CN108702051B - Rotating electrical machine, method for manufacturing rotating electrical machine, and coil unit - Google Patents

Abstract

The invention relates to a rotating electrical machine, a method of manufacturing the rotating electrical machine, and a coil unit, which can restrain the generation of partial discharge without reducing the conductor space factor. A rotating electrical machine (1) is provided with: a stator core (22) having teeth (24); and a coil unit (30) that is attached to the tooth section (24) and that has a lead wire (31) and a resin section (36), wherein the circumferential inner surfaces (37a1, 37b1) of the circumferential inner surfaces (37a1, 37b1) and the axial inner surfaces (38a1, 38b1) of the coil unit (30) that face the tooth section (24) are configured from the resin section (36) and the lead wire (31).

Description

Rotating electrical machine, method for manufacturing rotating electrical machine, and coil unit

Technical Field

The disclosed embodiments relate to a rotating electrical machine, a method of manufacturing the rotating electrical machine, and a coil unit.

Background

Non-patent documents 1 and 2 describe techniques for suppressing the generation of partial discharge and ensuring insulation of a coil by increasing the thickness of a coating film of the coil.

Documents of the prior art

Non-patent document

Non-patent document 1: wu teng medium, his 3 name, "research on partial discharge phenomenon に Seki する in the winding wire," guhe change man-hour , guhe electro corporation, leveling to 26 years, 2 months, No. 133, p.11-18

Non-patent document 2: high zewasaki, his 5, "small ハイブリッド automobile モータステータ four open game", math model the front brush set, the public society initiative game, 5 months 2012, nos. 58-12, p.5-8

Disclosure of Invention

Problems to be solved by the invention

In the above-described conventional technique, the conductor space factor is reduced because the coating of the coil is thick.

The present invention has been made in view of the above problems, and an object thereof is to provide a rotating electrical machine, a method of manufacturing the rotating electrical machine, and a coil unit, in which generation of partial discharge can be suppressed without reducing a conductor space factor.

Means for solving the problems

In order to solve the above problem, according to an aspect of the present invention, there is provided a rotating electrical machine including: a stator core having a tooth portion; and a coil unit attached to the tooth portion, the coil unit having a lead wire and a resin portion; at least one of a plurality of surfaces of the coil unit that face the tooth portion is formed of the resin portion and the conductive wire.

Further, according to another aspect of the present invention, a manufacturing method of a rotating electrical machine is applied, the manufacturing method of a rotating electrical machine having the steps of: deforming the cross-sectional shape of the wire by pressurization to form the outer shape of the air-core coil into a predetermined shape; reinforcing the air-core coil with a resin to form a coil unit so that at least one of a plurality of surfaces on an inner peripheral side of the air-core coil is composed of a resin portion and the lead; and mounting the coil unit to a tooth portion of a stator core.

Furthermore, according to still another aspect of the present invention, there is applied a coil unit having: a wire wound in a ring shape; and an annular resin portion that reinforces the lead, at least one of the plurality of inner peripheral sides being configured by the resin portion and the lead.

Further, according to still another aspect of the present invention, there is applied a rotating electrical machine having: a stator core having a tooth portion; a coil unit attached to the tooth portion and having a lead wire and a resin portion; and a unit in which the resin portion and the conductive wire constitute at least one of a plurality of surfaces of the coil unit that face the tooth portion.

Effects of the invention

According to the rotating electrical machine and the like of the present invention, generation of partial discharge can be suppressed without lowering the conductor space factor.

Drawings

Fig. 1 is an axial sectional view showing an example of the overall structure of a rotating electric machine according to embodiment 1.

Fig. 2 is a radial cross-sectional view of section a-a in fig. 1.

Fig. 3 is a perspective view showing an example of an external configuration of the coil unit.

Fig. 4 is a process diagram illustrating an example of a method of manufacturing the rotating electric machine.

Fig. 5 is an explanatory diagram illustrating an example of the first step 1 of the method for manufacturing the rotating electric machine.

Fig. 6 is an explanatory diagram illustrating an example of the 2 nd step of the method for manufacturing the rotating electric machine.

Fig. 7 is an explanatory diagram illustrating an example of the 2 nd step of the method for manufacturing the rotating electric machine.

Fig. 8A is an explanatory diagram illustrating an example of the 2 nd step of the method for manufacturing the rotating electric machine.

Fig. 8B is an explanatory diagram illustrating an example of the 2 nd step of the method for manufacturing the rotating electric machine.

Fig. 9 is an explanatory diagram illustrating an example of the 2 nd step of the method for manufacturing the rotating electric machine.

Fig. 10 is an explanatory diagram illustrating an example of an insulator mounting step of the method of manufacturing the rotating electric machine.

Fig. 11 is an explanatory diagram illustrating an example of a coil unit arranging step in the method of manufacturing the rotating electric machine.

Fig. 12 is an explanatory diagram illustrating an example of a wiring step of the method of manufacturing the rotating electric machine.

Fig. 13 is an explanatory diagram illustrating an example of a load bracket mounting process in the method of manufacturing the rotating electric machine.

Fig. 14 is an explanatory diagram illustrating an example of a divided core mounting step of the method of manufacturing the rotating electric machine.

Fig. 15 is an explanatory diagram illustrating an example of a frame mounting process in the method of manufacturing the rotating electric machine.

Fig. 16 is an explanatory diagram showing partial discharge start voltages of the coil unit of embodiment 1 and the coil of the comparative example in a comparative manner.

Fig. 17 is a perspective view showing an example of an external structure of the toroidal coil body in a modification in which the plurality of hollow coil portions are resin-molded.

Fig. 18 is a perspective view showing an example of an external structure of the coil unit in a modified example of the resin portion made of two types of resin.

Fig. 19 is an axial cross-sectional view showing an example of the entire structure of the rotating electric machine and the structure of the coil unit in the modified example in which the coil unit is arranged in the distributed winding manner.

Fig. 20 is an axial sectional view showing an example of the overall structure of the rotating electric machine according to embodiment 2.

Fig. 21 is an explanatory view showing an example of a cover member mounting step in the method of manufacturing the rotating electric machine.

Fig. 22 is an axial cross-sectional view showing an example of the overall configuration of the rotating electric machine in a modification in which the cover member contacts the load side bracket and the frame.

Detailed Description

<1 > embodiment 1 >

Hereinafter, embodiment 1 will be described with reference to the drawings. In the following, for convenience of explanation of the structure of the rotating electric machine and the like, directions such as up, down, left, and right directions are used as appropriate, but the positional relationship of the structures of the rotating electric machine and the like is not limited.

(1-1. example of the entire Structure of the rotating electric machine)

First, an example of the overall configuration of the rotating electric machine according to embodiment 1 will be described with reference to fig. 1 and 2.

The rotating electrical machine 1 is used as a motor or a generator of a rotating type. As shown in fig. 1 and 2, the rotating electric machine 1 includes: the rotor 2 having a shaft 10, a stator 3, a frame 5, a load side bracket 6 (corresponding to an example of a bracket), a load side bearing 7, an opposite load side bracket 8, and an opposite load side bearing 9.

In the present specification, a direction along the rotation axis AX of the shaft 10 (rotor 2) (the left-right direction in fig. 1) is referred to as an "axial direction", a radial direction around the rotation axis AX is referred to as a "radial direction", and a direction along a circumference around the rotation axis AX is referred to as a "circumferential direction". In the present specification, the "load side" refers to a side where a load is attached to the rotating electrical machine 1, that is, a side where the shaft 10 protrudes in this example (the right side in fig. 1), and the "opposite load side" refers to an opposite side to the load side (the left side in fig. 1).

The frame 5 is substantially cylindrical, and the stator 3 is fixed to an inner circumferential portion 5 a. The load side bracket 6 is provided at a load side end portion (corresponding to an example of an axial end portion) of the frame 5. The load-opposite-side bracket 8 is provided at the load-opposite-side end of the frame 5. The non-load-side bracket 8 and the frame 5 are fixed to the load-side bracket 6 by bolts not shown.

The load side bearing 7 is provided on the load side bracket 6. The non-load-side bearing 9 is provided to the non-load-side holder 8. The load-side bearing 7 and the opposite-load-side bearing 9 support the shaft 10 rotatably about the rotation axis AX. An encoder 12 is provided on the opposite side of the shaft 10 from the load, and the encoder 12 detects the rotational position of the rotor 2. In the load side bracket 6, a dust seal 11 is provided on the load side of the load side bearing 7 in order to prevent foreign matter from entering the rotating electric machine 1.

The rotor 2 is fixed to the outer periphery of the shaft 10. The rotor 2 has: a substantially cylindrical rotor core 14 having an inner circumferential portion 13; a plurality of (10 poles in this example) permanent magnets 15 are embedded in the rotor core 14 in a substantially V-shape for every 1 pole. The shaft 10 is fitted to an inner peripheral portion 13 of the rotor core 14.

The stator 3 is fixed to an inner peripheral portion 5a of the frame 5 so as to surround the rotor 2 radially outward with a magnetic gap therebetween. The stator 3 has: a substantially annular stator core 22 having a plurality of (12 in this example) slots 21 arranged in a circumferential direction over the entire circumference thereof; and a plurality of (12 in this example) coil units 30 housed in the plurality of slots 21 in a concentrated winding manner. A connecting portion 16 is disposed on the opposite side to the load of the stator 3, and the connecting portion 16 is connected such that end portions 31a and 31b (see fig. 3 described later in detail) of the plurality of coil units 30 form a predetermined connecting line pattern. An external power supply, not shown, is connected to the connecting portion 16 via a lead, not shown, and power is supplied from the external power supply to the coil unit 30 via the lead and the connecting portion 16.

The stator core 22 is formed in a ring shape by arranging a plurality of (12 in this example) divided cores (also referred to as "core pieces") 23 along the entire circumference in the circumferential direction of the inner peripheral portion 5a of the frame 5. Each of the divided cores 23 has a substantially T-shaped radial cross-sectional shape in this example, and has a substantially rectangular tooth portion 24 having a radial cross-sectional shape on the radially inner side. The slot 21 is formed between the teeth 24 and 24 of the circumferentially adjacent divided cores 23 and 23. The circumferential dimensions of the teeth 24 are substantially equal in the radial direction in this example, and the grooves 21 open to the inner circumferential side in this example. Therefore, the area occupied by the coil unit 30 can be set large to be substantially the same as the inner peripheral surface of the stator core 22, and accordingly, the resistance can be reduced and heat generation can be reduced by using a thick lead wire 31 (described in detail later). Each groove 21 has a substantially trapezoidal radial cross-sectional shape that narrows radially inward in this example, and has one circumferential side region 21a and the other circumferential side region 21 b.

Each coil unit 30 is attached to the tooth portion 24 by being housed in the slot 21. Specifically, each coil unit 30 is housed so as to straddle the other side region 21b of the groove 21 located on one side in the circumferential direction and the one side region 21a of the groove 21 located on the other side in the circumferential direction, of the circumferentially adjacent grooves 21, and is attached to one tooth portion 24. That is, the plurality of coil units 30 are individually mounted for each tooth portion 24. In each coil unit 30, an insulator 18 (corresponding to an example of an insulator) made of an appropriate insulating material (for example, polyester) is attached to ensure insulation between the surface thereof and the contact portion of the divided core 23 in contact with the surface. In fig. 1, the insulator 18 is not shown.

The load side coil ends 38a (described in detail later) of the plurality of coil units 30 are fitted into substantially conical recesses 6b provided inside the annular mounting portion 6a of the load side bracket 6, whereby the plurality of coil units 30 are mounted on the load side bracket 6. At this time, axially outer surfaces 38a2 (described in detail later) of the load side coil ends 38a of the plurality of coil units 30 are in close contact with the inner wall surface 6b1 of the recess 6b via an insulator 19 made of an appropriate insulating material (e.g., polyester). That is, the insulator 19 is interposed between the load side coil end 38a of the plurality of coil units 30 and the load side bracket 6. Further, the axially outer surface 38a2 of the load side coil end 38a of the plurality of coil units 30 may be directly in close contact with the inner wall surface 6b1 of the recess 6 b. By bringing the load side coil end 38a of the coil unit 30 into close contact with the load side bracket 6, heat can be favorably conducted from the load side coil end 38a of the coil unit 30 to the load side bracket 6. As a result, a larger load current can flow than the allowable temperature of the coil unit 30, and the rated output can be improved.

The above is an example, and the structure of the rotating electric machine 1 is not limited to the example shown in fig. 1 and 2. For example, in the rotor 2, the permanent magnets 15 may be radially embedded in the rotor core 14, or the permanent magnets 15 may be fixed to the outer peripheral surface of the rotor core 14. Further, the inner circumferential side tip of the tooth portion 24 of the stator 3 may be connected in a cylindrical shape. The stator core 22 may be integrated, instead of being formed by a plurality of divided cores. Further, the groove 21 may have a radial cross-sectional shape whose circumferential dimension is substantially equal in the radial direction. The rotating electric machine 1 may have a slot combination other than the 10-pole 12-slot shown in fig. 2.

(1-2. example of the structure of coil Unit)

In general, in a coil used in a rotating electrical machine, if partial discharge occurs in a gap between leads, it is one cause of insulation breakdown, and therefore, it is preferable to increase the partial discharge start voltage as much as possible in accordance with a required withstand voltage. It is assumed that the partial discharge start voltage can be increased by thickening the coating of the wire, but in this case, the conductor space factor is decreased, and therefore, the winding resistance is increased. In addition, there is a possibility that heat dissipation is reduced, the cost of the lead wire is increased, and the like.

Therefore, in the present embodiment, the coil unit 30 is configured such that the gaps between the wires are filled with resin to reduce the gaps. An example of a detailed configuration of the coil unit 30 will be described below with reference to fig. 2 and 3.

As shown in fig. 2 and 3, in this example, the coil unit 30 has: a hollow portion 30a formed in a substantially quadrangular frame shape into which the tooth portion 24 is inserted; two coil side portions 37a and 37 b; the load side coil end 38 a; and an opposite-load side coil end 38 b. The coil side portion 37a is accommodated in the other side region 21b of the groove 21 located on one side in the circumferential direction among the adjacent grooves 21, 21 so as to extend in the axial direction. The coil side portion 37b is accommodated in the one side region 21a of the groove 21 located on the other circumferential side of the adjacent grooves 21, 21 so as to extend in the axial direction. The load side coil end 38a extends between the coil sides 37a and 37b so as to connect load side ends of the coil sides 37a and 37b to each other at a position closer to the load side than the stator core 22. The non-load-side coil end 38b extends between the coil sides 37a and 37b so as to connect load-side end portions of the coil sides 37a and 37b to each other at a position on the non-load side of the stator core 22.

The coil unit 30 has: a substantially annular air-core coil portion 35 (corresponding to an example of an air-core coil) formed of the lead wire 31 having a substantially circular cross-sectional shape (round wire) before press molding; and a substantially annular resin portion 36 that reinforces and molds the hollow coil portion 35. The coil unit is also called a molded coil. The lead wire 31 has: a linear conductor 32 made of a suitable electrically conductive material (e.g., copper); an insulating coating 33 made of an appropriate insulating material (e.g., enamel) for covering the conductor 32; and a welding coating 34 made of an appropriate welding material (for example, nylon) for coating the insulating coating (see an enlarged view of fig. 5 described later). An end 31a of one (e.g., winding start end side) and an end 31b of the other (e.g., winding end side) of the conductive wire 31 protrude from the opposite-load side coil end 38b toward the opposite-load side.

The lead wire 31 of the hollow coil portion 35 is wound in a substantially annular shape a plurality of times, and is press-molded into a predetermined shape. The cross-sectional shape of each lead wire 31 is plastically deformed into an arbitrary shape (for example, a substantially quadrangular shape, a substantially pentagonal shape, a substantially hexagonal shape, a substantially circular shape, etc.) by pressing. The hollow coil portion 35 is formed by melting the welding coating 34 of the lead wire 31, and adhering and solidifying the adjacent conductors 32 from the insulating coating 33 by welding the welding coating 34. The outer shape of the portion of the air-core coil portion 35 corresponding to the coil side portion 37a is formed to substantially match the inner shape of the other side region 21b, and the outer shape of the portion corresponding to the coil side portion 37b is formed to substantially match the inner shape of the one side region 21 a. The outer shape of the portion corresponding to the load side coil end 38a is formed to substantially match the inner shape of the recess 6b of the load side bracket 6.

Of the surfaces of the coil unit 30, two circumferentially inner surfaces 37a1, 37b1 that face the teeth 24 inserted into the hollow portion 30a in the circumferential direction are formed of a resin portion 36 and a lead wire 31. Specifically, the lead wires 31 constituting the circumferential inner surfaces 37a1, 37b1 are formed of flat portions 310, and the flat portions 310 are plastically deformed into a flat shape by the above-described pressing of the lead wires 31 laminated on the circumferential inner side (8 layers in the illustrated example) of the air-core coil portion 35. The flat portion 310 of the lead 31 is not limited to the case where the entire surface exposed from the resin portion 36 is flat, and includes the case where at least a part of the exposed surface is flat. That is, flat portions 310 of lead wire 31 are exposed at a plurality of locations on circumferential inner surfaces 37a1, 37b1, and resin portion 36 is interposed between two adjacent flat portions 310. The circumferentially inner surfaces 37a1, 37b1 are opposed surfaces on the inner circumferential side of the coil sides 37a, 37 b. As shown in the drawing, the flat portion 310 of the lead wire 31 (8 layers in the example shown in the drawing) laminated on the inner side in the circumferential direction of the air-core coil portion 35 may be partially exposed instead of being partially exposed. Any one of the circumferential inner surfaces 37a1, 37b1 may be formed of only the resin portion 36.

The flat portion 310 of the lead wire 31 is formed not only on the surface of the coil unit 30 but also inside the coil unit 30 by press molding. That is, inside the coil unit 30, the flat portions 310 of the adjacent lead wires 31 are opposed to (in contact with) each other.

On the other hand, of the surfaces of the coil unit 30, two axially inner surfaces 38a1, 38b1 that axially face the teeth 24 inserted into the hollow portion 30a are formed only by the resin portion 36. That is, the flat portion 310 of the lead wire 31 laminated on the axial inner side of the air core coil portion 35 is not exposed on the axial inner surfaces 38a1 and 38b 1. The axially inner surfaces 38a1, 38b1 are opposed surfaces on the inner peripheral side of the coil ends 38a, 38 b. Further, at least one of the circumferential inner surfaces 37a1, 37b1 and at least one of the axial inner surfaces 38a1, 38b1 may be formed of the resin portion 36 and the flat portion 310 of the lead wire 31, or at least one of the axial inner surfaces 38a1, 38b1 may be formed of the resin portion 36 and the flat portion 310 of the lead wire 31 instead of at least one of the circumferential inner surfaces 37a1, 37b 1.

The radially inner surface 30b1 of the surface of the coil unit 30 is composed of the resin portion 36 and the flat portion 310 of the lead wire 31 (double-layered in the illustrated example) laminated radially inward of the air-core coil portion 35. That is, in the radially inner surface 30b1, the flat portions 310 of the lead wire 31 are exposed at a plurality of locations, and the resin portion 36 is interposed between two adjacent flat portions 310. The radially inner surface 30b1 is formed by the radially inner surfaces of the coil side portions 37a and 37b and the radially inner surfaces of the coil end portions 38a and 38 b. As shown in the drawing, the flat portion 310 of the lead wire 31 (double-layered in the example shown in the drawing) laminated on the inner side in the radial direction of the air-core coil portion 35 may be partially exposed, but not entirely exposed. The resin portion 36 may constitute all or part of the radially inner surface 30b 1.

Similarly, the radially outer surface 30b2 of the surface of the coil unit 30 is composed of the resin portion 36 and the flat portion 310 of the lead wire 31 (4 layers in the illustrated example) laminated radially outward of the air-core coil portion 35. That is, in the radially outer surface 30b2, the flat portions 310 of the lead wire 31 are exposed at a plurality of locations, and the resin portion 36 is interposed between two adjacent flat portions 310. The radially outer surface 30b2 is formed by a radially outer surface of the coil side portion 37a, 37b and a radially outer surface of the coil end portion 38a, 38 b. As shown in the drawing, the flat portion 310 of the lead wire 31 (4 layers in the example shown in the drawing) laminated on the outer side in the radial direction of the air-core coil portion 35 may be partially exposed instead of being partially exposed. The resin portion 36 may constitute all or part of the radially outer surface 30b 2.

Of the surfaces of the coil unit 30, the two circumferential outer surfaces 37a2, 37b2 are formed only by the resin portion 36. That is, the flat portion 310 of the lead wire 31 laminated on the outer side in the circumferential direction of the air core coil portion 35 is not exposed on the two outer surfaces 37a2, 37b2 in the circumferential direction. The two circumferential outer surfaces 37a2, 37b2 are circumferential outer surfaces of the coil sides 37a, 37 b. Further, at least one of the two circumferential outer surfaces 37a2, 37b2 may be formed by the resin portion 36 and the flat portion 310 of the lead wire 31.

Similarly, two axially outer surfaces 38a2, 38b2 of the surfaces of the coil unit 30 are formed only by the resin portion 36. That is, the flat portion 310 of the lead wire 31 laminated on the axial outer side of the air core coil portion 35 is not exposed on the two axial outer surfaces 38a2 and 38b 2. The two axially outer surfaces 38a2, 38b2 are axially outer surfaces of the coil ends 38a, 38 b. Further, resin portion 36 and flat portion 310 of lead wire 31 may form at least one of two axially outer surfaces 38a2, 38b 2.

Of the surfaces of the coil unit 30, the surface constituted by the resin portion 36 and the flat portions 310 of the wires 31 is formed such that the flat surface of the resin portion 36 is substantially coplanar with the flat portions 310 of the wires 31. The surface of the resin portion 36 and the flat portion 310 of the lead wire 31 are formed to be connected to each other in a substantially planar shape or a substantially curved shape along the end surface shape of the core pin 40, the die 41, the upper punch 44, and the like, which will be described later, used in press molding. In other words, the surfaces 37a1, 37b1 on the inner side in the circumferential direction of the coil unit 30 are formed such that the surface of the resin portion 36 and the flat portion 310 of the lead wire 31 are connected to each other along the surfaces of the opposing teeth 24 in a substantially planar manner.

The insulator 18 is attached to the coil unit 30 so as to cover the circumferential inner surfaces 37a1 and 37b1, the axial inner surfaces 38a1 and 38b1, the radial inner surface 30b1, and the radial outer surface 30b2 of the surfaces of the coil unit 30. The insulator 18 is disposed between the split cores 23 and the circumferential inner surfaces 37a1 and 37b1, the axial inner surfaces 38a1 and 38b1, the radial inner surface 30b1, and the radial outer surface 30b 2. The surface of the coil unit 30 covered with the insulator 18 is not limited to the above surface.

Between the adjacent coil units 30, the resin portion 36 constituting the circumferential outside surface 37b2 of the coil side 37b of one coil unit 30 housed in the one side region 21a of the groove 21 directly contacts the resin portion 36 constituting the circumferential outside surface 37a2 of the coil side 37a of the other coil unit 30 housed in the other side region 21b of the groove 21. Further, an appropriate insulating material may be interposed between the adjacent coil units 30 and 30 so that the coil units 30 and 30 do not directly contact each other. In this case, the circumferential outer surfaces 37a2, 37b2 of the coil unit 30 may be formed of the resin portion 36 and the flat portion 310 of the lead wire 31.

By configuring the surface of the coil unit 30 as described above, the outer dimensions of the coil unit 30 are substantially equal to the outer dimensions of the air-core coil portions 35 excluding the resin portion 36. In addition, which of the surfaces of the coil unit 30 is constituted by the resin portion 36 and the flat portion 310 of the lead wire 31 can be selectively changed according to the required specification.

In addition, in the coil unit 30, as described above, the flat portions 310 of the adjacent lead wires 31 face (contact) each other, but the lead wires 31 are not completely in close contact with each other, and a gap exists. In the coil unit 30, the resin portion 36 is filled in the gap between the adjacent lead wires 31. The resin constituting the resin portion 36 is preferably a resin having high impregnability (e.g., varnish (varnish)).

The above is an example, and the configuration of the coil unit 30 is not limited to the example shown in fig. 2 and 3.

(1-3. example of method for manufacturing rotating electric machine)

Next, an example of a method for manufacturing the rotating electric machine 1 will be described with reference to fig. 4 to 15.

As shown in fig. 4, the manufacturing process of the rotating electric machine 1 includes the manufacturing process of the coil unit 30. The coil unit 30 is manufactured substantially by the following processes: a1 st step of winding the lead wire 31 to form the hollow coil portion 35; a2 nd step of press-molding the outer shape of the wound hollow coil part 35; a 3 rd step of bonding and curing the conductors 32 of the hollow coil part 35 whose outer shape is press-molded; and a 4 th step of forming the coil unit 30 by resin molding the air-core coil portions 35 in which the conductors 32 are bonded and cured to each other.

(1-3-1. 1 st step)

First, as a first step 1, the wire 31, which is a round wire, is wound around a winding tool to form the air-core coil portion 35. Specifically, as shown in fig. 5, the winding upper spacer 42 and the winding lower spacer 43 are fixed to the core pin 40, which is a winding tool also used as a press molding tool, with a predetermined gap therebetween. Then, the core pin 40 is inserted and fixed in a mold 41 as a molding tool, and the wire 31 is wound around the core pin 40 in a substantially annular shape between the winding upper spacer 42 and the winding lower spacer 43, thereby forming the air-core coil portion 35.

Fig. 5 also shows the winding order and position of the lead wire 31 when the coil unit 30 is attached to the tooth portion 24 in a cross section perpendicular to the axial direction when viewed from the opposite side to the load. The upper side of fig. 5 corresponds to the radial outer side of the air-core coil portion 35, and the lower side corresponds to the radial inner side of the air-core coil portion 35. The X mark shown in the conductive wire 31 wound around the core pin 40 indicates the conductive wire 31 wound from the opposite side to the load side, and the number shown in the conductive wire 31 indicates the winding order of the conductive wire 31 wound from the opposite side to the load side. In this example, the lead wire 31 is wound so that the number of turns of the outer layer is less than that of the inner layer by 1 turn or more. In the range other than the non-load-side end portion, the conductive wire 31 is wound in a complete alignment, and the crossing of the conductive wire 31 is performed at the non-load-side end portion. As described above, the ends 31a and 31b of the lead wire 31 are provided on the load-opposite-side end. This enables the wire 31 to be wound at high speed and neatly, and the air-core coil portion 35 can be formed. The winding method of the lead wire 31 shown in fig. 5 is an example, and is not limited to this.

(1-3-2. 2 nd step)

Next, as a2 nd step, the end face of the wound air-core coil portion 35 is pressed with a press tool. Specifically, the radially inner and outer end surfaces of the hollow coil part 35 are pressed by a curved press tool constituting a part of the cylindrical shape, and the end surfaces of the hollow coil part 35 on both sides in the circumferential direction and both sides in the axial direction are pressed by a flat press tool. An example of the press molding of the outer shape of the core coil portion 35 will be described below with reference to fig. 6 to 9.

First, as shown in fig. 6 and 7, the above-described winding upper and lower spacers 42 and 43 are removed from the core pin 40. Then, the core pin 40 is attached to the upper punch 44 and set in the molding hole 50 of the die 41 accommodating the upper punch 44, and the core pin 40 is formed with the hollow coil part 35 by annularly winding the wire 31.

The molding holes 50 are bottomed holes that are open on the front side and the rear side of the hollow coil portion 35 corresponding to both sides in the axial direction. The hole shape of the molding hole 50 has a substantially trapezoidal shape corresponding to the shape of the groove 21. That is, the molding hole 50 has: a radially inner molding surface 50a for molding the radially inner outer shape of the hollow coil portion 35; and 1 pair of molding surfaces 50b for the circumferential direction, which mold the outer shapes of both sides of the hollow coil portion 35 in the circumferential direction. The molding surface 50a is a curved surface forming a part of the cylindrical shape, specifically, a curved wall surface curved at a predetermined curvature corresponding to the outer shape of the radially inner side of the air core coil portion 35. The pair of molding surfaces 50b 1 is planar, and specifically, is an inclined wall surface rising from the right and left sides of the molding surface 50a in an outwardly open shape with an inclination corresponding to the outer shape of both sides of the hollow coil portion 35 in the circumferential direction.

The upper punch 44 has a molding surface 53a, and the molding surface 53a molds the outer shape of the hollow coil portion 35 on the radial direction outer side. The molding surface 53a is a curved surface forming a part of the cylindrical shape, specifically, a curved wall surface curved at a predetermined curvature corresponding to the outer shape of the radially outer side of the air core coil portion 35.

After the hollow coil portion 35 is set in the molding hole 50 of the die 41, the upper punch 44 is lowered by a predetermined amount with respect to the die 41 as indicated by the blank arrow in fig. 6 and 7. As the upper punch 44 is lowered, as shown in fig. 8A, the end faces on both sides in the radial direction of the hollow coil portion 35 are pressed by the upper punch 44 and the die 41, whereby the cross-sectional shape of the lead wire 31 is plastically deformed, and the outer shape of both sides in the radial direction of the hollow coil portion 35 is press-molded. Further, the end faces on both sides in the circumferential direction of the air core coil portion 35 are pressed, the cross-sectional shape of the lead wire 31 is plastically deformed, and the outer shape of both sides in the circumferential direction of the air core coil portion 35 is press-molded. When the upper punch 44 is lowered to the predetermined outline S shown in fig. 7, as shown in fig. 8B, the press molding of the outline of the 4 end surfaces on both sides in the radial direction and both sides in the circumferential direction of the hollow coil portion 35 is completed, and the outline of the 4 end surfaces on both sides in the radial direction and both sides in the circumferential direction of the hollow coil portion 35 is formed into a shape substantially matching the shape of the slot 21.

Next, as shown in fig. 9, the horizontal punch 54 is inserted into the load-side opening 55, from among the 1 pair of openings 55 formed on both the front and rear sides between the upper punch 44 and the die 41, from which the end portions 31a, 31b do not protrude, as indicated by the blank arrows in fig. 9. In the horizontal punch 54, a wall surface that contacts the load-side end surface of the air core coil portion 35 is formed as a partially conical molded surface corresponding to the inner wall surface 6b1 of the recess 6b of the load-side bracket 6.

When the horizontal punch 54 inserted into the opening 55 of the die 41 advances by a predetermined amount, the load-side end surface of the hollow coil part 35 is pressed. Thereby, the cross-sectional shape of the lead wire 31 is plastically deformed, and the outer shape of the load side of the air core coil portion 35 is press-molded into an end face having a shape corresponding to the inner wall surface 6b1 of the recess 6b of the load side holder 6. Thus, the outer shape of the air core coil portion 35 matches the inner shape of the cell 21, and the outer shape of the load side end portion of the air core coil portion 35 is formed to have an end face that can be brought into close contact with the inner wall surface 6b1 of the recess 6b of the load side holder 6. Thus, the press molding of the outer shape of the hollow coil portion 35 is completed.

(1-3-3. step 3)

Next, in the 3 rd step, the hollow coil part 35 having completed the outer shape press molding is heated in a pressurized state, and the welding coating 34 is melted. That is, for example, in a state where the molding tool is attached and pressurized, the conductor 32 of the lead wire 31 is energized from the end portions 31a, 31b protruding from the load-opposite side end portion of the air-core coil portion 35. Thereby, the welding coating 34 is melted by heat generation of the conductors 32, and the conductors 32 adjacent to each other are bonded and cured from the insulating coating 33 by thermal welding of the welding coating 34. The conductors 32 may be bonded and cured by heating the lead 31 without the welding coating 34 with, for example, a thermosetting adhesive.

(1-3-4. step 4)

Next, in the 4 th step, the coil unit 30 shown in fig. 3 is formed by reinforcing and molding the air-core coil part 35 in which the conductors 32 are bonded and cured with a resin. In this case, the circumferential inner surfaces 37a1 and 37b1, the radial inner surface 30b1, and the radial outer surface 30b2 of the surfaces of the coil unit 30 are formed by the resin portion 36 and the flat portion 310 of the lead wire 31. The other surfaces are constituted only by the resin portion 36, and the resin portion 36 is filled in the gap between the adjacent lead wires 31 in the coil unit 30. In this case, the resin 36 is formed by filling the space inside the coil unit 30 with resin (e.g., varnish) having high impregnation property by, for example, vacuuming the resin, and then curing the resin (e.g., heat curing). In order to mold the molded outer shape, a tool used in the pressing step may be used as it is in the molding step, or a part of the tool used in the pressing step may be used as a tool in the molding step.

The ratio of the resin portion 36 to the lead wire 31 in the coil unit 30 manufactured as described above is as follows. That is, for example, when the conductor space factor in the groove 21 of the coil unit 30 is set to 90% or more and the conductor space factor in the coil end portion is set to 80% or more, the area ratio of the total area of the resin portion 36 to the total area of the lead wire 31 in the cross-sectional shape of the coil side portions 37a and 37b as the portions to be mounted in the groove 21 is set to 10% or less. In the cross-sectional shape of the coil ends 38a, 38b, the area ratio of the total area of the conductive resin portion 36 to the total area of the lead wire 31 is 20% or less. The area ratio described above is an example, and is a value corresponding to a design value of the conductor space factor of the coil unit 30.

(1-3-5. subsequent steps)

Then, as shown in fig. 4 and 10, the insulator 18 is attached to the coil unit 30. That is, the insulator 18 is attached to the coil unit 30 so as to cover the circumferential inner surfaces 37a1, 37b1, the axial inner surfaces 38a1, 38b1, the radial inner surface 30b1, and the radial outer surface 30b2 of the surfaces of the coil unit 30. In the example shown in fig. 10, the insulator 18 is composed of an insulator 18a attached to the radially inner side of the coil unit 30 and an insulator 18b attached to the radially outer side of the coil unit 30. In addition, the insulator 18 may be integral. At this time, the circumferential inner surfaces 37a1, 37b1 and the axial inner surfaces 38a1, 38b1 of the coil unit 30 and the insulator 18 are bonded with an adhesive.

Then, as shown in fig. 4 and 11, the plurality of coil units 30 to which the insulators 18 are respectively attached are arranged in a substantially ring shape (substantially cylindrical shape). In this case, for example, when high insulation reliability is required, an appropriate insulating material may be provided between the adjacent coil units 30, and in this case, high insulation reliability can be ensured as required.

As shown in fig. 4 and 12, a substantially disc-shaped wiring board 16A is attached to an axially outer surface 38b2 of the coil end portion 38b on the opposite-load side of the plurality of coil units 30 arranged in a substantially annular shape, and the wiring board 16A has a plurality of lead-out holes (not shown) through which the end portions 31a and 31b of the plurality of coil units 30 are inserted in a substantially axial direction. The wiring substrate 16A is formed with the wiring portions 16 by connecting the end portions 31a and 31b so as to form a predetermined wiring pattern. This step may be performed after the tooth portions 24 of the plurality of divided cores 23 are attached to the plurality of coil units 30.

Then, as shown in fig. 4 and 13, the load side coil end portions 38a of the plurality of coil units 30 on which the linking portions 16 are formed are fitted into the concave portions 6b of the mounting portions 6a of the load side bracket 6, and the plurality of coil units 30 are mounted on the load side bracket 6. At this time, the axially outer surface 38a2 of the load side coil end 38a of the coil unit 30 is in close contact with the inner wall surface 6b1 of the recess 6b via the insulator 19 (see fig. 1). In this case, when an insulator (for example, aluminum nitride, alumina, or the like) having high thermal conductivity is used as the insulator 19, the thermal conductivity from the coil unit 30 to the load side bracket 6 can be improved. Further, the axially outer surface 38a2 of the load side coil end 38a of the coil unit 30 may be in direct contact with the inner wall surface 6b1 of the recess 6 b. This step may be performed after the tooth portions 24 of the plurality of divided cores 23 are attached to the plurality of coil units 30.

Then, as shown in fig. 4 and 14, the tooth portions 24 of the plurality of divided cores 23 are inserted into the hollow portions 30a of the plurality of coil units 30 attached to the load side bracket 6 from the outside in the radial direction. Thereby, the plurality of teeth 24 of the stator core 22, which is the plurality of divided cores 23, are mounted on the plurality of coil units 30. In other words, it can be said that the plurality of coil units 30 are attached to the plurality of teeth 24 of the stator core 22. In this case, the insulator 18 and the tooth 24, which are attached to the coil unit 30 and bonded with an adhesive, are bonded with an adhesive. Thereby, the circumferential inner surfaces 37a1, 37b1 and the axial inner surfaces 38a1, 38b1 of the coil unit 30 are bonded to the teeth 24.

Then, as shown in fig. 4 and 15, the plurality of coil units 30 to which the stator core 22 is attached are inserted into the inner peripheral portion 5a of the frame 5 from the load side, and the frame 5 is attached to the attachment portion 6a of the load side bracket 6. Then, the shaft 10, the rotor 2, and the like are inserted and fixed inside the stator core 22. Then, the opposite-load side bracket 8 is attached to the opposite-load side end portion of the frame 5, and the opposite-load side bracket 8 and the frame 5 are fastened to the load side bracket 6 by bolts. Thereby, the rotating electric machine 1 is completed.

In addition, as an example, the method of manufacturing the rotating electric machine 1 may include the steps performed in time series in the above-described order, and may include the steps performed in parallel or individually, even if the steps are not necessarily performed in time series. In addition, in the steps performed in time series, the order can be changed as appropriate according to the circumstances.

(1-4. example of effects of embodiment 1)

The rotating electric machine 1 of the present embodiment described above achieves the following effects.

In the rotating electric machine 1, at least one of the surfaces 37a1, 37b1, 38a1, and 38b1 (in the above example, the surfaces 37a1 and 37b1 on the inner side in the circumferential direction) of the coil unit 30 attached to the tooth portion 24 of the stator core 22, which faces the tooth portion 24, is composed of the resin portion 36 and the lead wire 31. In the coil unit 30 having such a configuration, the space between the leads 31 can be reduced by filling resin. As a result, the partial discharge start voltage can be increased without increasing the thickness of the coating of the lead wire 31.

Fig. 16 shows, by way of comparison, partial discharge start voltages of the coil unit 30 of the present embodiment and a coil of a comparative example (for example, an air-core coil composed only of the unmolded lead wire 31). In the example shown in fig. 16, the partial discharge start voltages of 10 coil units 30 of the present embodiment and 10 coils of the comparative example are shown in a comparative manner, and in any comparison, the partial discharge start voltage of the coil unit 30 of the present embodiment is much higher than the partial discharge start voltage of the coil of the comparative example.

As described above, according to the present embodiment, the partial discharge start voltage can be increased without increasing the thickness of the coating of the lead wire 31, and therefore, the occurrence of partial discharge can be suppressed without decreasing the conductor space factor. Further, heat dissipation can be improved more than in the case where the coating of the lead 31 is thick, and the cost of the lead 31 can be reduced.

In the present embodiment, in particular, the lead wire 31 constituting the at least one surface (in the above example, the circumferential inner surfaces 37a1, 37b1) of the coil unit 30 has two adjacent flat portions 310, and the at least one surface of the coil unit 30 is configured such that the resin portion 36 is interposed between the two flat portions 310. The coil unit 30 is obtained by molding the air-core coil portion 35 with resin, and the air-core coil portion 35 is formed into a predetermined shape by deforming the cross-sectional shape of the lead wire 31 by pressing. This is because, when the outer shape of the core coil portion 35 is press-molded, the flat portion 310 of the lead wire 31 does not come into close contact with the flat portion 310, and the resin enters the gap. Therefore, the coil unit 30 having a high space factor can be realized.

In the present embodiment, in particular, the circumferential inner surfaces 37a1 and 37b1 are formed by the resin portion 36 and the flat portion 310 of the lead wire 31. This makes it possible to substantially equalize the inner dimensions of the coil unit 30 with those of the air-core coil part 35 before molding. This allows the coil unit 30 and the coil without molding to be replaced without changing the size of the tooth portion 24 according to the required specifications, and the insulator 18 can be shared.

In the present embodiment, the resin portion 36 is filled in the gaps between the lead wires 31 in the coil unit 30. This allows the gaps between the leads 31 in the coil unit 30 to be filled with resin, thereby reducing the gaps. As a result, the generation of partial discharge can be suppressed without lowering the conductor space factor. Further, heat dissipation can be improved more than in the case where the coating of the lead 31 is thick, and the cost of the lead 31 can be reduced.

In the present embodiment, in particular, the insulator 18 is provided between the teeth 24 and the plurality of surfaces 37a1, 37b1, 38a1, 38b1 of the coil unit 30 that face the teeth 24. Accordingly, the surface facing the tooth portion 24 is formed of the resin portion 36 and the flat portion 310 of the lead wire 31, and as a result, insulation of the coil unit 30 can be secured even when the lead wire 31 is exposed from the resin portion 36.

In the present embodiment, in particular, the coil unit 30 is mounted individually for each tooth portion 24. Thus, the rotating electric machine 1 in which the coil unit 30 is arranged in the concentrated winding manner can be realized, and the generation of partial discharge can be suppressed without lowering the conductor space factor.

In the present embodiment, in particular, the outer dimensions of the coil unit 30 are substantially equal to the outer dimensions of the air-core coil portion 35 formed by annularly winding the lead wire 31. Accordingly, the coil unit 30 can be replaced with the unmolded air-core coil according to the required specification, and therefore, the rotating electric machine 1 that can flexibly meet the required specification can be realized.

In the rotating electrical machine 1 manufactured by the manufacturing method of the present embodiment, the outer shape of the air-core coil portion 35 is formed into a predetermined shape by deforming the cross-sectional shape of the lead wire 31 by pressing, and therefore, the coil unit 30 having a high space factor can be realized.

Note that, the rotary electric machine 1 according to the present embodiment is not fixed with resin after the air-core coil portion 35 is attached to the tooth portion 24, but is attached to the tooth portion 24 after the air-core coil portion 35 is reinforced with resin to form the coil unit 30. Therefore, a gap may be formed between the coil unit 30 and the tooth portion 24 to generate looseness or the like.

Therefore, in the manufacturing method of the present embodiment, in particular, since the coil unit 30 is bonded to the tooth portion 24 using the adhesive, it is possible to prevent the coil unit 30 from being displaced or positionally displaced with respect to the tooth portion 24, and to prevent noise and vibration from being generated due to backlash.

In the manufacturing method of the present embodiment, in particular, the end portions 31a and 31b of the lead wires 31 of the plurality of coil units 30 are connected so as to form a predetermined connection pattern. Since the ends 31a and 31b of the lead wire 31 are wired after the plurality of coil units 30 are attached to the teeth 24 of the stator core 22, the wiring work can be performed in a state where the positions of the coil units 30 are fixed, and thus, the workability can be improved.

(1-5. variants, etc.)

Embodiment 1 is not limited to the above, and various modifications can be made without departing from the spirit and scope of the invention. Hereinafter, such a modification will be described.

(1-5-1. case of resin-molding a plurality of hollow coil parts)

As shown in fig. 17, in the present modification, the plurality of air-core coil portions 35 are reinforced and molded with resin in a state of being arranged in a substantially annular shape (substantially cylindrical shape), and thereby a plurality of coil unit portions 30 '(corresponding to an example of a coil unit) are integrally formed as an annular coil body 60 connected in a substantially annular shape (substantially cylindrical shape) by a resin portion 36'.

The annular coil body 60 has the hollow portion 30a at the molding position of the air-core coil portion 35, and the hollow portion 30a is inserted with one of the tooth portions 24 from the radial outside. The annular coil body 60 has the above-described circumferentially inner surfaces 37a1, 37b1 that oppose one tooth portion 24 in the circumferential direction, and the above-described axially inner surfaces 38a1, 38b1 that oppose one tooth portion 24 in the axial direction, at the molding position of the air-core coil portion 35. That is, the annular coil body 60 has 1 set of the circumferential inner surfaces 37a1, 37b1 and the axial inner surfaces 38a1, 38b1, and has a plurality of sets of these circumferential inner surfaces 37a1, 37b1 and axial inner surfaces 38a1, 38b1 in the circumferential direction for each tooth 24. In the annular coil body 60, the circumferential inner surfaces 37a1, 37b1 of each group are formed of the resin portion 36 'and the flat portion 310 of the lead wire 31, and the axial inner surfaces 38a1, 38b1 of each group are formed of only the resin portion 36'. In fig. 17, the flat portions 310 of the lead wires 31 exposed on the inner surfaces 37a1 and 37b1 in the circumferential direction of each group are not shown.

According to the present modification, the following effects are achieved. That is, in the rotary electric machine 1, as in the above-described embodiment 1, there are a case where a plurality of coil units 30 are formed by molding each of the air-core coil parts 35 with resin, and a case where a plurality of coil unit parts 30 'are connected in a ring shape by the resin part 36' to form the ring-shaped coil body 60 integrally. In the present modification, in the case of having the above-described annular coil body 60, the rotating electrical machine 1 capable of suppressing the generation of partial discharge without lowering the conductor space factor can be realized.

(1-5-2. case where the resin portion is composed of two kinds of resins)

As shown in fig. 18, the coil unit 30 "of the present modification example includes the 1 st resin portion 36a and the 2 nd resin portion 36b as the resin portions 36" for reinforcing the air-core coil portion 35. The 1 st resin portion 36a is provided so as to cover the axially outer surface of the load side coil end 38a ″ which is a direct or indirect contact portion with the load side bracket 6 of the coil unit 30 ″. The 1 st resin portion 36a may be provided in a portion of the coil unit 30 ″ other than the portion in contact with the load side bracket 6. The 2 nd resin portion 36b constitutes a portion of the resin portion 36 ″ other than the 1 st resin portion 36 a. The 1 st resin portion 36a is made of a resin having higher thermal conductivity than the 2 nd resin portion 36b (hereinafter referred to as "1 st resin" as appropriate). As the resin constituting the 2 nd resin part 36b (hereinafter, appropriately referred to as "2 nd resin"), a resin having a high impregnation property (for example, varnish) is preferable.

In the manufacturing process of the coil unit 30 ″, the 1 st resin is applied to the portion of the air-core coil portion 35 corresponding to the load-side coil end 38a ″, which is obtained by bonding and curing the conductors 32 as described above (or may be filled in a mold in advance). Then, after the air core coil part 35 is mounted on a mold, the 2 nd resin is vacuum cast, and the air core coil part 35 is reinforced and molded with the 1 st resin and the 2 nd resin, thereby forming the coil unit 30 ″ shown in fig. 18. That is, of the surfaces of the coil unit 30 ", the portions of the circumferential inner surfaces 37a1 and 37b1, the radial inner surface 30b1 other than the load side coil end 38 a", and the radial outer surface 30b2 other than the load side coil end 38a "are constituted by the 2 nd resin portion 36b and the flat portion 310 of the lead wire 31. In addition, of the other surfaces, the portion corresponding to the load side coil end 38a ″ is formed only by the 1 st resin portion 36a, and the portion other than the portion corresponding to the load side coil end 38a ″ is formed only by the 2 nd resin portion 36 b. Further, inside the coil unit 30 ″, the 2 nd resin portion 36b is filled in the gap between the adjacent lead wires 31.

According to the present modification, by forming the resin portion 36 ″ of the coil unit 30 ″ from two types of resin portions, i.e., the 1 st resin portion 36a and the 2 nd resin portion 36b, functions other than the function of suppressing partial discharge by the resin portion 36 ″ can be enhanced (e.g., a heat radiation function).

In the present modification, the 1 st resin portion 36a is formed using a resin having higher thermal conductivity than the 2 nd resin portion 36 b. This enables the heat of the coil unit 30 ″ to be efficiently transferred to the load side bracket 6 via the 1 st resin portion 36a, thereby further improving heat dissipation.

(1-5-3. case where coil units are arranged in a distributed winding manner)

As shown in fig. 19, a rotating electrical machine 110 according to the present modification includes a stator 130 and a rotor 120. The stator 130 is provided on the inner periphery of the frame 111. The rotor 120 is disposed on the inner circumferential side of the stator 130 and is provided on the outer circumference of the shaft 116. A load side bracket 112 (corresponding to an example of a bracket) is provided on the load side of the frame 111. An opposite-load side bracket (not shown) is provided on the opposite-load side of the frame 111.

The rotor 120 has: a rotor core 122 disposed to face the inner circumferential surface of the stator 130 in the radial direction with a magnetic gap therebetween; and a multipolar (8-pole in this example) permanent magnet 123 embedded in the rotor core 122 in a V-shape for every 1 pole. An inner peripheral portion 121 is formed in the rotor core 122, and the inner peripheral portion 121 of the rotor core 122 is fixed to the outer peripheral surface of the shaft 116 by being fitted to the shaft 116.

The stator 130 has: a substantially annular stator core 132 in which a plurality of (48 in this example) slots 131 are arranged over the entire circumference of the rotor 120 in the circumferential direction around the rotation axis AX 1; and a plurality of (48 in this example) coil units 141 housed in the plurality of slots 131 in a concentrated winding manner (double-layer lap winding manner in this example). A connecting portion (not shown) that connects one end portion and the other end portion (not shown) of the lead wires 31 of the plurality of coil units 141 so as to form a predetermined connecting line pattern is arranged on the opposite side to the load of the stator 130. The load side coil ends (not shown) of the plurality of coil units 141 are attached to the load side bracket 112.

The stator core 132 is formed into a substantially annular shape by arranging a plurality of (48 in this example) split cores 133 over the entire circumference in the circumferential direction along the inner circumference of the frame 111. Each of the divided cores 133 has a substantially T-shaped radial cross-sectional shape in this example, and has a substantially rectangular tooth portion 134 having a radial cross-sectional shape on the radially inner side. The slot 131 is formed between the teeth 134 and 134 of the circumferentially adjacent divided cores 133 and 133. The circumferential dimensions of the teeth 134 are substantially equal in the radial direction in this example, and the grooves 131 are open to the inner circumferential side in this example. Each groove 131 has a substantially trapezoidal radial cross-sectional shape that narrows radially inward in this example, and has a radially inner region 131a and a radially outer region 131 b.

Each coil unit 141 is attached to the tooth portion 134 by being housed in the slot 131. Specifically, each coil unit 141 is housed so as to straddle an inner region 131a of a groove 131 located on one circumferential side and an outer region 131b of a groove 131 located on the other circumferential side, among grooves 131 and 131 that are a plurality of (6 in this example) grooves spaced apart in the circumferential direction. Thus, each coil unit 141 is attached so as to straddle a plurality of (5 in this example) teeth 134. In each coil unit 141, an insulator 18A (corresponding to an example of an insulator) made of an appropriate insulating material (for example, polyester) is attached to ensure insulation between the surface thereof and the portion of the stator core 132 in contact with the surface.

The coil unit 141 includes two coil sides 150 and 151, a load side coil end (not shown), and a load opposite side coil end (not shown). The coil side 150 extends in the axial direction and is accommodated in the inner region 131a of the groove 131 located on one side in the circumferential direction among the grooves 131 and 131 that are separated by 6 grooves. The coil side 151 extends in the axial direction at a position spaced apart from the coil side 150 by a predetermined distance X in the substantially circumferential direction, and is accommodated in the outer region 131b of the groove 131 located on the other circumferential side among the 6-groove-spaced grooves 131 and 131. The load side coil end extends between the coil sides 150 and 151 so as to connect the load side ends of the coil sides 150 and 151 to each other at a position closer to the load side than the stator core 132. The load-opposing-side coil end portion extends between the coil side portions 150 and 151 so as to connect load-opposing-side end portions of the coil side portions 150 and 151 to each other at a position on the opposite side of the load from the stator core 132.

The coil unit 141 includes: a substantially annular air-core coil portion 142 (corresponding to an example of an air-core coil) formed of the lead wire 31; and a substantially annular resin portion 143 that reinforces and molds the hollow coil portion 142. One (e.g., winding start end side) end and the other (e.g., winding end side) end of the conductive wire 31 protrude from the load-opposite side coil end toward the load-opposite side.

The hollow coil portion 142 is formed by winding the lead wire 31 in a substantially annular shape a plurality of times, and plastically deforming the cross-sectional shapes of a plurality of portions of the lead wire 31 into arbitrary shapes (for example, substantially quadrangular, substantially pentagonal, substantially hexagonal, substantially circular, etc.) by pressing, thereby forming the outer shape into a predetermined shape. The welding coating 34 of the lead wire 31 is melted, and the conductors 32 adjacent to each other are bonded and cured from the insulating coating 33 by welding of the welding coating 34, thereby forming the air-core coil portion 142. Specifically, the outer shape of the portion of the air-core coil portion 142 corresponding to the coil side 150 is formed to substantially match the inner shape of the inner region 131a, and the outer shape of the portion corresponding to the coil side 151 is formed to substantially match the inner shape of the outer region 131 b. The outer shape of the portion of the air core coil portion 142 corresponding to the load side coil end is formed to substantially match the inner shape of the mounting recess (not shown) of the load side bracket 112.

Of the surfaces of the coil unit 141, two circumferentially inner surfaces 1501, 1511 facing the tooth portions 134 in the circumferential direction are formed by the resin portion 143 and the flat portion 310 of the lead wire 31 laminated on the circumferentially inner side of the air core coil portion 142. That is, the lead 31 constituting the circumferential inner surfaces 1501 and 1511 has two adjacent flat portions 310, and the circumferential inner surfaces 1501 and 1511 are configured such that the resin portion 143 is interposed between the two flat portions 310. The circumferentially inner surfaces 1501, 1511 are opposed surfaces on the inner circumferential side of the coil sides 150, 151. As shown in the drawing, the flat portion 310 of the lead wire 31 laminated on the inner side in the circumferential direction of the air-core coil portion 142 may be partially exposed instead of being partially exposed. Further, any one of the surfaces 1501 and 1511 on the inner side in the circumferential direction may be constituted only by the resin portion 143.

Similarly, of the surfaces of the coil unit 141, two circumferential outer surfaces 1502 and 1512 facing the tooth portions 134 in the circumferential direction are formed of the resin portion 143 and the flat portion 310 of the lead wire 31 laminated on the circumferential outer side of the air-core coil portion 142. That is, the lead 31 constituting the circumferential outer surfaces 1502, 1512 has two adjacent flat portions 310, and the circumferential outer surfaces 1502, 1512 are configured such that the resin section 143 is interposed between the two flat portions 310. The circumferential outer surfaces 1502 and 1512 are outer circumferential surfaces of the coil sides 150 and 151. As shown in the drawing, the flat portion 310 of the lead wire 31 laminated on the outer side in the circumferential direction of the air-core coil portion 142 may be partially exposed, instead of being partially exposed. Further, any one of the circumferential outer surfaces 1502, 1512 may be constituted only by the resin portion 143.

The flat portion 310 of the lead wire 31 is formed not only on the surface of the coil unit 141 but also inside the coil unit 141 by press molding. That is, inside the coil unit 141, the flat portions 310 of the adjacent wires 31 are opposed to (in contact with) each other.

On the other hand, of the surfaces of the coil unit 141, two axially inner surfaces (not shown) that axially face the teeth 134 are formed only by the resin portion 143. That is, the flat portions 310 of the lead wires 31 laminated on the axially inner sides of the air core coil portions 142 are not exposed on both axially inner surfaces. The two axially inner surfaces are inner circumferential side opposing surfaces of the two coil ends. Further, at least one of the circumferential inner surfaces 1501 and 1511 and the circumferential outer surfaces 1502 and 1512 and at least one of the two axially inner surfaces may be formed of the resin portion 143 and the flat portion 310 of the lead wire 31, or at least one of the two axially inner surfaces may be formed of the resin portion 143 and the flat portion 310 of the lead wire 31 instead of at least one of the circumferential inner surfaces 1501 and 1511 and the circumferential outer surfaces 1502 and 1512.

Of the surfaces of the coil unit 141, two axially outer surfaces (not shown) are formed only by the resin portion 143. That is, the flat portions 310 of the lead wires 31 laminated on the axially outer sides of the air core coil portions 142 are not exposed on both axially outer surfaces. The two axially outer surfaces are axially outer surfaces of the two coil ends. Further, at least one of the circumferential inner surfaces 1501 and 1511 and the circumferential outer surfaces 1502 and 1512 and at least one of the two axial outer surfaces may be formed of the resin portion 143 and the flat portion 310 of the lead wire 31, or at least one of the two axial outer surfaces may be formed of the resin portion 143 and the flat portion 310 of the lead wire 31 instead of at least one of the circumferential inner surfaces 1501 and 1511 and the circumferential outer surfaces 1502 and 1512.

Similarly, a radially inner surface 1411 of the surface of the coil unit 141 is formed only by the resin portion 143. That is, the flat portion 310 of the lead wire 31 laminated on the radially inner side of the air core coil portion 142 is not exposed on the radially inner surface 1411. The radially inner surface 1411 is formed of the radially inner surfaces of the coil side portions 150 and 151 and the radially inner surfaces of the coil end portions. Resin portion 143 and flat portion 310 of lead wire 31 may form all or a part of radially inner surface 1411.

Similarly, a radially outer surface 1412 of the surface of the coil unit 30 is constituted only by the resin portion 143. That is, the flat portion 310 of the lead wire 31 laminated radially outward of the air-core coil portion 142 is not exposed on the radially outer surface 1412. The radially outer surface 1412 includes radially outer surfaces of the coil side portions 150 and 151 and radially outer surfaces of the coil end portions. The resin portion 143 and the flat portion 310 of the lead 31 may form all or a part of the radially outer surface 1412.

Of the surfaces of the coil unit 141, the surface constituted by the resin portion 143 and the flat portion 310 of the lead wire 31 is formed such that the flat surface of the resin portion 143 is substantially coplanar with the flat portion 310 of the lead wire 31. The surface of the resin portion 143 and the flat portion 310 of the lead 31 are connected to each other to form a substantially planar shape or a substantially curved shape. In other words, of the circumferential inner surfaces 1501 and 1511 and the circumferential outer surfaces 1502 and 1512 of the coil unit 141, the surface of the resin portion 143 and the flat portion 310 of the lead wire 31 are formed so as to be connected substantially planarly along the surfaces of the opposing tooth portions 134.

Between the coil units 141, 141 separated by 6 coil units, the resin portion 143 constituting the radially outer surface 1412 of the coil side portion 150 of one coil unit 141 housed in the inner region 131a of the groove 131 directly contacts the resin portion 143 constituting the radially inner surface 1411 of the coil side portion 151 of the other coil unit 141 housed in the outer region 131b of the groove 131. Further, an appropriate insulating material may be interposed between the coil units 141, 141 that are separated by 6 coil units, so that the coil units 141, 141 do not directly contact each other. In this case, the radially inner and outer surfaces 1411, 1412 of the coil unit 141 may be formed of the resin portion 143 and the flat portion 310 of the lead wire 31.

By configuring the surface of the coil unit 141 as described above, the outer dimension of the coil unit 141 is substantially equal to the outer dimension of the air-core coil part 142 excluding the resin part 143. In addition, which surface of the coil unit 141 is constituted by the resin portion 143 and the flat portion 310 of the lead wire 31 can be selectively changed according to the required specification.

Further, inside the coil unit 141, the resin portion 143 is also filled in the gap between the adjacent lead wires 31. As the resin constituting the resin portion 143, a resin having high impregnation property (for example, varnish or the like) is preferable.

The ratio of the resin portion 143 to the lead wire 31 in the coil unit 141 having the above-described configuration is the same as that of the coil unit 30. The above is an example, and the configurations of the rotating electric machine 110 and the coil unit 141 are not limited to the example shown in fig. 19.

According to the present modification described above, as in embodiment 1, the partial discharge start voltage can be increased without making the coating of the lead wire 31 thick, and therefore, the occurrence of partial discharge can be suppressed without lowering the conductor space factor. Further, heat dissipation can be improved more than in the case where the coating of the lead 31 is thick, and the cost of the lead 31 can be reduced. In the present modification, the coil unit 141 is attached so as to straddle the plurality of teeth 134. Thus, in the rotating electrical machine 110 in which the coil units 141 are arranged in the distributed winding manner, the rotating electrical machine 110 in which the occurrence of partial discharge can be suppressed without lowering the conductor space factor can be realized.

<2 > embodiment 2 >

Next, embodiment 2 will be described with reference to the drawings.

(2-1. example of the entire Structure of the rotating electric machine)

First, an example of the overall configuration of the rotating electric machine according to embodiment 2 will be described with reference to fig. 20 and 21. The same components as those in fig. 1 and 13 are denoted by the same reference numerals, and description thereof will be omitted as appropriate.

As in embodiment 1 described above, when the load side coil end 38a of the coil unit 30 is brought into contact with the load side bracket 6 via the insulator 19 or directly, it is difficult to bring the load side coil end 38a into close contact with the load side bracket 6 at a high level due to dimensional tolerance or the like. In order to ensure insulation between the load side coil end 38a and the load side bracket 6, it is preferable to prevent damage to the insulating coating 33 of the lead wire 31 of the coil unit 30, which requires labor. When the specification of the coil unit 30 is changed, the shape of the load side bracket 6 needs to be changed, which leads to an increase in cost.

Therefore, in the rotating electric machine 1A according to embodiment 2, as shown in fig. 20, a cover member 70 is provided between the load side coil end 38a and the load side bracket 6. The cover member 70 is disposed so as to cover at least a part (in this example, the axial load side end portion and the radial outer side end portion) of the load side coil end portion 38a of the coil unit 30, and is in contact with the load side bracket 6.

As shown in fig. 20 and 21, the cover member 70 has a circular plate portion 71 and a cylindrical portion 72. The circular plate portion 71 is an annular plate member formed to have a larger plate thickness on the center side, and has a tapered surface 73 on the opposite side to the load. The tapered surface 73 faces and contacts the axially outer surface 38a2 of the surface of the coil unit 30 (load side coil end 38 a). The surface 74, which is the surface on the load side of the disc portion 71, is perpendicular to the axial direction and contacts the inner wall surface 6b2 of the recess 6b of the load side bracket 6. The inner peripheral surface 75 of the disc portion 71 is fitted into the annular protrusion 6c on the inner peripheral side of the recess 6b of the load side bracket 6.

The cylindrical portion 72 is a cylindrical member provided on the outer circumferential end of the disc portion 71, and is provided so as to project from the disc portion 71 toward the opposite side to the load. The inner circumferential surface 72a of the cylindrical portion 72 faces and contacts the radially outer surface of the load-side coil end 38a of the radially outer surface 30b2 of the coil unit 30. The outer peripheral surface 72b of the cylindrical portion 72 is fitted into the concave portion 6b of the load side bracket 6.

The material of the cover member 70 is not particularly limited, and may be made of metal such as aluminum, for example. In this case, an insulating film (e.g., an anodic oxide film) is formed on at least the surface facing (in contact with) the load side coil end 38a, that is, the tapered surface 73 and the inner peripheral surface 72 a. The insulating coating may be formed to reach at least a part of the inner circumferential surface 75 and the outer circumferential surface 72b of the cover member 70. This makes it easy to ensure a creepage distance between the lead wire 31 and the cover member 70. The cover member 70 may be made of ceramic or resin, which is an insulator. In this case, a resin having improved thermal conductivity by adding a filler such as carbon nanotubes may be used.

In the present modification, the circumferential inner surfaces 37a1, 37b1, the radial inner surface 30b1, the radial outer surface 30b2, and the axial outer surface 38a2 of the surfaces of the coil unit 30 are formed of the resin portion 36 and the lead wire 31. The axially outer surface 38a2 of the coil unit 30 is formed such that the flat surface of the resin portion 36 is substantially coplanar with the flat portion 310 of the lead wire 31. The surface of the resin portion 36 and the flat portion 310 of the lead wire 31 are formed to be connected to each other along the tapered surface 73 of the cover member 70 facing each other in a substantially planar or substantially curved shape. Similarly, the radially outer surface of the load side coil end 38a out of the radially outer surface 30b2 of the coil unit 30 is formed such that the flat surface of the resin portion 36 is substantially coplanar with the flat portion 310 of the lead wire 31. The surface of the resin portion 36 and the flat portion 310 of the lead wire 31 are formed to be connected to each other along the inner peripheral surface 72a of the cover member 70 facing each other in a substantially planar or substantially curved shape.

The rotating electric machine 1A is similar to the rotating electric machine 1 except for the above-described configuration.

(2-2. example of method for manufacturing rotating electric machine)

An example of a method of manufacturing the rotating electric machine 1A according to the present modification will be described with respect to a portion different from the rotating electric machine 1. As shown in fig. 21, in the manufacturing process of the rotating electric machine 1A, the cover member 70 is attached to the recess 6b of the load-side bracket 6 before the load-side coil end portions 38a of the plurality of coil units 30 arranged in a substantially annular shape are attached to the load-side bracket 6. Then, the load side coil end 38a of the coil unit 30 is fitted to the cover member 70 attached to the load side bracket 6, whereby the plurality of coil units 30 are attached to the load side bracket 6.

The rotating electric machine 1A is manufactured by the same method as the rotating electric machine 1.

(2-3. example of Effect of embodiment 2)

According to embodiment 2 described above, the following effects are achieved. That is, in the rotating electric machine 1A, the cover member 70 is disposed between the load side bracket 6 and the load side coil end 38a, and the cover member 70 covers at least a part of the load side coil end 38a and is in contact with the load side bracket 6. Since the cover member 70 can be freely designed in shape corresponding to the shapes of the load side coil end 38a and the load side bracket 6, it can be highly closely attached to both the load side coil end 38a and the load side bracket 6. Therefore, the heat of the coil unit 30 is efficiently transferred to the load-side bracket 6 via the cover member 70, and thus the heat dissipation performance can be improved. Further, by constituting the cover member 70 with an insulator or providing an insulating coating on the cover member 70, insulation can be secured regardless of whether the lead wire 31 of the coil unit 30 is damaged by the coating. Even when the specification of the coil unit 30 is changed, the cover member 70 can be changed to cope with the change, and the housings can be shared, so that the cost can be reduced. In addition, the cover member 70 is easier to machine than the load side bracket 6 with respect to the conical surface (tapered surface) to which the load side coil end 38a is in close contact, and the concave portion 6b of the load side bracket 6 is only required to be subjected to planar machining by using the cover member 70.

In the present embodiment, in particular, the axially outer surface 38a2 and the radially outer surface of the load side coil end 38a are formed by the resin portion 36 and the lead wire 31, and the cover member 70 is disposed in contact with the axially outer surface 38a2 and the radially outer surface of the load side coil end 38a, respectively.

This can increase the contact area between the cover member 70 and the lead wire 31 constituting the coil unit 30. Further, since the cover member 70 covers the axial end portion and the radial outer end portion of the load side coil end portion 38a, the heat of the coil unit 30 can be dissipated in both the axial direction and the radial direction via the cover member 70. Therefore, heat dissipation can be further improved.

(2-4. variants, etc.)

Embodiment 2 is not limited to the above, and various modifications can be made without departing from the spirit and scope of the invention. Hereinafter, such a modification will be described.

(2-4-1. case where cover member is in contact with load side bracket and frame)

As shown in fig. 22, in the rotating electric machine 1B of the present modification, a cover member 70A is provided between the load side coil end 38a and the load side bracket 6. Cover member 70B is provided between non-load-side coil end 38B and frame 5. The cover member 70A is disposed so as to cover at least a part of the load side coil end 38a (in this example, the axial load side end and the radial outer side end) and to contact the load side bracket 6 and the frame 5. The cover member 70B is disposed so as to cover at least a part of the non-load-side coil end 38B (in this example, the axial load-side end and the radial outer end) and to contact the frame 5.

For example, as shown in fig. 19, the coil unit 30 of the present modification is disposed in the stator core 22 in a distributed winding manner, and the load-side coil end 38a and the opposite-load-side coil end 38b have substantially rectangular cross-sectional shapes, respectively. The cover member 70A has a circular plate portion 71A and a cylindrical portion 72A having substantially constant plate thicknesses. The surface of the disc portion 71A on the opposite side to the load is in contact with the axially outer surface 38a2 of the load-side coil end 38 a. The load-side surface of the disc portion 71A contacts the inner wall surface 6b2 of the recess 6b of the load-side bracket 6. The inner circumferential surface of the cylindrical portion 72A faces and contacts the radially outer surface of the load-side coil end 38a of the radially outer surface 30b2 of the coil unit 30. The outer peripheral surface of the cylindrical portion 72A contacts the inner peripheral surfaces of the load side bracket 6 and the frame 5.

The cover member 70B has a circular plate portion 71B and a cylindrical portion 72B having substantially constant plate thicknesses. The load-side surface of the disc portion 71B faces and contacts the axially outer surface 38B2 of the load-side coil end 38 a. The surface of the disc portion 71B on the non-load side faces the inner wall surface of the non-load side bracket 8 with a gap therebetween, but may be in contact with the inner wall surface. The inner circumferential surface of the cylindrical portion 72B faces and contacts the radially outer surface of the non-load-side coil end 38B out of the radially outer surface 30B2 of the coil unit 30. The outer peripheral surface of the cylindrical portion 72B contacts the inner peripheral surface of the frame 5.

A cooling flow path 5b through which cooling water (oil may be used) flows is formed inside the frame 5. The rotating electric machine 1B is similar to the rotating electric machine 1A in other configurations and manufacturing methods.

According to the present modification, since the cover members 70A and 70B are provided on both the coil ends 38a and 38B on the load side and the opposite-to-load side, heat of the coil end 38B on the opposite-to-load side can be efficiently dissipated in addition to the coil end 38a on the load side. Further, since the cover member 70A is disposed in contact with the frame 5 in addition to the load-side bracket 6, heat of the coil unit 30 is efficiently dissipated via the load-side bracket 6 and the frame 5. Further, since the cooling passage 5b is formed in the frame 5, the coil unit 30 can be cooled more efficiently by water cooling. Therefore, the cooling performance of the rotating electrical machine 1B can be further improved.

In the above-described embodiments, the disclosed technology is applied to the rotating electric machine, but the technology is not limited to the rotating type, and may be applied to a linear motor and a generator.

In the above description, when there are descriptions such as "perpendicular", "parallel", "planar", etc., it is not a strict description. That is, these terms "perpendicular", "parallel", "planar", and the like allow design and manufacturing tolerances and errors, and are intended to mean "substantially perpendicular", "substantially parallel", "substantially planar", and the like.

In the above description, when there are descriptions such as "same", "equal", and "different" in terms of apparent size and dimension, they are not strictly described. That is, these terms "identical", "equal", "different", and the like are intended to allow design and manufacturing tolerances and errors, and are "substantially identical", "substantially equal", "substantially different", and the like.

In addition to the above, the methods of the above embodiments and the modifications can be used in appropriate combinations.

Although not illustrated, the above embodiment and the modifications may be implemented by various modifications without departing from the scope of the invention.

Description of the reference symbols

1: a rotating electric machine; 1A: a rotating electric machine; 1B: a rotating electric machine; 2: a rotor; 5: a frame; 6: a load side bracket (an example of a bracket); 18: an insulator (an example of an insulating member); 18A: an insulator (an example of an insulating member); 22: a stator core; 24: a tooth portion; 30: a coil unit; 30': a coil unit portion (an example of a coil unit); 30': a coil unit; 31: a wire; 310: a flat portion; 35: an air-core coil portion (an example of an air-core coil); 36: a resin part; 36': a resin part; 36 a: a1 st resin part; 36 b: a2 nd resin part; 37a1, b 1: a circumferential inner side surface; 38 a: a load side coil end (an example of a coil end); 38 b: an opposite-load side coil end (an example of a coil end); 38a1, b 1: an axially inner face; 60: an annular coil body; 70: a cover member; 70A: a cover member; 70B: a cover member; 110: a rotating electric machine; 111: a frame; 112: a load side bracket (an example of a bracket); 120: a rotor; 132: a stator core; 134: a tooth portion; 141: a coil unit; 142: an air-core coil portion (an example of an air-core coil); 143: a resin part; 1501: a circumferential inner side surface; 1511: a circumferential inner side surface; 1502: a circumferential outer side surface; 1512: a circumferential outer side surface; AX: rotating the axis; AX 1: the axis of rotation.

Claims (14)

1. A rotating electrical machine is characterized by comprising:

a stator core having a tooth portion; and

a coil unit attached to the tooth portion and having a lead wire and a resin portion;

wherein two circumferential inner surfaces of the plurality of surfaces of the coil unit facing the teeth in a circumferential direction around a rotation axis are formed of the resin portion and the conductive wire, and two circumferential outer surfaces of the plurality of surfaces of the coil unit facing the adjacent coil unit in the circumferential direction are formed of the resin portion,

the conductive wires constituting the two circumferentially inner sides have adjacent two flat portions,

the two circumferential inner surfaces are configured such that the resin portion is interposed between the two flat portions, and a flat surface of the resin portion is formed to be substantially flush with the flat portion of the lead wire.

2. The rotating electric machine according to claim 1,

the resin portion is filled in a gap between the wires inside the coil unit.

3. The rotating electric machine according to claim 2,

the rotating electric machine further includes an insulator disposed between the teeth and a plurality of surfaces of the coil unit that face the teeth.

4. The rotating electric machine according to claim 3,

the plurality of coil units are configured as a ring-shaped coil body connected by the resin portion,

the annular coil body has 1 set of the plurality of faces opposed to one of the teeth, and each of the teeth has a plurality of sets of the plurality of faces opposed to the teeth in a circumferential direction around a rotation axis.

5. The rotating electric machine according to claim 4, further comprising:

a frame that houses the stator core; and

a holder disposed at an axial end of the frame,

the resin part has:

a1 st resin portion disposed at least at a contact portion with the holder of the coil unit; and

and a2 nd resin part constituting a part of the resin parts other than the 1 st resin part.

6. The rotating electric machine according to claim 5,

the 1 st resin portion is made of a resin having a higher thermal conductivity than the 2 nd resin portion.

7. The rotating electric machine according to claim 6,

the coil units are individually mounted for each of the teeth.

8. The rotating electric machine according to claim 6,

the coil unit is mounted so as to straddle the plurality of teeth.

9. The rotating electric machine according to any one of claims 1 to 8,

the coil unit has a coil end portion disposed outside the slots of the stator core,

the rotating electric machine further includes:

a housing; and

and a cover member that is disposed between the housing and the coil end, covers at least a part of the coil end, and is in contact with the housing.

10. The rotating electric machine according to claim 9,

the coil end portion includes a surface of an end portion in an axial direction with respect to a rotation axis and a surface of at least one of an outer side or an inner side in a radial direction with respect to the rotation axis, the resin portion and the lead wire being formed,

the cover member is disposed so as to be in contact with a surface of the axial end of the coil end and a surface of at least one of the radial outer side and the radial inner side.

11. A method of manufacturing a rotating electrical machine, comprising:

deforming the cross-sectional shape of the wire by pressurization to form the outer shape of the air-core coil into a predetermined shape;

reinforcing the air-core coil with a resin so that two circumferential inner surfaces of the plurality of surfaces of the air-core coil facing teeth of a stator core in a circumferential direction around a rotation axis are formed of the resin portion and the conductive wire, and two circumferential outer surfaces of the air-core coil facing adjacent coil units in the circumferential direction are formed of the resin portion, the conductive wire forming the two circumferential inner surfaces has two adjacent flat portions, the two circumferential inner surfaces are configured so that the resin portion is interposed between the two flat portions, and the flat surfaces of the resin portion and the flat portions of the conductive wire are formed to be substantially coplanar, thereby forming the coil unit; and

and mounting the coil unit to the tooth portion of the stator core.

12. The manufacturing method of a rotating electric machine according to claim 11,

in the step of attaching the coil unit to the tooth portions, a plurality of surfaces on an inner peripheral side of the coil unit and the tooth portions are bonded with an adhesive.

13. The manufacturing method of a rotating electric machine according to claim 11 or 12,

the manufacturing method of the rotating electric machine further includes the steps of: the ends of the conductive wires of the plurality of coil units are wired so as to form a predetermined wiring pattern.

14. A coil unit, characterized by comprising:

a wire wound in a ring shape; and

an annular resin portion that reinforces the wire,

of the plurality of surfaces, the surfaces on the inner sides in two predetermined circumferential directions facing the teeth in the circumferential direction around the rotation axis when the stator core is attached to the teeth of the rotating electrical machine are formed of the resin portion and the conductive wire, and the surfaces on the outer sides in two predetermined circumferential directions facing the adjacent coil units in the circumferential direction are formed of the resin portion,

the conductive wire constituting the two circumferentially inner surfaces has two adjacent flat portions, and the two circumferentially inner surfaces are configured such that the resin portion is interposed between the two flat portions, and a flat surface of the resin portion is formed to be substantially coplanar with the flat portions of the conductive wire.

Images