Rotating electric machine, stator for rotating electric machine, neutral point terminal for stator for rotating electric machine, and method for manufacturing a rotating electric machine stator.

Abstract

This neutral point terminal comprises: a fixed portion which engages with an insulator at one end in a first axial direction; a conductor connection portion which locks three conductors per phase at the other end in the first axial direction; and an assembling portion interposed between the fixed portion and the conductor connection portion in the first axial direction. Each connection portion of the three phases of the conductor connection portion forms a first space in which two conductors are disposed along either one direction in a second axial direction, thereby suppressing the length in the first axial direction required for disposing the two conductors. In addition, since the two conductors are disposed in the first space, the length in the second axial direction can also be suppressed. Further, the height, in the first axial direction, of a central pole portion, the height, in the first axial direction, of a tilted first claw portion, and the height, in the first axial direction, of a tilted second claw portion are set to be substantially equal, thereby enabling the length of the connection portion in the first axial direction to be suppressed by means of the tilting of the first claw portion and the second claw portion.

Description

Cross-reference to Related Applications

[0001] This application is based on Japanese Patent Application No. 2023-33123 filed in Japan on March 3, 2023, and the contents of the base application are incorporated herein by reference in their entirety.

Technical Field

[0002] The description in this specification relates to a rotating electric machine, a stator for a rotating electric machine, a neutral point terminal of a stator for a rotating electric machine, and a method for manufacturing a stator for a rotating electric machine. The rotating electric machine is useful, for example, as a generator or a starter for a motorcycle.

Background Art

[0003] Patent Document 1 shows a neutral point terminal for a three-phase rotating electric machine.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

[0005] In the neutral point terminal of Patent Document 1, two groove portions are formed as coil holding portions, and conductors are arranged in these groove portions. Here, when the coils are star-connected in three phases and each phase of the three phases is also connected in three parallel, it is necessary to electrically connect three conductors for each phase to the neutral point terminal. Therefore, when using the neutral point terminal of Patent Document 1, two conductors must be arranged overlapping each other in one of the groove portions. To overlap the conductors, the arrangement process becomes complicated. Further, the depth of the groove portion also requires a sufficient distance to arrange two conductors, and the length in the depth direction (the first axial direction) must be increased.

[0006] One could consider forming three grooves here, but this would require increasing the length of the grooves in the direction in which they are aligned (the second axis direction). The neutral point terminal is located on the base of the stator for the rotating electric machine. Bolts for attaching the stator to the engine are located on this base. Terminals for electrical connection to the coil wires are also located on the base. Furthermore, a sensor case for detecting the rotational state of the rotating electric machine is also located there. Therefore, increasing the length of the grooves in the direction in which they are aligned (the second axis direction) would impair the ease of assembly of the rotating electric machine.

[0007] This disclosure assumes that the coil is star-connected to three phases, and that each of the three phases is also connected in parallel. In this case, the challenge is to accommodate the three conductors in each phase in a compact manner in the space between the first and second axial directions.

[0008] One of the present disclosures relates to a rotating electric machine comprising a rotor having a plurality of permanent magnets arranged circumferentially and rotating together with a shaft, a stator core having an annular base portion and a tooth portion having a number of multiples of 3 extending radially outward from the base portion, an insulator made of an insulating material disposed on at least a part of the base portion and the tooth portion of the stator core, and a coil wound around the outer circumference of the insulator at positions corresponding to the tooth portion of the stator core.

[0009] Furthermore, in the first disclosed rotating electric machine, the coils are star-connected to three phases, and three conductors for each phase are electrically connected to a neutral point terminal. The neutral point terminal is fixed to a fixed portion formed in the groove shape on the base of the insulator, and the neutral point terminal is a plate material extending in the first axis direction and in the second axis direction perpendicular to this first axis direction. The neutral point terminal is configured such that a fixed portion that engages with the insulator is located at one end in the first axis direction, and a conductor coupling portion that locks the three conductors for each phase is located at the other end in the first axis direction, with a manifold interposed between the conductor coupling portion and the fixed portion in the first axis direction.

[0010] Furthermore, the rotating electric machine of the first disclosure has a wire coupling section with three coupling sections arranged along the second axis direction, each holding three wires for each phase of the three-phase system. Each coupling section also has a central column section that extends along the first axis direction and forms a first space for arranging two wires along one direction of the second axis direction, and a second space for arranging one wire on the other side of the second axis direction, a first claw section that is positioned on the first space side of the central column section and inclined toward the central column section to hold two wires in the first space, and a second claw section that is positioned on the second space side of the central column section and inclined toward the central column section to hold one wire in the second space. Furthermore, the height of the central column section in the first axis direction, the height of the inclined first claw section in the first axis direction, and the height of the inclined second claw section in the first axis direction are set to be approximately equal.

[0011] Furthermore, in the rotating electric machine of the first disclosure, each coupling part forms a first space in which two conductors are arranged along either of the directions of the second axis, so that the length required in the first axis direction to arrange the two conductors can be reduced. Moreover, since the two conductors are arranged within the first space, the length in the second axis direction can also be reduced.

[0012] In addition, in the rotating electric machine of the first disclosure, the height of the central column in the first axial direction, the height of the inclined first claw in the first axial direction, and the height of the inclined second claw in the first axial direction are set to be approximately equal. Therefore, the inclination between the first claw and the second claw makes it possible to reduce the length of the joint in the first axial direction.

[0013] The second disclosure is a stator for a rotating electric machine, comprising a stator core having an annular base portion and multiples of three teeth portions extending radially outward from the base portion; an insulator made of insulating material disposed on at least a part of the base portion and the teeth portion of the stator core; and a coil wound around the outer circumference of the insulator at positions corresponding to the teeth portion of the stator core, wherein the coil is star-connected to three phases, and three conductors for each phase are electrically connected to a neutral point terminal.

[0014] In the stator for a rotating electric machine of the second disclosure, the neutral point terminal is fixed to a fixed portion formed in a groove on the base of the insulator. The neutral point terminal is a plate material extending in a first axis direction and a second axis direction perpendicular to the first axis direction. The neutral point terminal has a fixed portion that engages with the insulator at one end in the first axis direction, and a wire coupling portion that locks three wires for each phase at the other end in the first axis direction, with a manifold interposed between the wire coupling portion and the fixed portion in the first axis direction.

[0015] In the stator for a rotating electric machine of the second disclosure, the conductor coupling section has three coupling sections arranged along the second axis direction, each holding three conductors for each of the three phases. Each coupling section has a central column section that extends along the first axis direction and forms a first space for arranging two conductors along one direction of the second axis direction and a second space for arranging one conductor on the other side of the second axis direction, a first claw section that is positioned on the first space side of the central column section and inclined toward the central column section to hold two conductors in the first space, and a second claw section that is positioned on the second space side of the central column section and inclined toward the central column section to hold one conductor in the second space. Furthermore, the height of the central column section in the first axis direction, the height of the inclined first claw section in the first axis direction, and the height of the inclined second claw section in the first axis direction are set to be approximately equal.

[0016] Furthermore, in the stator for a rotating electric machine of the second disclosure, each coupling portion forms a first space for arranging two conductors along either of the second axial directions, thereby reducing the length required in the first axial direction for arranging the two conductors. Moreover, since the two conductors are arranged within the first space, the length in the second axial direction is also reduced.

[0017] In addition, in the stator for a rotating electric machine of the second disclosure, the height of the central column in the first axial direction, the height of the inclined first claw in the first axial direction, and the height of the inclined second claw in the first axial direction are set to be approximately equal. Therefore, the inclination between the first claw and the second claw makes it possible to reduce the length of the joint in the first axial direction.

[0018] The third disclosure is a neutral point terminal for a rotating electric machine stator, comprising a stator core having an annular base portion and multiples of three teeth portion extending radially outward from the base portion; an insulator made of insulating material disposed on at least a part of the base portion and the teeth portion of the stator core; and a coil wound around the outer circumference of the insulator at positions corresponding to the teeth portion of the stator core, wherein the coil is star-connected to three phases, and three conductors for each phase are electrically connected to the neutral point terminal.

[0019] The neutral point terminal of the stator for the rotating electric machine in the third disclosure is fixed to a fixed portion formed in a groove on the base of the insulator. The neutral point terminal is a plate material extending in a first axis direction and in a second axis direction perpendicular to the first axis direction. The neutral point terminal has a fixed portion that engages with the insulator at one end in the first axis direction, and a wire coupling portion that locks three wires for each phase at the other end in the first axis direction, with a manifold interposed between the wire coupling portion and the fixed portion in the first axis direction.

[0020] In the neutral point terminal of the stator for a rotating electric machine of the third disclosure, the conductor coupling section has three coupling sections arranged along the second axis direction, each holding three conductors for each of the three phases. Each coupling section has a central column section that extends along the first axis direction and forms a first space for arranging two conductors along one direction of the second axis direction and a second space for arranging one conductor on the other side of the second axis direction, a first claw section that is positioned on the first space side of the central column section and inclined toward the central column section to hold two conductors in the first space, and a second claw section that is positioned on the second space side of the central column section and inclined toward the central column section to hold one conductor in the second space. Furthermore, the height of the central column section in the first axis direction, the height of the inclined first claw section in the first axis direction, and the height of the inclined second claw section in the first axis direction are set to be approximately equal.

[0021] In the neutral point terminal of the stator for a rotating electric machine of the third disclosure, each coupling portion forms a first space for arranging two conductors along either of the second axis directions, thereby reducing the length required in the first axis direction for arranging the two conductors. Furthermore, since the two conductors are arranged within the first space, the length in the second axis direction can also be reduced.

[0022] In addition, in the neutral point terminal of the stator for the rotating electric machine of the third disclosure, the height of the central column in the first axial direction, the height of the inclined first claw in the first axial direction, and the height of the inclined second claw in the first axial direction are set to be approximately equal. Therefore, the inclination of the first claw and the second claw makes it possible to reduce the length of the joint in the first axial direction.

[0023] The fourth disclosure is that the first space side of the central column is recessed in the second axial direction, forming part of the first space. By recessing the central column and making it part of the first space, it is possible to make the length in the second axial direction even more compact.

[0024] The fifth disclosure states that the length of the manifold in the second axial direction is shorter than the length of the wire coupling in the second axial direction, and longer than the length of the connection between the first and second claws of the couplings located on both sides in the second axial direction, whichever is located on the inside in the second axial direction. First, because it is shorter than the length of the wire coupling in the second axial direction, the wire joint comes into direct contact with the insulator. As a result, the tolerance of the manifold becomes irrelevant, and the positional relationship of the wire joint can be stabilized. This makes it possible to stabilize the fixing position of the wire as well. As a result, it becomes easier to ensure the strength of the wire's vibration resistance. In addition, regarding the mounting, since the part of the wire coupling that comes into contact with the insulator is exposed, it becomes easier to visually check the mounting.

[0025] Next, since the length in the second axis direction of the claw portion disposed on the inner side in the second axis direction, which is either the first claw portion or the second claw portion, among the coupling portions disposed on both sides in the second axis direction, is set to be longer than the length in the second axis direction connecting the claw portions, even if the length in the second axis direction of the collective portion is shortened, it is possible to maintain a width capable of ensuring the current density. That is, it is possible to prevent a situation where the current concentrates on a specific narrow portion and heat is generated at that portion.

[0026] The sixth disclosure is that the length in the second axis direction of the fixing portion is shorter than the length in the second axis direction of the collective portion. Since the fixing portion is located on the opposite side of the wire coupling portion in the first axis direction, the insulator is located at the innermost portion in the first axis direction. If the length in the second axis direction of the fixing portion is shortened at this innermost portion, it is also possible to shorten the length in the second axis direction of the insulator. As a result, the area of the insulator occupying the base portion of the stator core can also be reduced at the portion corresponding to the fixing portion.

[0027] The seventh disclosure is that on both sides in the second axis direction of the fixing portion, first and second wedges for locking in the first axis direction are disposed. And the length in the second axis direction of the first wedge disposed on the outer side in the first axis direction is shorter than the length in the second axis direction of the second wedge disposed on the inner side in the first axis direction. Since the first wedge having a shorter length in the second axis direction is disposed on the outer side in the first axis direction, it is possible to make the first wedge function as a guide. Thereby, the assembly of the neutral point terminal to the insulator can be facilitated.

[0028] The eighth disclosure is a method for manufacturing a stator for a rotating electrical machine. This manufacturing method first employs a coupling part forming step of forming the central column part, the first claw part, and the second claw part of the coupling part all parallel to each other in the first axial direction, and such that the heights in the first axial direction of the first claw part and the second claw part are higher than the height in the first axial direction of the central column part. Next, a wire arranging step is performed of arranging two wires side by side in the second axial direction within the first space and arranging one wire on the second space side. Thereafter, a caulking step is performed of simultaneously inclining the first claw part and the second claw part toward the central column part until they contact the central column part, so that the height in the first axial direction of the central column part, the height in the first axial direction of the inclined first claw part, and the height in the first axial direction of the inclined second claw part are made substantially equal.

[0029] In the manufacturing method of the eighth disclosure, since the first claw part and the second claw part are simultaneously caulked toward the central column part, the caulking process for the two claw parts is facilitated. Also, by caulking the first claw part and the second claw part until they contact the central column part, the caulking process is facilitated. And in the caulking process, since the first claw part and the second claw part are inclined, the height in the first axial direction of the central column part, the height in the first axial direction of the inclined first claw part, and the height in the first axial direction of the inclined second claw part can be made substantially equal.

[0030] The ninth of the present disclosure is also a method for manufacturing a stator for a rotating electrical machine. The manufacturing method of the ninth of the present disclosure includes a press-fitting step of press-fitting, in the first axial direction, the fixed part and the gathering part within the neutral point terminal into the fixed part of the insulator. And this press-fitting step is performed until the coupling part contacts the insulator outside the fixed part of the base part. Since the press-fitting in the first axial direction is performed until the coupling part contacts the insulator outside the fixed part of the base part, it becomes easy to determine the press-fitting distance. And regarding the fitting condition during press-fitting, since the part in contact with the insulator is exposed, it becomes easy to visually confirm the attachability. The tenth and eleventh paragraphs of this disclosure replace the requirement that the first axial height of the first and second central columns of the disclosure and the first axial height of the first and second claws are approximately equal with the requirement that the first axial length required to arrange the two conductors be kept to a minimum.

Brief Description of the Drawings

[0031] [Figure 1] FIG. 1 is a cross-sectional view of a rotating electrical machine in a state combined with a crankshaft and a cylinder block. [Figure 2] Figure 2 is a front view showing the rotor, stator, power cable, and sensor case of a rotating electric machine. [Figure 3] Figure 3 is a perspective view showing the stator and sensor case of a rotating electric machine. [Figure 4] Figure 4 is a front view showing the steel plates that make up the stator core. [Figure 5] Figure 5 is a perspective view showing the first insulator. [Figure 6] Figure 6 is a perspective view of the first insulator shown in Figure 5, viewed from a different direction. [Figure 7] Figure 7 is an electrical circuit diagram showing a three-phase star connection with each phase wired in three parallel connections. [Figure 8] Figure 8 is a front view of the neutral point terminal with the conductors arranged. [Figure 9] Figure 9 is a side view of the neutral point terminal. [Figure 10] Figure 10 is a front view of the insulator shown in Figure 5. [Figure 11] Figure 11 is a cross-sectional view showing the fixing portion of the insulator. [Figure 12] Figure 12 is a cross-sectional view showing the insulator assembly state of the neutral point terminal. [Figure 13] Figure 13 is an explanatory diagram showing the crimping process of the neutral point terminal. [Figure 14] Figure 14 is a front view showing a comparative example of a neutral point terminal. [Figure 15] Figure 15 is a perspective view showing the second insulator. [Figure 16] Figure 16 is a perspective view of the second insulator shown in Figure 15, viewed from a different direction. [Modes for carrying out the invention]

[0032] An example of this disclosure will be described below with reference to the figures. First, an example of a rotating electric machine that is the subject of this disclosure will be described. Figure 1 is a cross-sectional view of the rotating electric machine 1 assembled to a crankshaft 100. 101 is a cylinder block, and a piston (not shown) reciprocates within a cylinder (not shown) inside the cylinder block 101. The movement of the piston rotates the crankshaft 100 via a connecting rod (not shown). The crankshaft 100 is made of iron with a diameter of about 20 millimeters and is rotatably supported by a bearing 102 on the cylinder block 101.

[0033] The rotor 300 of the rotating electric machine 1 is fixed to the crankshaft 100 by a base portion 301. Therefore, the rotor 300 rotates integrally with the crankshaft 100. The rotor 300 is made of iron and has a disc portion 302 that extends radially outward from the base portion 301 that engages with the crankshaft 100, and a cylindrical portion 303 formed on the radially outward portion of this disc portion 302. As shown in Figure 1, twelve permanent magnets 304 are arranged circumferentially inside the cylindrical portion 303. The thickness of the permanent magnets 304 is about 4 to 5 millimeters. Note that the number of permanent magnets 304 is not limited to 12, but can be appropriately set to provide the number of poles and magnetic flux according to the required performance, such as 10 or 24.

[0034] Inside the rotor 300, a stator 400 is arranged as shown in Figures 1 and 2. Figure 2 is a front view of the stator 400 as seen from the cylinder block 101 side. The stator 400 is made by laminating multiple magnetic steel plates 440 as shown in Figure 4, and integrally forms a base portion 401 that is attached to the cylinder block 101, and multiple tooth portions 402 that extend radially outward from this base portion 401. The outer diameter of the stator 400 is about 110 to 130 millimeters, and therefore the inner diameter of the rotor 300 is such that a small gap of about 1 millimeter is formed between the outer diameter of the stator 400 and the permanent magnet 304. By providing a small gap, deformation associated with the assembly of the rotor 300 and vibrations associated with the operation of the internal combustion engine can be absorbed.

[0035] The base portion 401 has three stator bolt holes 4030 for fixing the stator 400 to the cylinder block 101. The base portion 401 also has sensor case bolt holes 4031 for fixing the sensor case 500 to the stator 400. Furthermore, the base portion 401 has three terminal holes 4032 through which the electrical terminal fixing portion 4170 of the insulator 410, which will be described later, passes. The base portion 401 also has clip press-fit fixing holes 4033 for fixing the clip 610. Furthermore, it has terminal fixing holes 4034 for fixing the fixing portion 481 of the neutral point terminal 480, which will be described later.

[0036] The teeth portion 402 is electrically insulated by an insulator 410 made of an insulating resin such as polyamide or nylon 66, and a coil 404 made of copper wire or aluminum wire is wound on the insulator 410. Figure 3 is a perspective view showing the stator 400 and sensor case 500 with the rotor 300 removed from Figure 2.

[0037] As shown in Figure 3, a gap 405 is formed between adjacent coils 404, and this gap 405 widens radially outward. The sensor case 500 is placed in this gap 405. The sensor case 500 is molded from a resin such as polyamide, similar to the insulator 410 described above. Inside the sensor case 500 are sensors: the first magnetic detection sensor 541, the second magnetic detection sensor 542, the third magnetic detection sensor 543, and the fourth magnetic detection sensor 544.

[0038] Each of the first to fourth magnetic sensors 541-544 is equipped with a power line, a ground line, and a signal line, and as shown in Figure 2, each line is bundled together as a sensor wiring 545. The sensor wiring 545 is held together with the power cable 600 by a clip 610. The clip 610 is then fixed to the clip bolt hole of the base portion 401 by a clip bolt 611. However, the clip 610 only needs to be fixed to the base portion 401 of the stator 400, and is not limited to bolt fixing with a clip bolt 611. In the example shown in Figure 4, the clip 610 is press-fitted into the clip press-fit fixing hole 4033.

[0039] The insulator 410 is positioned to cover the stator 400 from both sides in the axial direction. Figures 5 and 6 show the first insulator 411 positioned on one side of the stator 400, and Figures 15 and 16 show the second insulator 412 positioned on the other side. As shown in these figures, the insulator 410 has a bobbin portion 4120 formed corresponding to the teeth portion 402.

[0040] Furthermore, the first insulator 411 shown in Figures 5 and 6 has a fixing portion 4100 formed in the part corresponding to the base portion 401 for holding the neutral point terminal 480. More specifically, a terminal holding portion 4105 is formed in the fixing portion 4100, and the fixing portion 481 of the neutral point terminal 480 is inserted into this terminal holding portion 4105. The terminal holding portion 4105 is then inserted into a terminal fixing hole 4034 formed in the base portion 401.

[0041] Furthermore, the first insulator 411 has three electrical terminal fixing portions 4170 formed in the area corresponding to the base portion 401. The electrical terminal fixing portions 4170 hold electrical terminals that electrically connect to the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 (shown in Figure 7). As mentioned above, the electrical terminal fixing portions 4170 pass through the terminal holes 4032 of the base portion 401. These electrical terminals allow the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70, which are wound on one side of the stator 400, to be routed to the other side.

[0042] As shown in Figures 15 and 16, the second insulator 412 has an electrical terminal positioning portion 4171 formed in the area corresponding to the base portion 401. Three electrical terminal holding holes 4172 are formed in this electrical terminal positioning portion 4171 in the area corresponding to the electrical terminal fixing portion 4170. Therefore, the tip of the electrical terminal fixing portion 4170 of the first insulator 411 is inserted into these electrical terminal holding holes 4172, thereby fitting the first insulator 411 and the second insulator 412 together. The second insulator 412 also has a terminal receiving portion 4106 formed in the area corresponding to the terminal holding portion 4105 of the first insulator 411, which passes through the terminal fixing hole 4034 of the base portion 401. Therefore, the terminal fixing hole 4034 and the terminal holding portion 4105 are covered by the terminal receiving portion 4106.

[0043] As shown in Figures 2 and 4, the base portion 401 has stator bolt holes 4030 formed at 120-degree intervals. The sensor case 500 and clip 610 are positioned between these stator bolt holes 4030. Furthermore, three electrical terminal fixing portions 4170 are formed in the insulator 410 at positions corresponding to the base portion 401. Therefore, the space available for positioning the fixing portion 4100 of the insulator 410 is limited.

[0044] As shown in Figure 3, there are 18 coils 404. Figure 7 shows the electrical circuit diagram for each coil 404. As shown in Figure 7, the rotating electric machine 1 is a three-phase AC with U-phase, V-phase, and W-phase. Furthermore, in this embodiment, each phase is connected in parallel with three conductors.

[0045] In the U phase, three U-phase conductors 60, U1 conductor 61, U2 conductor 62, and U3 conductor 63, are connected in parallel. Two coils 404 are wound around each of the conductors 61 to 63. In Figure 7, there are a total of six coils 404 in the U phase, indicated by the symbols U1-1 to U3-2. The same applies to the V phase and W phase. The V-phase conductors 50 in the V phase are indicated by the symbols 51, 52, and 53, and the W-phase conductors 70 in the W phase are indicated by the symbols 71, 72, and 73. The six coils 404 in the V phase are indicated by the symbols V1-1 to V3-2, and the six coils 404 in the W phase are indicated by the symbols W1-1 to W3-2. Therefore, the number of layers of the coil 404 is 18, the same as the number of teeth 402.

[0046] Furthermore, the rotating electric machine 1 is star-connected. Therefore, the three U-phase conductors 60 each have winding end points indicated by 64 to 66. Similarly, the three V-phase conductors 50 and the three W-phase conductors 70 each have winding end points. The winding end points of the V-phase conductors 50 are indicated by reference numerals 54 to 56, and the winding end points of the W-phase conductors 70 are indicated by reference numerals 74 to 76. These winding end points are common to the part indicated by C in Figure 7. That is, as shown in Figure 8, each winding end point is electrically connected to a single neutral point terminal 480. Note that in this example, "winding end point" is a convenient name and does not necessarily have to be the end of the winding of coil 404. It could also be the beginning of the winding of coil 404. Therefore, the winding end point refers to the end of the lead wire of coil 404.

[0047] The neutral point terminal 480 is a plate material that extends in a first axis direction (vertical in Figure 8) and in a second axis direction (horizontal in Figure 8) perpendicular to the first axis direction. Iron or brass can be used as the material for the neutral point terminal 480. The thickness of the plate material for the neutral point terminal 480 is about 1 millimeter. A fixing part 481 is formed at one end of the neutral point terminal 480 in the first axis direction (the lower end in Figure 8), extending in the first axis direction. This fixing part 481 is press-fitted and fixed to the fixing part 4100 of the insulator 410.

[0048] An engaging projection 4811 is formed protruding from the center of the fixed portion 481. The engaging projection 4811 is press-formed, and its protrusion direction is in the thickness direction of the neutral point terminal 480. In Figure 9, it protrudes to the left of the paper, perpendicular to both the first axial direction and the second axial direction. The amount of this protrusion is about 1 millimeter. Therefore, both sides of the engaging projection 4811 in the direction of the first axial direction are engaging inclined surfaces 4813. The middle portion of the engaging projection 4811 becomes an engaging plane 4814.

[0049] A first wedge portion 4815 and a second wedge portion 4816 for locking are positioned on both sides of the fixing portion 481 in the second axial direction. The order of arrangement is such that the first wedge portion 4815 is on one end side in the first axial direction (lower side in Figures 8 and 9) than the second wedge portion 4816. Both the first wedge portion 4815 and the second wedge portion 4816 have a tapered shape in which the length in the second axial direction decreases as they move toward one end in the first axial direction. Furthermore, both the first wedge portion 4815 and the second wedge portion 4816 protrude by about 0.5 millimeters. The length in the second axial direction of the first wedge portion 4815, which is positioned on the outside in the first axial direction, is shorter than the length in the second axial direction of the second wedge portion 4816, which is positioned on the inside in the first axial direction.

[0050] At the other end of the neutral point terminal 480 in the first axial direction (upper end in Figures 8 and 9), a conductor coupling portion 482 is formed to secure the winding ends 64-66, 54-56, and 74-76 of the three U-phase conductors 60, V-phase conductors 50, and W-phase conductors 70 for each phase. The conductor coupling portion 482 is arranged in three locations: a U-phase coupling portion 4821, a V-phase coupling portion 4822, and a W-phase coupling portion 4823. Each coupling portion 4821-4823 is arranged in a parallel line in the second axial direction and has the same shape as the others.

[0051] Each of the joints 4821 to 4823 consists of a central column 484 and first claws 485 and second claws 486 positioned on both sides of the central column 484 in the second axial direction. Therefore, the central column 484, the first claws 485, and the second claws 486 are each formed in three locations. The height H1 of the central column 484 is slightly lower than the height H2 of the first claws 485 and the second claws 486. For example, if the height H2 of the first claws 485 and the second claws 486 is about 4 millimeters, the height H1 of the central column 484 is about 3.7 millimeters. A first space 487 is formed between the central column 484 and the first claws 485, and two winding ends 64, 65, 54, 55, 74, and 75 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 are positioned in this first space 487. Furthermore, a second space 488 is formed between the central column 484 and the second claw 486. The remaining winding ends 66, 56, and 76 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 are located in this second space 488.

[0052] The central column 484 on the side of the first space 487 is recessed by about 1 millimeter in the second axial direction. Therefore, the central column 484 also constitutes a part of the first space 487. This allows the first space 487 to be expanded in the second axial direction. As described above, the first space 487 is where two winding end points 64, 65, 54, 55, 74, and 75 are located, so expanding in the second axial direction is important because it allows the two winding end points 64, 65, 54, 55, 74, and 75 to be aligned in the second axial direction. Furthermore, it becomes possible to align the winding end points 66, 56, and 76 located in the second space 488 in the second axial direction as well. This allows the nine winding end points 64-66, 54-56, and 74-76 to be arranged in a line along the second axial direction. This is a desirable arrangement when winding the coil 404.

[0053] Specifically, by arranging the nine winding end points 64-66, 54-56, and 74-76 in a line along the second axis direction, the position of the conductor connected to the neutral point terminal 480 in the first direction can be kept low. As a result, when using the rotating electric machine 1, the conductor will vibrate due to the vibrations associated with the operation of the internal combustion engine and / or the driving of the rotating electric machine 1, but this vibration of the conductor can be suppressed.

[0054] Furthermore, by recessing the first space 487 side of the central column 484 in the second axial direction, the first space 487 has a wide section 4871 that widens in the second axial direction and a narrow section 4872 that does not widen in the second axial direction. The length of the wide section 4871 in the second axial direction is longer than the sum of the diameters of the two conductors (U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70). On the other hand, the length of the narrow section 4872 in the second axial direction is longer than the diameter of one conductor (U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70) and shorter than the sum of the two. Therefore, the narrow section 4872 is used as a passage to guide the conductors to the wide section 4871, and the wide section 4871 is used as a space to fix and hold the conductors.

[0055] As a comparative example, Figure 14 shows an example where the width in the second axial direction is the same in the first space 487 and the second space 488. In the example in Figure 14, if we were to place the winding ends 64, 65, 54, 55, 74, and 75 of two of the U-phase conductors 60, V-phase conductors 50, and W-phase conductors 70 in the first space 487, they would be placed overlapping in the first axial direction (up and down direction in Figure 12). Therefore, the height H2 in the first axial direction of the first space 487 also needs to be increased. As shown in Figure 2, the neutral point terminal 480 needs to be placed between the stator bolt through holes 4030 in the narrow space of the base portion 401, and it is undesirable to increase the height H2 in the first axial direction.

[0056] More specifically, if the central column 484, first claw 485, and second claw 486 of the neutral point terminal 480 are positioned on the cylinder block 101 side of the stator 400, extending the height H2 in the first axial direction would necessitate avoiding interference with the cylinder block 101. To achieve this, the distance between the stator 400 and the cylinder block 101 needs to be increased. Conversely, if the central column 484, first claw 485, and second claw 486 of the neutral point terminal 480 are positioned on the rotor 300 side of the stator 400, extending the height H2 in the first axial direction would cause interference with the rotor 300. To avoid interference with the rotor 300, the distance between the stator 400 and the rotor 300 needs to be increased. In either case, extending the height H2 in the first axial direction is undesirable.

[0057] Compared to the comparative example in Figure 14, the width of the central column 484 is wider in the embodiment shown in Figure 8. However, widening the width of the central column 484 can be achieved by narrowing the width of the first width space 4824 between the U-phase coupling portion 4821 and the V-phase coupling portion 4822, and the second width space 4825 between the V-phase coupling portion 4822 and the W-phase coupling portion 4823. In the embodiment shown in Figure 8, the second axial length of the U-phase coupling portion 4821, the V-phase coupling portion 4822, and the W-phase coupling portion 4823 is approximately 6 millimeters. In contrast, the second axial length of the first width space 4824 and the second width space 4825 is approximately 3 millimeters. The first width space 4824 and the second width space 4825 are spaces used to receive the crimping tool when crimping the first claw portion 485 and the second claw portion 486. The crimping process involves deforming the first jaw portion 485 and the second jaw portion 486 from their initial acceptable shape to the tightening shape after processing. Therefore, it is not possible to make the length in the second axial direction zero, but a distance of about 3 millimeters is sufficient.

[0058] As shown in Figure 13, the winding ends 64-66, 54-56, and 74-76 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 are housed in the first space 487 and the second space 488. In this state, the first claw portion 485 and the second claw portion 486 are crimped toward the central column portion 484 to fix them in a tightened shape. By employing this crimping process, it is possible to securely hold the winding ends 64-66, 54-56, and 74-76 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 in the first space 487 and the second space 488.

[0059] However, in order to employ the crimping process, the height H2 of the first claw portion 485 and the second claw portion 486 must be greater than the diameter of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70. Here, as described above, two winding end points 64, 65, 54, 55, 74, and 75 are arranged in the second axial direction within each of the three first spaces 487. Therefore, even if two winding end points 64, 65, 54, 55, 74, and 75 are arranged within each first space 487, the height H2 of the first claw portion 485 and the second claw portion 486 in the first axial direction can be reduced to a height that allows crimping compared to the diameter of one U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70. In other words, the height H2 in the first direction can be reduced compared to the comparative example shown in Figure 14. As a result, as described above, it became possible to employ a crimping process, ensuring secure retention of the winding end points 64, 65, 54, 55, 74, and 75.

[0060] In the example shown in Figure 8, the first space 487 is located on one side (right side) of the central column 484 in the second axial direction, and the second space 488 is located on the other side (left side) of the central column 484 in the second axial direction, but the left and right directions are not limited. The first space 487 and the second space 488 only need to be formed on either side of the central column 484 in the second axial direction. Also, in the example shown in Figure 8, the U-phase coupling section 4821, the V-phase coupling section 4822, and the W-phase coupling section 4823 are arranged in order from one side (right side) in the second axial direction, but the positions in the second axial direction can be changed according to the wiring of the coils 404 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70. This is because at the neutral point (C in Figure 7), there is only one electrical connection and they are at the same potential. Therefore, it is also possible to place the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 in the joint section (for example, the U-phase joint section 4821) in the example above. Consequently, the designations of the U-phase joint section 4821, V-phase joint section 4822, and W-phase joint section 4823 in this example are merely for convenience, and it is not necessarily required that the conductors of the phases indicated by the names be placed in these sections.

[0061] The neutral point terminal 480 is configured with a manifold 483 interposed between the conductor coupling portion 482 and the fixed portion 481 in the first axial direction. The length L2 of the manifold 483 in the second axial direction is shorter than the length L1 of the conductor coupling portion 482 in the second axial direction. In the embodiment shown in Figure 8, the length L1 of the conductor coupling portion 482 is about 25 millimeters, and the length L2 of the manifold 483 is about 3 millimeters shorter than that.

[0062] In this example, the assembly of the neutral point terminal 480 is facilitated by shortening the length L2 of the manifold 483. This assembly will be described in detail later. However, if shortening the length L2 of the manifold 483 results in an excessively high current density at the conductor coupling portion 482, the performance of the neutral point terminal 480 cannot be maintained. Therefore, in this example, a minimum value L2Min is set for the length L2 of the manifold 483. This minimum value L2Min is the distance between the claw portion located on the inside in the second axial direction of the first claw portion 485 and the second claw portion 486 of the coupling portions located on both sides in the second axial direction of the U-phase coupling portion 4821, V-phase coupling portion 4822, and W-phase coupling portion 4823. In this example, the length L2 of the manifold 483 is made longer than this minimum value L2Min. This setting allows current from the U-phase conductors 60, V-phase conductors 50, and W-phase conductors 70 located on both sides in the second axial direction to flow to the manifold 483, even at the coupling sections located on both sides in the second axial direction among the U-phase coupling section 4821, V-phase coupling section 4822, and W-phase coupling section 4823. This prevents the current density from increasing at the conductor coupling section 482, which would otherwise cause a temperature rise.

[0063] The rotating electric machine 1 is composed of the above elements. When the rotating electric machine 1 is used as a generator, the rotor 300 rotates in synchronization with the rotation of the crankshaft 100 of the internal combustion engine. As the rotor 300 rotates, it receives the magnetic flux from the permanent magnet 304, generating an electromotive force in the coil 404 of the stator 400. This electromotive force is converted into three-phase alternating current, and this three-phase alternating current is rectified into direct current to charge a battery (not shown). Conversely, when the rotating electric machine 1 is used as a starter for the internal combustion engine, the voltage from the battery (DC power source) (not shown) is converted into three-phase alternating current to generate a magnetic force in the coil 404. The attractive and repulsive forces between the magnetic force generated in the coil 404 and the magnetic force of the permanent magnet 304 cause the rotor 300 to rotate. This rotation of the rotor 300 also rotates the crankshaft 100, starting the internal combustion engine. Second to fourth magnetic detection sensors 542, 543, and 544 are used for rotation control during power generation and starting. The first magnetic detection sensor 541 is used to detect the reference position of the internal combustion engine.

[0064] Next, the assembly process of the stator 400 will be explained. First, a magnetic steel sheet 440 having a base portion 401 and a tooth portion 402 as shown in Figure 4 is punched out. Multiple magnetic steel sheets 440 as shown in Figure 4 are stacked to manufacture the stator core 450. The base portion 401 of the magnetic steel sheet 440 has a protruding engaging portion 432 that fits into adjacent magnetic steel sheets 440 when stacked. That is, one side of the engaging portion 432 protrudes and the other side is recessed. As a result, the protruding engaging portion 432 fits into the recessed engaging portion 432 of the adjacent magnetic steel sheet 440. The tooth portion 402 of the magnetic steel sheet 440 also has a tooth engaging portion 433 formed therein.

[0065] Similar to the engagement portion 432 described above, the teeth engagement portion 433 also has one side protruding and the other side recessed. This mechanically fixes the teeth engagement portion 433 formed on the teeth portion 402 of the adjacent magnetic steel plate 440. However, in addition to mechanical fixing, or in addition to mechanical fixing, the magnetic steel plate 440 and the teeth magnetic steel plate may also be fixed with an adhesive.

[0066] Next, the insulator 410 is assembled to the stator core 450 in the insulator assembly process. Figures 5 and 6 show the first insulator 411 which is positioned on one side of the stator core 450. In addition, as shown in Figures 15 and 16, a second insulator 412 is positioned on the other side of the stator core 450. As described above, the first insulator 411 is positioned such that its electrical terminal fixing portion 4170 fits into the terminal hole 4032 formed in the base portion 401 of the stator 400. Furthermore, it is positioned so that its terminal holding portion 4105 is inserted into the terminal fixing hole 4034 of the base portion 401. The electrical terminal fixing portion 4170 of the first insulator 411 is then inserted into the electrical terminal holding hole 4172 of the second insulator 412.

[0067] Next, the neutral point terminal 480 is press-fitted into the fixing portion 4100 of the first insulator 411. As shown in Figure 10, the fixing portion 4100 is roughly the same size as the neutral point terminal 480 and has an arc shape. As shown in Figure 11, a fixing groove 4101 is formed on one end in the first axial direction (the lower side in Figure 10) corresponding to the fixing portion 481. The groove width of the fixing groove 4101 is set to be slightly larger than the plate thickness of the neutral point terminal 480, as shown in Figures 5 and 10. In other words, the manifold groove 4102, which corresponds to the manifold portion 483 within the fixing portion 481, is about 1 millimeter, which is about the same as the plate thickness of the neutral point terminal 480. Therefore, in the fixing portion 4100, the groove width of the fixing groove 4101 is about 0.2 millimeters larger than the groove width of the manifold groove 4102. Furthermore, the first width space 4824 and the second width space 4825 described above are also used when pressing in the neutral point terminal 480. When pressing in the fixing portion 481 of the neutral point terminal 480 into the fixing portion groove 4101 of the first insulator 411, a downward load in the first axial direction is applied to at least one of the first width space 4824 and the second width space 4825.

[0068] As described above, the fixing portion 481 has an engaging projection 4811 protruding from its center. Therefore, when the neutral point terminal 480 is pressed into the fixing portion groove 4101, it is guided by the engaging inclined surface 4813. Upon pressing, the engaging projection 4811 elastically deforms, and the elastic force associated with this deformation presses the engaging plane 4814 in the middle portion of the engaging projection 4811 against the fixing portion groove 4101.

[0069] Furthermore, as described above, the first wedge portion 4815 and the second wedge portion 4816 for locking are arranged on both sides of the fixing portion 481 in the second axial direction. The length of the first wedge portion 4815, which is located on the outside in the first axial direction, in the second axial direction is shorter than the length of the second wedge portion 4816, which is located on the inside in the first axial direction. Therefore, when the fixing portion 481 is pressed into the fixing portion groove 4101, the first wedge portion 4815 acts as a guide, making the press-fitting easier.

[0070] Furthermore, both the first wedge portion 4815 and the second wedge portion 4816 have a tapered shape in which the length in the second axial direction decreases as they advance toward one end in the first axial direction. This tapered shape also allows for smooth press-fitting. When press-fitting is complete, the second wedge portion 4816 in particular fits into both sides of the fixing groove 4101 in the second axial direction, preventing the neutral point terminal 480 from coming loose.

[0071] In this example, the length of the manifold 483 in the second axial direction is shorter than the length of the wire coupling portion 482 in the second axial direction. As a result, as shown in Figure 12, the wire coupling portion 482 comes into direct contact with the insulator 410. Consequently, it becomes easier to manage the press-fit allowance of the neutral point terminal 480 in the first axial direction. That is, the length of the manifold 483 in the second axial direction only needs to be shorter than the length of the fixing portion 4100 in the second axial direction, eliminating the need to strictly control the tolerance of the length of the manifold 483 in the second axial direction. Furthermore, the press-fitting of the neutral point terminal 480 in the first axial direction only needs to be done until the wire coupling portion 482 comes into contact with the insulator 410. As a result, the positional relationship of the wire coupling portion 482 in the first axial direction can be stabilized. This makes it possible to stabilize the fixing positions of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70. Since the fixing positions are stable, it becomes easier to ensure the vibration resistance strength of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70. Furthermore, regarding the installation, the contact point between the wire connection part 482 and the insulator 410 is exposed, making it easier to visually check the installation.

[0072] After assembling the neutral terminal 480 and electrical terminals, a copper wire coated with an insulating film such as enamel is prepared and wound around the teeth portion 402 of the insulator 410 to form a coil 404. As described above, the rotating electric machine 1 has three phases, U-phase, V-phase, and W-phase, each connected in parallel with three wires.

[0073] The U-phase conductor 60 winds two coils 404, U1-1 and U1-2, using the U1 conductor 61. It also winds two more coils 404, U2-1 and U2-2, using the U2 conductor 62. Finally, it winds two more coils 404, U3-1 and U3-2, using the remaining U3 conductor 63. The two coils 404 are connected by jumpers, and the three conductors 61, 62, and 63 of the U-phase conductor 60 form a single continuous wire up to the winding end points 64, 75, and 66, respectively.

[0074] The winding of coil 404 is the same for both the V-phase and W-phase. The V-phase conductor 50 consists of V1 conductor 51, V2 conductor 52, and V3 conductor 53, and is used to wind six V-phase coils 404 from V1-1 to V3-2. The V-phase conductor 50 also consists of W1 conductor 71, W2 conductor 72, and W3 conductor 73, and is used to wind six W-phase coils 404 from W1-1 to W3-2.

[0075] As shown in Figure 3, in order to increase the space factor, the coil 404 has more turns on the radially outer side than on the radially inner side. Therefore, in the case of aligned multi-layer winding, the end of the coil 404 winding is on the radially outer side of the coil 404.

[0076] From coil 404 whose insulation performance has been confirmed, the lead wires for the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 are routed, and any excess wire is cut and removed. Next, the insulation coating of the wires that will form the ends of coil 404 is stripped off. After that, the winding ends 64-66, 54-56, and 74-76 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 are placed in the first space 487 and the second space 488. As described above, two winding ends 64, 65, 54, 55, 74, and 75 are placed in the first space 487, and the remaining winding end 66, 56, and 76 is placed in the second space 488.

[0077] In this state, the first claw portion 485 and the second claw portion 486 are crimped toward the central column portion 484 to fix them in the processed shape. In this crimping process, as shown in Figure 13, the first claw portion 485 and the second claw portion 486 are crimped simultaneously. By crimping the first claw portion 485 and the second claw portion 486 simultaneously rather than separately, the crimping process for the two claw portions becomes easier. In addition, in this crimping process, the first claw portion 485 and the second claw portion 486 are crimped until they come into contact with the central column portion 484. Because the crimping is done until contact is made, fine adjustments to the amount of crimping are unnecessary. This also makes the crimping process easier.

[0078] The crimping process causes both the first claw portion 485 and the second claw portion 486 to become inclined. As described above, in the free state, the height H2 in the first axial direction of the first claw portion 485 and the second claw portion 486 was slightly higher than the height H1 in the first axial direction of the central column portion 484. By inclining the first claw portion 485 and the second claw portion 486, the height in the first axial direction of the inclined first claw portion and the height in the first axial direction of the inclined second claw portion can be made approximately equal to the height H1 in the first axial direction of the central column portion 484.

[0079] Furthermore, by employing a crimping process, it becomes possible to securely hold the winding ends 64-66, 54-56, and 74-76 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 in the first space 487 and the second space 488, respectively. Then, the winding ends 64-66, 54-56, and 74-76 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70, held in this crimping process, are soldered to the U-phase coupling part 4821, the V-phase coupling part 4822, and the W-phase coupling part 4823. Soldering further ensures a secure connection between the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 and the U-phase coupling part 4821, the V-phase coupling part 4822, and the W-phase coupling part 4823.

[0080] In the example described above, the first space 487 side of the central column 484 was recessed in the second axial direction so that the central column 484 constituted a part of the first space 487. This is a desirable shape because it allows one of the two winding end points 64, 65, 54, 55, 74, 75 to be held by a part of the central column 484. However, the first space 487 only needs to have a length in the second axial direction that can accommodate the two winding end points 64, 65, 54, 55, 74, 75. Therefore, forming a recess in the central column 484 is not necessarily required.

[0081] Furthermore, in the example described above, the length of the manifold 483 in the second axial direction was made shorter than the length of the wire coupling portion 482 in the second axial direction. This facilitates the process of press-fitting the neutral point terminal 480 into the fixing portion 4100 of the insulator 410 and is a desirable shape. However, it is possible to make the lengths of the manifold 483 and the wire coupling portion 482 the same as needed. Also, the neutral point terminal 480 does not necessarily have to be press-fitted and fixed to the insulator 410. It is also possible to insert-molde the neutral point terminal 480 when molding the resin insulator 410 (first insulator 411).

[0082] Furthermore, while the above is a preferred example of the disclosure, it is highly modifiable. For example, setting the number of coils 404 to 18 is just one example, and the number of coils 404 can be changed to other values. Also, the disclosure only requires a three-phase star connection, and does not necessarily require three parallel connections with three conductors. For example, even if two conductors are connected in parallel, the neutral point terminal 480 of the disclosure can still be used. In the case of two parallel connections, there will be two conductors in each phase, but the first space 487 may hold two conductors, and the two second spaces 488 may each hold one conductor. Alternatively, the first space 487 may hold only one conductor. Furthermore, the dimensions described in the above example are also just examples, and the materials and dimensions can be appropriately set according to the performance required of the rotating electric machine 1.

[0083] Other Embodiments The disclosures in this specification and drawings are not limited to the exemplary embodiments. The disclosures include the exemplary embodiments and variations thereof by those skilled in the art. For example, the disclosures are not limited to combinations of parts and / or elements shown in the embodiments. The disclosures are implementable in a variety of combinations. The disclosures may have additional parts that can be added to the embodiments. The disclosures include those in which parts and / or elements of an embodiment have been omitted. The disclosures include substitutions or combinations of parts and / or elements between one embodiment and another. The scope of the disclosed technical areas is not limited to the descriptions of the embodiments. Some of the scope of the disclosed technical areas are indicated by the claims and should be understood to include all modifications within the meaning and scope equivalent to the claims.

[0084] (Disclosure of technical ideas) This specification discloses several technical concepts, as listed in the following paragraphs. Some paragraphs are written in a multiple dependent form, where subsequent paragraphs optionally refer to preceding paragraphs. Furthermore, some paragraphs are written in a multiple dependent form, referring to other multiple dependent forms. These paragraphs written in multiple dependent forms define several technical concepts.

[0085] (Technical Concept 1) Multiple permanent magnets are arranged in the circumferential direction, and a rotor rotates together with the shaft, A rotating electric machine comprising a stator having a stator core having an annular base portion and multiples of 3 teeth portions extending radially outward from the base portion, an insulator made of insulating material disposed on at least a part of the base portion and the teeth portion of the stator core, and a coil wound around the outer circumference of the insulator at a position corresponding to the teeth portion of the stator core, The aforementioned coil is star-connected to three phases, and three conductors for each phase are electrically connected to the neutral terminal. The neutral point terminal is fixed to a fixed portion formed in a groove shape on the base of the insulator. The neutral point terminal is a plate extending in a first axial direction and in a second axial direction perpendicular to the first axial direction. The neutral point terminal is configured such that a fixing portion is provided at one end in the first axial direction to engage with the insulator, a wire coupling portion is provided at the other end in the first axial direction to secure three wires for each phase, and a manifold portion is interposed between the wire coupling portion and the fixing portion in the first axial direction. The aforementioned wire coupling section has three coupling sections arranged along the second axial direction, each holding three wires for each of the three phases. Each connecting portion has a central column portion that extends in the first axial direction and forms a first space for arranging two of the conductors along either direction in the second axial direction and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion that is positioned on the first space side of the central column portion and inclined toward the central column portion to hold two of the conductors in the first space, and a second claw portion that is positioned on the second space side of the central column portion and inclined toward the central column portion to hold one of the conductors in the second space. A rotating electric machine in which the height of the central column portion in the first axial direction, the height of the inclined first claw portion in the first axial direction, and the height of the inclined second claw portion in the first axial direction are approximately equal.

[0086] (Technical Concept 2) A stator core having an annular base portion and multiples of 3 teeth portions extending radially outward from the base portion, An insulator made of insulating material is disposed on at least a part of the base portion and the teeth portion of this stator core, The stator core has a coil wound around the outer circumference of the insulator at a position corresponding to the teeth portion, The coil is connected in a star configuration to three phases, and three conductors for each phase are electrically connected to the neutral terminal in a stator for a rotating electric machine. The neutral point terminal is fixed to a fixed portion formed in a groove shape on the base of the insulator. The neutral point terminal is a plate extending in a first axial direction and in a second axial direction perpendicular to the first axial direction. The neutral point terminal is configured such that a fixing portion is provided at one end in the first axial direction to engage with the insulator, a wire coupling portion is provided at the other end in the first axial direction to secure three wires for each phase, and a manifold is interposed between the wire coupling portion and the fixing portion in the first axial direction. The aforementioned wire coupling section has three coupling sections arranged along the second axial direction, each holding three wires for each of the three phases. Each connecting portion has a central column portion that extends in the first axial direction and forms a first space for arranging two of the conductors along either direction in the second axial direction and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion that is positioned on the first space side of the central column portion and inclined toward the central column portion to hold two of the conductors in the first space, and a second claw portion that is positioned on the second space side of the central column portion and inclined toward the central column portion to hold one of the conductors in the second space. A stator for a rotating electric machine in which the height of the central column portion in the first axial direction, the height of the inclined first claw portion in the first axial direction, and the height of the inclined second claw portion in the first axial direction are approximately equal.

[0087] (Technical Concept 3) A stator core having an annular base portion and multiples of 3 teeth portions extending radially outward from the base portion, An insulator made of insulating material is disposed on at least a part of the base portion and the teeth portion of this stator core, The stator core comprises a coil wound around the outer circumference of the insulator at a position corresponding to the teeth portion of the stator core, The coil is star-connected to three phases, and three conductors for each phase are electrically connected to the neutral point terminal, forming a neutral point terminal for a rotating electric machine stator. The neutral point terminal is fixed to a fixed portion formed in a groove shape on the base of the insulator. The neutral point terminal is a plate extending in a first axial direction and in a second axial direction perpendicular to the first axial direction. The neutral point terminal is configured such that a fixing portion is provided at one end in the first axial direction to engage with the insulator, a wire coupling portion is provided at the other end in the first axial direction to secure three wires for each phase, and a manifold is interposed between the wire coupling portion and the fixing portion in the first axial direction. The aforementioned wire coupling section has three coupling sections arranged along the second axial direction, each holding three wires for each of the three phases. Each connecting portion has a central column portion that extends in the first axial direction and forms a first space for arranging two of the conductors along either direction in the second axial direction and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion that is positioned on the first space side of the central column portion and inclined toward the central column portion to hold two of the conductors in the first space, and a second claw portion that is positioned on the second space side of the central column portion and inclined toward the central column portion to hold one of the conductors in the second space. A neutral point terminal for a rotating electric machine stator, wherein the height of the central column portion in the first axial direction, the height of the inclined first claw portion in the first axial direction, and the height of the inclined second claw portion in the first axial direction are approximately equal.

[0088] (Technical Idea 4) The first space side of the central column portion is recessed in the second axial direction and constitutes a part of the first space, a rotating electric machine according to Technical Idea 1, a stator for a rotating electric machine according to Technical Idea 2, or a neutral point terminal for a stator for a rotating electric machine according to Technical Idea 3.

[0089] (Technical Idea 5) The length of the manifold in the second axial direction is shorter than the length of the wire coupling in the second axial direction, and is longer than the length of the second axial direction connecting the first claw portion and the second claw portion of the coupling portions arranged on both sides in the second axial direction, which are located on the inside in the second axial direction, as described in Technical Idea 1 or Technical Idea 4 which is dependent on Technical Idea 1, a stator for a rotating electric machine as described in Technical Idea 2 or Technical Idea 4 which is dependent on Technical Idea 2, or a neutral point terminal for a stator for a rotating electric machine as described in Technical Idea 3 or Technical Idea 4 which is dependent on Technical Idea 3.

[0090] (Technical Idea 6) The length of the fixed portion in the second axial direction is shorter than the length of the manifold portion in the second axial direction, a rotating electric machine according to Technical Idea 1 or Technical Idea 4 or Technical Idea 5 which is dependent on Technical Idea 1, a stator for a rotating electric machine according to Technical Idea 2 or Technical Idea 4 or Technical Idea 5 which is dependent on Technical Idea 2, or a neutral point terminal for a stator for a rotating electric machine according to Technical Idea 3 or Technical Idea 4 or Technical Idea 5 which is dependent on Technical Idea 3.

[0091] (Technical Idea 7) A rotating electric machine according to any one of Technical Idea 1 or Technical Ideas 4 to 6 which are dependent on Technical Idea 1, a stator for a rotating electric machine according to any one of Technical Idea 2 or Technical Ideas 4 to 6 which are dependent on Technical Idea 2, or a neutral point terminal for a stator for a rotating electric machine according to any one of Technical Idea 3 or Technical Ideas 4 to 6 which are dependent on Technical Idea 3.

[0092] (Technical Idea 8) A method for manufacturing a stator for a rotating electric machine as described in Technical Idea 2, A joint forming step, in which the central column portion, the first claw portion, and the second claw portion of the joint are all formed parallel to each other in the direction of the first axis, and the height of the first claw portion and the second claw portion in the direction of the first axis is greater than the height of the central column portion in the direction of the first axis; A wire arrangement step involves arranging two of the aforementioned wires side by side in the second axial direction within the first space, and arranging one of the aforementioned wires on the second space side, A method for manufacturing a stator for a rotating electric machine, comprising the steps of simultaneously tilting the first claw portion and the second claw portion toward the central column portion until they come into contact with the central column portion, thereby making the height of the central column portion in the first axial direction, the height of the tilted first claw portion in the first axial direction, and the height of the tilted second claw portion in the first axial direction approximately equal.

[0093] (Technical Idea 9) A method for manufacturing a stator for a rotating electric machine as described in Technical Idea 5, which is subordinate to Technical Idea 2, The neutral point terminal includes a press-fitting step in which the fixing portion and the manifold portion are press-fitted into the fixing portion of the insulator in the first axial direction. This press-fitting process is carried out until the joint comes into contact with the insulator outside the fixing portion of the base portion, and is a method for manufacturing a stator for a rotating electric machine.

Claims

1. Multiple permanent magnets are arranged in the circumferential direction, and the rotor rotates together with the shaft, A rotating electric machine comprising a stator having a stator core having an annular base portion and multiples of 3 teeth portions extending radially outward from the base portion, an insulator made of insulating material disposed on at least a part of the base portion and the teeth portion of the stator core, and a coil wound around the outer circumference of the insulator at a position corresponding to the teeth portion of the stator core, The aforementioned coil is star-connected to three phases, and three conductors for each phase are electrically connected to the neutral terminal. The neutral point terminal is fixed to a fixed portion formed in a groove shape on the base of the insulator. The neutral point terminal is a plate extending in a first axial direction and in a second axial direction perpendicular to the first axial direction. The neutral point terminal is configured such that a fixing portion is provided at one end in the first axial direction to engage with the insulator, a wire coupling portion is provided at the other end in the first axial direction to secure three wires for each phase, and a manifold portion is interposed between the wire coupling portion and the fixing portion in the first axial direction. The aforementioned wire coupling section has three coupling sections arranged along the second axial direction, each holding three wires for each of the three phases. Each connecting portion has a central column portion that extends in the first axial direction and forms a first space for arranging two of the conductors along either direction in the second axial direction and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion that is positioned on the first space side of the central column portion and inclined toward the central column portion to hold the two conductors in the first space, and a second claw portion that is positioned on the second space side of the central column portion and inclined toward the central column portion to hold one of the conductors in the second space. The height of the central column in the first axial direction, the height of the inclined first claw in the first axial direction, and the height of the inclined second claw in the first axial direction are approximately equal. A rotating electric machine characterized by the following features.

2. A stator core having an annular base portion and a tooth portion that is multiples of 3 and extends radially outward from the base portion, An insulator made of insulating material is disposed on at least a part of the base portion and the teeth portion of this stator core, The stator core has a coil wound around the outer circumference of the insulator at a position corresponding to the teeth portion, The coil is connected in a star configuration to three phases, and three conductors for each phase are electrically connected to the neutral terminal in a stator for a rotating electric machine. The neutral point terminal is fixed to a fixed portion formed in a groove shape on the base of the insulator. The neutral point terminal is a plate extending in a first axial direction and in a second axial direction perpendicular to the first axial direction. The neutral point terminal is configured such that a fixing portion is provided at one end in the first axial direction to engage with the insulator, a wire coupling portion is provided at the other end in the first axial direction to secure three wires for each phase, and a junction is interposed between the wire coupling portion and the fixing portion in the first axial direction. The aforementioned wire coupling section has three coupling sections arranged along the second axial direction, each holding three wires for each of the three phases. Each connecting portion has a central column portion that extends in the first axial direction and forms a first space for arranging two of the conductors along either direction in the second axial direction and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion that is positioned on the first space side of the central column portion and inclined toward the central column portion to hold the two conductors in the first space, and a second claw portion that is positioned on the second space side of the central column portion and inclined toward the central column portion to hold one of the conductors in the second space. The height of the central column in the first axial direction, the height of the inclined first claw in the first axial direction, and the height of the inclined second claw in the first axial direction are approximately equal. A stator for rotating electric machines characterized by the following features.

3. A stator core having an annular base portion and a tooth portion that is multiples of 3 and extends radially outward from the base portion, An insulator made of insulating material is disposed on at least a part of the base portion and the teeth portion of this stator core, The stator core comprises a coil wound around the outer circumference of the insulator at a position corresponding to the teeth portion of the stator core, The coil is star-connected to three phases, and three conductors for each phase are electrically connected to the neutral point terminal, in the neutral point terminal of a stator for a rotating electric machine. The neutral point terminal is fixed to a fixed portion formed in a groove shape on the base of the insulator. The neutral point terminal is a plate extending in a first axial direction and in a second axial direction perpendicular to the first axial direction. The neutral point terminal is configured such that a fixing portion is provided at one end in the first axial direction to engage with the insulator, a wire coupling portion is provided at the other end in the first axial direction to secure three wires for each phase, and a junction is interposed between the wire coupling portion and the fixing portion in the first axial direction. The aforementioned wire coupling section has three coupling sections arranged along the second axial direction, each holding three wires for each of the three phases. Each connecting portion has a central column portion that extends in the first axial direction and forms a first space for arranging two of the conductors along either direction in the second axial direction and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion that is positioned on the first space side of the central column portion and inclined toward the central column portion to hold the two conductors in the first space, and a second claw portion that is positioned on the second space side of the central column portion and inclined toward the central column portion to hold one of the conductors in the second space. The height of the central column in the first axial direction, the height of the inclined first claw in the first axial direction, and the height of the inclined second claw in the first axial direction are approximately equal. A neutral point terminal for a stator of a rotating electric machine, characterized by the following features.

4. The first space side of the central column portion is recessed in the second axial direction and constitutes a part of the first space. The rotating electric machine according to feature 1.

5. The length of the assembly portion in the second axial direction is shorter than the length of the conductor coupling portion in the second axial direction, and longer than the length in the second axial direction connecting the first claw portion and the second claw portion of the coupling portion, which are located on the inside in the second axial direction. The rotating electric machine according to feature 1.

6. The length of the fixed portion in the second axial direction is shorter than the length of the assembly portion in the second axial direction. The rotating electric machine according to feature 1.

7. On both sides of the fixed portion in the second axial direction, a first wedge portion and a second wedge portion for locking are arranged in the first axial direction, and the length of the first wedge portion, which is located on the outside in the first axial direction, in the second axial direction is shorter than the length of the second wedge portion, which is located on the inside in the first axial direction. The rotating electric machine according to feature 1.

8. A method for manufacturing a stator for a rotating electric machine according to claim 2, A joint forming step, in which the central column portion, the first claw portion, and the second claw portion of the joint are all formed parallel to each other in the direction of the first axis, and the height of the first claw portion and the second claw portion in the first axis is greater than the height of the central column portion in the first axis; A wire arrangement step involves arranging two of the aforementioned wires side by side in the second axial direction within the first space, and arranging one of the aforementioned wires on the second space side, A crimping process is performed in which the first claw portion and the second claw portion are simultaneously inclined toward the central column portion until they come into contact with the central column portion, so that the height of the central column portion in the first axial direction, the height of the inclined first claw portion in the first axial direction, and the height of the inclined second claw portion in the first axial direction are approximately equal. A method for manufacturing a stator for a rotating electric machine, characterized by performing the process in radial time sequence.

9. A method for manufacturing a stator for a rotating electric machine according to claim 2, The length of the assembly portion in the second axial direction is shorter than the length of the conductor coupling portion in the second axial direction, and longer than the length in the second axial direction connecting the claw portion of either the first claw portion or the second claw portion of the coupling portion arranged on both sides in the second axial direction that is located on the inside in the second axial direction. The neutral point terminal includes a press-fitting step in which the fixing portion and the manifold portion are press-fitted into the fixing portion of the insulator in the first axial direction. This press-fitting process is carried out until the joint comes into contact with the insulator outside the fixing portion of the base. A method for manufacturing a stator for a rotating electric machine, characterized by the following features.

10. Multiple permanent magnets are arranged in the circumferential direction, and the rotor rotates together with the shaft, A rotating electric machine comprising a stator having a stator core having an annular base portion and multiples of 3 teeth portions extending radially outward from the base portion, an insulator made of insulating material disposed on at least a part of the base portion and the teeth portion of the stator core, and a coil wound around the outer circumference of the insulator at a position corresponding to the teeth portion of the stator core, The aforementioned coil is star-connected to three phases, and three conductors for each phase are electrically connected to the neutral terminal. The neutral point terminal is fixed to a fixed portion formed in a groove shape on the base of the insulator. The neutral point terminal is a plate extending in a first axial direction and in a second axial direction perpendicular to the first axial direction. The neutral point terminal is configured such that a fixing portion is provided at one end in the first axial direction to engage with the insulator, a wire coupling portion is provided at the other end in the first axial direction to secure three wires for each phase, and a manifold portion is interposed between the wire coupling portion and the fixing portion in the first axial direction. The aforementioned wire coupling section has three coupling sections arranged along the second axial direction, each holding three wires for each of the three phases. Each connecting portion has a central column portion extending in the first axial direction, which forms a first space for arranging two of the conductors along either of the directions in the second axial direction and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion positioned on the first space side of the central column portion and inclined toward the central column portion to hold the two conductors in the first space, and a second claw portion positioned on the second space side of the central column portion and inclined toward the central column portion to hold one of the conductors in the second space, thereby reducing the length in the first axial direction required to arrange the two conductors. A rotating electric machine characterized by the following features.

11. A stator core having an annular base portion and a tooth portion that is multiples of 3 and extends radially outward from the base portion, An insulator made of insulating material is disposed on at least a part of the base portion and the teeth portion of this stator core, The stator core has a coil wound around the outer circumference of the insulator at a position corresponding to the teeth portion, The coil is connected in a star configuration to three phases, and three conductors for each phase are electrically connected to the neutral terminal in a stator for a rotating electric machine. The neutral point terminal is fixed to a fixed portion formed in a groove shape on the base of the insulator. The neutral point terminal is a plate extending in a first axial direction and in a second axial direction perpendicular to the first axial direction. The neutral point terminal is configured such that a fixing portion is provided at one end in the first axial direction to engage with the insulator, a wire coupling portion is provided at the other end in the first axial direction to secure three wires for each phase, and a junction is interposed between the wire coupling portion and the fixing portion in the first axial direction. The aforementioned wire coupling section has three coupling sections arranged along the second axial direction, each holding three wires for each of the three phases. Each connecting portion has a central column portion extending in the first axial direction, which forms a first space for arranging two of the conductors along either of the directions in the second axial direction and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion positioned on the first space side of the central column portion and inclined toward the central column portion to hold the two conductors in the first space, and a second claw portion positioned on the second space side of the central column portion and inclined toward the central column portion to hold one of the conductors in the second space, thereby reducing the length in the first axial direction required to arrange the two conductors. A stator for rotating electric machines characterized by the following features.

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