Stator for rotating electric machine, rotating electric machine, method for manufacturing stator for rotating electric machine, and method for manufacturing rotating electric machine

Abstract

A stator (1) molded with a molding resin by using a mold (8) comprises a split coil wound body (11), a terminal holder (5) installed on an anti-load side (Y1) of the split coil wound body (11) in the axial direction (Y), and terminals (4) which have connection parts (42) installed at the terminal holder (5) for connection with the outside and to which terminal wires (31) of coils (3) are wired, the terminal holder (5) including a contact surface portion (52) that has a contact surface (520) in contact with the mold (8), where the connection parts (42) of the terminals (4) are press-fitted from a load side (Y2) to the anti-load side (Y1) in the axial direction (Y), and the connection parts (42) of the terminals (4) are installed so as to protrude on the anti-load side (Y1) in the axial direction (Y).

Description

[Technical Field]

[0001] The present application relates to a stator for a rotating electric machine, a rotating electric machine, a method for manufacturing a stator for a rotating electric machine, and a method for manufacturing a rotating electric machine. [Background technology]

[0002] In conventional resin-molded stators for rotating electrical machines, terminals onto which coil wire ends are wound are inserted into insulators attached to the stator core, or terminal holders are attached to the insulators and fixed in place by the terminal holders. During resin molding, the terminals are covered with protective members to prevent resin from adhering to the connection portions for connecting the terminals to the outside (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5708585 Summary of the Invention [Problem to be solved by the invention]

[0004] In a conventional stator for a rotating electrical machine, the position of the terminals after molding with resin is affected by manufacturing variations in the stator core and insulator, resulting in a problem of reduced positional accuracy of the terminals.

[0005] The present application discloses a technique for solving the above-mentioned problems, The object is to provide a stator for a rotating electric machine, a rotating electric machine, a method for manufacturing a stator for a rotating electric machine, and a method for manufacturing a rotating electric machine that are not affected by manufacturing variations in the stator core and insulator and that can improve the positional accuracy of terminals. [Means for solving the problem]

[0006] Book DisclosureThe stator of a rotating electrical machine is A stator for a rotating electric machine molded with resin using a mold, The coil winding is formed by arranging a plurality of split coil winding bodies in an annular shape, the split core having a yoke portion extending in the circumferential direction and teeth portion protruding radially inward from the inner peripheral surface of the yoke portion on the radially inner side, a counter-load side insulator covering one counter-load side in the axial direction of the split core and a load side insulator covering the other load side in the axial direction, and a coil wound around the teeth portion via the counter-load side insulator and the load side insulator, a terminal holder disposed on the opposite side of the split coil winding body in the axial direction to the load side; a terminal that is installed in the terminal holder, has a connection portion for connecting to an external device, and to which a terminal wire of the coil is wired, The terminal holder includes: the connection portion of the terminal is press-fit from the load side to the anti-load side in the axial direction, and the connection portion of the terminal is installed so as to protrude toward the anti-load side in the axial direction, and the abutment surface portion has an abutment surface having a structure that can abut against the mold, The terminal holder is a stator for a rotating electric machine, which includes a plurality of first protrusions having a structure that allows alignment of the connection portion of the terminal with the mold by abutting on a mold positioning portion of the mold. And, The first protrusion is formed in a cylindrical shape, the split core has a groove provided on an outer peripheral surface of the yoke portion on the radially outer side thereof, the terminal holder includes a plurality of fitting portions that fit into the grooves of the split cores, The center of a circle passing through the centers of the plurality of first protrusions and the center of a circle passing through the centers of the plurality of fitting portions coincide in the axial direction. The stator of the rotating electric machine of the present disclosure is A stator for a rotating electric machine molded with resin using a mold, The coil winding is formed by arranging a plurality of split coil winding bodies in an annular shape, the split core having a yoke portion extending in the circumferential direction and teeth portion protruding radially inward from the inner peripheral surface of the yoke portion on the radially inner side, a counter-load side insulator covering one counter-load side in the axial direction of the split core and a load side insulator covering the other load side in the axial direction, and a coil wound around the teeth portion via the counter-load side insulator and the load side insulator, a terminal holder disposed on the opposite side of the split coil winding body in the axial direction to the load side; a terminal that is installed in the terminal holder, has a connection portion for connecting to an external device, and to which a terminal wire of the coil is wired, The terminal holder includes: the connection portion of the terminal is press-fit from the load side to the anti-load side in the axial direction, and the connection portion of the terminal is installed so as to protrude toward the anti-load side in the axial direction, and the abutment surface portion has an abutment surface having a structure that can abut against the mold, the terminal holder is a stator for a rotating electric machine, the stator including a plurality of first protrusions having a structure that allows alignment of the connection portion of the terminal with the mold by abutting against a mold positioning portion of the mold, The first protrusion is formed to extend from the terminal holder toward the anti-load side in the axial direction, The connection portion of the terminal is formed to extend from the terminal holder toward the anti-load side in the axial direction, The height of the connecting portion of the terminal extending toward the anti-load side in the axial direction is formed to be smaller than the height of the first protruding portion extending toward the anti-load side in the axial direction. The stator of the rotating electric machine of the present disclosure is A stator for a rotating electric machine molded with resin using a mold, The coil winding is formed by arranging a plurality of split coil winding bodies in an annular shape, the split core having a yoke portion extending in the circumferential direction and teeth portion protruding radially inward from the inner peripheral surface of the yoke portion on the radially inner side, a counter-load side insulator covering one counter-load side in the axial direction of the split core and a load side insulator covering the other load side in the axial direction, and a coil wound around the teeth portion via the counter-load side insulator and the load side insulator, a terminal holder disposed on the opposite side of the split coil winding body in the axial direction to the load side; a terminal that is installed in the terminal holder, has a connection portion for connecting to an external device, and to which a terminal wire of the coil is wired, The terminal holder includes: the connection portion of the terminal is press-fit from the load side to the anti-load side in the axial direction, and the connection portion of the terminal is installed so as to protrude toward the anti-load side in the axial direction, and the abutment surface portion has an abutment surface having a structure that can abut against the mold, the terminal holder is a stator for a rotating electric machine, the stator including a plurality of first protrusions having a structure that allows alignment of the connection portion of the terminal with the mold by abutting against a mold positioning portion of the mold, The first protrusion is formed in a cylindrical shape with a bottom that fits into and comes into contact with the mold. Also, The present disclosure Rotating electric machines are The rotating electric machine includes the stator of the above-described rotating electric machine, and a rotor that is rotatably disposed opposite the teeth of the stator with a gap therebetween. Further, a method for manufacturing a stator of a rotating electric machine disclosed in the present application includes: A method for manufacturing the stator of the rotating electric machine described above, the terminal holder includes a first protrusion that abuts against a mold positioning portion of the mold, the split core has a groove provided on an outer peripheral surface of the yoke portion on the radially outer side thereof, When the terminal holder has a fitting portion that fits into the groove portion of the split core, The connection portion of the terminal is press-fitted from the load side to the anti-load side in the axial direction of the abutment surface portion of the terminal holder so that the connection portion protrudes toward the anti-load side in the axial direction, The fitting portion of the terminal holder is fitted into the groove portion of the split core, and the terminal wire of the coil is wired to the terminal, and then Using the mold having a mold contact surface portion on which the mold positioning portion and the mold recess are formed, the first protrusion of the terminal holder is brought into contact with the mold positioning portion of the mold; The connection portion of the terminal is inserted into the mold recess of the mold, and the abutment surface of the terminal holder is abutted against the mold abutment surface of the mold to seal the connection portion and perform molded resin molding. Also, The present disclosure A method for manufacturing a stator for a rotating electric machine includes the steps of: the terminal holder includes a first protrusion that abuts against a mold positioning portion of the mold, the split core has a groove provided on an outer peripheral surface of the yoke portion on the radially outer side thereof, The terminal holder has a fitting portion that fits into the groove of the split core. When the first protrusion is formed in a cylindrical shape, The connection portion of the terminal is press-fitted from the load side to the anti-load side in the axial direction of the abutment surface portion of the terminal holder so that the connection portion protrudes toward the anti-load side in the axial direction, The fitting portion of the terminal holder is fitted into the groove portion of the split core, and the terminal wire of the coil is wired to the terminal, and then Using the mold having a mold contact surface portion on which the mold positioning portion and the mold recess are formed, the cylindrical first protrusion of the terminal holder is inserted into and brought into contact with the mold positioning portion of the mold; The connection portion of the terminal is inserted into the mold recess of the mold, and the abutment surface of the terminal holder is abutted against the mold abutment surface of the mold to seal the connection portion and perform molded resin molding. Also, The present disclosure The manufacturing method of the rotating electric machine is A rotor is rotatably disposed opposite the teeth of the stator of the rotating electric machine manufactured by the above-described manufacturing method of the stator of the rotating electric machine via a gap. [Effects of the Invention]

[0007] According to the stator of a rotating electric machine, the rotating electric machine, the method for manufacturing a stator of a rotating electric machine, and the method for manufacturing a rotating electric machine disclosed in the present application, The positional accuracy of the terminals can be improved without being affected by manufacturing variations in the split coil winding body and insulator. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a perspective view showing the configuration of a stator (before molding) of a rotating electric machine according to Embodiment 1. FIG. [Figure 2]2 is a perspective view showing the configuration of a split core of the stator shown in FIG. 1. FIG. [Figure 3] 2 is a perspective view showing the configuration of a counter-load side insulator of the stator shown in FIG. 1. FIG. [Figure 4] FIG. 2 is a perspective view showing the configuration of a load-side insulator of the stator shown in FIG. [Figure 5] 1. FIG. 4 is a perspective view showing the configuration of another split core of the stator shown in FIG. [Figure 6] 2 is a front view showing the configuration of a terminal of the stator shown in FIG. 1. [Figure 7] 1. FIG. 4 is a front view showing another configuration of the terminal of the stator shown in FIG. [Figure 8] 1. FIG. 4 is a front view showing another configuration of the terminal of the stator shown in FIG. [Figure 9] 2 is a perspective view showing the configuration of a terminal holder of the stator shown in FIG. 1. FIG. [Figure 10] 10A is a perspective view of the terminal holder shown in FIG. 9 as seen from the load side, and FIG. 10B is an enlarged view showing the configuration of a main part of the terminal holder shown in FIG. 10A. [Figure 11] 11A is a perspective view of the stator shown in FIG. 1 as seen from the load side, and FIG. 11B is an enlarged view showing the configuration of a main part of the stator shown in FIG. 11A. [Figure 12] 12A is a cross-sectional perspective view showing a vertical cross section in the axial direction of the stator shown in FIG. 1, and FIG. 12B is an enlarged view showing the configuration of a main part of the stator shown in FIG. 12A. [Figure 13] 2 is a cross-sectional view showing a vertical cross section in the axial direction illustrating the relationship between the stator shown in FIG. 1 and a part of a mold. [Figure 14] 14 is a perspective view showing the configuration of a molded stator molded with resin using the mold shown in FIG. 13. FIG. [Figure 15] 10 is an exploded perspective cross-sectional view showing a vertical cross section in the axial direction illustrating the configuration of another molded stator and housing in the first embodiment. FIG. [Figure 16] 16 is an axial cross-sectional view showing the configuration of a rotating electric machine using the molded stator shown in FIG. 15. [Figure 17]FIG. 10 is a perspective view showing the configuration of a stator (before molding) of a rotary electric machine according to a second embodiment. [Figure 18] 2 is a cross-sectional view showing an axial vertical section illustrating the overall relationship between the stator shown in FIG. 1 and a mold. FIG. [Figure 19] FIG. 11 is a perspective view showing a part of the configuration of a terminal holder of a stator of a rotary electric machine according to a third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] In the following description, unless otherwise specified, the terms axial direction Y, radial direction X, outer side X1, inner side X2, and circumferential direction Z refer to the rotation axis Q (axial direction Y), radius (radial direction X), relatively toward the center of the radial direction X (inner side X2), relatively toward the outside of the radial direction X (outer side X1), and circumference (circumferential direction Z) of the rotation axis Q in a cylindrical coordinate system centered on the rotation axis Q of the stator 1 in Fig. 1. Furthermore, when terms anti-load side Y1 and load side Y2 are used, the top side in the axial direction Y of the stator 1 in Fig. 1 will be described as the anti-load side Y1, and the bottom side as the load side Y2.

[0010] In this application, the stator of the rotating electrical machine before molding with resin will be referred to as stator 1, and the stator 1 after molding with resin in a mold 8 (see FIG. 13) described later will be referred to as molded stator 100 (see FIG. 14).

[0011] Embodiment 1 FIG. 1 is a perspective view showing the configuration of a stator (before molding) of a rotating electric machine according to embodiment 1. FIG. 2 is a perspective view showing the configuration of a split core of the stator shown in FIG. 1. FIG. 3 is a perspective view showing the configuration of a non-load side insulator of the stator shown in FIG. 1. FIG. 4 is a perspective view showing the configuration of a load side insulator of the stator shown in FIG. 1. FIG. 5 is a perspective view showing the configuration of another split core of the stator shown in FIG. 1. FIG. 6 is a front view showing the configuration of a terminal of the stator shown in FIG. 1.

[0012] Fig. 7 is a front view showing another configuration of the terminal of the stator shown in Fig. 1. Fig. 8 is a front view showing another configuration of the terminal of the stator shown in Fig. 1. Fig. 9 is a perspective view showing the configuration of the terminal holder of the stator shown in Fig. 1. Fig. 10A is a perspective view of the terminal holder shown in Fig. 9 as seen from the load side, and Fig. 10B is an enlarged view showing the configuration of the main part of the terminal holder shown in Fig. 10A. Fig. 11A is a perspective view of the stator shown in Fig. 1 as seen from the load side, and Fig. 11B is an enlarged view showing the configuration of the main part of the stator shown in Fig. 11A.

[0013] Fig. 12A is a cross-sectional perspective view showing an axial vertical section of the stator shown in Fig. 1, and Fig. 12B is an enlarged view showing the configuration of a main part of the stator shown in Fig. 12A. Fig. 13 is a cross-sectional view showing an axial vertical section showing the relationship between the stator shown in Fig. 1 and a part of a mold. Fig. 14 is a perspective view showing the configuration of a molded stator molded with resin using the mold shown in Fig. 13. Fig. 14 is an exploded cross-sectional view showing an axial vertical section showing the configuration of the molded stator and housing shown in Fig. 13. Fig. 14 is an axial cross-sectional view showing the configuration of a rotating electric machine using the molded stator shown in Fig. 13.

[0014] Fig. 15 is an exploded perspective sectional view showing an axial vertical section illustrating the configuration of another molded stator and housing according to embodiment 1. Fig. 16 is an axial vertical section illustrating the configuration of a rotating electric machine using the molded stator shown in Fig. 15. Fig. 18 is a sectional view showing an axial vertical section illustrating the overall relationship between the stator shown in Fig. 1 and the mold.

[0015] First, the mold 8 used for molding the resin will be described with reference to Figures 13 and 18. The mold 8 has a mold positioning portion 81, a mold recess 82, a mold abutment surface portion 84 having a mold abutment surface 83, and a core rod portion 85. Each portion will be described together with the configuration of the stator 1, which will be described later.

[0016] In Fig. 1, the stator 1 includes a split coil winding body 11, a terminal 4, and a terminal holder 5. The stator 1 is formed by arranging a plurality of split coil winding bodies 11 in a ring shape in the circumferential direction Z. The split coil winding body 11 includes a split core 10, a counter-load side insulator 201, a load side insulator 202, and a coil 3. Note that when referring to both the counter-load side insulator 201 and the load side insulator 202, they are referred to as insulator 2.

[0017] 2, the split core 10 includes a yoke portion 12 extending in the circumferential direction Z, i.e., extending in an arc shape, a groove portion 13 extending in the axial direction Y provided on the outer peripheral surface of the yoke portion 12 on the outer side X1 in the radial direction X, and teeth portions 14 protruding from the yoke portion 12 on the inner side X2 in the radial direction X, i.e., toward the rotation axis Q. The split core 10 is formed of a magnetic material such as an electromagnetic steel plate.

[0018] The split core 10 is provided with a counter-load side insulator 201 disposed on the counter-load side Y1 in the axial direction Y as shown in Fig. 3, and a load side insulator 202 disposed on the load side Y2 in the axial direction Y of the split coil winding body 11 as shown in Fig. 4. The insulator 201 is formed of an insulating material such as resin.

[0019] 3 and 4, the insulator 2 includes a winding frame portion 21 that supports the wound coil 3, an inner flange portion 22 that extends in the circumferential direction Z on the inner side X2 in the radial direction X and rises in the axial direction Y, and an outer flange portion 23 that extends in the circumferential direction Z on the outer side X1 in the radial direction X and rises in the axial direction Y. The insulator 2 is shaped to cover parts of the yoke portions 12 and teeth portions 14 of the split core 10, and is fitted into and installed on the anti-load side Y1 and load side Y2 of the split core 10 in the axial direction Y.

[0020] As shown in Fig. 3, the non-load side insulator 201 has a hook groove 25 as a first engagement portion for engaging the terminal holder 5 and the non-load side insulator 201 with a snap-fit ​​mechanism. As shown in Fig. 4, the load side insulator 202 has a pressing portion 24 formed to protrude toward the load side Y2 in the axial direction Y for pressing the mold 8 during molding of the molded resin (see Fig. 18 for the relationship between the pressing portion 24 and the mold 8). Although Fig. 3 shows an example of a cylindrical shape for the pressing portion 24, the shape is not limited to this and may be, for example, a polygonal columnar shape as long as it fulfills the same function.

[0021] The coil 3 is formed by winding an electric wire made of a conductive material such as copper or aluminum around the teeth 14 of the split core 10 via a counter-load side insulator 201 and a load side insulator 202. The multiple split coil winding bodies 11 can be fixed in an annular manner in the circumferential direction Z by any method, such as welding split coil winding bodies 11 adjacent to each other in the circumferential direction Z. Alternatively, as shown in FIG. 5 , a convex portion 15 and a concave portion 16 may be provided on the side surfaces of split cores 10 adjacent to each other in the circumferential direction Z, and these convex portions 15 and concave portions 16 may be fitted together.

[0022] In this embodiment, as shown in Fig. 1, the stator 1 is configured with three sets of four split cores 10 each having a coil 3 wound continuously around them, totaling 12 split coil winding bodies 11 arranged in an annular shape. The coil 3 has two terminal wires 31 per set, one at the start and one at the end of the winding, so there are a total of six terminal wires 31 in the split coil winding body 11.

[0023] Terminal 4 is made of a conductive material such as copper, and has a shape as shown in Figures 6 and 7. Terminal 4 has a winding portion 41 for winding around terminal wire 31 of coil 3, a connection portion 42 for connecting to the outside after molding with the molded resin, and a hook portion 43 for hooking terminal wire 31. Terminal 4 in Figures 6 and 7 shows an example in which connection portion 42 has a tab terminal shape. However, other figures of the first embodiment show an example in which terminal 4 shown in Figure 7 is used.

[0024] 9 and 10, the terminal holder 5 is made of an insulating material such as resin, and has an annular shape and includes an insertion hole 51 into which the connection portions 42 of the three terminals 4 are inserted, and an abutment surface portion 52 having an abutment surface 520. As shown in FIG. 13, the abutment surface 520 of the abutment surface portion 52 is formed so as to abut against the mold abutment surface 83 when the connection portions 42 of the terminals 4 are inserted into the mold recesses 82 of the mold abutment surface portion 84. The abutment surface 520 of the abutment surface portion 52 is shaped to cover the periphery of the connection portions 42 of the terminals 4.

[0025] The insertion hole 51 is formed with dimensions that allow for a tight fit with the connection portion 42 of the terminal 4. The connection portion 42 of the terminal 4 is inserted by press-fitting so as to penetrate from the load side Y2 to the anti-load side Y1 in the axial direction Y of the contact surface portion 52 of the terminal holder 5. This allows the terminal 4 to be installed without any gaps between the insertion hole 51, preventing resin from passing through the insertion hole 51 and adhering to the connection portion 42 of the terminal 4 during molding.

[0026] 10 is a perspective view showing the configuration of the terminal holder 5 as seen from the load side Y2 in the axial direction Y. As shown in the figure, a slit 53 conforming to the shape of the terminal 4 is formed on the load side Y2 in the axial direction Y of the abutting surface portion 52. A suppression portion 54 that suppresses tilt of the terminal 4 is formed in a part of the slit 53. This prevents the terminal 4 from tilting after it is inserted.

[0027] 11B, the terminal holder 5 includes a support portion 55. As shown in the figure, the support portion 55 and the bottom surface 44 of the terminal 4 form a second engagement portion that engages the terminal 4 and the terminal holder 5 by a snap-fit ​​mechanism. This deforms as it is pressed by the side surface of the terminal 4 when the terminal 4 is inserted, and when the terminal 4 is pushed in until it contacts the terminal holder 5, the support portion 55 enters the bottom surface 44 of the terminal 4. This allows the support portion 55 to be disposed on the bottom surface 44 of the terminal 4 without compromising the ease of insertion of the terminal 4, and prevents the terminal 4 from falling off due to a load on the load side Y2 (downward) in the axial direction Y that is applied when winding the terminal wire 31 around the terminal 4.

[0028] As shown in Fig. 9, the outer periphery of the terminal holder 5 is provided with a plurality of first protrusions 56 that come into contact with mold positioning portions 81 (see Fig. 13) of the mold 8. Note that Fig. 13 shows an example in which the mold positioning portions 81 are formed by pins, but this is not limited to this and the first protrusions 56 may be formed by holes. Fig. 9 shows an example in which the first protrusions 56 are tubular, specifically a cylindrical shape, but this is not limited to this and the first protrusions 56 may be a pillar shape without a hole or a polygonal pillar shape.

[0029] 9 shows an example in which the first protrusions 56 are formed in four locations, but the number is not limited to this and can be two or more locations as long as the position relative to the mold 8 can be determined. Furthermore, the first protrusions 56 provided on the terminal holder 5 only need to be formed so that they fit into or abut against the mold positioning portion 81 provided on the mold 8 side during molding with the molded resin. This allows the position of the terminal holder 5 to be aligned with the mold 8 during molding with the molded resin, and the positions of the terminals 4 inserted into the terminal holder 5 are also aligned with the mold 8, so that the positions of the terminals 4 after molding with the molded resin are not affected by other components. Furthermore, if the position of the terminal 4 is not affected by other components, for example by controlling the position during molding with a mold resin using an image sensor, the first protrusion 56 may not be necessary.

[0030] 9 and 10, the outer periphery of the terminal holder 5 is provided with three fitting portions 58 that fit into the grooves 13 of the split core 10. Also, as shown in FIGS. 10 and 12, the outer periphery of the terminal holder 5 is provided with three engaging portions 57 that engage with the hooking grooves 25 of the anti-load side insulator 201. As shown in FIG. 12B, the engaging portions 57 are fitted into the hooking grooves 25 of the anti-load side insulator 201, and prevent the terminal holder 5 from being unintentionally detached when an external force is applied to the terminal holder 5 in a direction away from the split coil winding body 11. Thus, the hooking grooves 25 and the engaging portions 57 form a first engaging portion that engages the terminal holder 5 and the anti-load side insulator 201 with a snap-fit ​​mechanism.

[0031] As shown in FIG. 9 , the fitting portion 58 is formed for the purpose of aligning the center of a circle passing through the centers of the four first protrusions 56 of the terminal holder 5 with the center of the inner diameter of the split coil winding body 11, which has multiple first protrusions arranged in a ring shape. As shown in FIG. 13 , the mold 8 is formed with a core rod portion 85 that fits into the inner periphery of the split coil winding body 11 of the stator 1. When the stator 1 of FIG. 1 is inserted into the mold 8, the inner periphery of the split coil winding body 11 is positioned not only by the first protrusions 56 of the terminal holder 5 described above but also by the core rod portion 85. In other words, if the center of the circle passing through the four first protrusions 56 of the terminal holder 5 does not match the center of the inner diameter of the split coil winding body 11, the workability of inserting the stator 1 into the mold 8 deteriorates. Therefore, to prevent this, the fitting portion 58 that fits into the groove portion 13 of the split coil winding body 11 is provided.

[0032] The fitting portion 58 is formed in the shape of a rectangular prism that fits into the groove 13 of the split coil winding body 11, as shown in FIG. 1. The inner and outer peripheral surfaces and side surfaces of the fitting portion 58 are tapered, and either the left or right side surface at the tip of the fitting portion 58 is tapered to a greater extent, thereby improving the ease of insertion into the groove 13. The height of the fitting portion 58 in the axial direction Y is set to a height at which insertion into the groove 13 of the split coil winding body 11 begins before the engaging portion 57 shown in FIG. 9 comes into contact with the anti-load side insulator 201. This allows the position of the terminal holder 5 relative to the split coil winding body 11 to be determined first, improving the ease of formation of the first engaging portion by a snap-fit ​​mechanism between the hooking groove 25 of the anti-load side insulator 201 and the engaging portion 57 of the terminal holder 5.

[0033] The terminal holder 5 is also provided with a second protrusion 512, a third protrusion 59, and a fourth protrusion 510. The pair of second protrusions 512 is provided to sandwich the neutral point 32 (hereinafter referred to as the neutral point 32) of a connection formed by twisting three terminal wires 31. The gap between the pair of second protrusions 512 is formed to be sized so that the neutral point 32 can be sandwiched and sandwiched by intermediate fitting. The height of the second protrusions 512 in the axial direction Y is formed lower than the height of the first protrusions 56 in the axial direction Y. The third protrusions 59 and the fourth protrusions 510 prevent the terminal wires 31 from moving outward X1 in the radial direction X and from floating up to the anti-load side Y1 in the axial direction Y after wiring the terminal wires 31 or during molding with a molded resin, as described below.

[0034] While the third protrusion 59 is shown in FIG. 1 as having a cylindrical shape, the shape is not limited thereto and may be a polygonal prism. The height of the third protrusion 59 in the axial direction Y is at least twice the wire diameter of the lead wire 31 and is lower than the height of the first protrusion 56 in the axial direction Y. This configuration prevents the lead wire 31 from unintentionally climbing over the third protrusion 59 and moving outward X1 in the radial direction X. The fourth protrusion 510 has an inverted L-shape as shown in FIG. 9 and includes a wall perpendicular to the axial direction Y. This suppresses movement of the lead wire 31 toward the anti-load side Y1 in the axial direction Y. The height of the fourth protrusion 510 in the axial direction Y is lower than the height of the first protrusion 56 in the axial direction Y.

[0035] A method for manufacturing the rotating electric machine stator and rotating electric machine configured as described above will now be described. First, as shown in FIG. 1, a plurality of split coil winding bodies 11 are arranged in a ring shape and fixed. Next, the connection portion 42 of the terminal 4 is press-fitted into the insertion hole 51 of the terminal holder 5 from the load side Y2 toward the anti-load side Y1 in the axial direction Y. The terminal 4 is then held via the slit 53 and the suppression portion 54. Furthermore, the terminal holder 5 and the terminal 4 are joined together by a snap-fit ​​mechanism, forming a second engagement portion where the bottom surface 44 of the terminal 4 engages with the support portion 55, as shown in FIG.

[0036] Next, the fitting portion 58 of the terminal holder 5 is inserted into the groove portion 13 of the split core 10 of the annularly arranged split coil winding body 11. Then, the terminal holder 5 and the non-load side insulator 201 are connected by a snap-fit ​​mechanism, with the engaging portion 57 engaging with the hooking groove 25 to form a first engaging portion, as shown in FIG.

[0037] Next, the wire terminals 31 of the coil 3 are wired. First, as shown in Fig. 1, after the terminal holder 5 with the terminals 4 inserted is assembled to the split coil winding body 11, the wire terminals 31 of the coil 3 are pulled out from the notched portions 511 of the terminal holder 5. Then, three of the six wire terminals 31 of the coil 3 are wired on the terminal holder 5 to their corresponding terminals 4 and are entangled in the entanglement portions 41 of the terminals 4.

[0038] In the first embodiment, the terminal 4 as shown in Fig. 7 is used, and therefore, in the plane of the paper in the axial direction Y, the terminal wire 31 is hooked on the lower hook portion 43, and then placed on the notch of the entanglement portion 41, folded back, and hooked on the hook portion 43 near the entanglement portion 41 for installation. Note that, in the case of using the terminal 4 as shown in Fig. 6, the terminal wire 31 is hooked on the hook portion 43, passed through the hole in the entanglement portion 41, and then folded downward from the terminal 4 for installation.

[0039] The remaining three terminal wires 31 that are not entangled with the terminal 4 are routed on the terminal holder 5 up to a position for creating the neutral point 32, and the three terminal wires 31 are twisted together. When wiring the terminal wires 31, they are routed so as to come into contact with the inner side X2 in the radial direction X of the third protrusion 59 on the terminal holder 5 and the outer side X1 in the radial direction X of the fourth protrusion 510.

[0040] The neutral point 32 of the connection, which is created by twisting the three terminal wires 31, is sandwiched between a pair of second protrusions 512 by intermediate fitting. This makes it easier to maintain the neutral point 32 parallel to the axial direction Y, improving the ease of soldering. After the terminal wires 31 are wired, the terminal wires 31 of the binding portion 41 of the terminal 4 are soldered to the neutral point 32.

[0041] After the soldering, as shown in FIG. 13, the stator 1 is placed in the mold 8 so that the cylindrical first protrusion 56 of the terminal holder 5 is aligned with the corresponding mold positioning portion 81 of the mold 8. Then, the first protrusion 56 is inserted into the mold positioning portion 81 and brought into contact with it. At this time, the connection portion 42 of the terminal 4 is inserted into the mold recess 82 formed in the mold contact surface portion 84 of the mold 8. Then, the mold contact surface 83 of the mold contact surface portion 84 of the mold 8 and the contact surface 520 of the contact surface portion 52 of the terminal holder 5 are brought into close contact with each other. In this state, the molded stator 100 is formed by molding with a molded resin, as shown in FIG.

[0042] As described above, by forming molded stator 100 by placing mold 8 on stator 1, terminal 4 can be positioned after resin molding without being affected by split coil winding body 11, insulator 2, etc. Furthermore, adhesion of resin to connection portion 42 of terminal 4 can be prevented without the need for a protective member for connection portion 42 of terminal 4. Furthermore, by press-fitting terminal 4 into terminal holder 5 and abutting contact surface 520 of abutment surface portion 52 of terminal holder 5 against mold abutment surface 83 of mold abutment surface portion 84 of mold 8 for close contact, the entire periphery of connection portion 42 of terminal 4 can be sealed, and adhesion of resin to connection portion 42 of terminal 4 can be prevented without the need for a protective member for connection portion 42.

[0043] As another example, a case will be described in which terminal 4 uses connecting portion 420 having a bifurcated shape (tuning fork terminal shape) as shown in Fig. 8. As in the above case, molded stator 100 is formed as shown in Fig. 15. Then, tab terminal 61 mounted on substrate 62 built into bracket 102 is assembled to connecting portion 420 of terminal 4 of molded stator 100. Specifically, as shown in Fig. 16, tab terminal 61 and connecting portion 420 of terminal 4 on the stator 1 side are aligned, and tab terminal 61 and connecting portion 420 are fitted together for assembly.

[0044] 16, tab terminal 61 is formed in a direction perpendicular to the spacing direction of the bifurcated shape of connection portion 420 of terminal 4 of stator 1, and has a plate thickness equal to or greater than the gap at the tip of the bifurcated shape of connection portion 420. Rotor 111, which is rotatably arranged opposite teeth portion 14 of molded stator 100 with a gap therebetween, is then assembled, and bracket 102 is fitted to form rotating electric machine 110. When rotating electric machine 110 is formed in this way, parts such as lead wires can be reduced, which also leads to a reduction in labor hours.

[0045] The tab terminal 61 and the bracket 102 may be integrally formed as shown in Fig. 15, or may be formed separately. An electronic circuit may be provided in addition to the tab terminal 61. If the connection portion 42 of the terminal 4 of the stator 1 shown above has a tab terminal shape as shown in Figs. 6 and 7, it may be connected to the tab terminal 61 of the bracket 102 using, for example, a lead wire.

[0046] According to the stator of the rotating electric machine of the first embodiment configured as described above, A stator for a rotating electric machine molded with resin using a mold, a split core having a yoke portion extending in the circumferential direction, a groove portion provided on the outer peripheral surface of the yoke portion in the radial direction, and teeth portions protruding radially inward from the inner peripheral surface of the yoke portion in the radial direction, a counter-load side insulator covering one counter-load side in the axial direction of the split core and a load side insulator covering the other load side in the axial direction, and a coil wound around the teeth portions via the counter-load side insulator and the load side insulator, a terminal holder disposed on the opposite side of the split coil winding body in the axial direction to the load side; a terminal that is installed in the terminal holder, has a connection portion for connecting to an external device, and to which a terminal wire of the coil is wired, The terminal holder includes: a fitting portion that fits into the groove portion of the split core; a first protrusion that abuts against a mold positioning portion of the mold; The connection portion of the terminal is press-fit from the load side to the anti-load side in the axial direction, and the connection portion of the terminal is provided with an abutment surface portion that protrudes to the anti-load side in the axial direction and has an abutment surface that abuts against the mold. Moreover, according to the rotating electric machine of the first embodiment, The rotating electric machine includes the stator of the above-described rotating electric machine and a rotor rotatably disposed opposite the teeth portion of the stator via a gap. The position of the terminal during molding of the molded resin is determined by the first protrusion and the mold positioning portion of the mold used during molding of the molded resin, regardless of the stator and insulator, so the positioning accuracy of the terminal is improved without being affected by manufacturing variations in the stator and insulator.

[0047] Furthermore, according to the stator of the rotating electric machine of the first embodiment configured as described above, The first protrusion is formed in a cylindrical shape, Furthermore, according to the method for manufacturing the stator of the rotating electric machine of the first embodiment, A method for manufacturing the stator of the rotating electric machine described above, The connection portion of the terminal is press-fitted from the load side to the anti-load side in the axial direction of the abutment surface portion of the terminal holder so that the connection portion protrudes toward the anti-load side in the axial direction, The fitting portion of the terminal holder is fitted into the groove portion of the split core, and the terminal wire of the coil is wired to the terminal, and then Using the mold having a mold contact surface portion on which the mold positioning portion and the mold recess are formed, the cylindrical first protrusion of the terminal holder is inserted into and brought into contact with the mold positioning portion of the mold; The connection portion of the terminal is inserted into the mold recess of the mold, and the contact surface of the terminal holder is contacted with the mold contact surface of the mold to seal the connection portion, thereby performing mold resin molding. This further improves the positioning accuracy between the first protrusion of the terminal holder and the mold positioning portion of the mold.

[0048] Furthermore, according to the method for manufacturing the stator of the rotating electric machine of the first embodiment configured as described above, A method for manufacturing the stator of the rotating electric machine described above, The connection portion of the terminal is press-fitted from the load side to the anti-load side in the axial direction of the abutment surface portion of the terminal holder so that the connection portion protrudes toward the anti-load side in the axial direction, The fitting portion of the terminal holder is fitted into the groove portion of the split core, and the terminal wire of the coil is wired to the terminal, and then Using the mold having a mold contact surface portion on which the mold positioning portion and the mold recess are formed, the first protrusion of the terminal holder is brought into contact with the mold positioning portion of the mold; The connecting portion of the terminal is inserted into the mold recess of the mold, and the abutting surface of the terminal holder is abutted against the mold abutting surface of the mold to perform molding resin molding. By pressing the connection portion of the terminal into the abutment surface of the terminal holder and tightly adhering the abutment surface of the terminal holder to the mold, the entire area around the connection portion of the terminal can be sealed, and resin adhesion to the terminal can be prevented without the need for a protective member for the connection portion of the terminal.

[0049] Furthermore, according to the stator of the rotating electric machine of the first embodiment configured as described above, The terminal holder and the non-load side insulator are provided with a first engaging portion engaged with each other by a snap-fit ​​mechanism, When the axially opposite load side of the assembled terminal holder faces downward, the terminal holder can be prevented from falling off the split coil winding body.

[0050] Furthermore, according to the stator of the rotating electric machine of the first embodiment configured as described above, the terminal holder sandwiches a neutral point of a connection of a terminal wire of the coil and includes a pair of second protrusions that are lower in height than the first protrusions; The neutral point is fitted into the gap between the pair of second protrusions by intermediate fitting. Furthermore, when soldering the neutral point, the orientation of the neutral point can be prevented from tilting relative to the rotation axis, improving the ease of soldering work.

[0051] Furthermore, according to the stator of the rotating electric machine of the first embodiment configured as described above, The terminal includes a entanglement portion for entangling the end wire of the coil and a hook portion for hooking the end wire of the coil. The wires can be prevented from moving when they are entangled with the terminals, improving the workability of entangling the wires. The wires can also be prevented from moving during molding with a resin, improving the workability of molding with a resin.

[0052] Furthermore, according to the stator of the rotating electric machine of the first embodiment configured as described above, The terminal holder and the terminal are provided with a second engaging portion that is engaged with each other by a snap-fit ​​mechanism. When the terminal wire is entangled with the terminal, the terminal can be prevented from tilting or falling off.

[0053] Furthermore, according to the stator of the rotating electric machine of the first embodiment configured as described above, a third protrusion, the third protrusion being higher than twice the wire diameter of the terminal wire of the coil and lower than the first protrusion, on the axial anti-load side of the terminal holder; The terminal wire is brought into contact with the third protrusion and wired to the terminal, The wires can be prevented from moving when they are entangled with the terminals, improving the workability of entangling the wires. The wires can also be prevented from moving during molding with a resin, improving the workability of molding with a resin.

[0054] Furthermore, according to the stator of the rotating electric machine of the first embodiment configured as described above, a fourth protrusion having a height lower than that of the first protrusion, which is inverted L-shape, on the axially opposite load side of the terminal holder; The terminal wire is brought into contact with the fourth protrusion and wired to the terminal, This can prevent the wired terminals from floating in the axial direction during molding with the molded resin, improving the workability of molding with the molded resin.

[0055] Furthermore, according to the stator of the rotating electric machine of the first embodiment configured as described above, The connection portion of the terminal is formed in a bifurcated shape, The bracket has tab terminals fixed in a direction perpendicular to the spacing direction of the bifurcated shape of the connecting portion of the terminal. When connecting the connecting portion of the terminal to the tab terminal of the bracket, the connecting portion and the tab terminal can be connected without using other parts such as lead wires, which reduces the number of parts and the number of work steps.

[0056] Furthermore, according to the stator of the rotating electric machine of the first embodiment configured as described above, The contact surface of the contact surface portion is shaped to cover the periphery of the connection portion of the terminal. The positioning accuracy of the mold with respect to the mold positioning portion can be further improved.

[0057] Embodiment 2 In the second embodiment, the shape of the fitting portion 580 of the terminal holder 5 that fits into the groove portion 13 of the split core 10 of the split coil winding body 11 is formed in a bifurcated shape as shown in FIG. 17. Note that other parts are the same as those in the first embodiment, and therefore description thereof will be omitted as appropriate. With the shape of the fitting portion 58 of the terminal holder 5 in the first embodiment, when the split coil winding body 11 fits into the groove portion 13 of the split core 10, the insertion force is increased from the point where the circumferential side surface of the fitting portion 58 comes into contact with the split core 10, and the split coil winding body 11 is pushed in. However, by forming the fitting portion 580 shown in FIG. 17 into a bifurcated shape, the distance between the bifurcated portions is shortened and the load when inserting the terminal holder 5 can be reduced.

[0058] According to the stator of the rotating electric machine of the second embodiment configured as described above, In addition to providing the same effects as those of the first embodiment, The fitting portion of the terminal holder is formed in a bifurcated shape, When the fitting portion is inserted into the groove of the split coil winding body, the fitting portion is deformed by the amount of interference with the groove, improving the ease of insertion.

[0059] Embodiment 3 Fig. 19 is a perspective view showing a part of the configuration of a terminal holder of a stator of a rotating electric machine according to embodiment 3. In this embodiment 3, a fifth protrusion 550 as shown in Fig. 19 is formed at the location of the insertion hole 51 of the terminal holder 5 shown in each of the above embodiments. That is, the terminal holder 5 includes the fifth protrusion 550 formed on the anti-load side Y1 in the axial direction Y of the terminal holder 5, inside the abutment surface 520 of the abutment surface portion 52 and around the connection portion 42 of the terminal 4. Note that since the other parts are the same as those in each of the above embodiments, description thereof will be omitted as appropriate.

[0060] With the shape of insertion hole 51 in each of the above embodiments, when condensation occurs on contact surface 520 of terminal holder 5 and water droplets form, terminals 4 may connect with each other through the water droplets on contact surface 520, which may cause electrical connection between terminals 4 and short circuit. When fifth protrusion 550 shown in Fig. 19 of present embodiment 3 is provided, fifth protrusion 550 prevents terminals 4 from connecting with each other through water droplets, thereby preventing short circuit.

[0061] According to the stator of the rotating electric machine of the third embodiment configured as above, The same effects as those of the above embodiments can be achieved, and The terminal holder includes a fifth protrusion formed on the axial anti-load side of the terminal holder, inside the contact surface of the contact surface portion, and around the connection portion of the terminal, When condensation occurs on the contact surface of the terminal holder, it prevents the terminals from electrically connecting and shorting out, ensuring the integrity of the product.

[0062] Although the present application describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are conceivable within the scope of the technology disclosed in this application, including, for example, cases where at least one component is modified, added, or omitted, and cases where at least one component is extracted and combined with a component of another embodiment. [Explanation of symbols]

[0063] 1 stator, 10 divided core, 100 molded stator, 11 divided coil winding body, 110 rotating electric machine, 111 rotor, 12 yoke portion, 13 groove portion, 14 teeth portion, 15 convex portion, 16 concave portion, 2 insulator, 201 anti-load side insulator, 202 load side insulator, 21 winding frame portion, 22 inner flange portion, 23 outer flange portion, 24 pressing portion, 25 hooking groove, 3 coil, 31 terminal wire, 32 neutral point, 4 terminal, 41 entanglement portion, 42 connection portion, 420 connection portion, 43 hook portion, 44 bottom surface, 5 terminal holder, 51 insertion hole, 510 fourth protrusion portion, 511 notch portion, 512 second protrusion portion, 52 abutting surface portion, 520 abutting surface, 53 Slit, 54 suppression portion, 55 support portion, 550 fifth protrusion portion, 56 first protrusion portion, 57 engagement portion, 58 mating portion, 580 mating portion, 59 third protrusion portion, 61 tab terminal, 62 substrate, 8 mold, 81 mold positioning portion, 82 mold recess, 83 mold contact surface, 84 mold contact surface portion, 85 core rod portion, Q rotation axis, X radial direction, X1 outer side, X2 inner side, Y axial direction, Y1 anti-load side, Y2 load side, Z circumferential direction.

Claims

1. A stator for a rotating electric machine molded with resin using a mold, The coil winding is formed by arranging a plurality of split coil winding bodies in an annular shape, the split core having a yoke portion extending in the circumferential direction and teeth portion protruding radially inward from the inner peripheral surface of the yoke portion on the radially inner side, a counter-load side insulator covering one counter-load side in the axial direction of the split core and a load side insulator covering the other load side in the axial direction, and a coil wound around the teeth portion via the counter-load side insulator and the load side insulator, a terminal holder disposed on the opposite side of the split coil winding body in the axial direction to the load side; a terminal that is installed in the terminal holder, has a connection portion for connecting to an external device, and to which a terminal wire of the coil is wired, The terminal holder includes: the connection portion of the terminal is press-fit from the load side to the anti-load side in the axial direction, and the connection portion of the terminal is installed so as to protrude toward the anti-load side in the axial direction, and the abutment surface portion has an abutment surface having a structure that can abut against the mold, the terminal holder is a stator for a rotating electric machine, the stator including a plurality of first protrusions having a structure that enables alignment of the connection portion of the terminal with the mold by abutting against a mold positioning portion of the mold, The first protrusion is formed in a cylindrical shape, the split core has a groove provided on an outer peripheral surface of the yoke portion on the radially outer side thereof, the terminal holder includes a plurality of fitting portions that fit into the grooves of the split cores, A stator for a rotating electric machine, wherein the center of a circle passing through the centers of the plurality of first protrusions and the center of a circle passing through the centers of the plurality of fitting portions coincide in the axial direction.

2. A stator for a rotating electrical machine molded from resin using a mold, The coil winding is formed by arranging a plurality of split coil winding bodies in an annular shape, the split core having a yoke portion extending in the circumferential direction and teeth portion protruding radially inward from the inner peripheral surface of the yoke portion on the radially inner side, a counter-load side insulator covering one counter-load side in the axial direction of the split core and a load side insulator covering the other load side in the axial direction, and a coil wound around the teeth portion via the counter-load side insulator and the load side insulator, a terminal holder disposed on the opposite side of the split coil winding body in the axial direction to the load side; a terminal that is installed in the terminal holder, has a connection portion for connecting to an external device, and to which a terminal wire of the coil is wired, The terminal holder includes: the connection portion of the terminal is press-fit from the load side to the anti-load side in the axial direction, and the connection portion of the terminal is installed so as to protrude toward the anti-load side in the axial direction, and the abutment surface portion has an abutment surface having a structure that can abut against the mold, the terminal holder is a stator for a rotating electric machine, the stator including a plurality of first protrusions having a structure that enables alignment of the connection portion of the terminal with the mold by abutting against a mold positioning portion of the mold, The first protrusion is formed to extend from the terminal holder toward the anti-load side in the axial direction, The connection portion of the terminal is formed to extend from the terminal holder toward the anti-load side in the axial direction, A stator for a rotating electric machine, wherein the height of the connection portion of the terminal extending toward the anti-load side in the axial direction is formed to be lower than the height of the first protrusion extending toward the anti-load side in the axial direction.

3. The first protrusion is formed to extend from the terminal holder toward the anti-load side in the axial direction, The connection portion of the terminal is formed to extend from the terminal holder toward the anti-load side in the axial direction, 2. The stator of claim 1, wherein the fitting portion is formed to extend from the terminal holder toward a load side in the axial direction.

4. A stator for a rotating electrical machine molded from resin using a mold, The coil winding is formed by arranging a plurality of split coil winding bodies in an annular shape, the split core having a yoke portion extending in the circumferential direction and teeth portion protruding radially inward from the inner peripheral surface of the yoke portion on the radially inner side, a counter-load side insulator covering one counter-load side in the axial direction of the split core and a load side insulator covering the other load side in the axial direction, and a coil wound around the teeth portion via the counter-load side insulator and the load side insulator, a terminal holder disposed on the opposite side of the split coil winding body in the axial direction to the load side; a terminal that is installed in the terminal holder, has a connection portion for connecting to an external device, and to which a terminal wire of the coil is wired, The terminal holder includes: the connection portion of the terminal is press-fit from the load side to the anti-load side in the axial direction, and the connection portion of the terminal is installed so as to protrude toward the anti-load side in the axial direction, and the abutment surface portion has an abutment surface having a structure that can abut against the mold, the terminal holder is a stator for a rotating electric machine, the stator including a plurality of first protrusions having a structure that enables alignment of the connection portion of the terminal with the mold by abutting against a mold positioning portion of the mold, The first protrusion is a stator for a rotating electric machine formed in a cylindrical shape with a bottom that fits into and comes into contact with the mold.

5. 5. A rotating electric machine comprising: the stator of claim 1; and a rotor rotatably disposed opposite the teeth of the stator with a gap therebetween.

6. A method for manufacturing a stator for a rotating electric machine according to any one of claims 1 to 4, comprising the steps of: the terminal holder includes a first protrusion that abuts against a mold positioning portion of the mold, the split core has a groove provided on an outer peripheral surface of the yoke portion on the radially outer side thereof, When the terminal holder has a fitting portion that fits into the groove portion of the split core, The connection portion of the terminal is press-fitted from the load side to the anti-load side in the axial direction of the abutment surface portion of the terminal holder so that the connection portion protrudes toward the anti-load side in the axial direction, The fitting portion of the terminal holder is fitted into the groove portion of the split core, and the terminal wire of the coil is wired to the terminal, and then Using the mold having a mold contact surface portion on which the mold positioning portion and the mold recess are formed, the first protrusion of the terminal holder is brought into contact with the mold positioning portion of the mold; A method for manufacturing a stator for a rotating electric machine, comprising inserting the connection portion of the terminal into the mold recess of the mold, and abutting the abutment surface of the terminal holder against the mold abutment surface of the mold to seal the connection portion and perform molded resin molding.

7. A method for manufacturing a rotating electric machine, comprising: disposing a rotor rotatably opposite, via a gap, the teeth of the stator of the rotating electric machine manufactured by the method for manufacturing a stator of a rotating electric machine according to claim 6.

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