Motor and method for producing motor

Abstract

This motor has a stator core and a multi-phase coil. The coils of the respective phases each have: a plurality of pin parts that penetrate the inside of the slot in the axial direction, and that are flat conductive wires having end parts that protrude axially outward from one axial-direction end surface of the stator core; and a plurality of connection members that electrically interconnect the end parts of a pair of the pin parts in the coils of the same phase among the plurality of pin parts. The connection member has a connection portion electrically connected in the circumferential direction or the radial direction to the end parts of the pair of pin parts in the coils of the same phase, and at least a part of the connection portion of the connection member is located at a position from the one end surface of the stator core to one end in the axial direction at the end parts of the pin parts in the axial direction.

Description

Motor and Method for Manufacturing the Same

[0001] The present invention relates to a motor and a method for manufacturing the same. This application claims priority based on Japanese Patent Application No. 2024-177694 filed on October 10, 2024, the content of which is incorporated herein by reference.

[0002] A technique is known in which end portions of stator coils located in slots of a stator core are electrically connected by a bus bar.

[0003] For example, Patent Document 1 discloses a stator in which coil wires located in slots are electrically connected by a bus ring in which a bus bar is arranged in an annular shape. In the stator described in Patent Document 1, end portions of the coil wires protrude from one end face in the axial direction of the stator core. Also, the end portions of the coil wires have different protruding lengths for each phase. Each phase bus ring formed in the same shape is electrically connected to the end portions of the coil wires in a state of being laminated with respect to the stator core while being shifted in the circumferential phase.

[0004] Patent Document 2 discloses a stator in which a stator coil is formed by connecting end portions of copper plates constituting a coil by a bus bar that is a conductor. Specifically, in the stator described in Patent Document 2, a plurality of copper plates are located in a plurality of slots arranged in the circumferential direction. End portions of the plurality of copper plates each protrude axially outward from one end face in the axial direction of the stator core. At positions axially outward of the end portions of two copper plates located in different slots, the bus bar is electrically connected to the end portions of the copper plates.

[0005] Japanese Unexamined Patent Application Publication No. 2022-**157251**, Japanese Unexamined Patent Application Publication No. 2020-**89235**

[0006] By the way, there is a need to save space in a motor. For example, in order to improve the design freedom of components other than the stator, it is desired to make the stator more compact.

[0007] In contrast, in the stators described in Patent Documents 1 and 2, the busbars are connected axially to the ends of the coil wires. Therefore, there is room for further miniaturization in the axial direction in the stators described in Patent Documents 1 and 2.

[0008] The object of the present invention is to provide a motor that enables a more axially compact coil end configuration, including the connecting member, compared to a case where the connecting member is axially connected to each of the ends of a pair of pin portions.

[0009] A motor according to an exemplary embodiment of the present invention comprises a cylindrical stator core extending axially with respect to a central axis and having a plurality of slots arranged circumferentially, and a plurality of phase coils, a portion of which is located within the plurality of slots of the stator core. Each of the phase coils has a plurality of pin portions, which are flat rectangular conductors that penetrate the slot in the axial direction and whose ends protrude axially outward from one axial end face of the stator core, and a plurality of connecting members that electrically connect the ends of a pair of the pin portions in the same phase coil. The connecting members have connecting portions that electrically connect to the ends of a pair of the pin portions in the same phase coil in the circumferential or radial direction. At least a portion of the connecting portions of the connecting members is located in the axial direction from the one end face of the stator core to one axial end of the pin portion.

[0010] According to the present invention, compared to the case where the connecting member is axially connected to each of the ends of a pair of pin portions, the coil end including the connecting member can be made more compact in the axial direction.

[0011] Figure 1 is a perspective view showing the schematic configuration of a stator in a motor according to an embodiment. Figure 2 is a perspective view showing the ends of pins aligned in a slot. Figure 3 is an exploded perspective view showing some of the components of a coil. Figure 4 is a schematic process diagram showing one step in the motor manufacturing method. Figure 5 is a schematic process diagram showing another step following the first step in the motor manufacturing method. Figure 6 is an exploded perspective view showing the connected members in the motor shown in Figure 1 in an disassembled state. Figure 7 is an exploded perspective view showing the connection relationship between the outer ring and inner ring of the first layer ring. Figure 8 is an exploded perspective view showing the connection relationship between the outer ring and inner ring of the second layer ring. Figure 9 is an exploded perspective view showing the connection relationship between the outer ring and inner ring of the third layer ring. Figure 10 is a schematic process diagram showing one step in the motor manufacturing method according to Modification 1. Figure 11 is a diagram showing the workpiece obtained by the step shown in Figure 10. Figure 12 is a schematic process diagram showing another step following the first step in the motor manufacturing method according to Modification 1. Figure 13 is a diagram showing connected members according to another embodiment. Figure 14 is a perspective view showing the schematic configuration of a stator in a motor according to Modification 3. Figure 15 is an exploded perspective view of the laminate in the stator according to Modification 3. Figure 16 is a perspective view showing the schematic configuration of the stator of the motor according to Modification 4. Figure 17 is an exploded perspective view of the laminate in the stator according to Modification 4. Figure 18 is a diagram showing a part of the laminate according to Modification 4.

[0012] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the drawings. Note that identical or corresponding parts in the drawings are denoted by the same reference numerals, and their descriptions will not be repeated. Furthermore, the dimensions of the components in each drawing do not necessarily accurately represent the actual dimensions of the components or their dimensional ratios.

[0013] In the following explanation, the direction parallel to the central axis P of the motor 1 and stator core 20 will be referred to as the axial direction, the direction perpendicular to the central axis P will be referred to as the radial direction, and the direction along the arc centered on the central axis P will be referred to as the circumferential direction. In each figure, the axial direction is indicated by A, the radial direction by B, and the circumferential direction by C.

[0014] Furthermore, in the following explanation, the expressions "fix," "connect," and "attach" (hereinafter referred to as "fixing, etc.") include not only cases where components are directly fixed to each other, but also cases where they are fixed to each other via other components. In other words, in the following explanation, the expressions "fixing, etc." include both direct and indirect fixing of components to each other.

[0015] (Outline configuration of the motor) Figure 1 is a perspective view showing the outline configuration of the stator of the motor 1 according to this embodiment. Figure 2 is a perspective view showing the ends of the pins aligned in the slot 23. Figure 3 is an exploded perspective view showing some of the components of the coil 30.

[0016] Referring to Figures 1 to 3, the motor 1 has a stator core 20 and a multi-phase coil 30. The stator core 20 and the multi-phase coil 30 constitute the stator 5 of the motor 1. In the motor 1, configurations other than the stator core 20 and the multi-phase coil 30 can be the same as those of known motors.

[0017] The stator core 20 extends in the axial direction A, with a central axis P as its center. The stator core 20 has a plurality of slots 23. The stator core 20 is cylindrical.

[0018] The stator core 20 has a back yoke 21 and a plurality of teeth 22. The back yoke 21 is cylindrical and extends in the axial direction A with respect to a central axis P. The plurality of teeth 22 extend radially inward B2 from the inner circumferential end face of the back yoke 21. A slot 23 is formed by two adjacent teeth 22 in the circumferential direction C. The plurality of slots 23 are arranged in a line in the circumferential direction C.

[0019] A portion of the multi-phase coil 30 is located within a plurality of slots 23. A known winding method can be used for the winding of the multi-phase coil 30. Each phase coil has a circuit equivalent to, for example, a wave-wound coil. However, each phase coil may have a circuit equivalent to a lap-wound coil. The multi-phase coil 30 has a plurality of coil pieces 40 and a plurality of connecting members 60. The connecting members 60 are formed, for example, by multiforming a flat rectangular conductor having an insulating coating such as enamel. Hereinafter, when distinguishing each coil piece 40, different reference numbers will be assigned, for example, 401, 402, ... Connecting members 60 with desirable insulating properties can be easily realized by using a flat rectangular conductor with an enamel insulating coating.

[0020] As shown in Figure 3, the coil pieces 401 and 402 have a shape formed by folding a rectangular wire in one direction. The coil pieces 401 and 402 have a first portion 41 as a pin portion, a second portion 42 as a pin portion, and a connecting portion 43. The first portion 41, the second portion 42, and the connecting portion 43 are a single component. The coil pieces 401 and 402 are made of a rectangular wire having an insulating coating such as enamel.

[0021] As shown in Figure 2, the first portion 41 and the second portion 42, both pin portions, each penetrate the slot 23 in the axial direction A. The multiple first portions 41 and second portions 42, which are pin portions, are positioned side by side in the radial direction B and the circumferential direction C. Therefore, the distance in the circumferential direction C between pin portions located further outward in the radial direction B1 is greater than the distance in the circumferential direction C between pin portions located further inward in the radial direction B2.

[0022] One end 411 of the first portion 41 and one end 421 of the second portion 42 each protrude axially outward from one end face 24 in the axial direction A of the stator core 20. The protrusion length LN1 of the first portion 41 and the second portion 42 from one end face 24 of the stator core 20 is the same. One end 411 of the first portion 41 and one end 421 of the second portion 42 are exposed without the aforementioned insulating coating.

[0023] As shown in Figure 3, the connecting portion 43 connects the other end 412 of the first portion 41 and the other end 422 of the second portion 42 of the coil piece 40. That is, the connecting portion 43 electrically connects the other end 412 of the first portion 41 in the axial direction A, which is one pin portion, and the other end 422 of the second portion 42 in the axial direction A, which is another pin portion located in a different slot 23.

[0024] With this configuration of the coil piece 40, since the pin portion is part of a single member that is folded back in the axial direction A, the coil end 31 including the connecting member 60 can be made compact in the axial direction A.

[0025] Multiple connecting members 60 electrically connect two coil pieces 401 and 402 of the same phase. More specifically, each connecting member 60 has connecting portions 61 and 62 and an extended portion 64. The connecting portion 61 is electrically connected in the circumferential direction C to one end 411 of the first portion 41 of the coil piece 401. The connecting portion 62 is electrically connected in the circumferential direction C to one end 421 of the second portion 42 of the coil piece 402.

[0026] Furthermore, the connecting member 60 is positioned in the axial direction A from one end face 24 of the stator core 20 to the end face 4111 of one end 411 of the first portion 41 and the end face 4211 of one end 421 of the second portion 42.

[0027] In the above configuration, the connecting member 60 is electrically connected in the circumferential direction C to one end 411 of the first portion 41 and one end 421 of the second portion 42, which are a pair of pin portions. Moreover, at least a portion of the connecting portions 61 and 62 of the connecting member 60 with the pin portions is located in the axial direction A from one end face 24 of the stator core 20 to one end of the pin portion in the axial direction A.

[0028] Therefore, with the above configuration, compared to the case where the connecting member 60 is connected to each of the ends of the pair of pin portions in the axial direction A, the coil end 31 including the connecting member 60 can be made more compact in the axial direction A.

[0029] Moreover, in the above-described configuration, the multiple pin portions have the same position at one end in the axial direction A. In addition, the connecting member 60 is positioned in the axial direction A from one end face 24 of the stator core 20 to one end in the axial direction A at the end of the pin portion.

[0030] As a result, the connecting member 60 does not protrude in the axial direction A relative to the end of the pin portion. Therefore, the coil end 31 including the connecting member 60 can be made even more compact in the axial direction A.

[0031] Although not specifically shown in the figures, the coil end 31 may have a fixing portion for securing the connecting member 60 and the pin portion. The fixing portion may be made of a resin layer such as varnish or epoxy resin.

[0032] (Motor Manufacturing Method) Figure 4 is a schematic process diagram showing one step in the manufacturing method of motor 1. Figure 5 is a schematic process diagram showing another step following the aforementioned step in the manufacturing method of motor 1.

[0033] Referring to Figure 4, in the manufacturing method of the motor 1, first, multiple coil pieces 40 having multiple pin portions are inserted into the slots 23 of the stator core 20 (pin portion insertion step S11). In the pin portion insertion step S11, the first portion 41 and the second portion 42, which are multiple pin portions, are inserted into the slots 23 from the other end face 25 in the axial direction A of the stator core 20 in the axial direction A1, as shown by the white arrows in Figure 4. In addition, one end 411 of the first portion 41 and one end 421 of the second portion 42 are made to protrude from one end face 24 of the stator core 20 by a protrusion length LN1. That is, in the axial direction A, the position of the end face 4111 of the end 411 of the first portion 41 in the axial direction A is the same as the position of the end face 4211 of the end 421 of the second portion 42 in the axial direction A.

[0034] Next, referring to Figure 5, the connecting member 60 electrically connects one end 411 of the first portion 41 and one end 421 of the second portion 42 of the coil 30 of the same phase (joining step S12).

[0035] In joining step S12, at least a portion of the connecting portions 61 and 62 of the connecting member 60 is positioned in the axial direction A from position POS1 of one end face 24 of the stator core 20 to position POS2 of the end face 4111 of one end 411 of the first portion 41 and the end face 4211 of one end 421 of the second portion 42. For example, one end of the connecting portions 61 and 62 of the connecting member 60 in the axial direction A is positioned at position POS2 of the end faces 4111 and 4211.

[0036] Furthermore, with the connecting portions 61 and 62 of the connecting member 60 positioned at position POS2, the connecting portions 61 and 62 of the connecting member 60 are joined in the circumferential direction C to one end 411 of the first portion 41 and one end 421 of the second portion 42. This joining can be done by welding or the like. This electrically connects the connecting portions 61 and 62 of the connecting member 60 to one end 411 of the first portion 41 and one end 421 of the second portion 42 in the circumferential direction C.

[0037] The stator 5 is obtained through the above process. By attaching other parts to the stator 5, the motor 1 is obtained.

[0038] According to the above configuration, the connecting portions 61 and 62 located at both ends of the connecting member 60 are electrically connected in the circumferential direction C to one end 411 of the first portion 41, which is a pair of pin portions, and to one end 421 of the second portion 42, which is a pair of pin portions. Furthermore, the connecting member 60 does not protrude in the axial direction A relative to the axial ends of the pin portions. Therefore, according to the above configuration, the coil end 31 including the connecting member 60 can be made more compact in the axial direction A compared to the case where the connecting member 60 is connected to one of the ends of the pair of pin portions in the axial direction A.

[0039] (Details of the coil end) Figure 6 is an exploded perspective view showing the connected member 60 in the motor 1 shown in Figure 1 in a disassembled state.

[0040] The plurality of connection members 60 are stacked in the axial direction A with respect to the stator core 20 of the motor 1 in a state of being arranged annularly in the circumferential direction C, thereby constituting a laminate 600. A part of the plurality of connection members 60 constitutes the first layer ring L160. Another part of the plurality of connection members 60 constitutes the second layer ring L260. The remaining part of the plurality of connection members 60 constitutes the third layer ring L360. That is, the laminate 600 includes the first layer ring L160, the second layer ring L260, and the third layer ring L360. The first layer ring L160, the second layer ring L260, and the third layer ring L360 are stacked in order from the other axial direction A2 to the one axial direction A1.

[0041] The first layer ring L160, the second layer ring L260, and the third layer ring L360 each have an outer ring located radially outward B1 from a row 48 of pin portions arranged in the radial direction B and an inner ring located radially inward B2 from the row 48 of pin portions arranged in the radial direction B. The outer ring and the inner ring are each constituted by a plurality of connection members. The first layer ring L160, the second layer ring L260, and the third layer ring L360 correspond to, for example, three phases of U phase, V phase, and W phase.

[0042] The first layer ring L160 includes an outer ring L1610 and an inner ring L1620. The second layer ring L260 includes an outer ring L2610 and an inner ring L2620. The third layer ring L360 includes an outer ring L3610 and an inner ring L3620.

[0043] (Configuration of the first layer ring) FIG. 7 is an exploded perspective view showing the connection relationship between the outer ring L1610 and the inner ring L1620 of the first layer ring L160.

[0044] Referring to FIG. 7, in each slot 23 arranged in the circumferential direction in the stator core 20, four pin portions are arranged in the radial direction B. For example, as a row of four pin portions, a first row PN1, a second row PN2, a third row PN3, a fourth row PN4, a fifth row PN5, and a sixth row PN6 are arranged in order from the one circumferential direction C1 to the other circumferential direction C2.

[0045] In the first column PN1, the pin portions PN11, PN12, PN13, and PN14 are arranged in order from the radially outer side B1 to the radially inner side B2. In the second column PN2 adjacent to the other circumferential side C2 of the first column PN1, the pin portions PN21, PN22, PN23, and PN24 are arranged in order from the radially outer side B1 to the radially inner side B2.

[0046] The outer ring L1610 includes two connecting members 1611 and 1612 adjacent to each other in the circumferential direction C. The two connecting members 1611 and 1612 have the same shape. The extending portions 64 of the connecting members 1611 and 1612 are located, for example, radially outside B1 of the pin portion PN11 of the first column PN1.

[0047] The connecting portion 62 located at the end of the other circumferential side C2 of the connecting member 1611 extends radially inward B2 to the positions of the pin portions PN12 and PN22, and extends axially in one direction A1 from the said positions to the end faces 45 of the pin portions PN12 and PN22.

[0048] The connecting portion 62 of the connecting member 1611 is electrically connected to the pin portion PN12 at the position of one circumferential side C1, while being electrically connected to the pin portion PN22 at the position of the other circumferential side C2.

[0049] The extending portions 64 of the connecting members 1611 and 1612 have upward step portions 651 located at the ends of the one circumferential side C1 of the extending portions 64.

[0050] The upward step portion 651 of the connecting member 1612 overlaps axially in the direction A with the end of the other circumferential side C2 of the extending portion 64 of the connecting member 1611 when the plurality of connecting members 60 are stacked. The connecting portion 61 located at the end of the one circumferential side C1 of the connecting member 1612 extends radially inward B2 from the upward step portion 651 to the positions of the pin portions PN11 and PN21, and extends axially in one direction A1 from the said positions to the end faces 45 of the pin portions PN11 and PN21 in the one axial direction A1.

[0051] The connecting portion 61 of the connecting member 1612 is electrically connected to the pin portion PN11 at the position of one circumferential side C1, while being electrically connected to the pin portion PN21 at the position of the other circumferential side C2.

[0052] The inner ring L1620 includes two circumferentially adjacent connecting members 1621 and 1622. The two connecting members 1621 and 1622 have the same shape. The extended portions 64 of the connecting members 1621 and 1622 are located radially inward B2 than, for example, the pin portion PN11 of the first row PN1.

[0053] The connecting portion 61 of the connecting member 1622 extends radially outward B1 to the positions of the pin portions PN13 and PN23, and also extends axially in one direction A1 from the aforementioned position to the end faces 45 of the pin portions PN13 and PN23.

[0054] The connecting portion 61 of the connecting member 1622 is electrically connected to the pin portion PN13 at one position C1 in the circumferential direction, while it is electrically connected to the pin portion PN23 at the other position C2 in the circumferential direction.

[0055] The extended portion 64 of the connecting members 1621 and 1622 has an ascending step portion 652 located at the other end C2 in the circumferential direction of the extended portion 64.

[0056] The raised step portion 652 of the connecting member 1621 overlaps with one end C1 in the circumferential direction of the extended portion 64 of the connecting member 1622 in the axial direction A when multiple connecting members 60 are stacked.

[0057] The connecting portion 62 of the connecting member 1621 extends radially outward B1 from the upper step portion 652 of the extended portion 64 to the positions of the pin portions PN14 and PN24, and also extends axially in one direction A1 from the aforementioned position to the end faces 45 of the pin portions PN14 and PN24.

[0058] The connecting portion 62 of the connecting member 1621 is electrically connected to the pin portion PN14 at one circumferential position C1, while it is electrically connected to the pin portion PN24 at the other circumferential position C2.

[0059] (Configuration of the second layer ring) Figure 8 is an exploded perspective view showing the connection relationship between the outer ring L2610 and the inner ring L2620 of the second layer ring L260.

[0060] Referring to Figure 8, in the third row PN3, pin portions PN31, PN32, PN33, and PN34 are located in order from radially outward B1 to radially inward B2. In the fourth row PN4, adjacent to the other circumferential direction C2 of the third row PN3, pin portions PN41, PN42, PN43, and PN44 are located in order from radially outward B1 to radially inward B2.

[0061] The outer ring L2610 includes two circumferentially adjacent connecting members 2611 and 2612.

[0062] The connecting portion 62 of the connecting member 2611 is electrically connected to the pin portion PN32 at one circumferential position C1, while it is electrically connected to the pin portion PN42 at the other circumferential position C2. The connecting portion 61 of the connecting member 2612 is electrically connected to the pin portion PN31 at one circumferential position C1, while it is electrically connected to the pin portion PN41 at the other circumferential position C2.

[0063] The inner ring L2620 includes two circumferentially adjacent connecting members 2621 and 2622.

[0064] The connecting portion 62 of the connecting member 2621 is electrically connected to the pin portion PN34 at one circumferential position C1, while it is electrically connected to the pin portion PN44 at the other circumferential position C2. The connecting portion 61 of the connecting member 2622 is electrically connected to the pin portion PN33 at one circumferential position C1, while it is electrically connected to the pin portion PN43 at the other circumferential position C2.

[0065] Referring also to Figure 6, the axial direction of the connecting members 2611, 2612, 2621, and 2622 in the second layer ring L260 is shown, while the connecting members 1611, 1612, 1621, and 1622 in the first layer ring L160 are located at A2.

[0066] The extended portions 64 of the connecting members 2611, 2612, 2621, and 2622 have an overhanging step portion 66 that extends in the circumferential direction C at one axial position A1 of the upward step portions 651 and 652 of the extended portions 64 of the connecting members 1611, 1612, 1621, and 1622. The overhanging step portion 66 extends around the upward step portions 651 and 652, bypassing them, at a position that does not overlap with the upward step portions 651 and 652 located at the other axial position A2 when viewed in the radial direction B.

[0067] (Structure of the third layer ring) Figure 9 is an exploded perspective view showing the connection relationship between the outer ring L3610 and the inner ring L3620 of the third layer ring L360.

[0068] Referring to Figure 9, in the fifth row PN5, pin portions PN51, PN52, PN53, and PN54 are located in order from radially outward B1 to radially inward B2. In the sixth row PN6, adjacent to the other circumferential direction C2 of the fifth row PN5, pin portions PN61, PN62, PN63, and PN64 are located in order from radially outward B1 to radially inward B2.

[0069] The outer ring L3610 includes two adjacent connecting members 3611 and 3612 in the circumferential direction C.

[0070] The extended portions 64 of the connecting members 3611 and 3612 have a downward step portion 681 located at the other end C2 in the circumferential direction of the extended portion 64. When multiple connecting members 60 are stacked, the downward step portion 681 of the connecting member 3611 overlaps in the axial direction A with the end of one end C1 in the circumferential direction of the extended portion 64 of the connecting member 3612 that is adjacent in the circumferential direction C.

[0071] The connecting portion 61 of the connecting member 3612 is electrically connected to the pin portion PN51 at one circumferential position C1, while it is electrically connected to the pin portion PN61 at the other circumferential position C2. The connecting portion 62 of the connecting member 3611 is electrically connected to the pin portion PN52 at one circumferential position C1, while it is electrically connected to the pin portion PN61 at the other circumferential position C2.

[0072] The inner ring L3620 includes two circumferentially adjacent connecting members 3621 and 3622.

[0073] The extended portions 64 of the connecting members 3621 and 3622 have a downward step portion 682 located at one end C1 in the circumferential direction of the extended portion 64. When multiple connecting members 60 are stacked, the downward step portion 682 of the connecting member 3622 overlaps in the axial direction A with the other end C2 in the circumferential direction of the extended portion 64 of the connecting member 3621 that is adjacent in the circumferential direction C.

[0074] The connecting portion 62 of the connecting member 3621 is electrically connected to the pin portion PN54 at one circumferential position C1, while it is electrically connected to the pin portion PN64 at the other circumferential position C2. The connecting portion 61 of the connecting member 3622 is electrically connected to the pin portion PN53 at one circumferential position C1, while it is electrically connected to the pin portion PN63 at the other circumferential position C2.

[0075] As described above, in motor 1, the multiple pin portions PN11-PN64 are positioned in the radial direction B and the circumferential direction C within the multiple slots 23. Furthermore, the multiple pin portions PN11-PN64 have the same protruding length from one end face 24 of the stator core 20.

[0076] The connecting member 60 has an extended portion 64 that extends in the circumferential direction C. The extended portion 64 is located radially outward B1 or radially inward B2 with respect to the pin portions PN11-PN64 which are located side by side in the radial direction B and the circumferential direction C.

[0077] According to the above configuration, when viewed in the radial direction B, the ends of the pin portions PN11-PN64 and at least a portion of each of the multiple connecting members 60 overlap. As described above, the protruding lengths of the pin portions PN11-PN64 are the same, so there is no need to form pin portions of different lengths. Therefore, the man-hours required to form the pin portions can be reduced. Compared to the case where the extended portion 64 of the connecting member 60 is located in the axial direction A with respect to the end of the pin portion PN11-PN64, the coil end 31 including the connecting member 60 can be made more compact in the axial direction A.

[0078] Furthermore, in the above configuration, the multiple connecting members 60 are arranged in a ring shape in the circumferential direction C and stacked in the axial direction A.

[0079] According to the above configuration, the connecting member 60 can be arranged three-dimensionally around the pin portions PN11-PN64. Therefore, the connecting member 60 can be arranged more compactly with respect to the pin portions PN11-PN64.

[0080] Furthermore, as described above, the connecting member 60 has an extended portion 64 that extends in the circumferential direction C. Of the multiple connecting members 60, connecting members 3611, 3612, 3621, and 3622 are located in the outermost layer in the axial direction A.

[0081] The extended portions 64 of the connecting members 3611 and 3612 are located radially outward B1 relative to the pin portions PN11-PN64 located within the slot 23, when viewed in the axial direction A. The extended portions 64 of the connecting members 3611 and 3612 extend radially inward B2 from the position radially outward B1 relative to the pin portions PN11-PN64 and are connected to the pin portions PN11-PN64.

[0082] The extended portions 64 of the connecting members 3621 and 3622 are located radially inward B2 relative to the pin portions PN11-PN64 located within the slot 23, when viewed in the axial direction A. The extended portions 64 of the connecting members 3621 and 3622 extend radially outward B1 from the position radially inward B2 relative to the pin portions PN11-PN64 and are connected to the pin portions PN11-PN64.

[0083] According to the above configuration, the connecting member 60 is connected to the pin portions PN11-PN64 without taking a roundabout route. Therefore, the connecting member 60 can be arranged more compactly with respect to the pin portions PN11-PN64.

[0084] Furthermore, the motor 1 has a pair of coils. For example, the pin portions PN11-14 of the first row PN1 are part of one of the pair of coils. Similarly, the pin portions PN21-24 of the second row PN2 are part of the other of the pair of coils. For example, the pair of pin portions formed by pin portion PN11 of the first row PN1 and pin portion PN21 of the second row PN2 are located side by side in adjacent slots 23 in the circumferential direction C.

[0085] The connecting member 60 is electrically connected to each end of the pair of pin portions. For example, the connecting portion 61 of the connecting member 1612 extends between adjacent pin portions PN11 and PN21 in the circumferential direction C, and is electrically connected to adjacent pin portions PN11 and PN21 in the circumferential direction C.

[0086] According to the above configuration, in a multi-phase coil 30, the coil end 31 including the connecting member 60 can be made compact in the axial direction A.

[0087] Furthermore, in motor 1, the multiple pin portions PN11-PN64 are arranged at predetermined intervals in the circumferential direction C and the radial direction B.

[0088] The length in the circumferential direction C of the connection portions 61 and 62 between the pair of pin portions and the connecting member 60 is greater than the length in the circumferential direction C of the connection portions 61 and 62 between the pair of pin portions and the connecting member 60 that are located radially inward B2 relative to the connecting member 60 when viewed in the axial direction A.

[0089] For example, the length C in the circumferential direction of the connecting portions 61 and 62 of the connecting members 1611 and 1612 included in the outer ring L1610 is greater than the length C in the circumferential direction of the connecting portions 61 and 62 of the connecting members 1621 and 1622 included in the inner ring L1620.

[0090] As described above, in the arrangement of pin portions located at predetermined intervals in the circumferential and radial directions, the circumferential distance C between pin portions located further outward in the radial direction B1 is greater than the circumferential distance C between pin portions located further inward in the radial direction B2.

[0091] Therefore, according to the above configuration, adjacent pin portions in the circumferential direction can be electrically connected without gaps by the connecting member 60.

[0092] Furthermore, the manufacturing method of the motor 1 may further include a connecting member forming step, which is performed before the joining step S12, by multiforming a flat rectangular conductor having an enamel insulating coating to form the connecting member 60.

[0093] When a pressed sheet metal busbar is used as the connecting member 60, the insulating coating may be damaged during the pressing process of the sheet metal member used to form the busbar. In addition, after punching out the sheet metal member, waste material is generated, reducing the yield. With the above configuration, damage to the insulating coating of the connecting member 60 can be reduced. As a result, a coil with superior insulating properties can be obtained. Moreover, the connecting member 60 can be manufactured with a good yield.

[0094] (Modification 1) Figure 10 is a schematic process diagram showing one step of the manufacturing method of the motor 1 according to Modification 1. Figure 11 is a diagram showing the laminate 600 obtained by the step shown in Figure 10. Figure 12 is a schematic process diagram showing another step following the first step of the manufacturing method of the motor 1 according to Modification 1. The manufacturing method of the motor 1 according to Modification 1 differs from the manufacturing method of the motor 1 according to the above embodiment in that the connecting member 60 is pre-positioned by a jig when assembling the stator 5. In the following, the same configuration as in the above embodiment will not be described, and only the configuration that differs from the above embodiment will be described.

[0095] Referring to Figure 10, first, the multiple connecting members 60 are combined in accordance with the arrangement of the ends of the pin portion described above (connecting member combination step S15). In the connecting member combination step S15, first, the multiple connecting members 60 are arranged in a ring to form the first layer ring L160, the second layer ring L260, and the third layer ring L360.

[0096] The first layer ring L160, the second layer ring L260, and the third layer ring L360 are each placed on the jig 80. In detail, the jig 80 includes a first layer ring jig 81, a second layer ring jig 82, and a third layer ring jig 83.

[0097] With one end TH1 in the thickness direction TH of the first layer ring L160 aligned with the lower DN1 in the vertical direction, the first layer ring L160 is attached to the support portion 811 of the first layer ring jig 81. The connecting portions 61 and 62 of the first layer ring L160 extend from the other end TH2 in the thickness direction TH of the first layer ring L160 to the other end TH1. In the first layer ring L160, the end of one end TH1 in the thickness direction TH of the first layer ring L160 becomes the reference position LN11 for joining with respect to the pin portion.

[0098] With one end TH1 in the thickness direction TH of the second layer ring L260 aligned with the lower DN1 in the vertical direction, the second layer ring L260 is attached to the support portion 821 of the second layer ring jig 82. The connecting portions 61 and 62 of the second layer ring L260 extend from the other end TH2 in the thickness direction TH of the second layer ring L260 to the other end TH1. In the second layer ring L260, the end of one end TH1 in the thickness direction TH of the second layer ring L260 becomes the reference position LN21 for joining to the pin portion.

[0099] The third layer ring L360 is placed on the support surface 831 of the third layer ring jig 83 with one end TH1 in the thickness direction TH aligned with the lower DN1 in the vertical direction. The connecting portions 61 and 62 of the third layer ring L360 are supported by the support surface 831 of the third layer ring jig 83. In the third layer ring L360, the end of one end TH1 in the thickness direction TH of the third layer ring L360 becomes the reference position LN31 for joining with respect to the pin portion.

[0100] As the connecting portions 61 and 62 are supported by the support surface 831, one end TH1 in the thickness direction HT of the connecting portions 61 and 62 in the third layer ring L360 aligns with the reference position LN31.

[0101] Next, as shown by the white arrows in Figure 10, the second layer ring jig 82 and the second layer ring L260 are stacked on the upper UP1 in the vertical direction of the third layer ring jig 83 and the third layer ring L360, and then the first layer ring jig 81 and the first layer ring L160 are stacked on the upper UP1 in the vertical direction of the second layer ring jig 82 and the second layer ring L260.

[0102] Referring to Figure 11, the above lamination process makes it possible to align the reference positions LN11, LN21, and LN31 of the first layer ring L160, the second layer ring L260, and the third layer ring L360 with respect to the pin portion in the vertical direction and the thickness direction TH. As a result, a laminate 600 is obtained in which multiple connecting members 60 are supported by the jig 80.

[0103] In the laminate 600, the first layer ring L160, the second layer ring L260, and the third layer ring L360 are positioned at predetermined intervals by the first layer ring jig 81, the second layer ring jig 82, and the third layer ring jig 83. In addition, the multiple connecting members 60 are positioned within each of the first layer ring L160, the second layer ring L260, and the third layer ring L360 by the jig 80.

[0104] Referring to Figure 12, the laminate 600 obtained in the connecting member combination step S15 is then attached to the stator core 20 and the pin portion PIN 90. Specifically, first, the laminate 600 shown in Figure 11 is inverted vertically.

[0105] By inverting the laminate 600 vertically together with the jig 80, one of the thickness directions TH1 of the first layer ring L160, the second layer ring L260, and the third layer ring L360 is aligned with the axial direction A1 of the stator core 20.

[0106] Next, the inverted laminate 600 is attached to the pin portion PIN90 which is located protruding from one end A1 in the axial direction of the stator core 20. With the reference positions LN11, LN21, and LN31 of the first layer ring L160, the second layer ring L260, and the third layer ring L360 positioned at position POS2 at one end of the pin portion PIN90 in the axial direction A, the pin portion PIN90 and the connection portion of the connecting member 60 are joined (joining step S121).

[0107] The stator 5 is obtained through the above process. By attaching other parts to the stator 5, the motor 1 is obtained.

[0108] As described above, in the joining step S121 of the manufacturing method of the motor 1 according to the modified example 1, the connecting member 60 that was assembled in the connecting member combination step S15 is electrically connected to the pin portion PIN 90.

[0109] In the above configuration, multiple connecting members 60 are pre-assembled according to the arrangement of the ends of the pin portion. Therefore, the motor 1 can be manufactured more efficiently than when each connecting member 60 is individually joined to the pin portion PIN 90.

[0110] Furthermore, in the connecting member combination step S15, multiple connecting members 60 are combined using a jig 80 while maintaining a distance between them.

[0111] This ensures that insulation is maintained between the multiple connecting members 60. Therefore, a coil 30 with good insulation properties can be assembled. Furthermore, by positioning the multiple connecting members 60 with the jig 80 and then forming the aforementioned fixing portion with varnish or the like, a fixing portion with even better insulation properties can be formed.

[0112] Furthermore, in the connecting member combination step S15, the positions of the connecting portions 61 and 62 of the multiple connecting members 60 in the thickness direction TH are aligned at the reference positions LN11, LN21, and LN31, and the multiple connecting members 60 are combined. The thickness direction TH corresponds to the axial direction A.

[0113] According to the above configuration, by aligning the positions of the connecting portions 61 and 62 of the multiple connecting members 60 in the axial direction A at one point in the axial direction A, the position of the connecting member 60 when joining it to the pin portion PIN 90 can be pre-aligned. This allows for efficient manufacturing of the motor 1.

[0114] (Modification 2) Figure 13 shows the positional relationship between the connecting member 60 and the pin portions PIN91 and PIN92 in the motor 1 according to Modification 2. In the motor 1 in the above embodiment, one end of the connecting portion 61 and 62 of the connecting member 60 in the axial direction A coincides with the position POS2 of one end of the pin portion in the axial direction A. In contrast, in the motor 1 according to Modification 2, one end of the connecting portion 61 and 62 of the connecting member 601 in the axial direction A is located in either the axial direction A1 or the axial direction A2 position relative to the position POS2 of one end of the pin portion PIN91 and PIN92 in the axial direction A.

[0115] In the following, we will omit descriptions of configurations that are the same as those in the above embodiment and will only describe configurations that differ from those in the above embodiment.

[0116] Referring to Figure 13, one end of the connecting portion 61 of the connecting member 601 in the axial direction A is located in axial direction A1, which is further than the position POS2 of the other end of the pin portion PIN 91 in the axial direction A.

[0117] Furthermore, the extended portion 64 of the connecting member 60 may be bent in one axial direction A1. That is, the extended portion 64 may be located in one axial direction A1 at least in part, more so than the connecting portions 61 and 62. For this reason, one end of the connecting member 60 in the axial direction A may be located in one axial direction A1 more than the position POS2 of one end of the pin portion PIN 91 in the axial direction A.

[0118] Furthermore, one end of the connecting portion 62 of the connecting member 60 in the axial direction A is located at the other axial direction A2 position relative to the position POS2 of the other end of the pin portion PIN 92 in the axial direction A.

[0119] Furthermore, one end of the connecting member 60 in the axial direction A may be located in the other axial direction A2 position than the position POS2 of the other end of the pin portion PIN91, PIN92 in the axial direction A.

[0120] (Modification 3) Figure 14 is a perspective view showing the schematic configuration of the stator 6 of the motor 1 according to Modification 3. Figure 15 is an exploded perspective view of the laminate 610 in the stator 6 according to Modification 3. The motor 1 according to Modification 3 differs from the motor 1 according to the above embodiment in the number of pins arranged in the radial direction B. Also, the motor 1 according to Modification 3 differs from the motor 1 according to the above embodiment in the lamination method of the connecting member 611. In the following, the same configuration as in the above embodiment will be omitted from the explanation, and only the configuration that differs from the above embodiment will be explained.

[0121] Referring to Figure 14, in the stator core 20, each slot 23 arranged in the circumferential direction C has six pin portions positioned in the radial direction B.

[0122] The connecting member 611 is electrically connected to two adjacent pin portions PIN111 and PIN121 in the circumferential direction C. The connecting member 611 is electrically connected to every other pin portion in the circumferential direction C and the radial direction B.

[0123] For example, pins 111 and 121 are located at the outermost radially outward B1. Pin 111 is located adjacent to pin 121 in one circumferential direction C1. The connecting member 611 is not connected between pin 131, which is located adjacent to pin 121 in the other circumferential direction C2, and pin 121.

[0124] A connecting member 611 is electrically connected between pin portion PIN141, which is located adjacent to pin portion PIN131 in the other circumferential direction C2, and pin portion PIN131.

[0125] Furthermore, the connecting member 611 is not connected between the pin portion PIN112, which is located adjacent to the pin portion PIN111 in the radially inward B2 direction, and the pin portion PIN122, which is located adjacent to the pin portion PIN121 in the radially inward B2 direction.

[0126] Furthermore, a connecting member 611 is electrically connected between pin portion PIN 113, which is located radially inward B2 relative to pin portion PIN 112, and pin portion PIN 123, which is located radially inward B2 relative to pin portion PIN 122.

[0127] Referring to Figure 15, the laminate 610 is constructed by stacking connecting members 611. In the laminate 610, the first layer ring L161, the second layer ring L261, the third layer ring L361, the fourth layer ring L461, and the fifth layer ring L561 are stacked in order from the other axial direction A2 to the axial direction A1.

[0128] The first layer ring L161 has an inner ring L1621. The second layer ring L262, third layer ring L361, fourth layer ring L461, and fifth layer ring L561, located axially to one side A1 from the first layer ring L161, each have outer rings L2611, L3611, L4611, L5611 and inner rings L2621, L3621, L4621, L5621, respectively.

[0129] According to the above configuration, even in a stator 6 in which six pin sections are arranged radially in each slot 23, a compact configuration of the coil end 31 in the axial direction A can be easily realized.

[0130] (Modification 4) Figure 16 is a perspective view showing the schematic configuration of the stator 7 of the motor 1 according to Modification 4. Figure 17 is an exploded perspective view of the laminate 620 in the stator 7 according to Modification 4. Figure 18 is a diagram showing a part of the laminate 620 according to Modification 4. The motor 1 according to Modification 4 differs from the motor 1 according to Modification 3 in the lamination method of the connecting member 621. In the following, the same configuration as in Modification 3 will not be explained, and only the configuration that differs from Modification 3 will be explained.

[0131] The connecting member 621 is electrically connected to two adjacent pin portions PIN95 and PIN96 in the circumferential direction C.

[0132] Referring to Figure 17, the laminate 620 is constructed by stacking connecting members 621. In the laminate 620, the first layer ring L162, the second layer ring L262, the third layer ring L362, the fourth layer ring L462, and the fifth layer ring L562 are stacked in order from the other axial direction A2 to the axial direction A1.

[0133] The first layer ring L162, the third layer ring L362, the fourth layer ring L462, and the fifth layer ring L562 each have outer rings L1612, L3612, L4612, L5612 and inner rings L1622, L3622, L4622, L5622, respectively. The second layer ring L262 has an inner ring L2622.

[0134] Referring to Figure 18, the extended portion 64 of the connecting member 6261 constituting the second layer ring L262 is located radially outward B1 when viewed in the axial direction A than the extended portion 64 of the connecting member 6162 constituting the first layer ring L162. The extended portion 64 of the connecting member 6261 has a downward intersecting step portion 71 that extends intersecting the other axial direction A2 of the connecting member 6361 constituting the third layer ring L362.

[0135] The lower intersecting step portion 71 extends in the radial direction B, overlapping the connecting member 6161 that constitutes the first layer ring L162.

[0136] In this way, the lower intersecting step portion 71 allows the connecting member 6361 constituting the third layer ring L362 to be bypassed. Therefore, the second layer ring L262 and the third layer ring L362 can be stacked with an overlap in the axial direction A on one axial side A1 of the first layer ring L162.

[0137] Therefore, according to the above configuration, the axial dimension A of the laminate 620 can be made more compact.

[0138] (Other Embodiments) Although embodiments of the present invention have been described above, the embodiments described above are merely examples for carrying out the present invention. Therefore, the invention is not limited to the embodiments described above, and it is possible to carry out the invention by appropriately modifying the embodiments described above without departing from the spirit of the invention.

[0139] In the above embodiment and modified examples 1 to 4 (hereinafter referred to as "embodiments, etc."), the connecting member 60 is electrically connected in the circumferential direction C to one end 411 of the first portion 41 and one end 421 of the second portion 42, which are a pair of pin portions. However, the connecting member 60 may also be electrically connected radially to the pair of pin portions.

[0140] In the embodiments described above, the connecting member 60 connects pin portions in different slots 23. However, the connecting member may also connect pin portions in the same slot.

[0141] In the embodiments described above, the protrusion length LN1 of the first portion 41 and the second portion 42 from one end face 24 of the stator core 20 is the same. However, the protrusion lengths of the first portion and the second portion may be different.

[0142] In the above embodiments, the multi-phase coil 30 includes a plurality of coil pieces 40. The connecting member 60 is located on one side of the axial direction A relative to the stator core 20. However, the multi-phase coil does not have to be composed of coil pieces. The connecting member may be located on both the axial side and the other side relative to the stator core. In the axial direction, both ends of a pin portion that penetrates the slot axially may be electrically connected by the connecting member.

[0143] In the above embodiment 1, the first layer ring L160, the second layer ring L260, and the third layer ring L360 included in the laminate 600 correspond to, for example, three phases: U phase, V phase, and W phase. However, the annular layers included in the laminate do not necessarily correspond to each phase.

[0144] In the above embodiment 1, the raised step portion 651 of the connecting member 1612 overlaps in the axial direction A with the other circumferential C2 end of the extended portion 64 of the connecting member 1611 when multiple connecting members 60 are stacked. Similarly, the raised step portion 652 of the connecting member 1621 overlaps in the axial direction A with the one circumferential C1 end of the extended portion 64 of the connecting member 1622 when multiple connecting members 60 are stacked. However, the raised step portion may be located in a position that is circumferentially offset from the circumferential ends of circumferentially adjacent connecting members when viewed in the axial direction, without overlapping.

[0145] In the above embodiment 1, when multiple connecting members 60 are stacked, the descending step portion 681 of the connecting member 3611 overlaps in the axial direction A with the end of one circumferential C1 of the extended portion 64 of the connecting member 3612 adjacent in the circumferential direction C. Similarly, when multiple connecting members 60 are stacked, the descending step portion 682 of the connecting member 3622 overlaps in the axial direction A with the end of the other circumferential C2 of the extended portion 64 of the connecting member 3621 adjacent in the circumferential direction C. However, the descending step portion may be located at a position offset in the circumferential direction without overlapping with the circumferential ends of the circumferentially adjacent connecting members.

[0146] (Example Configuration) This technology can also be configured as follows:

[0147] (1) A motor comprising: a cylindrical stator core extending axially with a central axis and having a plurality of slots arranged circumferentially; and a plurality of phase coils, a portion of which is located within the plurality of slots of the stator core, wherein each phase coil penetrates the slot in the axial direction and has a plurality of pin portions which are flat rectangular conductors whose ends protrude axially outward from one axial end face of the stator core; and a plurality of connecting members which electrically connect the ends of a pair of pin portions in the same phase coil, wherein the connecting members have connecting portions which electrically connect to the ends of a pair of pin portions in the same phase coil in the circumferential or radial direction, and at least a portion of the connecting portions of the connecting members is located in the axial direction from one end face of the stator core to one axial end of the pin portion.

[0148] (2) In the motor described in (1), the plurality of pin portions have the same position at one end in the axial direction at the end, and the connecting member is located in the axial direction from the one end face of the stator core to the one end in the axial direction at the end of the pin portion.

[0149] (3) In the motor described in (1) or (2), the plurality of pin portions are arranged in the radial direction within the plurality of slots, and the connecting member has an extended portion that extends in the circumferential direction, the extended portion being located outward or inward in the radial direction with respect to the pin portions that are arranged in the radial direction.

[0150] (4) In the motor described in any one of (1) to (3), the plurality of connecting members are arranged in an annular shape in the circumferential direction and stacked in the axial direction.

[0151] (5) In the motor described in (4), the connecting member has an extended portion that extends in the circumferential direction, and the extended portion of the connecting member located in the outermost layer in the axial direction is located radially outward with respect to the pin portion located in the slot when viewed in the axial direction, and extends radially inward from the radially outward position to connect to the pin portion, or is located radially inward with respect to the pin portion located in the slot when viewed in the axial direction, and extends radially outward from the radially inward position to connect to the pin portion.

[0152] (6) The motor according to any one of (1) to (5) has a pair of coils, and the pair of pin portions, which are formed by the pin portion of one coil and the pin portion of the other coil, are located side by side in the circumferentially adjacent slots, and the connecting member is electrically connected to the respective ends of the pair of pin portions.

[0153] (7) In the motor described in (6), the plurality of pin portions are arranged at predetermined intervals in the circumferential and radial directions, and the length in the circumferential direction of the connection portion between the pair of pin portions and the connecting member is greater than the length in the circumferential direction of the connection portion between the pair of pin portions located radially inward with respect to the connecting member when viewed in the axial direction and the connecting member.

[0154] (8) In the motor described in any one of (1) to (7), the connecting member is a flat rectangular conductor having an enamel insulating coating.

[0155] (9) In the motor described in any one of (1) to (8), the coil has a connecting portion that electrically connects the other end of one pin portion in the axial direction to the other end of another pin portion located in a different slot in the axial direction, and the one pin portion, the other pin portion and the connecting portion are a single member.

[0156] (10) A method for manufacturing a motor having a cylindrical stator core that extends axially around a central axis and has a plurality of slots arranged in the circumferential direction, and coils, a portion of which are located within the plurality of slots of the stator core, wherein each phase of the coil has a plurality of pin portions which are flat rectangular conductors that penetrate the slots in the axial direction and whose ends protrude axially outward from one end face in the axial direction of the stator core, and a plurality of connecting members which electrically connect the ends of a pair of pin portions in the coil of the same phase, wherein the plurality of pin portions which are flat rectangular conductors that constitute a part of the coil are inserted into the slots in the axial direction. The method includes a pin insertion step in which the end of the pin portion protrudes from one end face of the stator core in the axial direction, and a joining step in which a plurality of connecting members having connecting portions that electrically connect the ends of a pair of pin portions in the same phase coil are electrically connected to the ends of the pair of pin portions, wherein in the joining step, at least a part of the connecting portion of the connecting member is positioned in the axial direction from one end face of the stator core to one end of the pin portion in the axial direction, and the connecting portion of the connecting member is electrically connected to the ends of the pair of pin portions in the circumferential or radial direction.

[0157] (11) The motor manufacturing method described in (10) further comprises a connecting member forming step, which is performed before the joining step by multiforming a flat rectangular conductor having an enamel insulating coating to form the connecting member.

[0158] (12) The motor manufacturing method described in (10) or (11) further comprises a connecting member combination step of combining a plurality of connecting members in accordance with the arrangement of the ends of the pin portion, and in the joining step, the connecting members combined in the connecting member combination step are electrically connected to the pin portion.

[0159] In the motor manufacturing method described in (13)(12), in the connecting member combination step, the plurality of connecting members are combined using a jig with a gap between them.

[0160] In the motor manufacturing method described in (14), (12), or (13), in the connecting member combination step, the axial positions of the connecting portions of the plurality of connecting members are aligned in one of the axial directions and the plurality of connecting members are combined.

[0161] The present invention is applicable, for example, to a motor having a stator core and multiple phase coils.

[0162] 1: Motor 5, 6, 7: Stator 20: Stator core 21: Back yoke 22: Teeth 23: Slot 24: One end face 25: Other end face 30: Coil 31: Coil end 40, 401, 402: Coil piece 41: First part 411: One end 4111: End face 412: Other end 42: Second part 421: One end 4211: End face 422: Other end 43: Connecting part 45: End face 48: Row of pins 60, 601, 611, 621, 1611, 1612, 1621, 1622, 2611, 2612, 2621, 2622, 3611, 3612, 3621, 3622, 6161, 6261, 6361: Connecting members 600, 610, 620: Laminates 61, 62: Connecting parts 64: Extended parts 651, 652: Ascending steps 66: Overcoming steps 681, 682: Descending steps 71: Lower crossing steps 80: Jig 81: First layer ring jig 82: Second layer ring jig 83: Third layer ring jig 811, 821: Support parts 831: Support surface L160: First layer ring L1610: Outer ring L1620: Inner ring L260: 2nd layer ring L2610: Outer ring L2620: Inner ring L360: 3rd layer ring L3610: Outer ring L3620: Inner ring P: Central axisPIN90, PIN91, PIN92, PIN111, PIN112, PIN113, PIN121, PIN122, PIN123, PIN131, PIN141, PN11, PN12, PN13, PN14, PN21, PN22, PN23, PN24, PN31, PN32, PN33, PN34, PN41, PN42, PN43, PN44, PN51, PN52, PN53, PN54, PN61, PN62, PN63, PN64: Pin section PN1: 1st row PN2: 2nd row PN3: 3rd row PN4: 4th row PN5: 5th row PN6: 6th row S11 : Pin insertion step S12: Joining step S121: Joining step S15: Connecting member combination step TH: Thickness direction TH1: One side TH2: Other side

Claims

1. A motor comprising: a cylindrical stator core extending axially with a central axis and having a plurality of slots arranged circumferentially; and a plurality of phase coils, a portion of which is located within the plurality of slots of the stator core, wherein each phase coil has a plurality of pin portions which are flat rectangular conductors that penetrate the slots axially and whose ends protrude axially outward from one axial end face of the stator core; and a plurality of connecting members which electrically connect the ends of a pair of pin portions in the same phase coil, wherein the connecting members have connecting portions which electrically connect to the ends of a pair of pin portions in the same phase coil in the circumferential or radial direction, and at least a portion of the connecting portions of the connecting members is located in the axial direction from one end face of the stator core to one axial end of the pin portion.

2. A motor according to claim 1, wherein the plurality of pin portions have the same position at one end in the axial direction at the end, and the connecting member is located in the axial direction from one end face of the stator core to one end in the axial direction at the end of the pin portion.

3. A motor according to claim 1, wherein the plurality of pin portions are arranged radially within the plurality of slots, and the connecting member has an extended portion extending in the circumferential direction, and the extended portion is located radially outward or inward with respect to the pin portions arranged radially.

4. A motor according to claim 1, wherein the plurality of connecting members are arranged in an annular shape in the circumferential direction and stacked in the axial direction.

5. A motor according to claim 4, wherein the connecting member has an extended portion extending in the circumferential direction, and the extended portion of the connecting member located in the outermost layer in the axial direction is located radially outward with respect to the pin portion located in the slot when viewed in the axial direction, and extends radially inward from the radially outward position to connect to the pin portion, or, when viewed in the axial direction, is located radially inward with respect to the pin portion located in the slot, and extends radially outward from the radially inward position to connect to the pin portion.

6. A motor according to claim 1, wherein it has a pair of coils, the pair of pin portions, which are formed by the pin portion of one coil and the pin portion of the other coil, are located side by side in the circumferentially adjacent slots, and the connecting member is electrically connected to the respective ends of the pair of pin portions.

7. A motor according to claim 6, wherein the plurality of pin portions are arranged at predetermined intervals in the circumferential and radial directions, and the length in the circumferential direction of the connection portion between the pair of pin portions and the connecting member is greater than the length in the circumferential direction of the connection portion between the pair of pin portions located radially inward with respect to the connecting member when viewed in the axial direction.

8. A motor according to claim 1, wherein the connecting member is a flat rectangular conductor having an enamel insulating coating.

9. A motor according to any one of claims 1 to 8, wherein the coil has a connecting portion that electrically connects the other end in the axial direction of one pin portion to the other end in the axial direction of another pin portion located in a different slot, and the one pin portion, the other pin portion and the connecting portion are a single component.

10. A method for manufacturing a motor having: a cylindrical stator core extending axially around a central axis and having a plurality of slots arranged circumferentially; a coil having a portion located within the plurality of slots of the stator core, wherein each phase of the coil has a plurality of pin portions which are flat rectangular conductors that penetrate the slots in the axial direction and whose ends protrude axially outward from one axial end face of the stator core; and a plurality of connecting members that electrically connect the ends of a pair of pin portions in the coil of the same phase, comprising: a pin portion insertion step of inserting a plurality of pin portions which are flat rectangular conductors constituting a part of the coil into the slots in the axial direction and causing the ends of the pin portions to protrude from one axial end face of the stator core; and a joining step of electrically connecting a plurality of connecting members which have connecting portions that electrically connect the ends of a pair of pin portions in the coil of the same phase to the ends of the pair of pin portions. A motor manufacturing method comprising the joining step, wherein at least a portion of the connecting portion of the connecting member is positioned in the axial direction from one end face of the stator core to one end of the pin portion in the axial direction, and the connecting portion of the connecting member is electrically connected to the ends of the pair of pin portions in the circumferential or radial direction.

11. A motor manufacturing method according to claim 10, further comprising a connecting member forming step, wherein the connecting member is formed by multiforming a flat rectangular conductor having an enamel insulating coating, prior to the joining step.

12. A motor manufacturing method according to claim 10, further comprising a connecting member combination step of combining a plurality of connecting members in accordance with the arrangement of the ends of the pin portion, wherein in the joining step, the connecting members combined in the connecting member combination step are electrically connected to the pin portion.

13. A motor manufacturing method according to claim 12, wherein in the connecting member combination step, the plurality of connecting members are combined with a jig while maintaining a distance between them.

14. A motor manufacturing method according to claim 12 or claim 13, wherein in the connecting member combination step, the plurality of connecting members are combined by aligning the axial positions of the connecting portions of the plurality of connecting members in one of the axial directions.

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