so the presence or absence of this bodily feedback is extremely important in ensuring that the work is completed.

[0059] Furthermore, even in cases of machine assembly, recording and managing this insertion force allows for reliable production management. Another advantage is that it can be saved as a manufacturing history for later use, making it possible to trace the reliability of individual products after shipment.

[0060] Next, as shown in Figure 7C, a tensile test was conducted on a rectangular test piece in which the recessed portion 12 had a groove and the protruding portion 22 had a protrusion. Figure 7D shows the results of the movement amount and tensile load transition of two test pieces (Sample 1 and Sample 2) during the tensile test. Both test pieces were initially difficult to remove, as shown by the peak at 91 in the figure, and it was found that they had a structure in which they could not be removed without a tensile force of about 80 N.

[0061] It was found that it came out with a pulling force of about 30N, and once it had come out, it could be removed with a small pulling force, almost like friction.

[0062] 6 and 7, the recess 12 described in this embodiment has a groove, and the protrusion 22 has a protrusion. The rectangular wire structure in which the two fit together can realize a structure in which the fitting is difficult to come loose, both as a joint structure and as a rotating electrical machine, without a welding process. Furthermore, the existence of bodily sensation feedback during assembly or the existence of an insertion peak value can prevent work errors and improve quality control.

[0063] FIG. 8 illustrates the relationship between the slot hole dimensions of the resin bobbin 3 and the deformation of the recessed portion during insertion in one embodiment.

[0064] 8A shows an example of a resin bobbin 3 in which the slot hole dimension width X1 is 4.3 mm with a tolerance of plus 0.05 mm and minus 0.00 mm, so that the slot hole width X1 is 4.3 to 4.35 mm.

[0065] Figure 8B shows the state in which the concave coil 11 and the convex coil 21 are inserted into the slot holes of the resin bobbin 3 in Figure 8A. Although the two coils will ultimately be fitted together, the concave coil 11 and the convex coil 21 are shown separated in the figure for the purpose of explaining the dimensional relationship.

[0066] The width X2 of the convex coil 21 is, for example, 4.0 mm to 4.1 mm. At the tip of the convex coil, a convex portion is formed with a width X4, for example, 1.4 mm. The protrusion formed on the convex portion has a protrusion height X3 of, for example, 0.1 mm or less.

[0067] The width X7 of the concave coil 11 is, for example, 4.0 mm to 4.1 mm. At the tip of the concave coil, a recess is formed with a width X5, for example, 1.4 mm. The groove formed in the recess has a depth X6 of, for example, 0.1 mm. Note that X3 must not be greater than X6.

[0068] There is a gap X8, for example 0.1 mm, between the concave coil 11 and the convex coil 21 and the inner wall surface of the resin bobbin 3. If this gap X8 did not exist, it would be difficult to insert the concave coil 11 and the convex coil 21 into the resin bobbin 3.

[0069] When the convex coil 21 shown in FIG. 8C is inserted into the concave coil 11 shown in FIG. 8D, the protrusions of the convex coil 21 contact the top surface of the concave coil, and the upper portion of the concave coil 11 (indicated by the arrows in the figure) expands or deforms to the left and right, widening the width X5 of the concave coil. If the height of the protrusions is 0.1 mm, the upper portion of the concave coil 11 expands or deforms by 0.1 mm to the left and right. For example, since X7 is 4.0 mm to 4.1 mm, the upper portion of the concave coil 11 deforms to a maximum size of X9. If the height of the protrusions is 0.1 mm, this becomes a maximum of 4.3 mm (4.1 + 0.1 + 0.1). Because there is a 0.1 mm gap X8 between the inner wall surface of the resin bobbin 3 and the end surface of the concave coil, even if temporary deformation occurs during insertion, insertion can continue and the engagement can be completed. Once the protrusions are fully engaged in the grooves and engagement is complete, the deformation is eliminated.

[0070] In addition, since the resin bobbin itself has some flexibility, it is possible to deal with a slight excess of deformation by temporarily deforming the resin bobbin.

[0071] To eliminate this deformation, it is effective to have a tapered shoulder at the tip of the concave coil, as shown by the arrow in Fig. 8D, because the presence of this taper applies stress in a direction that narrows the concave portion inward, which contributes to the restoration force from deformation.

[0072] If the tip of the convex portion hits the bottom of the concave portion first during insertion and fitting of the concave and convex portions, the closing operation by the shoulder will not be possible. Therefore, for example, it is desirable that the convex portion be shorter in dimension than the concave portion in the axial direction, or that there be a gap X10 between the tip 200 of the convex portion and the base 201 of the concave portion when the fitting is complete. X10 is, for example, 0.2 to 0.4 mm.

[0073] FIG. 9 is a diagram illustrating the influence of the positions of the protrusions on the convex coil and the positions of the grooves on the concave coil on deformation during the fitting process, when the fitting process is taken into consideration.

[0074] 9A shows an example in which the protrusion formed on the convex portion of the convex coil 21 is located on the base side of the convex portion, and the groove formed on the concave portion of the concave coil 11 is located on the shoulder side of the concave portion. The various explanations in this embodiment above apply to this case. In the case of FIG. 9A, deformation of the concave coil 11 due to insertion of the convex coil 21 occurs at a later stage of insertion. Therefore, as explained in FIG. 8, assembly is possible within the dimensional range of the resin bobbin 3.

[0075] FIG. 9B shows an example in which the protrusion formed on the protruding portion of the convex coil 21 is located at the tip of the protruding portion, and the groove formed on the recess of the concave coil 11 is located at the base of the recess. This is positioned as a comparative example to FIG. 9A. In the case of FIG. 9B, the deformation of the concave coil 11 due to the insertion of the convex coil 21 begins in the direction in which the recess opens immediately after the protrusion is inserted. The opening angle increases as the insertion dimension becomes deeper, and reaches its maximum opening angle just before reaching the bottom. Therefore, if there is little clearance with the resin bobbin, problems such as contact with the resin bobbin and increased insertion force may occur.

[0076] 9C shows an example in which a groove is formed on the tip side of the convex portion of the convex coil 21, and a protrusion is provided on the base side of the concave portion of the concave coil 11. This is another comparative example to FIG. 9A. In the case of FIG. 9C, deformation occurs during insertion, but the length from the protrusion provided on the concave portion to the shoulder of the concave portion is longer than in the case of FIG. 9A. As shown in FIG. 9C, the amount of deformation between the shoulder portion or between the left and right ends of the concave portion is larger than in FIG. 9A, which makes insertion into a resin bobbin difficult.

[0077] FIG. 9D shows an example in which a groove is formed at the base of the convex portion of the convex coil 21, and a protrusion is provided at the tip of the concave portion of the concave coil 11. This is another comparative example to FIG. 9A. In the case of FIG. 9D, a change occurs immediately after insertion, which causes a problem in that the insertion force required for assembly remains high. As a result, there is an issue of reduced manufacturing throughput compared to the case of FIG. 9A.

[0078] As can be seen from the above explanation of Figures 9A to 9D, from the viewpoint of productivity, it is understood that the structure shown in Figure 9A, i.e., the structure in which the protrusion formed on the convex portion of the convex side coil 21 is located on the base side of the convex portion and the groove formed on the concave portion of the concave side coil 11 is located on the shoulder side of the concave portion, is desirable.

[0079] As described above, this embodiment can realize a coupling structure between rectangular wires and a rotating electrical machine structure that does not require a welding process, is easy to assemble, is difficult to come loose, and has excellent productivity. [Example]

[0080] This embodiment is basically the same as embodiment 1. Differences from embodiment 1 will be explained below.

[0081] 10B is an explanatory diagram for assembling the convex coil 21 and the concave coil 11 by sequentially moving them close to each other and fitting them together as indicated by the arrows in the figure. For the sake of explanation, the resin bobbin and other components are omitted from the figure. For the sake of explanation, one of the mating sides is designated as 210 and the other as 220.

[0082] The feature of this embodiment is that the position of the protruding portion of the convex side coil 21 from the base of the protruding portion is different between FIG. 10A corresponding to 210 in FIG. 10B and FIG. 10C corresponding to 220 in FIG. 10B.

[0083] 10A, in the convex portion of convex side coil 21, distance 213 from base 216 to center 215 of protrusion is, for example, 1.5 mm. Also, distance 212 from center 215 of protrusion to tip 214 of the convex portion is 3.5 mm.

[0084] 10C, in the convex portion of the convex side coil 21, the distance 223 from the base 226 to the center 225 of the protrusion is, for example, 1.0 mm, and the distance 222 from the center 225 of the protrusion to the tip 224 of the convex portion is 4.0 mm.

[0085] When the groove portion 203 has an elongated hole shape for the concave coil 11 as shown on the left side of Figure 10A, the groove portion can be made compatible with both the convex coil 21 shown on the right side of Figure 10A and the convex coil 21 shown on the right side of Figure 10C.

[0086] For example, in the concave coil 11 of Fig. 10A, position 211, which is 1.5 mm away from shoulder tip 217 (distance 219), is located within the elongated hole, and therefore can accommodate 1.5 mm at 213. At the same time, position 221, which is 1.0 mm away from shoulder tip 217 (distance 218), is located within the elongated hole, and therefore can accommodate 1.0 mm at 223. In this way, by providing an elongated hole shape for the groove of concave coil 11, it is possible to accommodate multiple protrusion positions.

[0087] 10B, when joining a U-shaped coil or a hairpin coil, the concave coil 11 having such a long hole can be provided in both mating pairs 210 and 220. In this case, however, since 203 is a long hole, there will be some room for movement between 11 and 21.

[0088] When a stronger fit is required, for example, one of the mating pairs, 210, may be a concave coil 11 with a slot as shown in FIG. 10A, and the other of the mating pairs, 220, may be a concave coil 11 with a groove 204 that is not a slot as shown in FIG. 10C. In this case, the distance 228 from the groove center 221 to the shoulder 227 is 1.0 mm, which is the same as 223, and a stronger fit can be achieved in the mated state. This allows for both ease of assembly and a stronger fit.

[0089] The effect of making the length from the bottom to the center of the protrusion different between the convex coil 21 on the right side of FIG. 10A and the convex coil 21 on the right side of FIG. 10C will be further explained.

[0090] In Figure 10A, distance 213 is 1.5 mm, while in Figure 10C, distance 223 is 1.0 mm, which are different. Therefore, when a convex coil with such different distances is fitted into a concave coil, even if the convex coil is pressed into the concave coil in an attempt to fit them together at the same time, the timing at which the protrusions and grooves of the convex coil and concave coil fit together will be offset. In other words, the timing of the clicking sensation and tactile feedback during fitting will be offset. This means that the timing at which insertion peak 90 appears in Figure 7B will be offset.

[0091] As a result, for example, the worker can feel a click or insertion sensation twice, making it easy to know that both insertion operations have been completed successfully. Or, when performing insertion measurements, the peak change can be observed twice. This makes it possible to reliably avoid operational errors, and provides the distinctive effect of ensuring more reliable quality control during manufacturing operations.

[0092] FIG. 11A shows an example of detailed dimensions of the concave coil 11, and FIG. 11B shows an example of detailed dimensions of the convex coil 21.

[0093] In FIG. 11A, angle 302 formed by extension line 308 of the shoulder portion and horizontal line 309 is 10°. For example, it is desirable that this angle be within the range of 5° to 20°. Similarly, in FIG. 11B, angle 312 formed by extension line 318 of the tapered portion of the bottom and horizontal line 319 is 10°. For example, it is desirable that this angle be within the range of 5° to 20°. It is desirable that angles 302 and 312 are the same.

[0094] In FIG. 11A, the groove depth 303 of the groove is 0.1 mm. For example, it is desirable that it be in the range of 0.05 mm to 0.2 mm. Similarly, in FIG. 11B, the protrusion height 316 of the protrusion is 0.1 mm. For example, it is desirable that it be in the range of 0.05 mm to 0.2 mm. It is also desirable that 303 and 316 are the same.

[0095] In FIG. 11A, the width 300 of the recess is, for example, 1.4 mm. The deviation is -0.05 mm to -0.02 mm. Similarly, in FIG. 11B, the width 310 of the protrusion is, for example, 1.4 mm. The deviation is -0.025 mm to +0.025 mm. For the purpose of fitting, it is desirable that the finished dimension 300 is greater than 310.

[0096] In FIG. 11A, distance 301 from tip 307 of the shoulder to bottom 305 of the recess is, for example, 5.0 mm. The deviation is +0.1 mm to +0.3 mm. Similarly, in FIG. 11B, distance 311 from the bottom surface of the convex portion to the tip of the convex portion is, for example, 5.0 mm. The deviation is -0.1 mm to +0.1 mm. For the purpose of fitting, it is desirable that the finished dimension 301 is greater than 311.

[0097] The groove in Fig. 11A has, for example, a radius of 0.35 mm near its center and a radius of 2-0.3 mm near its end. The protrusion in Fig. 11B has, for example, a radius of 0.3 mm near its center and a radius of 2-0.3 mm near its end. For the purpose of fitting the groove and protrusion together, it is desirable that the radius of the groove center is greater than the radius of the protrusion center in the finished dimensions.

[0098] For example, it is desirable for the protrusions and grooves to be smoothly connected to the straight line sections and shapes with R. This can be achieved, for example, by machining the mold with wire electric discharge machining.

[0099] Fig. 12A shows an example in which a tin-plated layer 9 is provided from the recess to the shoulder of the concave coil 11. Similarly, Fig. 12B shows an example in which a tin-plated layer 9 is provided on the convex coil 21. By providing the tin-plated layer 9 in this way, improved conductivity and reliability during mating are achieved.

[0100] The thickness 00 of the tin-plated layer 9 is, for example, 0.01 mm. The punched surface of the concave-convex fitting portion is tin-plated. The tin plating can be performed by electrolytic plating or electroless plating.

[0101] The above examples illustrate the ideas and concepts of the present invention. Of course, the scope of the present invention also includes examples that are realized by combining the examples. Furthermore, as long as the disclosed ideas and concepts are used, any modifications or similar examples are also included within the scope of the present invention.

[0102] Furthermore, one example of the present invention described using the above embodiments can also be expressed as follows.

[0103] <Part 1> The stator coil has a first rectangular wire and a second rectangular wire fitted together, The first flat wire has a convex portion, and the second flat wire has a concave portion, and the convex portion and the concave portion are configured to be inserted and fitted into each other, Among the surfaces constituting the convex portion and the concave portion, on the surface along the extension direction of the first flat wire and the second flat wire, the convex portion has a protrusion portion, and the concave portion has a groove portion, The rotary electric machine has a pair of protrusions and a pair of grooves as the protrusions and the grooves, respectively. <Part 2> The rotating electric machine described in <Part 1>, wherein the pair of protrusions and the pair of grooves are configured by providing one protrusion and one groove on each of the opposing surfaces of the first flat wire and the second flat wire along the extension direction. <Part 3> The rotating electric machine according to <Item 2>, wherein the protrusion is smaller than the groove. <Part 4> The rotary electric machine according to <Item 3>, wherein the protrusion is located on the base side of the convex portion, and the groove is located on the shoulder side of the concave portion. <Part 5> The rotating electric machine according to <Item 4>, wherein the stator of the rotating electric machine has a resin bobbin, and the insertion and fitting portion of the first rectangular wire and the second rectangular wire is located within the resin bobbin. <Part 6> The rotating electric machine according to <Item 5>, wherein both the groove and the protrusion have an R shape. <Part 7> The rotating electric machine according to <Item 6>, wherein the R shape of the groove is larger than the R shape of the protrusion. <Part 8> The rotating electric machine according to <Item 6>, wherein the R shape is R0.3 mm or more. <No. 9> The rotating electric machine according to <Item 7>, wherein the shoulder of the recess and the bottom of the protrusion each have a tapered surface. <Part 10> The rotating electric machine according to <Item 9>, wherein the convex portion and the concave portion have a tin-plated layer. <Part 11> The rotating electric machine according to any one of <Items 1> to <Item 10>, wherein the first rectangular wire and the second rectangular wire each have a U-shape. <Part 12> The rotating electric machine described in <Item 11>, wherein the first rectangular wire has the convex portion at both ends of the U-shape, and the second rectangular wire has the concave portion at both ends of the U-shape. <Part 13> The rotating electric machine described in <No. 12>, wherein the length from the base of the convex portion formed on one end of the first flat wire to the protruding portion is different from the length from the base of the convex portion formed on the other end of the first flat wire to the protruding portion. <Part 14> The rotating electric machine described in <No. 13>, wherein at least one of the grooves formed in the second rectangular wire is an elongated hole shape corresponding to both protrusions having different lengths from the base of the convex portion to the protrusion. <Part 15> The rotating electric machine described in <No. 13> is configured so that the fitting positions of the protrusion and the groove are misaligned between the protrusion formed on one side of the tip portion and the protrusion formed on the other side of the tip portion. <Part 16> The rotating electric machine described in <No. 15> is configured so that the timing of engagement between the protrusion and the groove is offset between the protrusion formed on one side of the tip portion and the protrusion formed on the other side of the tip portion. [Explanation of symbols]

[0104] 1: Tea Score 2: Core back core 3: Resin bobbin 5: Stator 9: Tin-plated section 10: Concave coil end 11: Concave coil 12: Recess 13: Groove 20: Convex coil end 21: Convex coil 22: Convex 23:Protrusion 30: Concave outer coil end 32: Concave outer coil fitting part 40: Convex outer coil end 41: Convex outer coil 50: Concave inner coil end 51: Concave inner coil 60: Convex inner coil end 61: Convex inner coil 70:Outlet coil 72: Lead coil fitting protrusion

Claims

1. A stator coil is provided in which the first rectangular wire and the second rectangular wire are fitted together, The first flat wire has a convex portion, and the second flat wire has a concave portion, and the convex portion and the concave portion are configured to be inserted and fitted into each other, Among the surfaces constituting the convex portion and the concave portion, on the surface along the extension direction of the first flat wire and the second flat wire, the convex portion has a protrusion portion, and the concave portion has a groove portion, The rotary electric machine has a pair of protrusions and a pair of grooves as the protrusions and the grooves, respectively.

2. The rotating electric motor according to claim 1, wherein the pair of protrusions and the pair of grooves are configured by providing one protrusion and one groove on each of the opposing surfaces of the first flat wire and the second flat wire along the extension direction.

3. 3. The rotating electric machine according to claim 2, wherein the protrusion is smaller than the groove.

4. 4. The rotating electric machine according to claim 3, wherein the protrusion is located on the base side of the convex portion, and the groove is located on the shoulder side of the concave portion.

5. 5. The rotating electric machine according to claim 4, wherein a stator of the rotating electric machine has a resin bobbin, and an insertion fitting portion for the first rectangular wire and the second rectangular wire is located inside the resin bobbin.

6. 6. The rotating electric machine according to claim 5, wherein the groove and the protrusion both have an R-shape.

7. 7. The rotating electric machine according to claim 6, wherein the rounded shape of the groove is larger than the rounded shape of the protrusion.

8. 7. The rotating electric machine according to claim 6, wherein the R shape is 0.3 mm or more.

9. 8. A rotating electric machine according to claim 7, wherein the shoulder of said recess and the bottom of said protrusion each have a tapered surface.

10. 10. The rotating electric machine according to claim 9, wherein the protrusions and the recesses are provided with a tin-plated layer.

11. 11. The rotating electric machine according to claim 1, wherein the first rectangular wire and the second rectangular wire each have a U-shape.

12. The rotating electric machine according to claim 11, wherein the first rectangular wire has the convex portions at both ends of the U-shape, and the second rectangular wire has the concave portions at both ends of the U-shape.

13. 13. The rotating electric machine according to claim 12, wherein the length from the base of the convex portion formed on one end of the first flat wire to the protruding portion is different from the length from the base of the convex portion formed on the other end of the first flat wire to the protruding portion.

14. The rotating electric machine according to claim 13, wherein at least one of the grooves formed in the second rectangular wire has an elongated hole shape corresponding to both of the protrusions having different lengths from the base of the convex portion to the protrusion.

15. The rotating electric machine according to claim 13, wherein the protrusion formed on one end of the tip portion and the protrusion formed on the other end of the tip portion are configured so that the fitting positions of the protrusion and the groove are offset.

16. The rotating electric machine according to claim 15, wherein the timing of engagement between the protrusion and the groove is offset between the protrusion formed on one end of the tip portion and the protrusion formed on the other end of the tip portion.

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