Rotating electrical machine

Abstract

Provided is a rotating electrical machine that obviates the need for a welding step in the bonding of a distal end section and that achieves an improvement in productivity. The rotating electrical machine comprises a stator coil in which a first rectangular wire and a second rectangular wire fit together. The first rectangular wire has a protruding part and the second rectangular wire has an indented part. The protruding part and the indented part are configured so as to fit together by insertion. The protruding part has projections and the indented part has grooves on surfaces, from among surfaces constituting the protruding part and the indented part, that run along a direction of extension of the first rectangular wire and the second rectangular wire. A pair of projections and a pair of grooves are provided to serve as the projections and the grooves.

Description

rotating electrical machines

[0001] The present invention relates to a rotating electric machine.

[0002] Rotating electric machines are so-called motors and are widely used in industry. Therefore, mass production is required, and a structure that contributes to improving the production process is desired.

[0003] Patent Document 1 discloses a structure of a first tip portion and a second tip portion that are joined together.

[0004] JP 2022-162929 A

[0005] The tip structure disclosed in Patent Document 1 is a structure that requires welding. However, the welding process takes time and requires welding equipment. Therefore, the more points to be welded and the more units to be welded, the more expensive the manufacturing process becomes. Furthermore, in principle, a temperature rise around the welded part is unavoidable, which poses a risk of deformation of the non-welded part.

[0006] Therefore, the present application provides a rotating electric machine that does not require a welding process when joining the tip portion, thereby improving productivity.

[0007] A rotating electric machine having a stator coil in which a first flat wire and a second flat wire are fitted together, wherein the first flat wire has a protruding portion and the second flat wire has a recessed portion, and the protruding portion and the recessed portion are configured to be inserted and fitted together, and among the surfaces constituting the protruding portion and the recessed portion, on the surfaces along the extension direction of the first flat wire and the second flat wire, the protruding portion has a protruding portion and the recessed portion has a groove portion, and the protruding portion and the groove portion each have a pair of protruding portions and a pair of groove portions.

[0008] According to the rotating electric machine of the present invention, the welding process is not required when joining the tip portion, and productivity can be improved.

[0009] Furthermore, when the welding process is not required, a structure that is easy to manufacture and does not easily come loose can be realized.

[0010] Further means and effects of the present invention will become apparent throughout the entire specification below.

[0011] FIG. 1 is an explanatory diagram of an embodiment before mating. FIG. 2 is an explanatory diagram of an embodiment after mating. FIG. 3 is a perspective view showing the internal structure of a stator in an embodiment. FIG. 4 is an explanatory diagram of the mating relationship of the hairpin coil in an embodiment. FIG. 5 is an explanatory diagram of a stator core in an embodiment. FIG. 6 is an explanatory diagram of a resin bobbin in an embodiment. FIG. 7 is an explanatory diagram of the positional relationship of tooth cores in a stator in an embodiment. FIG. 8 is an explanatory diagram of the positional relationship of resin bobbins in a stator in an embodiment. FIG. 9 is an explanatory diagram of a top view of a stator in an embodiment. FIG. 10 is an explanatory diagram of a coil end 10 in an embodiment. FIG. 11 is an explanatory diagram of a coil end 50 in an embodiment. FIG. 12 is an explanatory diagram of a coil end 30 in an embodiment. FIG. 13 is an explanatory diagram of a stator and a coil in an embodiment. FIG. 14 is an explanatory diagram of a stator and a coil in an embodiment. FIG. 15 is an explanatory diagram of a compression test in a comparative example. FIG. 16 is a result of a compression test in a comparative example. FIG. 17 is a result of a tensile test in a comparative example. FIG. 18 is a result of a compression test in an embodiment. FIG. 19 is an explanatory diagram of a tensile test in an embodiment. FIG. 19 is a result of a tensile test in an embodiment. FIG. 19 is a three-dimensional perspective view of an insulating resin bobbin in an embodiment. 1 is an explanatory diagram showing an example of the relationship between a protrusion-side member and a recess-side member in one embodiment; an explanatory diagram showing a protrusion-side member in one embodiment; an explanatory diagram showing a recess-side member in one embodiment; a schematic explanatory diagram explaining the fitting process in one embodiment; a schematic explanatory diagram explaining the fitting process in a comparative example; a schematic explanatory diagram explaining the fitting process in a comparative example; a schematic explanatory diagram explaining the fitting process in a comparative example; an explanatory diagram explaining an example of the relationship between fitting members in another embodiment; an explanatory diagram explaining an example of the relationship between fitting members in another embodiment; an explanatory diagram of an example of the relationship between fitting members in another embodiment; an explanatory diagram of an example of a recess-side member; an explanatory diagram of an example of a protrusion-side member; an explanatory diagram of a plating layer of a recess-side member; an explanatory diagram of a plating layer of a protrusion-side member.

[0012] Hereinafter, embodiments of the present invention will be described with reference to the drawings as needed. For convenience of explanation, the same reference numeral may be used for a coil end portion and a coil having the coil end portion.

[0013] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0014] Figure 1A shows the shape of the recessed and protruding fitting portions of the rectangular conductor before mating, and Figure 1B shows the shape of the recessed and protruding fitting portions of the rectangular conductor after mating. This rectangular conductor is applicable to a variety of applications, including rectangular conductors used in the stators of rotating electrical machines. The type of rotating electrical machine is not particularly limited, but an example is a radial gap type rotating electrical machine.

[0015] The rectangular conductor is an enameled conductor coated with enamel, and is formed by punching out the recessed and protruding portions using a press die. The punched cross section has a recessed portion 12 shown on the left side of Figure 1A and a protruding portion 22 shown on the right side.

[0016] In Fig. 1A, for example, 11 is a recessed coil, 12 is a recessed portion, and 13 is a groove portion. In Fig. 1B, 21 is a protruding coil, 22 is a protruding portion, and 23 is a protrusion portion.

[0017] The recessed coil 11 and the protruding coil 21 are brought close to each other from the left and right in the figure and inserted into each other, thereby reaching the mated state shown in FIG. 1B.

[0018] 1B, the recessed coil 11 and the protruding coil 21 are fixed together by inserting the protruding portion 22 into the recessed portion 12 and fitting the protruding portion 23 into the groove portion 13. In this way, the first and second flat wires are fitted and fixed together without using a welding process.

[0019] The projections 23 are fixed in place by fitting into the grooves 13, preventing the assembly from coming loose after being fixed. In this way, the assembly is easy and the assembly is difficult to remove.

[0020] To achieve this effect, both the recessed coil 11 and the protruding coil 21 must be rectangular conductors. If they were round wires, it would be difficult to deform them when they are fitted together, making assembly itself difficult.

[0021] 2A shows an example of a rotating electric machine, in which the stator has 48 slots and the rotor has 8 poles, a coil shape (three phases per pole) that realizes concentric winding of flat conductors in the stator, and the connection of the axial coils. In the figure, the stator 5 is composed of a lead-side stator 5A and a non-lead-side stator 5B.

[0022] In FIG. 2A, a concentrically wound coil is formed by combining a coil 20 having a structure that connects the slots of the lead-out side stator 5A in the circumferential direction at the same diameter as the radial position of the slots, and a coil 10 having a structure that connects the slots of the anti-lead-out side stator 5B in the circumferential direction at the same diameter as the radial position of the slots.

[0023] Reference numeral 1 denotes a teeth core, 2 denotes a core-back core, 10 denotes a recessed-side coil end, 30 denotes a recessed-side outer coil end, 50 denotes a recessed-side inner coil end, 20 denotes a protruding-side coil end, 40 denotes a protruding-side outer coil end, 60 denotes a protruding-side inner coil end, 70 denotes an output coil, and 72 denotes a protruding portion. A concentrically wound coil is formed by combining a coil 60 having a shape that connects between the slots of the output-side stator 5A by locating the coil ends radially inward from the position where the conductors enter the slots, with a coil 30 having a structure that connects between the slots of the anti-output-side stator 5B on the outer diameter side from the radial position of the conductors.

[0024] Furthermore, a concentrically wound coil is formed by combining a coil 40 having a shape in which the slots of the outlet side stator 5A are connected by arranging the coil ends on the outer diameter side of the radial direction in which the conductors enter the slots, and a coil 50 having a structure in which the slots of the counter-lead side stator 5B are connected on the inner diameter side of the radial position of the conductors.

[0025] By configuring in this way, it is possible to prevent a difference in resistance value from occurring because the coil end passing through the inner periphery is shorter than the coil end passing through the outer periphery.

[0026] As shown in Figure 2B, these coils form a loop coil, starting from the lead coil 70 having a protruding portion 72, via the recessed coil 11 having a recessed portion 12, and then connecting the other recessed portion 12 of the recessed coil 11 to the protruding portion 22 of the protruding coil 21. The other protruding portion 22 of the protruding coil 21 fits into the recessed portion 12 of the next recessed coil 11, and this process is repeated to form successive loops. The rest of the process is repeated in the same way to form a concentric coil with four turns per slot.

[0027] In FIG. 2B, the recessed coil 11 and the protruding coil 21 are depicted as central coils, but they can also be applied to the inner coils and outer coils, or to all coils.

[0028] Also, 21 alone or a combination of 20 and 21 can be called the first rectangular wire, and 11 alone or a combination of 10 and 11 can be called the second rectangular wire.

[0029] Fig. 3A is a schematic diagram of a stator 4. Reference numeral 2 denotes a core-back core. Fig. 3B is a schematic external view of a resin bobbin 3. As shown in the schematic cross-sectional explanatory view of Fig. 3C, the stator 5 has teeth cores 1 inside the core-back core 2. Then, as shown in Fig. 3D, the resin bobbin 3 is disposed between adjacent teeth cores 1 so as to be close to the core-back core 2.

[0030] For example, the stator teeth are made of laminated amorphous metal foil strips cut into trapezoidal shapes. Because high-speed motors rotate at high frequencies, the iron loss in the teeth is large, so it is desirable to use low-loss magnetic materials. In addition to amorphous materials, the teeth may be made of Finemet, a nanocrystalline alloy material, or a nanocrystalline alloy with high saturation magnetization. For electrical steel sheets, using low-iron-loss materials, such as thin steel sheets containing 6.5% Si, is another way to improve performance.

[0031] As shown in Figure 3C, the core-back core 2, which holds the trapezoidal teeth together, is made of electromagnetic steel. The core-back portion has a lower magnetic flux density than the teeth portion and is less affected by harmonics, so it is sufficient to use a material with relatively low loss.

[0032] The shape of the core-back core 2 is designed in part because it is difficult to punch amorphous material into complex shapes, and so the core-back core 2 is made into a trapezoidal shape that can be formed simply by cutting.

[0033] A resin bobbin for insulation is assembled to fit the combined core shape. The resin bobbin 3 has the shape shown in Figure 3B. As shown as the upper rectangular portion in Figure 3B, it has slot holes for inserting rectangular conductors. Each slot hole has a wall (partition) for each conductor, allowing for insulation for each inserted rectangular conductor.

[0034] The resin bobbins 3 are assembled from the inner diameter of the stator core, and when all the resin bobbins are assembled, they form a structure that restrains the stator teeth in both the circumferential and axial directions.

[0035] 4A is a partial structural view for explaining the axial direction (opposite lead wire side) of a stator core for constructing the stator shown in FIG. 3A. It is also a view of the coil on the opposite lead wire side projected in the axial direction.

[0036] FIG. 4B is a schematic internal perspective view for explaining the shape of each coil.

[0037] Coil 10 (referred to as the central coil, for example) has coil ends arranged at the same diameter as the conductor insertion position of the slot, and is configured, as an example, as shown in the figure, with four coils connected radially from insertion hole 1 inside the slot to insertion hole 1 spanning five slots.

[0038] 4C is a perspective view of the shape of the central coil, which is bent slightly outward to ensure an inner area due to the overall arrangement space of the stator coils.

[0039] The tip has a recess. The inner portion is punched out, and the cut cross section is plated with a plating layer having a thickness of, for example, about 10 micrometers, for example, by electrolytic tin plating.

[0040] Since the inner coils are placed inside the central coil and the side coils are placed outside, the bending radius of the coils needs to be relatively small so as not to interfere with the other coils. As an example, as shown in Figure 4B, all four central coils have the same coil height (height from the end of the stator core).

[0041] Next, the shape of the inner coil will be explained with reference to Figure 4D. The coils rising from the straight section are bent radially inward so as not to interfere with the central coil and not to protrude toward the inner diameter of the stator. As shown in Figure 4B, the inner coils rising from the inside of the slot insertion holes are configured to have the lowest coil height. Furthermore, among the inner coils, the coils inserted at the rear are positioned higher than the coils inserted at the front insertion opening of the resin bobbin 3. The coil height of the rear coils is positioned higher than the coils in front of them, allowing for the thickness of the wire and a slight gap. The same applies to the following coils.

[0042] The inner coil, like the central coil, also has recesses at the ends of the coil and is, for example, tin-plated.

[0043] For convenience of illustration, FIG. 4B does not show the resin bobbin of the slot into which the inner coil 50 is inserted.

[0044] The coil with the recess is designed to be shorter than the length of the stator core, and the fitting is located at a predetermined distance from the end of the core. For example, the ends of the other coils are also located at the same axial position.

[0045] Next, the shape of the outer coil will be explained with reference to Figure 4E. The coil rising from the straight section is bent radially outward to form a shape that does not interfere with the central coil. Since the outer coil often has room in the core back section, it can be configured with a large bend outward. As an example, the bending angle can be set to a large angle of about 45 degrees.

[0046] As shown in Figure 4B, the outer coils are configured with the highest coil height, rising from the inside of the slot insertion hole. The next outer coil is then positioned below the coil in front of it, with the coil height being lowered to allow for the wire thickness and a slight gap. The same applies to the coils below.

[0047] The outer coil, like the central coil, also has recesses at the ends of the coil and is, for example, tin-plated.

[0048] Fig. 5A is a perspective view illustrating the coil assembly state of the rectangular conductor. Stators 5A and 5B are arranged in the axial direction. Fig. 5A shows the state in which all of the recessed coils are inserted into the stator core. Fig. 5B shows the state in which one protruding coil 20 is inserted in this state.

[0049] 5B shows the state in which the next protruding coil 20 is about to be inserted. In this state, if the connector does not have an appropriate fitting structure, touching the first inserted coil may cause the coil to come loose. For this reason, it is necessary to insert the coil without touching it, or to insert the subsequent coil while checking to see if the previous coil has come loose. Inserting all the coils while making such checks and checking the contact resistance of the coils makes assembly very difficult.

[0050] The present invention can eliminate such concerns and provide a fitting structure that is easy to assemble and difficult to come loose, and a rotating electric machine having the same.

[0051] The specific experimental results will be explained with reference to FIGS. 6 and 7.

[0052] Fig. 6A is an explanatory diagram of a compression test of a rectangular conductor having a recessed portion 12 and a protruding portion 22, which is a comparative example.

[0053] As shown in Figure 6A, a compression test was conducted on a rectangular test piece with a recessed portion 12 that does not have a groove and a protruding portion 22 that does not have a protrusion. Figure 6B shows the results of the movement and insertion force of two test pieces (Sample 1 and Sample 2) during the compression test. The insertion force gradually increases as the contact surface increases from the point where the straight recessed and protruding mating portions engage, and it was found that the insertion force was approximately 100 N at the specified insertion dimension of 5 mm.

[0054] As shown in Figure 6C, a tensile test was conducted on a rectangular test piece in which the recess 12 had no grooves and the protrusion 22 had no protrusions. Figure 6D shows the results of the movement and tensile load changes for three test pieces (Sample 1 to Sample 3) during the tensile test. All test pieces came out with a force of about 30 N, and after coming out once, they could be removed with a small pulling force, almost equivalent to friction.

[0055] 7A and 7B show the results of the compression test of the rectangular conductor having the recessed portion 12 and the protruding portion 22.

[0056] As shown in Figure 7A, a compression test was conducted on a rectangular test piece in which the recess 12 had a groove and the protrusion 22 had a protrusion. Figure 7B shows the results of the movement and insertion force changes for two test pieces (Sample 1 and Sample 2) during the compression test. The insertion force initially increased as the contact area increased, and then temporarily increased where the protrusion deformed the recess, before decreasing as the protrusion removed the insertion force. It was also found that when the protrusion and groove engaged, an insertion peak was observed, indicated by 90 in the figure.

[0057] The existence of this insertion peak has a secondary significant effect. That is, when fitting together a rectangular conductor with a protruding portion and a rectangular conductor with a recessed portion, the insertion force must rise and fall above the peak, which, when assembled by a human, serves as feedback to let the human know that the fitting has been completed successfully. If we were to express this in words, we could say that there is a clicking sensation, a feeling that the insertion is complete, a feeling that the work is complete, or a feeling that it clicks into place. This kind of tactile feedback can be obtained, making it possible to avoid operational mistakes by the worker.

[0058] In particular, when the mating portion is located inside a resin bobbin, the mating portion cannot be seen from the outside, so the presence or absence of this bodily feedback is extremely important in ensuring that the work is completed.

[0059] Furthermore, even in cases of machine assembly, recording and managing this insertion force allows for reliable production management. Another advantage is that it can be saved as a manufacturing history for later use, making it possible to trace the reliability of individual products after shipment.

[0060] Next, as shown in Figure 7C, a tensile test was conducted on a rectangular test piece having a groove in the recess 12 and a protrusion in the protrusion 22. Figure 7D shows the results of the movement amount and tensile load transition of two test pieces (Sample 1 and Sample 2) during the tensile test. Both test pieces were initially difficult to remove, as shown by the peak at 91 in the figure, and it was found that they had a structure that required a tensile force of about 80 N to remove.

[0061] It was found that it came out with a pulling force of about 30 N, and once it came out, it could be removed with a small pulling force, almost like friction.

[0062] 6 and 7, the recessed portion 12 described in this embodiment has a groove, and the protruding portion 22 has a protrusion. The rectangular wire structure in which the two fit together can realize a structure in which the fitting is difficult to come loose, both as a joint structure and as a rotating electrical machine, without a welding process. Furthermore, the existence of bodily sensation feedback during assembly or the existence of an insertion peak value can prevent work errors and improve quality control.

[0063] FIG. 8 illustrates the relationship between the slot hole dimensions of the resin bobbin 3 and the deformation of the recessed portion during insertion in one embodiment.

[0064] 8A shows an example of a resin bobbin 3 in which the width X1 of the slot hole dimension is 4.3 mm, with a tolerance of plus 0.05 mm and minus 0.00 mm, so that the width X1 of the slot hole is 4.3 to 4.35 mm.

[0065] Figure 8B shows the state in which the recessed coil 11 and the protruding coil 21 are inserted into the slot holes of the resin bobbin 3 in Figure 8A. Although the two coils will ultimately be fitted together, the recessed coil 11 and the protruding coil 21 are shown separated in the figure for the purpose of explaining the dimensional relationship.

[0066] The width X2 of the protruding side coil 21 is, for example, 4.0 mm to 4.1 mm. A protruding portion is formed at the tip of the protruding side coil with a width X4, for example, 1.4 mm. The protrusion formed on the protruding portion has a protrusion height X3 of, for example, 0.1 mm or less.

[0067] The width X7 of the recessed coil 11 is, for example, 4.0 mm to 4.1 mm. At the tip of the recessed coil, a recess is formed with a width X5, for example, 1.4 mm. The groove formed in the recess has a depth X6 of, for example, 0.1 mm. Note that X3 must not be greater than X6.

[0068] There is a gap X8, for example 0.1 mm, between the recessed side coil 11 and the protruding side coil 21 and the inner wall surface of the resin bobbin 3. If this gap X8 did not exist, it would be difficult to insert the recessed side coil 11 and the protruding side coil 21 into the resin bobbin 3.

[0069] When the protrusion-side coil 21 shown in FIG. 8C is inserted into the recess-side coil 11 shown in FIG. 8D , the protrusion of the protrusion-side coil 21 contacts the top surface of the recess-side coil, and the upper portion of the recess-side coil 11 (the portion indicated by the arrow in the figure) expands or deforms to the left and right, widening the width X5 of the recess-side coil. If the height of the protrusion is 0.1 mm, the upper portion of the recess-side coil 11 expands or deforms to the left and right by 0.1 mm. For example, since X7 is 4.0 mm to 4.1 mm, the upper portion of the recess-side coil 11 deforms to a maximum size of X9. If the height of the protrusion is 0.1 mm, this becomes a maximum of 4.3 mm (4.1 + 0.1 + 0.1). Because there is a gap X8 of 0.1 mm between the inner wall surface of the resin bobbin 3 and the end face of the recess-side coil, even if temporary deformation occurs during insertion, insertion can be continued and the engagement can be completed. When the projection is completely fitted into the groove and the fitting is completed, the deformation is eliminated.

[0070] In addition, since the resin bobbin itself has some flexibility, it is possible to deal with a slight excess of deformation by temporarily deforming the resin bobbin.

[0071] Furthermore, in order to eliminate this deformation, it is effective to have a tapered shoulder at the tip of the coil on the recessed side, as shown by the arrow in Fig. 8D, because the presence of this taper applies stress in a direction that narrows the recess inward, which contributes to the recovery force from deformation.

[0072] If the tip of the protruding portion hits the bottom of the recessed portion first when the recessed protruding portion is inserted and fitted, the closing operation by the shoulder will not be possible. Therefore, as an example, it is desirable that the protruding portion be shorter in the axial direction than the recessed portion, or that there be a gap X10 between the tip 200 of the protruding portion and the base 201 of the recessed portion when the fitting is complete. X10 is, for example, 0.2 to 0.4 mm.

[0073] FIG. 9 is a diagram illustrating the influence of the position of the protrusion on the protruding side coil and the position of the groove on the recessed side coil on deformation during the fitting process, when the fitting process is taken into consideration.

[0074] 9A shows an example in which the protrusion formed on the protruding portion of the protruding-side coil 21 is located on the base side of the protruding portion, and the groove formed on the recessed portion of the recessed-side coil 11 is located on the shoulder side of the recessed portion. The various explanations in the above embodiment apply to this case. In the case of FIG. 9A, deformation of the recessed-side coil 11 due to insertion of the protruding-side coil 21 occurs at a later stage of insertion. Therefore, as explained in FIG. 8, assembly is possible within the dimensional range of the resin bobbin 3.

[0075] 9B shows an example in which a protrusion formed on the protruding portion of the protruding-side coil 21 is located at the tip of the protruding portion, and a groove formed on the recessed portion of the recessed-side coil 11 is located at the base of the recessed portion. This is positioned as a comparative example to FIG. 9A . In the case of FIG. 9B , the deformation of the recessed-side coil 11 due to the insertion of the protrusion begins in the direction in which the recessed portion opens immediately after the protrusion is inserted. The deeper the insertion dimension, the larger the opening angle becomes, reaching a maximum opening angle just before reaching the bottom. Therefore, if there is little clearance with the resin bobbin, problems such as contact with the resin bobbin and increased insertion force may occur.

[0076] 9C shows an example in which a groove is formed on the tip side of the protruding portion of the protruding-side coil 21 and a protrusion is provided on the base side of the recessed portion of the recessed-side coil 11. This is another comparative example to FIG. 9A. In the case of FIG. 9C, deformation occurs during insertion, but the length from the protrusion provided on the recessed portion to the shoulder of the recessed portion is longer than in the case of FIG. 9A. Therefore, as shown in FIG. 9C, the amount of deformation between the shoulder or between the left and right ends of the recessed portion is larger than in FIG. 9A, which makes insertion into a resin bobbin difficult.

[0077] 9D shows an example in which a groove is formed at the base of the protruding portion of the protruding-side coil 21, and a protrusion is provided at the tip of the recessed portion of the recessed-side coil 11. This is another comparative example compared to FIG. 9A. In the case of FIG. 9D, because changes occur immediately after insertion, there is a problem in that the insertion force required for assembly remains high. As a result, there is a problem in that manufacturing throughput is reduced compared to the case of FIG. 9A.

[0078] As can be seen from the above explanation of Figures 9A to 9D, from the viewpoint of productivity, it is understood that the structure shown in Figure 9A, i.e., a structure in which the protrusion formed on the protruding portion of the protruding side coil 21 is provided on the base side of the protruding portion, and the groove formed in the recessed portion of the recessed side coil 11 is provided on the shoulder side of the recessed portion, is desirable.

[0079] As described above, this embodiment can realize a coupling structure between rectangular wires and a rotating electrical machine structure that does not require a welding process, is easy to assemble, is difficult to come loose, and has excellent productivity.

[0080] This embodiment is basically the same as embodiment 1. Differences from embodiment 1 will be described below.

[0081] 10B is a diagram for explaining the assembly of the protruding coil 21 and the recessed coil 11 by sequentially moving them close to each other and fitting them together as indicated by the arrows in the figure. For the sake of explanation, the resin bobbin and other components are omitted from the figure. For the sake of explanation, one of the mating sides is designated as 210 and the other as 220.

[0082] The feature of this embodiment is that the position of the protruding coil 21 from the base of the protruding portion differs between FIG. 10A corresponding to 210 in FIG. 10B and FIG. 10C corresponding to 220 in FIG. 10B.

[0083] 10A, in the protruding portion of the protruding-side coil 21, the distance 213 from the base 216 to the center 215 of the protruding portion is, for example, 1.5 mm. Also, the distance 212 from the center 215 of the protruding portion to the tip 214 of the protruding portion is 3.5 mm.

[0084] 10C, the distance 223 from the base 226 to the center 225 of the protruding portion of the protruding-side coil 21 is, for example, 1.0 mm, and the distance 222 from the center 225 of the protruding portion to the tip 224 of the protruding portion is 4.0 mm.

[0085] When the groove portion 203 has a long hole shape as in the recessed side coil 11 shown on the left side of Figure 10A, the groove portion can be made to be compatible with both the protruding side coil 21 shown on the right side of Figure 10A and the protruding side coil 21 shown on the right side of Figure 10C.

[0086] For example, in the recessed side coil 11 of Fig. 10A, position 211, which is 1.5 mm away from shoulder tip 217 and a distance 219, is located within the elongated hole, and therefore can accommodate 1.5 mm as indicated by 213. At the same time, position 221, which is 1.0 mm away from shoulder tip 217 and a distance 218, is located within the elongated hole, and therefore can accommodate 1.0 mm as indicated by 223. In this way, by providing the groove of the recessed side coil 11 with an elongated hole shape, it is possible to accommodate a plurality of protrusion positions.

[0087] 10B, when joining a U-shaped coil or a hairpin coil, the recessed coil 11 having such a long hole can be provided on both of the mating pairs 210 and 220. In this case, however, since 203 is a long hole, there will be some room for movement between 11 and 21.

[0088] When a stronger fit is desired, for example, one of the mating pairs, 210, may be a recessed coil 11 having a slot as shown in FIG. 10A , and the other of the mating pairs, 220, may be a recessed coil 11 having a groove 204 that is not a slot as shown in FIG. 10C . In this case, the distance 228 from the groove center 221 to the shoulder 227 is 1.0 mm, which is the same as 223, and a strong fit can be achieved in the mated state. This makes it possible to achieve both ease of assembly and a strong fit.

[0089] The effect of making the length from the bottom to the center of the protrusion different between the protruding side coil 21 on the right side of FIG. 10A and the protruding side coil 21 on the right side of FIG. 10C will be further described.

[0090] In Figure 10A, distance 213 is 1.5 mm, while in Figure 10C, distance 223 is 1.0 mm, which are different. Therefore, when a protrusion-side coil with such different distances is fitted into a recessed-side coil, even if the protrusion-side coil is pressed into and assembled into the recessed-side coil in an attempt to fit them together at the same time, the timing at which the protrusions and grooves of the protrusion-side coil and the recessed-side coil fit together will be offset. In other words, the timing of the clicking sensation and bodily feedback during fitting will be offset. This means that the timing at which insertion peak 90 in Figure 7B appears will be offset.

[0091] Therefore, for example, the operator can feel a click or insertion sensation twice, and can easily understand that both insertion operations have been completed successfully. Or, when performing insertion measurements, the peak change can be observed twice. Therefore, it is possible to reliably avoid operational errors, and it is possible to obtain the distinctive effect of more reliable quality control during manufacturing operations.

[0092] FIG. 11A shows an example of detailed dimensions of the recessed side coil 11, and FIG. 11B shows an example of detailed dimensions of the protruding side coil 21.

[0093] In Figure 11A, angle 302 formed by extension line 308 of the shoulder and horizontal line 309 is 10°. For example, it is desirable that this angle be within the range of 5° to 20°. Similarly, in Figure 11B, angle 312 formed by extension line 318 of the tapered portion of the bottom and horizontal line 319 is 10°. For example, it is desirable that this angle be within the range of 5° to 20°. It is desirable that angles 302 and 312 are the same.

[0094] In Fig. 11A, the groove depth 303 of the groove is 0.1 mm. For example, it is desirable that it be in the range of 0.05 mm to 0.2 mm. Similarly, in Fig. 11B, the protrusion height 316 of the protrusion is 0.1 mm. For example, it is desirable that it be in the range of 0.05 mm to 0.2 mm. It is also desirable that 303 and 316 are the same.

[0095] The width 300 of the recessed portion in Fig. 11A is, for example, 1.4 mm. The deviation is -0.05 mm to -0.02 mm. Similarly, in Fig. 11B, the width 310 of the protruding portion is, for example, 1.4 mm. The deviation is -0.025 mm to +0.025 mm. For the purpose of fitting, it is desirable that the finished dimension 300 is greater than 310.

[0096] In Figure 11A, the distance 301 from the tip 307 of the shoulder to the bottom 305 of the recess is, for example, 5.0 mm. The deviation is +0.1 mm to +0.3 mm. Similarly, in Figure 11B, the distance 311 from the bottom surface of the protrusion to the tip of the protrusion is, for example, 5.0 mm. The deviation is -0.1 mm to +0.1 mm. For the purpose of fitting, it is desirable that the finished dimension 301 is greater than 311.

[0097] The groove in Fig. 11A has, for example, an R of 0.35 mm near its center and an R of 2-0.3 mm near its end. The protrusion in Fig. 11B has, for example, an R of 0.3 mm near its center and an R of 2-0.3 mm near its end. For the purpose of fitting the groove and protrusion together, it is desirable that the R at the center of the groove is greater than the R at the center of the protrusion in the finished dimensions.

[0098] For example, it is desirable that the protrusions and grooves be smoothly connected to the straight line portions with a curved line, which can be achieved by machining the mold with wire electric discharge machining, for example.

[0099] Fig. 12A shows an example in which a tin-plated layer 9 is provided from the recessed portion to the shoulder portion of the recessed side coil 11. Similarly, Fig. 12B shows an example in which a tin-plated layer 9 is provided on the protruding side coil 21. By providing the tin-plated layer 9 in this way, improved conductivity and reliability during mating are realized.

[0100] The thickness 00 of the tin-plated layer 9 is, for example, 0.01 mm. The punched surface of the recessed, protruding, and fitting portion is tin-plated. The tin plating can be performed by electrolytic plating or electroless plating.

[0101] The above examples illustrate the ideas and concepts of the present invention. Of course, the scope of the present invention also includes examples that are realized by combining the examples. Furthermore, as long as the disclosed ideas and concepts are used, any modifications or similar examples are also included within the scope of the present invention.

[0102] Furthermore, one example of the present invention described using the above embodiments can also be expressed as follows.

[0103] <No. 1> A rotating electric machine having a stator coil in which a first flat wire and a second flat wire are fitted together, wherein the first flat wire has a protruding portion and the second flat wire has a recessed portion, and the protruding portion and the recessed portion are configured to be inserted into each other, and among the surfaces constituting the protruding portion and the recessed portion, on the surfaces along the extension direction of the first flat wire and the second flat wire, the protruding portion has a protrusion and the recessed portion has a groove, and the protrusion and the groove each have a pair of protrusions and a pair of grooves. <No. 2> The rotating electric machine of <No. 1>, wherein the pair of protrusions and the pair of grooves are configured by providing one protrusion and one groove on opposing surfaces of the surfaces along the extension direction of the first flat wire and the second flat wire. <No. 3> The rotating electric machine of <No. 2>, wherein the protrusions are smaller than the grooves. <No. 4> The rotating electric machine according to <No. 3>, wherein the protrusion is located on the base side of the protruding portion, and the groove is located on the shoulder side of the recessed portion. <No. 5> The rotating electric machine according to <No. 4>, wherein the stator of the rotating electric machine has a resin bobbin, and the insertion and fitting portions for the first rectangular wire and the second rectangular wire are located within the resin bobbin. <No. 6> The rotating electric machine according to <No. 5>, wherein the groove and the protrusion both have an R-shape. <No. 7> The rotating electric machine according to <No. 6>, wherein the R-shape of the groove is larger than the R-shape of the protrusion. <No. 8> The rotating electric machine according to <No. 6>, wherein the R-shape is 0.3 mm or more. <No. 9> The rotating electric machine according to <No. 7>, wherein the shoulder of the recessed portion and the bottom of the protruding portion each have a tapered surface. <No. 10> The rotating electric machine according to <No. 9>, wherein the protruding portion and the recessed portion have a tin-plated layer. <No. 11> The rotating electric machine according to any one of <No. 1> to <No. 10>, wherein the first rectangular wire and the second rectangular wire each have a U-shape. <No. 12> The rotating electric machine according to <No. 11>, wherein the first rectangular wire has the protruding portion at both ends of the U-shape, and the second rectangular wire has the indented portion at both ends of the U-shape. <No. 13> The rotating electric machine according to <No. 12>, wherein the protruding portion formed on one end of the first rectangular wire and the protruding portion formed on the other end of the first rectangular wire have different lengths from the base of the protruding portion to the protruding portion.<No. 14> The rotating electric machine according to <No. 13>, wherein at least one of the grooves formed in the second rectangular wire has an elongated hole shape corresponding to both protrusions having different lengths from the base of the protrusion to the protrusion. <No. 15> The rotating electric machine according to <No. 13>, wherein the protrusion formed on one of the tip portions and the protrusion formed on the other of the tip portions are configured to offset the mating positions of the protrusion and the groove. <No. 16> The rotating electric machine according to <No. 15>, wherein the protrusion formed on one of the tip portions and the protrusion formed on the other of the tip portions are configured to offset the mating timing of the protrusion and the groove.

[0104] 1: Tees core 2: Core-back core 3: Resin bobbin 5: Stator 9: Tin-plated portion 10: Recessed side coil end 11: Recessed side coil 12: Recessed portion 13: Groove portion 20: Protruding side coil end 21: Protruding side coil 22: Protruding portion 23: Protrusion portion 30: Recessed side outer coil end 32: Recessed side outer coil fitting portion 40: Protruding side outer coil end 41: Protruding side outer coil 50: Recessed side inner coil end 51: Recessed side inner coil 60: Protruding side inner coil end 61: Protruding side inner coil 70: Lead coil 72: Lead coil fitting protruding portion

Claims

1. A rotating electric machine having a stator coil in which a first flat wire and a second flat wire are fitted together, wherein the first flat wire has a protruding portion and the second flat wire has a recessed portion, and the protruding portion and the recessed portion are configured to be inserted and fitted together, and among the surfaces constituting the protruding portion and the recessed portion, on the surfaces along the extension direction of the first flat wire and the second flat wire, the protruding portion has a protruding portion and the recessed portion has a grooved portion, and the protruding portion and the grooved portion each have a pair of protruding portions and a pair of grooved portions.

2. A rotating electric motor as described in claim 1, wherein the pair of protrusions and the pair of grooves are configured by providing one protrusion and one groove on each of the opposing surfaces of the first rectangular wire and the second rectangular wire along the extension direction.

3. A rotating electric machine according to claim 2, wherein said protrusion is smaller than said groove.

4. A rotating electric machine according to claim 3, wherein said protrusion is located on the base side of said protruding portion, and said groove is located on the shoulder side of said recessed portion.

5. A rotating electric machine according to claim 4, wherein the stator of the rotating electric machine has a resin bobbin, and the insertion and fitting portions of the first rectangular wire and the second rectangular wire are located inside the resin bobbin.

6. A rotating electric machine according to claim 5, wherein said groove and said protrusion both have an R-shape.

7. A rotating electric machine according to claim 6, wherein the R-shape of said groove is larger than the R-shape of said protrusion.

8. A rotating electric machine according to claim 6, wherein the R shape is 0.3 mm or more.

9. A rotating electric machine according to claim 7, wherein the shoulder of said recess and the bottom of said protrusion each have a tapered surface.

10. A rotating electric machine according to claim 9, wherein said protruding portion and said recessed portion have a tin-plated layer.

11. A rotating electric machine according to any one of claims 1 to 10, wherein the first rectangular wire and the second rectangular wire each have a U-shape.

12. A rotating electric machine according to claim 11, wherein the first rectangular wire has the protruding portions at both ends of the U-shape, and the second rectangular wire has the recessed portions at both ends of the U-shape.

13. A rotating electric machine according to claim 12, wherein the protruding portion formed on one end of the first rectangular wire and the protruding portion formed on the other end of the first rectangular wire have different lengths from the base of the protruding portion to the protruding portion.

14. A rotating electric machine according to claim 13, wherein at least one of the grooves formed in the second rectangular wire is an elongated hole shaped to correspond to both of the protrusions, which have different lengths from the base of the protruding portion to the protrusion.

15. A rotating electric machine according to claim 13, wherein the protruding portion formed on one end of the tip and the protruding portion formed on the other end of the tip are configured so that the mating positions of the protrusion and the groove are offset.

16. A rotating electric machine according to claim 15, wherein the protruding portion formed on one end of the tip and the protruding portion formed on the other end of the tip are configured so that the timing of engagement between the protrusion and the groove is offset.

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