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

Rotating electric machine, stator for rotating electric machine, neutral point terminal of stator for rotating electric machine, and method for manufacturing stator for rotating electric machine CROSS-REFERENCE TO RELATED APPLICATIONS

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

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

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

[0004] Patent No. 6343394

[0005] The neutral terminal of Patent Document 1 has two grooves formed as coil holding portions, and conductors are placed in these grooves. Here, if the coils are star-connected into three phases and each of the three phases is also connected in parallel, three conductors for each phase must be electrically connected to the neutral terminal. Therefore, if the neutral terminal of Patent Document 1 is used, two conductors must be placed overlapping each other in one of the grooves. The overlapping of the conductors complicates the placement process. Furthermore, the depth of the grooves must be sufficient to accommodate the placement of the two conductors, which requires a large length in the depth direction (first axial direction).

[0006] Here, it is possible to form three grooves, but this would require increasing the length in the direction in which the grooves are aligned (the second axial direction). The neutral terminal is located in the base portion of the stator for the rotating electric machine. Bolts for attaching the stator to the engine are located in this base portion. Terminals for electrically connecting to the coil conductors are also located in the base portion. A sensor case for detecting the rotation state of the rotating electric machine is also located in the base portion. Therefore, increasing the length in the direction in which the grooves are aligned (the second axial direction) would impair the assembly of the rotating electric machine.

[0007] This disclosure is based on the premise that the coils are star-connected for three phases, and each of the three phases is also connected in three parallel connections. In this case, the objective is to accommodate three conductors for each phase in a compact space between the first axis direction and the second axis direction.

[0008] One aspect of the present disclosure relates to a rotating electric machine that includes a rotor that has a plurality of permanent magnets arranged circumferentially and rotates together with a shaft, a stator core that has an annular base portion and a number of teeth extending radially outward from the base portion, an insulator made of an insulating material that is arranged on at least a portion of the base portion and the teeth portion of the stator core, and a stator that has coils wound around the outer periphery of the insulator at positions corresponding to the teeth portion of the stator core.

[0009] In the rotating electric machine of the first disclosure, the coils are star-connected for three phases, and three conductors for each phase are electrically connected to a neutral terminal. The neutral terminal is fixed to a fixing portion formed in a groove in a base portion of the insulator, and is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction. The neutral terminal has a fixing portion that engages with the insulator at one end in the first axial direction, a conductor coupling portion that engages with the three conductors for each phase at the other end in the first axial direction, and a collecting portion interposed between the conductor coupling portion and the fixing portion in the first axial direction.

[0010] In the rotating electric machine of the first disclosure, the conductor coupling portions are arranged at three locations along the second axial direction, each coupling portion holding three conductors for each of the three phases. Each coupling portion has a central pillar portion extending in the first axial direction, forming a first space for arranging two conductors along one side of the second axial direction and a second space for arranging one conductor on the other side of the second axial direction, a first claw portion disposed on the first space side of the central pillar portion and inclined toward the central pillar portion to hold two conductors in the first space, and a second claw portion disposed on the second space side of the central pillar portion and inclined toward the central pillar portion to hold one conductor in the second space. The height of the central pillar 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 set to be approximately equal.

[0011] In the rotating electric machine of the first disclosure, each coupling portion forms a first space in which two conductors are arranged along either one of the second axial directions, thereby making it possible to reduce the length in the first axial direction required to arrange the two conductors. Furthermore, because the two conductors are arranged within the first space, it is also possible to reduce the length in the second axial direction.

[0012] In addition, in the rotating electric machine of the first disclosure, the height in the first axial direction of the central pillar portion, 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 are set to be approximately equal, so that the inclination of the first claw portion and the second claw portion can also reduce the length in the first axial direction of the joint portion.

[0013] The second disclosure is a stator for a rotating electric machine that includes a stator core having an annular base portion and a number of teeth extending radially outward from the base portion, an insulator made of an insulating material that is arranged on at least a portion of the base portion and the teeth portion of the stator core, and a coil wound around the outer periphery of the insulator at a position corresponding to the teeth portion of the stator core, the coil being star-connected in three phases and with three conductors for each phase electrically connected to a neutral terminal.

[0014] In the stator for a rotating electric machine of the second disclosure, the neutral terminal is fixed to a fixing portion formed in a groove in a base portion of the insulator. The neutral terminal is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction. The neutral terminal has a fixing portion disposed at one end in the first axial direction that engages with the insulator, and a wire coupling portion disposed at the other end in the first axial direction that engages three conductors for each phase, with a collection portion interposed between the wire coupling portion and the fixing portion in the first axial direction.

[0015] In a stator for a rotating electric machine according to a second disclosure, the conductor coupling portion has three coupling portions arranged along the second axial direction, each coupling portion holding three conductors for each of three phases. Each coupling portion has a central pillar portion extending in the first axial direction, forming a first space for arranging two conductors along one side of the second axial direction and a second space for arranging one conductor on the other side of the second axial direction, a first claw portion disposed on the first space side of the central pillar portion and inclined toward the central pillar portion to hold two conductors in the first space, and a second claw portion disposed on the second space side of the central pillar portion and inclined toward the central pillar portion to hold one conductor in the second space. The height of the central pillar portion in the first axial direction, the height of the inclined first claw portion, and the height of the inclined second claw portion in the first axial direction are set to be approximately equal.

[0016] In the stator for a rotating electric machine of the second disclosure, each coupling portion forms a first space in which two conductors are arranged along either one of the second axial directions, thereby making it possible to reduce the length in the first axial direction required to arrange the two conductors. Moreover, because the two conductors are arranged within the first space, it is also possible to reduce the length in the second axial direction.

[0017] In addition, in the stator for a rotating electric machine disclosed in the second disclosure, the height in the first axial direction of the central column portion, 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 are set to be approximately equal, so that the inclination of the first claw portion and the second claw portion can also reduce the length in the first axial direction of the joint portion.

[0018] The third disclosure is a neutral terminal of a stator for a rotating electric machine, which includes a stator core having a circular base portion and a number of teeth extending radially outward from the base portion, an insulator made of an insulating material that is arranged on at least a portion of the base portion and the teeth portion of the stator core, and a coil wound around the outer periphery of the insulator at a position corresponding to the teeth portion of the stator core, the coil being star-connected in three phases and three conductors for each phase being electrically connected to the neutral terminal.

[0019] The neutral terminal of the stator for a rotating electric machine of the third disclosure is fixed to a fixing portion formed in a groove in a base portion of the insulator. The neutral terminal is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction. The neutral terminal has a fixing portion disposed at one end in the first axial direction that engages with the insulator, and a wire coupling portion disposed at the other end in the first axial direction that engages three conductors for each phase, with a collection portion interposed between the wire coupling portion and the fixing portion in the first axial direction.

[0020] In the neutral terminal of a stator for a rotating electric machine according to the third disclosure, the conductor coupling portions are arranged at three locations along the second axial direction, each coupling portion holding three conductors for each of three phases. Each coupling portion has a central pillar portion extending in the first axial direction, forming a first space for arranging two conductors along one side of the second axial direction and a second space for arranging one conductor on the other side of the second axial direction, a first claw portion disposed on the first space side of the central pillar portion and inclined toward the central pillar portion to hold two conductors in the first space, and a second claw portion disposed on the second space side of the central pillar portion and inclined toward the central pillar portion to hold one conductor in the second space. The height of the central pillar 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 set to be approximately equal.

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

[0022] In addition, in the neutral terminal of the stator for a rotating electric machine disclosed in the third disclosure, the height in the first axial direction of the central pillar portion, 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 are set to be approximately equal, so that the inclination of the first claw portion and the second claw portion can also reduce the length in the first axial direction of the joint portion.

[0023] In the fourth disclosure, the first space side of the central pillar is recessed in the second axial direction to form part of the first space. By recessing the central pillar to form part of the first space, it is possible to further compact the length in the second axial direction.

[0024] In the fifth disclosure, the length of the collection portion in the second axial direction is shorter than the length of the wire coupling portion, but longer than the length in the second axial direction connecting the first claw portion and the second claw portion, whichever is located on the inner side in the second axial direction, of the coupling portions located on both sides in the second axial direction. First, because the length is shorter than the length of the wire coupling portion in the second axial direction, the wire joint portion directly contacts the insulator. As a result, the tolerance of the collection portion is irrelevant, thereby stabilizing the positional relationship of the wire joint portion. This also makes it possible to stabilize the fixed position of the wire. As a result, it is easy to ensure the vibration resistance strength of the wire. Furthermore, regarding the installation condition, since the portion where the wire coupling portion contacts the insulator is exposed, it is easy to visually check the installation.

[0025] Next, since the length in the second axial direction of either the first or second claw of the connecting portions arranged on both sides in the second axial direction is set to be longer than the length in the second axial direction connecting the claw portion arranged on the inner side in the second axial direction, it is possible to maintain a width sufficient to ensure current density even if the length in the second axial direction of the collecting portion is shortened. In other words, it is possible to prevent the current from concentrating in a specific narrow area and generating heat in that area.

[0026] In the sixth disclosure, 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. Since the fixed portion is located on the opposite side of the conductor coupling portion in the first axial direction, it is located at the innermost portion of the insulator in the first axial direction. If the length of the fixed portion in the second axial direction at this innermost portion is shortened, the length of the insulator in the second axial direction can also be shortened. As a result, the area of ​​the insulator that occupies the base portion of the stator core can be reduced in the area corresponding to the fixed portion.

[0027] In the seventh disclosure, first and second wedge portions for locking are arranged in the first axial direction on both sides of the fixed portion in the second axial direction. The length in the second axial direction of the first wedge portion arranged on the outer side in the first axial direction is shorter than the length in the second axial direction of the second wedge portion arranged on the inner side in the first axial direction. Because the first wedge portion with the shorter length in the second axial direction is arranged on the outer side in the first axial direction, it is possible for the first wedge portion to function as a guide. This makes it easier to assemble the neutral terminal to the insulator.

[0028] The eighth disclosure is a manufacturing method of a stator for a rotating electric machine. This manufacturing method first employs a joint forming process in which the central post portion, first claw portions, and second claw portions of the joint portion are all formed parallel to each other in the first axial direction and such that the heights of the first claw portions and second claw portions in the first axial direction are greater than the height of the central post portion in the first axial direction. Next, a conductor arrangement process is performed in which two conductor wires are arranged side by side in the second axial direction within the first space and one conductor wire is arranged in the second space. After that, a crimping process is performed in which the first claw portion and the second claw portion are simultaneously tilted toward the central post portion until they abut against the central post portion, thereby making the height of the central post portion, the height of the tilted first claw portion, and the height of the tilted second claw portion in the first axial direction approximately equal.

[0029] In the eighth disclosed manufacturing method, the first and second claws are simultaneously crimped toward the central pillar, making the crimping process of the two claws easier. Furthermore, the crimping process is also made easier by crimping the first and second claws until they abut against the central pillar. Furthermore, since the first and second claws are tilted during the crimping process, the height of the central pillar in the first axial direction, the height of the tilted first claw, and the height of the tilted second claw in the first axial direction can be made approximately equal.

[0030] The ninth disclosure also relates to a manufacturing method of a stator for a rotating electric machine. The manufacturing method of the ninth disclosure includes a press-fitting process in which the fixed portion and the assembly portion of the neutral terminal are press-fitted into the fixed portion of the insulator in a first axial direction. This press-fitting process is performed until the joint portion abuts against the insulator outside the fixed portion of the base portion. Because the press-fitting in the first axial direction is performed until the joint portion abuts against the insulator outside the fixed portion of the base portion, it is easy to determine the press-fit distance. Furthermore, since the portion that contacts the insulator is exposed during press-fitting, it is easy to visually check the fit.

[0031] FIG. 1 is a cross-sectional view of a rotating electric machine assembled with a crankshaft and a cylinder block. FIG. 2 is a front view showing a rotor, a stator, a power cable, and a sensor case of the rotating electric machine. FIG. 3 is a perspective view showing a stator and a sensor case of the rotating electric machine. FIG. 4 is a front view of a steel plate constituting a stator core. FIG. 5 is a perspective view of a first insulator. FIG. 6 is a perspective view of the first insulator shown in FIG. 5 from another direction. FIG. 7 is an electrical circuit diagram of a three-phase star-connected circuit in which each phase is wired in three parallel configurations. FIG. 8 is a front view of a neutral terminal with conductors arranged therein. FIG. 9 is a side view of the neutral terminal. FIG. 10 is a front view of the insulator shown in FIG. 5. FIG. 11 is a cross-sectional view showing a fixing portion of the insulator. FIG. 12 is a cross-sectional view showing the neutral terminal and the insulator assembled. FIG. 13 is an explanatory diagram showing a crimping process for the neutral terminal. FIG. 14 is a front view of a comparative example of a neutral terminal. FIG. 15 is a perspective view of a second insulator. 16 is a perspective view of the second insulator shown in FIG. 15 as viewed from another direction.

[0032] An example of the present disclosure will now be described with reference to the drawings. First, an example of a rotating electric machine to which the present disclosure is applied will be described. FIG. 1 is a cross-sectional view of a rotating electric machine 1 combined with a crankshaft 100. Reference numeral 101 denotes a cylinder block, and pistons (not shown) reciprocate within cylinders (not shown) within the cylinder block 101. The movement of the pistons rotates the crankshaft 100 via connecting rods (not shown). The crankshaft 100 is made of an iron material with a diameter of approximately 20 millimeters, and is rotationally supported by bearings 102 in the cylinder block 101.

[0033] A rotor 300 of the rotating electric machine 1 is fixed to the crankshaft 100 at a base 301. Therefore, the rotor 300 rotates integrally with the crankshaft 100. The rotor 300 is made of iron and includes a disk portion 302 extending radially outward from the base portion 301 that engages with the crankshaft 100, and a cylindrical portion 303 formed radially outward of the disk portion 302. As shown in FIG. 1 , twelve permanent magnets 304 are arranged circumferentially inside the cylindrical portion 303. The thickness of the permanent magnets 304 is approximately 4 to 5 millimeters. The number of permanent magnets 304 is not limited to 12, and can be set to 10, 24, or any other number appropriate to provide the number of poles and magnetic flux required for performance.

[0034] As shown in FIGS. 1 and 2, a stator 400 is disposed inside the rotor 300. FIG. 2 is a front view of the stator 400 viewed from the cylinder block 101 side. The stator 400 is formed by laminating a plurality of magnetic steel plates 440 as shown in FIG. 4, and integrally forms a base portion 401 attached to the cylinder block 101 and a plurality of teeth 402 extending radially outward from the base portion 401. The outer diameter of the stator 400 is approximately 110 to 130 millimeters. Therefore, the inner diameter of the rotor 300 is sized to form a minute gap of approximately 1 millimeter between the outer diameter of the stator 400 and the permanent magnets 304. Providing this minute gap makes it possible to absorb deformation associated with assembly of the rotor 300 and vibrations associated with operation of the internal combustion engine.

[0035] The base plate portion 401 has three stator bolt through-holes 4030 for fixing the stator 400 to the cylinder block 101. The base plate portion 401 also has sensor case bolt through-holes 4031 for fixing the sensor case 500 to the stator 400. The base plate portion 401 also has three terminal holes 4032 through which electrical terminal fixing portions 4170 of the insulator 410 described below pass. The base plate portion 401 also has a clip press-fit fixing hole 4033 for fixing the clip 610. The base plate portion 401 also has a terminal fixing hole 4034 to which a fixing portion 481 of the neutral terminal 480 described below is fixed.

[0036] Teeth 402 are electrically insulated by insulators 410 made of insulating resin such as polyamide or nylon 66, and coils 404 made of copper or aluminum wire are wound on insulator 410. Fig. 3 is a perspective view showing stator 400 and sensor case 500 with rotor 300 removed from Fig. 2.

[0037] 3, gaps 405 are formed between adjacent coils 404, and these gaps 405 widen radially outward. A sensor case 500 is disposed in this gap 405. The sensor case 500 is molded from a resin such as polyamide, similar to the insulator 410 described above. A first magnetic detection sensor 541, a second magnetic detection sensor 542, a third magnetic detection sensor 543, and a fourth magnetic detection sensor 544 are disposed within the sensor case 500.

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

[0039] The insulators 410 are arranged to cover both axial sides of the stator 400. Figures 5 and 6 show a first insulator 411 arranged on one side of the stator 400, and Figures 15 and 16 show a second insulator 412 arranged on the other side. As shown in these figures, bobbin portions 4120 are formed on the insulator 410 in correspondence with the tooth portions 402.

[0040] 5 and 6, a fixing portion 4100 for holding the neutral terminal 480 is formed in a portion corresponding to the base portion 401. More specifically, a terminal holding portion 4105 is formed in the fixing portion 4100, and the fixing portion 481 of the neutral 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 positions corresponding to the base portion 401. The electrical terminal fixing portions 4170 hold electrical terminals therein that electrically connect to the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 (shown in FIG. 7 ). As described above, the electrical terminal fixing portions 4170 pass through the terminal holes 4032 in the base portion 401. These electrical terminals route the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70, which are wound around one side of the stator 400, to the other side.

[0042] 15 and 16, an electric terminal positioning portion 4171 is formed in a portion corresponding to the base portion 401. The electric terminal positioning portion 4171 has three electric terminal holding holes 4172 formed in portions corresponding to the electric terminal fixing portions 4170. Therefore, the first insulator 411 and the second insulator 412 are fitted together by inserting the tip of the electric terminal fixing portion 4170 of the first insulator 411 into the electric terminal holding holes 4172. The second insulator 412 also has a terminal receiving portion 4106 formed in a position corresponding to the terminal holding portion 4105 of the first insulator 411 that 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] 2 and 4, the base portion 401 has stator bolt through-holes 4030 formed at 120-degree intervals. The sensor case 500 is disposed between these stator bolt through-holes 4030, and the clip 610 is also disposed therebetween. 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 arranging the fixing portions 4100 of the insulator 410 is limited.

[0044] As shown in Fig. 3, there are 18 coils 404. Fig. 7 shows an electrical circuit diagram of each coil 404. As shown in Fig. 7, the rotating electric machine 1 has three-phase AC, namely, U-phase, V-phase, and W-phase. In this embodiment, each phase is connected in three parallel connections with three conductors.

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

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

[0047] The neutral point terminal 480 is a plate member extending in a first axial direction, which is the up-and-down direction in FIG. 8 , and a second axial direction (left-and-right direction in FIG. 8 ) perpendicular to the first axial direction. Iron or brass is used as the material for the neutral point terminal 480. The plate member of the neutral point terminal 480 has a thickness of about 1 millimeter. A fixing portion 481 is formed at one end of the neutral point terminal 480 in the first axial direction (the lower end in FIG. 8 ) so as to extend in the first axial direction. This fixing portion 481 is press-fitted and fixed into a fixing portion 4100 of the insulator 410.

[0048] An engaging protrusion 4811 is formed protruding from the center of the fixing portion 481. The engaging protrusion 4811 is press-formed and protrudes in the thickness direction of the neutral terminal 480. In FIG. 9 , it protrudes to the left of the page, perpendicular to both the first axial direction and the second axial direction. This protrusion amount is approximately 1 millimeter. Therefore, both sides of the engaging protrusion 4811 in the first axial direction form engaging inclined surfaces 4813. The middle portion of the engaging protrusion 4811 forms an engaging flat surface 4814.

[0049] A first locking wedge portion 4815 and a second locking wedge portion 4816 are disposed on both sides of the fixing portion 481 in the second axial direction. The first locking wedge portion 4815 is disposed closer to one end in the first axial direction than the second locking wedge portion 4816 (lower side in FIGS. 8 and 9 ). Both the first locking wedge portion 4815 and the second locking wedge portion 4816 have a tapered shape in which the length in the second axial direction decreases toward the one end in the first axial direction. Furthermore, both the first locking wedge portion 4815 and the second locking wedge portion 4816 protrude by approximately 0.5 millimeters. The length in the second axial direction of the first locking wedge portion 4815 disposed on the outer side in the first axial direction is shorter than the length in the second axial direction of the second locking wedge portion 4816 disposed on the inner side in the first axial direction.

[0050] At the other end of the neutral terminal 480 in the first axial direction (the upper end in FIGS. 8 and 9), conductor coupling portions 482 are formed that lock the winding end points 64 to 66, 54 to 56, and 74 to 76 of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70, three for each phase. The conductor coupling portions 482 are arranged in three locations: a U-phase coupling portion 4821, a V-phase coupling portion 4822, and a W-phase coupling portion 4823. The coupling portions 4821 to 4823 are arranged side by side in the second axial direction and have the same shape as one another.

[0051] Each of the coupling portions 4821-4823 is composed of a central pillar portion 484 and a first claw portion 485 and a second claw portion 486, which are located on either side of the central pillar portion 484 in the second axial direction. Therefore, the central pillar portion 484, the first claw portion 485, and the second claw portion 486 are each formed in three locations. The height H1 of the central pillar portion 484 is slightly lower than the height H2 of the first claw portion 485 and the second claw portion 486. For example, the height H2 of the first claw portion 485 and the second claw portion 486 is approximately 4 millimeters, and the height H1 of the central pillar portion 484 is approximately 3.7 millimeters. A first space 487 is formed between the central pillar portion 484 and the first claw portion 485, and the winding end points 64, 65, 54, 55, 74, and 75 of two of the U-phase conducting wire 60, the V-phase conducting wire 50, and the W-phase conducting wire 70 are disposed in this first space 487. A second space 488 is formed between the central pillar portion 484 and the second claw portion 486. The remaining winding end points 66, 56, 76 of the U-phase conducting wire 60, the V-phase conducting wire 50, and the W-phase conducting wire 70 are disposed in this second space 488.

[0052] The side of the central pillar 484 facing the first space 487 is recessed by approximately 1 millimeter in the second axial direction. Therefore, the central pillar 484 also constitutes a portion 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 the two winding end points 64, 65, 54, 55, 74, and 75 are located. Expanding the first space 487 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 also allows the winding end points 66, 56, and 76 located in the second space 488 to be aligned in the second axial direction. This allows the nine winding end points 64 to 66, 54 to 56, and 74 to 76 to be aligned in a row along the second axial direction. This is a preferable arrangement for winding the coil 404.

[0053] That is, by arranging the nine winding end points 64 to 66, 54 to 56, and 74 to 76 in a row along the second axial direction, it is possible to keep the position in the first direction low of the conductor connected to the neutral terminal 480. As a result, when the rotating electric machine 1 is used, the conductor also vibrates due to vibrations associated with operation of the internal combustion engine and / or 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 pillar portion 484 in the second axial direction, the first space 487 has a wide portion 4871 that widens in the second axial direction and a narrow portion 4872 that does not widen in the second axial direction. The length of the wide portion 4871 in the second axial direction is longer than the combined diameter of the two conductors (the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70). On the other hand, the length of the narrow portion 4872 in the second axial direction is longer than the combined diameter of one conductor (the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70) but shorter than the combined diameter of the two conductors. Therefore, the narrow portion 4872 is used as a passageway to guide the conductors to the wide portion 4871, and the wide portion 4871 is used as a space that securely holds the conductors.

[0055] As a comparative example, Fig. 14 shows an example in which the widths in the second axial direction of the first space 487 and the second space 488 are the same. In the example of Fig. 14, when winding end points 64, 65, 54, 55, 74, 75 of two of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 are arranged in the first space 487, they are arranged overlapping in the first axial direction (the up-and-down direction in Fig. 12). Therefore, the height H2 of the first space 487 in the first axial direction must also be increased. As shown in Fig. 2, the neutral terminal 480 must be arranged between the stator bolt through-holes 4030 in the narrow space of the base portion 401, and therefore it is undesirable to increase the height H2 in the first axial direction.

[0056] More specifically, if the central pillar portion 484, the first claw portion 485, and the second claw portion 486 of the neutral point terminal 480 are disposed on the cylinder block 101 side of the stator 400, increasing the height H2 in the first axial direction will prevent interference with the cylinder block 101. To achieve this, the distance between the stator 400 and the cylinder block 101 must be increased. Conversely, if the central pillar portion 484, the first claw portion 485, and the second claw portion 486 of the neutral point terminal 480 are disposed on the rotor 300 side of the stator 400, increasing the height H2 in the first axial direction will cause interference with the rotor 300. To prevent interference with the rotor 300, the distance between the stator 400 and the rotor 300 must be increased. In any case, increasing the height H2 in the first axial direction is undesirable.

[0057] Compared to the comparative example of FIG. 14 , the width of the central pillar portion 484 is wider in the embodiment shown in FIG. 8 . However, widening the width of the central pillar portion 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 FIG. 8 , the lengths of the U-phase coupling portion 4821, the V-phase coupling portion 4822, and the W-phase coupling portion 4823 in the second axial direction are approximately 6 millimeters. In contrast, the lengths of the first width space 4824 and the second width space 4825 in the second axial direction are approximately 3 millimeters. The first width space 4824 and the second width space 4825 are used to receive a crimping tool when crimping the first claw portion 485 and the second claw portion 486. The crimping process is a process for deforming the first claw portion 485 and the second claw portion 486 from their initial acceptability shapes to their clamping shapes after processing. Therefore, the length in the second axial direction cannot be set to zero, but a distance of about 3 millimeters is sufficient.

[0058] 13 , the winding end points 64 to 66, 54 to 56, and 74 to 76 of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 are housed in a first space 487 and a second space 488. In this state, the first claws 485 and the second claws 486 are crimped toward the central pillar 484 to secure the winding end points in a fastened shape. By employing this crimping process, it is possible to reliably hold the winding end points 64 to 66, 54 to 56, and 74 to 76 of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 in the first space 487 and the second space 488.

[0059] However, to employ the crimping process, the height H2 of the first claws 485 and the second claws 486 must be greater than the diameters of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70. As described above, two winding end points 64, 65, 54, 55, 74, and 75 are disposed in each of the three first spaces 487 in the second axial direction. Therefore, even if two winding end points 64, 65, 54, 55, 74, and 75 are disposed in each first space 487, the height H2 of the first claws 485 and the second claws 486 in the first axial direction can be made small enough to be crimped relative to the diameters of one of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70. In other words, the height H2 in the first direction can be reduced compared to the comparative example shown in FIG. 14 . As a result, it is possible to employ the crimping process as described above, and the winding end points 64, 65, 54, 55, 74, and 75 can be reliably held.

[0060] In the example of FIG. 8 , the first space 487 is disposed on one side (right side) of the central pillar portion 484 in the second axial direction, and the second space 488 is disposed on the other side (left side) of the central pillar portion 484 in the second axial direction, but the left-right direction is not limited. The first space 487 and the second space 488 may be formed on either side of the central pillar portion 484 in the second axial direction. In addition, in the example of FIG. 8 , the U-phase coupling portion 4821, the V-phase coupling portion 4822, and the W-phase coupling portion 4823 are disposed in this order from one side (right side) in the second axial direction, but their positions in the second axial direction can be changed depending on the wiring of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 for each coil 404. This is because the neutral point (C in FIG. 7 ) is electrically connected to one another and has the same potential. Therefore, it is also possible to arrange the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 at the portion designated as the coupling portion in the above example (for example, the U-phase coupling portion 4821). Therefore, in this example, the names U-phase coupling portion 4821, the V-phase coupling portion 4822, and the W-phase coupling portion 4823 are names given for convenience, and it is not necessarily required that the conductors of the named phases are arranged therein.

[0061] The neutral terminal 480 is configured such that a collection portion 483 is interposed between the conductor coupling portion 482 and the fixed portion 481 in the first axial direction. The length L2 of the collection portion 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 of Fig. 8, the length L1 of the conductor coupling portion 482 is approximately 25 millimeters, and the length L2 of the collection portion 483 is approximately 3 millimeters shorter than that length L1.

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

[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 magnetic flux from the permanent magnet 304 and generates an electromotive force in the coil 404 of the stator 400. This electromotive force is converted into three-phase alternating current, which is then rectified to direct current and charged into a battery (not shown). Conversely, when the rotating electric machine 1 is used as a starter for the internal combustion engine, the voltage from a battery (not shown) (a direct current power source) is converted into three-phase alternating current to generate a magnetic force in the coil 404. The attraction and repulsion between the magnetic force generated in the coil 404 and the magnetic force of the permanent magnet 304 rotates the rotor 300. The 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 to control rotation during power generation and startup. 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 described. First, a magnetic steel plate 440 having a base portion 401 and teeth portions 402 as shown in FIG. 4 is punched out. A plurality of magnetic steel plates 440 shown in FIG. 4 are stacked to manufacture a stator core 450. Note that the base portion 401 of the magnetic steel plate 440 has a protruding engagement portion 432 formed thereon, into which adjacent magnetic steel plates 440 mate when stacked. That is, the engagement portion 432 is protruding on one side and recessed on the other side. This allows the protruding engagement portion 432 to mate with the recessed engagement portion 432 of the adjacent magnetic steel plate 440. The magnetic steel plate 440 also has a tooth engagement portion 433 formed on the tooth portion 402.

[0065] Like the engaging portion 432 described above, the tooth engaging portion 433 also protrudes on one side and is recessed on the other side. This allows the tooth engaging portion 433 formed on the tooth portion 402 of the adjacent magnetic steel plate 440 to be mechanically fixed. However, in addition to the mechanical fixation, the magnetic steel plate 440 and the tooth magnetic steel plate may also be fixed with an adhesive.

[0066] Next, the insulator 410 is assembled to the stator core 450 to perform the insulator assembly process. Figures 5 and 6 show a first insulator 411 arranged on one side of the stator core 450. Furthermore, as shown in Figures 15 and 16 , the insulator 410 has a second insulator 412 arranged on the other side of the stator core 450. As described above, the first insulator 411 is arranged so that the electrical terminal fixing portion 4170 fits into the terminal hole 4032 formed in the base plate portion 401 of the stator 400. The first insulator 411 is also arranged so that the terminal holding portion 4105 is inserted into the terminal fixing hole 4034 of the base plate 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 FIG. 10 , the fixing portion 4100 has an arc shape and is sized roughly to correspond to the neutral point terminal 480. As shown in FIG. 11 , a fixing portion groove 4101 is formed at one end (the lower side in FIG. 10 ) in the first axial direction, corresponding to the fixing portion 481. As shown in FIGS. 5 and 10 , the groove width of the fixing portion groove 4101 is set to be slightly larger than the plate thickness of the neutral point terminal 480. In other words, the collecting portion groove 4102 of the fixing portion 481, which corresponds to the collecting portion 483, has a thickness of approximately 1 millimeter, which is the same as the plate thickness of the neutral point terminal 480. Therefore, in the fixing portion 4100, the groove width of the fixing portion groove 4101 is approximately 0.2 millimeters larger than the groove width of the collecting portion groove 4102. The above-mentioned first width space 4824 and second width space 4825 are also used when press-fitting the neutral point terminal 480. When press-fitting 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 engaging protrusion 4811 is formed protruding from the center of the fixing portion 481. Therefore, when the neutral point terminal 480 is press-fitted into the fixing portion groove 4101, it is guided by the engaging inclined surface 4813. The press-fitting causes the engaging protrusion 4811 to elastically deform, and the elastic force associated with this deformation presses the engaging flat surface 4814 in the middle of the engaging protrusion 4811 against the fixing portion groove 4101.

[0069] As described above, the first and second locking wedges 4815 and 4816 are disposed on both sides in the second axial direction of the fixing portion 481. The length in the second axial direction of the first wedge 4815 disposed on the outer side in the first axial direction is shorter than the length in the second axial direction of the second wedge 4816 disposed on the inner side in the first axial direction. Therefore, when the fixing portion 481 is press-fitted into the fixing portion groove 4101, the first wedge 4815 acts as a guide, making the press-fitting easier.

[0070] Furthermore, since 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 toward one end in the first axial direction, this tapered shape also allows for smooth press-fitting. When the press-fitting is complete, the second wedge portion 4816 in particular fits into both sides of the fixing portion groove 4101 in the second axial direction, preventing the neutral point terminal 480 from coming loose.

[0071] In this example, the length of the collection portion 483 in the second axial direction is shorter than the length of the conductor coupling portion 482 in the second axial direction. Therefore, as shown in FIG. 12 , the conductor coupling portion 482 directly contacts the insulator 410. As a result, the press-fitting allowance of the neutral terminal 480 in the first axial direction is easily controlled. That is, the length of the collection portion 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 collection portion 483 in the second axial direction. Furthermore, the neutral terminal 480 can be press-fitted in the first axial direction only until the conductor coupling portion 482 contacts the insulator 410. As a result, the positional relationship of the conductor coupling portion 482 in the first axial direction can be stabilized. This also stabilizes the fixed positions of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70. Because the fixed positions are stable, it is easy to ensure the vibration resistance strength of the U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70. Furthermore, with regard to the condition of attachment, since the portion where the conductor coupling portion 482 contacts the insulator 410 is exposed, it is easy to visually check the condition of attachment.

[0072] After the neutral terminal 480 and the electrical terminal are assembled, a copper conductor coated with an insulating coating such as enamel is prepared and wound around the teeth 402 of the insulator 410 to form the coil 404. As described above, the rotating electric machine 1 has three phases, U, V, and W, each connected in parallel with three conductors.

[0073] The U-phase conductor 60 has two coils 404, U1-1 and U1-2, wound around it by the U1 conductor 61. Also, two coils 404, U2-1 and U2-2, wound around it by the U2 conductor 62. And two coils 404, U3-1 and U3-2, wound around it by the remaining U3 conductor 63. The two coils 404 are continuous with each other by a crossover wire, and the three conductors 61, 62, and 63 of the U-phase conductor 60 form a single continuous wire to the winding end points 64, 65, and 66, respectively.

[0074] The V-phase and W-phase coils 404 are wound in the same manner. The V-phase conductor 50 has six V-phase coils 404, V1-1 to V3-2, wound thereon using a V1 conductor 51, a V2 conductor 52, and a V3 conductor 53. The V-phase conductor 50 also has six W-phase coils 404, W1-1 to W3-2, wound thereon using a W1 conductor 71, a W2 conductor 72, and a W3 conductor 73.

[0075] 3, in order to increase the space factor of the coil 404, the number of turns on the radially outer side is made greater than the number of turns on the radially inner side. Therefore, in the case of aligned multilayer winding, the winding end of the coil 404 is located on the inner radial outer side of the coil 404.

[0076] The U-phase conductor 60, V-phase conductor 50, and W-phase conductor 70 are routed from the coil 404 whose insulation performance has been confirmed, and any excess conductor wire is cut and removed. Next, the insulating coating of the conductor wires at the ends of the coil 404 is stripped off. Thereafter, the winding end points 64 to 66, 54 to 56, and 74 to 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. As described above, two winding end points 64, 65, 54, 55, 74, and 75 are placed in the first space 487, and the remaining winding end point 66, 56, and 76 are 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 pillar portion 484 to fix the processed shape. In this crimping process, as shown in FIG. 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. Also, in this crimping process, the first claw portion 485 and the second claw portion 486 are crimped until they abut against the central pillar portion 484. Because the crimping process is performed until they abut, delicate adjustment of the crimping amount is not necessary. This also makes the crimping process easier.

[0078] By performing the crimping process, both the first claw portion 485 and the second claw portion 486 are 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 is slightly higher than the height H1 in the first axial direction of the central pillar 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 pillar portion 484.

[0079] Furthermore, by employing the crimping process, it is possible to reliably hold the winding end points 64 to 66, 54 to 56, and 74 to 76 of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 in the first space 487 and the second space 488. Then, the winding end points 64 to 66, 54 to 56, and 74 to 76 of the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 held in this crimping process are soldered to the U-phase coupling portion 4821, the V-phase coupling portion 4822, and the W-phase coupling portion 4823. Soldering further reliably connects the U-phase conductor 60, the V-phase conductor 50, and the W-phase conductor 70 to the U-phase coupling portion 4821, the V-phase coupling portion 4822, and the W-phase coupling portion 4823.

[0080] In the above example, the side of the central pillar 484 facing the first space 487 is recessed in the second axial direction, so that the central pillar 484 forms 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, and 75 to be held by part of the central pillar 484. However, it is sufficient that the length of the first space 487 in the second axial direction is long enough to accommodate the two winding end points 64, 65, 54, 55, 74, and 75. Therefore, forming a recess in the central pillar 484 is not necessarily required.

[0081] In the above example, the length of the collection portion 483 in the second axial direction is shorter than the length of the conductor coupling portion 482 in the second axial direction. This is a desirable shape because it facilitates the operation of press-fitting the neutral terminal 480 into the fixing portion 4100 of the insulator 410. However, if necessary, it is possible to make the lengths of the collection portion 483 and the conductor coupling portion 482 the same in the second axial direction. Also, the neutral terminal 480 does not necessarily have to be press-fitted into the insulator 410. The neutral terminal 480 can also be insert-molded when molding the resin insulator 410 (first insulator 411).

[0082] Furthermore, while the above is a preferred example of the present disclosure, various modifications are possible. For example, the number of coils 404 is 18, and the number of coils 404 can be changed. Furthermore, the present disclosure requires only a three-phase star connection, and does not necessarily require a three-parallel connection using three conductors. For example, the neutral terminal 480 of the present disclosure can be used with a two-parallel connection of two conductors. In the case of a two-parallel connection, each phase has two conductors. However, the first space 487 may hold two conductors, and the two second spaces 488 may each hold one conductor. It is also possible for the first space 487 to hold only one conductor. Furthermore, the size described in the above example is merely an example, and the material and size can be appropriately selected depending on the performance required of the rotating electric machine 1.

[0083] Other Embodiments The disclosure in this specification and drawings, etc. is not limited to the exemplified embodiments. The disclosure encompasses the exemplified embodiments and variations thereon by those skilled in the art. For example, the disclosure is not limited to the combinations of parts and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure can have additional parts that can be added to the embodiments. The disclosure encompasses the omission of parts and / or elements from the embodiments. The disclosure encompasses the substitution or combination of parts and / or elements between one embodiment and another embodiment. The disclosed technical scope is not limited to the description of the embodiments. Some disclosed technical scopes are defined by the claims, and should be interpreted as including all modifications within the meaning and scope equivalent to the claims.

[0084] (Disclosure of Technical Ideas) This specification discloses multiple technical ideas described in the following multiple clauses. Some clauses may be described in a multiple dependent form, in which the subsequent clause alternatively refers to the preceding clause. Furthermore, some clauses may be described in a multiple dependent form, in which the subsequent clause refers to another multiple dependent clause. The clauses described in these multiple dependent forms define multiple technical ideas.

[0085] (Technical Idea 1) A rotating electric machine including a stator having: a rotor in which a plurality of permanent magnets are arranged in the circumferential direction and which rotates together with a shaft; a stator core having an annular base portion and a number of teeth extending radially outward from the base portion, an insulator made of an insulating material which is arranged on at least a part of the base portion and on the teeth portion of the stator core; and a coil wound around the outer periphery of the insulator at a position corresponding to the teeth portion of the stator core, wherein the coil is star-connected in three phases, and three conductors for each phase are electrically connected to a neutral terminal, and the neutral terminal is fixed to a fixing portion of the insulator which is formed in a groove shape in the base portion, and the neutral terminal is a plate material which extends in a first axial direction and a second axial direction which is perpendicular to the first axial direction, the neutral terminal has a fixing portion disposed at one end in the first axial direction for engaging with the insulator, and a conductor coupling portion disposed at the other end in the first axial direction for locking the three conductors for each phase, with a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction, the conductor coupling portion having three coupling portions disposed along the second axial direction for holding the three conductors for each of the three phases, each coupling portion having a central pillar portion extending in the first axial direction, forming a first space for arranging two of the conductors along one of the second axial directions and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion disposed on the first space side of the central pillar portion and inclined toward the central pillar portion for holding the two conductors in the first space, and a second claw portion disposed on the second space side of the central pillar portion and inclined toward the central pillar portion for holding the one conductor in the second space, A rotating electric machine in which the height of the central pillar 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 Idea 2) A stator for a rotating electric machine, comprising: a stator core having an annular base portion and a number of teeth extending radially outward from the base portion, the number of teeth being a multiple of three; an insulator made of an insulating material arranged on at least a part of the base portion and on the teeth of the stator core; and a coil wound around the outer periphery of the insulator at a position corresponding to the teeth of the stator core, the coil being star-connected in three phases, with three conductors for each phase electrically connected to a neutral terminal, the neutral terminal being fixed to a fixing portion of the insulator that is formed in a groove shape in the base portion, the neutral terminal being a plate material extending in a first axial direction and a second axial direction perpendicular to the first axial direction, the neutral terminal has a fixing portion disposed at one end in the first axial direction for engaging with the insulator, and a conductor coupling portion disposed at the other end in the first axial direction for locking the three conductors for each phase, with a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction, the conductor coupling portion having three coupling portions disposed along the second axial direction for holding the three conductors for each of the three phases, each coupling portion having a central pillar portion extending in the first axial direction, forming a first space for arranging two of the conductors along one of the second axial directions and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion disposed on the first space side of the central pillar portion and inclined toward the central pillar portion for holding the two conductors in the first space, and a second claw portion disposed on the second space side of the central pillar portion and inclined toward the central pillar portion for holding the one conductor in the second space, A stator for a rotating electric machine, in which the height of the central pillar 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 Idea 3) A neutral point terminal of a stator for a rotating electric machine, comprising: a stator core having an annular base portion and a number of teeth extending radially outward from the base portion; an insulator made of an insulating material arranged on at least a part of the base portion and the teeth of the stator core; and a coil wound around the outer periphery of the insulator at a position corresponding to the teeth of the stator core, wherein the coil is star-connected in three phases and three conductors for each phase are electrically connected to a neutral point terminal, the neutral point terminal being fixed to a fixing portion of the insulator that is formed in a groove shape in the base portion, and the neutral point terminal being a plate material extending in a first axial direction and a second axial direction perpendicular to the first axial direction, the neutral terminal has a fixing portion disposed at one end in the first axial direction for engaging with the insulator, and a conductor coupling portion disposed at the other end in the first axial direction for locking the three conductors for each phase, with a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction, the conductor coupling portion having three coupling portions disposed along the second axial direction for holding the three conductors for each of the three phases, each coupling portion having a central pillar portion extending in the first axial direction, forming a first space for arranging two of the conductors along one of the second axial directions and a second space for arranging one of the conductors on the other side in the second axial direction, a first claw portion disposed on the first space side of the central pillar portion and inclined toward the central pillar portion for holding the two conductors in the first space, and a second claw portion disposed on the second space side of the central pillar portion and inclined toward the central pillar portion for holding the one conductor in the second space, A neutral point terminal of a stator for a rotating electric machine, in which the height of the central pillar 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) A rotating electric machine as described in Technical Idea 1, a stator for a rotating electric machine as described in Technical Idea 2, or a neutral point terminal of a stator for a rotating electric machine as described in Technical Idea 3, wherein the first space side of the central pillar portion is recessed in the second axial direction to form part of the first space.

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

[0091] (Technical Idea 7) A rotating electric machine described in Technical Idea 1 or any of Technical Ideas 4 to 6 that are dependent on Technical Idea 1, a stator for a rotating electric machine described in Technical Idea 2 or any of Technical Ideas 4 to 6 that are dependent on Technical Idea 2, or a neutral point terminal of a stator for a rotating electric machine described in Technical Idea 3 or any of Technical Ideas 4 to 6 that are dependent on Technical Idea 3, wherein a first wedge portion and a second wedge portion for engagement are arranged in the first axial direction on both sides of the fixed portion in the second axial direction, and the length in the second axial direction of the first wedge portion arranged on the outside of the first axial direction is shorter than the length in the second axial direction of the second wedge portion arranged on the inside of the first axial direction.

[0092] (Technical Idea 8) A manufacturing method of a stator for a rotating electric machine according to Technical Idea 2, comprising: a joint forming process for forming the central pillar portion, the first claw portion, and the second claw portion of the joint portion so that they are all parallel in the first axial direction and so that the heights of the first claw portion and the second claw portion in the first axial direction are greater than the height of the central pillar portion in the first axial direction; a conductor arrangement process for arranging two of the conductors side by side in the second axial direction within the first space and arranging one of the conductors on the second space side; and a crimping process for simultaneously tilting the first claw portion and the second claw portion toward the central pillar portion until they abut against the central pillar portion, thereby making the height of the central pillar portion in the first axial direction, the height of the tilted first claw portion, and the height of the tilted second claw portion in the first axial direction approximately equal.

[0093] (Technical Idea 9) A manufacturing method of a stator for a rotating electric machine according to Technical Idea 5, which is dependent on Technical Idea 2, comprising a press-fitting process for press-fitting the fixed portion and the collecting portion of the neutral terminal into the fixed portion of the insulator in the first axial direction, and this press-fitting process is carried out until the connecting portion abuts the insulator outside the fixed portion of the base portion.

Claims

1. A rotor having a plurality of permanent magnets arranged in a circumferential direction and rotating together with the shaft; A rotating electric machine including a stator having a stator core having an annular base portion and a number of teeth portions extending radially outward from the base portion, an insulator made of an insulating material disposed on at least a portion of the base portion and the teeth portions of the stator core, and a coil wound around an outer periphery of the insulator at a position corresponding to the teeth portions of the stator core, The coil is star-connected for three phases, and three conductors for each phase are electrically connected to a neutral terminal. The neutral terminal is fixed to a fixing portion of the insulator that is formed in a groove shape in the base portion, the neutral point terminal is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction, the neutral terminal has a fixing portion disposed at one end in the first axial direction for engaging with the insulator, and a conductor coupling portion disposed at the other end in the first axial direction for engaging the conductors (three for each phase), and a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction; The conductor coupling portion includes three coupling portions arranged along the second axial direction, the coupling portions holding three conductors for each of three phases, Each coupling portion has a central pillar portion that forms a first space in which two of the conductors are disposed along one of the directions in the second axial direction and a second space in which one of the conductors is disposed on the other side in the second axial direction and that extends in the first axial direction, a first claw portion that is disposed on the first space side of the central pillar portion and inclined toward the central pillar portion to hold the two conductors in the first space, and a second claw portion that is disposed on the second space side of the central pillar portion and inclined toward the central pillar portion to hold the one conductor in the second space, A height of the central pillar portion in the first axial direction, a height of the inclined first claw portion in the first axial direction, and a height of the inclined second claw portion in the first axial direction are approximately equal to each other. A rotating electric machine characterized by:

2. A stator core having an annular base portion and a plurality of teeth portions each extending radially outward from the base portion; an insulator made of an insulating material that is disposed on at least a portion of the base portion and on the teeth portion of the stator core; a coil wound around an outer periphery of the insulator at a position corresponding to the teeth of the stator core; The coil is star-connected for three phases, and three conductors for each phase are electrically connected to a neutral terminal. The neutral terminal is fixed to a fixing portion of the insulator that is formed in a groove shape in the base portion, the neutral point terminal is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction, the neutral terminal has a fixing portion disposed at one end in the first axial direction for engaging with the insulator, and a conductor coupling portion disposed at the other end in the first axial direction for engaging the conductors (three for each phase), and a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction, The conductor coupling portion includes three coupling portions arranged along the second axial direction, the coupling portions holding three conductors for each of three phases, Each coupling portion has a central pillar portion that forms a first space in which two of the conductors are disposed along one of the directions in the second axial direction and a second space in which one of the conductors is disposed on the other side in the second axial direction and that extends in the first axial direction, a first claw portion that is disposed on the first space side of the central pillar portion and inclined toward the central pillar portion to hold the two conductors in the first space, and a second claw portion that is disposed on the second space side of the central pillar portion and inclined toward the central pillar portion to hold the one conductor in the second space, A height of the central pillar portion in the first axial direction, a height of the inclined first claw portion in the first axial direction, and a height of the inclined second claw portion in the first axial direction are approximately equal to each other. A stator for a rotating electric machine comprising:

3. A stator core having an annular base portion and a plurality of teeth portions each extending radially outward from the base portion; an insulator made of an insulating material that is disposed on at least a portion of the base portion and on the teeth portion of the stator core; a coil wound around an outer periphery of the insulator at a position corresponding to the teeth portion of the stator core, The coil is star-connected into three phases, and three conductors for each phase are electrically connected to a neutral terminal, The neutral terminal is fixed to a fixing portion of the insulator that is formed in a groove shape in the base portion, the neutral point terminal is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction, the neutral terminal has a fixing portion disposed at one end in the first axial direction for engaging with the insulator, and a conductor coupling portion disposed at the other end in the first axial direction for engaging the conductors (three for each phase), and a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction, The conductor coupling portion includes three coupling portions arranged along the second axial direction, the coupling portions holding three conductors for each of three phases, Each coupling portion has a central pillar portion that forms a first space in which two of the conductors are disposed along one of the directions in the second axial direction and a second space in which one of the conductors is disposed on the other side in the second axial direction and that extends in the first axial direction, a first claw portion that is disposed on the first space side of the central pillar portion and inclined toward the central pillar portion to hold the two conductors in the first space, and a second claw portion that is disposed on the second space side of the central pillar portion and inclined toward the central pillar portion to hold the one conductor in the second space, A height of the central pillar portion in the first axial direction, a height of the inclined first claw portion in the first axial direction, and a height of the inclined second claw portion in the first axial direction are approximately equal to each other. A neutral terminal of a stator for a rotating electric machine, comprising:

4. The first space side of the central pillar portion is recessed in the second axial direction to form a part of the first space.

2. The rotating electric machine according to claim 1 .

5. The length of the collection portion in the second axial direction is shorter than the length of the conductor coupling portion in the second axial direction, and is longer than the length in the second axial direction connecting the first claw portion and the second claw portion, which are the coupling portions arranged on both sides in the second axial direction, and which are arranged on the inner side in the second axial direction.

2. The rotating electric machine according to claim 1 .

6. The length of the fixing portion in the second axial direction is shorter than the length of the assembly portion in the second axial direction.

2. The rotating electric machine according to claim 1 .

7. A first wedge portion and a second wedge portion for engagement are disposed in the first axial direction on both sides of the fixing portion in the second axial direction, and a length in the second axial direction of the first wedge portion disposed on the outer side in the first axial direction is shorter than a length in the second axial direction of the second wedge portion disposed on the inner side in the first axial direction.

2. The rotating electric machine according to claim 1 .

8. A method for manufacturing a stator for a rotating electric machine according to claim 2, comprising the steps of: a joint portion forming process in which the central pillar portion, the first claw portion, and the second claw portion of the joint portion are all formed in parallel in a first axial direction, and the height of the first claw portion and the second claw portion in the first axial direction is greater than the height of the central pillar portion in the first axial direction; a conductor arrangement step of arranging two of the conductors in the first space so as to be aligned in the second axial direction, and arranging one of the conductors on the second space side; a crimping process in which the first claw portion and the second claw portion are simultaneously inclined toward the central pillar portion until they abut against the central pillar portion, so that the height of the central pillar 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 to each other; A method for manufacturing a stator for a rotating electric machine, comprising the steps of:

9. A method for manufacturing a stator for a rotating electric machine according to claim 2, comprising the steps of: a length in the second axial direction of the collection portion is shorter than a length in the second axial direction of the conductor coupling portion, and is longer than a length in the second axial direction connecting a claw portion, which is either the first claw portion or the second claw portion, of the coupling portions arranged on both sides in the second axial direction and which is located on the inner side in the second axial direction, a press-fitting step of press-fitting the fixing portion and the assembly portion of the neutral terminal into the fixing portion of the insulator in the first axial direction; This press-fitting step is performed until the joint portion abuts against the insulator outside the fixed portion of the base portion. A method for manufacturing a stator for a rotating electric machine comprising the steps of:

10. A rotor having a plurality of permanent magnets arranged in a circumferential direction and rotating together with the shaft; A rotating electric machine including a stator having a stator core having an annular base portion and a number of teeth portions extending radially outward from the base portion, an insulator made of an insulating material disposed on at least a portion of the base portion and the teeth portions of the stator core, and a coil wound around an outer periphery of the insulator at a position corresponding to the teeth portions of the stator core, The coil is star-connected for three phases, and three conductors for each phase are electrically connected to a neutral terminal. The neutral terminal is fixed to a fixing portion of the insulator that is formed in a groove shape in the base portion, the neutral point terminal is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction, the neutral terminal has a fixing portion disposed at one end in the first axial direction for engaging with the insulator, and a conductor coupling portion disposed at the other end in the first axial direction for engaging the conductors (three for each phase), and a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction; The conductor coupling portion includes three coupling portions arranged along the second axial direction, the coupling portions holding three conductors for each of three phases, Each coupling portion has a central pillar portion that forms a first space in which two of the conductors are disposed along one of the directions in the second axial direction and a second space in which one of the conductors is disposed on the other side in the second axial direction and extends in the first axial direction, a first claw portion that is disposed on the first space side of the central pillar portion and inclined toward the central pillar portion to hold the two conductors in the first space, and a second claw portion that is disposed on the second space side of the central pillar portion and inclined toward the central pillar portion to hold the one conductor in the second space, thereby reducing the length in the first axial direction required to dispose the two conductors. A rotating electric machine characterized by:

11. A stator core having an annular base portion and a plurality of teeth portions each extending radially outward from the base portion; an insulator made of an insulating material that is disposed on at least a portion of the base portion and on the teeth portion of the stator core; a coil wound around an outer periphery of the insulator at a position corresponding to the teeth of the stator core; The coil is star-connected for three phases, and three conductors for each phase are electrically connected to a neutral terminal. The neutral terminal is fixed to a fixing portion of the insulator that is formed in a groove shape in the base portion, the neutral point terminal is a plate member extending in a first axial direction and a second axial direction perpendicular to the first axial direction, the neutral terminal has a fixing portion disposed at one end in the first axial direction for engaging with the insulator, and a conductor coupling portion disposed at the other end in the first axial direction for engaging the conductors (three for each phase), and a collection portion interposed between the conductor coupling portion and the fixing portion in the first axial direction, The conductor coupling portion includes three coupling portions arranged along the second axial direction, the coupling portions holding three conductors for each of three phases, Each coupling portion has a central pillar portion that forms a first space in which two of the conductors are disposed along one of the directions in the second axial direction and a second space in which one of the conductors is disposed on the other side in the second axial direction and extends in the first axial direction, a first claw portion that is disposed on the first space side of the central pillar portion and inclined toward the central pillar portion to hold the two conductors in the first space, and a second claw portion that is disposed on the second space side of the central pillar portion and inclined toward the central pillar portion to hold the one conductor in the second space, thereby reducing the length in the first axial direction required to dispose the two conductors. A stator for a rotating electric machine comprising: