JP2017070174A - Rotary electric machine and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotary electric machine suitable for forming a desired connection state, and a manufacturing method thereof.SOLUTION: A coil end of the rotary electric machine is operated as shown by positions PS1, PS2, PS3 and PS4. The coil end is pushed from a wide intake part 46 into a narrow positioning part 47. The coil end can be surely positioned. By deforming a thin plate part 44 in the positioning part 47, the coil end is firmly held. A coil end 33a and a terminal 71 are held and welded by electrodes for welding. When the coil end 33a is pushed by the electrodes for welding, the thin plate part 44 may be further deformed. Thus, the holding of the coil end 33a by a guide part 36 is loosened. The guide part 36 allows the coil end 33a to move, so that the movement of the coil end like sliding on the terminal 71 is suppressed.SELECTED DRAWING: Figure 4

Description

  The disclosure in this specification relates to a rotating electrical machine and a method for manufacturing the same.

  Patent Documents 1 to 4 disclose a rotating electrical machine and a manufacturing method thereof. In this technique, an insulator (bobbin) provided in the stator is provided with a guide groove (112C) for guiding a coil end. The coil end is disposed in the guide groove. The guide groove positions the coil end in the vicinity of the terminal. The contents of the prior art documents listed as the prior art are incorporated by reference as an explanation of the technical elements in this specification.

JP 2013-233030 A JP2013-27252A Patent No. 5064279 JP2015-130785A

  In one aspect, in the structure of Patent Document 4, it is difficult to work to house the coil end in the guide groove and to bend the coil end so as to contact the terminal. For this reason, a coil end may remove | deviate from a guide groove during an operation | work. In addition, it is difficult to bend the coil end stably into a desired shape.

  From another viewpoint, Patent Document 4 does not disclose any strength of fitting between the guide groove and the coil end. However, a too loose fit may allow undesired and unstable movement of the coil end in the process of connecting the coil end and the terminal, and hinder the formation of a desired connection state. In addition, the fitting that is too tight may hinder the desired movement of the coil end for fitting to the terminal in the step of connecting the coil end and the terminal, and may hinder the formation of a desired connection state.

  In the above-mentioned viewpoints or other aspects not mentioned, further improvement is required for the rotating electrical machine and the manufacturing method thereof.

  One disclosed object is to provide a rotating electrical machine suitable for forming a desired connection state and a method for manufacturing the same.

  Another object of the present disclosure is to provide a rotating electrical machine capable of guiding a coil end suitable for forming a desired connection state and a manufacturing method thereof.

  A plurality of aspects disclosed in this specification adopt different technical means to achieve each purpose. The reference numerals in parentheses described in the claims and / or in this section indicate the correspondence with the embodiments described later, and do not limit the technical scope.

  According to one aspect, a rotating electrical machine is disclosed. The rotating electrical machine includes a coil end (33a) that is an end of the stator coil (33), a terminal (71) to which the coil end is connected, and a groove that guides the coil end toward the terminal by accommodating the coil end. And a guide part (36) for partitioning (43). The guide portion is provided at a predetermined position of the coil end in the groove, and is positioned at the position of the positioning portion (47) deformed by contact with the coil end. And inlet portions (46, 446, 546, 646) having a width (WW) larger than the width (WN) of the positioning portion.

  The rotating electrical machine has a positioning portion and an inlet portion in a groove for guiding the coil end toward the terminal. The positioning part is deformed by contacting the coil end. The positioning unit can position the coil end so that the coil end and the terminal are in a desired connection state. Further, the guide part has an inlet part provided at the inlet of the groove. The width of the inlet portion is larger than the diameter of the coil end and larger than the width of the positioning portion. The inlet portion can position the coil end more loosely than the positioning portion. The coil end is operated toward the positioning portion via the inlet portion. When the coil end is placed in the groove, the coil end is loosely positioned at the inlet and then manipulated toward the positioning portion. For this reason, a coil end can be easily operated toward a positioning part.

  According to one aspect, a method for manufacturing a rotating electrical machine is disclosed. The rotating electrical machine includes a coil end (33a) that is an end of the stator coil (33), a terminal (71) to which the coil end is connected, and a groove that guides the coil end toward the terminal by accommodating the coil end. And a guide section (36) for defining (43). A method for manufacturing a rotating electrical machine includes loosely positioning a coil end at an inlet portion (46, 446, 546, 646) provided at an entrance of a groove and having a width (WW) larger than a diameter (DC) of the coil end. The guide end is deformed by moving the end of the coil through the inlet portion toward the positioning portion (47) provided at a predetermined position of the end of the coil, and bringing the end of the coil into contact with the guide at the positioning portion. The coil end is firmly positioned, and the coil end and the terminal are connected in a state where the coil end is positioned by the positioning portion.

  The rotating electrical machine has a positioning portion and an inlet portion in a groove for guiding the coil end toward the terminal. After the coil end is loosely positioned at the inlet portion, it is firmly positioned at the positioning portion. At this time, the guide portion is deformed. The positioning unit can position the coil end so that the coil end and the terminal are in a desired connection state. The inlet portion positions the coil end more loosely than the positioning portion. The coil end is operated toward the positioning portion via the inlet portion. When the coil end is placed in the groove, the coil end is loosely positioned at the inlet and then manipulated toward the positioning portion. For this reason, a coil end can be easily operated toward a positioning part.

  According to one aspect, a method for manufacturing a rotating electrical machine is disclosed. The rotating electrical machine includes a coil end (33a) that is an end of the stator coil (33), a terminal (71) to which the coil end is connected, and a groove that guides the coil end toward the terminal by accommodating the coil end. And a guide section (36) for defining (43). In the manufacturing method of the rotating electrical machine, the coil end is inserted into the groove, the coil end is brought into contact with the guide portion, the guide portion is deformed to firmly position the coil end, and the coil end is positioned by the groove. Further, when the coil end and the terminal are sandwiched by the electrodes (81, 82), the coil end and the terminal are welded, and when the coil end and the terminal are sandwiched by the electrode, the guide portion is further deformed by the movement of the coil end. To allow movement of the coil end.

  In the manufacturing method of a rotating electrical machine, the coil end is positioned firmly before welding. In welding, the coil end is pushed by the electrode. When the coil end moves along with this, the guide portion is further deformed. Thereby, a guide part accept | permits the movement of a coil end. Therefore, when the coil end and the terminal are sandwiched between the electrodes, the coil end is prevented from moving so as to slide on the terminal. Thereby, a desirable weld is formed.

  According to one aspect, a method for manufacturing a rotating electrical machine is disclosed. The rotating electrical machine includes a coil end (33a) that is an end of the stator coil (33), a terminal (71) to which the coil end is connected, and a groove that guides the coil end toward the terminal by accommodating the coil end. And a guide section (36) for defining (43). A method of manufacturing a rotating electrical machine includes inserting a coil end into a groove, bringing the coil end into contact with the guide portion, deforming the guide portion and positioning the coil end firmly, and the coil end on the terminal, The coil end is bent so that the coil end is arranged so as to be farther from the terminal toward the tip of the end, and the coil end and the terminal are sandwiched by the electrodes (81, 82) in a state where the coil end is positioned by the groove. And welding the terminals.

  In the manufacturing method of a rotating electrical machine, the coil end is positioned firmly before welding. In welding, the coil end is pushed by the electrode. The coil end is arranged on the terminal so as to move away from the terminal toward the tip of the coil end. Therefore, the electrode and the coil end first contact at the tip of the coil end. Compared with the case where the suspended portion of the coil end spanned between the guide portion and the terminal is pushed, the coil end is prevented from moving so as to slide on the terminal. Thereby, a desirable weld is formed.

According to one aspect, a method for manufacturing a rotating electrical machine is disclosed. The rotating electrical machine includes a coil end (33a) that is an end of the stator coil (33), a terminal (71) to which the coil end is connected, and a groove that guides the coil end toward the terminal by accommodating the coil end. And a guide section (36) for defining (43). A method of manufacturing a rotating electrical machine includes inserting a coil end into a groove to bring the coil end into contact with the guide portion, deforming the guide portion and positioning the coil end firmly, and spanning between the guide portion and the terminal. The coil end is bent so as to form a slack in the suspended portion of the coil end passed, and the coil end and the terminal are sandwiched by the electrodes (81, 82) while the coil end is positioned by the groove. It includes welding the terminals and deformation of the slack when the coil ends are rotated along the terminals.

  In the manufacturing method of a rotating electrical machine, the coil end is positioned firmly before welding. A slack is formed in the suspension portion of the coil end that is spanned between the guide portion and the terminal. In welding, the coil end is pushed by the electrode. Therefore, the coil end tends to rotate along the terminal. At this time, the slack is deformed. The deformation of the slack suppresses the coil end from moving so as to slide on the terminal. Thereby, a desirable weld is formed.

It is sectional drawing of the rotary electric machine which concerns on 1st Embodiment. It is a top view of the stator of a 1st embodiment. It is the elements on larger scale of the stator of 1st Embodiment. It is the elements on larger scale of the stator of 1st Embodiment. It is the elements on larger scale of the stator of 1st Embodiment. It is the elements on larger scale of the stator of 1st Embodiment. It is the elements on larger scale of the stator of 1st Embodiment. It is the elements on larger scale of the stator of 1st Embodiment. It is a fragmentary perspective view of the stator of a 2nd embodiment. It is a fragmentary perspective view of the stator of a 2nd embodiment. It is the elements on larger scale of the stator of 2nd Embodiment. It is the elements on larger scale of the stator of 2nd Embodiment. It is the elements on larger scale of the stator of 2nd Embodiment. It is the elements on larger scale of the stator of 3rd Embodiment. It is the elements on larger scale of the stator of 3rd Embodiment. It is the elements on larger scale of the stator of 4th Embodiment. It is the elements on larger scale of the stator of 5th Embodiment. It is the elements on larger scale of the stator of 6th Embodiment. It is sectional drawing by which the stator of 7th Embodiment was modeled. It is sectional drawing modeled of the stator of 8th Embodiment.

  A plurality of embodiments will be described with reference to the drawings. In embodiments, functionally and / or structurally corresponding parts and / or associated parts may be assigned the same reference signs or reference signs that differ by more than a hundred. For the corresponding parts and / or associated parts, the description of other embodiments can be referred to.

(First embodiment)
In FIG. 1, a rotating electrical machine for an internal combustion engine (hereinafter simply referred to as a rotating electrical machine 10) is a generator. The rotating electrical machine 10 is electrically connected to an electric circuit 11 including a rectifier circuit (AC / DC). The electric circuit 11 provides a single-phase power conversion circuit. An example of the use of the rotating electrical machine 10 is a generator connected to an internal combustion engine 12 for a vehicle. The rotating electrical machine 10 can be used for a motorcycle, for example.

  The electric circuit 11 rectifies AC power output from the rotating electrical machine 10 and provides a rectifier circuit that supplies power to an electric load including a battery. The electric circuit 11 may provide a signal processing circuit that receives a reference position signal for ignition control supplied from the rotating electrical machine 10. The electric circuit 11 may provide an ignition controller that performs ignition control.

  The rotating electrical machine 10 is assembled to the internal combustion engine 12. The internal combustion engine 12 includes a body 13 and a rotary shaft 14 that is rotatably supported by the body 13 and rotates in conjunction with the internal combustion engine 12. The rotating electrical machine 10 is assembled to the body 13 and the rotating shaft 14. The body 13 is a structure such as a crankcase or a transmission case of the internal combustion engine 12. The rotating shaft 14 is a crankshaft of the internal combustion engine 12 or a rotating shaft interlocking with the crankshaft.

  The rotating electrical machine 10 is an outer rotor type rotating electrical machine. The rotating electrical machine 10 includes a rotor 21 and a stator 31. In the following description, the term “axial direction” refers to a direction along the central axis when the rotor 21, the stator 31, or the stator core 32 is regarded as a cylinder. The term “radial direction” refers to a radial direction when the rotor 21, the stator 31, or the stator core 32 is regarded as a cylinder.

  The rotor 21 is a field element. The stator 31 is an armature. The entire rotor 21 is cup-shaped. The rotor 21 is connected to the end of the rotating shaft 14. The rotor 21 rotates together with the rotating shaft 14. The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 provides a yoke for a permanent magnet described later. The rotor core 22 is made of a magnetic metal. The rotor 21 has a permanent magnet 23 disposed on the inner surface of the rotor core 22. The rotor 21 provides a field by a permanent magnet 23.

  The stator 31 is an annular member. The stator 31 is disposed so as to face the rotor 21. The stator 31 has a stator core 32. The stator core 32 is fixed to the body 13 of the internal combustion engine 12. The stator 31 has a stator coil 33 wound around a stator core 32. The stator coil 33 provides an armature winding. The stator coil 33 is a single-phase winding. The coil wire forming the stator coil 33 is a single wire conductor covered with an insulating coating. The coil wire is made of an aluminum-based metal such as aluminum or an aluminum alloy.

  The rotating electrical machine 10 includes a wire harness 15 that provides an electrical connection between the rotating electrical machine 10 and the electric circuit 11. The wire harness 15 includes a plurality of electric wires. The wire harness 15 includes a plurality of power lines that connect the stator coil 33 and the electric circuit 11. The electric circuit 11 is an external circuit to which a power line is connected. The electric power line supplies the electric circuit 11 with electric power induced in the stator coil 33 when the rotating electrical machine 10 functions as a generator.

  In FIG. 2, a stator 31 is an outer salient pole type stator. The stator core 32 has a plurality of magnetic poles 32a. The magnetic pole 32a is a part also called a tooth. An insulator 35 is disposed between the stator core 32 and the stator coil 33. The insulator 35 is made of an electrically insulating resin. The insulator 35 is provided on the stator 31. The insulator 35 is also called a bobbin. A portion of the insulator 35 is positioned adjacent to the magnetic pole 32a to provide a bobbin flange. A part of the insulator 35 is disposed on both sides in the axial direction of the magnetic pole 32a. In the following description, in many cases, the insulator 35 includes an annular inner flange portion disposed in the central annular portion of the stator core 32 and an electrode support portion that extends so as to cover a part of the axial surface of the central annular portion. Point to.

  The stator 31 has a connection portion 50 for connecting a coil end 33a which is an end portion of the stator coil 33 so as to form an electric circuit. The connection unit 50 connects the coil end 33 a and the terminal 71. The connection unit 50 is used to connect a plurality of coil wires included in the stator coil 33 or to connect the stator coil 33 to a power line. In the illustrated example, the stator 31 has two connection portions 50. One connecting portion 50 provides connection between one coil wire and one electrode on one end face of the stator 31. One electrode is connected to the power line at the other end face of the stator 31. The other electrode is connected to the coil end of another coil wire on the other end face of the stator 31. In this embodiment, the electrode provides a connection portion separated on one end surface and the other end surface of the stator 31.

  The stator core 32 has a plurality of bolt holes for fixing the stator core 32 to the body 13. The two connection portions 50 forming a group are disposed between two bolt holes adjacent in the circumferential direction.

  The connection part 50 has the protective resin 61 which wraps the terminal 71 to which the coil end 33a and the coil end 33a are connected. In the drawing, in order to show the coil end 33a and the terminal 71, the range covered with the protective resin 61 is indicated by a broken line. The protective resin 61 is an electrically insulating resin. The protective resin 61 is closely attached to the coil end 33a and the surface of the coil end 33a. The protective resin 61 is applied or dropped in an uncured state and cured. The protective resin 61 is also called potting resin or sealing resin.

  FIG. 3 is an enlarged view showing a part of the stator 31, in particular, a connecting portion 50. In the drawing, the state after the coil end 33a and the terminal 71 are joined is shown. In order to illustrate the coil end 33a and the terminal 71, the protective resin 61 is not illustrated. The application range of the protective resin 61 is indicated by a broken line.

  The insulator 35 has a guide part 36. The guide part 36 is used to arrange the coil end 33a for the connection part 50 in a prescribed shape. Moreover, the guide part 36 is utilized in order to hold | maintain the coil end 33a in a regular position. The guide portion 36 is formed as a protrusion extending in the axial direction on the end surface of the stator 31. The insulator 35 has a bobbin portion 37. The bobbin portion 37 is disposed between the magnetic pole 32 a and the stator coil 33. The bobbin portion 37 has a cylindrical shape surrounding the magnetic pole 32a. In the drawing, the stator coil 33 is not shown.

  The coil end 33a is disposed so as to extend inward from the radially outer side. The coil end 33 a is disposed so as to be adjacent to the terminal 71 from the stator coil 33 via the guide portion 36. The coil end 33a is slightly curved. The coil end 33 a is bent along the surface of the terminal 71. The coil end 33 a has a portion that extends along the circumferential direction of the stator 31, a portion that bends along the radial direction of the stator 31, and a portion that extends along the surface of the terminal 71.

  The guide portion 36 accommodates the coil end 33 a, thereby defining a groove 43 that guides the coil end 33 a toward the terminal 71. The guide part 36 has a first protrusion 41 and a second protrusion 42. The first protrusion 41 and the second protrusion 42 define a groove 43 that can receive the coil end 33a therebetween. The first protrusion 41 and the second protrusion 42 may be provided by an elongated wall along the circumferential direction of the stator 31.

  The 1st protrusion 41 is located in the curve of the coil end 33a, ie, the inside of the bending part 33b. The 1st protrusion 41 restrict | limits the movement to the inner side of the bending shape of the coil end 33a. The 1st protrusion 41 prescribes | regulates the bending shape of the coil end 33a. The first protrusion 41 is also called an inner protrusion. The 1st protrusion 41 provides the wall surface 41a facing the coil end 33a. The wall surface 41a has a curved surface that defines the curved shape of the coil end 33a.

  The 2nd protrusion 42 is located in the curve of the coil end 33a, ie, the outer side of the bending part 33b. The 2nd protrusion 42 restrict | limits the movement to the outer side of the bending shape of the coil end 33a. The second protrusion 42 is also referred to as an outer protrusion. The second protrusion 42 has a thin plate portion 44 that faces the coil end 33a and contacts the coil end 33a. The thin plate portion 44 is formed in a plate shape thinner than other portions of the second protrusion 42. The thin plate portion 44 is formed only on the second protrusion 42. The second protrusion 42 is not provided at the entrance of the groove 43, but is provided only at the back in the axial direction of the groove 43. The thin plate portion 44 holds the coil end 33a by contacting the coil end 33a from the outside of the bent shape of the coil end 33a.

  A deformed portion 45 is formed at the tip of the thin plate portion 44, that is, at the contact portion with the coil end 33a. The deformation portion 45 is provided on the second protrusion 42. The deformation part 45 is provided in a positioning part 47 described later. The deformation part 45 is formed by the resin material being deformed by contact with the coil end 33a. The deformation part 45 is formed by elastic deformation and / or plastic deformation of a resin material. The deforming portion 45 prevents excessive movement of the coil end 33a while allowing movement of the coil end 33a. For example, the thin plate portion 44 is formed to be deformed by the movement of the coil end 33a in a normal manufacturing method. On the other hand, the other part of the 2nd protrusion 42 is formed so that it may not deform | transform greatly by the movement of the coil end 33a in a normal manufacturing method. For this reason, the thin plate portion 44 is formed thinner or thinner than other portions of the second protrusion 42. The size of the deforming portion 45 changes due to an error in the shape of each portion, a shift in the arrangement position, and the like. The deformable portion 45 may not be formed.

  A gap 48 is formed between the wall surface 41a and the coil end 33a. The width of the gap 48 corresponds to the amount of deformation in the deformation portion 45. The width of the gap 48 changes due to an error in the shape of each part, a shift in the arrangement position, and the like. The gap 48 may not be formed.

  The insulator 35 has a wall 38 for suppressing the outflow of the protective resin 61. The guide part 36 and the wall 38 are arranged so as to surround the connection part 50. The wall 38 limits the range in which the protective resin 61 flows. The axial height of the wall 38 is lower than that of the guide portion 36. The axial height of the wall 38 is lower than that of the terminal 71. By the wall 38, the protective resin 61 is thickly applied around the coil end 33 a and the terminal 71.

  The terminal 71 is plate-shaped. The terminal 71 is arranged so that its surface extends along the radial direction. In other words, the terminal 71 is arrange | positioned so that it can be pinched | interposed between a pair of electrodes for welding opened and closed in the circumferential direction. The terminal 71 is provided on a part of the plate-like electrode 72. In the illustrated example, the electrode 72 has both ends protruding from both end faces of the stator 31. The terminal 71 is formed at the end of the electrode 72. The electrode 72 is supported by the insulator 35 by being insert-molded or inserted into the insulator 35. The electrode 72 is also called a bus bar. The other end of the electrode 72 is connected to another coil end or a power line.

  The terminal 71 has a shape suitable for welding. For example, the terminal 71 has a protrusion 73 having a ridge line intersecting with the coil end 33a. The protrusion 73 is a protrusion extending along the axial direction. The terminal 71 is made of metal suitable for welding with the coil end 33a made of aluminum metal. The terminal 71 is also called a welding terminal. The terminal 71 is supported by the insulator 35. The terminal 71 is supported so as to extend along the axial direction of the stator 31.

  The coil end 33a and the terminal 71 are welded by electrical resistance welding or spot welding, and are electrically and mechanically joined. Between the coil end 33a and the terminal 71, there is formed a welded portion 51 formed by melting and once again curing these two metals. The weld 51 is also called a welding mark. The terminal 71 and the coil end 33a arranged in the connection part 50 have a surface with exposed metal.

  The cross-sectional shape of the coil end 33a before welding is circular. The cross-sectional shape of the coil end 33a after welding is a slightly flat shape. In the welding process, the coil end 33a and the terminal 71 are sandwiched between electrodes for welding. The coil end 33a and the terminal 71 are slightly deformed due to compression for welding and melting accompanying welding. The coil end 33a may have a flat surface portion that is a contact mark with the welding electrode. The coil end 33 a is deformed along the protrusion 73 at the contact portion with the terminal 71. The protrusion 73 is also deformed. The cross-sectional shape of the coil end 33 a is an ellipse or an ellipse having a long axis in the axial direction of the stator 31. The coil end 33 a is positioned along the plate-like surface of the terminal 71. The coil end 33 a is arranged such that its longitudinal direction intersects the longitudinal direction of the protrusion 73. The coil end 33 a is disposed such that the surface thereof is in contact with the top of the protrusion 73, both slopes of the protrusion 73, and the flat surface of the terminal 71. Thereby, the coil end 33a and the terminal 71 are firmly joined.

  FIG. 4 shows the guide unit 36. In the drawing, the broken line and the alternate long and short dash line indicate the coil end 33a. A thick solid arrow indicates a moving path of the coil end 33a in the manufacturing method.

  The groove 43 provides various functions. The groove 43 provides a guide groove for guiding the coil end 33a toward a specified position in the manufacturing method. The groove 43 provides a holding groove for holding the coil end 33a at a predetermined position before the coil end 33a and the terminal 71 are welded in the manufacturing method. In the manufacturing method, the groove 43 allows a slight movement of the coil end 33a to allow the coil end 33a and the terminal 71 to be desirably welded while positioning the coil end 33a within a specified position range. I will provide a. The function as a welding support part is provided by the deformation of the shape of the groove 43, that is, the deformation of the first protrusion 41 and the second protrusion 42 that define the groove 43. More specifically, the function as the welding support part is provided by deformation of the thin plate part 44. The groove 43 provides a movement suppressing unit that suppresses excessive movement of the coil end 33 a after being manufactured as the rotating electrical machine 10. The manufacturing method of the rotating electrical machine 10 may include a step of bonding and fixing the stator coil 33 and the coil end 33a with an adhesive, that is, a resin. In this case, the groove 43 also functions as a function of accumulating the adhesive and a portion that holds the adhesive so as to prevent excessive spread of the adhesive. In this case, the loose holding by the groove 43 and the thin plate portion 44 and the deforming portion 45 therein is firmly fixed by cooperation with the adhesive.

  The groove 43 has an inlet 46 for receiving the coil end 33 a into the groove 43. The inlet 46 has a width WW that can receive the coil end 33a. The width WW of the inlet 46 is larger than the diameter DC of the coil end 33a. The inlet portion 46 has a depth equal to or greater than the diameter DC of the coil end 33 a along the axial direction of the stator 31. The inlet 46 desirably has a depth greater than DC / 2 to hold the coil end 33a loose therein. The inlet 46 guides the coil end 33 a operated along the axial direction of the stator 31 toward the bottom of the groove 43. The inlet 46 is used for temporarily positioning the coil end 33a in the manufacturing method. The inlet 46 is also called an opening or a wide part.

  The groove 43 has a positioning portion 47. The positioning portion 47 is provided at the bottom of the groove 43. The positioning portion 47 is provided at a prescribed position in the axial direction of the stator 31 where the coil end 33a is finally positioned. The positioning portion 47 has a depth equal to or greater than the diameter DC of the coil end 33 a along the axial direction of the stator 31. The positioning portion 47 desirably has a depth exceeding DC / 2 in order to stably hold the coil end 33a therein. At least a part of the positioning portion 47 is partitioned by the thin plate portion 44. A slope is provided between the inlet portion 46 and the positioning portion 47. The slope smoothly connects the inlet portion 46 and the positioning portion 47. The inclined surface enables a smooth press-fitting of the coil end 33a.

  The positioning portion 47 has a width WN that can receive the coil end 33a when the first protrusion 41 and the second protrusion 42 are deformed. The width WN of the positioning portion 47 is smaller than the diameter DC of the coil end 33a. The width WN of the positioning portion 47 may be set to be equal to or smaller than the diameter DC of the coil end 33a. The width WN of the positioning portion 47 is smaller than the width WW of the inlet portion 46. The positioning portion 47 receives the coil end 33a operated along the axial direction of the stator 31 while the first protrusion 41 and the second protrusion 42 are deformed. The positioning portion 47 is deformed by being in contact with the coil end 33a. It can be said that the coil end 33 a is press-fitted into the positioning portion 47. The deformation is mainly deformation of the thin plate portion 44. The positioning part 47 is also called a bottom part or a narrow part.

  The positioning portion 47 is deformed when the coil end 33a is operated from the position PS1 indicated by the broken line to the position PS2. This deformation is provided by elastic deformation or plastic deformation. At this time, the coil end 33a is held firmly by the positioning portion 47. The positioning part 47 may be further deformed by the movement of the coil end 33a in the welding process. This deformation is provided by the deformation of the thin plate portion 44. Due to this deformation, a deformable portion 45 may be formed in the thin plate portion 44. When the deforming portion 45 is formed, the holding of the coil end 33a by the positioning portion 47 is changed from the hard holding to the loose holding. At this time, the positioning portion 47 has a portion that is deformed by contact with the coil end 33a at a portion where the coil end 33a is positioned and provides a width equal to or larger than the diameter DC of the coil end 33a. Further, the positioning portion 47 has a portion having a width WN smaller than the diameter DC of the coil end 33a.

  The coil end 33a is positioned at the position PS2 in the groove 43. Further, the coil end 33a is operated from the position PS3 indicated by the alternate long and short dash line to the position PS4 at the portion in contact with the terminal 71, and is positioned at the position PS4. In the figure, the position of the coil end 33a before welding is shown.

  The method for manufacturing the rotating electrical machine 10 includes a step of manufacturing the rotor 21, a step of manufacturing the stator 31, and a step of mounting the rotor 21 and the stator 31 on the internal combustion engine 12.

  The step of manufacturing the stator 31 includes a step of assembling the stator 31 so that the coil end 33a and the terminal 71 are arranged at regular positions. In this step, the insulator 35 and the stator coil 33 are attached to the stator core 32. In this step, the electrode 72 is fixed on the stator 31.

  The process of manufacturing the stator 31 includes a process of arranging the coil end 33a and the terminal 71 at regular positions. The regular position is a position immediately before the coil end 33 a is welded to the terminal 71. As shown in FIGS. 4, 5, and 6, the coil end 33 a is inserted into the groove 43 and bent so as to contact the terminal 71. The operation of the coil end 33a is provided by manual operation by an operator or mechanized tool movement by an assembly machine.

  As shown by the arrow P1 in FIG. 4, the coil end 33a is operated so as to move in the groove 43 in the axial direction. The coil end 33 a is inserted into the groove 43 from the outside of the groove 43. This provides a step of loosely positioning the coil end 33a at the inlet 46. Here, the coil end 33 a is movable within the range restricted by the inlet portion 46 in the radial direction of the coil end 33 a in the inlet portion 46. The coil end 33a is slightly movable in the axial direction of the coil end 33a.

  Further, coil end 33a is pushed from position PS1 indicated by the broken line to position PS2. Thereby, a step of moving the coil end 33 a toward the positioning portion 47 via the inlet portion 46 is provided. At this time, the thin plate portion 44 is at least elastically deformed. In this embodiment, a part of the thin plate portion 44 is plastically deformed. As a result, the coil end 33a is firmly held in the groove 43 using the elasticity of the resin material. Tight holding is also a tight tightening. As a result, by bringing the coil end 33a and the guide portion 36 into contact with each other in the positioning portion 47, a step of deforming the guide portion 36 and firmly positioning the coil end 33a is provided. However, the thin plate portion 44 is formed thin in the direction in which the coil end 33a extends, that is, in the radial direction. Therefore, the thin plate portion 44 is more easily deformed than other portions of the first protrusion 41 and the second protrusion 42. Further, since the contact area between the coil end 33 a and the thin plate portion 44 is small, the frictional force provided by the thin plate portion 44 is adjusted to be smaller than the frictional force due to the thickness of the second protrusion 42.

  As illustrated by arrows P2 and P3 in FIG. 4, the coil end 33 a is operated so as to move from the top of the terminal 71 toward the surface of the terminal 71 outside the groove 43. The tip end of the coil end 33a extends from the groove 43, and the tip end portion is positioned at a position PS3 illustrated by a one-dot chain line. The coil end 33 a is operated so as to be in contact with the protrusion 73 via the terminal 71. At this time, the coil end 33a is bent.

  In FIG. 5, a state in which the coil end 33 a is disposed in the groove 43 by the operation indicated by the arrow P <b> 1 is illustrated by a solid line. The coil end 33a is disposed in the groove 43 as indicated by an arrow P1 from above the groove 43.

  A portion of the coil end 33a extending from the groove 43 is operated as indicated by an arrow P2. That is, the coil end 33 a is bent via the terminal 71. At this time, the coil end 33a is bent with the first protrusion 41 as an inner mold. Instead of this, the coil end 33a may be bent by using a member different from the first protrusion 41 as an inner mold. The coil end 33a is bent as indicated by a broken line. A bent portion 33b is formed at the coil end 33a. The bent portion 33 b is bent so that the coil end 33 a is along the terminal 71.

  Next, the coil end 33a is operated so as to be pushed in along the axial direction of the stator 31 so as to be in contact with the top of the protrusion 73 with respect to the protrusion direction of the protrusion 73 as indicated by an arrow tail P3. . Accordingly, the coil end 33 a is positioned on the surface of the terminal 71, that is, on the side of the protrusion 73 with respect to the axial direction of the stator 31.

  The operations indicated by the arrows P1, P2, and P3 described above may be performed simultaneously in parallel. Moreover, you may carry out in order of arrow P1, P2, and P3. For example, the operation of the arrow P2 and the operation of the arrow P3 may be sequentially performed while the coil end 33a is gradually pushed into the groove 43 by the operation of the arrow P1.

  FIG. 6 shows a state where the coil end 33a is positioned at a normal position. This state is a state before welding. The coil end 33 a is firmly held between the first protrusion 41 and the thin plate portion 44. The coil end 33a extends straight from the bent portion 33b. The outer peripheral surface of the coil end 33 a is in contact with the protrusion 73. The coil end 33a is held at a predetermined position by the guide portion 36 and the elasticity of the coil end 33a itself.

  The step of manufacturing the stator 31 includes a step of electrically connecting the coil end 33a and the terminal 71. This step is a step of connecting the coil end 33 a and the terminal 71 with the coil end 33 a positioned by the positioning portion 47. This step is also a step of sandwiching the coil end 33a and the terminal 71 by the electrodes 81 and 82 and welding the coil end 33a and the terminal 71. This process is called a joining process or a welding process. This step includes a step of sandwiching the coil end 33a and the terminal 71 between the pair of welding electrodes, a step of welding the coil end 33a and the terminal 71 by energizing the welding electrode, and a step of removing the welding electrode. This step may include a step of inspecting the welding state between the coil end 33a and the terminal 71.

  FIG. 7 shows an initial stage in which the coil end 33 a and the terminal 71 are sandwiched between the welding electrodes 81 and 82. The electrode 81 is operated as indicated by the arrow P5 and contacts the terminal 71. The electrode 82 is operated as indicated by the arrow P6 and contacts the coil end 33a. At this time, the coil end 33a and the electrode 82 may not contact in parallel due to the inclination of the coil end 33a.

  For example, as shown in the figure, the corner of the electrode 82 contacts the suspended portion of the coil end 33 a that is spanned between the guide portion 36 and the protrusion 73. In this embodiment, both the shape of the guide 36 and the step of bending the coil end 33a are set to provide the shape of the illustrated coil end 33a. The coil end 33a is arranged and bent so that the suspended portion thereof is not positioned on the terminal 71 side beyond the virtual plane PP. The virtual plane PP is a plane that is parallel to the surface of the terminal 71 and is in contact with the top in the protruding direction of the protrusion 73. The virtual plane PP is also parallel to the surfaces of the electrodes 81 and 82 that are about to sandwich the terminal 71.

  The guide portion 36 is formed so that the coil end 33a is arranged in the shape shown in the figure. That is, both of the edges 41c and 42c of the groove 43 on the radially inner side of the stator 31 are positioned on the side opposite to the terminal 71 with respect to the virtual plane PP. In other words, of the edges 41c and 42c on the radially inner side of the groove 43, the edge 42c located outside the bending of the coil end 33a is positioned so as to be in contact with the virtual plane PP or closer to the electrode 82 than the virtual plane PP. It has been. Note that the edge 41 c is provided by the first protrusion 41. The edge 42c is provided by the second protrusion 42. As a result, the coil end 33 a extends from the edges 41 c and 42 c so as to approach the terminal 71 and the virtual plane PP, and reaches the terminal 71. In the step of bending the coil end 33 a, the coil end 33 a is bent so as to extend straight from the edges 41 c and 42 c toward the terminal 71.

  When the electrode 82 is operated along the arrow P6, the electrode 82 first contacts the coil end 33a at the contact portion 33c and pushes the contact portion 33c. As a result, the coil end 33 a is not only pressed in parallel toward the terminal 71 but also rotated along the terminal 71.

  At this time, the coil end 33a may move undesirably in order to form a proper weld. For example, since one end of the suspended portion of the coil end 33 a is held by the guide portion 36, the coil end 33 a may move so as to slide on the protrusion 73. Such movement may result in movement of the melted part in the welding process and may hinder the proper amount of melting. In addition, the melted portion may protrude from the proper position.

  FIG. 8 shows the movement of the coil end 33 a by the electrode 82. The electrode 82 is operated as indicated by an arrow P6. The coil end 33a and the terminal 71 sandwiched between the pair of electrodes 81 and 82 form a welded portion 51 as welding progresses.

  In this process, the coil end 33a is pulled in the direction of the arrow P7 in order to contact the terminal 71. At this time, since the thin plate portion 44 holds the coil end 33a with a relatively small frictional force, the coil end 33a is allowed to be pulled in the direction of the arrow P7.

  Further, the force component indicated by the arrow P <b> 7 deforms the thin plate portion 44 to form a deformed portion 45. Since the deformable portion 45 is formed at the contact portion with the coil end 33a, the thin plate portion 44 continues to hold the coil end 33a in the axial direction. As a result, the coil end 33a is separated from the first protrusion 41 and a gap 48 is formed. Such deformation of the thin plate portion 44 also allows the movement of the coil end 33a. In this step, when the coil end 33a and the terminal 71 are sandwiched between the electrodes 81 and 82, the guide portion 36 is further deformed by the movement of the coil end 33a, thereby allowing the movement of the coil end 33a.

  The first protrusion 41 and the second protrusion 42 suppress excessive movement of the coil end 33a in the circumferential direction and the axial direction of the stator 31 even after the coil end 33a is drawn along the arrow P7. The first protrusion 41 and the second protrusion 42 suppress excessive movement of the coil end 33a in the circumferential direction and the axial direction of the stator 31 even after the thin plate portion 44 is deformed.

  Thus, the guide portion 36, particularly the thin plate portion 44, holds the coil end 33a firmly until the initial stage of the welding process. The thin plate portion 44 allows the coil end 33a to move during the process for welding. As a result, the coil end 33a moves to the illustrated welding state without moving so as to be dragged over the terminal 71. The coil end 33a is welded to the terminal 71 on the protrusion 73 without being displaced in the length direction of the coil end 33a.

  The step of manufacturing the stator 31 includes a step of applying the protective resin 61. The coil end 33a and the terminal 71 are wrapped by the protective resin 61. The protective resin 61 is applied so as to completely cover the exposed metal surfaces of the coil end 33 a and the terminal 71 disposed in the connection portion 50. The protective resin 61 covers at least the metal surface exposed by removing the protective film of the coil end 33 a and the exposed metal surface of the terminal 71. The protective resin 61 is applied in an uncured state. Thereafter, the protective resin 61 is cured.

  The protective resin 61 provides insulation protection for electrically insulating the coil end 33a and the terminal 71 from other members. The protective resin 61 further provides anti-corrosion protection for suppressing corrosion of the coil end 33a and the terminal 71. Due to the corrosion resistance protection, the coil end 33a made of aluminum metal can be used. Furthermore, welding of the coil end 33a made of aluminum metal and the terminal 71 made of iron metal can be used due to corrosion resistance protection.

  The protective resin 61 prevents direct contact between the coil end 33a and the terminal 71 and other members. When the rotating electrical machine 10 is air-cooled, the protective resin 61 protects the coil end 33a and the terminal 71 from foreign matters such as liquid and mud. When the rotating electrical machine 10 is disposed in the lubricating oil accommodating space of the internal combustion engine 12, the protective resin 61 protects the coil end 33a and the terminal 71 from metal powder in the lubricating oil.

  The protective resin 61 contributes to maintain the connection between the coil end 33a and the terminal 71 against vibration. The protective resin 61 not only contacts the coil end 33 a and the terminal 71, but also contacts the insulator 35. The protective resin 61 fills the space between the coil end 33 a, the terminal 71, and the insulator 35. Thereby, movement and deformation | transformation of the coil end 33a, the terminal 71, and the insulator 35 are suppressed. In this embodiment, the coil end 33a that is relatively easy to move and the terminal 71 that is relatively firmly fixed are connected, but the protective resin 61 contributes to maintaining the connection between them. Further, even if the coil end 33a and the terminal 71 are deformed by a connecting method such as welding, they contribute to reinforcing them and maintaining their connection.

  The process of manufacturing the stator 31 further includes another connection process. This step can include a step of connecting the electrode 72 and the power line, or a step of connecting the electrode 72 and another coil end.

  According to the embodiment described above, the groove 43 is provided with the inlet portion 46 and the positioning portion 47. As a result, the coil end 33 a can be inserted into the positioning portion 47 using the inlet 46. Thereby, the positioning part 47 can be formed so as to provide guidance of the coil end 33a suitable for forming a desired connection state.

  The positioning part 47 allows the movement of the coil end 33a in the welding process. For this reason, the sliding movement of the coil end 33a on the terminal 71 is suppressed. As a result, a desirable connection state is formed between the coil end 33a and the terminal 71.

  The positioning part 47 holds the coil end 33a in the deformed part 45 deformed in the welding process. Therefore, the positioning part 47 holds the coil end 33a firmly before the deformation part 45 is formed, and holds the coil end 33a loosely after the deformation part 45 is formed. Thereby, in the process which welds them by pinching the coil end 33a and the terminal 71, the positioning part 47 can accept | permit the movement of the coil end 33a. For this reason, the sliding movement of the coil end 33a on the terminal 71 is suppressed. As a result, a desirable connection state is formed between the coil end 33a and the terminal 71.

(Second Embodiment)
This embodiment is a modification based on the preceding embodiment. In the above embodiment, the positioning portion 47 can be deformed so as to hold the coil end 33a loosely. Instead, in this embodiment, the guide portion 36 that provides the positioning portion 47 continues to hold the coil end 33a firmly.

  9 and 10 are perspective views showing the guide portion 36 in this embodiment. 11, FIG. 12, and FIG. 13 show a process of electrically connecting the coil end 33a and the terminal 71 in this embodiment.

  Also in this embodiment, the guide part 36 has a first protrusion 41 and a second protrusion 242. The second protrusion 242 does not include the thin plate portion 44 and the deformation portion 45 in the preceding embodiment. The second protrusion 242 is in contact with the coil end 33a over substantially the entire thickness in the radial direction. Also in this embodiment, the first protrusion 41 and the second protrusion 242 define the groove 43. The groove 43 has an inlet portion 46 and a positioning portion 47. The positioning portion 47 holds the coil end 33 a with substantially the entire thickness of the second protrusion 242.

  FIG. 11 shows the initial stage of the welding process. In this embodiment, the coil end 33 a is firmly held in the groove 43. In addition, the coil end 33a is firmly held in the groove 43 both before and after the joining step.

  The electrodes 81 and 82 are operated so as to contact the coil end 33a and the terminal 71, respectively. At this time, in this embodiment, of the coil end 33 a, a free end portion protruding radially inward from the protrusion 73 is in contact with the electrode 82. The electrode 82 first contacts the contact portion 233c. The contact portion 233c is located at the free end portion from which the coil end 33a protrudes.

  In this embodiment, the coil end 33a is bent so that the contact portion 233c is located at the free end portion. From another viewpoint, the shape of the guide portion 36 and the position of the protrusion 73 are set so that the contact portion 233c is located at the free end portion. The coil end 33a is arranged on the terminal 71 so as to be away from the terminal 71 toward the tip of the coil end 33a.

  In this embodiment, both the shape of the guide 36 and the step of bending the coil end 33a are set to provide the shape of the illustrated coil end 33a. The coil end 33a is arranged and bent so that a part of the suspended portion is located on the terminal 71 side beyond the virtual plane PP.

  The guide portion 36 is formed so that the coil end 33a is arranged in the shape shown in the figure. That is, the edge 42c is positioned on the terminal 71 side with respect to the virtual plane PP. In other words, of the edges 41c and 42c on the radially inner side of the groove 43, the edge 42c located outside the bend of the coil end 33a is positioned closer to the terminal 71 than the virtual plane PP. As a result, the coil end 33a extends from the edges 41c and 42c so as to return to the top of the protrusion 73 after passing through the terminal 71 side beyond the virtual plane PP. In the step of bending the coil end 33a, the coil end 33a is bent from the edges 41c and 42c so as to pass through the terminal 71 side beyond the virtual plane PP.

  In this embodiment, a step of bending the coil end 33a is employed to provide this arrangement. Such arrangement of the coil end 33a makes it possible to form the contact portion 233c at the free end portion.

  FIG. 12 illustrates a stage where the electrode 82 is gradually pressed. The coil end 33 a is gradually deformed along the terminal 71. The coil end 33a is gradually deformed from its free end portion, that is, from the tip. Therefore, the coil end 33a contacts the terminal 71 while maintaining contact with the protrusion 73 at a certain portion.

  FIG. 13 shows the final stage of the welding process. The electrode 82 is pressed to a specified end position. The coil end 33 a is welded to the terminal 71.

  According to this embodiment, the coil end 33 a can be inserted into the positioning portion 47 using the inlet portion 46. Thereby, the positioning part 47 can be formed so as to provide guidance of the coil end 33a suitable for forming a desired connection state.

  The guide part 36 holds the coil end 33a firmly. Moreover, the coil end 33a and the electrode 82 are disposed so that the electrode 82 contacts the free end portion of the coil end 33a. The electrode 82 and the coil end 33a first contact each other at a portion near the tip of the coil end 33a. In other words, it is avoided that the contact portion 33c is formed on the suspended portion of the coil end 33a. Thereby, it is suppressed that the coil end 33a moves on the terminal 71 so that it may slide on the receiving of the protrusion 73 especially. As compared with the case where the suspension portion is pushed, the coil end 33a is prevented from moving so as to slide on the terminal 71. Thereby, a desirable connection state is formed between the coil end 33a and the terminal 71.

(Third embodiment)
This embodiment is a modification based on the preceding embodiment. In this embodiment, the bent portion 33b of the coil end 33a is used so as to suppress the movement of the coil end 33a on the terminal 71.

  14 and 15 show a process of electrically connecting the coil end 33a and the terminal 71 in this embodiment. Also in this embodiment, the coil end 33a is guided and held by the guide portion 36. The coil end 33a is pushed between the first protrusion 41 and the second protrusion 342 and is held firmly. The second protrusion 342 is formed so as not to be deformed by a force acting on the coil end 33a in the manufacturing process. Also in this embodiment, a groove 43 is formed between the first protrusion 41 and the second protrusion 342. The groove 43 has an inlet portion 46 and a positioning portion 47.

  The coil end 33a has an S-shaped bent portion 333d including a bent portion 33b at a portion extending from the guide portion 36 toward the terminal 71. Here, an S-shaped word is defined as including an inverted S-shape. The bending portion 333d slightly detours the coil end 33a in a direction approaching the terminal 71. The bent portion 333d enables the coil end 33a to be arranged so as to have a desired positional relationship with respect to the terminal 71. The coil end 33a is arranged on the terminal 71 so as to be away from the terminal 71 toward the tip of the coil end 33a. Such an arrangement of the open ends is provided by the bent portion 333d. Similar to the second embodiment, the arrangement of the open ends allows the contact portion 233c to be positioned at the free end portion of the coil end 33a.

  From another viewpoint, the bent portion 333d is formed as a portion that is easily bent in the coil end 33a. The bent portion 333d is used to make the coil end 33a bend more easily than the case where only the bent portion 33b is formed in the suspended portion of the coil end 33a spanned between the guide portion 36 and the protrusion 73. It is formed as a part. The bending portion 333 d allows the coil end 33 a ahead of the bending portion 333 d to rotate along the terminal 71 by deformation of the bending portion 333 d itself. In other words, the bending part 333d prevents the coil end 33a from sliding so as to slide on the protrusion 73 by deforming itself.

  The bent portion 333d can also be called a slack portion formed by loosening the coil end 33a between the guide portion 36 and the protrusion 73. In this embodiment, a step of bending the coil end 33a so as to form a sag in a suspended portion of the coil end 33a between the guide portion 36 and the terminal 71 is employed.

  In this embodiment, both the shape of the guide 36 and the step of bending the coil end 33a are set to provide the shape of the illustrated coil end 33a. The coil end 33a is arranged and bent so that a part of the suspended portion thereof, that is, a part of the bent portion 333d is located on the terminal 71 side beyond the virtual plane PP.

  The guide portion 36 is formed so that the coil end 33a is arranged in the shape shown in the figure. The edge 42c is positioned on the electrode 82 side with respect to the virtual plane PP, that is, on the protruding direction side of the protrusion 73 with respect to the virtual plane PP. In other words, both of the radially inner edges 41c and 42c of the groove 43 are positioned on the side opposite to the terminal 71 with respect to the virtual plane PP. Further, the guide portion 36 is formed so as to be separated from the terminal 71 radially outward of the stator 31 so as to provide a space necessary for forming the bent portion 333 d between the guide portion 36 and the terminal 71. ing. In the step of bending the coil end 33a, the coil end 33a is bent from the edges 41c and 42c so as to pass through the terminal 71 side beyond the virtual plane PP. In other words, the coil end 33a is bent so as to meander from the edges 41c and 42c.

  Also in this embodiment, the electrode 82 first contacts the contact portion 233c of the free end portion. The electrode 82 presses the coil end 33 a toward the terminal 71. As a result, the coil end 33 a is deformed along the terminal 71. At this time, the bending portion 333 d allows the coil end 33 a on the distal end side of the bending portion 333 d to rotate along the terminal 71. The bent portion 333d functions as a hinge portion in the coil end 33a. Also in this embodiment, the electrode 82 does not contact only the suspended portion of the coil end 33 a that is spanned between the protrusion 73 and the guide portion 36. Compared with the case where the suspended portion of the coil end 33 a spanned between the guide portion 36 and the terminal 71 is pushed, the coil end 33 a is restrained from sliding so as to slide on the terminal 71. Thereby, a desirable weld is formed.

  According to this embodiment, the coil end 33a is firmly positioned before welding. A slack is formed in the suspended portion of the coil end spanned between the guide portion 36 and the terminal 71. In the welding process, the coil end 33 a is pushed by the electrodes 81 and 82. Therefore, the coil end 33 a tends to rotate along the terminal 71. At this time, the slack is deformed. Due to the deformation of the slack, the coil end 33a is prevented from moving so as to slide on the terminal 71. Thereby, a desirable weld is formed.

(Fourth embodiment)
This embodiment is a modification based on the preceding embodiment. Instead of the preceding embodiment, various shapes of grooves 43 can be employed. FIG. 16 shows the groove 43 of this embodiment. The groove 43 has a rectangular inlet portion 446 defined by a pair of edges parallel to the axial direction of the stator 31. Also in this embodiment, the coil end 33 a can be guided by the inlet portion 446.

(Fifth embodiment)
This embodiment is a modification based on the preceding embodiment. FIG. 17 shows the groove 43 of this embodiment. The groove 43 has an inlet portion 546 which can be called a triangle or a trapezoid defined by a pair of edges inclined with respect to the axial direction of the stator 31. Also in this embodiment, the coil end 33 a can be guided by the inlet portion 546.

(Sixth embodiment)
This embodiment is a modification based on the preceding embodiment. FIG. 18 shows the groove 43 of this embodiment. The groove 43 has an inlet portion 646 defined by one edge parallel to the axial direction and one edge inclined with respect to the axial direction. Also in this embodiment, the coil end 33 a can be guided by the inlet portion 646.

(Seventh embodiment)
This embodiment is a modification based on the preceding embodiment. In the preceding embodiment, an electrode 72 for a single phase coil is illustrated. Instead, the configuration of the guide portion 36 employed in the preceding embodiment can be applied to electrodes for various uses.

  FIG. 19 is a cross-sectional view modeling the stator 31 of this embodiment. In this embodiment, electrodes 72 and 775 for a three-phase coil are shown. The plurality of electrodes 72 and 775 are arranged so that their surfaces extend in the circumferential direction. The plurality of electrodes 72 and 775 are arranged so as to be sandwiched between welding electrodes that can be opened and closed along the radial direction of the stator 31.

  The electrode 72 connects the coil end 33 a and the power line of the wire harness 15. The electrode 72 has a terminal 71 and a terminal 74. The electrode 72 is a through electrode that penetrates the stator 31 in the axial direction. The electrode 72 has terminals 71 and 74 that are separated from each other on both surfaces of the stator 31.

  Electrode 775 provides a neutral point connection for the three-phase coil. The electrode 775 has a plurality of terminals 71. The electrode 775 is an E-shaped multi-head electrode. Also in this embodiment, the guide part 36 can employ the same structure as the preceding embodiment.

(Eighth embodiment)
This embodiment is a modification based on the preceding embodiment. In this embodiment, other electrodes 875 and 872 are illustrated.

  FIG. 20 is a cross-sectional view modeling the stator 31 of this embodiment. In this embodiment, electrodes 872, 875 for a three-phase coil are shown. The plurality of electrodes 872 and 875 are arranged so that the surfaces thereof extend in the radial direction. The plurality of electrodes 872 and 875 are arranged so as to be sandwiched by welding electrodes that can be opened and closed along the circumferential direction of the stator 31.

  The electrode 872 connects the coil end 33 a and the power line of the wire harness 15. The electrode 872 is an L-shaped plate. The electrode 872 includes a terminal 71 and a terminal 874. The electrode 872 is a non-penetrating electrode that does not penetrate the stator 31. The electrode 872 has a fixing portion to the insulator 35 at one end thereof. The electrode 872 has a terminal 874 connected to the power line at the other end. The electrode 872 has a terminal 71 between the terminal 874 and the fixed portion.

  A plurality of electrodes 875 provide a neutral point connection for the three-phase coil. The plurality of electrodes 875 are provided on the insulator 35 electrically independent from each other. Each electrode 875 has a terminal 71 connected to the coil end 33 a and a terminal 877 connected to the electrode 878. The electrode 875 has a fixed portion to the insulator 35 at one end and a terminal 877 at the other end. The terminal 71 is provided at the center in the length direction of the electrode 875. The electrode 875 is an I-shaped plate.

  The electrode 878 is a common electrode connected to the plurality of electrodes 875. The electrode 878 can be provided by a conductor piece or an electric wire. The electrode 875 and the electrode 878 are electrically and mechanically connected by soldering. Also in this embodiment, the guide part 36 can employ the same structure as the preceding embodiment.

(Other embodiments)
The disclosure of this specification is not limited to the illustrated embodiments. The disclosure encompasses the illustrated embodiments and variations by those skilled in the art based thereon. For example, the disclosure is not limited to the combinations of parts and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure may have additional parts that can be added to the embodiments. The disclosure includes those in which parts and / or elements of the embodiments are omitted. The disclosure encompasses the replacement or combination of parts and / or elements between one embodiment and another. The technical scope disclosed is not limited to the description of the embodiments. Some technical scope disclosed is indicated by the description of the claims, and should be understood to include all modifications within the meaning and scope equivalent to the description of the claims. .

  In the said embodiment, the coil end 33a and the terminal 71 are welded by electrical resistance welding or spot welding. Instead of this, the coil end 33a and the terminal 71 may be joined by soldering or by caulking by mechanically deforming and joining the members.

  In the said embodiment, the rotary electric machine 10 is a generator. Instead, the structure of the connecting portion disclosed herein may be applied to a connecting portion of a rotating electrical machine called a generator motor or an AC generator starter. In this case, the rotating electrical machine 10 includes a multiphase stator coil 33. For example, the three-phase stator coil 33 outputs three-phase AC power when functioning as a generator. The three-phase stator coil 33 functions as an electric motor when supplied with three-phase AC power. The electric circuit 11 can include an inverter circuit (INV) and a control device (ECU). The rotating electrical machine 10 may include a rotational position sensor for controlling the electric motor and a rotational position sensor for controlling the ignition. Regarding such application, the contents described in JP 2013-233030 A, JP 2013-27252 A, or Japanese Patent No. 5064279 are incorporated by reference.

  In the above embodiment, the guide portion 36 is integrally formed of the resin material of the insulator 35. Instead of this, the guide portion 36 may be formed of a resin material separate from the insulator 35. In this case, the guide part 36 is connected via a connection mechanism such as being inserted into the stator core 32 or the insulator 35.

10 rotating electrical machines, 11 electrical circuits, 12 internal combustion engines, 13 bodies,
14 Rotating shaft, 15 Wire harness, 21 Rotor, 22 Rotor core,
23 Permanent magnet, 31 Stator, 32 Steer core, 32a Magnetic pole,
33 Stator coil, 33a Coil end, 33b, 233b Bending part,
33c, 233c contact part, 333d bent part,
35 insulators, 36 guides, 37 bobbins, 38 walls,
41 1st protrusion, 42, 242 and 342 2nd protrusion, 43 groove,
44 Thin plate part, 45 Deformation part, 46, 446, 546, 646 Inlet part,
47 Positioning part, 48 gap, 50 connection part, 51 welded part,
71 terminals, 72, 775, 872, 875, 878 electrodes,
73 Projection, 74, 874, 877 Terminal, 81, 82 Electrode.

Claims (13)

A coil end (33a) which is an end of the stator coil (33);
A terminal (71) to which the coil end is connected;
A guide portion (36) for defining and forming a groove (43) for guiding the coil end toward the terminal by accommodating the coil end;
The guide part is
A positioning portion (47) provided at a predetermined position of the coil end in the groove and deformed by contact with the coil end;
An inlet portion (46, 446, 546, 646) provided at the inlet of the groove and having a width (WW) larger than a diameter (DC) of the coil end and larger than a width (WN) of the positioning portion. Rotating electric machine. A rotor (21) connected to the rotating shaft (14) of the internal combustion engine;
A stator (31) disposed opposite the rotor;
An electrically insulating insulator (35) provided on the stator,
The stator coil is provided on the stator,
The terminal is supported by the insulator so as to extend along the axial direction of the stator,
The rotating electrical machine according to claim 1, wherein the guide portion includes a first protrusion (41) and a second protrusion (42, 242 and 342) provided in the insulator and defining the groove. The coil end has a bent portion (33b, 333d) that protrudes from the guide portion and is bent along the terminal.
The first protrusion is located inside the bent portion,
The second protrusion is located outside the bent portion,
The rotating electrical machine according to claim 2, wherein the second protrusion includes a deforming portion (45) that is provided in the positioning portion and is deformed by contacting the coil end.   4. The rotating electrical machine according to claim 3, wherein the second protrusion is formed in a thin plate shape, and has a thin plate portion (44) that forms the deformation portion by contacting the coil end. The positioning part is
A portion that is deformed by contact with the coil end at a position where the coil end is positioned to provide a width equal to or greater than the diameter (DC) of the coil end;
5. The rotating electrical machine according to claim 1, further comprising a portion having a width (WN) smaller than a diameter (DC) of the coil end. A coil end (33a) which is an end of the stator coil (33);
A terminal (71) to which the coil end is connected;
In a method of manufacturing a rotating electrical machine, comprising a guide portion (36) for defining a groove (43) for guiding the coil end toward the terminal by accommodating the coil end,
Loosely positioning the coil end at an inlet portion (46, 446, 546, 646) provided at the inlet of the groove and having a width (WW) greater than the diameter (DC) of the coil end;
Moving the coil end via the inlet portion toward a positioning portion (47) provided at a predetermined position of the coil end in the groove;
In the positioning unit, the coil end and the guide unit are brought into contact with each other, the guide unit is deformed to position the coil end firmly, and the coil end is positioned by the positioning unit, A method of manufacturing a rotating electrical machine including connecting a terminal. The connection is provided by sandwiching the coil end and the terminal with electrodes (81, 82) and welding the coil end and the terminal with the coil end positioned by the positioning portion. ,
further,
The rotating electrical machine according to claim 6, further comprising: permitting movement of the coil end by further deforming the guide portion by movement of the coil end when the coil end and the terminal are sandwiched by the electrode. Manufacturing method. further,
The rotation according to claim 7, comprising bending the coil end so that the coil end is arranged on the terminal so as to be farther from the terminal toward the tip of the coil end before the welding. Electric manufacturing method. further,
The method for manufacturing a rotating electrical machine according to claim 7 or 8, comprising bending the coil end so as to form a sag at the coil end between the guide portion and the terminal before the welding.   The method for manufacturing a rotating electrical machine according to claim 8 or 9, wherein the coil end is bent into an S shape. A coil end (33a) which is an end of the stator coil (33);
A terminal (71) to which the coil end is connected;
In a method of manufacturing a rotating electrical machine, comprising a guide portion (36) for defining a groove (43) for guiding the coil end toward the terminal by accommodating the coil end,
Inserting the coil end into the groove to bring the coil end into contact with the guide part, deforming the guide part, and firmly positioning the coil end;
With the coil end positioned by the groove, the coil end and the terminal are sandwiched by electrodes (81, 82), the coil end and the terminal are welded, and the coil end and the terminal are A method of manufacturing a rotating electrical machine including allowing the movement of the coil end by further deforming the guide portion by movement of the coil end when the terminal is sandwiched. A coil end (33a) which is an end of the stator coil (33);
A terminal (71) to which the coil end is connected;
In a method of manufacturing a rotating electrical machine, comprising a guide portion (36) for defining a groove (43) for guiding the coil end toward the terminal by accommodating the coil end,
Inserting the coil end into the groove to bring the coil end into contact with the guide part, deforming the guide part, and firmly positioning the coil end;
Bending the coil end so that the coil end is arranged on the terminal so as to be farther away from the terminal toward the tip of the coil end, and in the state where the coil end is positioned by the groove, (81, 82) A method for manufacturing a rotating electrical machine, comprising sandwiching the coil end and the terminal and welding the coil end and the terminal. A coil end (33a) which is an end of the stator coil (33);
A terminal (71) to which the coil end is connected;
In a method of manufacturing a rotating electrical machine, comprising a guide portion (36) for defining a groove (43) for guiding the coil end toward the terminal by accommodating the coil end,
Inserting the coil end into the groove to bring the coil end into contact with the guide part, deforming the guide part, and firmly positioning the coil end;
Bending the coil end to form a slack in a suspended portion of the coil end spanned between the guide portion and the terminal;
With the coil end positioned by the groove, the coil end and the terminal are sandwiched by electrodes (81, 82), the coil end and the terminal are welded, and the coil end is along the terminal A method of manufacturing a rotating electrical machine that includes the deformation of the slack when rotating.

Images