JP2014007938A - Rotary electric machine and process of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To achieve a technology capable of downsizing a coil end part while suppressing performance reduction of a rotary electric machine.SOLUTION: A core is integrally formed at least in a circumferential direction C. A coil is constituted by combining a plurality of continuous coil parts 60 formed with a linear conductor that continues over a range equal to one cycle or greater around the core while being inserted into a plurality of slots and each of the plurality of continuous coil parts 60 is disposed in such a manner that at least a part of other continuous coil parts 60 and slots at which coil side parts 71 are disposed are different.

Description

  In the present invention, a plurality of slots extending in the axial direction of a cylindrical core reference surface and having openings on one side in the radial direction of the core reference surface are distributed in the circumferential direction of the core reference surface. The present invention relates to a rotating electrical machine including a core and a coil having a coil side portion disposed in a slot and wound around the core, and a method of manufacturing the rotating electrical machine for manufacturing the rotating electrical machine.

  As a conventional technique related to the rotating electrical machine as described above, there is a technique described in, for example, Japanese Patent Application Laid-Open No. 2002-176552 (Patent Document 1). In Patent Document 1, the stator core is bent into a cylindrical shape with a coil unit (winding assembly 12 in Patent Document 1) wound around a rectangular parallelepiped stator core, and both ends of the stator core are joined together. A method of manufacturing a stator is described. At this time, as shown in FIG. 2 of Patent Document 1, the coil unit wound around the rectangular parallelepiped stator core is configured by a plurality of linear conductors continuous between both ends in the circumferential direction of the coil unit. ing. Thereby, as described in paragraph 0036 of Patent Document 1, the stator is downsized.

  Japanese Patent Laying-Open No. 2000-139048 (Patent Document 2) also manufactures a stator using a coil unit (see FIG. 10 of the document) composed of a plurality of linear conductors continuous over a wide range in the circumferential direction. A method is described. In the configuration described in Patent Document 2, as shown in FIGS. 11 to 13 of the document, a plurality of divided cores are moved radially inward with respect to the annularly formed coil unit, and then the plurality of divided cores are divided. Join the core in the circumferential direction.

  However, in the configurations of Patent Document 1 and Patent Document 2, since the stator core has a circumferential joint that joins the circumferentially divided portions in the circumferential direction, the stator core rotates due to an increase in magnetic resistance or the like at the circumferential joint. There is a risk that the performance of the electric machine will deteriorate. Further, in the configuration of Patent Document 1, since it is necessary to bend the rectangular parallelepiped stator core into a cylindrical shape, restrictions are likely to occur on the material and shape of the stator core, and the performance of the rotating electrical machine may be reduced in this respect as well. .

JP 2002-176552 A (paragraph 0036, FIG. 2 etc.) JP 2000-139048 A (FIGS. 10 to 13 etc.)

  Therefore, it is desired to realize a technique capable of reducing the size of the coil end portion while suppressing a decrease in performance of the rotating electrical machine.

  According to the present invention, a plurality of slots extending in the axial direction of the cylindrical core reference surface and having openings on the opening direction side that is one side in the radial direction of the core reference surface are distributed in the circumferential direction of the core reference surface. A characteristic configuration of a rotating electrical machine comprising: a core disposed; and a coil having a coil side disposed in the slot and wound around the core, wherein the core is at least in the circumferential direction The coil is integrally formed, and the coil is configured by combining a plurality of continuous coil portions formed by a single linear conductor that is inserted in a plurality of the slots and is continuous over a range that goes around the core. In addition, each of the plurality of continuous coil portions is arranged such that at least a part of the other continuous coil portions and the slots in which the coil side portions are arranged are different. There to that point.

  According to said characteristic structure, since a core is integrally formed at least in the circumferential direction, it becomes easy to ensure the performance of a rotary electric machine compared with the case where the core is parted in the circumferential direction. At this time, the coil is configured by combining a plurality of continuous coil portions formed by a single linear conductor that is inserted over a range of more than one round of the core while being inserted into a plurality of slots. Therefore, the number of electrical connection locations that need to be formed in the coil end portion can be reduced, and the coil end portion can be reduced in size. That is, it is possible to reduce the size of the coil end portion while suppressing a decrease in the performance of the rotating electrical machine.

  Here, it is preferable that the core is integrally formed in the circumferential direction by having a configuration in which the circumferentially divided portion does not have a circumferential joining portion that joins the circumferentially divided portion. .

  For example, the core is preferably formed by stacking a plurality of annular plate-like magnetic plates in the axial direction.

  According to this structure, the core which does not have a circumferential direction junction part can be formed easily, suppressing the iron loss in a core.

  The opening width, which is the width in the circumferential direction of the opening, is formed to be narrower than the width in the circumferential direction inside the slot, and the linear conductor is a set of a plurality of flexible bare conductor strands. The periphery of the bare conductor wire bundle is covered with a flexible insulating coating material, and the circumferential width is less than the first circumferential width narrower than the opening width and the opening width. A configuration that can be deformed between a wide width in the second circumferential direction is preferable.

Here, the “bare conductor wire” is a bare conductor wire whose surface is not covered with an insulator. Therefore, a conductor wire provided with a coating or a coating with an electrically insulating material such as resin on its surface is not included in the bare conductor wire. On the other hand, a conductor wire having an oxide film formed on the surface is included in the bare conductor wire.
Further, the “periphery of the bare conductor wire bundle” means a periphery (outer periphery) of a cross section in a plane orthogonal to the extending direction of the bare conductor wire bundle.

  According to this configuration, since the opening width of the slot is formed narrower than the circumferential width inside the slot, the effective magnetic flux acting between the stator and the rotor can be increased to improve the performance of the rotating electrical machine. it can. Since the linear conductor can be deformed between a first circumferential width that is narrower than the opening width of the slot and a second circumferential width that is wider than the opening width of the slot. Also for the slot, the coil side portion can be inserted into the slot through the opening. At this time, the linear conductor is formed by covering the periphery of a bundle of bare conductor wires in which a plurality of flexible bare conductor wires are assembled with a flexible insulating coating material. The linear conductor can be deformed while suppressing the loosening of the wire bundle, and the coil can be easily wound around the core. In addition, since the conductor wire disposed inside the insulation coating material is a bare conductor wire, the coil space is larger than when the surface of the conductor wire is provided with a coating or coating with an electrically insulating material. It is easy to secure the performance of the rotating electrical machine by increasing the rate. Thus, according to said structure, the improvement of the performance of a rotary electric machine can be aimed at, suppressing the fall of manufacturability of a rotary electric machine.

  Further, it is preferable that the continuous coil portion is configured to surround the core a plurality of times while being inserted into the plurality of slots.

  According to this configuration, the number of electrical connection points that need to be formed in the coil end portion is reduced as compared with the case where the coil is configured by using a plurality of continuous coil portions formed so as to make one round of the core. Therefore, the coil end portion can be reduced in size.

  Further, it is preferable that the continuous coil portion is configured to be wound around the core so as to be wave-wound.

  According to this structure, compared with the case where a continuous coil part has a lap | wrapping part, the number of the transition parts which connect two coil side parts in the outer side of the axial direction of a core can be restrained small. Therefore, the coil end portion can be reduced in size, and further, the length of the linear conductor constituting the continuous coil portion can be kept short, thereby suppressing the copper loss and reducing the manufacturing cost.

  Further, a plurality of the continuous coil units for constituting the coil are arranged such that the coil side portions arranged in the same layer in the slot have the same positional relationship as the state in which the coil side portions are wound around the core. The coil unit is configured by combining the coil units, and the coil unit is arranged on the opening direction side of the core and is disposed at a position overlapping the core when viewed in the radial direction. It is preferable that each of the coil side portions is inserted into the slot through the opening by moving to the opposite side.

  According to this configuration, when performing the coil side portion insertion step of inserting each of the coil side portions into the slot, there is no need to change the positional relationship between the continuous coil portions. It can be a simple process.

  As described above, in the configuration including the coil unit for configuring the coil, the coil unit has a length in the extending direction that makes one or more rounds of the core in a spiral shape along the circumferential direction. In the end region on one side of the extending direction, all of the other coil side portions and the first target coil side portion that is the coil side portion disposed at a different position in the extending direction, In the other end region in the extending direction, there is a second target coil side portion that is the coil side portion arranged at a different position in the extending direction with all the other coil side portions, When the coil unit is configured to be wound around the core so that the first target coil side and the second target coil side overlap with each other in the radial direction when viewed in the radial direction. Is preferred.

  According to said structure, when a coil unit has a 1st object coil side and a 2nd object coil side, a 1st object coil side and a 2nd object coil side are arrange | positioned in the same slot, and a coil Can be configured appropriately.

  In the rotating electric machine having each configuration described above, the single linear conductor constituting the continuous coil portion is inserted into the plurality of slots so as to have a wave shape, and the wave that makes one or more rounds of the core. As the winding part, when the arrangement order of the coil side parts along the extending direction of the linear conductor is opposite to each other in the circumferential direction, the first wave winding part and the second wave winding part are included. Is preferred.

  According to this configuration, compared to the case where the first wave winding portion and the second wave winding portion are included in different continuous coil portions, the number of electrical connection portions that need to be formed in the coil end portion is reduced. The coil end portion can be reduced in size, and the length of the linear conductor constituting the continuous coil portion can be reduced to reduce the copper loss and the manufacturing cost.

  In addition, the coil includes a transition portion that connects a pair of the coil side portions respectively disposed in layers adjacent to each other in the slots different from each other on the outer side in the axial direction of the core. The top portion that is the portion farthest from the core in the axial direction and the top portion of the transition portion that is disposed adjacent to the transition portion in the radial direction are arranged at different positions in the axial direction. It is preferable to adopt the configuration described above.

  According to this configuration, it is possible to dispose the top portion, which is likely to have a large radial width, as compared with other portions in the transition portion, while being shifted in the axial direction between the transition portions disposed adjacent to each other in the radial direction. Therefore, compared to the case where the top portions are arranged at the same position in the axial direction between the crossing portions arranged adjacent to each other in the radial direction, the top portions that are likely to have a large radial width are partially viewed in the axial direction. It becomes easy to arrange so that it may overlap, or to arrange | position close to radial direction, As a result, size reduction of the coil end part in radial direction can be achieved.

  According to the present invention, a plurality of slots extending in the axial direction of the cylindrical core reference surface and having openings on the opening direction side that is one side in the radial direction of the core reference surface are distributed in the circumferential direction of the core reference surface. A rotating electrical machine comprising: a core that is disposed and integrally formed at least in the circumferential direction; and a coil that has a coil side portion disposed in the slot and is wound around the core. A characteristic configuration of the manufacturing method for manufacturing is that a coil unit for forming the coil is continuously inserted over a range of more than one round of the core while being inserted into the plurality of slots, and is a flexible bare conductor element A combination of a plurality of continuous coil portions formed by a single linear conductor formed by covering a bare conductor strand bundle of a plurality of wires with a flexible insulating coating material The coil side portions arranged in the same layer in the slot in the plurality of continuous coil portions are arranged so as to have the same positional relationship as the state wound around the core, and the coil unit is A coil unit supplying step for supplying the coil unit to a position overlapping with the core in the opening direction, and moving the coil unit to the side opposite to the opening direction; A coil side insertion step of inserting a plurality of the coil side portions having the coil side portions into the slot from the opening.

According to said characteristic structure, a coil unit can be wound around a core by performing a coil unit supply process and a coil side part insertion process. At this time, for the plurality of continuous coil portions constituting the coil unit, the coil side portions arranged in the same layer within the slots in the plurality of continuous coil portions have the same positional relationship as the state wound around the core. Are arranged as follows. Therefore, when performing a coil side part insertion process, it is not necessary to replace the positional relationship between continuous coil parts, and the said coil side part insertion process can be made into a simple process. In addition, the linear conductor is configured by covering the periphery of a bare conductor wire bundle in which a plurality of flexible bare conductor wires are assembled with a flexible insulating coating material. Therefore, the linear conductor can be deformed while suppressing the loosening of the bare conductor strands, and the coil can be easily wound around the core formed integrally in the circumferential direction. That is, according to said characteristic structure, the simplification of the manufacturing process of a rotary electric machine can be aimed at.
Furthermore, according to the above characteristic configuration, the coil unit that constitutes the coil includes a continuous coil portion that is formed by a single linear conductor that is inserted into a plurality of slots and that extends continuously over a range that goes around the core. It is composed of multiple combinations. Therefore, the number of electrical connection points that need to be formed after the coil unit is wound around the core can be reduced, and also from this point, the manufacturing process of the rotating electrical machine can be simplified.
Moreover, according to said characteristic structure, since a core is integrally formed at least in the circumferential direction, it becomes easy to ensure the performance of a rotary electric machine compared with the case where the core is divided in the circumferential direction. Furthermore, since the conductor wire disposed inside the insulation coating material is a bare conductor strand, the coil space is larger than when the surface of the conductor wire is provided with a coating or coating with an electrically insulating material. It is easy to secure the performance of the rotating electrical machine by increasing the rate. And as mentioned above, since the number of the electrical connection parts which need to be formed after winding a coil unit around a core can be restrained small, size reduction of a coil end part can be achieved. That is, according to said characteristic structure, it becomes possible to achieve size reduction of a coil end part, suppressing the fall of the performance of a rotary electric machine.

  Here, the coil unit supplying step is a step of forming the coil unit in a spiral shape around the axial direction and bringing the coil unit close to the axial direction with respect to the core, and the coil side portion inserting step However, it is preferable that the coil side portions supplied in the coil unit supply step are sequentially inserted into the slots.

  According to this configuration, even when the circumferential length or radial thickness of the coil unit is large, the coil unit is supplied to the opening direction side of the core and overlapped with the core when viewed in the radial direction. Becomes easy.

  The coil side insertion step preferably includes a step of changing the cross-sectional shape of the linear conductor before and after inserting the coil side into the slot.

  According to this configuration, the restriction on the shape of the slot in which the coil side portion can be inserted from the opening can be relaxed, and the degree of freedom in the shape of the core is increased to improve the performance of the rotating electrical machine. Can do.

  The coil side insertion step includes a pressing step of changing the cross-sectional shape of the coil side by pressing the coil side inserted in the slot to the side opposite to the opening direction. It is preferable.

  According to this configuration, the cross-sectional shape of the coil side portion can be deformed in accordance with the shape of the slot, and the space between the coil side portion and the inner wall surface of the slot can be kept small, and the coil space factor can be increased. It becomes easy.

It is a perspective view of the rotary electric machine which concerns on embodiment of this invention. It is a partial sectional view of a stator concerning an embodiment of the present invention. It is a perspective view which shows the structure of the linear conductor which concerns on embodiment of this invention. It is sectional drawing which shows the structure of the linear conductor which concerns on embodiment of this invention. It is a wiring diagram of the phase coil which concerns on embodiment of this invention. It is a connection diagram of a part of a coil according to an embodiment of the present invention. It is an axial view of the continuous coil part which concerns on embodiment of this invention. It is a radial direction view of the continuous coil part which concerns on embodiment of this invention. It is a radial view of two continuous coil parts arrange | positioned at the same slot which concerns on embodiment of this invention. It is a radial view of the coil unit which concerns on embodiment of this invention. It is a flowchart which shows the manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is a perspective view which shows typically the coil unit supply process which concerns on embodiment of this invention. It is an axial direction view showing typically the coil side part insertion process concerning the embodiment of the present invention. It is explanatory drawing of the coil side part insertion process which concerns on embodiment of this invention. It is sectional drawing of the rotary electric machine which concerns on embodiment of this invention. It is an axial view seen typically showing the state after completion of the coil side portion insertion step according to the embodiment of the present invention. It is an axial view seen typically showing the state after completion of the coil unit supply process according to another embodiment of the present invention. It is a wiring diagram of the phase coil which concerns on other embodiment of this invention. It is a connection diagram of a part of a coil according to another embodiment of the present invention. It is a radial view of the continuous coil part which concerns on other embodiment of this invention. It is a radial view of the six continuous coil parts arrange | positioned at the same layer which concerns on other embodiment of this invention. It is a radial view of the coil unit which concerns on other embodiment of this invention. It is a radial view of two in-phase continuous coil portions arranged in the same layer according to another embodiment of the present invention. It is a radial view of the six continuous coil parts arrange | positioned at the same layer which concerns on other embodiment of this invention. It is a radial view of the coil unit which concerns on other embodiment of this invention. It is a radial view of the coil unit which concerns on other embodiment of this invention. It is a radial view of the coil unit which concerns on other embodiment of this invention. FIG. 6 is a partial cross-sectional view of a rotating electrical machine according to another embodiment of the present invention. FIG. 6 is a partial cross-sectional view of a rotating electrical machine according to another embodiment of the present invention. It is a radial direction view which shows typically the coil unit which concerns on other embodiment of this invention. FIG. 6 is a partial cross-sectional view of a rotating electrical machine according to another embodiment of the present invention. It is sectional drawing of the slot which concerns on other embodiment of this invention.

  Embodiments of the present invention will be described with reference to the drawings. Here, a case where the present invention is applied to an inner rotor type rotating electrical machine 100 (see FIG. 1) will be described as an example. In this embodiment, the rotating electrical machine 100 is a rotating field type rotating electrical machine, and the core to be wound with the coil 3 is the core of the stator 1 (stator core 2). That is, the stator core 2 corresponds to a “core” in the present invention. In this specification, the rotating electrical machine is used as a concept including a motor (electric motor), a generator (generator), and a motor / generator that performs both functions of the motor and the generator as necessary.

  In the following description, unless otherwise specified, the “axial direction L”, “circumferential direction C”, and “radial direction R” are the cylindrical core reference surface 21 (see FIGS. 1 and 2). ) Axis. The “circumferential first direction C1” and the “circular second direction C2” represent a direction toward the one side and a direction toward the other side in the circumferential direction C, respectively. In the present embodiment, of the coil end portions 3a (see FIG. 15) on both sides in the axial direction L, the coil in which ends 60a and 60b (see FIGS. 7 and 8) of the continuous coil portion 60 described later are arranged. When the stator core 2 is viewed from the end portion 3a side (upper side in FIG. 1) along the axis (axial direction L) of the core reference surface 21 (see FIG. 2), the counterclockwise direction is the circumferential first direction C1. The clockwise direction is the second circumferential direction C2. The “diameter first direction R1” and the “diameter second direction R2” represent a direction toward the inner side and an outer side of the radial direction R of the core reference surface 21, respectively. In the present embodiment, the first radial direction R1 that is a direction toward one side of the radial direction R corresponds to the “opening direction” in the present invention.

  In this specification, in order to facilitate understanding of the invention, the state in which the coil 3 is wound around the stator core 2 (see FIGS. 15 and 16) is assumed with respect to the arrangement direction of each part constituting the coil 3 in the manufacturing stage. In the following description, each of the axial direction L, the circumferential direction C, and the radial direction R is used. Further, in the present specification, terms relating to the arrangement direction, arrangement position, and the like of each member are used as a concept including a state in which there is a difference due to an error (an error that is acceptable in manufacturing).

1. Overall configuration of rotating electrical machine The overall configuration of the rotating electrical machine 100 according to the present embodiment will be described. As shown in FIG. 1, the rotating electrical machine 100 includes a stator 1 and a rotor 6 that is rotatably provided on the first radial direction R1 side of the stator 1 (that is, radially inner side). The stator 1 includes a stator core 2 and a coil 3 wound around the stator core 2. The stator core 2 is formed using a magnetic material. In FIG. 1, in order to avoid complexity, the coil end portion 3a (see FIG. 15), which is the portion of the coil 3 protruding in the axial direction L from the stator core 2, is not shown, and the slot 22 in FIG. At the end portion in the axial direction L, a cross section of a coil side portion 71 that is a portion of the coil 3 disposed in the slot 22 appears. Further, in FIG. 1, the rotor 6 is shown in a simplified manner, and a part of the rotor 6 is drawn in perspective.

  The stator core 2 is integrally formed at least in the circumferential direction C. That is, the stator core 2 does not have a circumferential joint that joins a portion divided in the circumferential direction C in the circumferential direction C. For example, in the case where a cylindrical core is formed by bending a rectangular parallelepiped core, or in the case where a cylindrical core is formed by arranging a plurality of divided cores in the circumferential direction, the circumferential joint portion is adjacent to each other in the circumferential direction. It is formed in order to join end faces. In the present embodiment, the stator core 2 is integrally formed in the circumferential direction C and the radial direction R, and is not integrally formed in the axial direction L. That is, the stator core 2 has an axial joint that joins the part divided in the axial direction L in the axial direction L. In the present embodiment, the stator core 2 is formed by laminating a plurality of annular plate-like magnetic plates 7 in the axial direction L, as shown in FIG. The magnetic plates 7 in the laminated state are joined to each other by welding or caulking or the like, and the joint between the magnetic plates 7 adjacent in the axial direction L constitutes the above-described axial joint. As the magnetic plate 7, for example, an electromagnetic steel plate (for example, a silicon steel plate) can be used.

  A plurality of slots 22 are distributed in the circumferential direction C in the stator core 2. A tooth 23 is formed between two slots 22 adjacent to each other in the circumferential direction C. The above-described “cylindrical core reference surface 21” is a virtual surface that serves as a reference for the arrangement and configuration of the slots 22, and in the present embodiment, a plurality of (the same number as the slots 22) teeth 23 in the first diameter direction. A cylindrical virtual surface (core inner peripheral surface) including the end surface on the R1 side is used as the core reference surface 21. A surface on the second radial direction R2 side (core outer peripheral surface) of the stator core 2 may be used as the core reference surface 21.

  The plurality of slots 22 are distributed at regular intervals along the circumferential direction C. Each slot 22 extends in the axial direction L and is formed to have an opening 22b on the first radial direction R1 side. The slot 22 is formed so as to penetrate the stator core 2 in the axial direction L. The slots 22 are formed so as to extend radially from the axis of the core reference surface 21 in the radial direction R. In the present embodiment, as shown in FIG. 2, the opening width W1, which is the width in the circumferential direction C of the opening 22b, is the circumferential direction C inside the slot 22 (the portion on the radial second direction R2 side from the opening 22b). The slot 22 is formed so as to be narrower than the internal width W2, which is the width of the. That is, in the present embodiment, the slot 22 is a semi-open slot. In the present embodiment, a closing member 25 for closing the opening 22b is disposed in the opening 22b in order to suppress the coil side portion 71 from protruding from the opening 22b.

  In the present embodiment, as shown in FIG. 2, each tooth 23 is a parallel tooth in which two tooth side surfaces 23 a facing opposite sides in the circumferential direction C are parallel to each other, and each slot 22 has a width in the circumferential direction C. Is formed so as to gradually become wider toward the second radial direction R2. Moreover, in this embodiment, the circumferential direction protrusion part 23b which protrudes in the circumferential direction C with respect to the other part of the teeth side surface 23a is formed in the front-end | tip part of each teeth 23, and the opening part 22b of the slot 22 is formed. The space is formed as a space sandwiched on both sides in the circumferential direction C by the circumferential protrusion 23b. As shown in FIG. 2, in this embodiment, a slot insulating portion 24 is formed on a wall surface portion (a portion including the tooth side surface 23 a) that forms the slot 22 in the stator core 2. Therefore, in the present embodiment, the opening width W1 and the internal width W2 of the slot 22 are determined according to the thickness of the slot insulating portion 24 in addition to the circumferential width C and the arrangement pitch of the teeth 23. The slot insulating part 24 is formed by, for example, insulating powder coating or a slot insulating sheet.

  In this embodiment, the rotating electrical machine 100 is a three-phase AC motor or a three-phase AC generator driven by a three-phase AC. The coil 3 includes a U-phase coil, a V-phase coil, and a W-phase coil corresponding to each of the three phases (U-phase, V-phase, and W-phase). And the W-phase slots 22 are arranged so as to repeatedly appear along the circumferential direction C. In the present embodiment, the number of slots per phase (per pole per phase) of one pole and three phases of the field is “2”, and the stator core 2 has slots 22 for each phase in the circumferential direction C. Are arranged so that they appear repeatedly two by two. In the present embodiment, the number of magnetic poles per phase is “8”, and the stator core 2 is provided with a total of 48 (= 3 × 2 × 8) slots 22. The number of phases of the AC power source that drives the rotating electrical machine 100, the number of slots per phase per pole, and the number of magnetic poles per phase can be changed as appropriate. For example, the number of phases of the AC power source that drives the rotating electrical machine 100 can be set to “1”, “2”, “4”, and the like. For example, the number of slots per pole per phase can be set to “1”, “3”, and the like. For example, the number of magnetic poles per phase can be set to “12” or the like.

2. Next, the configuration of the linear conductor 4 according to this embodiment will be described. The linear conductor 4 is a conductor constituting the coil 3, and the coil 3 is configured by winding the linear conductor 4 around the stator core 2. As shown in FIG. 3, the linear conductor 4 is configured by covering the periphery of a bare conductor wire bundle 42 in which a plurality of flexible bare conductor wires 41 are assembled with a flexible insulating coating material 46. Has been.

  The bare conductor wire 41 is a linear bare conductor, and is made of, for example, copper or aluminum. In the present embodiment, the bare conductor wire 41 has a circular cross-sectional shape orthogonal to the extending direction. For example, a bare wire having a diameter (wire diameter) of 0.2 mm or less is used as the bare conductor wire 41. be able to. The surface of the bare conductor wire 41 is not covered with an insulator, and the conductor surface is exposed. The “insulator” here does not include an oxide film formed by oxidizing the surface of the conductor. A plurality of such bare conductor strands 41 are assembled to form a bare conductor strand bundle 42. The bare conductor strand bundle 42 is configured by twisting and bundling a plurality of bare conductor strands 41 or by bundling a plurality of bare conductor strands 41 without twisting.

  The insulating coating material 46 is a flexible electrical insulating member, and is made of, for example, a synthetic resin such as a fluorine resin, an epoxy resin, or polyphenylene sulfide. Here, “flexibility” means a property that can be bent or bent. The insulating covering material 46 is provided so as to cover the periphery of the bare conductor wire bundle 42. Specifically, the insulation coating material 46 covers the entire circumference of the bare conductor strand bundle 42 and extends in the extending direction except for the connection portion provided at the end in the extending direction A of the bare conductor strand bundle 42. It is provided so as to cover the entire area along A. Here, the connecting portion is a portion for electrically connecting one linear conductor 4 to another linear conductor 4 or another conductor. In the present embodiment, the insulating coating material 46 is made of a flexible sheet-like material (tubular material) that wraps around the bare conductor wire bundle 42.

  As shown in FIG. 4, a gap G is formed between the plurality of bare conductor strands 41 constituting the bare conductor strand bundle 42. Therefore, the plurality of bare conductor wires 41 can move relative to each other in the insulating coating material 46. In the present embodiment, since the cross-sectional shape of the bare conductor wire 41 is a circular shape, the three bare conductor strands 41 are placed between the three bare conductor strands 41 even when they are in close contact with each other. A gap G is formed. The insulating coating material 46 has flexibility, and the insulating coating material 46 itself can be deformed. Therefore, as shown in FIG. 14, the linear conductor 4 can change the cross-sectional shape in the extending orthogonal plane P (refer FIG. 3) orthogonal to the extending direction A. As shown in FIG. That is, the cross-sectional shape of the linear conductor 4 is deformed by following the deformation of the insulating covering material 46 and moving the plurality of bare conductor wires 41 relative to each other within the insulating covering material 46.

  In the present embodiment, as shown in FIG. 14, the width in the circumferential direction C (circumferential width D) in a state where the cross-sectional shape of the linear conductor 4 is a perfect circle, that is, the cross-sectional shape of the linear conductor 4 is The diameter in the state of being a perfect circle is set to be larger than the opening width W1 of the slot 22. The linear conductor 4 can be deformed with a circumferential width D between a first circumferential width D1 narrower than the opening width W1 and a second circumferential width D2 wider than the opening width W1.

3. Coil Arrangement Configuration Next, an arrangement configuration of the coil 3 according to the present embodiment will be described. As described above, in the present embodiment, the coil 3 includes three phase coils, a U-phase coil, a V-phase coil, and a W-phase coil, corresponding to each of the three phases. The phase coils of each phase are configured similarly to each other, and only the U-phase coil is representatively shown in FIGS. In FIG. 5, the numbers in parentheses attached to the upper portions of the slots 22 represent the arrangement order of the slots 22 in the circumferential direction C. As shown in FIG. 6, in this embodiment, the phase coils of each phase are star-connected (Y-connected), and one end of the phase coil is connected to the power supply terminal 81 and the other of the phase coils. The end is connected to a neutral point 82. Here, the power supply terminal 81 is a terminal for connecting a lead wire (power line) that connects the rotating electrical machine 100 and an inverter (not shown).

  As shown in FIG. 8, the coil 3 includes a coil side portion 71 (see FIG. 2) disposed in the slot 22 and a crossing portion that connects the two coil side portions 71 on the outer side in the axial direction L of the stator core 2. 72. The coil side portion 71 is formed in a straight line parallel to the axial direction L. The crossover portion 72 constitutes the coil end portion 3a (see FIG. 15). In the present embodiment, as shown in FIG. 5, the coil side portions 71 are arranged in a plurality of layers B in each slot 22. As will be described later, each identification symbol given in the slot 22 in FIG. 5 represents one coil side portion 71. Here, “layer B” represents the position (arrangement region) in the radial direction R of the coil side portion 71 in the slot 22. Below, the layer B on the most radial second direction R2 side in the slot 22 is defined as a first layer B1, and the second layer B2, the third layer B3,. And In the present embodiment, the coil side portion 71 is divided into N layers B (N is an even number) and the coil 3 has an even layer winding structure. Specifically, in this embodiment, “N” is “6”, and the layer B closest to the radial first direction R1 in the slot 22 is the sixth layer B6.

  In the present embodiment, as shown in FIG. 2, the plurality of coil sides 71 in each slot 22 are arranged in a line along the radial direction R at the same position in the circumferential direction C. The coil side portions 71 adjacent to R are in contact with each other. Here, as described above, the cross-sectional shape of the linear conductor 4 constituting the coil 3 can be changed. As a result, as shown in FIG. 2, the cross-sectional shape of each coil side portion 71 is deformed in accordance with the shape of the slot 22, so that the gap between the coil side portions 71 and the coil side portion 71 and the inner wall surface of the slot 22 It is possible to increase the space factor of the coil 3 while keeping the gap of the coil 3 small.

  As shown in FIG. 6, the phase coil is configured using a continuous coil unit 60. Here, as shown in FIGS. 7 and 8, the continuous coil portion 60 is formed by a single linear conductor 4 that is inserted in the plurality of slots 22 and continues over a range that goes around the stator core 2 once. It is a coil part. That is, the continuous coil portion 60 is a coil portion formed by a single linear conductor 4, and the single linear conductor 4 constituting the continuous coil portion 60 is a plurality of different arrangement positions in the circumferential direction C. And the coil side portion 71 are arranged so as to be continuous over a range more than one round of the stator core 2 (that is, a range in the circumferential direction C of 360 degrees or more). Here, “continuous” for the linear conductor 4 means that the bare conductor wire 41 or the insulating coating material 46 (see FIG. 3) is integrally formed in the extending direction A without a joint. In the present embodiment, the continuous coil portion 60 is formed so as to make a plurality of turns (three turns in this example) of the stator core 2 while being inserted into the plurality of slots 22. In the present embodiment, the continuous coil portion 60 is formed so as to go around the stator core 2 toward the same side in the circumferential direction C. As shown in FIG.7 and FIG.8, the continuous coil part 60 has the 1st end part 60a which is the edge part of the circumferential first direction C1 side, and the 2nd end part 60b which is an edge part of the circumferential second direction C2 side. And have. The first end portion 60a and the second end portion 60b are end portions of the continuous coil portion 60 along the extending direction A of the linear conductor.

  In this embodiment, as shown in FIG. 6, the phase coil is configured by connecting a plurality of continuous coil sections 60 in series or in parallel. In other words, the phase coil is configured by combining a plurality of continuous coil portions 60. Specifically, the U-phase coil includes four U-phase first continuous coil portion 61U, U-phase second continuous coil portion 62U, U-phase third continuous coil portion 63U, and U-phase fourth continuous coil portion 64U. The continuous coil unit 60 is used. U-phase first continuous coil portion 61U and U-phase fourth continuous coil portion 64U are connected in series, U-phase second continuous coil portion 62U and U-phase third continuous coil portion 63U are connected in series. The serial circuit portion thus formed is connected in parallel between the power supply terminal 81 and the neutral point 82.

  In the present embodiment, as shown in FIG. 8, the continuous coil portion 60 is formed in a wave shape, and the continuous coil portion 60 is wound around the stator core 2 so as to have a wave shape. Specifically, the plurality of coil side parts 71 constituting the same continuous coil part 60 have the same circumferential direction C as the electrical connection order (that is, the order of arrangement along the extending direction A of the linear conductors 4). Arranged in order. In the present embodiment, the plurality of coil side portions 71 constituting the same continuous coil portion 60 are arranged along the circumferential direction C at an interval of 6 times the arrangement pitch of the slots 22. In the present embodiment, as shown in FIGS. 7 and 8, the two coil side portions 71 connected by the crossover portion 72 are arranged at different positions in the radial direction R, and the coil 3 is wound around the stator core 2. In the mounted state, the two coil side portions 71 connected by the crossover portion 72 are arranged in the layers B adjacent to each other in different slots 22. That is, the crossover portion 72 connects the pair of coil side portions 71 respectively disposed in the layers B adjacent to each other in the different slots 22 on the outside in the axial direction L of the stator core 2. In the present embodiment, as shown in FIG. 7, the crossover portion 72 is formed with an offset portion that offsets the linear conductor 4 by one layer in the radial direction R. The offset portion is formed in the top portion 72a that is the portion of the crossover portion 72 that is farthest from the stator core 2 in the axial direction L. Thereby, as shown in FIG.10 and FIG.16, it becomes possible to arrange | position the several continuous coil part 60, without making the crossing parts 72 of the different continuous coil parts 60 mutually interfere in the coil end part 3a. Yes. In addition, in FIG. 10 etc., in order to make an understanding of invention easy, the one part continuous coil part 60 of the several continuous coil parts 60 is hatched.

  The plurality of continuous coil portions 60 constituting the phase coil are configured in the same manner except that the arrangement positions in the circumferential direction C are different. And the coil 3 is arrange | positioned in the position which overlaps the stator core 2 seeing in radial direction R on the radial first direction R1 side of the stator core 2 so that it may explain later in the section of "4. Manufacturing method of rotating electrical machine". Each coil side portion 71 is inserted into the slot 22 from the opening 22b by moving the coil unit 30 in the second radial direction R2 side. As shown in FIG. 10, the coil unit 30 is configured by combining a plurality of continuous coil portions 60, and coil side portions 71 arranged in the same layer B in the slots 22 of the plurality of continuous coil portions 60 are arranged. It arrange | positions so that it may become the same positional relationship as the state wound by the stator core 2. As shown in FIG. That is, as schematically shown in FIG. 12, the coil unit 30 is formed in a band shape as a whole by combining a plurality of (in this example, 12) continuous coil portions 60, and the M unit (M is It has a thickness in the radial direction R of a natural number, in this example, M = 2). The extending direction E of the coil unit 30 coincides with the circumferential direction C in a state where the coil unit 30 is wound around the stator core 2.

  As shown in FIG. 10, the coil unit 30 includes a first end 30a that is an end on the circumferential first direction C1 side (that is, an end on one side in the extending direction E), and a second circumferential direction C2 side. And a second end portion 30b which is the other end portion (that is, the other end portion in the extending direction E). Such a coil unit 30 is wound around the stator core 2 so as to be concentrically wound around the stator core 2 in a concentric manner or a plurality of turns in a spiral shape (three turns in the example shown in FIG. 16). The coil 3 can be formed by winding from the first direction R1 side. That is, as shown in FIG. 16, the coil unit 30 has a length in the extending direction E that makes the stator core 2 one or more turns (three turns in this example) spirally along the circumferential direction C. Strictly speaking, the coil unit 30 according to the present embodiment has a length in the extending direction E that exceeds three rounds as shown in FIG. This is due to the portion 71a and the second target coil side portion 71b, and the substantial length is three turns. That is, the number of turns for the coil unit 30 is determined according to the number of coil side portions 71 arranged in each slot 22 by winding the coil unit 30 around the stator core 2. In the present embodiment, since the coil unit 30 basically has two coil side portions 71 at the same position in the extending direction E, the number of coil side portions 71 arranged in each slot 22 is “6”. “3” that is a value obtained by dividing (see FIG. 2) by “2” that is the number of coil side portions 71 arranged at the same position in the extending direction E is the number of turns of the coil unit 30.

  In the present embodiment, as shown in FIG. 10, the coil unit 30 includes the first target coil side portion 71 a in a region including the first end portion 30 a (that is, an end region on one side in the extending direction E). And has a second target coil side portion 71b in a region including the second end portion 30b (that is, the other end region in the extending direction E). Each of the first target coil side portion 71a and the second target coil side portion 71b is a coil side portion 71 arranged at a different position in the extending direction E from all the other coil side portions 71. Therefore, as described above, the coil unit 30 has a thickness in the radial direction R corresponding to two layers as a whole, but at least the axis of the arrangement position of the first target coil side portion 71a and the second target coil side portion 71b. In the central part in the direction L, it has a thickness in the radial direction R for one layer.

  In the present embodiment, the coil unit 30 has two first target coil side portions 71a and two second target coil side portions 71b for each of the three phases (U phase, V phase, and W phase). In total, the three phases include six first target coil sides 71a and six second target coil sides 71b. As shown in FIG. 10, the six first target coil side portions 71 a extend in the region including the first end portion 30 a of the coil unit 30 at intervals corresponding to the arrangement pitch of the slots 22. The six second target coil side portions 71b are arranged in line with E, and extend in the extending direction E at intervals corresponding to the arrangement pitch of the slots 22 in the region including the second end portion 30b of the coil unit 30. It is arranged to line up. Therefore, in the present embodiment, as shown in FIG. 16, the coil unit 30 has a thickness in the radial direction R at least in the axial direction L in each of the region including the first end 30a and the region including the second end 30b. In the central portion of the region, the thickness is half of the radial direction R in the intermediate region located between these regions. Then, specifically, the first object is arranged so that the region including the first end 30a and the region including the second end 30b overlap each other when viewed in the radial direction R. The coil unit 30 is wound around the stator core 2 so that the coil side portion 71a and the second target coil side portion 71b are arranged at a position in the circumferential direction C that overlaps when viewed in the radial direction R. Specifically, the in-phase first target coil side 71a and second target coil side 71b are arranged in different layers B in the same slot 22, as shown in FIG. 12 and 13, the thickness in the radial direction R of the coil unit 30 is drawn uniformly along the extending direction E, unlike FIG.

  Hereinafter, the configurations of the U-phase first continuous coil portion 61U, the U-phase second continuous coil portion 62U, the U-phase third continuous coil portion 63U, and the U-phase fourth continuous coil portion 64U constituting the U-phase coil will be described with reference to FIG. It demonstrates concretely with reference to. In FIG. 5, a symbol given in the slot 22 is an identification symbol indicating the arrangement order of the coil side portions 71 along the extending direction (current flow direction) of the linear conductor 4. "Or" b ") in combination with the identification symbol. Here, the numbers constituting the identification symbols are numbered sequentially from “1” to each of the pair of coil side parts 71 (coil side part pairs) from the power supply terminal 81 side toward the neutral point 82 side. Assigned.

  In FIG. 5, the 24 coil side parts 71 to which the identification symbols “1a”, “2a”,... “12a” are attached constitute a U-phase first continuous coil part 61U. As described above, in this embodiment, the number of magnetic poles per phase is “8”. Therefore, in the continuous coil portion 60, eight coil side portions 71 correspond to one turn of the stator core 2, and 24 coil side portions 71 correspond to three turns of the stator core 2. In addition, in FIG. 5, the 24 coil sides 71 to which the identification symbols “13b”, “14b”,... “24b” are attached constitute a U-phase third continuous coil portion 63U. As shown in FIG. 9, the U-phase third continuous coil portion 63U has an interval corresponding to one magnetic pole pitch with respect to the U-phase first continuous coil portion 61U (in this example, an interval that is six times the arrangement pitch of the slots 22). ) Only in the circumferential first direction C1 side. Therefore, as shown in FIGS. 5 and 9, the coil side 71 constituting the U-phase first continuous coil portion 61U and the coil side 71 constituting the U-phase third continuous coil portion 63U are the same slot 22 as each other. Of layers B adjacent to each other. By arranging the U-phase first continuous coil portion 61U and the U-phase third continuous coil portion 63U in such a positional relationship, as shown in FIG. 10, the second end of the U-phase first continuous coil portion 61U is the second end. The coil side portion 71 (coil side portion 71 with the identification symbol “12a” in FIG. 5) disposed on the side of the portion 60b becomes the second target coil side portion 71b, which is the most of the U-phase third continuous coil portion 63U. The coil side portion 71 (the coil side portion 71 with the identification symbol “24b” in FIG. 5) arranged on the first end portion 60a side is the first target coil side portion 71a.

  In FIG. 5, the 24 coil side portions 71 to which the identification symbols “1b”, “2b”,... “12b” are attached constitute a U-phase second continuous coil portion 62U. That is, the U-phase second continuous coil portion 62U is arranged in a positional relationship shifted to the circumferential second direction C2 side by the interval of the arrangement pitch of the slots 22 with respect to the U-phase first continuous coil portion 61U. In addition, in FIG. 5, the 24 coil side portions 71 to which the identification symbols “13a”, “14a”,... “24a” are attached constitute a U-phase fourth continuous coil portion 64U. That is, the U-phase fourth continuous coil portion 64U is arranged in a positional relationship shifted to the circumferential second direction C2 side by the interval of the arrangement pitch of the slots 22 with respect to the U-phase third continuous coil portion 63U. By arranging the U-phase second continuous coil portion 62U and the U-phase fourth continuous coil portion 64U in such a positional relationship, as shown in FIG. 10, the second end of the U-phase second continuous coil portion 62U is the second end. The coil side portion 71 (coil side portion 71 with the identification symbol “12b” in FIG. 5) arranged on the side of the portion 60b becomes the second target coil side portion 71b, and is the most of the U-phase fourth continuous coil portion 64U. The coil side portion 71 (coil side portion 71 with the identification symbol “24a” in FIG. 5) arranged on the first end portion 60a side is the first target coil side portion 71a.

  As shown in FIG. 5, the second end 60 b of the U-phase first continuous coil portion 61 </ b> U and the second end 60 b of the U-phase fourth continuous coil portion 64 </ b> U are connected via a connection point 90. Further, the first end 60a of the U-phase first continuous coil portion 61U is connected to the power supply terminal 81, and the first end 60a of the U-phase fourth continuous coil portion 64U is connected to the neutral point 82. . Thereby, the series circuit part which consists of U-phase 1st continuous coil part 61U and U-phase 4th continuous coil part 64U as shown in FIG. 6 is comprised. Similarly, as shown in FIG. 5, the second end 60b of the U-phase second continuous coil portion 62U and the second end 60b of the U-phase third continuous coil portion 63U are connected via a connection point 90. ing. Further, the first end 60a of the U-phase second continuous coil portion 62U is connected to the power supply terminal 81, and the first end 60a of the U-phase third continuous coil portion 63U is connected to the neutral point 82. . Thereby, the series circuit part which consists of U phase 2nd continuous coil part 62U and U phase 3rd continuous coil part 63U as shown in FIG. 6 is comprised.

  Each of the V-phase coil and the W-phase coil is configured in the same manner as the U-phase coil except that the arrangement position in the circumferential direction C is different. Specifically, as shown in FIG. 10, the V-phase coil includes a V-phase first continuous coil portion 61V corresponding to the U-phase first continuous coil portion 61U and a V-phase corresponding to the U-phase second continuous coil portion 62U. 4 of the V-phase fourth continuous coil portion 64V corresponding to the second continuous coil portion 62V, the V-phase third continuous coil portion 63V corresponding to the U-phase third continuous coil portion 63U, and the U-phase fourth continuous coil portion 64U. Two continuous coil portions 60 are provided. Each of these V-phase continuous coil portions 60 is arranged in a positional relationship shifted from the corresponding U-phase continuous coil portion 60 toward the second circumferential direction C2 by an interval four times the arrangement pitch of the slots 22. Has been. As shown in FIG. 10, the W-phase coil includes a W-phase first continuous coil portion 61W corresponding to the U-phase first continuous coil portion 61U and a W-phase second continuous coil portion corresponding to the U-phase second continuous coil portion 62U. 62W, four continuous coil portions 60, a W-phase third continuous coil portion 63W corresponding to the U-phase third continuous coil portion 63U, and a W-phase fourth continuous coil portion 64W corresponding to the U-phase fourth continuous coil portion 64U. It has. Among these W-phase continuous coil portions 60, the W-phase first continuous coil portion 61 </ b> W and the W-phase second continuous coil portion 62 </ b> W are each provided with a slot 22 with respect to the corresponding U-phase continuous coil portion 60. The W-phase third continuous coil portion 63W and the W-phase fourth continuous coil portion 64W are respectively arranged in the corresponding U-phase. The continuous coil portion 60 is arranged in a positional relationship shifted to the second circumferential direction C2 side by an interval of 8 times the arrangement pitch of the slots 22.

  As described above, each of the U-phase coil, the V-phase coil, and the W-phase coil includes four continuous coil units 60. Therefore, in the present embodiment, the coil 3 includes a total of 12 continuous coil portions 60. As shown in FIG. 10, these twelve continuous coil portions 60 are configured in the same manner except that the arrangement positions in the circumferential direction C are different from each other. The central positions in the circumferential direction C are distributed at 12 positions set along the circumferential direction C at intervals of the arrangement pitch of the slots 22. In other words, the end portions (the first end portion 60 a or the second end portion 60 b) on the same side in the circumferential direction C of the 12 continuous coil portions 60 are circumferentially arranged at intervals of the arrangement pitch of the slots 22. Dispersed at 12 positions set along C. And each 1st end part 60a of the 12 continuous coil parts 60 is arrange | positioned with respect to the stator core 2 at the same side (upper side in FIG. 10) of the axial direction L, and each of the 12 continuous coil parts 60 is each. The second end portion 60b is disposed on the same side in the axial direction L with respect to the stator core 2 (upper side in FIG. 10). In the present embodiment, since the continuous coil portion 60 has an even number of coil side portions 71, the first end portion 60 a and the second end portion 60 b of the continuous coil portion 60 are in the axial direction L with respect to the stator core 2. Placed on the same side. Therefore, in this embodiment, as shown in FIG. 10, all of the end portions 60 a and 60 b of the continuous coil portion 60 included in the coil unit 30 are arranged on the same side in the axial direction L with respect to the stator core 2. As a result, the electrical connection process with respect to the continuous coil portion 60 can be simplified, and the coil end portion 3a in the axial direction L can be reduced in size.

  As shown in FIG. 10, each of the plurality of continuous coil parts 60 is arranged such that at least a part of the other continuous coil parts 60 is different from the slots 22 in which the coil side parts 71 are arranged. For example, the U-phase first continuous coil portion 61U is arranged such that the slots 22 where the coil side portions 71 are arranged are different from all the other continuous coil portions 60 except the U-phase third continuous coil portion 63U. .

4). Next, a method for manufacturing the rotating electrical machine 100 according to the present embodiment will be described with reference to the flowchart shown in FIG. As shown in FIG. 11, the process of manufacturing the rotating electrical machine 100 includes a coil unit supply process # 01 and coil side part insertion processes # 02 to # 04. Here, in the coil unit supply step # 01, the coil unit 30 is located on the first radial direction R1 side of the stator core 2 and overlaps with the stator core 2 in the radial direction R (hereinafter referred to as “supply target position”). It is the process of supplying to. In coil side portion insertion steps # 02 to # 04, the coil unit 30 is moved in the second radial direction R2 side, and a plurality of coil side portions 71 included in the coil unit 30 are inserted into the slots 22 from the openings 22b. It is.

  In the present embodiment, as schematically shown in FIG. 12, in the coil unit supply step # 01, the coil unit 30 is formed in a spiral shape around the axial direction L, and the coil unit 30 is pivoted with respect to the stator core 2. A step of approaching in the direction L is executed. In addition, in FIG. 12, the coil unit 30 (refer FIG. 10) is simplified and shown. As shown in FIG. 12, in this embodiment, the coil unit 30 is formed in a planar belt shape before being formed into a spiral shape. And in coil unit supply process # 01, the part by the side of the 1st end part 30a in the part which has not been shape | molded helically in the coil unit 30 is the axial direction L circumference, and is helical with a small diameter rather than a core internal peripheral surface. The portion formed in a spiral shape is supplied to the supply target position from the outside in the axial direction L with respect to the stator core 2. The supply target position is a position where the central position in the axial direction L of the coil side portion 71 included in the spirally formed portion matches the central position in the axial direction L of the stator core 2, and in this embodiment, the stator core 2. Is set to the inner diameter side.

  As shown in FIG. 11, after executing the coil unit supply step # 01, the coil side portion insertion steps # 02 to # 04 are executed. In the present embodiment, as shown in FIG. 13, in the coil side portion insertion steps # 02 to # 04, the step of sequentially inserting the coil side portions 71 supplied in the coil unit supply step # 01 into the slots 22 is performed. Run. The cross-sectional shape of the linear conductor 4 is highly likely to be circular when no external force is applied to the linear conductor 4. In the present embodiment, as shown in FIG. 14A, the circumferential width D in a state where the cross-sectional shape of the linear conductor 4 is a perfect circle is set to be larger than the opening width W1 of the slot 22. ing. Therefore, in the present embodiment, in the coil side portion insertion step, as shown in FIG. 14A, the flattening step # 02 is executed, and the portion of the linear conductor 4 inserted into the slot 22 (coil side) After the circumferential width D of the portion 71) is set to the first circumferential width D1 narrower than the opening width W1, the insertion step # 03 is executed to insert the coil side portion 71 into the slot 22 from the opening 22b. Note that the coil side portion 71 to be inserted in the single insertion step # 03 may be a plurality of coil side portions 71 that are inserted in a plurality of slots 22 adjacent in the circumferential direction C. In the present embodiment, as shown in FIG. 14A, the flattening step # 02 is performed using the flattening jig 51. The first circumferential width D1 is determined according to the gap width in the circumferential direction C of the portion through which the linear conductor 4 passes in the flattening jig 51.

  In the insertion step # 03, the coil side portion 71 is inserted up to the position on the most radial second direction R2 side that can travel inside the slot 22. At this time, for example, an insertion jig (not shown) for pushing the linear conductor 4 in the radial direction R is used. In FIG. 14, the case where the coil side part 71 is arrange | positioned in the 1st layer B1 which is the layer B in the radial second direction R2 side most is shown as an example. Subsequent to the insertion step # 03, as shown in FIGS. 14B and 14C, a pressing step # 04 is performed. In the pressing step # 04, the coil side portion 71, which is a portion of the linear conductor 4 inserted into the slot 22, is pressed toward the radial second direction R 2 side that is opposite to the opening direction of the slot 22. In this embodiment, as shown in FIG. 14B and FIG. 14C, the pressing step # 04 is performed using the pressing jig 53, and the linear conductor 4 is aligned with the cross-sectional shape of the slot 22. Change the cross-sectional shape. At this time, in this embodiment, since the slot 22 is formed so that the opening width W1 is narrower than the internal width W2 (see FIG. 2), as shown in FIG. The circumferential width D of the linear conductor 4 after execution is a second circumferential width D2 wider than the opening width W1. In the present embodiment, the second circumferential width D2 varies depending on the position in the radial direction R within the slot 22.

  In the present embodiment, as shown in FIG. 10, the plurality of coil side portions 71 constituting the coil unit 30 are at the same position in the circumferential direction C except for the end portions 30 a and 30 b in the circumferential direction C of the coil unit 30. The two coil side portions 71 are arranged in the radial direction R. Therefore, although illustration is omitted, in the insertion step # 03 according to the present embodiment, basically, the two coil side portions 71 are continuously inserted into the same slot 22. At this time, as shown in FIG. 14B and FIG. 14C, the pressing step # 04 is not performed for each coil side portion 71 but two coil side portions 71 arranged in the radial direction R are performed. The pressing step # 04 can be performed. In this case, the coil side portion 71 positioned on the second radial direction R2 side is pressed toward the second radial direction R2 side by the pressing jig 53 via the coil side portion 71 positioned on the first radial direction R1 side.

  Thus, in this embodiment, a coil side part insertion process is a process of performing flattening process # 02, insertion process # 03, and press process # 04 in order. At this time, the cross-sectional shape of the linear conductor 4 is changed by the flattening process # 02 and also by the pressing process # 04. That is, in this embodiment, the coil side portion insertion steps # 02 to # 04 include a step of deforming the cross-sectional shape of the linear conductor 4 before and after the coil side portion 71 is inserted into the slot 22.

  In the coil unit supply step # 01 according to the present embodiment, as shown in FIG. 12, the coil unit 30 is supplied to the supply target position in order from the portion on the first end portion 30a side, and the coil side portion insertion steps # 02 to ## In 04, as shown in FIG. 13, the coil side portions 71 supplied in the coil unit supply step # 01 are sequentially inserted into the slots 22. Therefore, as shown in FIG. 11, in this embodiment, until the entire supply of the coil unit 30 is completed (step # 05: No), the coil unit supply step # 01 and the coil side portion insertion step # are performed. 02 to # 04 are repeatedly executed. And after supply of the whole coil unit 30 is completed (step # 05: Yes), until insertion in the slot 22 of all the coil side parts 71 is completed (step # 06: No), a coil The side insertion steps # 02 to # 04 are repeatedly executed.

  FIG. 16 schematically shows the state of the coil unit 30 in a state after the insertion of all the coil side portions 71 into the slot 22 is completed (step # 06: Yes). Although details are omitted, thereafter, as shown in FIG. 5, the end portions 60a and 60b of each continuous coil portion 60, the end portions 60a and 60b of the other continuous coil portions 60 in phase, the power supply terminal 81, or the middle The connection process with the sex point 82 is executed, and in the present embodiment, the arrangement process of the closing member 25 (see FIG. 2) is further executed.

  By the way, the position in the axial direction L of the top portion 72a of the crossover portion 72 is the length of the crossover portion 72 along the extending direction A of the linear conductor, the distance between the slots 22 along the circumferential direction C, and the coil unit 30. Is determined according to the positional relationship in the axial direction L of the coil unit 30 with respect to the stator core 2 when the coil unit 30 is wound around the stator core 2. In the present embodiment, the coil unit 30 is wound around the stator core 2 a plurality of times without changing the positional relationship of the coil unit 30 in the axial direction L with respect to the stator core 2 depending on the order of turns. Specifically, for all the turns, the coil unit 30 is wound around the stator core 2 in a state where the center position in the axial direction L of the coil unit 30 is matched with the center position in the axial direction L of the stator core 2.

  And in this embodiment, as shown in FIG. 15, the extension direction of a linear conductor is arrange | positioned so that the top part 72a may be arrange | positioned in the same position of the axial direction L irrespective of the order of the circumference | surroundings with respect to the stator core 2 of the coil unit 30. The length of the crossover 72 along A is varied depending on the order of the laps. Specifically, the coil side portion 71 after the turn order of the coil unit 30 with respect to the stator core 2 is the layer B (that is, the circumference) in the first radial direction R1 side than the coil side portion 71 with the turn order earlier. Therefore, the length of the crossover 72 along the extending direction A of the linear conductor is set to be shorter as the order of the wrapping becomes later. ing. Such adjustment of the length of the transition portion 72 can be realized, for example, by adjusting the width in the axial direction L when the coil unit 30 is manufactured, as will be described later with reference to FIG. In FIG. 15, the coil unit 30 has a coil side portion 71 disposed in each of the first layer B1 and the second layer B2, and each of the third layer B3 and the fourth layer B4 in the coil unit 30. The portion having the coil side portion 71 to be arranged and the portion having the coil side portion 71 arranged in each of the fifth layer B5 and the sixth layer B6 in the coil unit 30 are respectively the first round portion 31 and the second round. As the eye part 32 and the third circumference part 33, the top part 72a included in the first part 31, the top part 72a included in the second part 32, and the top part 72a included in the third part 33 are respectively axes. It shows a state of being arranged at the same position in the direction L.

5. Other Embodiments Finally, other embodiments of the rotating electrical machine and the method for manufacturing the rotating electrical machine according to the present invention will be described. Note that the configurations disclosed in the following embodiments can be applied in combination with the configurations disclosed in other embodiments as long as no contradiction arises.

(1) In the above embodiment, the coil unit supply step # 01 forms the coil unit 30 in a spiral shape around the axial direction L as shown in FIG. A configuration that is a process of approaching the axial direction L has been described as an example. However, the embodiment of the present invention is not limited to this. For example, as shown in FIG. 17, as the coil unit supply step # 01, the coil unit 30 is formed in a spiral shape around the axial direction L when viewed in the axial direction L, and then the coil unit 30 has a diameter relative to the stator core 2. It is also possible to adopt a configuration in which the step of moving in the axial direction L to a position overlapping in the direction R is executed.

(2) In the above embodiment, as shown in FIG. 5, the end portions 60 a and 60 b of each continuous coil portion 60 are the end portions 60 a and 60 b of the other continuous coil portion 60 in phase, the power supply terminal 81, or the middle The configuration connected to the sex point 82 has been described as an example. However, the embodiment of the present invention is not limited to this. For example, a connection relationship as shown in FIG. 18 is possible. In this configuration, as shown in FIG. 19, the four continuous coil portions 60 connected in series constitute a phase coil that connects the power supply terminal 81 and the neutral point 82.

(3) In the above embodiment, as shown in FIGS. 7 and 8, the configuration in which the two coil side portions 71 connected by the crossover portion 72 are arranged at different positions in the radial direction R will be described as an example. did. However, the embodiment of the present invention is not limited to this. That is, the two coil side portions 71 connected by the crossover portion 72 are arranged at the same position in the radial direction R, and the two coils connected by the crossover portion 72 in a state where the coil 3 is wound around the stator core 2. The coil side portions 71 may be arranged in the same layer B in different slots 22. Hereinafter, as an example of such a configuration, a first example shown in FIGS. 20 to 22 and a second example shown in FIGS. 23 to 25 will be described. 20 to 25, the U-phase continuous coil section 60, the V-phase continuous coil section 60, and the W-phase continuous coil section 60 are respectively represented as a U-phase continuous coil section 60U and a V-phase continuous coil section. 60V and the W-phase continuous coil section 60W.

[First example]
As shown in FIG. 20, in this example as well, the continuous coil portion 60 is formed in a wave shape like the above embodiment, but unlike the above embodiment, the same continuous coil portion 60 is the same. A plurality of coil side portions 71 constituting the circumference of the same are arranged at the same position in the radial direction R. Further, in this example, unlike the above-described embodiment, an odd number of coil side portions 71 constitute one continuous coil portion 60, and the first end portion 60 a and the second end portion 60 b are in the axial direction L. Are arranged on opposite sides of each other. And the coil unit 30 which concerns on this example is comprised by combining 12 such continuous coil parts 60 as shown in FIG. Note that the coil unit 30 illustrated in FIG. 22 is configured by stacking two combinations of the six continuous coil portions 60 illustrated in FIG. 21 in the radial direction R. The plurality of coil side portions 71 constituting the coil unit 30 shown in FIG. 22 are arranged so that the two coil side portions 71 are aligned in the radial direction R at the same circumferential direction C as in the above embodiment. On the other hand, unlike the above embodiment, the coil unit 30 shown in FIG. 22 does not have the first target coil side 71a or the second target coil side 71b (see FIG. 10), and all the coil sides 71 are included. The other coil side portion 71 and the other coil side portion 71 are arranged at the same position in the extending direction E. The same applies to the coil unit 30 shown in FIG. 25 described below.

  In the combination shown in FIG. 21, the coil side 71 of the U-phase continuous coil unit 60U, the coil side 71 of the V-phase continuous coil unit 60V, and the W-phase continuous coil unit 60W that are adjacent to each other in the circumferential direction C. Each of the coil side portions 71 is disposed at the same position in the radial direction R.

[Second example]
As shown in FIG. 23, in this example as well, as in the first example, a plurality of coil side portions 71 constituting the same circumference of the same continuous coil portion 60 are arranged at the same radial direction R position. Has been. However, in this example, unlike the first example, as shown in FIG. 23, the in-phase continuous coil parts 60 are arranged without intersecting each other when viewed in the radial direction R. In other words, in this example, the plurality of coil side portions 71 constituting the same continuous coil portion 60 are arranged along the circumferential direction C at unequal intervals. Also in this example, the coil unit 30 (FIG. 25) is configured by overlapping two combined bodies (see FIG. 24) including six continuous coil portions 60 in the radial direction R, as in the first example. ing.

(4) In the above embodiment, the configuration in which the coil unit 30 is configured by combining 12 continuous coil units 60 has been described as an example. However, the embodiment of the present invention is not limited to this. For example, the coil unit 30 may be configured by combining six continuous coil units 60. As such a configuration, for example, when the number of slots per pole per phase is “1”, the combination of the continuous coil portions 60 shown in FIG. A coil unit 30 can be formed by arranging three while shifting. Further, the combination shown in FIG. 21 and FIG. In this case, the coil 3 can be wound around the stator core 2 in units of one layer, and the coil 3 having an odd-numbered layer winding structure can be configured using the coil unit 30. That is, the present invention can be applied to the coil 3 having an odd layer winding structure.

(5) In the above embodiment, the configuration in which the continuous coil portion 60 is formed so as to make three rounds of the stator core 2 while being inserted into the plurality of slots 22 has been described as an example. However, the embodiment of the present invention is not limited to this. For example, the continuous coil part 60 can also be set as the structure currently formed so that the stator core 2 may make 1 round, 2 rounds, or 4 rounds. Further, the coil 3 may be configured by winding a plurality of continuous coil portions 60 instead of one around the stator core 2 in order.

  In the above-described embodiment, the configuration in which the continuous coil portion 60 is formed so as to go around the stator core 2 toward the same side in the circumferential direction C has been described as an example. However, the embodiment of the present invention is not limited to this. That is, the continuous coil part 60 can also be configured to have a turn-back part that reverses the direction of rotation in the circumferential direction C when the stator core 2 is circulated. Specifically, a single linear conductor 4 constituting the continuous coil portion 60 is inserted into the plurality of slots 22 so as to have a wave shape, and the stator core 2 is made as a wave winding portion that makes one or more turns. The arrangement includes the first wave winding part 11 and the second wave winding part 12 in which the arrangement order of the coil side parts 71 along the extending direction A of the linear conductor 4 is opposite to each other in the circumferential direction C. Can do. Hereinafter, a third example shown in FIG. 26 and a fourth example shown in FIG. 27 will be described as examples of such a configuration.

[Third example]
As shown in FIG. 26, the coil unit 30 according to this example is connected in series via a connection point 90 (see FIGS. 5 and 6) in the coil unit 30 (see FIG. 10) according to the above embodiment. One continuous coil part 60 is integrally formed as one continuous coil part 60 by one linear conductor. Specifically, the U-phase first continuous coil portion 61U according to this example includes the first wave winding portion 11 corresponding to the U-phase first continuous coil portion 61U according to the embodiment and the U-phase according to the embodiment. It has a structure in which the second wave winding portion 12 corresponding to the fourth continuous coil portion 64U is connected by a deformed crossover portion 73 that functions as a turn-up portion. Unlike the normal transition portion 72, the odd-shaped transition portion 73 is formed by connecting a pair of coil side portions 71 arranged in the same layer B in different slots 22 to each other on the outer side in the axial direction L of the stator core 2. Connect with. Similarly, the U-phase second continuous coil portion 62U according to this example includes the first wave winding portion 11 corresponding to the U-phase second continuous coil portion 62U according to the above-described embodiment and the U-phase third continuous coil portion according to the above-described embodiment. It has a structure in which the second wave winding portion 12 corresponding to the continuous coil portion 63U is connected by a deformed crossover portion 73 that functions as a folded portion. The same applies to the V phase and the W phase. In addition, about the W phase, the 1st wave winding part 11 contained in the W phase 1st continuous coil part 61W which concerns on this example is 2 in the circumferential second direction C2 side in the W phase 1st continuous coil part 61W in FIG. The first wave winding portion 11 included in the W-phase second continuous coil portion 62W according to this example corresponds to a structure that is shifted by an interval corresponding to the magnetic pole pitch (12 times the arrangement pitch of the slots 22). 10 corresponds to a structure in which the W-phase second continuous coil portion 62W in FIG. 10 is shifted to the circumferential second direction C2 side by an interval corresponding to two magnetic pole pitches (12 times the arrangement pitch of the slots 22). It is different from the phase and the V phase. Since it has such an arrangement configuration, although details are omitted, in the coil unit 30 according to this example, the arrangement positions of the first target coil side 71a and the second target coil side 71b are set for the W-phase coil. This is different from the above embodiment (see FIG. 10).

  As shown in FIG. 26, in this example, the first wave winding part 11 and the second wave winding part 12 included in the same continuous coil part 60 are not the same slot 22 but adjacent to the circumferential direction C. Inserted into. Therefore, the width in the circumferential direction C of the odd-shaped transition part 73 is different from the width in the circumferential direction C of the normal transition part 72. The W-phase coil hatched in FIG. 26 will be specifically described. The width in the circumferential direction C of the deformed crossover portion 73 included in the W-phase first continuous coil portion 61W is narrower than the width in the circumferential direction C of the crossover portion 72 by the interval of the arrangement pitch of the slots 22, and the W-phase second continuous portion. The width in the circumferential direction C of the deformed crossover portion 73 included in the coil portion 62W is wider than the width in the circumferential direction C of the crossover portion 72 by the interval of the arrangement pitch of the slots 22. The deformed crossing portion 73 included in the W-phase first continuous coil portion 61W and the deformed crossing portion 73 included in the W-phase second continuous coil portion 62W do not intersect with each other in the radial direction R, and the axial direction L It is arranged to line up. In this example, the deformed crossing portion 73 is on the end of the continuous coil portion 60 along the extending direction A of the linear conductor and on the same side in the axial direction L with respect to the stator core 2 (upper side in FIG. 26). Has been placed. The deformed crossing portion 73 is disposed on the opposite side of the stator core 2 in the axial direction L (lower side in FIG. 26) from the end of the continuous coil portion 60 along the extending direction A of the linear conductor. It is also possible to adopt a configuration. The W-phase coil will be specifically described. For example, the circumferential position of the coil side portion 71 disposed on the most circumferential second direction C2 side in the W-phase first continuous coil portion 61W and the W-phase second continuous coil portion 62W. If the configuration in which the circumferential position of the coil side portion 71 disposed on the most circumferential second direction C2 side in FIG. 6 is replaced is provided, the deformed crossover portion 73 is disposed on the lower side in FIG. As shown in FIG. 26, in this example, the first wave winding portion 11 of the U-phase first continuous coil portion 61U and the second wave winding portion 12 of the U-phase second continuous coil portion 62U are the same slot 22 as each other. The second wave winding portion 12 of the U-phase first continuous coil portion 61U and the first wave winding portion 11 of the U-phase second continuous coil portion 62U are the same slot 22 (however, adjacent to the slot 22). Slot 22). Therefore, when the U-phase first continuous coil portion 61U and the U-phase second continuous coil portion 62U are connected in parallel between the power supply terminal 81 and the neutral point 82, they are arranged on the rotor 6. The distance between the permanent magnet and the electromagnet to be made can be made uniform to suppress the difference in impedance between the two continuous coil portions 60, and as a result, the circulating current can be suppressed. The same applies to the V-phase and W-phase continuous coil sections 60. The same applies to the embodiment shown in FIGS. 6 and 10.

[Fourth example]
As shown in FIG. 27, the coil unit 30 according to this example includes two continuous coil portions 60 connected in series via a connection point 90 in the configuration shown in FIG. 18 and FIG. Thus, a single continuous coil portion 60 is integrally formed. Therefore, in this example, unlike the third example, the first wave winding part 11 and the second wave winding part 12 included in the same continuous coil part 60 are inserted into the same slot 22. Therefore, the width in the circumferential direction C of the odd-shaped transition part 73 is the same as the width in the circumferential direction C of the normal transition part 72. Further, in this example, unlike the third example, the continuous coil part 60 constituting the W-phase coil is arranged in the same positional relationship in the circumferential direction C as the coil unit 30 (FIG. 10) according to the above embodiment. Has been.

(6) In the above-described embodiment, as illustrated in FIG. 15, the configuration in which the top portions 72a are arranged at the same position in the axial direction L has been described as an example regardless of the order of the winding of the coil unit 30 with respect to the stator core 2. However, the embodiment of the present invention is not limited to this. That is, the top portion 72a of the crossover portion 72 and the top portion 72a of the crossover portion 72 disposed adjacent to the crossover portion 72 in the radial direction R are arranged in the axial direction L as shown in FIGS. It can also be set as the structure arrange | positioned in a mutually different position.

  In the example shown in FIG. 28, the coil unit 30 in the axial direction L between the two portions (for example, the first round portion 31 and the second round portion 32) in which the turn order of the stator core 2 in the coil unit 30 continues. By making the central positions different from each other, the top portions 72a are arranged so as to be shifted in the axial direction L between the transition portions 72 arranged adjacent to each other in the radial direction R. In FIG. 28, with respect to the first-round portion 31 and the third-round portion 33, the central position in the axial direction L of the coil unit 30 is one side in the axial direction L with respect to the central position in the axial direction L of the stator core 2. 28, the center position in the axial direction L of the coil unit 30 is the other side in the axial direction L (in FIG. 28) with respect to the central position in the axial direction L of the stator core 2. (Upper side). In this example, the coil unit supply step # 01 (see FIG. 11) includes a position adjustment step in which the supply target position of the coil unit 30 is adjusted in the axial direction L in accordance with the turn order with respect to the stator core 2. In the position adjustment step, a step of shifting the supply target position from each other in the axial direction L is performed between two portions of the coil unit 30 in which the turn order is continuous.

  In the example shown in FIG. 29, the length of the crossover portion 72 along the extending direction A of the linear conductor is adjusted for at least one of the two portions of the coil unit 30 in which the winding order of the stator core 2 is continuous. By doing so, the top part 72a is shifted in the axial direction L between the transition parts 72 arranged adjacent to the radial direction R. Specifically, in the example shown in FIG. 29, by making the length along the extending direction A of the linear conductor longer than that in the above-described embodiment, for the transition portion 72 included in the second round portion 32, On both sides in the axial direction L, the top portion 72a included in the second-round portion 32 is disposed at a position farther from the stator core 2 in the axial direction L than the top portion 72a included in the first-round portion 31 or the third-round portion 33. Yes. Such adjustment of the length of the transition portion 72 can be realized, for example, by adjusting the width in the axial direction L when the coil unit 30 is manufactured as shown in FIG. Note that FIG. 30 shows the planar shape of the coil unit 30 as a band-like region having a width that is a line connecting the tips of the top portions 72 a of the crossover portions 72 along the circumferential direction C. In the example shown in FIG. 30, the width in the axial direction L of the second round portion 32 is the same as the top 72 a included in the first round portion 31 or the third round portion 33 in the axial direction. By making it wider than the width (see the two-dot chain line) in the case of being arranged at the same position of L, the length of the crossover portion 72 included in the second round portion 32 is increased. Note that FIG. 30 shows a case where the coil side portions 71 are arranged at the same interval along the extending direction E regardless of the order of rotation with respect to the stator core 2, so that the top portion 72 a is the same in the axial direction L. The width in the axial direction L also differs between the first-round portion 31 and the third-round portion 33 arranged at the positions.

  Although details are omitted, as shown in FIG. 31, in addition to the first-round portion 31, the second-round portion 32, and the third-round portion 33, the coil unit 30 also has a fourth-round portion 34. Similarly, it is possible to adopt a configuration in which the apex portion 72a is arranged so as to be shifted in the axial direction L between the transition portions 72 arranged adjacent to each other in the radial direction R.

(7) In the above embodiment, the configuration in which the circumferential protrusion 23 b is formed at the tip of the tooth 23 has been described as an example. However, the embodiment of the present invention is not limited to this. That is, as shown in FIG. 32, a configuration in which the circumferential protrusion 23 b is not formed at the tip of the tooth 23, that is, a configuration in which the slot 22 is an open slot may be employed. In the example shown in FIG. 32, unlike the above-described embodiment, the slot 22 facing in the circumferential direction C has a parallel slot structure in which the inner wall surfaces are parallel to each other, and the opening width W1 and the inner width W2 are Slots 22 are formed to be equal. In this case, the circumferential width D of the linear conductor 4 after execution of the pressing step # 04 (see FIG. 11) is equal to the opening width W1 unlike the above embodiment. Also in this case, as shown in FIG. 32, when the circumferential width D in the state where the cross-sectional shape of the linear conductor 4 is a perfect circle is set to be larger than the opening width W1 of the slot 22. Similarly to the above-described embodiment, the linear conductor 4 can be said to be capable of deforming the width in the circumferential direction C to a second circumferential width wider than the opening width W1.

(8) In the above embodiment, the configuration in which the circumferential width D in a state where the cross-sectional shape of the linear conductor 4 is a perfect circle is set larger than the opening width W1 of the slot 22 has been described as an example. . However, the embodiment of the present invention is not limited to this. That is, the circumferential width D in a state in which the cross-sectional shape of the linear conductor 4 is a perfect circle may be set to be equal to or smaller than the opening width W1 of the slot 22. In such a configuration, unlike the above-described embodiment, the coil side portion insertion step does not include the flattening step # 02, and the coil side portion insertion step is executed in order of the insertion step # 03 and the pressing step # 04. It can be a process. Even in this case, since the cross-sectional shape of the linear conductor 4 changes in the pressing step # 04, the cross-sectional shape of the linear conductor 4 before and after the coil side portion insertion step inserts the coil side portion 71 into the slot 22. It can be said to include a step of deforming

(9) In the above embodiment, the configuration in which the continuous coil portion 60 is wound around the stator core 2 so as to have a wave winding shape has been described as an example. However, the embodiment of the present invention is not limited to this. For example, the continuous coil part 60 may have a configuration having an overlapping winding part that is wound a plurality of times between the pair of slots 22.

(10) In the above embodiment, the configuration in which the shape of the cross section orthogonal to the extending direction of the bare conductor wire 41 is a circular shape has been described as an example. However, the embodiment of the present invention is not limited to this. That is, the cross-sectional shape of the bare conductor wire 41 may be various polygonal shapes such as a quadrangular shape, a triangular shape, a pentagonal shape, a hexagonal shape, and an octagonal shape.

(11) In the above embodiment, the configuration in which the first radial direction R1 that is the direction toward the inner side of the radial direction R corresponds to the “opening direction” in the present invention has been described as an example. However, the embodiment of the present invention is not limited to this. That is, the radial second direction R2 that is the direction toward the outside of the radial direction R corresponds to the “opening direction” in the present invention, in other words, the slot 22 has an opening on the radial second direction R2 side. It is also possible to do. That is, the present invention can also be applied to an outer rotor type rotating electrical machine in which the rotor is disposed on the second radial direction R2 side of the stator.

(12) In the above embodiment, the configuration in which the stator core 2 is formed by laminating a plurality of annular plate-like magnetic plates 7 in the axial direction L has been described as an example. However, the embodiment of the present invention is not limited to this. For example, the stator core 2 may have a configuration in which a compact material formed by pressing a magnetic material powder is formed as a main component. In this case, the stator core 2 can be formed integrally in both the radial direction R and the axial direction L in addition to the circumferential direction C.

(13) In the above embodiment, the configuration in which the stator core 2 corresponds to the “core” in the present invention has been described as an example. However, the embodiment of the present invention is not limited to this. For example, the present invention is applied to a fixed field type rotating electrical machine, and the core to be wound by the coil 3 is a rotor core, that is, the rotor core corresponds to the “core” in the present invention. It is also possible. Thus, the “core” according to the present invention can be applied to an armature core other than the stator core 2.

(14) In the above embodiment, as shown in FIG. 4, a plurality of bare conductor strands are formed by forming gaps G between the bare conductor strands 41 constituting the bare conductor strand bundle 42. The configuration in which the components 41 can move relative to each other in the insulating coating material 46 has been described as an example. However, the embodiment of the present invention is not limited to this. That is, even a linear conductor in which a gap is not substantially formed between a plurality of bare conductor wires, the linear conductor can be applied to the present invention as long as the cross-sectional shape can be deformed by pressurization. Is possible.

(15) Regarding other configurations, the embodiments disclosed in this specification are merely examples in all respects, and the embodiments of the present invention are not limited thereto. In other words, configurations that are not described in the claims of the present application can be modified as appropriate without departing from the object of the present invention.

  In the present invention, a plurality of slots extending in the axial direction of a cylindrical core reference surface and having openings on one side in the radial direction of the core reference surface are distributed in the circumferential direction of the core reference surface. Suitable for a rotating electrical machine including a core and a coil having a coil side portion disposed in a slot and wound around the core, and a method of manufacturing the rotating electrical machine for manufacturing the rotating electrical machine Can be used.

2: Stator core (core)
3: Coil 4: Wire conductor 7: Magnetic plate 11: First wave winding portion 12: Second wave winding portion 21: Core reference surface 22: Slot 22b: Opening portion 30: Coil unit 41: Bare conductor wire 42 : Bare conductor wire bundle 46: Insulation coating material 60: Continuous coil part 71: Coil side part 71 a: First target coil side part 71 b: Second target coil side part 72: Crossing part 72 a: Top part 100: Rotating electrical machine A: Wire Extending direction C: circumferential direction D1: first circumferential direction width D2: second circumferential direction width E: extending direction of the coil unit L: axial direction R: radial direction R1: first radial direction (opening direction)
W1: Opening width

Claims (14)

A core that extends in the axial direction of the cylindrical core reference surface and has a plurality of slots that are distributed in the circumferential direction of the core reference surface in the opening direction side that is one side in the radial direction of the core reference surface. And a coil having a coil side portion disposed in the slot and wound around the core,
The core is integrally formed at least in the circumferential direction,
The coil is configured by combining a plurality of continuous coil portions formed by a single linear conductor that is continuous over a range of more than one round of the core while being inserted into the plurality of slots. A rotating electrical machine in which each of the continuous coil portions is arranged such that at least a part of the other continuous coil portions is different from the slots in which the coil side portions are arranged.   2. The rotating electrical machine according to claim 1, wherein the core does not have a circumferential joint that joins a portion divided in the circumferential direction in the circumferential direction.   The rotating electrical machine according to claim 1, wherein the core is formed by laminating a plurality of annular plate-like magnetic plates in the axial direction. An opening width that is a width in the circumferential direction of the opening is formed narrower than a width in the circumferential direction inside the slot;
The linear conductor is formed by covering a bundle of bare conductor strands in which a plurality of flexible bare conductor strands are gathered with a flexible insulating coating material, and having a width in the circumferential direction. 4. The rotating electrical machine according to claim 1, wherein the rotating electrical machine is deformable between a first circumferential width narrower than the opening width and a second circumferential width wider than the opening width.   5. The rotating electrical machine according to claim 1, wherein the continuous coil portion is formed so as to go around the core a plurality of times while being inserted into the plurality of slots.   The rotating electrical machine according to any one of claims 1 to 5, wherein the continuous coil portion is wound around the core so as to have a wave shape. A plurality of the continuous coil portions are arranged such that a coil unit for constituting the coil has the same positional relationship as a state in which the coil side portions arranged in the same layer in the slot are wound around the core. Is a combination of
The coil is moved to the side opposite to the opening direction by moving the coil unit arranged on the opening direction side of the core and overlapping with the core when viewed in the radial direction, so that the coil side portion The rotating electrical machine according to any one of claims 1 to 6, wherein each of the rotating electrical machines is inserted into the slot through the opening. The coil unit has a length in the extending direction that makes one or more rounds of the core in a spiral shape along the circumferential direction, and the other coil side portion in one end region in the extending direction. And the first target coil side portion that is the coil side portion disposed at a different position in the extending direction, and the other end side region of the extending direction has another coil side portion. Having a second target coil side that is the coil side placed at a different position in all and the extending direction;
The coil unit is wound around the core so that the first target coil side and the second target coil side are arranged at a position in the circumferential direction where they overlap when viewed in the radial direction. The rotating electrical machine according to claim 7.   One linear conductor constituting the continuous coil portion is inserted into a plurality of slots so as to have a wave shape, and is used as a wave winding portion that makes one or more rounds of the core. The arrangement of the coil side portions along the extending direction includes a first wave winding portion and a second wave winding portion that are opposite to each other in the circumferential direction. Rotating electric machine. The coil has a bridging part that connects a pair of the coil side parts respectively arranged in layers adjacent to each other in the different slots on the outer side in the axial direction of the core,
The top portion of the transition portion that is the portion farthest from the core in the axial direction and the top portion of the transition portion that is disposed adjacent to the transition portion in the radial direction are different from each other in the axial direction. The rotating electrical machine according to any one of claims 1 to 9, wherein the rotating electrical machine is disposed at a position. A plurality of slots extending in the axial direction of the cylindrical core reference surface and having openings on the opening direction side, which is one side in the radial direction of the core reference surface, are distributed in the circumferential direction of the core reference surface. Manufacturing for manufacturing a rotating electrical machine comprising: a core that is integrally formed in at least the circumferential direction; and a coil that has a coil side portion disposed in the slot and is wound around the core. A method,
A bare conductor strand bundle in which a plurality of flexible bare conductor strands are gathered, and a coil unit for constituting the coil is continuous over a range that goes around the core while being inserted into the plurality of slots. Are formed by combining a plurality of continuous coil portions formed by a single linear conductor formed by covering the periphery of the substrate with a flexible insulating coating material, and in the slots in the plurality of continuous coil portions. The coil sides arranged in the same layer are arranged so as to have the same positional relationship as the state wound around the core, and the coil unit is on the opening direction side of the core. A coil unit supply step for supplying the core and a position overlapping with the radial direction as viewed in the radial direction;
A coil side insertion step of moving the coil unit to the side opposite to the opening direction and inserting the plurality of coil sides of the coil unit into the slot from the opening;
The manufacturing method of the rotary electric machine which has. The coil unit supplying step is a step of forming the coil unit in a spiral shape around the axial direction and bringing the coil unit closer to the axial direction with respect to the core,
12. The method of manufacturing a rotating electrical machine according to claim 11, wherein the coil side portion insertion step is a step of sequentially inserting the coil side portions supplied in the coil unit supply step into the slot.   The method of manufacturing a rotating electrical machine according to claim 11 or 12, wherein the coil side portion inserting step includes a step of deforming a cross-sectional shape of the linear conductor before and after inserting the coil side portion into the slot.   The coil side portion insertion step includes a pressing step of pressing the coil side portion inserted into the slot to the side opposite to the opening direction to change a cross-sectional shape of the coil side portion. The method for manufacturing a rotating electrical machine according to any one of claims 13 to 14.

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