Rotating electric machine stator structure

Abstract

To save space in the connection section that electrically connects a coil of a stator to a given component.SOLUTION: The present invention relates to a stator structure of a rotary electric machine, comprising a stator core 15, a coil 17 formed by winding a winding 20 onto the stator core 15, a support member 22 mounted to the stator core 15, an intermediate connecting wire 23 connected to one end 20a of the winding 20 on one side of the stator core 15 in the axial direction, extending continuously from one end 20a of the winding 20 to the other side of the stator core 15 in the axial direction and supported by the stator core 15 via the support member 22, and a tip 23b of the other side of the intermediate connecting wire 23 is provided with a component connecting portion 30 that can connect a lead wire 3.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] The present disclosure relates to a stator structure for a rotating electric machine. to Regarding. [Background technology]

[0002] Patent Document 1 discloses an outer rotor type rotating electric machine. The stator of this rotating electric machine has a connection portion for electrically connecting the stator coil so as to form a predetermined electric circuit. The connection portion is provided with an electrode having terminals on both ends. The electrode is disposed so as to penetrate the stator core and protrude from both end faces of the stator. One terminal of the electrode is connected to a coil end of the stator coil, and the other terminal is connected to a wire harness. The electrode is a long, thin, plate-shaped member. The electrode has a wide portion that provides one terminal and a narrow portion that provides the other terminal.

[0003] The connection portion also has a protective member for protecting the coil end and one terminal. The protective member includes a protective resin and a wall member. The protective resin is an electrically insulating resin, also known as a potting resin or a sealing resin, and is tightly adhered to the surfaces of the coil end and one terminal. The wall member forms an enclosing wall that surrounds the coil end and one terminal. This enclosing wall defines a reservoir for storing the electrically insulating protective resin that encases the connection portion of the coil end and one terminal. The wall member receives the coil end so as to prevent the protective resin from leaking out. The publication also illustrates a state in which three electrodes are provided on the connection portion. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2017-99223 Summary of the Invention [Problem to be solved by the invention]

[0005] In the stator of the rotating electric machine described in Patent Document 1, three elongated plate-shaped electrodes, each having a wide portion providing one terminal and a narrow portion providing the other terminal, are arranged to penetrate the stator core, with both ends of the electrodes protruding from both end faces of the stator. In this way, three plate-shaped electrodes are arranged to penetrate the stator core at a connection portion for electrically connecting a predetermined component (wire harness) to the stator coil, so the plate-shaped electrodes are bulky and may require a large space for the connection portion.

[0006] Therefore, the present disclosure provides a stator structure for a rotating electric machine that can reduce the space required for a connection portion that electrically connects a stator coil to a predetermined member. of The purpose is to provide. [Means for solving the problem]

[0007] In order to solve the above problems, a first aspect of the present invention is a stator structure for a rotating electric machine, comprising a stator core, a coil formed by winding a winding around the stator core, an insulating support member attached to the stator core, and a conductive linear member connected to an end of the winding on one axial side of the stator core, extending continuously from the end of the winding to the other axial side of the stator core, and supported by the stator core via the insulating support member, wherein a member connection portion to which a specified member can be connected is provided at the tip of the other side of the linear member.

[0008] A second aspect of the present invention is a stator structure of a rotating electric machine of the first aspect, wherein the insulating support member defines a space that opens to one side, the linear member penetrates a bottom of the insulating support member that defines the other side of the space, the connection portion between the end of the winding and the linear member is arranged within the space, the member connection portion of the linear member is arranged on the other side of the bottom of the insulating support member, and the space of the insulating support member is filled with a sealing material that seals the connection portion between the end of the winding and the linear member.

[0009] A third aspect of the present invention is a stator structure of a rotating electric machine of the first aspect or the second aspect, wherein one end of the one side of the linear member is cold-press welded to the end of the winding.

[0010] A fourth aspect of the present invention is the stator structure of the rotating electric machine according to the first or second aspect, wherein the linear member is formed of a metal different from that of the winding of the coil.

[0011] A fifth aspect of the present invention is the stator structure for a rotating electric machine of the third aspect, wherein the linear member is formed of a metal different from that of the winding of the coil.

[0012] A sixth aspect of the present invention is a method for manufacturing a stator for a rotating electric machine, comprising: a first step of connecting a conductive linear member to an end of a winding of a coil wound around a stator core so that the conductive linear member extends continuously from the end of the winding while pulling out the end of the winding to one axial side of the stator core; a second step of inserting the linear member from one side into a space that opens to the one side of an insulating support member attached to the stator core, and passing the linear member through a through hole provided in the bottom of the insulating support member that partitions the other axial side of the space; and a third step of filling the space in the insulating support member with a sealing material and sealing the connection portion between the end of the winding and the linear member within the space. [Effects of the Invention]

[0013] According to the present disclosure, it is possible to reduce the space required for a connection portion that electrically connects a stator coil and a predetermined member. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a cross-sectional view of a rotating electric machine according to an embodiment of the present invention. [Figure 2] 1 is a plan view of a stator according to an embodiment of the present invention, viewed from one side in the axial direction. [Figure 3]3 is a plan view of the stator in FIG. 2 as viewed from the other axial side. [Figure 4] FIG. 3 is a perspective view of FIG. 2 as viewed in the direction of arrow IV. [Figure 5] FIG. 4 is a perspective view of the first connecting portion from one side in the axial direction. [Figure 6] FIG. 4 is a perspective view of FIG. 3 as viewed in the direction of arrow VI. [Figure 7] FIG. 7 is a cross-sectional view taken along the line VII-VII in FIG. 5. [Figure 8] FIG. 10 is a perspective view of the second connecting portion from the other axial side. [Figure 9] 1A, 1B, and 1C are explanatory views of a stator manufacturing method according to an embodiment of the present invention, in which (a) shows a first step, (b) shows a second step, and (c) shows a third step. DETAILED DESCRIPTION OF THE INVENTION

[0015] An embodiment of the present invention will now be described with reference to the drawings, in which X indicates one side in the axial direction and Y indicates the inner side in the radial direction.

[0016] FIG. 1 is a cross-sectional view of a rotating electric machine 10 according to an embodiment of the present invention. FIG. 2 is a plan view of a stator 11 according to an embodiment of the present invention, viewed from one axial side. FIG. 3 is a plan view of the stator 11 of FIG. 2, viewed from the other axial side. FIG. 4 is a perspective view of FIG. 2, viewed from the direction of arrow IV. FIG. 5 is a perspective view of a first connecting portion 18, viewed from one axial side. FIG. 6 is a perspective view of FIG. 3, viewed from the direction of arrow VI. FIG. 7 is a cross-sectional view taken along arrows VII-VII in FIG. 5. FIG. 8 is a perspective view of a second connecting portion 19, viewed from the other axial side.

[0017] As shown in FIG. 1, a stator structure according to one embodiment of the present invention is applied to the structure of a stator 11 of an outer rotor type rotating electrical machine 10.

[0018] The rotating electric machine 10 is an ACG (alternating current generator) starter used, for example, as a starter and generator for a motorcycle. When starting an engine (not shown), it operates as a starter motor by receiving a drive current from an on-board battery (not shown), and after the engine has started, it operates as an AC generator by the driving force of the engine. The rotating electric machine 10 is connected to a three-phase power conversion circuit (not shown). The rotating electric machine 10 is formed in a disk shape as a whole. The rotating electric machine 10 includes a stator 11 fixed to the vehicle body (for example, the crankcase 1 of the engine), and a rotor 12 fixed to the crankshaft 2 of the engine and rotating relative to the stator 11.

[0019] The rotor 12 has a cylindrical rotor yoke 13 with a bottom, and permanent magnets 14 fixed to the inner peripheral surface of the rotor yoke 13. A plurality of permanent magnets 14 are provided around the rotor yoke 13 so that different magnetic poles are arranged alternately in the circumferential direction. The stator 11 is disposed radially inside the permanent magnets 14 of the rotor 12 with a gap provided between them. In the following description, the axial direction refers to the direction along the rotation axis (axial center) CL of the rotor 12, the radial direction refers to the direction perpendicular to the rotation axis CL, and the circumferential direction refers to the direction along the rotation direction of the rotor 12 centered on the rotation axis CL.

[0020] As shown in FIGS. 2 and 3, a stator 11 of a rotating electric machine 10 according to the first embodiment of the present invention includes an annular stator core 15, an insulator 16, a coil 17, and two connection portions 18 and 19.

[0021] The stator core 15 is formed by stacking multiple steel plates (magnetic materials) in the axial direction. The stator core 15 has a cylindrical central portion 15a extending in the axial direction and multiple teeth 15b protruding radially outward from the central portion 15a. The base ends (radially inner sides) of the multiple teeth 15b are integrated with the central portion 15a. In this embodiment, a total of 18 teeth 15b are provided, six for each of the U phase, V phase, and W phase. Note that in Figures 2 and 3, only one tooth 15b is shown, and the other teeth 15b are not shown.

[0022] Insulator 16 is an insulating member molded from resin, and is attached to multiple teeth 15b, continuing from the outer periphery of center portion 15a of stator core 15. Insulator 16 covers the surfaces of multiple teeth 15b and blocks the flow of current between windings 20 (described later) of coil 17 and teeth 15b.

[0023] The coil 17 is formed by winding a winding 20 around the plurality of teeth 15b of the stator core 15. Insulators 16 are interposed between the winding 20 and the plurality of teeth 15b. The winding 20 is a solid metal conductor whose surface is covered with an insulating coating 21 (see FIG. 7). In this embodiment, the winding 20 is made of aluminum or an aluminum alloy. However, the winding 20 is not limited to being made of aluminum or an aluminum alloy, and can be made of various electrically conductive materials (such as copper).

[0024] Two connection portions 18, 19 are provided so as to axially penetrate a central portion 15a of the stator core 15. One of the two connection portions 18, 19, a first connection portion 18, electrically connects a three-phase lead wire (a predetermined member) 3 that functions as a power supply path to (or from) the coil 17 to one end (end) 20a (see FIG. 7) of the winding 20 of the three-phase coil 17. The other of the two connection portions 18, 19, a second connection portion 19, is disposed at a position spaced apart from the first connection portion 18 in the circumferential direction and electrically connects the other end (end) 20b (see FIG. 8) of the winding 20 of the three-phase coil 17 to each other. The coating 21 is peeled off from the one end 20a and the other end 20b of the winding 20 of the coil 17.

[0025] 4 to 8, the first connection portion 18 includes a support member (insulating support member) 22, three intermediate connection wires (linear members) 23 (see FIGS. 6 and 7) corresponding to the U phase, V phase, and W phase, and a sealing material 24 (see FIG. 7). Note that the three intermediate connection wires 23 have substantially the same configuration, and therefore, the following description will focus on one intermediate connection wire 23, and descriptions of the other intermediate connection wires 23 will be omitted.

[0026] The support member 22 is an insulating support member (insulating support member) that supports the three intermediate connection wires 23, is molded from resin, and is attached to the stator core 15. A core through hole 25 that penetrates in the axial direction is provided in the central portion 15a of the stator core 15. The support member 22 is inserted into the core through hole 25 of the stator core 15 from one axial side (hereinafter referred to as "the one side") and passes through the core through hole 25. One end 22a of the one side of the support member 22 is located on the other side of the one side of the stator core 15. In other words, the one side of the support member 22 does not protrude toward the one side beyond the surface of the one side of the stator core 15. The other end 22b of the support member 22 on the other axial side (hereinafter referred to as "the other side") is located on the other axial side of the other axial surface of the stator core 15 and on the one side of the other edge 16a of the radial inner end of the insulator 16.

[0027] The support member 22 is formed in a shape that defines three spaces 26 (see FIGS. 5 and 7 ) that open to the one side. The three spaces 26 are formed to a size that allows the intermediate connection wires 23 to be inserted therein and are arranged side by side in the circumferential direction. As shown in FIG. 7 , the opening on the one side of each space 26 is located on the other side of the one side of the stator core 15. The other side of each space 26 is defined by a bottom 22c of the support member 22. The bottom 22c of the support member 22 is located on the other side of the other side of the stator core 15. A through hole 27 is formed in the bottom 22c of the support member 22, connecting the spaces 26 inside the support member 22 to the outside on the other side. The through hole 27 is formed to a size that is in contact with (close contact with) the surface of the intermediate connection wire 23 to prevent the sealing material 24 from leaking from the spaces 26 to the other side, and extends linearly in the axial direction.

[0028] One end portion 20a of each of the windings 20 of the three-phase coils 17 is inserted from the one side into each of the three spaces 26 of the support member 22. In this embodiment, one end portion 20a of each of the three-phase windings 20 is drawn from the coil 17 to the one side of the stator core 15, extends radially inward from the coil 17 side, bends at a position facing the space 26, extends to the other side, and is inserted into each of the three spaces 26 of the support member 22 from the one side.

[0029] The intermediate connection wire 23 is a conductive linear member (linear member) disposed between one end 20a of the winding 20 of the coil 17 and the lead wire 3, and electrically connects the one end 20a of the winding 20 to the lead wire 3. The intermediate connection wire 23 is a solid metal conductor whose surface is coated with an insulating coating 28 (see FIG. 7 ), and extends linearly in the axial direction. The coating 28 is removed from both ends 23a, 23b of the intermediate connection wire 23. The intermediate connection wire 23 of this embodiment is formed from a different metal (copper in this embodiment) from that of the winding 20 of the coil 17. Furthermore, the intermediate connection wire 23 of this embodiment is a linear member having approximately the same thickness as that of the winding 20 of the coil 17.

[0030] The intermediate connecting wire 23 is inserted through a through hole 27 in the bottom portion 22c of the support member 22 and is supported by the support member 22. In other words, the intermediate connecting wire 23 is supported by the stator core 15 via the support member 22. The region of the intermediate connecting wire 23 that is covered with the coating 28 is inserted through the through hole 27 in the bottom portion 22c of the support member 22. The surface (outer peripheral surface) of the intermediate connecting wire 23 is in contact with the through hole 27 of the support member 22. One end 23a on the one side of the intermediate connecting wire 23 is disposed within the space 26 of the support member 22, and the other end (tip) 23b on the other side of the intermediate connecting wire 23 protrudes to the other side from the through hole 27 in the bottom portion 22c.

[0031] One end 23a of the intermediate connection wire 23 is electrically and physically connected to one end 20a of the winding 20 of the coil 17. In this embodiment, the one end 23a of the intermediate connection wire 23 is connected to the one end 20a of the winding 20 of the coil 17 by cold welding. Furthermore, in this embodiment, the connection is made such that the end face of the one end 20a of the winding 20 of the coil 17 and the end face of the one end 23a of the intermediate connection wire 23 abut against each other. When the one end 23a of the intermediate connection wire 23 and the one end 20a of the winding 20 of the coil 17 are connected, the intermediate connection wire 23 extends continuously from the one end 20a of the winding 20 of the coil 17 to the other side in the extension direction of the one end 20a of the winding 20 (in this embodiment, the axial direction). In other words, the intermediate connection wire 23 is connected to the one end 20a of the winding 20 of the coil 17 so as to extend the winding 20 in the extension direction. The method of connecting one end 23a of the intermediate connecting wire 23 to one end 20a of the winding 20 of the coil 17 is not limited to the above-mentioned cold pressure welding method, and various methods capable of electrically and physically connecting the wires (e.g., welding, crimping, etc.) can be applied.

[0032] The other end 23b of the intermediate connecting wire 23 is electrically and physically connectable to the lead wire 3. In this embodiment, the other end 23b of the intermediate connecting wire 23 is electrically and physically connected to the end 3a of the lead wire 3 using a terminal joint 29. That is, the other end 23b of the intermediate connecting wire 23 functions as a member connecting portion 30 that can connect a predetermined member (the lead wire 3 in the first connecting portion 18). Note that FIGS. 3, 4, 6, and 7 show a state in which the lead wire 3 is connected to the member connecting portion 30 of the intermediate connecting wire 23. Furthermore, the method of connecting the lead wire 3 to the member connecting portion 30 of the intermediate connecting wire 23 is not limited to the connection method using the terminal joint 29, and various methods that allow for electrical and physical connection (e.g., welding, crimping, etc.) can be applied.

[0033] The lead wire 3 is a power line connected to the rotating electric machine 10 from the power conversion circuit (not shown) side, and is a stranded wire whose surface is covered with an insulating coating. In this embodiment, the lead wire 3 is made of copper. That is, the intermediate connection wire 23 in this embodiment is made of the same type of metal (copper in this embodiment) as the lead wire 3.

[0034] The sealant 24 is an electrically insulating protective resin filled in the space 26 of the support member 22, and covers the entire connection C between one end 20a of the winding 20 of the coil 17 and one end 23a of the intermediate connecting wire 23, sealing the connection C within the space 26. As shown in FIG. 7 , the surface 24a on the one side of the sealant 24 is located on the one side of the connection C between one end 20a of the winding 20 of the coil 17 and one end 23a of the intermediate connecting wire 23, and on the other side of the one side of the surface of the stator core 15. In this embodiment, the entire one end 20a of the winding 20 is sealed within the space 26 by the sealant 24, and the region of the winding 20 covered with the coating 21 protrudes from the surface 24a of the sealant 24 to the one side.

[0035] 2 and 8, the second connection portion 19 is a connection portion that electrically connects the other ends 20b of the windings 20 of the three-phase coils 17 to each other, and includes a support member (insulating support member) 31, three intermediate connection wires (linear members) 32, a sealing material (not shown), and a neutral point connection member (predetermined member) 33. While the first connection portion 18 connects one end 20a of the windings 20 of the coil 17 to one end 23a of the intermediate connection wire 23 and connects the lead wire 3 to the member connection portion 30 of the other end 23b of the intermediate connection wire 23, the second connection portion 19 differs in that the other end 20b of the windings 20 of the coil 17 is connected to one end 32a of the intermediate connection wire 32 and the neutral point connection member 33 is connected to the member connection portion 34 of the other end (tip end) 32b of the intermediate connection wire 32. In FIG. 8, one end 32a of one of the three intermediate connecting lines 32 is shown by a broken line.

[0036] The support member 31 is an insulating support member (insulating support member) that supports the three intermediate connection wires 32, is molded from resin, and is attached to the stator core 15. Note that the configuration of the support member 31 and the manner in which the support member 31 is attached to the stator core 15 are similar to those of the support member 22 of the first connection portion 18, and therefore detailed description thereof will be omitted.

[0037] The other ends 20b of the windings 20 of the three-phase coils 17 are inserted from one side into the three spaces that open to the one side of the support member 31. In this embodiment, the other ends 20b of the three-phase windings 20 are drawn out to the one side of the stator core 15, extend radially inward from the coil 17 side, bend at a position facing the spaces in the support member 31, extend to the other side, and are inserted from the one side into the three spaces in the support member 31. Note that the three spaces in the support member 31 are similar to the three spaces 26 in the support member 22 of the first connection portion 18, and are therefore not shown in the figure.

[0038] The three intermediate connection wires 32 are conductive linear members (wire-shaped members) for electrically connecting the other ends 20b of the windings 20 of the coil 17 to the common neutral point connecting member 33. The intermediate connection wires 32 of this embodiment are formed from a metal (copper in this embodiment) different from that of the windings 20 of the coil 17. The intermediate connection wires 32 of this embodiment are linear members of approximately the same diameter as the windings 20 of the coil 17. Note that the configuration of the intermediate connection wires 32, the manner in which the intermediate connection wires 32 are attached to the support member 31, the manner in which the intermediate connection wires 32 are connected to the other ends 20b of the windings 20, and the manner in which the connection portion C between the intermediate connection wires 32 and the windings 20 is sealed with a sealing material are similar to those of the intermediate connection wire 23 of the first connecting portion 18, and therefore detailed description thereof will be omitted.

[0039] The other ends 32b of the intermediate connection wires 32 can be electrically and physically connected to the neutral point connecting member 33. A common neutral point connecting member 33 is electrically and physically connected to the other ends 32b of the three intermediate connection wires 32. In other words, the other ends 32b of the intermediate connection wires 32 function as a member connecting portion 34 that can connect a predetermined member (the neutral point connecting member 33 in the second connection portion 19).

[0040] The neutral point connecting member 33 is a conductive member for electrically connecting the other ends 32b of the three intermediate connection wires 32 to each other. The neutral point connecting member 33 of this embodiment is formed in a plate shape that intersects the axial direction and extends in the circumferential direction. The neutral point connecting member 33 has three through holes 35 that penetrate in the axial direction. The neutral point connecting member 33 is connected (joined) to the member connecting portions 34 of the other ends 32b of the three intermediate connection wires 32 with the member connecting portions 34 inserted into the three through holes 35 of the neutral point connecting member 33. This electrically connects the other ends 20b of the windings 20 of the three-phase coils 17 to each other via the three intermediate connection wires 32 and the neutral point connecting member 33. In this embodiment, the neutral point connecting member 33 is made of copper. That is, the intermediate connection wire 32 of this embodiment is made of the same metal as the neutral point connecting member 33 to prevent electrolytic corrosion. In this embodiment, the intermediate connection wire 32 and the neutral point connecting member 33 are made of the same type of metal, but this is not limiting and the intermediate connection wire 32 and the neutral point connecting member 33 may be made of different types of metal. For example, the intermediate connection wire 32 may be made of copper, and the neutral point connecting member 33 may be made of iron. In this case, the neutral point connecting member 33 may be subjected to a surface treatment to prevent electrolytic corrosion before the intermediate connection wire 32 is soldered.

[0041] Next, a method for manufacturing a stator according to an embodiment of the present invention will be described.

[0042] FIG. 9 is an explanatory diagram of a stator manufacturing method according to one embodiment of the present invention, where (a) shows the first step, (b) shows the second step, and (c) shows the third step.

[0043] The stator manufacturing method according to this embodiment is applied to, for example, a method for manufacturing the stator 11 of the rotating electric machine 10. The insulator 16, the coil 17, and support members 22, 31 for the two connection portions 18, 19 are attached in advance to the stator core 15 of the stator 11. Note that the first connection portion 18 and the second connection portion 19 of the stator 11 are manufactured in approximately the same process, so the following description will focus on the first connection portion 18, and a detailed description of the second connection portion 19 will be omitted.

[0044] As shown in FIG. 9, the stator manufacturing method includes the following first, second, and third steps.

[0045] 9(a), in the first step, one end 20a of the winding 20 of the coil 17 is pulled out to the one side of the stator core 15, and one end 23a of the intermediate connecting wire 23 is connected to one end 20a of the winding 20 so that the intermediate connecting wire 23 extends continuously from the one end 20a of the winding 20 along the extension direction of the winding 20. The connection between the one end 20a of the winding 20 and the one end 23a of the intermediate connecting wire 23 is preferably made by cold welding.

[0046] 9(b), in the second step, the intermediate connecting wire 23 connected to one end 20a of the winding 20 is inserted into the space 26 of the support member 22 from the one side and passed through the through-hole 27 in the bottom 22c of the support member 22. In this state, the connection portion C between the one end 20a of the winding 20 and one end 23a of the intermediate connecting wire 23 is disposed within the space 26 of the support member 22, and the member connection portion 30 of the other end 23b of the intermediate connecting wire 23 protrudes from the through-hole 27 in the bottom 22c of the support member 22 to the other side.

[0047] 9(c), in the third step, the sealant 24 is filled into the space 26 of the support member 22, and the connection portion C between the one end 20a of the winding 20 and the one end 23a of the intermediate connecting wire 23 is sealed within the space 26 of the support member 22. In this state, the entire one end 20a of the winding 20 is sealed within the space 26 by the sealant 24, and the area of ​​the winding 20 that is covered with the coating 21 protrudes from the surface 24a of the sealant 24 to the one side.

[0048] The stator manufacturing method may include at least the first, second, and third steps, and may also include steps other than the first, second, and third steps. For example, as shown in Fig. 9(c), the first connection portion 18 may include, after the third step, a step of connecting the lead wire 3 to the member connection portion 30 at the other end 23b of the intermediate connection wire 23. Furthermore, the second connection portion 19 may include, after the third step, a step of connecting the neutral point connection member 33 to the member connection portion 34 at the other end 32b of the intermediate connection wire 32.

[0049] In the stator 11 of the rotating electric machine 10 configured as described above, the first connection portion 18 electrically connecting one end 20a of the winding 20 of the coil 17 to the lead wire (predetermined member) 3 is provided with a linear intermediate connection wire 23 that continues from one end 20a of the winding 20 and extends toward the other side of the stator core 15. Because the linear intermediate connection wire 23 is a linear member, its cross-sectional area can be kept small, unlike when a plate-shaped terminal member having a terminal portion is provided, and the bulkiness of the intermediate connection wire 23 can be reduced. In this way, the linear intermediate connection wire 23, which can be reduced in bulk, extends from one end 20a of the winding 20 to the other side of the stator core 15, thereby reducing the space required for the first connection portion 18 electrically connecting the coil 17 of the stator 11 to the lead wire (predetermined member) 3. This allows the area of ​​the stator core 15 to be secured, thereby suppressing magnetic saturation and characteristic degradation.

[0050] Furthermore, second connection portion 19, which electrically connects other end 20b of winding 20 of coil 17 to neutral point connecting member (predetermined member) 33, is provided with linear intermediate connection wire 32 that continues from other end 20b of winding 20 and extends to the other side of stator core 15. In this way, similar to first connection portion 18, linear intermediate connection wire 32, which can be reduced in bulk, extends from other end 20b of winding 20 to the other side of stator core 15, so that second connection portion 19, which electrically connects coil 17 of stator 11 to neutral point connecting member (predetermined member) 33, can be made more space-saving. This allows the area of ​​stator core 15 to be secured, thereby suppressing magnetic saturation and characteristic degradation.

[0051] Furthermore, since both the first connection portion 18 and the second connection portion 19 can be made space-saving, the area of ​​the stator core 15 can be further secured compared to when only one of them is made space-saving, and magnetic saturation can be suppressed, thereby preventing deterioration of characteristics.

[0052] Furthermore, in the first connecting portion 18 and the second connecting portion 19, the connection portion C between the end portions 20a, 20b of the winding 20 and the intermediate connecting wires 23, 32 is disposed within the space 26 of the support members 22, 31. That is, since the winding 20 extends from the space 26 of the support members 22, 31 to the above-mentioned one side, the above-mentioned one side of the connecting portions 18, 19 can be simplified and made compact.

[0053] Furthermore, since the connection portions C between the ends 20a, 20b of the winding 20 and the intermediate connecting wires 23, 32 are sealed within the spaces 26 of the support members 22, 31, even if the winding 20 and the intermediate connecting wires 23, 32 are made of different metals, it is possible to prevent electrolytic corrosion of the connection portions C between the ends 20a, 20b of the winding 20 and the intermediate connecting wires 23, 32.

[0054] Furthermore, because the connection portions C between the ends 20a, 20b of the winding 20 and the intermediate connecting wires 23, 32 are sealed within the spaces 26 of the support members 22, 31, unlike when the connection portions C are exposed to the one side of the stator core 15, a wall portion for blocking the sealing material 24 does not need to protrude from the one side surface of the stator core 15 to the one side. This makes it possible to reduce the amount of protrusion of the connection portions 18, 19 of the stator 11 to the one side. In this embodiment, one end 22a of the one side of the support member 22 can be positioned on the other side of the one side surface of the stator core 15.

[0055] Since the connection portion C between the ends 20a, 20b of the winding 20 and the intermediate connecting wires 23, 32 is sealed within the space 26 of the support members 22, 31, the amount of sealing material 24 can be reduced, unlike when the connection portion C is exposed and sealed on the one side of the stator core 15, and the material cost of the sealing material 24 can be reduced.

[0056] Furthermore, since the spaces 26 of the support members 22, 31 are filled with the sealing material 24, the movement of the intermediate connection wires 23, 32 relative to the support members 22, 31 can be restricted by the sealing material 24. This ensures the strength of the intermediate connection wires 23, 32.

[0057] It is also preferable to connect the ends 20a, 20b of the winding 20 to the ends 23a, 32a of the intermediate connecting wires 23, 32 by cold pressure welding. This allows the winding 20 and the intermediate connecting wires 23, 32 to be connected without applying electricity or heat, thereby preventing changes in the characteristics of the winding 20 and the intermediate connecting wires 23, 32 due to electricity or heat.

[0058] Furthermore, the intermediate connecting wires 23, 32 are formed of a metal different from that of the winding 20 of the coil 17. Therefore, when a predetermined member (lead wire 3, neutral point connecting member 33) connected to the intermediate connecting wires 23, 32 and the winding 20 are made of a different metal, the intermediate connecting wires 23, 32 can be set to be made of the same metal as the predetermined member. This makes it possible to connect different metals at the connection points between the winding 20 and the intermediate connecting wires 23, 32, where connection work can be performed relatively easily by pulling the winding 20 of the coil 17 out to the one side of the stator core 15. Furthermore, it is possible to connect metals of the same type at the connection points between the intermediate connecting wires 23, 32 and the predetermined member, where connection work is performed with the intermediate connecting wires 23, 32 set on the stator core 15 side.

[0059] Furthermore, in the above-described stator manufacturing method, the intermediate connecting wires 23, 32 are connected to the winding 20 in a state in which the ends 20a, 20b of the winding 20 of the coil 17 are drawn out to the one side of the stator core 15 (first step). Therefore, even if the intermediate connecting wires 23, 32 and the winding 20 of the coil 17 are made of different metals and are relatively difficult to connect, as described above, it is possible to draw the winding 20 of the coil 17 out to the one side of the stator core 15 and connect the winding 20 and the intermediate connecting wires 23, 32 in a state in which the connection work is easy.

[0060] Furthermore, since linear intermediate connecting wires 23, 32, which can reduce bulkiness, are connected to the windings 20, the intermediate connecting wires 23, 32 can be easily inserted into the spaces 26 of the support members 22, 31 after the ends 20a, 20b of the windings 20 of the coil 17 are pulled out to the above-mentioned one side of the stator core 15 and the intermediate connecting wires 23, 32 are connected to the windings 20.

[0061] In this embodiment, the winding 20 and the intermediate connecting wire 23 are connected in a state in which the end faces of the ends 20a, 20b of the winding 20 of the coil 17 abut against the end faces of the intermediate connecting wires 23, 32, but this is not limiting. For example, the winding 20 and the intermediate connecting wire 23 may be connected in a state in which the side faces of the ends 20a, 20b of the winding 20 abut against the side faces of one ends 23a, 32a of the intermediate connecting wires 23, 32, so that the intermediate connecting wires 23, 32 extend continuously from the ends 20a, 20b of the winding 20.

[0062] In addition, in this embodiment, the intermediate connecting wires 23, 32 are made of a metal different from that of the winding 20 of the coil 17, but this is not limitative and they may be made of the same metal as that of the winding 20.

[0063] In addition, in this embodiment, the support members 22, 31 are provided as separate members from the insulator 16 as insulating support members for supporting the intermediate connection wires 23, 32, but the insulating support members are not limited to this. For example, the insulator 16 may be formed into a shape that can support the intermediate connection wires 23, 32, and the insulator 16 may function as an insulating support member.

[0064] Furthermore, in this embodiment, the stator structure according to the present disclosure is applied to both the first connection portion 18 and the second connection portion 19, but this is not limited to this, and it may be applied to at least one of the first connection portion 18 and the second connection portion 19.

[0065] Furthermore, in this embodiment, the stator structure according to the present disclosure is applied to the stator 11 of an ACG starter (rotating electric machine 10) used as a starter and generator for a motorcycle, but is not limited to this and may be applied, for example, to the stator of a rotating electric machine that functions as either a motor or a generator.

[0066] Although the present invention has been described above based on the above embodiment, the present invention is not limited to the content of the above embodiment, and can be modified as appropriate without departing from the scope of the present invention. In other words, all other embodiments, examples, operational techniques, etc. made by those skilled in the art based on this embodiment are naturally included in the scope of the present invention. [Explanation of symbols]

[0067] 3: Lead wire (specified part) 10: Rotating electric machine 11: Stator 15: Stator core 17: Coil 20: Winding 20a: One end of the winding (end) 20b: other end (end) of the winding 22, 31: Support member (insulating support member) 22c: bottom 23, 32: Intermediate connecting wire (linear member) 23a, 32a: one end of the intermediate connecting line 23b, 32b: other end (tip) of the intermediate connecting wire 24: Encapsulant 26: Space 27:Through hole 30, 34: Component connection part 33: Neutral point connection member (specified member)

Claims

1. A stator core; a coil formed by winding a winding around the stator core; an insulating support member attached to the stator core; a conductive linear member connected to an end of the winding on one axial side of the stator core, extending continuously from the end of the winding to the other axial side of the stator core, and supported by the stator core via the insulating support member, a member connecting portion to which a predetermined member can be connected is provided at the other end of the linear member; the insulating support member defines a space that is open to the one side, the linear member passes through a bottom portion of the insulating support member that defines the other side of the space, a connection portion between the end of the winding and the linear member is disposed within the space, the member connection portion of the linear member is disposed on the other side of the bottom portion of the insulating support member, The space in the insulating support member is filled with a sealant that seals the connection between the end of the winding and the linear member. A stator structure for a rotating electric machine characterized by:

2. One end of the one side of the wire member is cold-welded to the end of the winding.

2. The stator structure of a rotating electrical machine according to claim 1.

3. The wire member is made of a metal different from that of the winding of the coil.

2. The stator structure of a rotating electrical machine according to claim 1.

4. The wire member is made of a metal different from that of the winding of the coil.

3. The stator structure of a rotating electrical machine according to claim 2.

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