Manufacturing method of the stator

Abstract

To suppress lengthening of a connection portion.SOLUTION: A stator 14 includes a plurality of coils 16 of two or more different sizes including a pair of facing portions 36, a pair of coil end portions 38 that connect the pair of facing portions 36 in the circumferential direction on one axial side and the other axial side, respectively, and a pair of terminal portions 40 pulled out to one side in the axial direction from the pair of facing portions 36. The pair of end portions 40 of each of the coils 16 is arranged at the same position in the radial direction. The stator 14 also includes a bus bar 96 arranged on one side in the axial direction with respect to the plurality of coils 16 and connecting a pair of terminal portions 40 of the plurality of coils 16 in a specific connection pattern.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to Manufacturing method of the stator Regarding. [Background technology]

[0002] The following Patent Document 1 discloses a motor equipped with a stator configured with multiple coils arranged along a coil back yoke. In the stator described in this document, the coil end portion of one coil is bent in the radial direction relative to the coil end portion of the other coil. As a result, the coil end portion of one coil is arranged offset in the radial direction relative to the coil end portion of the other coil. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2013-017341 A Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, the terminals of the multiple coils that constitute a part of the stator need to be connected to each other in a predetermined manner using a connection part such as a lead wire, etc. As the length of this connection part increases, the electrical resistance increases, but the configuration described in the above Patent Document 1 does not take this into consideration.

[0005] In consideration of the above, an object of the present disclosure is to provide a stator, a motor, and a method for manufacturing a stator that can prevent the length of a connection portion from increasing. [Means for solving the problem]

[0006] The stator (14) that solves the above-mentioned problems is formed by winding a conductive winding (30) in an annular shape, and includes a pair of opposing portions (36) that form an axial central portion and are arranged at a distance in the circumferential direction, a pair of coil end portions (38) that circumferentially connect the pair of opposing portions on one axial side and the other axial side, respectively, and a pair of terminal portions (40) drawn out from the pair of opposing portions to one axial side, the plurality of coils having the pair of terminal portions arranged at the same radial position, and a connecting portion (96) that is arranged on one axial side of the plurality of coils and connects the pair of terminal portions of the plurality of coils in a specific connecting pattern.

[0007] With this configuration, the length of the connection portion can be prevented from increasing. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a partially cutaway perspective view showing a rotor and a stator of the motor according to the first embodiment. [Diagram 2] 2 is a side cross-sectional view showing a cross section of the motor taken along the axial direction. FIG. [Diagram 3] FIG. 2 is a plan view showing a stator and a rotor. [Figure 4] FIG. 2 is a cross-sectional view showing a stator and a rotor. [Diagram 5] FIG. [Figure 6] FIG. [Figure 7] FIG. [Figure 8A] FIG. 4 is a perspective view showing a winding step for forming a coil. [Figure 8B] 11 is a perspective view showing a process of bending a coil end portion. FIG. [Figure 8C] FIG. 11 is a perspective view showing a terminal portion moving step. [Figure 9A] FIG. 2 is a perspective view showing a first winding frame and a second winding frame. [Figure 9B]11 is a perspective view showing a frame engaging step of engaging the second winding frame with the first winding frame. FIG. [Figure 9C] FIG. 4 is a perspective view showing a winding step for forming a coil. [Figure 9D] 11 is a perspective view showing a winding frame separating step of separating the second winding frame from the first winding frame. FIG. [Figure 10] 4 is an enlarged cross-sectional side view showing a boundary between an opposing portion and a coil end portion. FIG. [Figure 11] FIG. 2 is a schematic diagram for explaining connections of a U phase, a V phase, and a W phase. [Figure 12] FIG. 2 is a schematic diagram for explaining connections and arrangements of U-phase, V-phase, and W-phase. [Figure 13] 4 is a side cross-sectional view showing a cross section of a part of the stator taken along the axial direction. FIG. [Figure 14] 2 is a perspective view showing an insulator and a coil supported by a stator core via the insulator; FIG. [Figure 15] 2 is a perspective view showing an insulator and a U-phase coil, a V-phase coil, and a W-phase coil supported by a stator core via the insulator. FIG. [Figure 16] FIG. 4 is an enlarged perspective view showing a state in which short coils are arranged along a stator core. [Figure 17] FIG. 2 is an enlarged perspective view showing a state in which short coils and long coils are arranged along a stator core. [Figure 18A] 10 is a side view showing a schematic diagram of a process of arranging the long coil along the stator core, in which the long coil is arranged on one axial side of the short coil. FIG. [Figure 18B] 11 is a side view showing a schematic diagram of a process of arranging the long coil along the stator core, and showing a process of tilting the long coil with respect to the axial direction. FIG. [Figure 18C] 11 is a perspective view showing a process of arranging the long coil along the stator core, in which an end portion of the short coil is inserted between a pair of opposing portions of the long coil. FIG. [Figure 18D]10 is a side view showing a schematic diagram of a process of arranging the long coil along the stator core, illustrating a process of overlapping the coil end portion of the long coil with the coil end portion of the short coil. FIG. [Figure 18E] 11 is a side view showing a schematic diagram of a process of arranging the long coil along the stator core, and showing a process of pressing an opposing portion of the long coil toward the stator core. FIG. [Figure 19A] FIG. 4 is a perspective view showing a winding step for forming a coil. [Figure 19B] 11 is a perspective view showing a process of bending a coil end portion. FIG. [Figure 19C] 11 is a perspective view showing a process of arranging the long coil along the stator core, in which an end portion of the short coil is inserted between a pair of opposing portions of the long coil. FIG. [Figure 19D] 11 is a side view showing a schematic diagram of a process of arranging the long coil along the stator core, in which the opposing portion of the long coil is pressed toward the stator core and the terminal portion of the long coil is moved. FIG. [Figure 20A] 11 is a side view showing a process of pressing the opposing portion of the long coil toward the stator core while moving the terminal portion of the long coil, and a process of engaging the terminal portion of the long coil with an engaging portion of the insulator. FIG. [Figure 20B] 4 is a plan view showing a terminal portion of a long coil and a locking portion of an insulator as viewed from one axial side. FIG. [Figure 21A] 11 is a side view showing a process of pressing the opposing portion of the long coil toward the stator core and moving the terminal portion of the long coil, and a process of locking the terminal portion of the long coil with the locking portion of the locking member. FIG. [Figure 21B] 4 is a plan view showing a terminal portion of a long coil and a locking portion of a locking member as viewed from one axial side. FIG. [Figure 22]This is a side view that typically shows the process of pressing the opposing portions of the long coil toward the stator core and moving the terminal portions of the long coil and short coil, and the process of engaging the terminal portions of the long coil and short coil with the engaging portions of the engaging member, and shows an enlarged view of the terminal portions of the long coil and short coil with the coating stripped off. [Figure 23] FIG. 2 is an enlarged perspective view showing long coils and short coils connected by a plurality of bus bars. [Figure 24A] FIG. 2 is an enlarged plan view showing a schematic view of bus bars and the like. [Figure 24B] 24B is an enlarged plan view showing a schematic diagram of a bus bar and the like having a different form from that shown in FIG. 24A. [Figure 25A] 13 is a side view showing a schematic diagram of a process of arranging coils along a stator core in a motor according to a second embodiment, illustrating a process of passing an end portion of one coil between a pair of opposing portions of another coil. FIG. [Figure 25B] 25B is a side view corresponding to FIG. 25A, showing the state upon completion of the step shown in FIG. 25A. [Figure 26A] 13A to 13C are side views each showing a schematic process of arranging coils along a stator core in a motor according to a third embodiment, illustrating a process of passing an end portion of one coil between a pair of opposing portions of another coil. [Figure 26B] 26B is a side view corresponding to FIG. 26A, showing the state upon completion of the step shown in FIG. 26A. [Figure 27] FIG. 13 is a schematic diagram for explaining connections of a U-phase, a V-phase, and a W-phase of a motor according to a fourth embodiment. [Figure 28] 13 is a schematic diagram for explaining connections and arrangements of U-phase, V-phase, and W-phase of a motor according to a fourth embodiment. FIG. [Figure 29] FIG. 13 is a schematic diagram for explaining connections of a U-phase, a V-phase, and a W-phase of a motor according to a fifth embodiment. [Diagram 30] FIG. 13 is a schematic diagram for explaining connections and arrangements of U-phase, V-phase, and W-phase of a motor according to a fifth embodiment. [Diagram 31] FIG. 13 is a schematic diagram showing a rotor and a stator of a motor according to a sixth embodiment. [Diagram 32] FIG. 13 is a schematic diagram showing a rotor and a stator of a motor according to a seventh embodiment. [Diagram 33] 11A to 11C are side cross-sectional views for explaining variations in bending of the coil end portion. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] (First embodiment) A motor 10 according to a first embodiment of the present disclosure will be described with reference to Figures 1 to 15. Note that the direction of arrow Z, the direction of arrow R, and the direction of arrow C, appropriately shown in the figures, respectively indicate one side in the rotational axial direction, the outer side in the rotational radial direction, and one side in the rotational circumferential direction of a rotor 12, which will be described later. In the following, when simply indicating an axial direction, a radial direction, or a circumferential direction, this refers to the rotational axial direction, the rotational radial direction, and the rotational circumferential direction of the rotor 12, unless otherwise specified.

[0010] 1 to 3, motor 10 of this embodiment is an inner rotor type brushless motor in which rotor 12 as a rotating body is disposed radially inside stator 14. Note that the drawings shown in Figs. 1 to 5 are drawings of motor 10 etc. shown as an example, and there are some parts in which the number of coils 16 and the number of magnets 18 do not match those described below.

[0011] The rotor 12 includes a rotating shaft 22 rotatably supported via a pair of bearings 20, a rotor core 24 formed in a bolt-type cylindrical shape and fixed to the rotating shaft 22, and a plurality of magnets 18 fixed to the radially outer surface of the rotor core 24.

[0012] The rotor core 24 includes a first cylindrical portion 24A to which the rotating shaft 22 is fixed by press-fitting or the like, a second cylindrical portion 24B disposed radially outside the first cylindrical portion 24A and formed cylindrically, and a disk-shaped connecting plate portion 24C that radially connects one axial end of the first cylindrical portion 24A to one axial end of the second cylindrical portion 24B. The outer peripheral surface, which is the radially outer surface of the second cylindrical portion 24B, is formed into a cylindrical surface along the circumferential direction. A magnet 18, which will be described later, is fixed to the outer peripheral surface of the second cylindrical portion 24B.

[0013] The magnets 18 are formed using a magnetic compound having an intrinsic coercivity Hc of 400 kA / m or more and a residual magnetic flux density Br of 1.0 T or more. 11 TiN, Nd2Fe 14 B, SmFe 17 The rotor core 24 is formed of a magnetic compound such as N3, FeNi, etc. A plurality of magnets 18 are fixed to the outer peripheral surface of the second cylindrical portion 24B of the rotor core 24. The magnets 18 whose radially outer surfaces are N poles and the magnets 18 whose radially outer surfaces are S poles are arranged alternately in the circumferential direction. The number of magnets 18 may be appropriately set in consideration of the output required for the motor 10, etc.

[0014] 5, the stator 14 includes a stator core 26 as a core formed in an annular shape, an insulator 28 attached to the stator core 26 by adhesion, fitting, or the like, and a plurality of coils 16 attached to the stator core 26 via the insulators 28. The stator 14 of this embodiment has a teethless structure in which no part of the stator core 26 is disposed inside the coils 16.

[0015] 1 and 5, the stator core 26 is formed in an annular shape using a magnetic material such as steel. A cross section of the stator core 26 cut in the axial and radial directions has a rectangular cross section with the axial direction as the longitudinal direction. The radial thickness of the stator core 26 is set to be larger than the radial dimension of a coil end portion 38 of the coil 16, which will be described later. The stator core 26 is disposed coaxially with the rotor 12, and the axial center position of the stator core 26 and the axial center position of the multiple magnets 18 fixed to the rotor core 24 coincide in the axial direction.

[0016] The insulator 28 is made of a highly insulating material such as a resin material. The insulator 28 covers the radially inner surface and both axial end surfaces of the stator core 26 when the insulator 28 is attached to the stator core 26. The specific configuration of the insulator 28 will be described in detail later.

[0017] As shown in Figs. 5 to 7, the coils 16 are formed by winding a conductive wire (conductor) in a circular shape. Here, as shown in Figs. 6 and 7, the winding 30 forming the coil 16 of this embodiment has a rectangular cross section in which a dimension L1 of the winding 30 in a first direction (arrow A1 direction) is set to be larger than a dimension L2 in a second direction (arrow A2) perpendicular to the first direction, in a cross section cut along the longitudinal direction. The winding 30 may be a wire assembly formed by bundling conductive wires. The resistance between the bundled wires is larger than the resistance of the wire itself. The cross-sectional shape of the winding 30 may be an oval or elliptical shape. In general, an enameled wire is preferably used for the winding 30, and the conductive material may be copper or aluminum.

[0018] As shown in Figures 5 to 7, the stator 14 of this embodiment is configured to include two types of coils 16 with different axial dimensions. Here, the coils 16 shown in Figure 6 are referred to as short coils 32. Also, the coils 16 shown in Figure 7 are referred to as long coils 34. The number of coils 16 may be appropriately set in consideration of the output required of the motor 10, etc.

[0019] As shown in Fig. 6, the short coil 32 is formed by winding the wire 30 in a rectangular shape so as to be stacked in the second direction (arrow A2 direction), and then bending both axial ends radially outward. As a result, the short coil 32 has a pair of opposing parts 36 in which parts of the wire 30 are arranged side by side in the circumferential direction and spaced apart from each other in the circumferential direction, one coil end part 38 connecting the ends of the pair of opposing parts 36 on one axial side in the circumferential direction, and the other coil end part 38 connecting the ends of the pair of opposing parts 36 on the other axial side in the circumferential direction. In addition, a terminal part 40 on one side of the wire 30 forming the short coil 32 is drawn out from one circumferential side of the opposing part 36 on the other circumferential side between the pair of opposing parts 36 to one axial side. In addition, a terminal part 40 on the other side of the wire 30 forming the short coil 32 is drawn out from the opposite side (one circumferential side) of the opposing part 36 on one circumferential side to the opposing part 36 on the other circumferential side in the circumferential direction to one axial side. In the following description, the terminal portion 40 on one side of the winding 30 forming the short coil 32 may be referred to as the "winding start terminal portion 40A," and the terminal portion 40 on the other side of the winding 30 forming the short coil 32 may be referred to as the "winding end terminal portion 40B." In addition, by arranging the terminal portion 40 in this manner, in the short coil 32 of this embodiment, the number of layers of the winding 30 in the coil end portion 38 on one axial side is less than the number of layers of the winding 30 in the coil end portion 38 on the other axial side. In more detail, the number of layers of the winding 30 in the coil end portion 38 on one axial side is six, and the number of layers of the winding 30 in the coil end portion 38 on the other axial side is seven. The number of layers of the winding 30 in the pair of opposing portions 36 is seven.

[0020] 6 and 7, the long coil 34 has the same configuration as the short coil 32, except that the axial dimension H2 of the long coil 34 is larger than the axial dimension H1 of the short coil 32. Here, the parts of the long coil 34 that correspond to the short coil 32 are given the same reference numerals as the short coil 32, and the description of these parts will be omitted. The long coil 34 is manufactured through the same process as the short coil 32. Incidentally, the length of the winding 30 forming the long coil 34 is longer than the length of the winding 30 forming the short coil 32. As a result, the electrical resistance of the long coil 34 is higher than the electrical resistance of the short coil 32.

[0021] Here, a method for manufacturing the short coil 32, which is one of the steps in the method for manufacturing the stator 14, will be described. As shown in Figures 6 and 8A, the short coil 32 is formed using a winding frame 90. A winding frame axis 90A is set on this winding frame 90. A cross section of the winding frame 90, taken along a direction perpendicular to the winding frame axis 90A, around which the winding 30 is wound, is rectangular. The winding frame axis 90A is located at the centroid of this cross section.

[0022] In the manufacturing process of the short coil 32, first, the winding 30 is wound around the winding frame 90 in the circumferential direction of the winding frame axis 90A with the portion of the winding 30 that will become the winding start terminal portion 40A tilted relative to the direction perpendicular to the winding frame axis 90A. At this time, the winding 30 is wound in a rectangular shape so that the winding 30 is layered in the second direction (the direction of arrow A2). This process is the winding process. In this winding process, a pair of opposing portions 36 and a pair of coil end portions 38 are formed around the winding frame 90. Note that an appropriate R-shape is provided at the position where it abuts against the inner R-shaped portion of the coil corner formed by winding the coil around the winding frame 90, but this is omitted in the drawing for simplification.

[0023] Next, as shown in FIG. 6 and FIG. 8B, the pair of coil end portions 38 are bent at a substantially right angle to the pair of opposing portions 36. That is, the boundary between the pair of coil end portions 38 and the pair of opposing portions 36 is bent at a substantially right angle in the first direction. In this example, a bending jig 91 that matches the bending shape of the short coil 32 is used, and the pair of coil end portions 38 are bent along the bending jig 91 in the opposite direction to the inclination direction of the winding start terminal portion 40A relative to the pair of opposing portions 36. This process is the folding process. Note that an appropriate R-shape is provided at the position where the coil corner portion formed by bending the coil of the winding frame 90 abuts against the inner R-shaped portion, but is omitted in the drawing for simplification. In addition, before this folding process, the rectangularly wound portion of the short coil 32 except for the pair of terminal portions 40 may be joined using a joining member not shown. As a result, the portions (stacked windings 30) forming the pair of opposing portions 36, the coil end portion 38 on one axial side, and the coil end portion 38 on the other axial side in the short coil 32 are inseparably joined in the second direction.

[0024] Next, as shown in Figures 6 and 8C, the winding-start terminal portion 40A is moved toward one of the opposing portions 36 between the pair of opposing portions 36. This step is the winding-start terminal portion moving step. After this terminal portion moving step, the pair of terminal portions 40 in the short coil 32 may be joined using a joining member (not shown). This joins the pair of terminal portions 40 in the short coil 32 inseparably in the second direction.

[0025] 10, the short coil 32 is formed in such a manner that the pair of opposing portions 36 are arranged along the radially inner surface of the stator core 26 and the coil end portions 38 on one and the other axial sides are arranged along both axial end surfaces of the stator core 26. The long coil 34 is also manufactured through the same process as the short coil 32, using a winding frame 90 of a different size.

[0026] Next, another method for manufacturing the short coil 32 will be described with reference to FIGS. 9A to 9D.

[0027] As shown in FIG. 6 and FIG. 9A, the short coil 32 is formed using a first winding frame 92 and a second winding frame 94. The first winding frame 92 has a main body 92A formed in a rectangular parallelepiped shape and a cylindrical engagement protrusion 92B protruding from the main body 92A. The second winding frame 94 is formed in a three-dimensional shape corresponding to the space between the pair of opposing parts 36 and the pair of coil end parts 38 in the short coil 32. The second winding frame 94 has a main plate 94A formed in a rectangular plate shape and a pair of side plate parts 94B protruding from both ends of the main plate part 94A in the longitudinal direction toward the first winding frame 92 side. The main plate part 94A has an engagement hole 94C with which the engagement protrusion part 92B of the first winding frame 92 engages. In addition, an appropriate R-shape is provided at the position where it abuts against the inner R-shaped portion of the coil corner formed by winding and bending the coil of the first winding frame 92 and the second winding frame 94, but this is omitted in the illustration for simplification.

[0028] In the manufacturing process of the short coil 32, first, as shown in FIG. 9A and FIG. 9B, the engaging protrusion 92B of the first winding frame 92 is inserted into the engaging hole 94C of the second winding frame 94 to engage the second winding frame 94 with the first winding frame 92. This process is the winding frame engaging process. As shown in FIG. 9B, when the winding frame engaging process is completed, a part of the first winding frame 92 is disposed between a pair of side plate portions 94B of the second winding frame 94. Note that a locking member (not shown) is used to prevent the second winding frame 94 from moving away from the first winding frame 92. One example is a nut that is fastened to a screw provided on the engaging protrusion. Also, the second winding frame 94 may be held by a pressing device instead of the locking member.

[0029] 6 and 9C, the winding 30 is wound around the first winding frame 92 and the second winding frame 94. This process is the winding process. In this winding process, a pair of opposing portions 36 and a pair of coil end portions 38 are formed around the first winding frame 92 and the second winding frame 94.

[0030] Next, as shown in Figures 6 and 9D, the second winding frame 94 is separated from the first winding frame 92. This step is a winding frame separating step. Here, the second winding frame 94 can be separated from the first winding frame 92 by removing the locking member (not shown). Next, the short coil 32 is removed from the first winding frame 92. This step is a coil removing step.

[0031] Through the above steps, the short coil 32 is formed. The long coil 34 is also manufactured through the same steps as the short coil 32, using a first winding frame 92 and a second winding frame 94 of different sizes.

[0032] Next, the connections of the multiple coils 16 will be described.

[0033] As shown in FIG. 11, the coils 16 are connected in a star connection, for example. In this example, the U-phase 42U, the V-phase 42V, and the W-phase 42W are each configured to include two short coils 32 and two long coils 34. In the U-phase 42U, the four coils 16 are connected in series in the order of the long coil 34, the short coil 32, the long coil 34, and the short coil 32 from the neutral point 44 side. In the V-phase 42V, the four coils 16 are connected in series in the order of the long coil 34, the short coil 32, the long coil 34, and the short coil 32 from the neutral point 44 side. In the W-phase 42W, the four coils 16 are connected in series in the order of the short coil 32, the long coil 34, the short coil 32, and the long coil 34 from the neutral point 44 side. Note that the coils 16 are connected to each other using a bus bar 96, which will be described later, for example.

[0034] Here, in the U phase 42U, the range from the short coil 32 farthest from the neutral point 44 to the neutral point 44 is referred to as the U-phase coil connection body 46U. In addition, in the V phase 42V, the range from the short coil 32 farthest from the neutral point 44 to the neutral point 44 is referred to as the V-phase coil connection body 46V. Furthermore, in the W phase 42W, the range from the long coil 34 farthest from the neutral point 44 to the neutral point 44 is referred to as the W-phase coil connection body 46W. In this embodiment, the number of long coils 34 and the number of short coils 32 are set to the same number in the coil connection bodies 46U, 46V, 46W of each phase, so that the combined resistance of the coil connection bodies 46U, 46V, 46W of each phase is the same. Here, the combined resistance of the coil connections 46U, 46V, 46W of each phase being the same means that the difference between the combined resistance of the coil connection 46U of one phase and the combined resistance of the coil connections 46V, 46W of the other phase is within plus or minus 5%.

[0035] Fig. 12 shows the relative positions of the coils 16 in the U phase 42U, the coils 16 in the V phase 42V, and the coils 16 in the W phase 42W. As shown in Fig. 12 and Fig. 13, the short coil 32 farthest from the neutral point 44 in the U phase 42U and the short coil 32 farthest from the neutral point 44 in the V phase 42V are arranged adjacent to each other in the circumferential direction along the stator core 26. In addition, the long coil 34 farthest from the neutral point 44 in the W phase 42W is arranged so as to straddle the short coil 32 farthest from the neutral point 44 in the U phase 42U and the short coil 32 farthest from the neutral point 44 in the V phase 42V.

[0036] In addition, the short coil 32 farthest from the neutral point 44 in the V phase 42V and the short coil 32 on the opposite side of the neutral point 44 in the W phase 42W are arranged adjacent to each other in the circumferential direction along the stator core 26. Furthermore, the long coil 34 on the opposite side of the neutral point 44 in the U phase 42U is arranged so as to straddle the short coil 32 farthest from the neutral point 44 in the V phase 42V and the short coil 32 on the opposite side of the neutral point 44 in the W phase 42W.

[0037] In addition, the short coil 32 on the opposite side of the neutral point 44 in the W phase 42W and the short coil 32 on the neutral point 44 side in the U phase 42U are arranged adjacent to each other in the circumferential direction along the stator core 26. Furthermore, the long coil 34 on the opposite side of the neutral point 44 in the V phase 42V is arranged so as to straddle the short coil 32 on the opposite side of the neutral point 44 in the W phase 42W and the short coil 32 on the neutral point 44 side in the U phase 42U.

[0038] In addition, the short coil 32 on the neutral point 44 side in the U phase 42U and the short coil 32 on the neutral point 44 side in the V phase 42V are arranged adjacent to each other in the circumferential direction along the stator core 26. Furthermore, the long coil 34 on the neutral point 44 side in the W phase 42W is arranged so as to straddle the short coil 32 on the neutral point 44 side in the U phase 42U and the short coil 32 on the neutral point 44 side in the V phase 42V.

[0039] In addition, the short coil 32 on the neutral point 44 side in the V phase 42V and the short coil 32 on the neutral point 44 side in the W phase 42W are arranged adjacent to each other in the circumferential direction along the stator core 26. Furthermore, the long coil 34 on the neutral point 44 side in the U phase 42U is arranged so as to straddle the short coil 32 on the neutral point 44 side in the V phase 42V and the short coil 32 on the neutral point 44 side in the W phase 42W.

[0040] In addition, the short coil 32 on the neutral point 44 side in the W phase 42W and the short coil 32 farthest from the neutral point 44 in the U phase 42U are arranged adjacent to each other in the circumferential direction along the stator core 26. Furthermore, the long coil 34 on the neutral point 44 side in the V phase 42V is arranged so as to straddle the short coil 32 on the neutral point 44 side in the W phase 42W and the short coil 32 farthest from the neutral point 44 in the U phase 42U.

[0041] Here, as shown in Fig. 13 and Fig. 14, the insulator 28 to which each coil 16 is attached includes an inner surface covering portion 28A covering the radially inner surface of the stator core 26, a pair of axial end surface covering portions 28B covering both axial end surfaces of the stator core 26, and a pair of outer circumferential flange portions 28C extending in the axial direction from the radially outer ends of the pair of axial end surface covering portions 28B. The insulator 28 also includes a plurality of circumferential positioning portions 28D for positioning the short coil 32 in the circumferential direction. The plurality of circumferential positioning portions 28D are formed in a convex shape toward the radially inner side from the outer circumferential flange portion 28C, and are arranged at equal intervals along the circumferential direction. The coil end portion 38 of the short coil 32 is arranged between a pair of circumferential positioning portions 28D adjacent to each other in the circumferential direction, so that the short coil 32 is positioned in the circumferential direction. Although the multiple circumferential positioning portions 28D may be provided on one outer circumferential flange portion 28C, they may be provided on both outer circumferential flange portions 28C.

[0042] As shown in Fig. 12, Fig. 13 and Fig. 15, the facing portions 36 of the short coils 32 and the facing portions 36 of the long coils 34 are disposed along the radially inner surface of the stator core 26 via the inner covering portion 28A of the insulator 28, and are disposed at the same position in the radial direction. In detail, in the state shown in Fig. 15, the facing portions 36 on one circumferential side of the U-phase short coils 32 and the facing portions 36 on the other circumferential side of the V-phase short coils 32 that are adjacent in the circumferential direction are disposed adjacent to each other in the circumferential direction, and the facing portions 36 on one circumferential side of the U-phase short coils 32 and the facing portions 36 on the other circumferential side of the V-phase short coils 32 that are adjacent in the circumferential direction are disposed between a pair of facing portions 36 of the W-phase long coils 34. As shown in Fig. 12 and Fig. 15, the facing portions 36 of the other short coils 32 and the facing portions 36 of the other long coils 34 are also disposed along the radially inner surface of the stator core 26 in a similar relationship. In addition, with the axial center position of the opposing portion 36 of the short coil 32 and the axial center position of the opposing portion 36 of the long coil 34 and the axial center position of the magnet 18 aligned in the axial direction, the opposing portions 36 of the short coil 32 and the opposing portions 36 of the long coil 34 and the magnet 18 are arranged facing each other in the radial direction. In addition, the first direction of the windings 30 constituting the opposing portions 36 of the short coil 32 and the opposing portions 36 of the long coil 34 is directed towards the magnet 18.

[0043] As shown in Figs. 12, 13 and 15, the pair of coil end portions 38 of the short coil 32 are disposed along both axial end faces of the stator core 26 via the pair of axial end surface covering portions 28B of the insulator 28. The pair of coil end portions 38 of the long coil 34 are disposed along both axial end faces of the stator core 26 via the coil end portions 38 of the two short coils 32 adjacent in the circumferential direction and the pair of axial end surface covering portions 28B of the insulator 28. That is, the pair of coil end portions 38 of the long coil 34 are disposed so as to overlap in the axial direction with the pair of coil end portions 38 of the two short coils 32 adjacent in the circumferential direction. More specifically, in the state shown in Fig. 15, the pair of coil end portions 38 of the W-phase long coil 34 are disposed so as to overlap in the axial direction with the circumferentially one side portion of the pair of coil end portions 38 of the U-phase short coil 32 adjacent in the circumferential direction and the circumferentially other side portion of the pair of coil end portions 38 of the V-phase short coil 32. As shown in FIGS. 12 and 15, the coil end portions 38 of the other short coils 32 and the coil end portions 38 of the other long coils 34 are also arranged along both axial end faces of the stator core 26 in a similar relationship.

[0044] Next, the process of arranging each coil 16 along stator core 26, which is one of the steps in the method of manufacturing stator 14, will be described in detail with reference to FIGS. 16, 17, and 18A to 18E.

[0045] As shown in Fig. 16, in this embodiment, first, the short coils 32 are arranged along the stator core 26, and then, as shown in Fig. 17, the long coils 34 are arranged along the stator core 26. Note that the insulators 28 are not shown in Figs. 16 and 17.

[0046] 16, first, the multiple short coils 32 are arranged along the stator core 26. This process is a first coil arrangement process. In this embodiment, in this process, the opposing portions 36 of the short coils 32 adjacent to each other in the circumferential direction are brought into contact with each other in the circumferential direction.

[0047] 17, the multiple long coils 34 are arranged along the stator core 26. This process is the second coil arrangement process. Here, in the second coil arrangement process, when the long coils 34 are arranged along the stator core 26, the long coils 34 are not brought into contact with the terminal portions 40 of the short coils 32.

[0048] Specifically, as shown in FIGS. 17 and 18A, the long coils 34 are disposed on one axial side of the short coils 32 disposed along the stator core 26.

[0049] Next, as shown in Figures 17 and 18B, the long coil 34 is tilted with respect to the axial direction so that the coil end portion 38 on one axial side of the long coil 34 is positioned radially inward relative to the coil end portion 38 on the other axial side.

[0050] 17 and 18C, when the long coil 34 is moved toward the other axial side while remaining tilted, the winding start terminal portion 40A of the short coil 32 and the winding end terminal portion 40B of the adjacent short coil 32 (not shown) are passed between a pair of opposing portions 36 of the long coil 34, while the long coil 34 is brought closer to the stator core 26. Note that the coil end portion 38 on the other axial side of the long coil 34 and the coil end portion 38 on the other axial side of the short coil 32 are not shown in FIG.

[0051] Next, as shown in Figures 17 and 18D, from a state in which the coil end portion 38 on one axial side of the long coil 34 is brought close to the coil end portion 38 on one axial side of the short coil 32, the opposing portion 36 of the long coil 34 is brought close to the radially inner surface of the stator core 26, and the coil end portion 38 on the other axial side of the long coil 34 is brought close to the coil end portion 38 on the other axial side of the short coil 32.

[0052] 17 and 18E, the facing portion 36 of the long coil 34 is pressed radially outward using a pressing jig 98 to move the long coil 34 radially outward. Here, the long coil 34 is moved radially outward until the radial position of the facing portion 36 of the long coil 34 becomes the same as the radial position of the facing portion 36 of the short coil 32.

[0053] Using the procedure described above, each long coil 34 is arranged along the stator core 26.

[0054] Next, a configuration and process for realizing the arrangement of each coil 16 along stator core 26 in a process different from the process described above will be described in detail with reference to Figs. 19A to 19D.

[0055] 19A, the portion of the winding 30 that will become the winding start terminal portion 40A is inclined relative to a direction perpendicular to the winding frame axis 90A, and the winding 30 is wound around the winding frame 90 in the circumferential direction of the winding frame axis 90A. Similarly to the winding start terminal portion 40A, the winding end terminal portion 40B is inclined relative to a direction perpendicular to the winding frame axis 90A. This process is the first winding process.

[0056] 19B, the pair of coil end portions 38 are bent at approximately right angles to the opposite direction to the inclination of the winding end terminal portion 40B and the winding start terminal portion 40A with respect to the pair of opposing portions 36. This step is the bending step.

[0057] Through the above steps, a short coil 32 is manufactured in a state in which the winding end portion 40B and the winding start portion 40A are inclined. Furthermore, through the same steps as the short coil 32, a long coil 34 is manufactured in a state in which the winding end portion 40B and the winding start portion 40A are inclined. The step of manufacturing the long coil 34 is the second winding step.

[0058] Next, the multiple short coils 32 are arranged along the stator core 26. This step is a first coil arrangement step.

[0059] 19C, while maintaining the posture of the long coil 34 in the same posture as that of the short coil 32, the long coil 34 is moved along the tilted direction of the terminal portion 40 of the short coil 32, and the terminal portion 40 of the short coil 32 is passed between the pair of opposing portions 36 of the long coil 34, while the long coil 34 is brought closer to the stator core 26. Then, the coil end portion 38 on one axial side of the long coil 34 is overlapped with the coil end portion 38 on one axial side of the short coil 32, and the coil end portion 38 on the other axial side of the long coil 34 is overlapped with the coil end portion 38 on the other axial side of the short coil 32. Note that the coil end portion 38 on the other axial side of the long coil 34 and the coil end portion 38 on the other axial side of the short coil 32 are not shown in FIG. 19C.

[0060] Next, as shown in FIG. 19D, the facing portion 36 of the long coil 34 is pressed radially outward using a pressing tool 98 to move the long coil 34 radially outward. Here, the long coil 34 is moved radially outward until the radial position of the facing portion 36 of the long coil 34 is the same as the radial position of the facing portion 36 of the short coil 32. At the same time, the terminal portion 40 of the long coil 34 and the terminal portion 40 of the short coil 32 are pressed radially outward using a pressing tool 98 to move (tilt) the terminal portion 40 of the long coil 34 and the terminal portion 40 of the short coil 32 to the same position as the facing portion 36 of the long coil 34 and the facing portion 36 of the short coil 32. This process is the terminal portion moving process. After this terminal portion moving process, the terminal portion 40 may be joined using a joining member not shown. As a result, the terminal portion 40 is joined inseparably.

[0061] Using the procedure described above, each long coil 34 is disposed along the stator core 26. Note that, in the embodiment described using Figures 19A to 19D, an example was shown in which all of the terminal portions 40 of the short coils 32 and long coils 34 are inclined with respect to their respective opposing portions 36, but the terminal portion 40 of the long coil 34 does not have to be inclined with respect to the opposing portions 36 by the manufacturing method described using Figures 8A to 8C or 9A to 9D.

[0062] Here, even if the terminal portion 40 of the long coil 34 and the terminal portion 40 of the short coil 32 are moved (tilted) to the same position as the opposing portion 36 of the long coil 34 and the opposing portion 36 of the short coil 32 in the process shown in Figure 19D, it is possible that the terminal portion 40 of the long coil 34 and the terminal portion 40 of the short coil 32 will restore their original position (spring back), causing the terminal portion 40 of the long coil 34 and the terminal portion 40 of the short coil 32 to tilt slightly in the axial direction.

[0063] 20A and 20B, after the terminal portion moving step, the terminal portion 40 of the long coil 34 and the terminal portion 40 of the short coil 32 are locked to the terminal locking portion 28J so that the terminal portion 40 of the long coil 34 and the terminal portion 40 of the short coil 32 are oriented along the axial direction. This step is the terminal locking step. Here, in the example shown in Fig. 20A and 20B, the terminal locking portion 28J is provided on the insulator 28, but as in the example shown in Fig. 21A and 21B, a locking member 100 that is a separate member from the insulator 28 may be provided, and the terminal locking portion 28J may be provided on this locking member 100.

[0064] Furthermore, in a configuration having a terminal locking portion 28J at which the terminal portion 40 of the long coil 34 and the terminal portion 40 of the short coil 32 are locked, as in the example shown in Figures 20A to 21B, it is desirable to carry out a coating removal process for removing the insulating coating 102 around the terminal portion 40 of the long coil 34 and the terminal portion 40 of the short coil 32 before the terminal locking process, as shown in Figure 22.

[0065] FIG. 17 shows the coils 16 arranged along the stator core 26 by going through any one of the steps described above. As shown in this figure, the terminal portions 40 of the coils 16 are arranged at the same radial position. In addition, the end portion 40B of the long coil 34 is arranged next to the start portion 40A of the short coil 32, and the start portion 40A of the long coil 34 is arranged next to the end portion 40B of the short coil 32. The start portion 40A and the end portion 40B are arranged alternately in the circumferential direction, and the circumferential interval between the start portion 40A and the end portion 40B adjacent to each other in the circumferential direction is a constant interval P1.

[0066] As shown in FIG. 23, the terminals 40 of each coil 16 are connected in the above-mentioned star connection (see FIG. 11) via a plurality of bus bars 96 as connection parts. As shown in FIG. 24A, the bus bars 96 are formed by bending a metal plate formed in a plate shape. The bus bars 96 are provided with a pair of joints 96A that are spaced apart from each other in the circumferential direction and to which the terminals 40 of the coils 16 are joined, and a circumferential connection part 96B that connects the pair of joints 96A in the circumferential direction. The circumferential distance between the pair of joints 96A is called the joint pitch P2. As shown in FIG. 23, the bus bars 96 are arranged along the coil end parts 38 on one axial side of each coil 16 to connect predetermined terminals 40. In this embodiment, the bus bars 96 are arranged in the circumferential direction in a state where they are overlapped to form two rows in the axial direction. The multiple bus bars 96 arranged circumferentially in a row on one axial side and the multiple bus bars 96 arranged circumferentially in a row on the other axial side are circumferentially offset by half the inter-joint pitch P2 (see FIG. 24A).

[0067] The shape of the busbar 96 may be appropriately set in consideration of the configuration of the terminal portion 40 of the coil 16. For example, as shown in Fig. 24B, in a configuration in which the terminal portion 40 of the coil 16 is bent radially outward, a pair of joint portions 96A and a circumferential connection portion 96B may be arranged in a straight line or an arc.

[0068] (Actions and Effects of the Present Embodiment) Next, the operation and effects of this embodiment will be described.

[0069] 3, 6, 7, 11, and 12, in the motor 10 of this embodiment, a rotating magnetic field is generated on the inner circumference of the stator 14 by switching the energization of the U-phase coil connection body 46U, the V-phase coil connection body 46V, and the W-phase coil connection body 46W that constitute a part of the stator 14. This causes the rotor 12 to rotate.

[0070] In the motor 10 of this embodiment, the number of long coils 34 and the number of short coils 32 in the coil connections 46U, 46V, 46W of each phase are set to be the same, so that the combined resistances of the coil connections 46U, 46V, 46W of each phase are the same. This makes it difficult for electrical imbalances to occur in the coil connections 46U, 46V, 46W of each phase. As a result, it is possible to suppress deterioration of the torque ripple of the motor 10.

[0071] Furthermore, in the motor 10 of this embodiment, the coil end portions 38 of the long coils 34 and the coil end portions 38 of the short coils 32 are configured to be bent at right angles radially outward relative to the opposing portions 36, and the coil end portions 38 of the long coils 34 and the coil end portions 38 of the short coils 32 are configured to be overlapped in the axial direction. This makes it possible to prevent the stator 14 from becoming large in size in the axial direction. As a result, it is possible to prevent the motor 10 from becoming large in size in the axial direction.

[0072] Furthermore, in the motor 10 of this embodiment, the cross-sectional shape of the winding 30 forming the coil 16 is a rectangle with the first direction (arrow A1 direction) as the longitudinal direction. In addition, the first direction of the winding 30 of the portion forming the opposing portion 36 of the short coil 32 and the opposing portion 36 of the long coil 34 is directed toward the magnet 18. This makes it possible to reduce the area of ​​the portion of the winding 30 facing the magnet 18 while ensuring the cross-sectional area of ​​the winding 30. This makes it possible to suppress an increase in the electrical resistance of the winding 30 while suppressing an increase in AC copper loss due to eddy currents generated in the opposing portion 36. In addition, in the motor 10 of this embodiment, the opposing portion 36 has a single-layer structure along the radially inner surface of the stator core 26. This makes it possible to easily form the shape of the opposing portion 36 as viewed from the axial direction into a curved shape corresponding to the radially inner surface of the stator core 26, as shown in FIG. 8. This makes it possible to improve the space factor.

[0073] In the motor 10 of this embodiment, the pair of terminal portions 40 are disposed on one axial side in a state in which the number of laminations of the winding 30 in the coil end portion 38 on one axial side of the coil 16 is smaller than the number of laminations of the winding 30 in the coil end portion 38 on the other axial side. With this configuration, the length of the portion of the coil 16 around which the winding 30 is wound can be shortened. This makes it possible to suppress an increase in the electrical resistance of the coil 16.

[0074] Furthermore, in the motor 10 of this embodiment, a plurality of circumferential positioning portions 28D are provided on the outer peripheral flange portion 28C of the insulator 28. This improves the workability when attaching the short coils 32 to the stator core 26 via the insulator 28. Also, the circumferential position of each of the short coils 32 can be stabilized, and each of the short coils 32 can be arranged more evenly in the circumferential direction. Note that a configuration may be adopted in which only the circumferential positioning portions 28D for positioning the short coils 32 of one phase in the circumferential direction are provided.

[0075] 17 and 23, in this embodiment, the terminal portions 40 of the coils 16 are disposed at the same radial position. This makes it possible to prevent the length of the connection portion connecting the terminal portions 40 of the coils 16 from increasing. In more detail, in a configuration in which the terminal portions 40 of the coils 16 are connected using a plurality of bus bars 96, it is possible to prevent the length of the connection by the plurality of bus bars 96 from increasing. As a result, it is possible to prevent the motor 10 from being hindered from being made larger in output and smaller in size.

[0076] In this embodiment, the winding start terminal portions 40A and the winding end terminal portions 40B are alternately arranged in the circumferential direction, which allows the coils 16 to be arranged in a space-saving manner in a so-called distributed winding configuration such as this embodiment.

[0077] Furthermore, in this embodiment, the circumferential distance between the winding start terminal portion 40A and the winding end terminal portion 40B that are adjacent in the circumferential direction is a constant distance P1. As a result, in the connection pattern of this embodiment, except for the connection of the neutral point 44, each coil 16 can be connected using a bus bar 96 of a common dimension.

[0078] Furthermore, a plurality of bus bars 96 are arranged circumferentially in a state where they are stacked in two rows in the axial direction. This makes it possible to suppress an increase in the radial size of the stator 14, and as a result, makes it possible to suppress an increase in the radial size of the motor 10. Furthermore, by combining this configuration with a configuration in which the coil end portions 38 on one axial side are stacked in the axial direction, as in this embodiment, it is possible to suppress an increase in the axial size of the motor 10.

[0079] In the present embodiment, the bus bar 96 includes a pair of joint portions 96A and a circumferential connection portion 96B. In this configuration, the electrical resistance between the pair of joint portions 96A in the bus bar 96 can be adjusted by changing the length of the circumferential connection portion 96B.

[0080] 8A to 8C, the winding 30 can be wound around the winding frame 90 in the circumferential direction of the winding frame axis 90A with the portion of the winding 30 that becomes the winding-start terminal portion 40A tilted relative to a direction perpendicular to the winding frame axis 90A. This makes it possible to prevent the winding-start terminal portion 40A from interfering with the winding operation of the winding 30 when winding the winding 30 around the winding frame 90.

[0081] 9A to 9D, the steps of forming the coil 16 may include a winding frame engaging step to a coil removing step using a first winding frame 92 and a second winding frame 94. This method of going through the steps may eliminate the need for the step of tilting the portion that will become the winding start terminal portion 40A shown in Fig. 8A and the step of bending the pair of coil end portions 38 relative to the pair of opposing portions 36 shown in Fig. 8B.

[0082] 18A to 18E, when the long coil 34 is moved toward the other axial side while being tilted, the long coil 34 is brought closer to the stator core 26 while the winding start terminal portion 40A of the short coil 32 and the winding end terminal portion 40B of the adjacent short coil 32 are passed between a pair of opposing portions 36 of the long coil 34. This makes it possible to prevent the long coil 34 from hitting the terminal portion 40 of the short coil 32 and deforming the terminal portion 40 of the short coil 32 when the long coil 34 is brought closer to the stator core 26. Furthermore, by performing the steps shown in FIGS. 19A to 19D, the long coil 34 can be brought closer to the stator core 26 while maintaining the same posture as the short coil 32.

[0083] 20A to 21B, by providing a terminal locking portion 28J to which the terminal portion 40 of the long coil 34 and the terminal portion 40 of the short coil 32 are locked, the terminal portions 40 of the long coil 34 and the terminal portions 40 of the short coil 32 can be easily maintained in an axial orientation. Furthermore, by undergoing a coating removal process before the terminal portions 40 of the long coil 34 and the terminal portions 40 of the short coil 32 are locked to the terminal locking portion 28J as shown in FIG. 22, damage to the terminal locking portion 28J, which is a concern when the terminal portions 40 of the long coil 34 and the terminal portions 40 of the short coil 32 are locked to the terminal locking portion 28J and undergo the coating removal process, can be prevented.

[0084] (Motors of the second and third embodiments) 25A to 26B, the configuration of stator 14 of motors of second and third embodiments, which can suppress torque ripples in the same way as motor 10 of the first embodiment and can also suppress an increase in the length of the connection portion, will be described. Note that members and parts of the motors of the second and third embodiments that correspond to those of the motors of the embodiments already described are given the same reference numerals as those of the motors of the embodiments already described, and their description may be omitted.

[0085] 25A, the stator 14 of the motor of the second embodiment is configured similarly to the stator 14 of the motor 10 of the first embodiment, except that the coil end portion 38 on the other axial side of the coil 16 is bent at a substantially right angle toward the opposite side from the stator core 26, and the axial dimensions of one coil 16 and the other coil 16 are substantially the same. As shown in Figures 25A and 25B, in this example, the coil 16 can be arranged along the stator core 26 by linearly moving the coil 16 toward the other axial side toward the stator core 26.

[0086] 26A, the stator 14 of the motor of the third embodiment is configured similarly to the stator 14 of the motor 10 of the first embodiment described above, except that the stator 14 is configured to include two types of coils: one in which the coil end portion 38 on the other axial direction of the coil 16 is bent at a substantially right angle toward the opposite side to the stator core 26, and the other in which the coil end portion 38 on the other axial direction extends linearly from the opposing portion 36 toward the other axial direction. As shown in Fig. 26A and Fig. 26B, in this example, the coil 16 can be arranged along the stator core 26 by moving the coil 16 linearly toward the other axial direction side toward the stator core 26 side.

[0087] (Motors of the fourth and fifth embodiments) 27 to 30, the configuration of stator 14 of motors of the fourth and fifth embodiments, which can suppress torque ripples in the same way as motor 10 of the first embodiment and can also suppress an increase in the length of the connection portion, will be described. Note that members and parts of the motors of the fourth and fifth embodiments that correspond to those of the motors of the embodiments already described are given the same reference numerals as those of the motors of the embodiments already described, and their description may be omitted.

[0088] (Motor of the fourth embodiment) As shown in FIG. 27, in the stator 14 of the motor of the fourth embodiment, the coils 16 are connected in a star connection. The U-phase 42U, the V-phase 42V, and the W-phase 42W of the present embodiment are each configured to include two short coils 32 and two long coils 34. In the U-phase 42U, two coils 16 connected in series from the neutral point 44 side in the order of the short coil 32 and the long coil 34 are connected in parallel to two coils 16 connected in series from the neutral point 44 side in the order of the short coil 32 and the long coil 34. In the V-phase 42V, two coils 16 connected in series from the neutral point 44 side in the order of the short coil 32 and the long coil 34 are connected in parallel to two coils 16 connected in series from the neutral point 44 side in the order of the short coil 32 and the long coil 34. Furthermore, in the W-phase 42W, two coils 16 connected in series in the order of the long coil 34 and the short coil 32 from the neutral point 44 side, and two coils 16 connected in series in the order of the long coil 34 and the short coil 32 from the neutral point 44 side, are connected in parallel. Also in this embodiment, the combined resistances of the coil connections 46U, 46V, 46W of each phase are the same combined resistance.

[0089] 28, the short coil 32 of one wiring path in the U-phase 42U and the short coil 32 of one wiring path in the V-phase 42V are disposed adjacent to each other in the circumferential direction along the stator core 26. In addition, the long coil 34 of one wiring path in the W-phase 42W is disposed so as to straddle the short coil 32 of one wiring path in the U-phase 42U and the short coil 32 of one wiring path in the V-phase 42V.

[0090] Moreover, the short coil 32 of one wiring path in the V phase 42V and the short coil 32 of one wiring path in the W phase 42W are disposed adjacent to each other in the circumferential direction along the stator core 26. Moreover, the long coil 34 of one wiring path in the U phase 42U is disposed so as to straddle the short coil 32 of one wiring path in the V phase 42V and the short coil 32 of one wiring path in the W phase 42W.

[0091] Moreover, the short coil 32 of one wiring path in the W phase 42W and the short coil 32 of the other wiring path in the U phase 42U are disposed adjacent to each other in the circumferential direction along the stator core 26. Moreover, the long coil 34 of one wiring path in the V phase 42V is disposed so as to straddle the short coil 32 of one wiring path in the W phase 42W and the short coil 32 of the other wiring path in the U phase 42U.

[0092] Additionally, the short coil 32 of the other wiring path in the U phase 42U and the short coil 32 of the other wiring path in the V phase 42V are disposed adjacent to each other in the circumferential direction along the stator core 26. Additionally, the long coil 34 of the other wiring path in the W phase 42W is disposed so as to straddle the short coil 32 of the other wiring path in the U phase 42U and the short coil 32 of the other wiring path in the V phase 42V.

[0093] Moreover, the short coil 32 of the other wiring path in the V phase 42V and the short coil 32 of the other wiring path in the W phase 42W are disposed adjacent to each other in the circumferential direction along the stator core 26. Moreover, the long coil 34 of the other wiring path in the U phase 42U is disposed so as to straddle the short coil 32 of the other wiring path in the V phase 42V and the short coil 32 of the other wiring path in the W phase 42W.

[0094] Additionally, the short coil 32 of the other wiring path in the W phase 42W and the short coil 32 of one wiring path in the U phase 42U are disposed adjacent to each other in the circumferential direction along the stator core 26. Additionally, the long coil 34 of the other wiring path in the V phase 42V is disposed so as to straddle the short coil 32 of the other wiring path in the W phase 42W and the short coil 32 of one wiring path in the U phase 42U.

[0095] The motor of the fourth embodiment, which is configured to include the stator 14 described above, can also suppress deterioration of torque ripple.

[0096] (Motor of the fifth embodiment) As shown in FIG. 29, in the stator 14 of the motor of the fifth embodiment, the coils 16 are connected in a star connection. The U-phase 42U, the V-phase 42V, and the W-phase 42W of the present embodiment are each configured to include one short coil 32, one long coil 34, and two middle coils 48. The middle coil 48 is a coil 16 whose axial dimension is set to be larger than the axial dimension of the short coil 32 and smaller than the axial dimension of the long coil 34. In the U-phase 42U, the four coils 16 are connected in series in the order of the middle coil 48, the long coil 34, the middle coil 48, and the short coil 32 from the neutral point 44 side. In the V-phase 42V, the four coils 16 are connected in series in the order of the middle coil 48, the short coil 32, the middle coil 48, and the long coil 34 from the neutral point 44 side. Furthermore, in the W-phase 42W, the four coils 16 are connected in series in the order of the long coil 34, the middle coil 48, the short coil 32, and the middle coil 48 from the neutral point 44 side. Also in this embodiment, the combined resistances of the coil connections 46U, 46V, and 46W of each phase are the same.

[0097] 30, the short coil 32 of the U-phase 42U and the long coil 34 of the V-phase 42V are disposed adjacent to each other in the circumferential direction along the stator core 26. In addition, the middle coil 48 on the opposite side of the neutral point 44 in the W-phase 42W is disposed so as to straddle the short coil 32 of the U-phase 42U and the long coil 34 of the V-phase 42V.

[0098] The long coil 34 of the V-phase 42V and the short coil 32 of the W-phase 42W are disposed adjacent to each other in the circumferential direction along the stator core 26. The intermediate coil 48 on the opposite side of the neutral point 44 in the U-phase 42U is disposed so as to straddle the long coil 34 of the V-phase 42V and the short coil 32 of the W-phase 42W.

[0099] The short coil 32 of the W-phase 42W and the long coil 34 of the U-phase 42U are disposed adjacent to each other in the circumferential direction along the stator core 26. The middle coil 48 on the opposite side of the neutral point 44 in the V-phase 42V is disposed so as to straddle the short coil 32 of the W-phase 42W and the long coil 34 of the U-phase 42U.

[0100] The long coil 34 of the U-phase 42U and the short coil 32 of the V-phase 42V are disposed adjacent to each other in the circumferential direction along the stator core 26. In the W-phase 42W, the intermediate coil 48 on the neutral point 44 side is disposed so as to straddle the long coil 34 of the U-phase 42U and the short coil 32 of the V-phase 42V.

[0101] The short coil 32 of the V-phase 42V and the long coil 34 of the W-phase 42W are disposed adjacent to each other in the circumferential direction along the stator core 26. In the U-phase 42U, the middle coil 48 on the neutral point 44 side is disposed so as to straddle the short coil 32 of the V-phase 42V and the long coil 34 of the W-phase 42W.

[0102] The long coil 34 of the W-phase 42W and the short coil 32 of the U-phase 42U are disposed adjacent to each other in the circumferential direction along the stator core 26. In the V-phase 42V, the intermediate coil 48 on the neutral point 44 side is disposed so as to straddle the long coil 34 of the W-phase 42W and the short coil 32 of the U-phase 42U.

[0103] In the motor of the fifth embodiment configured including the stator 14 described above, the deterioration of torque ripple can also be suppressed.

[0104] (Motor of the sixth embodiment and motor of the seventh embodiment) 31 and 32, a motor 84 of the sixth embodiment and a motor 86 of the seventh embodiment are formed using the same short coils 32 and long coils 34. In this case, by adjusting the circumferential length of the stator core 26, etc., it is possible to manufacture a plurality of types of motors 84, 86 with different outputs and sizes using the same short coils 32 and long coils 34.

[0105] The configurations of the motor 10 and the like in each of the embodiments described above can be combined with each other. This combination can be set appropriately taking into consideration the output and size required of the motor. Furthermore, the configurations of the motor 10 and the like in each of the embodiments described above can be applied not only to inner rotor type motors but also to outer rotor type motors.

[0106] In the above-described examples, the coil end portions 38 of the coil 16 are bent at approximately right angles toward the axial end face of the stator core 26, bent at approximately right angles toward the opposite side of the stator core 26, and one of the coil end portions 38 is not bent. However, the present invention is not limited to these examples. For example, in the example shown in Fig. 33, a pair of coil end portions 38 of the short coil 32 are bent toward the axial end face of the stator core 26 so as to be inclined with respect to the axial direction, and a pair of coil end portions 38 of the long coil 34 are bent toward the axial end face of the stator core 26 so as to be inclined with respect to the axial direction. In this way, whether or not the pair of coil end portions 38 of the coil 16 are bent, and the bending direction and bending angle may be appropriately set in consideration of the physical size required for the motor, etc.

[0107] In each of the above-described embodiments, the configuration has been described in which the side on which the magnet 18 is provided is the rotor 12, and the side on which the coil 16 is provided is the stator 14, but the configuration of the present disclosure can also be applied to a configuration in which the side on which the coil 16 is provided is the rotor 12, and the side on which the magnet 18 is provided is the stator 14. Needless to say, the configuration of the present disclosure can also be applied to a generator in which the rotor is rotated by an external force.

[0108] While one embodiment of the present disclosure has been described above, the present disclosure is not limited to the above, and it goes without saying that the present disclosure can be implemented in various other modified forms without departing from the spirit and scope of the present disclosure. [Explanation of symbols]

[0109] 10 motor, 12 rotor, 14 stator, 16 coil, 18 magnet, 26 stator core, 28J terminal locking portion, 30 winding, 36 opposing portion, 38 coil end portion, 40 terminal portion, 40A winding start terminal portion, 40B winding end terminal portion, 90 winding frame, 90A winding frame shaft, 92 first winding frame, 94 second winding frame, 96 bus bar (connection portion), 96A joint portion, 96B circumferential connection portion, 102 coating

Claims

1. a plurality of coils (16) each having a pair of opposing portions (36) formed by winding a conductive winding (30) in an annular shape, the pair of opposing portions (36) forming an axial central portion and arranged at a distance in the circumferential direction, a pair of coil end portions (38) connecting the pair of opposing portions in the circumferential direction on one axial side and the other axial side, respectively, and a pair of terminal portions (40) drawn out from the pair of opposing portions to one axial side, the plurality of coils each having a pair of terminal portions arranged at the same radial position; a connection portion (96) arranged on one axial side of the plurality of coils and connecting a pair of the terminal portions of the plurality of coils in a specific connection pattern; The present invention is applied to a manufacturing method of a stator in which at least one of the coil end portions is bent toward one radial direction side with respect to a pair of the opposing portions, A first winding frame (92) and a second winding frame (94) engaged with the first winding frame are used, a winding frame engaging step of engaging the second winding frame with the first winding frame; a winding process for winding the winding around the first winding frame and the second winding frame to form the coil having a pair of the opposing portions and the coil end portions bent in a radial direction relative to the pair of the opposing portions; a winding frame separating step of separating the second winding frame from the first winding frame; a coil removing step of removing the coil from the first winding frame; A method for manufacturing a stator having the above structure.

2. a plurality of coils (16) each having a pair of opposing portions (36) formed by winding a conductive winding (30) in an annular shape, the pair of opposing portions (36) forming an axial central portion and arranged at a distance in the circumferential direction, a pair of coil end portions (38) connecting the pair of opposing portions in the circumferential direction on one axial side and the other axial side, respectively, and a pair of terminal portions (40) drawn out from the pair of opposing portions to one axial side, the plurality of coils each having a pair of terminal portions arranged at the same radial position; a connection portion (96) arranged on one axial side of the plurality of coils and connecting a pair of the terminal portions of the plurality of coils in a specific connection pattern; Equipped with The plurality of coils include two or more types of coils, at least one of which has a coil end portion bent with respect to a pair of the opposing portions and arranged in a stacked manner, The present invention is applied to a method for manufacturing a stator having a stator core (26) formed in an annular shape, in which at least one of the coil end portions is bent toward the stator core with respect to a pair of the opposing portions, a first coil arrangement step of arranging one type of the coil along the stator core; a second coil arrangement step of bringing the other type of coil closer to the stator core while passing the terminal portion of the one type of coil between the pair of opposing portions of the other type of coil, thereby arranging the other type of coil along the stator core; A method for manufacturing a stator having the above structure.

3. a plurality of coils (16) each having a pair of opposing portions (36) formed by winding a conductive winding (30) in an annular shape, the pair of opposing portions (36) forming an axial central portion and arranged at a distance in the circumferential direction, a pair of coil end portions (38) connecting the pair of opposing portions in the circumferential direction on one axial side and the other axial side, respectively, and a pair of terminal portions (40) drawn out from the pair of opposing portions to one axial side, the plurality of coils each having a pair of terminal portions arranged at the same radial position; a connection portion (96) arranged on one axial side of the plurality of coils and connecting a pair of the terminal portions of the plurality of coils in a specific connection pattern; Equipped with The plurality of coils include two or more types of coils, at least one of which has a coil end portion bent with respect to a pair of the opposing portions and arranged in a stacked manner, The present invention is applied to a method for manufacturing a stator having a stator core formed in an annular shape, in which a pair of the coil end portions are bent toward the stator core with respect to a pair of the opposing portions, Using a reel with a set reel axis, a first winding step of winding the wire around the spool in a circumferential direction of the spool axis with the start terminal portion inclined relative to a direction perpendicular to the spool axis, thereby forming one type of coil having a pair of the opposing portions and a pair of the coil end portions, and tilting the end terminal portion of the one type of coil in the same direction as the start terminal portion; a second winding process for forming another type of coil having a pair of the opposing portions, a pair of the coil end portions, and a pair of the terminal portions; a first coil arrangement step of arranging one type of the coil along the stator core; a second coil arrangement step of bringing the other type of coil closer to the stator core while passing the terminal portion of the one type of coil between the pair of opposing portions of the other type of coil, thereby arranging the other type of coil along the stator core; a terminal portion moving step of moving the terminal portion of one type of the coil toward the opposing portion of each of the coils; A method for manufacturing a stator having the above structure.

4. The present invention is applied to a method for manufacturing a stator having a terminal locking portion to which the terminal portion is locked, 4. The method for manufacturing a stator according to claim 3, further comprising, after the terminal portion moving step, a terminal locking step of locking each of the terminal portions with the terminal locking portions (28J).

5. The method for manufacturing a stator according to claim 4, further comprising a coating removal step of removing an insulating coating (102) around the terminal portion before the terminal fixing step.

6. a plurality of coils (16) each having a pair of opposing portions (36) formed by winding a conductive winding (30) in an annular shape, the pair of opposing portions (36) forming an axial central portion and arranged at a distance in the circumferential direction, a pair of coil end portions (38) connecting the pair of opposing portions in the circumferential direction on one axial side and the other axial side, respectively, and a pair of terminal portions (40) drawn out from the pair of opposing portions to one axial side, the plurality of coils each having a pair of terminal portions arranged at the same radial position; a connection portion (96) arranged on one axial side of the plurality of coils and connecting a pair of the terminal portions of the plurality of coils in a specific connection pattern; Equipped with The plurality of coils include two or more types of coils, at least one of which has a coil end portion bent with respect to a pair of the opposing portions and arranged in a stacked manner, This is applied to a manufacturing method of a stator having a stator core formed in an annular shape, in which the coil end portion on one axial side is bent toward the stator core and the coil end portion on the other axial side is bent toward the opposite side to the stator core or extends linearly from the opposing portion toward the other axial side, a first coil arrangement step of arranging one type of the coil along the stator core; a second coil arrangement step of arranging the other type of coil along the stator core while moving the other type of coil to the other axial side and causing the terminal portion of the one type of coil to pass between the pair of opposing portions of the other type of coil; A method for manufacturing a stator having the above structure.

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