Stator for axial gap type rotating electric machine, motor for axial gap type rotating electric machine, and method for manufacturing stator for axial gap type rotating electric machine

Abstract

Provided are a stator for an axial gap type rotating electric machine in which variation in the position of the opposing surfaces of the flange portions of multiple teeth relative to a yoke in the axial direction is suppressed, a motor for an axial gap type rotating electric machine, and a method for manufacturing a stator for an axial gap type rotating electric machine. [Solution] The stator 2 of an axial gap type rotating electric machine comprises a yoke 21, a main body 222 supporting an excitation coil 23, and a plurality of teeth 22 each having a flange 221 including an opposing surface 221A facing the rotor 3, and a tooth support 30 interposed between the flange 221 of the plurality of teeth 22 and the first surface 21A, with a thickness corresponding to the dimension in the axial direction AD of each of the plurality of teeth 22, so that each of the opposing surfaces 221A of the flange 221 of the plurality of teeth 22 is arranged in a line in the circumferential direction CD along a first reference plane AA set at a first interval on one side of the axial direction AD from the first surface 21A.

Description

[Technical Field]

[0001] The present invention relates to a rotating electric machine such as a motor or a generator, and more particularly to a stator of an axial gap type rotating electric machine in which a stator having an excitation coil and a rotor having a permanent magnet are arranged with an axial gap therebetween. [Background technology]

[0002] Axial gap rotating electric machines have advantages over radial gap rotating electric machines in which the stator is provided on the outer periphery of the rotor, such as being able to be made thinner and being able to easily obtain large torque. Patent Document 1 discloses a structure of such a rotating electric machine in which a stator including a stator core and an excitation coil and a rotor including a permanent magnet are arranged with a small gap (axial gap) in the axial direction. The stator has a yoke and a plurality of teeth protruding from the yoke, and each of the plurality of teeth has a flange formed at its upper end to promote the formation of a magnetic field between the rotor and the stator. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6609138 Summary of the Invention [Problem to be solved by the invention]

[0004] In a rotating electric machine such as that described in Patent Document 1, there is a need to make the air gap (symbol G in FIG. 1 of the present application) as thin as possible to improve output torque. While such rotating electric machines are typically characterized by their flatness, the disk-shaped gap G necessitates appropriate tolerance management of the components used in the rotating electric machine. In particular, medium- to large-sized rotating electric machines are assembled by assembling divided core components. For example, in an assembly method in which teeth are placed on a circular back yoke, as shown in FIG. 14 of Patent Document 1, gaps are generated between the back yoke and the teeth due to adhesive materials or surface roughness, and the position of the upper surface of each tooth (flange portion) relative to the back yoke is determined by chance. Furthermore, assembly errors resulting from this process result in different heights for each of the multiple teeth. Furthermore, because it is difficult to predict such assembly errors in advance, the thickness of the gap G, which is the axial length AD of the gap G, must be estimated with a margin of error. This value is usually set based on the manufacturer's experience. Setting the thickness, which is the length of the axial direction AD of the gap G, in this way increases the magnetic resistance in the magnetic circuit, which is the main cause of reduced output torque. Furthermore, during the manufacturing process, molding may be performed on the part that corresponds to the motor's stator. When fixing the stator core material in a mold, if there are parts that are determined by chance (such as the top surface of the teeth), it becomes difficult to properly hold them in the mold.

[0005] The present invention has been made in consideration of the above-mentioned problems, and aims to provide a stator for an axial gap type rotating electric machine, a motor for an axial gap type rotating electric machine, and a method for manufacturing a stator for an axial gap type rotating electric machine in which variation in the position of the opposing surfaces of the flange portions of multiple teeth relative to the yoke in the axial direction is suppressed. [Means for solving the problem]

[0006] The present invention provides a stator for an axial gap type rotating electric machine that forms a magnetic field for rotating a rotor around a central axis of rotation, comprising: a yoke having a first surface arranged on one axial side of the central axis of rotation and a second surface arranged on the other axial side; a plurality of teeth arranged circumferentially spaced on the first surface of the yoke, each tooth having a main body portion that supports an excitation coil and a flange portion arranged on one axial side of the main body portion, the flange portion including an opposing surface that faces the rotor; and a teeth support body that supports at least the flange portions of the plurality of teeth from the yoke side, the teeth support body being interposed between the flange portions of the plurality of teeth and the first surface, with a thickness corresponding to the axial dimension of each of the plurality of teeth, so that each of the opposing surfaces of the flange portions of the plurality of teeth are arranged in a row circumferentially along a first reference plane set at a first interval on one axial side of the first surface.

[0007] According to this configuration, even if the axial dimensions of each of the multiple teeth are different, the tooth support is arranged with a thickness corresponding to the axial dimensions of each of the multiple teeth. As a result, it is possible to suppress variation in the position of the opposing surfaces of the flanges of the multiple teeth relative to the yoke in the axial direction. Therefore, with this configuration, since variation in the position of the opposing surfaces of the flanges of the multiple teeth relative to the yoke in the axial direction is suppressed, it is less necessary to set a large median value for the distance (thickness, which is the axial length) between the rotor and the opposing surfaces of the flange, for example, in consideration of assembly errors of the stator, and a higher output torque can be achieved by reducing the distance.

[0008] In the above configuration, the thickness in the axial direction of the portion of the tooth support body corresponding to each of the plurality of teeth is set to differ depending on the difference in the axial dimension of each of the plurality of teeth, so that each of the opposing surfaces of the flange portions of the plurality of teeth are arranged in a line in the circumferential direction along the first reference plane, and it is desirable that the thickness of the portion of the tooth support body corresponding to a tooth having a first dimension in the axial direction is set to be greater than the thickness of the portion of the tooth support body corresponding to a tooth having a second dimension in the axial direction that is greater than the first dimension.

[0009] According to this configuration, the thickness of the portion of the tooth support body corresponding to the tooth having a first dimension is set to be greater than the thickness of the portion of the tooth support body corresponding to the tooth having a second dimension larger than the first dimension, so that a stator can be obtained in which the variation in the position of the opposing surfaces of the flange portions of multiple teeth is reliably suppressed.

[0010] In the above configuration, it is desirable that the rotor further comprises a plurality of pins having a first end located on one side in the axial direction and a second end located on the other side in the axial direction, and that in each of the plurality of teeth, the main body portion and the flange portion are an integral member, and that the yoke has a plurality of yoke through holes formed therein that are spaced apart in the circumferential direction corresponding to the plurality of teeth and that penetrate the yoke along the axial direction, and that the first ends of the plurality of pins inserted into the plurality of yoke through holes respectively abut against the main body portions of the plurality of teeth, and that the tooth support body is interposed between the surface on the other side in the axial direction of the main body portion and the first surface so as to surround the pins.

[0011] With this configuration, the pin serves as the core of the tooth support, and the tooth support surrounds the pin, preventing the tooth support from moving between the yoke and the main body even when subjected to vibrations during motor operation, thereby maintaining stable positions of the teeth relative to the yoke.

[0012] In the above configuration, it is desirable that each of the main body portions of the plurality of teeth has at least two hole portions formed therein extending from the first surface side along the axial direction, and that the first end portion of the pin passing through the yoke through hole is positioned in each of the at least two hole portions.

[0013] With this configuration, at least two pins are firmly fixed to the main body, and the teeth supporter is arranged to surround the at least two pins, which further prevents the teeth supporter from moving between the yoke and the main body even when subjected to vibrations during motor operation, thereby more stably maintaining the position of the teeth relative to the yoke.

[0014] In the above configuration, it is desirable that the position of the first end of the pin corresponding to the tooth having a first dimension in the axial direction be positioned on one side of the axial direction relative to the position of the first end of the pin corresponding to the tooth having a second dimension in the axial direction that is larger than the first dimension.

[0015] If the first ends of multiple pins are positioned at the same axial position, there is a possibility that the pins may not be inserted sufficiently into the holes of the teeth with a first dimension, which is relatively small in the axial direction. In contrast, with this configuration, the first ends of the pins corresponding to the teeth with the first dimension are positioned on one side of the axial direction relative to the first ends of the pins corresponding to the teeth with the second dimension, so that the pins can be inserted sufficiently into the holes of the teeth with the first dimension. As a result, the teeth with the first dimension can be stably supported by the yoke.

[0016] In the above configuration, it is desirable that the pins further include a plurality of pins having a first end located on one side in the axial direction and a second end located on the other side in the axial direction, and that in each of the plurality of teeth, the main body portion and the flange portion are independent of each other, the yoke has a plurality of yoke through holes formed in it that are spaced apart in the circumferential direction corresponding to the plurality of teeth and that penetrate the yoke along the axial direction, and that each of the main body portions of the plurality of teeth has a tooth through hole formed in it that penetrates the main body portion along the axial direction, and that the first ends of the plurality of pins inserted into the plurality of yoke through holes of the yoke and the tooth through holes of the plurality of main body portions abut against the flange portions of the plurality of teeth, respectively, and that the tooth support body be interposed between the surface on the other side in the axial direction of the flange portion and the surface on the one side in the axial direction of the main body portion so as to surround the pin.

[0017] With this configuration, the pin serves as the core of the tooth support, and the tooth support surrounds the pin, preventing the tooth support from moving between the flange and the main body even when subjected to vibrations during motor operation, thereby stably maintaining the position of the teeth relative to the yoke.

[0018] In the above configuration, it is desirable that each of the flange portions of the plurality of teeth has at least two hole portions formed therein extending from the first surface side along the axial direction, and that the first end portion of the pin that passes through the tooth through-hole of the main body portion is positioned in each of the at least two hole portions.

[0019] With this configuration, at least two pins are firmly fixed to the flange, and the teeth supporter is arranged to surround the at least two pins, which further prevents the teeth supporter from moving between the flange and the main body even when subjected to vibrations during motor operation, thereby more stably maintaining the position of the flange relative to the yoke.

[0020] In the above configuration, it is desirable that the position of the first end of the pin corresponding to the flange portion having a first dimension in the axial direction be positioned on one side of the axial direction relative to the position of the first end of the pin corresponding to the flange portion having a second dimension in the axial direction that is larger than the first dimension.

[0021] If the first ends of multiple pins were positioned at the same axial position, there is a possibility that the pins would not be inserted sufficiently into the holes of the flanges with a first dimension, which is relatively small in the axial direction. In contrast, with this configuration, the first ends of the pins corresponding to the flanges with the first dimension are positioned on one side of the axial direction relative to the first ends of the pins corresponding to the flanges with the second dimension, ensuring the pins' insertion depth even into the holes of the flanges with the first dimension. As a result, the flanges with the first dimension can be stably supported by the yoke.

[0022] In the above configuration, it is preferable that the teeth support body be made of a solidified adhesive material.

[0023] With this configuration, the teeth and the yoke are firmly bonded by the tooth supporter, which prevents the teeth from coming off the yoke even when subjected to vibrations during motor operation.

[0024] In the above configuration, it is preferable that the first interval is the dimension of a tooth having the largest dimension in the axial direction among the plurality of teeth arranged on the first surface.

[0025] This configuration prevents the tooth support from becoming too thick, thereby reducing the amount of material used for the tooth support, and allows the tooth with the largest axial dimension to be used as the positioning member.

[0026] In the above configuration, it is desirable that the configuration further includes a case portion having a support surface that faces the second surface in the axial direction and supports the yoke, and a plurality of yoke supports that support the yoke, wherein the yoke has a plurality of split yokes divided along the circumferential direction, and the plurality of teeth are a plurality of tooth groups consisting of at least two teeth arranged in each of the plurality of split yokes, and each of the opposing surfaces of the flange portion in each tooth group is arranged at the first distance from the first surface, and the plurality of yoke supports are each interposed between the support surface and the second surface of the plurality of split yokes with a thickness corresponding to the axial distance between the opposing surface in each tooth group and the second surface of the split yoke, so that each of the opposing surfaces of the flange portion in each tooth group is arranged in a row in the circumferential direction along a second reference plane set at a second distance larger than the first distance on one side of the axial direction with respect to the support surface.

[0027] According to this configuration, even if the distance between the opposing surfaces of the teeth sets and the second surface of the split yoke differs among the multiple teeth sets, the multiple yoke supports are arranged in the case portion with a thickness corresponding to the distance between the opposing surfaces of the teeth sets and the second surface of the split yoke. Therefore, according to this configuration, since the variation in the position of the opposing surfaces of the flanges of the multiple teeth sets relative to the case portion in the axial direction is suppressed, there is less need to set a large median value for the distance (thickness, which is the axial length) between the rotor and the opposing surfaces of the flange in consideration of, for example, assembly errors of the stator, and it becomes possible to increase the output torque by reducing the distance.

[0028] In the above configuration, it is desirable that the stator includes a first split stator having one teeth set among the plurality of teeth sets and one split yoke among the plurality of split yokes, and a second split stator having another teeth set among the plurality of teeth sets and another split yoke among the plurality of split yokes, wherein in the first split stator, the distance between the opposing surface of the teeth set and the second surface of the split yoke is a first distance, and in the second split stator, the distance between the opposing surface of the teeth set and the second surface of the split yoke is a second distance greater than the first distance, and the thickness of the yoke support corresponding to the first split stator is set greater than the thickness of the yoke support corresponding to the second split stator.

[0029] According to this configuration, the thickness of the yoke support corresponding to the first split stator having a first distance is set to be greater than the thickness of the yoke support corresponding to the second split stator having a second distance greater than the first distance, thereby making it possible to obtain a stator in which the variation in the position of the opposing surfaces of the flange portions of multiple teeth is reliably suppressed.

[0030] In the above configuration, it is desirable that the yoke support further includes a plurality of contact bodies made of an elastic material, each having one end located on one side of the axial direction and the other end located on the other side of the axial direction, wherein the yoke support is made of a solidified adhesive material, each of the one ends of the plurality of contact bodies abutting the second surfaces of different split yokes among the plurality of split yokes, and each of the other ends of the plurality of contact bodies abutting the support surface, with the contact bodies abutting the case portion and the split yoke with a length corresponding to the axial distance between the opposing surfaces of the flange portions of the plurality of teeth in each tooth group and the second surface of the split yoke, and the yoke support is solidified between the case portion and the split yoke so as to surround the contact bodies.

[0031] With this configuration, the contact body serves as the core of the yoke support, and the yoke support solidifies and surrounds the contact body, preventing the yoke support from moving between the split yoke and the case, even when subjected to vibrations during motor operation. As a result, the position of the split yoke relative to the case can be stably maintained.

[0032] In the above configuration, it is desirable that the multiple contact bodies have multiple contact body sets, each including three contact bodies arranged corresponding to one of the split yokes, and that one end of the three contact bodies of each contact body set abuts against the second surface of each of the multiple split yokes.

[0033] With this configuration, each of the three contact bodies serves as the core of the yoke support, and each of the yoke supports is solidified and surrounds the three contact bodies, which further reduces movement of the yoke support between the split yoke and the case, even when subjected to vibrations during motor operation. As a result, the position of the split yoke relative to the case can be more stably maintained.

[0034] The present invention also provides a motor for an axial gap type rotating electric machine, comprising the stator and the rotor facing the stator with a gap in the axial direction, wherein the rotor rotates relative to the stator around a central axis of rotation along the axial direction due to the magnetic field formed by the stator.

[0035] The present invention also provides a method for manufacturing a stator for an axial gap type rotating electric machine, the method comprising a preparation step and an arrangement step, the preparation step including a yoke preparation step of preparing a yoke having a first surface disposed on one side in the axial direction and a second surface disposed on the other side in the axial direction, a teeth preparation step of preparing a plurality of teeth, each having a main body portion supporting an excitation coil and a flange portion disposed on the one side in the axial direction relative to the main body portion and including an opposing surface, and a first jig preparation step of preparing a first jig having a first reference plate, and the arrangement step including a teeth arrangement step of arranging the plurality of teeth at intervals in the circumferential direction on the first surface of the yoke. The method includes a first jig placement process for placing the first jig so that the first reference plate and the opposing surfaces of the flange portions of the plurality of teeth face each other in the axial direction; a flange portion placement process for arranging each of the opposing surfaces of the flange portions of the plurality of teeth in a line along the first reference plate in the circumferential direction; and a tooth support body placement process for placing a tooth support body between the flange portions of the plurality of teeth and the first surface so that each of the opposing surfaces of the flange portions of the plurality of teeth maintains a state in which they are arranged in a line along the circumferential direction along the first reference plate.

[0036] According to this method, by using a first jig having a first reference plate, the facing surfaces of the flanges of the multiple teeth can be arranged in a line in the circumferential direction along the first reference plate, which makes it possible to easily manufacture a stator in which the axial positional variation of the facing surfaces of the flanges of the multiple teeth relative to the yoke is reduced.

[0037] In the above method, it is desirable that in the tooth arrangement process, a first adhesive material is filled between the other axial side surface of the main body portion of the plurality of teeth and the first surface, and in the flange portion arrangement process, the plurality of teeth are pressed toward the first reference plate so that each of the opposing surfaces of the flange portions of the plurality of teeth are arranged in a line in the circumferential direction along the first reference plate, and in the tooth support body arrangement process, the first adhesive material is solidified so that the tooth support body formed of the solidified first adhesive material is arranged between the other axial side surface of the main body portion of the plurality of teeth and the first surface.

[0038] According to this method, by pressing the plurality of teeth against the first reference plate, the facing surfaces of the flanges of the plurality of teeth can be arranged in a circumferential direction along the first reference plate. Furthermore, by solidifying the first adhesive material while the plurality of teeth are pressed against the first reference plate, the tooth support can be arranged. As a result, the tooth support having a thickness corresponding to the axial dimension of each of the plurality of teeth can be easily arranged.

[0039] The above method further comprises a pin preparation step of preparing a plurality of pins, each having a first end portion disposed on one side in the axial direction and a second end portion disposed on the other side in the axial direction; in the yoke preparation step, a yoke is prepared, in which a plurality of yoke through holes are formed, the yoke through holes being spaced apart in the circumferential direction corresponding to the plurality of teeth and penetrating the yoke along the axial direction; in the teeth preparation step, a plurality of teeth are prepared, in which the main body portion and the flange portion are formed as an integral member; in the first jig preparation step, a first jig is prepared, which further comprises a mounting plate having a plurality of jig through holes that are spaced apart in the circumferential direction corresponding to the plurality of teeth and penetrating along the axial direction; and placing the yoke, with the plurality of teeth arranged on the first surface, on the mounting plate by inserting a number of pins into the plurality of jig through holes, respectively, and inserting the first ends of the plurality of pins into the plurality of yoke through holes, respectively, and abutting them against the main bodies of the plurality of teeth, and in the first jig arrangement step, arranging the first reference plate at a first interval from the mounting plate so as to sandwich the plurality of teeth and the yoke therebetween, and in the flange arrangement step, moving the plurality of pins toward the first reference plate in the axial direction and pressing the plurality of teeth toward the first reference plate, thereby arranging each of the opposing surfaces of the flanges of the plurality of teeth in a line along the circumferential direction along the first reference plate.

[0040] According to this method, a stator can be manufactured while supporting the teeth in a predetermined position using multiple pins moved toward the first reference plate, making it possible to manufacture a stator in which each of the opposing surfaces of the flange portions of the multiple teeth is precisely positioned along the first reference surface.

[0041] In the above method, it is desirable that in the tooth preparation process, the plurality of teeth are prepared, each of whose main body portions has at least two hole portions formed therein extending from the first surface side along the axial direction, and in the tooth arrangement process, the first end portion of the pin that has passed through the yoke through hole is arranged in each of the at least two hole portions.

[0042] According to this method, a stator can be manufactured while preventing the main body of the tooth from rotating by using pins inserted into at least two holes formed in the main body of the tooth, making it possible to manufacture a stator in which the opposing surfaces of the flange portions of multiple teeth are precisely aligned in the circumferential direction.

[0043] The above method further comprises a pin preparation step of preparing a plurality of pins each having a first end portion disposed on one side in the axial direction and a second end portion disposed on the other side in the axial direction, wherein the yoke preparation step prepares the yoke having a plurality of yoke through holes formed therein that are spaced apart in the circumferential direction corresponding to the plurality of teeth and that pass through the yoke along the axial direction, the teeth preparation step prepares the plurality of teeth whose main body portion and flange portion are independent of each other and whose main body portion has tooth through holes that pass through them along the axial direction, and the first jig preparation step further comprises a mounting plate having a plurality of jig through holes that are spaced apart in the circumferential direction corresponding to the plurality of teeth and that pass through them along the axial direction. and in the teeth arrangement step, the pins are inserted into the jig through-holes, the yoke through-holes, and the teeth through-holes, respectively, and the yoke, with the teeth arranged on the first surface, is placed on the mounting plate. In the first jig arrangement step, the first reference plate is arranged at a first interval from the mounting plate so as to sandwich the teeth and the yoke therebetween. In the flange arrangement step, the pins are moved in the axial direction toward the first reference plate to press the flanges of the teeth toward the first reference plate, thereby arranging the opposing surfaces of the flanges of the teeth in a line along the circumferential direction along the first reference plate.

[0044] According to this method, a stator can be manufactured while supporting the flange portion in a predetermined position using multiple pins moved toward the first reference plate, making it possible to manufacture a stator in which each of the opposing surfaces of the flange portions of multiple teeth is precisely positioned along the first reference surface.

[0045] In the above method, in the tooth preparation process, it is desirable to prepare the plurality of teeth having at least two hole portions formed in the flange portions of each of the plurality of teeth extending from the first surface side along the axial direction, and in the tooth arrangement process, to arrange the first end portion of the pin that has passed through the tooth through-hole of the main body portion in each of the at least two hole portions.

[0046] According to this method, a stator can be manufactured while preventing the flanges of the teeth from rotating by using pins inserted into at least two holes formed in the flanges of the teeth, making it possible to manufacture a stator in which the opposing surfaces of the flanges of multiple teeth are precisely aligned in the circumferential direction.

[0047] In the above method, it is desirable that the preparation step and the arrangement step further include the following steps: a case part preparation step in which the yoke is divided circumferentially into a plurality of split yokes, each of which has a plurality of teeth sets, each consisting of at least two teeth, arranged on the first surface thereof, and a case part preparation step in which the split yokes are prepared having a support surface for supporting the plurality of split yokes; a split yoke arrangement step in which the plurality of split stators are arranged at circumferential intervals on the support surface of the case part; a second jig arrangement step in which a second jig having a second reference plate is prepared and the second jig is arranged so that the second reference plate and the opposing surfaces of the flanges of the plurality of teeth face each other in the axial direction; a teeth set arrangement step in which the opposing surfaces of the flanges of each tooth set are arranged in a row in the circumferential direction along the second reference plate; and a yoke support arrangement step in which a plurality of yoke supports are arranged between the support surface and the second surfaces of the plurality of split yokes so that the opposing surfaces of the flanges of each tooth set are maintained in a row in the circumferential direction along the second reference plate.

[0048] According to this method, by using a second jig having a second reference plate, the facing surfaces of the flanges of the multiple teeth can be arranged in a circumferential direction along the second reference plate, which makes it possible to easily manufacture a stator in which the axial positional variation of the facing surfaces of the flanges of the multiple teeth relative to the case is reduced.

[0049] The above method further includes a contact body preparing step of preparing a plurality of contact bodies made of an elastic material, each having one end disposed on one side in the axial direction and the other end disposed on the other side in the axial direction, and in the split yoke arranging step, a second adhesive material is filled between the second surfaces of the plurality of split yokes and the support surface, and the plurality of contact bodies are arranged so that each of the one ends of the plurality of contact bodies abuts against the second surface of a different split yoke among the plurality of split yokes and each of the other ends of the plurality of contact bodies abuts against the support surface, thereby circumferentially positioning the plurality of split yokes relative to the support surface. In the tooth set arrangement process, the second reference plate is brought close to the support surface and the plurality of contact bodies are compressed against the elastic force of the plurality of contact bodies, thereby arranging each of the opposing surfaces of the flange portion of each tooth set in a line in the circumferential direction along the second reference plate, and in the yoke support arrangement process, the second adhesive material is solidified, and the yoke support is arranged between the case portion and the split yoke so that the yoke support, which is made of the solidified second adhesive material, surrounds the contact bodies with the contact bodies abutting against the case portion and the split yoke.

[0050] According to this method, by bringing the second reference plate close to the support surface and compressing the contact bodies against the elastic force of the contact bodies, the opposing surfaces of the flanges of each tooth set can be aligned in the circumferential direction along the second reference plate. Furthermore, by solidifying the second adhesive material while the contact bodies are compressed, the yoke support can be positioned. As a result, multiple yoke supports having thicknesses corresponding to the axial dimensions of each of the multiple stator segments can be easily positioned. [Effects of the Invention]

[0051] According to the present invention, it is possible to provide a stator for an axial gap type rotating electric machine, a motor for an axial gap type rotating electric machine, and a method for manufacturing a stator for an axial gap type rotating electric machine, in which variation in the position of the opposing surfaces of the flange portions of multiple teeth relative to the yoke in the axial direction is suppressed. [Brief explanation of the drawings]

[0052] [Figure 1] 1 is a diagram illustrating a schematic structure of an axial gap type rotating electric machine according to an embodiment of the present invention; [Figure 2] 1 is a side view of a stator and a rotor of a rotating electric machine according to an embodiment of the present invention. [Figure 3] 1 is an exploded perspective view of a rotating electrical machine according to an embodiment of the present invention; [Figure 4] 2 is an exploded perspective view of the stator of the rotating electric machine according to the embodiment; FIG. [Figure 5] FIG. 2 is a perspective view of a stator segment of the rotating electric machine according to the present embodiment. [Figure 6] 2 is a schematic cross-sectional view showing a divided stator of the rotary electric machine according to the present embodiment. FIG. [Figure 7] FIG. 2 is a perspective view showing a case portion of the rotating electric machine according to the embodiment. [Figure 8] 2 is a schematic cross-sectional view showing a part of a stator of the rotating electric machine according to the present embodiment. FIG. [Figure 9] 4 is a flowchart showing a manufacturing process of the divided stator of the rotating electric machine according to the present embodiment. [Figure 10] FIG. 2 is a perspective view showing a first jig according to the present embodiment. [Figure 11] 4 is a schematic cross-sectional view showing a first jig and components of a divided stator according to the present embodiment. FIG. [Figure 12] 4 is a cross-sectional view showing a first jig and components of a divided stator according to the present embodiment. FIG. [Figure 13] 3 is a schematic cross-sectional view showing a first jig and a divided stator according to the present embodiment. FIG. [Figure 14] 4 is a flowchart showing an assembly process of the stator of the rotating electric machine according to the present embodiment. [Figure 15] 2 is a schematic cross-sectional view showing two divided stators and a case portion of the rotary electric machine according to the present embodiment. FIG. [Figure 16] 4 is a schematic cross-sectional view showing two divided stators, a case portion, and a second jig of the rotary electric machine according to the present embodiment. FIG. [Figure 17] FIG. 6 is a schematic cross-sectional view showing a part of a stator of a rotating electric machine according to a second embodiment of the present invention. [Figure 18] 10 is a flowchart showing a method for manufacturing a stator for a rotating electric machine according to a second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0053] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. In the drawings, a direction parallel to the central axis of rotation AX of a rotating electric machine will be simply referred to as the "axial direction AD," and radial and circumferential directions about the central axis of rotation AX of the rotating electric machine will be simply referred to as the "radial direction RD" and the "circumferential direction CD." In this specification, "parallel direction" also includes a direction that is approximately parallel.

[0054] [Overall structure of an axial gap type rotating electric machine] FIG. 1 is a diagram schematically illustrating the structure of an axial gap rotating electric machine 1 according to an embodiment of the present invention. FIG. 1 also illustrates the rotational center axis AX of the rotor 3 (the axis of the rotating shaft portion 11). The rotational center axis AX also corresponds to the central axis of the stator 2. The axial gap rotating electric machine 1 generates a magnetic field for rotating the rotor 3 about the rotational center axis AX. In the present invention, the axial gap rotating electric machine 1 may take the form of, for example, a motor or a generator, or a machine that serves both purposes. In this embodiment, an axial gap DC brushless motor is illustrated as a preferred example of an axial gap rotating electric machine.

[0055] The rotating electric machine 1 includes a casing 10, a disk-shaped stator 2, a disk-shaped rotor 3, and a cylindrical rotating shaft 11. The casing 10 houses the stator 2 and the rotor 3. A portion of the rotating shaft 11 protrudes from the casing 10. The rotating shaft 11 serves as an output rotating shaft that generates torque when the rotating electric machine 1 is used as a motor, and serves as an input rotating shaft to which rotational driving force is input when the rotating electric machine 1 is used as a generator.

[0056] The stator 2 and rotor 3 are arranged side by side in the axial direction AD of the rotating shaft portion 11. In this embodiment, the rotor 3 faces a disk surface on one side of the stator 2 in the axial direction AD, thereby illustrating a single-stator, single-rotor rotating electric machine 1. Of course, the rotating electric machine may also be a double-stator, single-rotor rotating electric machine in which one stator 2 faces one disk surface of the rotor 3 and the other stator 2 faces the other disk surface of the rotor 3, thereby sandwiching the rotor 3 between the two stators 2. Furthermore, the rotating electric machine 1 may also be a single-stator, double-rotor rotating electric machine in which the stator 2 is sandwiched between the two rotors 3.

[0057] The rotor 3 is disposed at a distance G in the axial direction AD from the stator 2. The distance G is a so-called axial gap, and the length of the distance G is approximately 0.5 mm to several mm. The rotating shaft 11 is fixed to the disc-shaped rotor 3 and aligned with the center of rotation of the rotor 3.

[0058] Next, the stator 2 and the rotor 3 will be described in detail with reference to Fig. 2 and Fig. 3. Fig. 2 is a side view of the stator 2 and the rotor 3 of the rotating electric machine 1 according to this embodiment. Fig. 3 is a perspective view in which the stator 2 and the rotor 3 shown in Fig. 2 are exploded so as to be spread apart laterally.

[0059] The rotor 3 may have south and north poles aligned in the circumferential direction CD around the center point O of the rotor support surface 31S (the point intersecting with the rotation center axis AX). For example, the rotor 3 may have south and north pole magnets alternately aligned in the circumferential direction CD, multiple magnets aligned in a Halbach array in the circumferential direction CD, multiple magnets aligned in a three-dimensional magnetic pole structure, or no magnets, as in an induction motor. In this embodiment, the rotor 3 includes, for example, multiple (e.g., 36) permanent magnets 32 and a disk-shaped substrate 31 supporting the multiple permanent magnets 32. Each permanent magnet 32 ​​is made of neodymium or the like and is a flat, sector-shaped magnet when viewed in the axial direction AD. The substrate 31 has a circular rotor support surface 31S on the side facing the stator 2 that is perpendicular to the rotation center axis AX. The multiple permanent magnets 32 are arranged in a ring shape near the outer circumferential edge of the rotor support surface 31S around the center point O (the point where it intersects with the rotation center axis AX) of the rotor support surface 31S, with the south poles and north poles arranged alternately in the circumferential direction CD.

[0060] The disk-shaped substrate 31 is a member made of a magnetic material such as steel, and serves both to support the permanent magnets 32 and to function as a back yoke for the permanent magnets 32. The surface of the permanent magnet 32 ​​facing the stator 2 is magnetized to an S pole, and its back surface is an N pole. The adjacent permanent magnet 32 ​​has an N pole on its front surface and an S pole on its back surface. The substrate 31 supports the back surfaces of the multiple permanent magnets 32 and also serves to form a magnetic path between the S pole and N pole on the back surface. The permanent magnets 32 are fixed to the rotor support surface 31S using an adhesive such as an epoxy resin adhesive. Of course, the permanent magnets 32 may also be fixed to the rotor support surface 31S using mechanical fixing means such as screws.

[0061] (First embodiment) [Overall structure of stator] Next, the stator 2 according to the first embodiment will be described in detail with reference to Fig. 4. Fig. 4 is an exploded perspective view of the stator 2. Note that, for clarity, the excitation coil 23 is omitted from Fig. 4. As shown in Fig. 4, the stator 2 includes a disk-shaped yoke 21, a plurality of teeth 22 (tooth group) arranged in the circumferential direction CD of the yoke 21 (the direction of rotation of the rotor 3), and a plurality of excitation coils 23 (Figs. 2 and 3).

[0062] The number of the teeth 22 may be any multiple of three and is not particularly limited, but may be, for example, 36. The 36 teeth 22 are arranged on the first surface 21A at intervals in the circumferential direction CD. The teeth 22 are members that form magnetic cores and serve as winding cores for the excitation coils 23. Specifically, the teeth 22 have main bodies 222 that support the excitation coils 23, and flanges 221 that are arranged on one side of the main bodies 222 in the axial direction AD. In the first embodiment, the main bodies 222 and flanges 221 of the teeth 22 are integral members.

[0063] When viewed along the axial direction AD, the main body portion 222 has an annular sector shape centered on the central axis of rotation AX.

[0064] When viewed along the axial direction AD, the flange portion 221 has an annular sector shape centered on the central axis of rotation AX. The flange portion 221 has a width greater than that of the main body portion 222 in the circumferential direction CD. The width of the flange portion 221 in the radial direction RD may be the same as that of the main body portion 222, but the flange portion 221 may protrude inward in the radial direction RD than the main body portion 222, protrude outward in the radial direction RD than the main body portion 222, or protrude on both the inner side and the outer side of the radial direction RD than the main body portion 222. As a result, the main body portion 222 and the flange portion 221 form a bobbin shape onto which the excitation coil 23 can be attached. The flange portion 221 also includes an opposing surface 221A. The opposing surface 221A is a surface (flat surface) on one side of the flange portion 221 in the axial direction AD. The opposing surface 221A faces the rotor 3 when the axial gap type rotating electric machine 1 is in use.

[0065] 2 and 3, the excitation coil 23 will be described. As shown in FIGS. 2 and 3, the excitation coil 23 is attached to the main body 222. Specifically, the excitation coil 23 is formed by winding an insulated wire a required number of turns. When a direct current is passed through the excitation coil 23, a magnetic flux is generated that penetrates the teeth 22 in a direction parallel to the rotating shaft 11. Furthermore, the direction of the magnetic flux can be reversed by reversing the direction of the direct current passing through the excitation coil 23. The supply of current to each excitation coil 23 and the switching of the current flow direction are controlled by a driver circuit (not shown), which forms magnetic lines of force (magnetic flux) that rotate the rotor 3 around the rotation center axis AX.

[0066] Referring again to FIG. 4, the yoke 21 will be described. As shown in FIG. 4, the yoke 21 functions as a support for supporting the 36 teeth 22. Specifically, the yoke 21 has a first surface 21A disposed on one side in the axial direction AD and a second surface 21B disposed on the other side in the axial direction AD. Each of the first surface 21A and the second surface 21B is perpendicular to the axial direction AD. In other words, the first surface 21A and the second surface 21B are disposed on opposite sides of each other in the thickness direction of the yoke 21.

[0067] The annular yoke 21 may be a single ring. In this embodiment, however, the annular yoke 21 has multiple split yokes 210 split along the circumferential direction CD. For example, the yoke 21 has 12 split yokes 210. Each of the 12 split yokes 210 is a flat, fan-shaped dust core when viewed in the axial direction AD. The split yokes 210 do not necessarily have to be formed by 12 split yokes 210 at 30-degree intervals. Instead, the split yokes 210 may be formed by four split yokes 210 at 90-degree intervals, six split yokes 210 at 60-degree intervals, or eight split yokes 210 at 45-degree intervals. The multiple split yokes 210 are arranged so that the arcs of each split yoke 210 are connected to form the outer circle of the yoke 21. In FIG. 4, the area of ​​the yoke 21 where the teeth 22 are arranged is shaded.

[0068] A dust core is a core formed by firmly compressing iron powder coated with an electrical insulating film. Dust cores are preferable as split yokes 210 because they are more airtight than laminated cores and offer greater flexibility in molding. However, dust cores can have different dimensions for the split yokes 210 due to machining processes, such as cutting, during the manufacture of the split yokes 210. Details will be described later using FIG. 8 . For example, two split yokes 210, a first split yoke 210A and a second split yoke 210B, are manufactured. As a result, the dimension in the axial direction AD of the first split yoke 210A is a first length. The dimension in the axial direction AD of the second split yoke 210B is a second length. The first length and the second length may differ from each other. For example, the dimensional values ​​may vary within the tolerance range specified in standards such as JIS B 0405, with the dimensional difference being, for example, up to several hundred microns. In the first embodiment, the variation in dimensions of the twelve divided yokes 210 is adjusted by the plurality of second synthetic resin layers 40 described later.

[0069] The yoke 21 also has a plurality of yoke through holes 21C that are spaced apart in the circumferential direction CD and that penetrate along the axial direction AD. As a result, as will be described in detail below, 36 teeth 22 are attached to the yoke 21 using the plurality of yoke through holes 21C and a plurality of pins 50 ( FIG. 6 ). More specifically, each tooth 22 is positioned and attached to the yoke 21 on a plane perpendicular to the axial direction AD using two yoke through holes 21C. Furthermore, each tooth 22 is positioned and attached to the yoke 21 in the axial direction AD depending on the insertion amount of the plurality of pins 50 in the axial direction AD.

[0070] The 36 teeth 22 (tooth groups) include 12 tooth sets 220 corresponding to the 12 split yokes 210. Each of the 12 tooth sets 220 includes, for example, three teeth 22. For example, the first tooth set 220A includes a first tooth 22A, a second tooth 22B, and a third tooth 22C. The three teeth 22 are erected at intervals in the circumferential direction CD on the first surface 21A of one split yoke 210. Each of the 12 split yokes 210 also includes six yoke through holes 21C. As a result, three teeth 22 are positioned and attached to one split yoke 210.

[0071] With reference to Fig. 5, a split stator 230 in which one teeth set 220 is attached to one split yoke 210 will be described. Fig. 5 is a perspective view showing split stator 230. Note that excitation coil 23 is omitted from Fig. 5 for clarity. As shown in Fig. 5, first split stator 230A has first teeth set 220A, first split yoke 210A, and three excitation coils (not shown). First teeth set 220A has first teeth 22A, second teeth 22B, and third teeth 22C.

[0072] Further, referring to FIG. 6, the first stator segment 230A of the twelve stator segments 230 will be described in detail. FIG. 6 is a schematic cross-sectional view showing the first stator segment 230A. The schematic cross-sectional view shows the curved shape in the circumferential direction CD expanded (developed). The circumferential direction CD in FIG. 6 is aligned with three yoke through holes 21C that are located on the inside of the radial direction RD out of the six yoke through holes 21C in the first yoke segment 210A. In other words, FIG. 6 illustrates three of the six yoke through holes 21C in the first yoke segment 210A. Note that the excitation coil 23 is also omitted in FIG. 6.

[0073] 6, first stator segment 230A includes first teeth set 220A, first yoke segment 210A, and first synthetic resin layer 30. First synthetic resin layer 30 is an example of the "tooth support body" of the present invention.

[0074] The teeth 22 are preferably dust cores. Dust cores are preferable for the teeth 22 because they have higher airtightness and greater molding flexibility than laminated cores. However, dust cores can have different dimensions among the teeth 22 due to machining processes, such as cutting, during tooth manufacturing. For example, three teeth 22 are manufactured: first teeth 22A, second teeth 22B, and third teeth 22C. As a result, the axial dimension AD of the first teeth 22A is a first dimension TA. The axial dimension AD of the second teeth 22B is a second dimension TB. The axial dimension AD of the third teeth 22C is a third dimension TC. The first dimension TA, second dimension TB, and third dimension TC may differ from one another. For example, the dimensional values ​​may vary within the tolerance range specified in standards such as JIS B 0405, with the dimensional difference being, for example, up to several hundred μm.

[0075] Furthermore, each of the main body portions 222 of the teeth 22 has at least two holes 223 formed therein, extending from the first surface 21A along the axial direction AD. In the first embodiment, two holes 223 are formed in the surface of each of the main body portions 222 of the three teeth 22 on the other side in the axial direction AD. The two holes 223 are arranged with an interval in the radial direction RD. Note that the depths of the hole portions 223 of the three teeth 22 may be the same or different from each other, but in the first embodiment, the depths of the hole portions 223 of the three teeth 22 are the same from each other.

[0076] The other end faces of the three teeth 22 in the axial direction AD are joined to the first surface 21A of the first split yoke 210A. Specifically, the other end faces of the three teeth 22 in the axial direction AD are fixed to the first surface 21A of the first split yoke 210A by the first synthetic resin layer 30.

[0077] The first synthetic resin layer 30 supports the three teeth 22 from the first split yoke 210A side. Specifically, the first synthetic resin layer 30 is disposed on the other side in the axial direction AD of each of the flange portions 221 of the three teeth 22. In the first embodiment, the first synthetic resin layer 30 is disposed between the main body portion 222 and the first surface 21A.

[0078] The first synthetic resin layer 30 is made of a solidified first adhesive material. The first synthetic resin layer 30 is, for example, an epoxy resin adhesive. This fixes the three teeth 22 to the first surface 21A. The first synthetic resin layer 30 may be a plurality (three pieces) of first synthetic resin layers 30, each divided and arranged individually for each of the plurality (three) teeth 22, or may be a single, integrated layer continuously formed over the entire first surface 21A.

[0079] The first synthetic resin layer 30 has a thickness corresponding to the dimensions of each of the three teeth 22 in the axial direction AD so that the opposing surfaces 221A of the flange portions 221 of the three teeth 22 are aligned in the circumferential direction CD along the first reference plane AA. The first reference plane AA is set at a first distance on one side of the first surface 21A in the axial direction AD. In other words, the thicknesses of the first synthetic resin layer 30 in the axial direction AD of the portions corresponding to each of the three teeth 22 are set to differ according to the differences in the dimensions of the three teeth 22 in the axial direction AD.

[0080] Specifically, the thickness of the first synthetic resin layer 30A in the axial direction AD corresponding to the first teeth 22A having a first dimension TA is set to be greater than the thickness of the first synthetic resin layer 30B in the axial direction AD corresponding to the second teeth 22B having a second dimension TB larger than the first dimension TA. More specifically, the thicknesses in the axial direction AD of the first synthetic resin layer 30 corresponding to the three teeth 22 are set so that the distances between the first surface 21A and the opposing surfaces 221A of the flanges 221 of the three teeth 22 are the same.

[0081] For example, the first teeth 22A, having a first dimension TA, are fixed to the first surface 21A by the first synthetic resin layer 30A, having a first thickness RA. The second teeth 22B, having a second dimension TB, are fixed to the first surface 21A by the first synthetic resin layer 30B, having a second thickness RB. The third teeth 22C, having a third dimension TC, are fixed to the first surface 21A by the first synthetic resin layer 30C, having a third thickness RC. Here, the third dimension TC is smaller than the first dimension TA. The first thickness RA is larger than the second thickness RB, and the third thickness RC is larger than the first thickness RA. The distance between the first surface 21A and the opposing surfaces 221A of the flanges 221 of the three teeth 22 is approximately the same as the second dimension TB, and the second thickness RB is extremely thin. As a result, the thicknesses of the first synthetic resin layer 30A and the first synthetic resin layer 30C are prevented from increasing.

[0082] As described above, in the first embodiment, even if the dimensions of each of the three teeth 22 in the axial direction AD are different from one another, the first synthetic resin layer 30 is disposed with a thickness corresponding to the dimensions of each of the three teeth 22 in the axial direction AD. As a result, it is possible to suppress variation in the position of the opposing surfaces 221A of the flanges 221 of the three teeth 22 relative to the first surface 21A of the split yoke 210 in the axial direction AD. Therefore, with this configuration, since variation in the position of the opposing surfaces 221A of the flanges 221 of the three teeth 22 relative to the first surface 21A of the split yoke 210 in the axial direction AD is suppressed, there is less need to set a large median value for the gap (thickness, which is the length in the axial direction AD) between the rotor 3 and the opposing surfaces 221A of the flanges 221 in consideration of, for example, an assembly error of the stator 2, and thus it is possible to increase the output torque by reducing the gap G.

[0083] Referring again to Fig. 6, the multiple pins 50 will be described in detail. As shown in Fig. 6, the first split stator 230A further includes multiple pins 50 in addition to the first teeth 22A, the second teeth 22B, the third teeth 22C, the first split yoke 210A, and the first synthetic resin layer 30.

[0084] The number of pins 50 corresponds to the number of yoke through holes 21C, and is, for example, six. Each of the six pins 50 has a first end 51 disposed on one side in the axial direction AD and a second end 52 disposed on the other side in the axial direction AD. Each of the six pins 50 is, for example, a cylindrical rod-like body. Furthermore, the dimension of each of the six pins 50 in the axial direction AD is greater than the dimension of the split yoke 210. In other words, each of the six pins 50 protrudes from the split yoke 210 in the axial direction AD. In the first embodiment, in order to adjust for dimensional variations of the three teeth 22 in a stator manufacturing method described later, it is preferable that the dimension of each of the six pins 50 in the axial direction AD be greater than the sum of the depth of the hole 223 of the tooth 22 and the dimension (thickness) of the split yoke 210 in the axial direction AD.

[0085] The first ends 51 of the six pins 50 inserted into the six yoke through holes 21C respectively come into contact with the main body portions 222 of the three teeth 22. Specifically, the first ends 51 of two of the six pins 50 on one side in the circumferential direction CD are inserted into the hole 223 of the main body portion 222 of the first tooth 22A. The first ends 51 of two of the six pins 50 on the other side in the circumferential direction CD are inserted into the hole 223 of the main body portion 222 of the third tooth 22C. The first ends 51 of the remaining two of the six pins 50 (the pins 50 at the center in the circumferential direction CD) are inserted into the hole 223 of the main body portion 222 of the second tooth 22B.

[0086] As a result, the position of the first end 51 of the pin 50 corresponding to the first tooth 22A having the first dimension TA in the axial direction AD is located on one side in the axial direction AD of the position of the first end 51 of the pin 50 corresponding to the second tooth 22B having the second dimension TB. Similarly, the position of the first end 51 of the pin 50 corresponding to the third tooth 22C having the third dimension TC in the axial direction AD is located on one side in the axial direction AD of the position of the first end 51 of the pin 50 corresponding to the first tooth 22A having the first dimension TA. In other words, the insertion amount of the pin 50 is also ensured for the hole 223 of the third tooth 22C having the third dimension TC. As a result, the third tooth 22C having the third dimension TC can be stably supported by the first split yoke 210A.

[0087] The first synthetic resin layer 30 is interposed between the first surface 21A and the surfaces of the main bodies 222 of the three teeth 22 on the other side in the axial direction AD so as to surround the six pins 50. In other words, to adjust for dimensional variations among the three teeth 22 in a stator manufacturing method described below, the pins 50 are moved along the axial direction AD. After adjusting for dimensional variations among the three teeth 22, the first synthetic resin layer 30 solidifies, preventing the six pins 50 from moving along the axial direction AD. Note that the second ends 52 of the six pins 50 are located on the other side in the axial direction AD of the second surface 21B. In other words, the second ends 52 of the six pins 50 protrude from the second surface 21B.

[0088] As described above, in the first embodiment, each of the six pins 50 serves as a core of the first synthetic resin layer 30, and the first synthetic resin layer 30 surrounds and is entangled with the six pins 50, so that even if subjected to vibrations during motor operation, the first synthetic resin layer 30 can be prevented from detaching from between the split yoke 210 and the main body portion 222. As a result, deviation in the position of the teeth 22 relative to the split yoke 210 can be further prevented.

[0089] Furthermore, in the first embodiment, the two pins 50 are firmly fixed to the main body portion 222, and the first synthetic resin layer 30A is entangled with the two pins 50. Therefore, even when subjected to vibrations during motor operation, the first synthetic resin layer 30A can be more effectively prevented from moving or coming off between the split yoke 210 and the main body portion 222. As a result, the position of the teeth 22 relative to the split yoke 210 can be more effectively prevented from shifting.

[0090] Next, the case portion 60 will be described with reference to Figs. 7 and 8. Fig. 7 is a perspective view showing the case portion 60. Fig. 8 is a schematic cross-sectional view showing a portion of the stator 2 of the rotating electric machine 1 according to this embodiment. The schematic cross-sectional view shows the curved shape in the circumferential direction CD expanded (developed). Fig. 8 shows two stator segments 230. The two stator segments 230 are a first stator segment 230A and a second stator segment 230B.

[0091] 8, the stator 2 further includes a case portion 60, a plurality of second synthetic resin layers 40, and a plurality of contact bodies 70 (contact body group), in addition to a plurality of stator segments 230. The second synthetic resin layer 40 corresponds to an example of the "yoke support" in the present invention.

[0092] 7, the case 60 is a disk-shaped base material that supports the multiple split stators 230. The case 60 is a member made of synthetic resin, metal, or the like. The case 60 may be disposed on the other side of the casing 10 in the axial direction AD as part of the casing 10 shown in FIG. 1, or may be disposed inside the casing 10.

[0093] Specifically, the case portion 60 is circular and perpendicular to the rotational axis AX. The multiple split stators 230 are arranged in an annular shape around the center point O of the case portion 60 (the point intersecting with the rotational axis AX) and near the outer periphery of the case portion 60 so as to line up in the circumferential direction CD. In the first embodiment, twelve split stators 230 are arranged in annular shape around the center point O of the case portion 60 and near the outer periphery of the case portion 60 so as to line up in the circumferential direction CD.

[0094] The case portion 60 has a plurality of large hole portions 610 and a plurality of small hole portions 620. The plurality of large hole portions 610 and the plurality of small hole portions 620 are spaced apart in the circumferential direction CD and extend from the support surface 61 along the axial direction AD. The diameter of the large hole portions 610 is larger than the diameter of the small hole portions 620. The diameter of the small hole portions 620 is larger than the diameter of the pin 50.

[0095] Specifically, the case 60 has 36 large holes 610 and 48 small holes 620. Note that in Fig. 7, some of the 36 large holes 610 and 48 small holes 620 are labeled with reference numerals. The 36 large holes 610 and 48 small holes 620 are arranged in the case 60 such that three large holes 610 and four small holes 620 correspond to one split yoke 210. Note that the case 60 may have a plurality of positioning pins for positioning the split yoke 210.

[0096] As shown in FIG. 8 , the large hole 610 accommodates the contact body 70 and the second synthetic resin layer 40, and allows the second end 52 of the pin 50 protruding from the second surface 21B of the split stator 230 to be inserted therein. The case 60 also has a support surface 61 that faces the second surface 21B of the split stator 230 in the axial direction AD. The support surface 61 is an imaginary surface that extends perpendicular to the axial direction AD. The support surface 61 and the bottom surface of the large hole 610 are coincident. Meanwhile, the small hole 620 allows the second end 52 of the pin 50 protruding from the second surface 21B of the split stator 230 to be inserted therein.

[0097] 7, the second end portions 52 of three pins 50 that are disposed on the inside in the radial direction RD out of the six pins 50 protruding from one split yoke 210 are inserted into three of the four small hole portions 620. The second end portion 52 of one pin 50 that is disposed on the outside in the radial direction RD and in the center in the circumferential direction CD out of the six pins 50 protruding from one split yoke 210 is inserted into the remaining small hole portion 620 out of the four small hole portions 620. The second end portions 52 of two pins 50 that are disposed on the outside in the radial direction RD and in the circumferential direction CD out of the six pins 50 protruding from one split yoke 210 are inserted into the two radially outer large hole portions 610 out of the three large hole portions 610 that are indicated by the reference numerals in FIG. The remaining large hole 610 of the three large holes 610 corresponds to the inner side of the split yoke 210 in the radial direction RD and the center of the split yoke 210 in the circumferential direction CD.

[0098] The multiple second synthetic resin layers 40 support the multiple stator segments 230. Specifically, the multiple second synthetic resin layers 40 are interposed between the multiple yoke segments 210 and the support surface 61. The multiple second synthetic resin layers 40 are made of a solidified second adhesive material. The multiple second synthetic resin layers 40 are, for example, an epoxy resin adhesive. This fixes the multiple yoke segments 210 to the support surface 61.

[0099] The plurality of second synthetic resin layers 40 are disposed in the plurality of large hole portions 610. Specifically, the plurality of second synthetic resin layers 40 are 36 second synthetic resin layers 40. The 36 second synthetic resin layers 40 are disposed in the 36 large hole portions 610, respectively. Specifically, one split yoke 210 is fixed to the support surface 61 by three second synthetic resin layers 40. As a result, tilting of one split yoke 210 with respect to the support surface 61 is suppressed. Note that one split yoke 210 may be fixed to the support surface 61 by four or more second synthetic resin layers 40.

[0100] Furthermore, the plurality of second synthetic resin layers 40 have a thickness corresponding to the distance in the axial direction AD between the opposing surfaces 221A of the flanges 221 in each tooth set 220 and the second surface 21B of the split yoke 210 so that the opposing surfaces 221A of the flanges 221 in each tooth set 220 are aligned in the circumferential direction CD along the second reference plane BB. The second reference plane BB is set at a second distance on one side of the support surface 61 in the axial direction AD. The second distance is greater than the first distance. More specifically, in the split stator 230, the opposing surfaces 221A of the three flanges 221 are positioned at a first distance from the first surface 21A by the first synthetic resin layer 30. In the stator 2, the opposing surfaces 221A of the 36 flanges 221 are positioned at a second distance from the support surface 61 by the second synthetic resin layer 40.

[0101] Specifically, the thickness of the second synthetic resin layer 40A corresponding to the first split stator 230A is set to be greater than the thickness of the second synthetic resin layer 40B corresponding to the second split stator 230B. In the first split stator 230A, the distance between the opposing surface 221A of the first teeth set 220A and the second surface 21B of the first split yoke 210A is a first distance DA. In the second split stator 230B, the distance between the opposing surface 221A of the second teeth set 220B and the second surface 21B of the second split yoke 210B is a second distance DB.

[0102] The thicknesses in the axial direction AD of the second synthetic resin layers 40 corresponding to each of the multiple stator segments 230 are set so that the distances between the support surface 61 and the opposing surfaces 221A of the flange portions 221 of the multiple tooth sets 220 are the same. For example, a first stator segment 230A having a first distance DA in the axial direction AD is fixed to the support surface 61 by a second synthetic resin layer 40A having a first thickness RRA. A second stator segment 230B having a second distance DB in the axial direction AD is fixed to the support surface 61 by a second synthetic resin layer 40A having a second thickness RRB. Here, the first thickness RRA is greater than the second thickness RRB.

[0103] As described above, in the first embodiment, even if the dimensions of each of the multiple stator segments 230 in the axial direction AD are different from one another, the multiple second synthetic resin layers 40 are arranged with thicknesses corresponding to the dimensions of each of the multiple stator segments 230 in the axial direction AD. As a result, it is possible to suppress variation in the position of the opposing surfaces 221A of the flanges 221 of the multiple tooth sets 220 relative to the case portion 60 in the axial direction AD. Therefore, with this configuration, since variation in the position of the opposing surfaces 221A of the flanges 221 of the multiple tooth sets 220 relative to the case portion 60 in the axial direction AD is suppressed, it is not necessary to set a large median value for the gap (thickness, which is the length in the axial direction AD) between the rotor 3 and the opposing surfaces 221A of the flanges 221 in consideration of, for example, an assembly error of the stator 2, and thus it is possible to increase the output torque by reducing the gap G.

[0104] Referring again to FIG. 8, the multiple contact bodies 70 (contact body group) will be described in detail. As shown in FIG. 8, each of the multiple contact bodies 70 is made of an elastic material. Each of the multiple contact bodies 70 is, for example, a spring washer or a wave washer. The multiple contact bodies 70 are respectively disposed in the multiple large hole portions 610. Specifically, 36 contact bodies 70 are respectively disposed in 36 large hole portions 610. As a result, the second synthetic resin layer 40 is interposed between the case portion 60 and the split yoke 210 so as to surround the contact bodies 70. More specifically, the second synthetic resin layer 40 is solidified between the case portion 60 and the split yoke 210 so as to surround the contact bodies 70. In other words, in order to adjust the dimensional variations of the multiple split stators 230 in the stator manufacturing method described below, the contact body 70 acts along the axial direction AD, and after adjusting the dimensional variations of the multiple split stators 230, the second synthetic resin layer 40 solidifies to prevent the contact body 70 from elastically deforming.

[0105] The plurality of contact bodies 70 (contact body group) have one end 71 disposed on one side in the axial direction AD and the other end 72 disposed on the other side in the axial direction AD. The other end 72 of each of the plurality of contact bodies 70 abuts against the support surface 61 (the bottom of the large hole portion 610) of the case portion 60. Meanwhile, the plurality of contact bodies 70 (contact body group) have a plurality of contact body sets 700. Each of the plurality of contact body sets 700 includes three contact bodies 70 disposed corresponding to one split yoke 210. As a result, one split yoke 210 abuts against one end 71 of the three contact bodies 70. As a result, tilting of one split yoke 210 with respect to the support surface 61 is suppressed.

[0106] Specifically, the contact body 70 abuts against the case portion 60 and the split yoke 210 with a dimension corresponding to the distance in the axial direction AD between the opposing surfaces 221A of the flange portions 221 of the teeth 22 of each tooth group 220 and the second surface 21B of the split yoke 210. More specifically, the dimension of the contact body 70 corresponding to the first split stator 230A having the first distance DA is larger than the dimension of the contact body 70 corresponding to the second split stator 230B having the second distance DB. For example, the first split stator 230A having the first distance DA abuts against the first contact body group 700A having the first dimension RRA. The second split stator 230B having the second distance DB abuts against the second contact body group 700B having the second dimension RRB. Here, the first dimension RRA is larger than the second dimension RRB.

[0107] As described above, in the first embodiment, the three contact bodies 70 serve as the core of the second synthetic resin layer 40, and the second synthetic resin layer 40A surrounds and solidifies the three contact bodies 70, entangling them. This prevents the second synthetic resin layer 40 from detaching from between the split yoke 210 and the main body 222, even when subjected to vibrations during motor operation. As a result, displacement of the split yoke 210 relative to the case 60 can be further prevented.

[0108] [Stator manufacturing method] Next, the method for manufacturing stator 2 will be described in detail. The method for manufacturing stator 2 includes a manufacturing process for split stator 230 and a process for assembling stator 2. In other words, stator 2 is manufactured through a manufacturing process for split stator 230 and a process for assembling stator 2. In the first embodiment, the method for manufacturing stator 2 includes a manufacturing process for split stator 230 that is performed 12 times, and a process for assembling stator 2 that is performed once. Specifically, the manufacturing process for split stator 230 manufactures split stator 230 in which teeth group 220 consisting of three teeth 22 is arranged on split yoke 210. The process for assembling stator 2 combines the 12 split stators 230 manufactured in the manufacturing process for split stator 230 to manufacture one stator 2.

[0109] [Manufacturing process of split stator 230] 9 is a flowchart showing the manufacturing process of split stator 230. As shown in FIG. 9, the manufacturing process of split stator 230 includes a yoke preparation process (step S101), a teeth preparation process (step S102), a pin preparation process (step S103), a first jig preparation process (step S104), a teeth arrangement process (step S105), a first jig arrangement process (step S106), a flange arrangement process (step S107), a teeth supporter arrangement process (step S108), and a first jig removal process (step S109). The yoke preparation process, teeth preparation process, pin preparation process, and first jig preparation process are collectively referred to as the preparation process. Similarly, the teeth arrangement process, first jig arrangement process, flange arrangement process, and teeth supporter arrangement process are collectively referred to as the arrangement process. Furthermore, the yoke preparing step, the teeth preparing step, the pin preparing step, and the first jig preparing step may be carried out together as one step.

[0110] In the yoke preparation step (step S101) of FIG. 9, a yoke 21 is prepared, which has a first surface 21A disposed on one side in the axial direction AD and a second surface 21B disposed on the other side in the axial direction AD (see FIG. 4). Specifically, a split yoke 210 is prepared. In the first embodiment, the split yoke 210 is a flat dust core that is sector-shaped when viewed in the axial direction AD. The split yoke 210 also has six yoke through holes 21C.

[0111] In the teeth preparation step (step S102) of FIG. 9, a plurality of teeth 22 are prepared, each having a main body 222 that supports the excitation coil 23 and a flange 221 that is disposed on one side of the main body 222 in the axial direction AD (see FIG. 6). The flange 221 includes an opposing surface 221A. Specifically, three teeth 22 are prepared for one split yoke 210. In the first embodiment, each of the three teeth 22 is a flat, fan-shaped dust core when viewed in the axial direction AD. In each of the three teeth 22, the main body 222 and the flange 221 are an integral member. The main body 222 further has two holes 223.

[0112] In the pin preparation step (step S103) of FIG. 9, a plurality of pins 50 are prepared, each having a first end 51 disposed on one side in the axial direction AD and a second end 52 disposed on the other side in the axial direction AD (see FIG. 6). Specifically, six pins 50 are prepared for one split yoke 210. Each of the six pins 50 is, for example, a cylindrical rod-shaped body. In addition, in the axial direction AD, the dimension of each of the six pins 50 is greater than the sum of the depth of the hole portion 223 of the tooth 22 and the dimension of the split yoke 210.

[0113] In the first jig preparation step (step S104) of FIG. 9, a first jig 300 having a first reference plate 311 and a mounting plate 321 is prepared. Referring to FIG. 10, the first jig 300 used in the manufacturing process of the divided stator 230 will be described. FIG. 10 is a perspective view showing the first jig 300. For ease of understanding, the X-axis, Y-axis, and Z-axis of a three-dimensional Cartesian coordinate system are appropriately indicated. The positive direction of the Z-axis indicates the upward direction, and the negative direction of the Z-axis indicates the downward direction. However, the up-down direction, the upward direction, and the downward direction are defined for convenience of explanation and do not necessarily correspond to the vertical direction. Furthermore, the up-down direction is defined merely for convenience of explanation and does not limit the orientation during assembly of the rotating electric machine according to one embodiment of the present invention. Furthermore, in the manufacturing method of the stator 2, the components of the stator 2 are used so that the axial direction AD of the components of the stator 2 is aligned with the Z direction.

[0114] As shown in FIG. 10 , first jig 300 includes upper portion 310 and lower portion 320. Lower portion 320 functions as a support for split stator 230. Specifically, lower portion 320 includes disk-shaped mounting plate 321 and six cylindrical push-up members 322. Mounting plate 321 has upper surface 321A disposed on the Z direction side and lower surface 321B disposed on the −Z direction side. Upper surface 321A and lower surface 321B are each perpendicular to the Z direction. In other words, upper surface 321A and lower surface 321B are disposed on opposite sides of mounting plate 321 in the thickness direction.

[0115] The disk-shaped mounting plate 321 has six jig through holes 321C in the center thereof. Each of the six jig through holes 321C extends along the Z direction. The six jig through holes 321C are spaced apart to correspond to the yoke through holes 21C of the split yoke 210 (see FIG. 11). The second ends 52 of the six pins 50 are inserted into the upper portions of the six jig through holes 321C, respectively (see FIG. 12). Six push-up members 322 are inserted into the lower portions of the six jig through holes 321C, respectively. The disk-shaped mounting plate 321 also has a plurality of screw holes 321D near the outer periphery of the disk-shaped mounting plate 321. Each of the plurality of screw holes 321D extends along the Z direction. A screw (not shown) for adjusting the distance between first reference plate 311 and mounting plate 321 is inserted into each of the plurality of screw holes 321D.

[0116] The upper portion 310 includes a disk-shaped first reference plate 311. The first reference plate 311 has an upper surface 311A ​​disposed on the Z direction side and a lower surface 311B disposed on the -Z direction side. The lower surface 311B forms the "first reference plane AA" in the present invention. In other words, the first jig 300 is used to set the first reference plane AA. The first reference plate 311 has a size sufficient to encompass the three opposing surfaces 211A. The upper surface 311A ​​and the lower surface 311B are each perpendicular to the Z direction. In other words, the upper surface 311A ​​and the lower surface 311B are disposed on opposite sides of each other in the thickness direction of the first reference plate 311.

[0117] The first reference plate 311 has a plurality of screw holes 311C near the outer periphery of the disk-shaped first reference plate 311. Each of the plurality of screw holes 311C extends along the Z direction. The plurality of screw holes 311C are arranged at positions corresponding to the plurality of screw holes 321D. A screw (not shown) for adjusting the distance between the first reference plate 311 and the mounting plate 321 is to be inserted into each of the plurality of screw holes 311C.

[0118] In the teeth arrangement process (step S105) of FIG. 9, three teeth 22 are arranged on the first surface 21A of the split yoke 210 at intervals in the circumferential direction CD. FIG. 11 is a schematic cross-sectional view showing the first jig 300 and the components of the split stator 230. The schematic cross-sectional view shows the curved shape in the circumferential direction CD expanded (developed). The circumferential direction CD is aligned with three of the six yoke through holes 21C in the split yoke 210 that are located on the inside in the radial direction RD. In other words, three of the six yoke through holes 21C in the split yoke 210 are shown in the figure.

[0119] As shown in FIG. 11 , in this teeth arrangement process, three teeth 22 are erected at intervals in the circumferential direction CD on the first surface 21A of the split yoke 210. Specifically, first, a mounting plate 321 is arranged with six boost members 322 inserted into the lower portions of six jig through holes 321C. Next, the second ends 52 of the six pins 50 are inserted into the jig through holes 321C. As a result, the second ends 52 of the six pins 50 abut against the boost members 322. Meanwhile, the first ends 51 of the six pins 50 protrude in the Z direction from the mounting plate 321. Next, the first ends 51 of the six pins 50 are inserted into the yoke through holes 21C, respectively, to mount the split yoke 210 on the mounting plate 321. At this time, the first ends 51 of the pins 50 protrude in the Z direction from the first surface 21A of the split yoke 210.

[0120] Next, a first adhesive material is applied to the other surface in the axial direction AD of the main body portions 222 of the three teeth 22 on which the excitation coil (not shown) is arranged. The first adhesive material is, for example, an epoxy resin adhesive before hardening. Next, the first ends 51 of two pins 50 aligned along the radial direction RD are inserted into the two holes 223 of the main body portions 222 of the teeth 22, respectively, to arrange the teeth 22 on the first surface 21A. Similarly, the other two teeth 22 are placed on the first surface 21A, and the split yoke 210 with the three teeth 22 arranged on the first surface 21A is placed on the mounting plate 321. Note that insulating paper may be placed on both sides of the excitation coil in the axial direction AD. Furthermore, filling the first adhesive material between the other surface in the axial direction AD of the main body portions 222 of the three teeth 22 and the first surface 21A of the split yoke 210 may be performed in the subsequent first jig arrangement process, rather than in the teeth arrangement process.

[0121] In the first jig placement step (step S106) of FIG. 9, first jig 300 is placed so that first reference plate 311 and opposing surfaces 221A of flange portions 221 of multiple teeth 22 face each other in the axial direction AD. FIG. 12 is a cross-sectional view showing first jig 300 and components of split stator 230. As shown in FIG. 12, first reference plate 311 is placed at a predetermined distance from mounting plate 321. Specifically, the distance between first reference plate 311 and mounting plate 321 is adjusted by inserting multiple screws into multiple screw holes 311C (FIG. 10) and multiple screw holes 321D (FIG. 10), respectively. As a result, as shown in FIG. 11, the distance between first reference plate 311 and mounting plate 321 is the sum of second dimension TB (FIG. 6) of second tooth 22B, which has the largest dimension among the three teeth 22, and the dimension of first split yoke 210A. In the first embodiment, the specified distance is the sum of the second dimension TB of the second tooth 22B, which has the largest dimension among the three teeth 22, and the dimension of the first split yoke 210A, but a spacer may be prepared separately and the specified distance may be the dimension of the spacer placed between the first reference plate 311 and the mounting plate 321.

[0122] In the flange portion arrangement process (step S107) of Fig. 9, the opposing surfaces 221A of the flange portions 221 of the three teeth 22 are arranged side by side in the circumferential direction CD along the first reference plate 311 of the first jig 300. Fig. 13 is a schematic cross-sectional view showing the first jig 300 and the split stator 230. The schematic cross-sectional view shows the curved shape in the circumferential direction CD expanded (developed). The circumferential direction CD is aligned with three of the six yoke through holes 21C in the split yoke 210 that are arranged on the inside in the radial direction RD.

[0123] 13, from the state in FIG. 11, by tightening the push-up members 322 into the jig through holes 321C toward the first reference plate 311, the pins 50 are moved within the jig through holes 321C toward the first reference plate 311, and the opposing surfaces 221A of the flanges 221 of the teeth 22 are pressed against the first reference plate 311. By tightening the other push-up members 322 into the jig through holes 321C toward the first reference plate 311, the pins 50 are moved within the jig through holes 321C toward the first reference plate 311, and the opposing surfaces 221A of the flanges 221 of the teeth 22 are pressed against the first reference plate 311.

[0124] As a result, the opposing surfaces 221A of the flanges 221 of the three teeth 22 are arranged side by side in the circumferential direction CD along the first reference plate 311. Specifically, the first teeth 22A, having a first dimension TA, are spaced a first distance RA (FIG. 6) from the first surface 21A. The second teeth 22B, having a second dimension TB, are spaced a second distance RB from the first surface 21A. The third teeth 22C, having a third dimension TC, are spaced a third distance RC (FIG. 6) from the first surface 21A. Note that the multiple boost members 322 may be fastened into the jig through holes 321C one by one, or multiple boost members 322 may be fastened into the jig through holes 321C simultaneously.

[0125] In the teeth supporter arrangement process (step S108) of FIG. 9, the opposing surfaces 221A of the flanges 221 of the three teeth 22 are arranged in a line in the circumferential direction CD along the first reference plate 311, and a first synthetic resin layer 30 is arranged between the flanges 221 of the three teeth 22 and the first surface 21A. Specifically, the first adhesive material is solidified by heating or the like to form the first synthetic resin layer 30 made of the solidified first adhesive material. At this time, the first synthetic resin layer 30 is interposed so as to surround the pin 50. In other words, because the first adhesive material is solidified, it prevents the pin 50 from moving in the axial direction AD.

[0126] 9, in the first jig removal process (step S109), upper portion 310 and lower portion 320 are removed to obtain split stator 230 in which teeth set 220 consisting of three teeth 22 is arranged on split yoke 210. Note that second end 52 of pin 50 protruding in the −Z direction from second surface 21B may be cut off.

[0127] As described above, in the first embodiment, by using first jig 300 having first reference plate 311, it is possible to arrange each of opposing surfaces 221A of flange portions 221 of multiple teeth 22 side by side in circumferential direction CD along first reference plate 311. As a result, it is possible to easily manufacture split stator 230 in which variation in the positions of opposing surfaces 221A of flange portions 221 of three teeth 22 relative to split yoke 210 in axial direction AD is reduced.

[0128] Furthermore, in the first embodiment, by pressing the three teeth 22 against the first reference plate 311, the opposing surfaces 221A of the flanges 221 of the three teeth 22 can be arranged side by side in the circumferential direction CD along the first reference plate 311. Furthermore, by solidifying the first adhesive material while the three teeth 22 are pressed against the first reference plate 311, the first synthetic resin layer 30 can be arranged. As a result, the first synthetic resin layer 30 having a thickness according to the dimensions of each of the three teeth 22 in the axial direction AD can be easily arranged.

[0129] Furthermore, in the first embodiment, the split stator 230 (stator) can be manufactured while supporting the teeth 22 in a predetermined position using six pins 50 moved toward the first reference plate 311, making it possible to manufacture a split stator 230 in which each of the opposing surfaces 221A of the flange portions 221 of the three teeth 22 is precisely positioned along the first reference plane AA.

[0130] Furthermore, in the first embodiment, the split stator 230 can be manufactured while preventing the main body 222 of the tooth 22 from rotating by using the pins 50 inserted into the two holes 223 formed in the main body 222 of the tooth 22, and therefore it is possible to manufacture a split stator 230 in which the opposing surfaces 221A of the flange portions 221 of the three teeth 22 are precisely aligned in the circumferential direction CD.

[0131] [Stator assembly process] Next, the assembly process of the stator 2 will be described in detail with reference to FIG. 14. FIG. 14 is a flowchart showing the assembly process of the stator 2 of the rotating electric machine 1 according to this embodiment. As shown in FIG. 14, the assembly process of the stator 2 includes a case portion preparation process (step S201), a contact body preparation process (step S202), a split yoke arrangement process (step S203), a second jig arrangement process (step S204), a teeth set arrangement process (step S205), a yoke support arrangement process (step S206), and a second jig removal process (step S207). The case portion preparation process and the contact body preparation process are collectively referred to as the preparation process. Similarly, the split yoke arrangement process, the second jig arrangement process, the teeth set arrangement process, and the yoke support arrangement process are collectively referred to as the arrangement process. Furthermore, the case portion preparation process and the contact body preparation process may be performed together as a single process.

[0132] 14, a case part preparing step (step S201) prepares a disk-shaped case part 60 having a support surface 61. Specifically, the case part 60 has 36 large holes 610 and 48 small holes 620 (see FIG. 7).

[0133] In the contact body preparation step (step S202) of FIG. 14, a plurality of contact bodies 70 are prepared, each having one end 71 located on one side of the axial direction AD and the other end 72 located on the other side of the axial direction AD (see FIG. 8). Each of the plurality of contact bodies 70 is made of an elastic material. Specifically, 36 contact bodies 70 are prepared for one stator 2. Each of the 36 contact bodies 70 is, for example, a spring washer or a wave washer. Each of the 36 contact bodies 70 acts along the axial direction AD. In the axial direction AD, the dimension of each of the 36 contact bodies 70 is greater than the depth of the large hole portion 610.

[0134] In the split yoke arrangement step (step S203) of FIG. 14, the 12 split stator pieces 230 are arranged at intervals in the circumferential direction CD on the support surface 61 of the case portion 60. FIG. 15 is a schematic cross-sectional view showing the 12 split stator pieces 230 and a portion of the case portion 60. The schematic cross-sectional view shows the curved shape in the circumferential direction CD expanded (developed). The circumferential direction CD is aligned with 24 of the 36 large holes 610 in the case portion 60 that are arranged on the outside in the radial direction RD. Note that FIG. 15 illustrates a first split stator piece 230A and a second split stator piece 230B.

[0135] As shown in FIG. 15 , first, the case 60 is positioned so that the support surface 61 faces the Z direction. Next, a second adhesive material is applied to the support surface 61. The second adhesive material may be, for example, an epoxy resin adhesive before solidification. Alternatively, the second adhesive material may be applied to the upper surface of the case 60 in a ring shape. Next, 36 contact bodies 70 are placed in the 36 large holes 610. The other end portions 72 of the 36 contact bodies 70 each abut against the support surface 61. Next, 12 split yokes 210 are placed so that one end portion 71 of each of the three contact bodies 70 abuts against the second surface 21B of one split yoke 210. As a result, the second adhesive material is filled between the 12 split yokes 210 and the support surface 61.

[0136] In the second jig placement step (step S204) of FIG. 14, a second jig 500 having a second reference plate 511 is prepared, and the second jig 500 is placed so that the second reference plate 511 and the opposing surfaces 221A of the flange portions 221 of the 36 teeth 22 face each other in the axial direction AD. Here, the second jig 500 used in the assembling step of the stator 2 will be described. FIG. 16 is a schematic cross-sectional view showing a portion of the second jig 500, a case portion 60, and a plurality of split stators 230. The schematic cross-sectional view shows the curved shape in the circumferential direction CD expanded (developed). The circumferential direction CD is aligned with 24 of the 36 large holes 610 in the case portion 60 that are located on the outside in the radial direction RD. Note that FIG. 16 also shows a first split stator 230A and a second split stator 230B.

[0137] As shown in FIG. 16 , the second jig 500 includes a disk-shaped second reference plate 511 and a plurality of spacers 520. The second reference plate 511 has an upper surface 511A disposed on the Z direction side and a lower surface 511B disposed on the −Z direction side. The lower surface 511B forms the “second reference plane BB” of the present invention. In other words, the second jig 500 is used to set the second reference plane BB. The upper surface 511A and the lower surface 511B are each perpendicular to the Z direction. In other words, the upper surface 511A and the lower surface 511B are disposed on opposite sides of each other in the thickness direction of the second reference plate 511.

[0138] Each of the spacers 520 is a rod-shaped body extending along the Z direction. In FIG. 16 , each of the spacers 520 is located behind a tooth 22 when viewed from the inside in the radial direction RD. Although the spacers 520 are divided in FIG. 16 , the spacers 520 may be connected to each other so as to be aligned in the circumferential direction CD near the outer periphery of the case portion 60. The dimension of the spacers 520 in the Z direction is a second interval. The second interval is set based on the distance between the opposing surface 221A of the flange portion 221 in each tooth group 220 of the stator 2 on the design drawing and the support surface 61. Each of the spacers 520 is disposed between the second reference plate 511 and the case portion 60. Specifically, the spacers 520 are disposed between the outer periphery of the second reference plate 511 and the outer periphery of the case portion 60. More specifically, the upper end of each of the plurality of spacers 520 abuts against the second reference plate 511, and the lower end of each of the plurality of spacers 520 abuts against the case portion 60.

[0139] In the teeth set arrangement process (step S205) of FIG. 14 , the opposing surfaces 221A of the flange portions 221 in each teeth set 220 are arranged side by side in the circumferential direction CD along the second reference plate 511. Specifically, the second reference plate 511 is brought close to the support surface 61, and the dimensions of the 36 contact bodies 70 are compressed against the elastic force of the 36 contact bodies 70, thereby arranging the opposing surfaces 221A of the flange portions 221 in each teeth set 220 side by side in the circumferential direction CD along the second reference plate 511. At this time, the dimension of the first contact body set 700A corresponding to the first split stator 230A having the first distance DA ( FIG. 8 ) is a first dimension RRA ( FIG. 8 ). Furthermore, the dimension of the second contact body set 700B corresponding to the second split stator 230B having the second distance DB ( FIG. 8 ) is a second dimension RRB ( FIG. 8 ).

[0140] In the yoke support arrangement process (step S206) of FIG. 14 , the opposing surfaces 221A of the flange portions 221 in each tooth set 220 are aligned in the circumferential direction CD along the second reference plate 511, and multiple second synthetic resin layers 40 are arranged between the support surface 61 and the second surfaces 21B of the twelve split yokes 210. Specifically, the second synthetic resin layer 40 is arranged by solidifying the second adhesive material that has already been applied by heating or the like. At this time, the second synthetic resin layer 40 is solidified so as to surround the contact body 70 between the case portion 60 and the split yoke 210. In other words, the solidified second adhesive material prevents the contact body 70 from elastically deforming along the axial direction AD.

[0141] In the second jig removal step (step S207) of FIG. 14, second jig 500 is removed, and stator 2 having 36 teeth 22 arranged on yoke 21 is obtained.

[0142] As described above, in the first embodiment, by using the second jig 500 having the second reference plate 511, it is possible to arrange the opposing surfaces 221A of the flange portions 221 of the 36 teeth 22 side by side in the circumferential direction CD along the second reference plate 511. As a result, it is possible to easily manufacture the stator 2 in which variation in the positions of the opposing surfaces 221A of the flange portions 221 of the 36 teeth 22 relative to the case portion 60 in the axial direction AD is reduced.

[0143] Furthermore, in the first embodiment, by bringing the second reference plate 511 close to the support surface 61 and compressing the 36 contact bodies 70 against their elastic force, the opposing surfaces 221A of the flange portions 221 in each tooth set 220 can be arranged side by side in the circumferential direction CD along the second reference plate 511. Furthermore, by solidifying the second adhesive material while the 36 contact bodies 70 are compressed, the multiple second synthetic resin layers 40 can be arranged. As a result, the multiple second synthetic resin layers 40 having thicknesses corresponding to the dimensions of each of the 12 divided stator parts 230 in the axial direction AD can be easily formed.

[0144] (Second embodiment) [Overall structure of stator] Next, a stator 602 according to the second embodiment will be described in detail with reference to Fig. 17. Fig. 17 is a schematic cross-sectional view showing a portion of a stator 602 of a rotary electric machine according to the second embodiment of the present invention. Note that the excitation coil 23 is omitted from Fig. 17. The stator 602 includes a disk-shaped yoke 621, a plurality of teeth 622 (tooth group) arranged in a circumferential direction CD of the yoke 621 (the direction of rotation of the rotor 3), a first synthetic resin layer 630, and a plurality of pins 650.

[0145] The yoke 621 functions as a support for the multiple teeth 622. Specifically, the yoke 621 has a first surface 621A disposed on one side in the axial direction AD and a second surface 621B disposed on the other side in the axial direction AD. The yoke 621 also has multiple yoke through holes 621C that are spaced apart in the circumferential direction CD and that penetrate along the axial direction AD.

[0146] The teeth 622 have a main body 822 that supports the excitation coil 23, and a flange 821 that is disposed on one side in the axial direction AD of the main body 822. In the second embodiment, the main body 822 and the flange 821 are independent of each other in each of the multiple teeth 622.

[0147] The yoke 621 and the main body 822 are an integral member. The teeth 622 are arranged on the first surface 621A at intervals in the circumferential direction CD. The main body 822 further has a plurality of teeth through-holes 822C that penetrate along the axial direction AD.

[0148] The flange portion 821 includes an opposing surface 821A. The opposing surface 821A is a surface (flat surface) on one side in the axial direction AD of the flange portion 821. Each of the plurality of flange portions 821 is formed with two holes 821C extending from the first surface 621A side along the axial direction AD.

[0149] An end face on the other side in the axial direction AD of the flange portion 821 is a joint face with a face on one side in the axial direction AD of the main body portion 822. Specifically, the end face on the other side in the axial direction AD of the flange portion 821 is fixed to the face on one side in the axial direction AD of the main body portion 822 by the first synthetic resin layer 630.

[0150] The first synthetic resin layer 630 is disposed between the flange portion 821 and one surface of the main body portion 822 in the axial direction AD. The first synthetic resin layer 630 is, for example, an epoxy resin adhesive. This fixes the multiple flange portions 821 to the one surface of the main body portion 822 in the axial direction AD.

[0151] The first synthetic resin layer 630 has a thickness corresponding to the dimension in the axial direction AD of each of the plurality of teeth 622 so that the opposing surfaces 821A of the flange portions 821 of the plurality of teeth 622 are aligned in the circumferential direction CD along the first reference plane AA. The thickness in the axial direction AD of the first synthetic resin layer 630 corresponding to each of the plurality of teeth 622 is set so that the distances between the first surfaces 621A and the opposing surfaces 821A of the flange portions 821 of the plurality of teeth 622 are the same.

[0152] The pins 650 have a first end 651 disposed on one side in the axial direction AD and a second end 652 disposed on the other side in the axial direction AD. Each of the pins 650 is, for example, a cylindrical rod-shaped body. The first end 651 of the pins 650 inserted into the yoke through holes 621C and the tooth through holes 822C of the main body 822 abuts against the flange portions 821 of the teeth 622. Specifically, the first end 651 of the pins 650 inserted into the yoke through holes 621C and the tooth through holes 822C of the main body 822 are inserted into the holes 821C of the flange portions 821 of the teeth 622.

[0153] As described above, in the second embodiment, even if the dimensions of each of the plurality of teeth 622 in the axial direction AD are different from one another, the first synthetic resin layer 630 is arranged with a thickness corresponding to the dimension of each of the plurality of teeth 622 in the axial direction AD. As a result, it is possible to suppress variation in the position of the opposing surfaces 821A of the flange portions 821 of the plurality of teeth 622 relative to the yoke 621 in the axial direction AD. Therefore, with this configuration, since variation in the position of the opposing surfaces 821A of the flange portions 821 of the plurality of teeth 622 relative to the yoke 621 in the axial direction AD is suppressed, it is not necessary to set a large median value for the gap (thickness, which is the length in the axial direction AD) between the rotor 3 and the opposing surfaces 821A of the flange portions 821 in consideration of, for example, an assembly error of the stator 602, and thus it is possible to increase the output torque by reducing the gap G.

[0154] Furthermore, in the second embodiment, the two pins 650 serve as the core of the first synthetic resin layer 630, and the first synthetic resin layer 630 surrounds and is entangled with the two pins 650, so that even if vibrations are received when the motor is driven, the first synthetic resin layer 630 can be prevented from coming off between the flange portion 821 and the main body portion 222. As a result, it is possible to further prevent the position of the teeth 622 from shifting relative to the yoke 621.

[0155] [Stator manufacturing method] 17 and 18, a method for manufacturing the stator 602 will be described in detail. Fig. 18 is a flowchart showing a method for manufacturing the stator 602. As shown in Fig. 18, the method for manufacturing the stator 602 includes a yoke and teeth preparation step (step S301), a pin preparation step (step S302), a first jig preparation step (step S303), a teeth arrangement step (step S304), a first jig arrangement step (step S305), a flange arrangement step (step S306), a teeth supporter arrangement step (step S307), and a first jig removal step (step S308).

[0156] In the yoke and teeth preparing step (step S301), a yoke 621 is prepared, which has a first surface 621A disposed on one side in the axial direction AD and a second surface 621B disposed on the other side in the axial direction AD. Also, a plurality of teeth 622 are prepared, each having a main body portion 822 and a flange portion 821 disposed on one side of the main body portion 822 in the axial direction AD. The flange portion 821 includes an opposing surface 821A. The yoke 621 and the main body portion 822 are an integral member. Furthermore, in each of the plurality of teeth 622, the main body portion 822 and the flange portion 821 are independent. Furthermore, an excitation coil (not shown) is disposed for each of the main body portions 822 of the plurality of teeth 622. The yoke 621 further has a plurality of yoke through holes 621C. The main body portion 822 further has a plurality of tooth through holes 822C penetrating along the axial direction AD. Each of the plurality of flange portions 821 is formed with two holes 821C extending from the first surface 621A side along the axial direction AD.

[0157] In the pin preparation step (step S302), a plurality of pins 650 are prepared, each having a first end 651 disposed on one side in the axial direction AD and a second end 652 disposed on the other side in the axial direction AD. Each of the plurality of pins 650 is, for example, a cylindrical rod-shaped body.

[0158] In the first jig preparation step (step S303), a first jig (see 300 in FIG. 10) having the same configuration as that used in the first embodiment is prepared.

[0159] In the teeth arrangement process (step S304), the teeth 622 are arranged at intervals in the circumferential direction CD on the first surface 621A of the yoke 6210. Specifically, first, a mounting plate with six boost members (see 322 in FIG. 10) inserted into the lower portions of six jig through holes (see 321C in FIG. 10) is arranged. Next, second ends 652 of the pins 650 are inserted into the jig through holes. As a result, the second ends 652 of the pins 650 abut against the boost members. Meanwhile, first ends 651 of the pins 650 protrude in the Z direction from the mounting plate (see 321A in FIG. 10). Next, the first ends 651 of the pins 650 are inserted into the yoke through holes 621C and the teeth through holes 822C, respectively, to mount the yoke 621 and the main body 822 on the mounting plate. At this time, the first end 651 of the pin 650 protrudes from the main body 822 in the Z direction.

[0160] Next, a first adhesive material is applied to the other surface of the flange portions 821 of the multiple teeth 622 in the axial direction AD. The first adhesive material is, for example, an epoxy resin adhesive before hardening. Next, the first ends 51 of the two pins 650 aligned along the radial direction RD are inserted into the two holes 821C of the flange portions 821, respectively, to place the flange portions 821 on the main body portion 822.

[0161] In the first jig placement step (step S305), the first jig is placed so that a first reference plate (see 311 in FIG. 10) and opposing surfaces 821A of flange portions 821 of the plurality of teeth 622 face each other in the axial direction AD. Specifically, the first reference plate is placed at a first distance from the mounting plate.

[0162] In the flange portion arrangement process (step S306), opposing surfaces 821A of flange portions 821 of multiple teeth 622 are arranged side by side in the circumferential direction CD along a first reference plate of a first jig. Specifically, by tightening a push-up member into a jig through-hole toward the first reference plate, pin 650 is moved within the jig through-hole toward the first reference plate, and opposing surfaces 821A of flange portions 821 of teeth 622 are pressed against the first reference plate.

[0163] In the teeth supporter arrangement process (step S307), the opposing surfaces 821A of the flange portions 821 of the multiple teeth 622 are arranged in a line in the circumferential direction CD along the first reference plate, and a first synthetic resin layer 630 is arranged between the flange portions 821 of the multiple teeth 622 and the first surfaces 621A. Specifically, the first adhesive material is solidified by heating or the like to arrange the first synthetic resin layer 630 made of the solidified first adhesive material. At this time, the first synthetic resin layer 630 is interposed so as to surround the pin 650. In other words, because the first adhesive material is solidified, it prevents the pin 650 from moving in the axial direction AD.

[0164] In the first jig removing step (step S308), the first jig is removed, and the stator 602 is obtained.

[0165] As described above, in the second embodiment, by using the first jig having the first reference plate, it is possible to arrange each of the opposing surfaces 821A of the flange portions 821 of the plurality of teeth 622 side by side in the circumferential direction CD along the first reference plate. As a result, it is possible to easily manufacture the stator 602 in which variation in the position of the opposing surfaces 821A of the flange portions 821 of the plurality of teeth 622 relative to the yoke 621 in the axial direction AD is reduced.

[0166] In the second embodiment, by pressing the plurality of teeth 622 against the first reference plate, the opposing surfaces 821A of the flange portions 821 of the plurality of teeth 622 can be aligned in the circumferential direction CD along the first reference plate. Furthermore, by solidifying the first adhesive material while the plurality of teeth 622 are pressed against the first reference plate, the first synthetic resin layer 630 can be positioned. As a result, the first synthetic resin layer 630 having a thickness according to the dimensions of each of the plurality of teeth 622 in the axial direction AD can be easily positioned.

[0167] Furthermore, in the second embodiment, the stator 602 can be manufactured while supporting the flange portion 821 in a predetermined position by a plurality of pins 650 moved toward the first reference plate, making it possible to manufacture a stator 602 in which each of the opposing surfaces 821A of the flange portion 821 is precisely positioned along the first reference plane AA.

[0168] Furthermore, in the second embodiment, the stator 602 can be manufactured while preventing the main body 822 of the tooth 622 from rotating by using the pins 650 inserted into the two holes 823 formed in the main body 822 of the tooth 622, so that it is possible to manufacture a stator 602 in which the opposing surfaces 821A of the flange portions 821 of the multiple teeth 622 are precisely aligned in the circumferential direction CD.

[0169] In the above embodiments, the yoke 21 and the teeth 22 are described as being made of dust cores, but the present invention is not limited to this, and these components may be manufactured by other manufacturing methods. At least one of the yoke 21 and the teeth 22 may also be made of dust cores. According to the present invention, the variation in component dimensions that tends to occur when these components are made of dust cores can be eliminated by the structure and manufacturing method of the stator 2. For example, it is possible to provide a rotating electric machine 1 that can achieve high output torque by shortening the thickness, which is the axial length AD of the gap G. [Explanation of symbols]

[0170] 1 Rotating electric machine 11 Rotation axis 2 stator 21 York 21A 1st page 22 Teeth 221 Tsuba 221A Opposite side 23 Excitation coil 3 rotors 30 First synthetic resin layer (teeth support) 31 Base material 32 Permanent magnets 40 Second synthetic resin layer (yoke support) 50 pin AA 1st reference plane AD Axial direction AX Rotational axis CD circumferential direction G spacing (axial gap)

Claims

1. A stator of an axial gap type rotating electric machine that forms a magnetic field for rotating a rotor around a rotation center axis, a yoke having a first surface disposed on one side of the rotation center shaft in the axial direction and a second surface disposed on the other side of the rotation center shaft in the axial direction; a plurality of teeth arranged at intervals in a circumferential direction on the first surface of the yoke, each tooth having a main body portion supporting an excitation coil and a flange portion arranged on the one side in the axial direction with respect to the main body portion, the flange portion including an opposing surface facing the rotor; a teeth supporter that supports at least the flange portions of the plurality of teeth from the yoke side, the teeth supporter being interposed between the flange portions of the plurality of teeth and the first surface with a thickness corresponding to the dimension of each of the plurality of teeth in the axial direction so that each of the opposing surfaces of the flange portions of the plurality of teeth are arranged side by side in the circumferential direction along a first reference plane that is set at a first interval on one side of the first surface in the axial direction; A stator of an axial gap type rotating electric machine comprising:

2. a thickness in the axial direction of the teeth support body of a portion corresponding to each of the plurality of teeth is set to be different according to a difference in the dimension of each of the plurality of teeth in the axial direction, so that each of the opposing surfaces of the flange portions of the plurality of teeth is arranged side by side in the circumferential direction along the first reference plane, 2. A stator for an axial gap type rotating electric machine as described in claim 1, wherein the thickness of the portion of the tooth support body corresponding to the tooth having a first dimension in the axial direction is set to be larger than the thickness of the portion of the tooth support body corresponding to the tooth having a second dimension in the axial direction that is larger than the first dimension.

3. a plurality of pins each having a first end disposed on the one side in the axial direction and a second end disposed on the other side in the axial direction; In each of the plurality of teeth, the main body portion and the flange portion are an integral member, a plurality of yoke through holes are formed in the yoke, the yoke being spaced apart in the circumferential direction in correspondence with the plurality of teeth and penetrating the yoke along the axial direction; 2. A stator for an axial gap type rotating electric machine as described in claim 1, wherein the first ends of the plurality of pins inserted into the plurality of yoke through holes are in contact with the main body portions of the plurality of teeth, and the tooth support body is interposed between the other axial side surface of the main body portion and the first surface so as to surround the pins.

4. At least two holes extending from the first surface side along the axial direction are formed in each of the main body portions of the plurality of teeth, 4. The stator of claim 3, wherein the first end of the pin passing through the yoke through-hole is disposed in each of the at least two holes.

5. 5. The stator of claim 4, wherein the position of the first end of the pin corresponding to the tooth having a first dimension in the axial direction is positioned on one side in the axial direction of the position of the first end of the pin corresponding to the tooth having a second dimension in the axial direction that is larger than the first dimension.

6. a plurality of pins each having a first end disposed on the one side in the axial direction and a second end disposed on the other side in the axial direction; In each of the plurality of teeth, the main body portion and the flange portion are independent of each other, a plurality of yoke through holes are formed in the yoke, the yoke being spaced apart in the circumferential direction in correspondence with the plurality of teeth and penetrating the yoke along the axial direction; a tooth through-hole is formed in each of the body portions of the plurality of teeth, the tooth through-hole penetrating the body portion along the axial direction; 2. The stator of claim 1, wherein the first ends of the pins inserted into the yoke through holes of the yoke and the tooth through holes of the main body portions are in contact with the flange portions of the teeth, respectively, and the tooth support body is interposed between the other axial surface of the flange portion and the one axial surface of the main body portion so as to surround the pins.

7. At least two holes extending from the first surface side along the axial direction are formed in each of the flange portions of the plurality of teeth, 7. The stator of claim 6, wherein the first end of the pin passing through the tooth through-hole of the main body is disposed in each of the at least two holes.

8. 8. The stator of claim 7, wherein the position of the first end of the pin corresponding to the flange portion having a first dimension in the axial direction is positioned on one side in the axial direction of the position of the first end of the pin corresponding to the flange portion having a second dimension in the axial direction that is larger than the first dimension.

9. 7. The stator of claim 3, wherein the teeth support body is made of a solidified adhesive material.

10. 2. The stator of claim 1, wherein the first interval is a dimension of a tooth having a largest dimension in the axial direction among the plurality of teeth arranged on the first surface.

11. a case portion having a support surface that faces the second surface in the axial direction and supports the yoke; a plurality of yoke supports for supporting the yoke; Further provided with the yoke has a plurality of split yokes split along the circumferential direction, the plurality of teeth are a plurality of teeth sets each consisting of at least two teeth arranged on each of the plurality of divided yokes, and each of the opposing surfaces of the flange portion in each teeth set is arranged at the first distance from the first surface, 2. The stator of claim 1, wherein the plurality of yoke supports are respectively interposed between the support surface and the second surfaces of the plurality of split yokes with a thickness corresponding to the axial distance between the opposing surfaces of the flange portions of each tooth group and the second surfaces of the split yokes, so that the opposing surfaces of the flange portions of each tooth group are arranged in a line in the circumferential direction along a second reference plane set on one side of the axial direction with a second interval larger than the first interval.

12. a first split stator having one teeth set of the plurality of teeth sets and one split yoke of the plurality of split yokes; a second split stator having another teeth set of the plurality of teeth sets and another split yoke of the plurality of split yokes; Including, In the first split stator, a distance between the opposing surface of the teeth set and the second surface of the split yoke is a first distance, In the second split stator, a distance between the opposing surface of the teeth set and the second surface of the split yoke is a second distance that is greater than the first distance, 12. The stator of claim 11, wherein a thickness of the yoke support member corresponding to the first stator segment is set to be larger than a thickness of the yoke support member corresponding to the second stator segment.

13. a plurality of contact bodies each having one end portion disposed on the one side in the axial direction and another end portion disposed on the other side in the axial direction, the contact bodies being made of an elastic material; the yoke support is made of a solidified adhesive material; the one ends of the plurality of contact bodies each come into contact with the second surfaces of different split yokes among the plurality of split yokes, each of the other ends of the plurality of contact bodies abuts against the support surface; 12. The stator of claim 11, wherein the yoke support is solidified between the case portion and the split yoke so as to surround the contact body, with the contact body abutting against the case portion and the split yoke, with a length corresponding to the axial distance between the opposing surfaces of the flange portions of the plurality of teeth in each tooth group and the second surface of the split yoke.

14. the plurality of contact bodies include a plurality of contact body sets each including three contact bodies arranged corresponding to one of the divided yokes, 14. The stator of claim 13, wherein the one ends of the three contact bodies of each contact body set abut against the second surfaces of the plurality of divided yokes.

15. The stator according to claim 1 ; the rotor facing the stator in the axial direction with a gap therebetween; Equipped with The rotor is an axial gap type rotating electric motor, in which the rotor rotates relative to the stator around a central axis of rotation along the axial direction due to a magnetic field generated by the stator.

16. A method for manufacturing a stator of an axial gap type rotating electric machine that forms a magnetic field for rotating a rotor around a rotation center axis, comprising: The preparation process and A placement process; Equipped with The preparation step includes: a yoke preparation step of preparing a yoke having a first surface disposed on one side in an axial direction and a second surface disposed on the other side in the axial direction; a teeth preparation step of preparing a plurality of teeth, each of which has a main body portion supporting an excitation coil and a flange portion including an opposing surface and disposed on the one side of the main body portion in the axial direction; a first jig preparation step of preparing a first jig having a first reference plate; and The placing step includes: a teeth arranging step of arranging the plurality of teeth on the first surface of the yoke at intervals in a circumferential direction; a first jig arrangement step of arranging the first jig so that the first reference plate and the opposing surfaces of the flange portions of the plurality of teeth face each other in the axial direction; a flange portion arranging step of arranging the opposing surfaces of the flange portions of the plurality of teeth in the circumferential direction along the first reference plate; a teeth supporter arranging step of arranging a teeth supporter between the flange portions of the plurality of teeth and the first surface so that the opposing surfaces of the flange portions of the plurality of teeth are maintained in a state of being aligned in the circumferential direction along the first reference plate; A method for manufacturing a stator for an axial gap type rotating electric machine, comprising:

17. In the teeth arranging step, a first adhesive material is filled between the first surface and the other surface of the main body portion of the plurality of teeth in the axial direction; In the flange portion arrangement step, the teeth are pressed against the first reference plate, so that the opposing surfaces of the flange portions of the teeth are arranged side by side in the circumferential direction along the first reference plate; 17. A method for manufacturing a stator for an axial gap type rotating electric machine as described in claim 16, wherein in the tooth support member placement process, the first adhesive material is solidified, thereby placing the tooth support member formed of the solidified first adhesive material between the other axial side surface of the main body portion of the plurality of teeth and the first surface.

18. a pin preparing step of preparing a plurality of pins, each of the pins having a first end portion disposed on the one side in the axial direction and a second end portion disposed on the other side in the axial direction; In the yoke preparation step, the yoke is prepared, in which a plurality of yoke through holes are formed, the yoke through holes being spaced apart in the circumferential direction in correspondence with the plurality of teeth and penetrating the yoke along the axial direction; In the tooth preparation step, the plurality of teeth are prepared, each of which has the main body portion and the flange portion as an integral member; In the first jig preparation step, the first jig is prepared, further including a mounting plate having a plurality of jig through holes that are arranged at intervals in the circumferential direction corresponding to the plurality of teeth and that penetrate along the axial direction; In the teeth arrangement step, the pins are inserted into the jig through holes and the yoke through holes, respectively, and the yoke having the teeth arranged on the first surface is placed on the mounting plate; In the first jig placement step, the first reference plate is placed at a first interval from the mounting plate so as to sandwich the plurality of teeth and the yoke therebetween; 17. The method for manufacturing a stator for an axial gap type rotating electric machine according to claim 16, wherein in the flange portion arrangement process, the pins are moved in the axial direction toward the first reference plate to press the teeth toward the first reference plate, thereby arranging each of the opposing surfaces of the flange portions of the teeth in a line in the circumferential direction along the first reference plate.

19. In the tooth preparing step, the plurality of teeth are prepared, each of whose main body portions has at least two holes formed therein, the holes extending from the first surface side along the axial direction; 19. The method for manufacturing a stator for an axial gap type rotating electric machine according to claim 18, wherein in the teeth arrangement process, the first end of the pin passing through the yoke through hole is arranged in each of the at least two hole portions.

20. a pin preparing step of preparing a plurality of pins each having a first end portion disposed on the one side in the axial direction and a second end portion disposed on the other side in the axial direction, In the yoke preparation step, the yoke is prepared, in which a plurality of yoke through holes are formed, the yoke through holes being spaced apart in the circumferential direction in correspondence with the plurality of teeth and penetrating the yoke along the axial direction; In the tooth preparing step, the plurality of teeth are prepared, the main body portion and the flange portion being independent of each other, and each of the plurality of teeth has a tooth through hole formed in the main body portion that penetrates along the axial direction; In the first jig preparation step, the first jig is prepared, further including a mounting plate having a plurality of jig through holes that are arranged at intervals in the circumferential direction corresponding to the plurality of teeth and that penetrate along the axial direction; In the teeth arrangement step, the pins are inserted into the jig through holes, the yoke through holes, and the teeth through holes, respectively, and the yoke with the teeth arranged on the first surface is placed on the mounting plate; In the first jig placement step, the first reference plate is placed at a first interval from the mounting plate so as to sandwich the plurality of teeth and the yoke therebetween; 17. The method for manufacturing a stator for an axial gap type rotating electric machine according to claim 16, wherein in the flange portion arrangement process, the pins are moved in the axial direction toward the first reference plate to press the flange portions of the plurality of teeth toward the first reference plate, thereby arranging each of the opposing surfaces of the flange portions of the plurality of teeth in a line in the circumferential direction along the first reference plate.

21. In the teeth preparing step, the plurality of teeth are prepared, each of the flange portions of which has at least two holes extending from the first surface side along the axial direction; 21. The method for manufacturing a stator for an axial gap type rotating electric machine according to claim 20, wherein in the tooth arrangement process, the first end of the pin that passes through the tooth through hole of the main body portion is arranged in each of the at least two hole portions.

22. In the preparation step and the arrangement step, the yoke is divided in a circumferential direction into a plurality of divided yokes, and a plurality of divided stators are fabricated, each of which has a plurality of tooth sets, each of which includes at least two teeth, arranged on the first surface of each divided yoke. a case portion preparation step of preparing a case portion having a support surface that supports the plurality of split yokes; a split yoke arrangement step of arranging a plurality of split stators at intervals in a circumferential direction on the support surface of the case portion; a second jig arrangement step of preparing a second jig having a second reference plate, and arranging the second jig so that the second reference plate and the opposing surfaces of the flange portions of the plurality of teeth face each other in the axial direction; a teeth set arranging step of arranging the opposing surfaces of the flange portions of each teeth set in line in the circumferential direction along the second reference plate; a yoke support arrangement step of arranging a plurality of yoke supports between the support surface and the second surfaces of the plurality of divided yokes so that the opposing surfaces of the flange portions in each tooth set are maintained in a state of being aligned in the circumferential direction along the second reference plate; The method for manufacturing a stator for an axial gap type rotating electric machine according to claim 16, further comprising:

23. a contact body preparing step of preparing a plurality of contact bodies made of an elastic material, each contact body having one end portion disposed on the one side in the axial direction and another end portion disposed on the other side in the axial direction; In the split yoke arrangement step, a second adhesive material is filled between the second surfaces of the split yokes and the support surface, and the contact bodies are arranged such that each of the one ends of the contact bodies abuts against the second surfaces of different split yokes among the split yokes and each of the other ends of the contact bodies abuts against the support surface, thereby arranging the split yokes at intervals in the circumferential direction relative to the support surface; In the teeth set arrangement step, the second reference plate is brought close to the support surface, and the plurality of contact bodies are compressed against the elastic force of the plurality of contact bodies, thereby arranging the opposing surfaces of the flange portions of each teeth set side by side in the circumferential direction along the second reference plate, 23. The method for manufacturing a stator for an axial gap type rotating electric machine according to claim 22, wherein in the yoke support arrangement step, the second adhesive material is solidified, and the yoke support is arranged between the case portion and the split yoke so that the yoke support, formed of the solidified second adhesive material, surrounds the contact body with the contact body abutting against the case portion and the split yoke.

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