CN114679028A - Generator for manpower-driven vehicle, stator of generator, and method for manufacturing stator - Google Patents

Abstract

The invention provides a generator of a manpower-driven vehicle, a stator of the generator and a manufacturing method of the stator. The invention aims to improve the assembling performance of a plurality of magnetic yoke sheets in a stator of a generator. A stator of a generator for a human-powered vehicle includes a coil, a plurality of yoke pieces, and a connecting member. The coil is wound around the axis. The plurality of yoke pieces are arranged in a circumferential direction of the shaft center. The connecting member is configured as a member separate from the plurality of yoke pieces. The plurality of yoke pieces are fixed to the connecting member, respectively.

Description

Generator for manpower-driven vehicle, stator of generator, and method for manufacturing stator

Technical Field

The present disclosure relates to a generator for a human powered vehicle, a stator for the generator, and a method of manufacturing the stator.

Background

The generator described in patent document 1 includes a magnet, a coil, a yoke, and a support. The yoke includes a plurality of yoke pieces. The plurality of yoke pieces are each formed of a single member and arranged in the circumferential direction. The coil and the plurality of yoke pieces are mounted on the support.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open No. 2016-158421

Disclosure of Invention

Problems to be solved by the invention

Since the plurality of yoke pieces are separate members, it is difficult to adjust the positions of the plurality of yoke pieces when the plurality of yoke pieces are attached to the support. If it is difficult to adjust the positions of the plurality of yoke pieces, the accuracy of arrangement of the plurality of yoke pieces with respect to each other is lowered.

One of the problems of the present disclosure is to improve the assemblability of a plurality of yoke pieces in a stator of a generator.

Means for solving the problems

A stator of a generator for a human-powered vehicle according to a first aspect of the present invention includes a coil, a plurality of yoke pieces, and a connecting member. The coil is wound around the core. The plurality of yoke pieces are arranged in a circumferential direction of the shaft center. The connecting member is configured as a member separate from the plurality of yoke pieces. The plurality of yoke pieces are fixed to the connecting member, respectively.

In the stator according to the first aspect, since the plurality of yoke pieces are fixed to the connecting member, the plurality of yoke pieces and the connecting member can be handled as an integral unit. Thus, the assembling property when the plurality of yoke pieces are assembled to the support such as the hub shaft can be improved as compared with the case where the plurality of yoke pieces are not connected by the connecting member.

According to the stator of the first aspect, in the stator of the second aspect, the plurality of yoke pieces are fixed to the connecting member by at least one of welding, adhesion, and fitting.

In the stator according to the second aspect, the plurality of yoke pieces can be fixed to the connecting member by a relatively simple method.

According to the stator of the first or second aspect, in the stator of the third aspect, the coupling member extends in the circumferential direction.

In the stator according to the third aspect, the plurality of yoke pieces arranged in the circumferential direction can be easily fixed to the connecting member.

The stator according to any one of the first to third aspects, wherein the coupling member is annular.

In the stator according to the fourth aspect, since the connecting member is annular, the strength of the connecting member can be increased, and the connecting strength of the plurality of yoke pieces can be increased.

The stator according to any one of the first to fourth aspects, wherein in the stator according to the fifth aspect, the coupling member is disposed at least partially between the plurality of yoke pieces and the shaft center in the shaft center radial direction.

In the stator according to the fifth aspect, the plurality of yoke pieces are easily supported in the radial direction by the coupling member.

The stator according to any one of the first to fifth aspects, wherein the coupling member includes a cylindrical portion extending along the axial center.

In the stator according to the sixth aspect, since the connecting member includes the cylindrical portion, the strength of the connecting member can be increased, and the connecting strength of the plurality of yoke pieces can be increased.

According to a sixth aspect of the stator, in the seventh aspect of the stator, the plurality of yoke pieces are fixed to the cylindrical portion by at least one of welding, bonding, and fitting.

In the stator according to the seventh aspect, the coupling strength of the plurality of yoke pieces can be further improved.

According to the sixth or seventh aspect of the stator, in the eighth aspect of the stator, the coupling member includes a flange extending outward from the cylindrical portion in a radial direction of the shaft center.

In the stator according to the eighth aspect, the strength of the connecting member can be more reliably increased.

According to a stator of an eighth aspect, in the stator of the ninth aspect, the plurality of yoke pieces are fixed to the flange by at least one of welding, bonding, and fitting, respectively.

In the stator according to the ninth aspect, the connection strength of the plurality of yoke pieces can be more reliably increased.

The stator according to any one of the first to ninth aspects, in the stator according to the tenth aspect, the plurality of yoke segments each include a yoke body and a fixing portion. The yoke body is disposed to face the coil in a radial direction of the axial center. The fixing portion extends from the yoke body in the radial direction toward the axial center and is fixed to the connecting member.

In the stator according to the tenth aspect, the connection strength of the plurality of yoke pieces can be more reliably increased.

According to a tenth aspect of the stator, the stator of the eleventh aspect further includes a bobbin configured as a member separate from the plurality of yoke pieces and the connecting member. The coil is wound on the bobbin. The bobbin includes a support hole extending along the axial center. The fixing part is at least partially arranged in the supporting hole.

In the stator according to the eleventh aspect, the coupling strength between the plurality of yoke pieces and the coil can be improved.

The stator according to any one of the first to twelfth aspects, wherein the stator according to the twelfth aspect further comprises a spline shaft for supporting the coil and the plurality of yoke pieces. The coupling member is disposed at least partially between the plurality of yoke pieces and the hub shaft in a radial direction of the shaft center.

In the stator according to the twelfth aspect, the connection strength of the plurality of yoke pieces can be more reliably increased.

The generator for a human-powered vehicle of the thirteenth aspect comprises: the stator according to any one of the first to twelfth aspects; a rotating body provided to be rotatable about an axis with respect to the stator; and a rotor provided to the rotating body and including a magnet.

In the stator of the thirteenth aspect, the assemblability of the generator can be improved by the stator.

The stator manufacturing method of the fourteenth aspect includes: a yoke arrangement step of attaching a plurality of yoke pieces, which are separate members, to a jig so as to be arranged around a reference axis; a connecting member arranging step of attaching the connecting member to the jig; and a fixing step of fixing the plurality of yoke pieces to the connecting member, respectively.

In the stator manufacturing method according to the fourteenth aspect, since the plurality of yoke pieces are fixed to the coupling member, respectively, the plurality of yoke pieces and the coupling member can be handled as an integral unit. Thus, the assembling property when assembling the plurality of yoke pieces to a support such as a hub shaft can be improved as compared with a case where the plurality of yoke pieces are not connected by the connecting member.

According to the manufacturing method of the fourteenth aspect, the manufacturing method of the fifteenth aspect further includes a mounting step of mounting the plurality of yoke pieces coupled by the coupling member to the hub shaft.

In the stator manufacturing method according to the fifteenth aspect, the ease of assembly when assembling the plurality of yoke plates to the drum shaft can be improved.

The stator of the generator for a human-powered vehicle of the sixteenth aspect is manufactured by the manufacturing method of the fourteenth or fifteenth aspect.

In the stator according to the sixteenth aspect, since the stator is manufactured by the manufacturing method according to the fourteenth or fifteenth aspect, the assembling property when the plurality of yoke pieces are assembled to the support such as the hub shaft can be improved.

Effects of the invention

According to the present disclosure, assemblability of a plurality of yoke pieces in a stator of a generator can be improved.

Drawings

Fig. 1 is a sectional view of a human-powered vehicle including a generator according to a first embodiment.

Fig. 2 is a perspective view of the generator stator shown in fig. 1.

Fig. 3 is an exploded perspective view of the generator stator shown in fig. 1.

Fig. 4 is a side view of a yoke assembly of the stator shown in fig. 3.

Fig. 5 is another side view of the yoke assembly shown in fig. 4.

Fig. 6 is a side view of another yoke assembly of the stator shown in fig. 3.

Fig. 7 is another side view of the yoke assembly shown in fig. 6.

Fig. 8 is a perspective view of a coupling member of the yoke assembly shown in fig. 4.

Fig. 9 is a plan view of the coupling member shown in fig. 8.

Fig. 10 is a perspective view of a coupling member of the yoke assembly shown in fig. 6.

Fig. 11 is a plan view of the coupling member shown in fig. 10.

Fig. 12 is a cross-sectional view of the generator shown in fig. 1.

Fig. 13 is another cross-sectional view of the generator shown in fig. 1.

FIG. 14 is a cross-sectional view of the generator of FIG. 12, line XIV-XIV.

Fig. 15 is a cross-sectional view of the generator of fig. 12 taken along line XV-XV.

Fig. 16 is a flowchart illustrating a method of manufacturing the stator shown in fig. 2.

Fig. 17 is a plan view for explaining the stator manufacturing method shown in fig. 2.

Fig. 18 is a cross-sectional view of the clip of lines XVIII-XVIII of fig. 17 and 22.

Fig. 19 is a cross-sectional view of the clamp of fig. 20, line XIX-XIX.

Fig. 20 is a plan view for explaining a method of manufacturing the stator shown in fig. 2.

Fig. 21 is a plan view for explaining the stator manufacturing method shown in fig. 2.

Fig. 22 is a plan view for explaining a method of manufacturing the stator shown in fig. 2.

Fig. 23 is a plan view for explaining a method of manufacturing the stator shown in fig. 2.

Fig. 24 is a plan view for explaining the stator manufacturing method shown in fig. 2.

Fig. 25 is a sectional view of a human-powered vehicle including the generator according to the second embodiment.

Fig. 26 is a perspective view of the generator stator shown in fig. 25.

Fig. 27 is an exploded perspective view of the generator stator shown in fig. 25.

Fig. 28 is a side view of the yoke assembly of the stator shown in fig. 27.

Fig. 29 is another side view of the yoke assembly shown in fig. 28.

Fig. 30 is a side view of another yoke assembly of the stator shown in fig. 27.

Fig. 31 is another side view of the yoke assembly shown in fig. 30.

Fig. 32 is a perspective view of a coupling member of the yoke assembly shown in fig. 27.

Fig. 33 is a sectional view of the stator shown in fig. 27.

Fig. 34 is another cross-sectional view of the stator shown in fig. 27.

Fig. 35 is a cross-sectional view of the stator of fig. 33 taken along line XXXV-XXXV.

FIG. 36 is a cross-sectional view of the generator of FIG. 33 taken along line XXXVI-XXXVI.

Fig. 37 is a sectional view of a human-powered vehicle including the generator according to the third embodiment.

Fig. 38 is a perspective view of the generator stator shown in fig. 37.

Fig. 39 is an exploded perspective view of the generator stator shown in fig. 37.

Fig. 40 is a side view of the yoke assembly of the stator shown in fig. 39.

Fig. 41 is another side view of the yoke assembly shown in fig. 40.

Fig. 42 is a side view of another yoke assembly of the stator shown in fig. 39.

Fig. 43 is another side view of the yoke assembly shown in fig. 42.

Fig. 44 is a perspective view of a coupling member of the yoke assembly shown in fig. 39.

Fig. 45 is a sectional view of the stator shown in fig. 39.

Fig. 46 is another cross-sectional view of the stator shown in fig. 39.

Fig. 47 is a flowchart showing a method of manufacturing the stator shown in fig. 39.

Fig. 48 is a plan view for explaining the stator manufacturing method shown in fig. 39.

FIG. 49 is a cross-sectional view of the clamp of line XLIX-XLIX of FIG. 48.

Fig. 50 is a sectional view of a generator according to a modification.

Fig. 51 is a sectional view of a generator according to a modification.

Fig. 52 is a sectional view of a generator according to a modification.

Fig. 53 is a sectional view of a generator according to a modification.

Fig. 54 is a sectional view of a generator according to a modification.

Detailed Description

Hereinafter, embodiments will be described with reference to the drawings. Like reference symbols in the drawings indicate corresponding or identical structures.

(first embodiment)

As shown in fig. 1, the human-powered vehicle 2 includes a generator 10 according to the first embodiment. The human powered vehicle 2 includes a frame 4 and wheels 6. The generator 10 is mounted to the frame 4. The wheel 6 includes a generator 10, a plurality of spokes 6A, and a rim (not shown). The generator 10 is coupled to the rim via a plurality of spokes 6A. In the present embodiment, the generator 10 may also be referred to as a hub generator 10. The generator 10 is not limited to a hub generator.

The human-powered vehicles include various bicycles, such as mountain bicycles, road bicycles, city bicycles, freight bicycles, hand bicycles, and horizontal bicycles. In addition, the human-powered vehicle includes an electric bicycle (E-bike). Electric bicycles include electric-assisted bicycles that utilize an electric motor to assist in propelling the vehicle. The number of wheels of the human-powered vehicle is not limited to two. The human-powered vehicle also includes a vehicle having one wheel and three or more wheels, for example. Vehicles using only motive power other than human power are not human-powered vehicles. In particular, vehicles using only an internal combustion engine as a prime mover are not human powered vehicles. In general, a human-powered vehicle is assumed to be a small light vehicle, and can travel on a public road without license.

In the present application, the terms "front", "rear", "left", "right", "lateral", "above", and "below" indicating directions and any other similar terms indicating directions refer to directions defined with reference to a user (i.e., a rider) facing a steering device such as a handlebar at a user reference position (e.g., saddle or seat cushion) of the human-powered vehicle 2. Thus, these terms, as used to describe the generator 10, are to be understood as being used to indicate an upright riding position on a horizontal surface in a human powered vehicle 2 that includes the generator 10.

As shown in fig. 1, the generator 10 of the human-powered vehicle 2 includes a stator 12 and a rotor 14. The rotary body 14 is provided rotatably about a shaft center a1 with respect to the stator 12. The generator 10 is configured to generate electric power by relative rotation of the stator 12 and the rotor 14. The stator 12 is configured to be mounted on the frame 4. The rotating body 14 is coupled to the rim via a plurality of spokes 6A.

The generator 10 of the human-powered vehicle 2 includes a rotor 16. The rotor 16 is provided on the rotating body 14 and includes a magnet 18. The rotor 16 is provided rotatably about a shaft center a1 with respect to the stator 12. Axis a1 may also be referred to as rotational axis a 1. The rotor 16 is fixed to the inner peripheral surface 14A of the rotating body 14. The rotor 14 and the rotor 16 are provided rotatably about an axial center a1 with respect to the stator 12. The rotor 16 is, for example, cylindrical. At least a part of the stator 12 is disposed on the inner circumferential side of the rotor 16.

The generator 10 further includes a sprocket support 19, a first bearing 20, a second bearing 22, a third bearing 24, a fourth bearing 26, and a one-way clutch mechanism 28. The sprocket support 19 is rotatable about the axial center a1 with respect to the stator 12 and the rotating body 14. The sprocket support 19 includes a plurality of outer spline teeth 19A that engage with the sprocket assembly 8. The first bearing 20 and the second bearing 22 are disposed between the rotor 14 and the stator 12, and are configured to support the rotor 14 so as to be rotatable about the axis a1 with respect to the stator 12. The third bearing 24 and the fourth bearing 26 are disposed between the sprocket support body 19 and the stator 12, and are configured to support the sprocket support body 19 so as to be rotatable about the axis a1 with respect to the stator 12.

The one-way clutch mechanism 28 is configured to restrict rotation of the sprocket support body 19 relative to the rotating body 14 in one direction. Specifically, the one-way clutch mechanism 28 is configured to transmit rotational force from the sprocket support body 19 to the rotating body 14 during pedaling. The one-way clutch mechanism 28 is configured to restrict the transmission of rotational force from the rotational body 14 to the sprocket support body 19 during Coasting (Coasting).

The stator 12 of the generator 10 of the human-powered vehicle 2 includes a coil 30. Coil 30 is wound about axis a 1. The coil 30 is made of a conductor such as a copper wire. The stator 12 is also provided with a bobbin 32. The coil 30 is wound around a bobbin 32. The bobbin 32 is made of an electrically insulating material such as plastic. The coil 30 is disposed on the inner peripheral side of the magnet 18. The magnet 18 is configured to generate a magnetic field. When the rotor 16 rotates relative to the coil 30, an induced current flows through the coil 30. Therefore, the rotation of the rotating body 14 relative to the stator 12 can be converted into electric power by the coil 30 and the rotor 16.

The stator 12 is also provided with a spline shaft 34. The hub axle 34 extends in an axial direction D1 from an axis A1. Spool 32 includes a support hole 32A extending along axis a 1. The hub axle 34 passes through the support hole 32A. The first bearing 20 and the second bearing 22 are disposed between the rotary body 14 and the hub shaft 34, and are configured to support the rotary body 14 so as to be rotatable about the axis a1 with respect to the hub shaft 34. The third bearing 24 and the fourth bearing 26 are disposed between the sprocket support 19 and the hub shaft 34, and are configured to rotatably support the sprocket support 19 with respect to the hub shaft 34 about the axis a 1. The hub axle 34 includes a through hole 34H extending along the axial center a 1. For example, a rod of a wheel fixing mechanism configured to detachably fix the wheel 6 to the frame 4 is inserted into the through hole 34H.

The generator 10 includes a first stationary component 36 and a second stationary component 38. The hub axle 34 includes a first axle end 34A and a second axle end 34B. The hub axle 34 extends along an axle center A1 between a first axle end 34A and a second axle end 34B. The first fixing member 36 is mounted to the first shaft end 34A of the hub shaft 34. The second fixing member 38 is mounted to the second axial end 34B of the hub axle 34.

The generator 10 includes a support member 40, a cover 42, a controller 44, and an electrical cable 45. The support member 40 and the cover 42 are attached to the stator 12. The controller 44 is disposed in the housing space 42A formed by the stator 12 and the cover 42. The controller 44 is mounted to the cover 42. The controller 44 is electrically connected to the coil 30. The controller 44 is connected to other electrical devices 9 such as a vehicle lamp via a cable 45. The drum shaft 34 includes a guide groove 34G extending along the axial center a 1. The cable wire 45 is disposed in the guide groove 34G.

The controller 44 includes, for example, a control circuit and a substrate. The control circuit is configured to control the power generated by the magnet 18 and the coil 30. The control circuit is mounted on the substrate. The controller 44 includes an arithmetic processing device configured to execute a predetermined control program. The arithmetic processing device includes, for example, a Central Processing Unit (CPU) and a memory. The structure of the controller 44 is not limited to the above structure. The controller 44 may be at least partially mounted to the rotor 16 instead of the stator 12, or may be at least partially mounted to a device other than an electric motor.

As shown in fig. 2, the stator 12 of the generator 10 of the human-powered vehicle 2 includes a plurality of yoke pieces 46. The plurality of yoke pieces 46 are arranged in the circumferential direction D2 of the axial center a 1. The plurality of yoke pieces 46 are attached to the hub shaft 34. The hub axle 34 supports the coil 30 and the plurality of yoke pieces 46. The stator 12 of the generator 10 of the human-powered vehicle 2 includes a plurality of yoke pieces 48. The plurality of yoke pieces 48 are arranged in the circumferential direction D2 of the axial center a 1. The plurality of yoke pieces 48 are attached to the hub shaft 34. The hub axle 34 supports the coil 30 and the plurality of yoke pieces 48. The yoke pieces 46 and 48 are made of, for example, a magnetic material.

The stator 12 includes a lock nut 50. The lock nut 50 is mounted to the hub shaft 34 to hold the coil 30, the bobbin 32, the plurality of yoke pieces 46, the plurality of yoke pieces 48, the cover 42, and the support member 40 on the hub shaft 34. The yoke piece 46 is also referred to as a first yoke piece 46. The yoke piece 48 is also referred to as a second yoke piece 48.

As shown in fig. 3, the plurality of yoke pieces 46 are each formed as an independent member. The plurality of yoke pieces 46 are arranged at equal intervals in the circumferential direction D2. The plurality of yoke pieces 46 have the same shape as each other. However, at least one of the plurality of yoke pieces 46 may have a different shape from the other yoke pieces 46.

The plurality of yoke pieces 48 are formed as separate members. The plurality of yoke pieces 48 are arranged at equal intervals in the circumferential direction D2. The plurality of yoke pieces 48 have the same shape as each other. However, at least one of the plurality of yoke pieces 48 may have a different shape from the other yoke pieces 48.

The lock nut 50 includes a threaded hole 50A. The drum shaft 34 includes a threaded portion 34C. The screw hole 50A of the lock nut 50 is engaged with the screw portion 34C of the hub shaft 34. The drum shaft 34 includes a large diameter portion 34D. The support member 40 contacts the large diameter portion 34D in the axial direction D1. The coil 30, the bobbin 32, the support member 40, the cover 42, the plurality of yoke pieces 46, and the plurality of yoke pieces 48 are sandwiched between the support member 40 and the large diameter portion 34D of the hub shaft 34 in the axial direction D1.

As shown in fig. 3, the stator 12 of the generator 10 of the human-powered vehicle 2 includes a coupling member 56. The coupling member 56 is configured as a member separate from the plurality of yoke pieces 46. The bobbin 32 is configured as a member independent from the plurality of yoke pieces 46 and the coupling member 56. The coupling member 56 may also be referred to as a first coupling member 56.

The coupling member 56 extends in the circumferential direction D2. The connecting member 56 is annular. The coupling member 56 includes a cylindrical portion 56A extending along the axial center a 1. The coupling member 56 includes a flange 56B extending outward from the cylindrical portion 56A in the radial direction of the axial center a 1. The cylindrical portion 56A includes a through hole 56C through which the hub shaft 34 passes.

The stator 12 of the generator 10 of the human-powered vehicle 2 includes a coupling member 58. The coupling member 58 is formed as a member separate from the plurality of yoke pieces 48. The bobbin 32 is formed as a member separate from the plurality of yoke pieces 48 and the connecting member 58. The coupling member 58 is also referred to as a second coupling member 58.

The coupling member 58 extends in the circumferential direction D2. The connecting member 58 is annular. The coupling member 58 includes a cylindrical portion 58A extending along the axial center a 1. The coupling member 58 includes a flange 58B extending outward from the cylindrical portion 58A in the radial direction of the axial center a 1. The cylindrical portion 58A has a through hole 58C through which the hub shaft 34 passes.

As shown in fig. 4, the plurality of yoke pieces 46 are arranged at equal intervals in the circumferential direction D2. The yoke pieces 46 are fixed to the connecting member 56, respectively. The yoke pieces 46 and the coupling member 56 are configured to be detachably attached to the hub shaft 34 as an integral unit. The plurality of yoke pieces 46 and the connecting member 56 constitute a yoke assembly 60. The yoke assembly 60 is also referred to as a first yoke assembly 60.

As shown in fig. 4 and 5, each of the plurality of yoke pieces 46 is fixed to the connecting member 56 by at least one of welding, adhesion, and fitting. The plurality of yoke pieces 46 are fixed to the cylindrical portion 56A by at least one of welding, adhesion, and fitting. The plurality of yoke pieces 46 are fixed to the flange 56B by at least one of welding, bonding, and fitting. In the present embodiment, the plurality of yoke pieces 46 are fixed to the connecting member 56 by welding. As shown in fig. 5, the plurality of yoke pieces 46 are fixed to the cylindrical portion 56A by welding. As shown in fig. 4, the plurality of yoke pieces 46 are fixed to the flange 56B by welding. However, the plurality of yoke pieces 46 may be fixed to the connecting member 56 by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. However, the plurality of yoke pieces 46 may be fixed to the cylindrical portion 56A by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. The plurality of yoke pieces 46 may be fixed to the flange 56B by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. Examples of welding include laser welding. Examples of the adhesion include adhesive bonding. The fitting may be, for example, a structure in which the plurality of yoke pieces 46 are fitted into a plurality of grooves provided in the coupling member 56.

As shown in fig. 4, the yoke assembly 60 includes at least one welding part 62. At least one welded portion 62 is a portion formed by welding and is used to fix the yoke piece 46 to the coupling member 56. In the present embodiment, the yoke assembly 60 includes a plurality of welding portions 62. The welded portion 62 fixes the yoke piece 46 to the flange 56B of the connecting member 56. The plurality of welding portions 62 are arranged at equal intervals in the circumferential direction D2.

As shown in fig. 5, the yoke assembly 60 includes at least one welding part 64. At least one welding portion 64 is a portion formed by welding and is used to fix the yoke piece 46 to the connecting member 56. In the present embodiment, the yoke assembly 60 includes a plurality of welding portions 64. The welding portion 64 fixes the yoke piece 46 to the cylindrical portion 56A of the connecting member 56. The plurality of welding portions 64 are arranged at equal intervals in the circumferential direction D2.

As shown in fig. 6, the plurality of yoke pieces 48 are arranged at equal intervals in the circumferential direction D2. The plurality of yoke pieces 48 are fixed to the connecting member 58, respectively. The plurality of yoke pieces 48 and the coupling member 58 are configured to be detachably attached to the hub shaft 34 as an integral unit. The plurality of yoke pieces 48 and the connecting member 58 constitute a yoke assembly 66. The yoke assembly 66 may also be referred to as a second yoke assembly 66.

As shown in fig. 6 and 7, each of the plurality of yoke pieces 48 is fixed to the connecting member 58 by at least one of welding, adhesion, and fitting. The plurality of yoke pieces 48 are fixed to the cylindrical portion 58A by at least one of welding, adhesion, and fitting. The plurality of yoke pieces 48 are fixed to the flange 58B by at least one of welding, bonding, and fitting. In the present embodiment, the plurality of yoke pieces 48 are fixed to the connecting member 58 by welding. The plurality of yoke pieces 48 are fixed to the cylindrical portion 58A by welding. The plurality of yoke pieces 48 are fixed to the flange 58B by welding, respectively. However, the plurality of yoke pieces 48 may be fixed to the connecting member 58 by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. The plurality of yoke pieces 48 may be fixed to the cylindrical portion 58A by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. The plurality of yoke pieces 48 may be fixed to the flange 58B by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. Examples of welding include laser welding. Examples of the adhesion include adhesive bonding. The fitting may be, for example, a structure in which the plurality of yoke pieces 48 are fitted into a plurality of grooves provided in the coupling member 58.

As shown in fig. 6, the yoke assembly 66 includes at least one welding portion 68. At least one of the welding portions 68 is a portion formed by welding, and is used to fix the yoke piece 48 to the coupling member 58. In the present embodiment, the yoke assembly 66 includes a plurality of welding portions 68. The welding portion 68 fixes the yoke piece 48 to the flange 58B of the connecting member 58. The plurality of welding portions 68 are arranged at equal intervals in the circumferential direction D2.

As shown in fig. 7, the yoke assembly 66 includes at least one welding part 70. At least one of the welding portions 70 is a portion formed by welding and is used to fix the yoke piece 48 to the coupling member 58. In the present embodiment, the yoke assembly 66 includes a plurality of welding portions 70. The welding portion 70 fixes the yoke piece 48 to the cylindrical portion 58A of the connecting member 58. The plurality of welding portions 70 are arranged at equal intervals in the circumferential direction D2.

As shown in fig. 8, the coupling member 56 includes at least one protruding portion 56D that protrudes radially inward from the cylindrical portion 56A. In the present embodiment, the coupling member 56 includes a plurality of protruding portions 56D that protrude radially inward from the cylindrical portion 56A. The plurality of projections 56D are configured to position the plurality of yoke pieces 46 with respect to the drum shaft 34 in the circumferential direction D2.

The coupling member 56 includes at least one protrusion 56E protruding from the flange 56B in the axial direction D1 of the axial center a 1. In the present embodiment, the coupling member 56 includes a plurality of projections 56E projecting in the axial direction D1 from the flange 56B. The plurality of protrusions 56E are arranged between two yoke pieces 46 adjacent in the circumferential direction D2. At least one of the plurality of projections 56E may be omitted from the coupling member 56.

As shown in fig. 9, the flange 56B includes at least one aperture 56F. In this embodiment, the flange 56B includes a plurality of holes 56F. The plurality of holes 56F are arranged at equal intervals in the circumferential direction D2. The plurality of holes 56F respectively include long holes extending in the circumferential direction D2. The shape of the hole 56F is not limited to a long hole. At least one of the plurality of holes 56F may be omitted from the coupling member 56.

As shown in fig. 10, the coupling member 58 has substantially the same shape as the coupling member 56. The coupling member 58 includes at least one protruding portion 58D that protrudes radially inward from the cylindrical portion 58A. In the present embodiment, the coupling member 58 includes a plurality of protruding portions 58D that protrude radially inward from the cylindrical portion 58A. The plurality of projections 58D are configured to position the plurality of yoke pieces 46 with respect to the drum shaft 34 in the circumferential direction D2.

The coupling member 58 includes at least one projection 58E projecting from the flange 58B in the axial direction D1. In the present embodiment, the coupling member 58 includes a plurality of projections 58E projecting in the axial direction D1 from the flange 58B. The plurality of projections 58E are arranged between two yoke pieces 48 adjacent in the circumferential direction D2. As shown in fig. 9 and 11, the circumferential positions of the plurality of projections 58E are different from the circumferential positions of the plurality of projections 56E.

As shown in fig. 11, the flange 58B includes at least one aperture 58F. In this embodiment, the flange 58B includes a plurality of holes 58F. The plurality of holes 58F are arranged at equal intervals in the circumferential direction D2. The plurality of holes 58F respectively include long holes extending in the circumferential direction D2. The shape of the hole 58F is not limited to a long hole.

As shown in fig. 12, the coupling member 56 is disposed at least partially between the plurality of yoke pieces 46 and the shaft center a1 in the radial direction D3 of the shaft center a 1. The coupling member 56 is disposed at least partially between the plurality of yoke pieces 46 and the hub shaft 34 in the radial direction D3 of the axial center a 1. In the present embodiment, the coupling member 56 is partially disposed between the plurality of yoke pieces 46 and the axial center a1 in the radial direction D3. The coupling member 56 is partially disposed between the plurality of yoke pieces 46 and the hub shaft 34 in the radial direction D3. The cylindrical portion 56A is disposed between the plurality of yoke pieces 46 and the hub shaft 34 in the radial direction D3 of the axial center a 1. However, the coupling member 56 may be disposed between the plurality of yoke pieces 46 and the axial center a1 as a whole in the radial direction D3. The coupling member 56 may be disposed entirely between the plurality of yoke pieces 46 and the hub shaft 34 in the radial direction D3. The cylindrical portion 56A may be partially disposed between the plurality of yoke pieces 46 and the hub shaft 34 in the radial direction D3.

The plurality of yoke pieces 46 include a yoke body 46A and a fixing portion 46B, respectively. The yoke body 46A is disposed to face the coil 30 in a radial direction D3 of the axial center a 1. The fixing portion 46B extends from the yoke body 46A toward the axial center a1 in the radial direction D3. The yoke piece 46 includes a first yoke end 46C and a second yoke end 46D. The yoke piece 46 extends from the first yoke end 46C to the second yoke end 46D along the shaft center a 1. The fixing portion 46B is provided at the first yoke end 46C and extends inward from the first yoke end 46C toward the axial center a1 in the radial direction D3. The fixing portion 46B includes a first fixing portion 46E and a second fixing portion 46F. The first fixing portion 46E protrudes radially inward from the yoke main body 46A in the radial direction D3. The second fixing portion 46F protrudes from the first fixing portion 46E in the axial direction D1.

The fixing portion 46B is disposed at least partially in the support hole 32A. The connecting member 56 is disposed at least partially in the support hole 32A. In the present embodiment, the fixing portion 46B is partially disposed in the support hole 32A. The second fixing portion 46F is partially disposed in the support hole 32A. The coupling member 56 is partially disposed in the support hole 32A. However, the fixing portion 46B may be disposed entirely in the support hole 32A. The connecting member 56 may be disposed entirely in the support hole 32A.

The fixing portion 46B is fixed to the connecting member 56. In the present embodiment, the fixing portion 46B of the yoke piece 46 is fixed to the connecting member 56 by welding. The fixing portion 46B of the yoke piece 46 is fixed to the cylindrical portion 56A and the flange 56B by welding. The first fixing portion 46E is fixed to the flange 56B by welding. The second fixing portion 46F is fixed to the cylindrical portion 56A by welding. However, the fixing portion 46B of the yoke piece 46 may be fixed to the connecting member 56 (the cylindrical portion 56A and/or the flange 56B) by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting.

The cylindrical portion 56A of the coupling member 56 contacts the outer peripheral surface of the hub shaft 34. The yoke pieces 46 are fixed to the connecting member 56, respectively. Therefore, the radial positions of the plurality of yoke pieces 46 with respect to the hub shaft 34 are determined by the coupling member 56.

As shown in fig. 13, the coupling member 58 is disposed at least partially between the plurality of yoke pieces 48 and the shaft center a1 in the radial direction D3 of the shaft center a 1. The coupling member 58 is disposed at least partially between the plurality of yoke pieces 48 and the hub shaft 34 in the radial direction D3 of the axial center a 1. In the present embodiment, the coupling member 58 is partially disposed between the plurality of yoke pieces 48 and the axial center a1 in the radial direction D3. The coupling member 58 is partially disposed between the plurality of yoke pieces 48 and the hub shaft 34 in the radial direction D3. The cylindrical portion 58A is disposed between the plurality of yoke pieces 48 and the hub shaft 34 in the radial direction D3 of the axial center a 1. However, the coupling member 58 may be disposed between the plurality of yoke pieces 48 and the axial center a1 as a whole in the radial direction D3. The coupling member 58 may be disposed entirely between the plurality of yoke pieces 48 and the hub shaft 34 in the radial direction D3. The cylindrical portion 58A may be partially disposed between the plurality of yoke pieces 48 and the hub shaft 34 in the radial direction D3.

The plurality of yoke pieces 48 include a yoke body 48A and a fixing portion 48B, respectively. The yoke body 48A is disposed to face the coil 30 in a radial direction D3 of the axial center a 1. The fixing portion 48B extends from the yoke body 48A toward the axial center a1 in the radial direction D3. The yoke piece 48 includes a first yoke end 48C and a second yoke end 48D. The yoke piece 48 extends from the first yoke end 48C to the second yoke end 48D along the axial center a 1. The fixing portion 48B is provided at the first yoke end 48C and extends inward from the first yoke end 48C toward the axial center a1 in the radial direction D3. The fixing portion 48B includes a first fixing portion 48E and a second fixing portion 48F. The first fixing portion 48E protrudes radially inward from the yoke body 48A in the radial direction D3. The second fixing portion 48F protrudes from the first fixing portion 48E in the axial direction D1.

The fixing portion 48B is disposed at least partially in the support hole 32A. The connecting member 58 is disposed at least partially in the support hole 32A. In the present embodiment, the fixing portion 48B is partially disposed in the support hole 32A. The second fixing portion 48F is partially disposed in the support hole 32A. The coupling member 58 is partially disposed in the support hole 32A. However, the fixing portion 48B may be disposed entirely in the support hole 32A. The coupling member 58 may be disposed entirely within the support hole 32A.

The fixing portion 48B is fixed to the connecting member 58. In the present embodiment, the fixing portion 48B of the yoke piece 48 is fixed to the connecting member 58 by welding. The fixing portion 48B of the yoke piece 48 is fixed to the cylindrical portion 58A and the flange 58B by welding. The first fixing portion 48E is fixed to the flange 58B by welding. The second fixing portion 48F is fixed to the cylindrical portion 58A by welding. However, the fixing portion 48B of the yoke piece 48 may be fixed to the connecting member 58 (the cylindrical portion 58A and/or the flange 58B) by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting.

The cylindrical portion 58A of the connecting member 58 contacts the outer peripheral surface of the hub shaft 34. The plurality of yoke pieces 48 are fixed to the connecting member 58, respectively. Therefore, the radial positions of the plurality of yoke pieces 48 with respect to the hub shaft 34 are determined by the coupling member 58.

As shown in fig. 12 and 13, the spool 32 includes a spool main body 32B, a first support portion 32C, and a second support portion 32D. The bobbin main body 32B is cylindrical. The first support portion 32C protrudes radially outward from the spool main body 32B. The second support portion 32D protrudes radially outward from the bobbin main body 32B. The first support portion 32C is disposed at an interval from the second support portion 32D in the axial direction D1 of the axis a 1. The coil 30 is wound around the bobbin main body 32B and disposed between the first support portion 32C and the second support portion 32D.

The coil 30 and the bobbin 32 are disposed between the plurality of fixing portions 46B of the plurality of yoke pieces 46 and the plurality of fixing portions 48B of the plurality of yoke pieces 48 in the axial direction D1. The fixing portion 46B of the yoke piece 46 contacts the fixing portion 48B of the yoke piece 48 in the axial direction D1. The cylindrical portion 56A of the coupling member 56 is disposed apart from the cylindrical portion 58A of the coupling member 58 in the axial direction D1. Therefore, the plurality of fixing portions 46B of the plurality of yoke pieces 46 and the plurality of fixing portions 48B of the plurality of yoke pieces 48 can determine the relative positions of the plurality of yoke pieces 46 and the plurality of yoke pieces 48 in the axial direction D1.

As shown in fig. 14, the pitch of the plurality of yoke pieces 46 is the same as the pitch of the plurality of yoke pieces 48. The phases of the plurality of yoke pieces 46 are shifted by half a pitch from the phases of the plurality of yoke pieces 48 in the circumferential direction D2. The plurality of yoke pieces 46 are respectively arranged between two adjacent yoke pieces 48 of the plurality of yoke pieces 48 in the circumferential direction D2. The plurality of yoke bodies 46A of the plurality of yoke pieces 46 are arranged between two adjacent yoke bodies 48A of the plurality of yoke pieces 48 in the circumferential direction D2.

The hub axle 34 includes at least one detent 34E. In the present embodiment, the hub shaft 34 includes a plurality of positioning grooves 34E. The plurality of positioning grooves 34E are provided on the outer peripheral surface of the drum shaft 34. The protruding portion 56D of the coupling member 56 is disposed in the positioning groove 34E to restrict the rotation of the plurality of yoke pieces 46 and the coupling member 56 with respect to the drum shaft 34.

As shown in fig. 15, the protruding portion 58D of the coupling member 58 is disposed in the positioning groove 34E to restrict the rotation of the coupling member 58 with respect to the drum shaft 34. That is, the plurality of yoke pieces 48 and the coupling member 58 are restricted from rotating with respect to the hub shaft 34 by the plurality of projections 58D.

As shown in fig. 14 and 15, in the present embodiment, the support hole 32A of the bobbin 32 has a polygonal shape. The inner peripheral surface forming the support hole 32A includes a plurality of flat surfaces arranged in the circumferential direction D2. As shown in fig. 14, the plurality of flat surfaces forming the support hole 32A are in contact with the plurality of fixing portions 46B of the plurality of yoke pieces 46. As shown in fig. 15, the plurality of flat surfaces forming the support hole 32A are in contact with the plurality of fixing portions 48B of the plurality of yoke pieces 48. However, the shape of the support hole 32A is not limited to a polygon.

The stator 12 of the generator 10 of the human-powered vehicle 2 is manufactured by the manufacturing method shown in fig. 16. As shown in fig. 17, a jig 80 is used in a method of manufacturing the stator 12 of the generator 10 of the human-powered vehicle 2. The jig 80 is used when assembling the yoke assembly 60. The fixture 80 may also be referred to as a first fixture 80. The jig 80 includes a jig main body 82 and a plurality of positioning magnets 84. The jig main body 82 includes an outer circumference positioning portion 86 and an inner circumference positioning portion 88. The jig main body 82 has a reference axial center A8 corresponding to the axial center a1 of the stator 12. The inner circumference positioning portion 88 is disposed inside the outer circumference positioning portion 86 in the radial direction of the reference axial center A8. The outer circumferential positioning portion 86 includes an inner circumferential surface 86A, and a plurality of positioning grooves 86B provided in the inner circumferential surface 86A. The positioning grooves 86B are arranged at equal intervals in the circumferential direction D82 of the reference axis A8, with the reference axis A8 as the center. The pitch of the positioning grooves 86B is the same as the pitch of the yoke pieces 46. The outermost circumferential position of the positioning grooves 86B with respect to the reference axial center A8 in the radial direction is the same as the outermost circumferential position of the yoke pieces 46 with respect to the axial center a1 in the radial direction. The positioning magnets 84 are disposed at positions corresponding to the positioning grooves 86B.

As shown in fig. 18, the positioning magnet 84 is provided in the outer periphery positioning portion 86 so as to be exposed from the positioning groove 86B. The inner circumference positioning portion 88 includes a positioning surface 88A and a shaft portion 88B. The positioning surface 88A is perpendicular to the reference axis A8 and faces the axial direction D81 of the reference axis A8. The shaft portion 88B projects from the positioning surface 88A in the axial direction D8. The positioning surface 88A is configured to determine the position of the plurality of yoke pieces 46 in the axial direction D81 in a state where the plurality of yoke pieces 46 are disposed in the plurality of positioning grooves 86B. The positioning surface 88A is configured to contact the fixing portions 46B of the yoke pieces 46 in a state where the yoke pieces 46 are arranged in the positioning grooves 86B.

As shown in fig. 16 and 17, the method for manufacturing the stator 12 of the generator 10 of the human-powered vehicle 2 includes a yoke disposing step S1, and in the yoke disposing step S1, the plurality of yoke pieces 46 are attached to the jig 80 so that the plurality of yoke pieces 46, which are independent members, are arranged around the reference axial center A8. As shown in fig. 17, in the yoke arranging step S1, the plurality of yoke pieces 46 are inserted into the plurality of positioning grooves 86B. More specifically, in the yoke disposing step S1, the yoke body 46A of the yoke piece 46 is inserted into the positioning groove 86B. Since the yoke piece 46 is made of a magnetic material, when the yoke piece 46 is inserted into the positioning groove 86B, the yoke piece 46 is attracted to the positioning magnet 84. Therefore, the positions of the plurality of yoke pieces 46 with respect to the reference shaft center A8 in the circumferential direction and the radial direction are determined.

As shown in fig. 18, in the yoke disposing step S1, the plurality of yoke pieces 46 are disposed on the jig 80 so as to contact the positioning surface 88A. More specifically, in the yoke arranging step S1, the plurality of fixing portions 46B of the plurality of yoke pieces 46 are arranged on the jig 80 so as to contact the positioning surface 88A in a state where the plurality of yoke pieces 46 are inserted into the plurality of positioning grooves 86B. Therefore, the positions of the plurality of yoke pieces 46 relative to the reference shaft center A8 in the axial direction are determined. At this time, a gap 89 is formed between the plurality of yoke pieces 46 and the shaft portion 88B in the radial direction D3, and the gap 89 is used for inserting the cylindrical portion 56A of the coupling member 56.

As shown in fig. 16 and 19, the method for manufacturing the stator 12 of the generator 10 of the human-powered vehicle 2 includes a connecting member disposing step S2 of attaching the connecting member 56 to the jig 80. As shown in fig. 19, in the coupling member arranging step S2, the coupling member 56 is attached to the jig 80 such that the axial center a1 of the coupling member 56 substantially coincides with the reference axial center a 8. More specifically, the cylindrical portion 56A of the coupling member 56 is inserted into the gap 89 formed between the plurality of yoke pieces 46 and the shaft portion 88B.

As shown in fig. 20, the shaft portion 88B includes a plurality of additional positioning grooves 88C. When the cylindrical portion 56A of the coupling member 56 is inserted into the gap 89 (see fig. 19, for example), the plurality of projections 56D of the coupling member 56 are inserted into the plurality of additional positioning grooves 88C, respectively. This allows the coupling member 56 to be disposed at a predetermined angle with respect to the plurality of yoke pieces 46.

As shown in fig. 16 and 21, the method for manufacturing the stator 12 of the generator 10 of the human-powered vehicle 2 includes a fixing step S3 of fixing each of the plurality of yoke pieces 46 to the connecting member 56. In the fixing step S3, the plurality of yoke pieces 46 are fixed to the connecting member 56 by at least one of welding, bonding, and fitting (S3A). In the fixing step S3, each of the plurality of yoke pieces 46 is fixed to the flange 56B of the connecting member 56 by at least one of welding, bonding, and fitting. In the present embodiment, each of the plurality of yoke pieces 46 is fixed to the flange 56B of the connecting member 56 by welding. However, the plurality of yoke pieces 46 may be fixed to the connecting member 56 by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting. The plurality of yoke pieces 46 may be fixed to the flange 56B by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. In the present embodiment, the plurality of yoke pieces 46 may be fixed to the outer peripheral edge of the flange 56B by welding. Therefore, in the fixing step S3, the plurality of welded portions 62 are formed on the outer peripheral side of the flange 56B.

As shown in fig. 16 and 5, in the fixing step S3, the plurality of yoke pieces 46 fixed to the coupling member 56 are removed from the jig 80 (S3B). In the fixing step S3, the plurality of yoke pieces 46 removed from the jig 80 are further fixed to the coupling member 56 by welding, respectively (S3C). More specifically, the plurality of fixing portions 46B of the plurality of yoke pieces 46 are fixed to the cylindrical portion 56A of the coupling member 56 by welding. Therefore, in the fixing step S3, the plurality of welded portions 64 are formed on the inner peripheral side of the plurality of fixing portions 46B. However, in the fixing step S3, the step S3C of fixing the plurality of yoke pieces 46 detached from the jig 80 to the connecting member 56 by welding may be omitted.

As shown in fig. 16, the plurality of yoke pieces 48 are fixed to the connecting member 58, respectively, similarly to the connecting member 56 and the plurality of yoke pieces 46. As shown in fig. 22, a jig 90 is used in a method of manufacturing the stator 12 of the generator 10 of the human-powered vehicle 2. The structure of the jig 90 is substantially the same as that of the jig 80. The jig 90 is used when assembling the yoke assembly 66. The fixture 90 may also be referred to as a second fixture 90. The clamp 90 includes a clamp body 92 and a plurality of positioning magnets 94. The jig main body 92 includes an outer circumference positioning portion 96 and an inner circumference positioning portion 98. The jig main body 92 has a reference axial center a9 corresponding to the axial center a1 of the stator 12. The inner circumferential positioning portion 98 is disposed inside the outer circumferential positioning portion 96 in the radial direction of the reference axial center a 9. The outer circumferential positioning portion 96 includes an inner circumferential surface 96A, and a plurality of positioning grooves 96B provided on the inner circumferential surface 96A. The positioning grooves 96B are arranged at equal intervals in the circumferential direction D92 of the reference axis a9 at the center of the reference axis a 9. The pitch of the positioning grooves 96B is the same as the pitch of the yoke pieces 48. The outermost circumferential position of the plurality of positioning grooves 96B with respect to the reference shaft center a9 in the radial direction is the same as the outermost circumferential position of the plurality of yoke pieces 48 with respect to the shaft center a1 in the radial direction. The positioning magnets 94 are disposed at positions corresponding to the positioning grooves 96B.

The shaft portion 98B includes a plurality of additional positioning grooves 98C. As shown in fig. 17 and 22, the positional relationship in the circumferential direction D92 between the plurality of positioning grooves 96B and the plurality of additional positioning grooves 98C is different from the positional relationship in the circumferential direction D82 between the plurality of positioning grooves 86B and the plurality of additional positioning grooves 88C.

As shown in fig. 18, the positioning magnet 94 is provided on the outer periphery positioning portion 96 so as to be exposed from the positioning groove 96B. The inner circumference positioning portion 98 includes a positioning surface 98A and a shaft portion 98B. The positioning surface 98A is perpendicular to the reference axis a9 and faces the axial direction D91 of the reference axis a 9. The shaft portion 98B projects from the positioning surface 98A in the axial direction D8. The positioning surface 98A is configured to position the plurality of yoke pieces 48 in the axial direction D91 in a state where the plurality of yoke pieces 48 are arranged in the plurality of positioning grooves 96B. The positioning surface 98A is configured to contact the plurality of fixing portions 48B of the plurality of yoke pieces 48 in a state where the plurality of yoke pieces 48 are arranged in the plurality of positioning grooves 96B.

As shown in fig. 16 and 22, the method for manufacturing the stator 12 of the generator 10 of the human-powered vehicle 2 includes a yoke disposing step S4, and in the yoke disposing step S4, the plurality of yoke pieces 48 are attached to the jig 90 such that the plurality of yoke pieces 48, which are independent members, are arranged around the reference axial center a 9. As shown in fig. 22, in the yoke arranging step S4, the plurality of yoke pieces 48 are inserted into the plurality of positioning grooves 96B. More specifically, in the yoke disposing step S4, the yoke body 48A of the yoke piece 48 is inserted into the positioning groove 96B. Since the yoke piece 48 is made of a magnetic material, when the yoke piece 48 is inserted into the positioning groove 96B, the yoke piece 48 is attracted to the positioning magnet 94. Therefore, the positions of the plurality of yoke pieces 48 with respect to the reference shaft center a9 in the circumferential direction and the radial direction are determined.

As shown in fig. 18, in the yoke disposing step S4, the plurality of yoke pieces 48 are disposed on the jig 90 so as to contact the positioning surface 98A. More specifically, in the yoke arranging step S4, the plurality of fixing portions 48B of the plurality of yoke pieces 48 are arranged on the jig 90 so as to contact the positioning surface 98A in a state where the plurality of yoke pieces 48 are inserted into the plurality of positioning grooves 96B. Therefore, the positions of the plurality of yoke pieces 48 with respect to the reference shaft center a9 in the axial direction are determined. At this time, a gap 99 is formed between the plurality of yoke pieces 48 and the shaft portion 98B in the radial direction D3, and the cylindrical portion 58A of the coupling member 58 is inserted into the gap 99.

As shown in fig. 16 and 19, the method for manufacturing the stator 12 of the generator 10 of the human-powered vehicle 2 includes a connecting member arranging step S5 of attaching the connecting member 56 to the jig 80. As shown in fig. 19, in the coupling member arranging step S5, the coupling member 58 is attached to the jig 90 such that the axial center a1 of the coupling member 58 substantially coincides with the reference axial center a 9. More specifically, the cylindrical portion 58A of the coupling member 58 is inserted into the gap 99 formed between the plurality of yoke pieces 48 and the shaft portion 98B.

As shown in fig. 23, when the cylindrical portion 58A of the coupling member 58 is inserted into the gap 99 (see, for example, fig. 22), the plurality of projections 58D of the coupling member 58 are inserted into the plurality of additional positioning grooves 98C, respectively. This allows the coupling member 58 to be disposed at a predetermined angle with respect to the plurality of yoke pieces 48.

As shown in fig. 16 and 24, the method for manufacturing the stator 12 of the generator 10 of the human-powered vehicle 2 includes a fixing step S6 of fixing each of the plurality of yoke pieces 48 to the connecting member 58. In the fixing step S6, the plurality of yoke pieces 48 are fixed to the connecting member 58 by at least one of welding, adhesion, and fitting (S6A). In the fixing step S6, each of the plurality of yoke pieces 48 is fixed to the flange 58B of the connecting member 58 by at least one of welding, adhesion, and fitting. In the present embodiment, each of the plurality of yoke pieces 48 is fixed to the flange 58B of the coupling member 58 by welding. However, the plurality of yoke pieces 48 may be fixed to the connecting member 58 by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. The plurality of yoke pieces 48 may be fixed to the flange 58B by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. In the present embodiment, the plurality of yoke pieces 48 are fixed to the outer peripheral edge of the flange 58B by welding. Therefore, in the fixing step S6, the plurality of welded portions 62 are formed on the outer peripheral side of the flange 58B.

As shown in fig. 16 and 7, in the fixing step S6, the plurality of yoke pieces 48 fixed to the coupling member 58 are removed from the jig 90 (S6B). In the fixing step S6, the plurality of yoke pieces 48 detached from the jig 90 are further fixed to the connecting member 58 by welding (S6C). More specifically, the plurality of fixing portions 48B of the plurality of yoke pieces 48 are fixed to the cylindrical portion 58A of the connecting member 58 by welding. Therefore, in the fixing step S6, the plurality of welded portions 64 are formed on the inner peripheral side of the plurality of fixing portions 48B. However, the step of fixing the plurality of yoke pieces 48 detached from the jig 90 to the connecting member 58 by welding may be omitted from the fixing step S6.

As shown in fig. 16 and 3, the method of manufacturing the stator 12 further includes an attaching step S7 of attaching the plurality of yoke pieces 46 (i.e., the yoke assembly 60) coupled by the coupling member 56 to the hub shaft 34. More specifically, in the mounting step S7, the support member 40, the cover 42, and the controller 44 are mounted on the hub shaft 34 before the coupling member 56 and the plurality of yoke pieces 46 are mounted on the hub shaft 34 (S7A). In the mounting step S7, the coupling member 56 and the plurality of yoke pieces 46 (i.e., the yoke assembly 60) are mounted on the coil 30 and the bobbin 32 (S7B). In the mounting step S7, the plurality of yoke pieces 48 (i.e., the yoke assembly 66) coupled via the coupling members 58 are mounted on the coil 30 and the bobbin 32 (S7C). In the mounting step S7, after the support member 40, the cover 42, and the controller 44 are mounted on the hub shaft 34, the coil unit including the yoke assembly 60, the yoke assembly 66, the coil 30, and the bobbin 32 is mounted on the hub shaft 34 (S7D). In the mounting step S7, the lock nut 50 is mounted on the hub shaft 34 (S7E). By screwing the locknut 50 into the threaded portion 34C, the support member 40, the cover 42, the coupling member 56, the plurality of yoke pieces 46, the bobbin 32, the plurality of yoke pieces 48, and the coupling member 58 are sandwiched between the locknut 50 and the large diameter portion 34D. The order of assembling the support member 40, the cover 42, the controller 44, the coil 30, the bobbin 32, the yoke assembly 60, and the yoke assembly 66 is not limited to the above-described order. For example, at least two of the yoke assembly 60, the yoke assembly 66, and the bobbin 32 may be attached to the drum shaft 34.

(second embodiment)

The generator 210 according to the second embodiment will be described below with reference to fig. 25 to 36. The generator 210 has substantially the same structure as the generator 10 according to the first embodiment, except for the stator 12. Therefore, components having substantially the same configurations as those of the first embodiment are denoted by the same reference numerals, and detailed description and/or drawings are omitted for the sake of simplifying the description.

As shown in fig. 25, the generator 210 of the human-powered vehicle 2 includes a stator 212 and the rotary body 14. The rotary body 14 is provided to be rotatable about the axial center a1 with respect to the stator 212. The generator 210 is configured to generate electric power by relative rotation of the stator 212 and the rotary body 14. The stator 212 is configured to be attached to the frame 4.

In the second embodiment, the sprocket support body 19, the third bearing 24, the fourth bearing 26, the one-way clutch mechanism 28, the support member 40, the cover 42, and the controller 44 are omitted from the generator 210. However, the generator 210 may have these structures.

Stator 212 is also provided with a spline shaft 234. The hub axle 234 extends in an axial direction D1 from an axis a 1. The hub shaft 234 includes substantially the same structure as the hub shaft 34 of the first embodiment. The through hole 34H is omitted from the hub shaft 234.

As shown in fig. 26, a stator 212 of a generator 210 of a human-powered vehicle 2 includes a plurality of yoke pieces 46. The plurality of yoke pieces 46 are arranged in the circumferential direction D2 of the axial center a 1. The plurality of yoke pieces 46 are attached to the hub shaft 234. The hub axle 234 supports the coil 30 and the plurality of yoke pieces 46. The stator 212 of the generator 210 of the human-powered vehicle 2 includes a plurality of yoke pieces 48. The plurality of yoke pieces 48 are arranged in the circumferential direction D2 of the axial center a 1. The plurality of yoke pieces 48 are attached to the hub shaft 234. The hub axle 234 supports the coil 30 and the plurality of yoke pieces 48.

As shown in fig. 27, the stator 212 of the generator 210 of the human-powered vehicle 2 includes a coupling member 256. The coupling member 256 is configured as a member separate from the plurality of yoke pieces 46. The bobbin 32 is configured as a member independent from the plurality of yoke pieces 46 and the connecting member 256. The coupling member 256 may also be referred to as a first coupling member 256.

The coupling member 256 extends in the circumferential direction D2. The connecting member 256 is annular. The coupling member 256 includes a cylindrical portion 256A extending along the axial center a 1. The coupling member 256 includes a flange 256B extending outward from the cylindrical portion 256A in the radial direction of the axial center a 1.

The stator 212 of the generator 210 of the human-powered vehicle 2 includes a coupling member 258. The coupling member 258 is formed as a member separate from the plurality of yoke pieces 48. The bobbin 32 is formed as a separate member from the plurality of yoke pieces 48 and the connecting member 258. The coupling member 258 may also be referred to as a second coupling member 258.

The coupling member 258 extends in the circumferential direction D2. The connecting member 258 is annular. The coupling member 258 includes a cylindrical portion 258A extending along the axial center a 1. The coupling member 258 includes a flange 258B extending outward from the cylindrical portion 258A in the radial direction of the axis a 1.

The stator 212 includes a lock nut 255. The lock nut 255 has the same structure as the lock nut 50. The lock nut 50 is also referred to as a first lock nut 50. The lock nut 255 may also be referred to as a second lock nut 255. The locking nut 255 includes a threaded bore 255A. The hub axle 234 includes a threaded portion 234F. The screw hole 255A of the lock nut 255 is engaged with the screw portion 234F of the hub shaft 234. The lock nut 50 and the lock nut 255 are attached to the hub shaft 34 to hold the coil 30, the bobbin 32, the plurality of yoke pieces 46, and the plurality of yoke pieces 48 to the hub shaft 234.

As shown in fig. 28, the plurality of yoke pieces 46 are fixed to the coupling member 256, respectively. Therefore, the plurality of yoke pieces 46 and the coupling member 256 are configured to be detachably attached to the hub shaft 234 as an integral unit. That is, the plurality of yoke pieces 46 and the connecting member 256 constitute the yoke assembly 60.

As shown in fig. 28 and 29, each of the plurality of yoke pieces 46 is fixed to the connecting member 256 by at least one of welding, adhesion, and fitting. The plurality of yoke pieces 46 are fixed to the cylindrical portion 256A by at least one of welding, bonding, and fitting. The plurality of yoke pieces 46 are fixed to the flange 256B by at least one of welding, bonding, and fitting. In the present embodiment, each of the plurality of yoke pieces 46 is fixed to the connecting member 256 by welding. The plurality of yoke pieces 46 are fixed to the cylindrical portion 256A by welding. The plurality of yoke pieces 46 are fixed to the flange 256B by welding, respectively. However, the plurality of yoke pieces 46 may be fixed to the connecting member 256 by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting. However, the plurality of yoke pieces 46 may be fixed to the cylindrical portion 256A by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. The plurality of yoke pieces 46 may be fixed to the flange 256B by any of (1) adhesion bonding, (2) fitting, (3) welding and adhesion, (4) adhesion and fitting, (5) welding and fitting, and (6) welding, adhesion, and fitting, respectively.

The fixing portion 46B is fixed to the coupling member 256. In the present embodiment, the fixing portion 46B of the yoke piece 46 is fixed to the connecting member 256 by welding. The fixing portion 46B of the yoke piece 46 is fixed to the cylindrical portion 256A and the flange 256B by welding. The first fixing portion 46E is fixed to the flange 256B by welding. The second fixing portion 46F is fixed to the cylindrical portion 256A by welding. That is, the yoke assembly 60 includes a plurality of welding portions 62 and a plurality of welding portions 64. However, the fixing portion 46B of the yoke piece 46 may be fixed to the connecting member 256 (the cylindrical portion 256A and/or the flange 256B) by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting.

As shown in fig. 30, the plurality of yoke pieces 48 are fixed to the coupling member 258, respectively. Therefore, the plurality of yoke pieces 48 and the coupling member 258 are configured to be detachably attached to the hub shaft 234 as an integral unit. That is, the plurality of yoke pieces 48 and the connecting member 258 constitute the yoke assembly 66.

As shown in fig. 30 and 31, each of the plurality of yoke pieces 48 is fixed to the connecting member 258 by at least one of welding, adhesion, and fitting. The plurality of yoke pieces 48 are fixed to the cylindrical portion 258A by at least one of welding, adhesion, and fitting. The plurality of yoke pieces 48 are fixed to the flange 258B by at least one of welding, bonding, and fitting. In the present embodiment, each of the plurality of yoke pieces 48 is fixed to the coupling member 258 by welding. The plurality of yoke pieces 48 are fixed to the cylindrical portion 258A by welding. The plurality of yoke pieces 48 are fixed to the flange 258B by welding, respectively. However, the plurality of yoke pieces 48 may be fixed to the connecting member 258 by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting. The plurality of yoke pieces 48 can be fixed to the cylindrical portion 258A by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. The plurality of yoke pieces 48 may be fixed to the flange 258B by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively.

The fixing portion 48B is fixed to the coupling member 258. In the present embodiment, the fixing portion 48B of the yoke piece 48 is fixed to the connecting member 258 by welding. The fixing portion 48B of the yoke piece 48 is fixed to the cylindrical portion 258A and the flange 258B by welding. The first fixing portion 48E is fixed to the flange 258B by welding. The second fixing portion 48F is fixed to the cylindrical portion 258A by welding. That is, the yoke assembly 66 includes a plurality of welds 68 and a plurality of welds 70. However, the fixing portion 48B of the yoke piece 48 may be fixed to the connecting member 258 (the cylindrical portion 258A and/or the flange 258B) by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting.

As shown in fig. 32, the coupling member 256 includes at least one protruding portion 256D that protrudes radially inward from the cylindrical portion 256A. In the present embodiment, the coupling member 256 includes a plurality of protruding portions 256D that protrude radially inward from the cylindrical portion 256A. The plurality of protrusions 256D are configured to position the plurality of yoke pieces 46 with respect to the hub axle 234 in the circumferential direction D2. Flange 256B includes at least one aperture 256F. In this embodiment, flange 256B includes a plurality of apertures 256F. The plurality of holes 56F are arranged at equal intervals in the circumferential direction D2. The aperture 256F is circular. However, the shape of the hole 256F is not limited to a circle. Although the projection 56E of the first embodiment is omitted from the coupling member 256, the projection 56E may be included. At least one of the plurality of holes 256F may be omitted from the coupling member 256.

In the second embodiment, the coupling member 258 has the same shape as the coupling member 256, and therefore, the description of the coupling member 258 is omitted. The coupling member 258 may have a different shape from the coupling member 256.

As shown in fig. 33, the coupling member 256 is disposed at least partially between the plurality of yoke pieces 46 and the shaft center a1 in the radial direction D3 of the shaft center a 1. The coupling member 256 is disposed at least partially between the plurality of yoke pieces 46 and the hub shaft 234 in the radial direction D3 of the axial center a 1. In the present embodiment, the coupling member 256 is partially disposed between the plurality of yoke pieces 46 and the shaft center a1 in the radial direction D3. The coupling member 256 is partially disposed between the plurality of yoke pieces 46 and the hub shaft 234 in the radial direction D3. The cylindrical portion 256A of the coupling member 256 is disposed between the plurality of yoke pieces 46 and the hub shaft 234 in the radial direction D3 of the axial center a 1. However, the coupling member 256 may be disposed between the plurality of yoke pieces 46 and the shaft center a1 as a whole in the radial direction D3. The coupling member 256 may be disposed between the plurality of yoke pieces 46 and the hub shaft 234 as a whole in the radial direction D3. The cylindrical portion 256A of the coupling member 256 may be partially disposed between the plurality of yoke pieces 46 and the hub shaft 234 in the radial direction D3.

As shown in fig. 34, the coupling member 258 is disposed at least partially between the plurality of yoke pieces 48 and the shaft center a1 in the radial direction D3 of the shaft center a 1. The coupling member 258 is disposed at least partially between the plurality of yoke pieces 48 and the hub shaft 234 in the radial direction D3 of the axis a 1. In the present embodiment, the coupling member 258 is partially disposed between the plurality of yoke pieces 48 and the axial center a1 in the radial direction D3. The coupling member 258 is partially disposed between the plurality of yoke pieces 48 and the hub shaft 234 in the radial direction D3. The cylindrical portion 258A is disposed between the plurality of yoke pieces 48 and the hub shaft 234 in the radial direction D3 of the axial center a 1. However, the coupling member 258 may be disposed between the plurality of yoke pieces 48 and the shaft center a1 as a whole in the radial direction D3. The coupling member 258 may be disposed between the plurality of yoke pieces 48 and the hub shaft 234 in the radial direction D3 as a whole. The cylindrical portion 258A may be partially disposed between the plurality of yoke pieces 48 and the hub shaft 234 in the radial direction D3.

As shown in fig. 35, the hub axle 234 includes at least one positioning slot 234E. In the present embodiment, the hub shaft 234 includes a plurality of positioning grooves 234E. The plurality of positioning grooves 234E are provided on the outer peripheral surface of the drum shaft 234. The projections 256D of the coupling member 256 restrict the rotation of the plurality of yoke pieces 46 and the coupling member 256 with respect to the hub shaft 234 by the plurality of projections 256D.

As shown in fig. 36, the projections 258D of the coupling member 258 restrict the rotation of the plurality of yoke pieces 48 and the coupling member 258 with respect to the hub shaft 234 by the plurality of projections 258D.

The method of manufacturing the stator 212 is substantially the same as the method of manufacturing the stator 12 according to the first embodiment, except that the step of attaching the support member 40, the cover 42, and the controller 44 to the drum shaft 34 is omitted from the attaching step S7. The jig used in the method of manufacturing the stator 212 has substantially the same structure as the jigs 80 and 90 of the first embodiment. Therefore, the description of the method of manufacturing the stator 212 is omitted.

(third embodiment)

The generator 310 according to the third embodiment will be described below with reference to fig. 37 to 45. The generator 310 has substantially the same structure as the generator 210 according to the second embodiment, except for the stator 212. Therefore, the same reference numerals are given to the components having substantially the same configurations as those of the first and second embodiments, and detailed description and/or illustration thereof is omitted for the sake of simplifying the description.

As shown in fig. 37, the generator 310 of the human-powered vehicle 2 includes a stator 312 and the rotor 14. The rotating body 14 is provided to be rotatable about an axial center a1 with respect to the stator 312. The generator 310 is configured to generate electric power by relative rotation of the stator 312 and the rotary body 14. The stator 312 is configured to be attached to the frame 4.

As shown in fig. 38 and 39, the stator 312 of the generator 310 of the human-powered vehicle 2 includes a plurality of yoke pieces 46 and a plurality of yoke pieces 48. The stator 312 also has a spline shaft 234. The stator 312 includes a lock nut 50 and a lock nut 255.

As shown in fig. 39, the stator 312 of the generator 310 of the human-powered vehicle 2 includes a coupling member 356. The coupling member 356 is formed as a member separate from the plurality of yoke pieces 46. The bobbin 32 is configured as a member independent from the plurality of yoke pieces 46 and the coupling member 356. The coupling member 356 may also be referred to as a first coupling member 356.

The coupling member 356 extends in the circumferential direction D2. The connecting member 356 is annular. The coupling member 356 includes a cylindrical portion 256A extending along an axial center a 1. The coupling member 356 includes a flange 356B extending outward from the cylindrical portion 256A in the radial direction of the axial center a 1.

The stator 312 of the generator 310 of the human-powered vehicle 2 includes a coupling member 358. The coupling member 358 is configured as a member separate from the plurality of yoke pieces 48. The bobbin 32 is formed as a member separate from the plurality of yoke pieces 48 and the coupling member 358. The coupling member 358 may also be referred to as a second coupling member 358.

The coupling member 358 extends in the circumferential direction D2. The connecting member 358 has a ring shape. The coupling member 358 includes a cylindrical portion 258A extending along the axial center a 1. The coupling member 358 includes a flange 358B extending outward from the cylindrical portion 258A in the radial direction of the axial center a 1.

As shown in fig. 40, the plurality of yoke pieces 46 are fixed to the coupling member 356. Therefore, the plurality of yoke pieces 46 and the coupling member 356 are configured to be detachably attached to the hub shaft 234 as an integral unit. That is, the plurality of yoke pieces 46 and the coupling member 356 constitute the yoke assembly 60.

As shown in fig. 40 and 41, each of the plurality of yoke pieces 46 is fixed to the connecting member 356 by at least one of welding, adhesion, and fitting. The plurality of yoke pieces 46 are fixed to the cylindrical portion 256A by at least one of welding, bonding, and fitting. The plurality of yoke pieces 46 are fixed to the flange 356B by at least one of welding, bonding, and fitting. In the present embodiment, each of the plurality of yoke pieces 46 is fixed to the connecting member 356 by welding. The plurality of yoke pieces 46 are fixed to the cylindrical portion 256A by welding. The plurality of yoke pieces 46 are fixed to the flange 356B by welding, respectively. However, the plurality of yoke pieces 46 may be fixed to the connecting member 356 by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting. However, the plurality of yoke pieces 46 may be fixed to the cylindrical portion 256A by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. The plurality of yoke pieces 46 may be fixed to the flange 356B by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively.

The fixing portion 46B is fixed to the coupling member 356. In the present embodiment, the fixing portion 46B of the yoke piece 46 is fixed to the connecting member 356 by welding. The fixing portion 46B of the yoke piece 46 is fixed to the cylindrical portion 256A and the flange 356B by welding. The first fixing portion 46E is fixed to the cylindrical portion 256A by welding. The second fixing portion 46F is fixed to the flange 356B by welding. That is, the yoke assembly 66 includes a plurality of welds 68 and a plurality of welds 70. However, the fixing portion 46B of the yoke piece 46 may be fixed to the connecting member 356 (the cylindrical portion 256A and/or the flange 356B) by any of (1) adhesion, (2) fitting, (3) welding and adhesion, (4) adhesion and fitting, (5) welding and fitting, and (6) welding, adhesion, and fitting.

As shown in fig. 42, the plurality of yoke pieces 48 are fixed to the coupling member 358, respectively. Therefore, the plurality of yoke pieces 48 and the coupling member 358 are configured to be detachably attached to the hub shaft 234 as an integral unit. That is, the plurality of yoke pieces 48 and the coupling member 358 constitute the yoke assembly 66.

As shown in fig. 42 and 43, each of the plurality of yoke pieces 48 is fixed to the connecting member 358 by at least one of welding, adhesion, and fitting. The plurality of yoke pieces 48 are fixed to the cylindrical portion 258A by at least one of welding, adhesion, and fitting. The plurality of yoke pieces 48 are fixed to the flange 358B by at least one of welding, adhesion, and fitting. In the present embodiment, each of the plurality of yoke pieces 48 is fixed to the coupling member 358 by welding. The plurality of yoke pieces 48 are fixed to the cylindrical portion 258A by welding. The plurality of yoke pieces 48 are fixed to the flange 358B by welding, respectively. However, the plurality of yoke pieces 48 may be fixed to the connecting member 358 by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting. The plurality of yoke pieces 48 may be fixed to the cylindrical portion 258A by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively. The plurality of yoke pieces 48 may be fixed to the flange 358B by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting, respectively.

The fixing portion 48B is fixed to the coupling member 358. In the present embodiment, the fixing portion 48B of the yoke piece 48 is fixed to the coupling member 358 by welding. The fixing portion 48B of the yoke piece 48 is fixed to the cylindrical portion 258A and the flange 358B by welding. The first fixing portion 48E is fixed to the cylindrical portion 258A by welding. The second fixing portion 48F is fixed to the flange 358B by welding. That is, the yoke assembly 66 includes a plurality of welds 68 and a plurality of welds 70. However, the fixing portion 48B of the yoke piece 48 may be fixed to the connecting member 358 (the cylindrical portion 258A and/or the flange 358B) by any of (1) bonding, (2) fitting, (3) welding and bonding, (4) bonding and fitting, (5) welding and fitting, and (6) welding, bonding, and fitting.

As shown in fig. 44, the coupling member 356 includes at least one protruding portion 356D that protrudes radially inward from the cylindrical portion 256A. In the present embodiment, the coupling member 356 includes a plurality of protruding portions 356D that protrude radially inward from the cylindrical portion 256A. The plurality of projections 356D are configured to position the plurality of yoke pieces 46 with respect to the hub axle 234 in the circumferential direction D2. The flange 356B includes a plurality of apertures 256F. The projection 56E of the first embodiment is omitted from the coupling member 356. At least one of the plurality of holes 256F may also be omitted from the connecting member 356.

Since the coupling member 358 has the same shape as the coupling member 356, the description of the coupling member 358 is omitted. The coupling member 358 may have a different shape from the coupling member 356.

As shown in fig. 40, the projections 356D of the coupling member 356 restrict the rotation of the yoke pieces 46 and the coupling member 356 with respect to the hub shaft 234 by the projections 356D.

As shown in fig. 42, the projections 358D of the coupling member 358 restrict the plurality of yoke pieces 48 and the coupling member 358 from rotating with respect to the drum shaft 234 by the plurality of projections 358D.

As shown in fig. 45, the coupling member 356 is disposed at least partially between the plurality of yoke pieces 46 and the shaft center a1 in the radial direction D3 of the shaft center a 1. The coupling member 356 is disposed at least partially between the plurality of yoke pieces 46 and the hub shaft 234 in the radial direction D3 of the axial center a 1. In the present embodiment, the coupling member 356 is partially disposed between the plurality of yoke pieces 46 and the axial center a1 in the radial direction D3. The coupling member 356 is partially disposed between the plurality of yoke pieces 46 and the hub shaft 234 in the radial direction D3. The cylindrical portion 256A of the coupling member 356 is disposed between the plurality of yoke pieces 46 and the hub shaft 234 in the radial direction D3 of the axial center a 1. However, the coupling member 356 may be disposed between the plurality of yoke pieces 46 and the shaft center a1 as a whole in the radial direction D3. The coupling member 356 may be disposed between the plurality of yoke pieces 46 and the hub shaft 234 in the radial direction D3. The cylindrical portion 256A of the coupling member 356 may be partially disposed between the plurality of yoke pieces 46 and the hub shaft 234 in the radial direction D3.

As shown in fig. 46, the coupling member 358 is disposed at least partially between the plurality of yoke pieces 48 and the shaft center a1 in the radial direction D3 of the shaft center a 1. The coupling member 358 is disposed at least partially between the plurality of yoke pieces 48 and the hub shaft 234 in the radial direction D3 of the axial center a 1. In the present embodiment, the coupling member 358 is partially disposed between the plurality of yoke pieces 48 and the axial center a1 in the radial direction D3. The coupling member 358 is partially disposed between the plurality of yoke pieces 48 and the hub shaft 234 in the radial direction D3. The cylindrical portion 258A of the coupling member 358 is disposed between the plurality of yoke pieces 48 and the hub shaft 234 in the radial direction D3 of the axial center a 1. However, the coupling member 358 may be disposed between the plurality of yoke pieces 48 and the axial center a1 as a whole in the radial direction D3. The coupling member 358 may be disposed between the plurality of yoke pieces 48 and the hub shaft 234 as a whole in the radial direction D3. The cylindrical portion 258A of the coupling member 358 may be partially disposed between the plurality of yoke pieces 48 and the hub shaft 234 in the radial direction D3.

The coupling members 356 and 358 are clamped between the lock nut 50 and the lock nut 255 in the axial direction D1. The flanges 356B and 358B are sandwiched between the plurality of yoke pieces 46 and 48 in the axial direction D1. The plurality of yoke pieces 46 are spaced apart from the lock nut 255 in the axial direction D1. The plurality of yoke pieces 48 are spaced apart from the lock nut 50 in the axial direction D1.

The stator 312 of the generator 10 of the human-powered vehicle 2 is manufactured by the manufacturing method shown in fig. 47. As shown in fig. 47, the manufacturing method of the stator 312 is partially different from the manufacturing method of the stator 12 in the order of steps. As shown in fig. 48 and 49, the jig used in the method of manufacturing the stator 312 has substantially the same configuration as the jig 80 and the jig 90 of the first and second embodiments.

As shown in fig. 47, the method for manufacturing the stator 312 of the generator 10 of the human-powered vehicle 2 includes a connecting member arranging step S31 of attaching the connecting member 356 to the jig 80. As shown in fig. 48 and 49, in the coupling member arranging step S31, the coupling member 356 is attached to the jig 80 such that the axial center a1 of the coupling member 356 substantially coincides with the reference axial center a 8. More specifically, the plurality of projections 356D of the coupling member 356 are inserted into the plurality of additional positioning grooves 88C.

As shown in fig. 47, the method for manufacturing the stator 312 of the generator 10 of the human-powered vehicle 2 includes a yoke disposing step S32, and in the yoke disposing step S32, the plurality of yoke pieces 46 are attached to the jig 80 such that the plurality of yoke pieces 46, which are independent members, are arranged around the reference axial center a 8. As shown in fig. 48 and 49, in the yoke arranging step S32, the plurality of yoke pieces 46 are inserted into the plurality of positioning grooves 86B. Therefore, the plurality of yoke pieces 46 can be arranged at a predetermined angle with respect to the coupling member 356.

As shown in fig. 47, the method for manufacturing the stator 312 of the generator 10 of the human-powered vehicle 2 includes a fixing step S3 of fixing each of the plurality of yoke pieces 46 to the connecting member 356. As shown in fig. 48 and 49, in the fixing step S3, each of the plurality of yoke pieces 46 is fixed to the cylindrical portion 256A of the connecting member 356 by welding (S3A). As shown in fig. 41, in the fixing step S3, the plurality of yoke pieces 46 fixed to the coupling member 356 are removed from the jig 80 (S3B). In the fixing step S3, the plurality of yoke pieces 46 removed from the jig 80 are further fixed to the coupling member 356 by welding (S3C). More specifically, the plurality of fixing portions 46B of the plurality of yoke pieces 46 are fixed to the flange 356B of the coupling member 356 by welding. However, the step S3C of fixing the plurality of yoke pieces 46 detached from the jig 80 to the connecting member 356 by welding may be omitted from the fixing step S3.

As shown in fig. 47, the plurality of yoke pieces 48 are fixed to the connecting member 358 in the connecting member arranging step S34, the yoke arranging step S35, and the fixing step S6, respectively, similarly to the connecting member 356 and the plurality of yoke pieces 46. The coupling member disposing step S34, the yoke disposing step S35, and the fixing step S6 are substantially the same as the coupling member disposing step S31, the yoke disposing step S32, and the fixing step S3. Therefore, the detailed description of the coupling member disposing step S34, the yoke disposing step S35, and the fixing step S6 is omitted.

As shown in fig. 47, the method of manufacturing the stator 312 further includes an attaching step S37 of attaching the plurality of yoke pieces 46 (i.e., the yoke assembly 60) coupled by the coupling member 356 to the hub shaft 234. More specifically, in the mounting step S37, the locknut 255 is mounted to the hub axle 234 before the coupling member 356 and the plurality of yoke pieces 46 are mounted to the hub axle 234 (S37A). In the mounting step S37, the yoke assembly 60 and the yoke assembly 66 are mounted on the coil 30 and the bobbin 32(S7B, S7C), similarly to the mounting step S7 of the first embodiment. In the mounting step S37, the coil unit including the yoke assembly 60, the yoke assembly 66, the coil 30, and the bobbin 32 is mounted on the hub shaft 234 (S7D). In the mounting step S37, the lock nut 50 is mounted on the hub axle 234 (S7E). By screwing the lock nut 50 into the threaded portion 34C, the coupling member 356, the plurality of yoke pieces 46, the bobbin 32, the plurality of yoke pieces 48, and the coupling member 358 are sandwiched between the lock nut 50 and the lock nut 255. The order of assembling the coil 30, the bobbin 32, the yoke assembly 60, and the yoke assembly 66 is not limited to the above order. For example, at least two of the yoke assembly 60, the yoke assembly 66, and the bobbin 32 may be attached to the hub shaft 234.

(modification example)

(1) In the first, second, and third embodiments, the welded portion 62 is formed by fillet welding. However, as shown in fig. 50, the welding portion 62 may be formed by butt welding. As shown in fig. 51, the weld 62 may also be formed by penetration welding. As shown in fig. 52, a weld 62 may also be formed in the bore 56F. The same applies to the welded portions 64, 68, and 70 of the first, second, and third embodiments.

(2) As shown in fig. 53, in the first embodiment, the cylindrical portion 56A may be omitted from the coupling member 56. As shown in fig. 54, in the first embodiment, the flange 56B may be omitted from the coupling member 56.

(3) In the first embodiment, when the plurality of yoke pieces 46 are fixed to the connecting member 56 by bonding, for example, a step of applying an adhesive to at least one of the connecting member 56 and the plurality of yoke pieces 46 is added before the connecting member 56 is attached to the jig 80 in the connecting member disposing step S2 of the manufacturing method shown in fig. 16, and the step of attaching the connecting member 56 to the jig 80 becomes a part of the fixing step together with the connecting member disposing step S2 as a part of the fixing step. In this case, the fixing step S3 is omitted. The same applies to the fixing step S6. In the second and third embodiments, the steps of the manufacturing method may be similarly modified as appropriate when the fixing method is bonding.

(4) In the first embodiment, when the plurality of yoke pieces 46 are fixed to the connecting member 56 by fitting, for example, when the connecting member 56 is attached to the jig 80 in the connecting member arranging step S2 of the manufacturing method shown in fig. 16, the plurality of yoke pieces 46 are fitted into the plurality of grooves provided in the connecting member 56, and the plurality of yoke pieces 46 are fixed to the connecting member 56. In this case, the connecting member arranging step S2 and the fixing step S3 may be performed in one step. In this case, the fixing step S3 is omitted. The same applies to the fixing step S6. In the second and third embodiments, the steps of the manufacturing method may be similarly changed as appropriate when the fixing method is fitting.

In the present application, the terms "include" and derivatives are non-limiting terms used to describe the presence of a component, and do not exclude the presence of other components not described. This also applies to "having," "including," and their derivatives.

The terms "component", "part", "element", "body", and "structure" have various meanings, and may be a single part or a plurality of parts.

The ordinal numbers "first", "second", etc. are merely terms used to identify a structure and do not have other meanings (e.g., a certain order, etc.). For example, the presence of "a first element" does not imply the presence of "a second element," and the presence of "a second element" does not imply the presence of "a first element.

The term "a pair" as used herein includes not only a case where a pair of elements has the same shape and structure but also a case where a pair of elements has different shapes and structures.

The expression "at least one" as used in the present specification means that the desired option is "one or more". As an example, the expression "at least one" used in the present specification means "only one option" or "two options" when the number of options is two. As another example, the expression "at least one" used in the present specification means "only one option" or "a combination of two or more arbitrary options" when the number of options is three or more. For example, "at least one of a and B" includes (1) only a, (2) only B, and (3) both a and B. "A, B, and at least one of C" includes (1) only A, (2) only B, (3) only C, (4) both A and B, (5) both B and C, (6) both A and C, and (7) A, B and C. In other words, in the present disclosure, "at least one of a and B" does not mean "at least one a and at least one B".

The terms "substantially," "about," and "approximately" are intended to mean a reasonable amount of deviation that does not materially alter the end result. All numbers recited in this application are to be interpreted as including "substantially," "about," and "approximately" etc.

Obviously, many variations and modifications of the present invention are possible in light of the above teachings. Therefore, the present invention can be carried out by other methods than the specific disclosure of the present application within a scope not departing from the gist of the present invention.

Description of the symbols:

2, manually driving the vehicle;

10. 210, 310 generators;

12. 212, 312 stators;

14 a rotating body;

16 a rotor;

18 a magnet;

30 coils;

a 32-spool;

32A support holes;

34 a drum shaft;

46a yoke piece;

46A yoke body;

46B fixed part;

46E a first fixing portion;

46F second fixed part;

48 yoke pieces;

a 48A yoke body;

48B fixed part;

48E a first fixing portion;

a 48F second fixed portion;

56. 256, 356 connecting members;

a 56A cylindrical portion;

a 56B flange;

56C through holes;

a 56D projection;

58. 258, 358 connecting members;

a 58A cylindrical portion;

a 58B flange;

58C through holes;

a 58D projection;

80. 90, a clamp;

a yoke arrangement step of S1, S4, S32, and S35;

an S2, S5, S31, S34 connecting member arranging step;

s3 and S6;

and S7 and S37 mounting procedures.

Claims (16)

1. A stator of a generator for a human-powered vehicle, comprising:

A coil wound around the axis;

a plurality of yoke pieces arranged in a circumferential direction of the shaft center; and

a connecting member configured as a member separate from the plurality of yoke pieces;

the plurality of yoke pieces are fixed to the connecting member, respectively.

2. The stator according to claim 1,

the plurality of yoke pieces are fixed to the connecting member by at least one of welding, bonding, and fitting.

3. The stator according to claim 1 or 2,

the coupling member extends in the circumferential direction.

4. A stator according to any one of claims 1 to 3,

the connecting member is annular.

5. The stator according to any one of claims 1 to 4,

the coupling member is disposed at least partially between the plurality of yoke pieces and the shaft center in a radial direction of the shaft center.

6. The stator according to any one of claims 1 to 5,

the coupling member includes a cylindrical portion extending along the axial center.

7. The stator according to claim 6,

the plurality of yoke pieces are fixed to the cylindrical portion by at least one of welding, bonding, and fitting.

8. The stator according to claim 6 or 7,

the coupling member includes a flange extending outward from the cylindrical portion in a radial direction of the shaft center.

9. The stator according to claim 8,

the plurality of yoke pieces are fixed to the flange by at least one of welding, bonding, and fitting.

10. The stator according to any one of claims 1 to 9,

the plurality of yoke pieces respectively include:

a yoke body disposed to face the coil in a radial direction of the axial center; and

and a fixing portion that extends from the yoke body in the radial direction toward the axial center and is fixed to the coupling member.

11. The stator as set forth in claim 10, wherein,

the magnetic yoke further comprises a bobbin which is configured as a member independent from the plurality of yoke pieces and the connecting member,

the coil is wound on the bobbin and,

the bobbin includes a support hole extending along the axial center,

the fixing part is at least partially arranged in the supporting hole.

12. The stator according to any one of claims 1 to 12, further comprising

A hub shaft for supporting the coil and the plurality of yoke pieces,

The coupling member is disposed at least partially between the plurality of yoke pieces and the hub shaft in a radial direction of the shaft center.

13. An electrical generator which is an electrical generator for a human powered vehicle and which comprises:

a stator according to any one of claims 1 to 12;

a rotating body provided to be rotatable about the shaft center with respect to the stator; and

and a rotor provided to the rotating body and including a magnet.

14. A method of manufacturing a stator of a generator for a human powered vehicle, comprising:

a yoke arrangement step of attaching a plurality of yoke pieces, which are independent members of each other, to a jig so that the plurality of yoke pieces are arranged around a reference axis;

a connecting member arranging step of attaching a connecting member to the jig; and

and a fixing step of fixing the plurality of yoke pieces to the coupling member, respectively.

15. The manufacturing method according to claim 14,

further comprising an attaching step of attaching the plurality of yoke pieces connected by the connecting member to a hub shaft.

16. A stator, which is a stator of a generator of a human-powered vehicle,

and manufactured by the manufacturing method according to claim 14 or 15.

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