JP6816811B2 - Manufacturing method of rotary electric machine - Google Patents

Description

Cross-reference of related applications

This application is based on Patent Application No. 2017-110301 filed in Japan on June 2, 2017, and the content of the basic application is incorporated by reference in its entirety.

The disclosure in this specification relates to a rotary electric machine and a method of manufacturing the rotary electric machine.

Patent Documents 1-4 disclose a rotary electric machine and a method for manufacturing the rotary electric machine. In this technique, a cover containing a sensor element for detecting a rotation position is inserted between a plurality of magnetic poles. The contents of the prior art documents listed as prior art are incorporated by reference as an explanation of the technical elements in this specification.

JP-A-2017-34732 Japanese Unexamined Patent Publication No. 2013-23030 Japanese Unexamined Patent Publication No. 2013-27252 Patent No. 5064279

In the conventional configuration, if the coil and the cover interfere with each other, the position of the sensor element may deviate from the desired position. For example, it is desirable that the outer shape of the coil mounted on the tooth portion has a specified shape. However, if the shape of the coil deviates from the specified shape, the coil and the cover may interfere with each other. In this case, the position of the cover may shift, and the position of the sensor element in the cover may shift. The deviation of the sensor element may reduce the detection accuracy of the rotation position.

Further improvements are required in the rotary electric machine and the manufacturing method of the rotary electric machine in the above-mentioned viewpoint or in other viewpoints not mentioned.

One object disclosed is to provide a rotary electric machine and a method for manufacturing a rotary electric machine having high accuracy of detecting a rotational position.

Another object disclosed is to provide a rotary electric machine and a method for manufacturing a rotary electric machine in which the deviation of the sensor element for detecting the rotation position is suppressed.

Yet another object to be disclosed is a rotary electric machine and a rotary electric machine which can accurately arrange the coil wire on the bobbin and suppress the deviation of the sensor element due to the interference between the coil wire and the sensor unit. Is to provide a manufacturing method of.

Yet another object disclosed is that the coil strands can be placed on the bobbin accurately and at high speed, which makes them suitable for mass production and suppresses the displacement of the sensor element due to the interference between the coil strands and the sensor unit. It is to provide the rotary electric machine and the manufacturing method of the rotary electric machine.

According to this disclosure, a method of manufacturing a rotary electric machine is provided. The method of manufacturing a rotary electric machine is adjacent to a winding step of winding a stator coil (33) around the outer periphery of a plurality of bobbin portions (36) mounted on a plurality of teeth portions (32c) having magnetic poles (32a) at the tip. The gap between the two magnetic poles includes an insertion step of inserting the sensor (43) from one end surface (SD1) of the stator (31), and in the winding step, the coil strand (33d) of the stator coil is used. in one end face side, so as to be spaced apart from the magnetic pole in a radial direction, the coil wire winding Iteori, insertion step, a plurality of normal gap in which a plurality of magnetic poles formed (38a) and the sensor gap (38b) Of these, the step is to insert the sensor only into the sensor gap (38b), and the winding step is the coil wire (33d) of the stator coil only in the sensor bobbin portion (36b) located next to the sensor gap (38b). ) Is a step of winding the coil wire so that it is arranged radially away from the magnetic pole on one end face side.

According to the disclosed rotary electric machine, a coil shape that does not easily interfere with the sensor when inserting the sensor is provided. As a result, the deterioration of the detection accuracy of the rotation position due to the interference between the sensor and the coil wire is suppressed.

The disclosed aspects of this specification employ different technical means to achieve their respective objectives. The claims and the reference numerals in parentheses described in this section exemplify the correspondence with the parts of the embodiments described later, and are not intended to limit the technical scope. The objectives, features, and effects disclosed herein will be made clearer by reference to the subsequent detailed description and accompanying drawings.

It is a modeled sectional view of the rotary electric machine which concerns on 1st Embodiment. It is a top view of the stator. It is a perspective view of a stator. It is a top view of an insulator. It is a perspective view of an insulator. It is a side view which shows the magnetic pole and the insulator in the direction of the VI arrow of FIG. It is a top view in the VII arrow of FIG. 6 is a cross-sectional view taken along the line VIII-VIII of FIG. It is a partial perspective view of an insulator. It is a partial perspective view of an insulator. It is a top view of the sensor unit. It is a perspective view of a sensor unit. It is a side view of the inside in the radial direction of a sensor unit. It is a perspective view of a sensor unit. It is a modeled perspective view of a cover. It is sectional drawing of a cover. It is a side view which shows the stator core and a sensor unit. It is a side view which shows a part of one pole by a cross section. It is sectional drawing which shows the relationship between a cover and a coil. It is a side view which shows a part of one pole of 2nd Embodiment in a cross section. It is a partial perspective view of the insulator of 3rd Embodiment. It is a partial perspective view of the insulator of 4th Embodiment. It is a partial perspective view of the insulator of 5th Embodiment. It is a partial perspective view of the insulator of the sixth embodiment. It is a partial perspective view of the insulator of 7th Embodiment. It is a partial perspective view of the insulator of 8th Embodiment. It is a side view which shows a part of one pole of 9th Embodiment in the cross section. FIG. 5 is an external view of a bare core in one pole of a tenth embodiment. It is an external view which shows one pole after the inner layer is attached. It is an external view which shows one pole after the outermost layer is attached. It is sectional drawing which shows the winding apparatus. It is a diagram showing the moving process of the molding machine. It is a diagram showing the moving process of the molding machine.

A plurality of embodiments will be described with reference to the drawings. In a plurality of embodiments, functionally and / or structurally corresponding parts and / or associated parts may be designated with the same reference code or reference codes having a hundreds or more different digits. References can be made to the description of other embodiments for the corresponding and / or associated parts.

1st Embodiment In FIG. 1, a rotary electric machine for an internal combustion engine (hereinafter, simply referred to as a rotary electric machine) 10 is also referred to as a generator motor or an AC generator starter. The rotary electric machine 10 is electrically connected to an electric circuit 11 including an inverter circuit (INV) and a control device (ECU). The electric circuit 11 provides a three-phase power conversion circuit. An example of the use of the rotary electric machine 10 is a generator motor of an internal combustion engine 12 for a vehicle. The vehicle is a vehicle, ship, or aircraft, and a typical example is a saddle-riding vehicle.

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

The electric circuit 11 provides a drive circuit that causes the rotary electric machine 10 to function as an electric motor. The electric circuit 11 receives a rotation position signal from the rotary electric machine 10 for causing the rotary electric machine 10 to function as an electric motor. The electric circuit 11 causes the rotary electric machine 10 to function as an electric motor by controlling the energization of the rotary electric machine 10 according to the detected rotation position.

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

The rotary shaft 14 rotates the rotary electric machine 10 so that the rotary electric machine 10 functions as a generator. The rotary shaft 14 is a rotary shaft capable of starting the internal combustion engine 12 by the rotation of the rotary electric machine 10 when the rotary electric machine 10 functions as an electric motor. Further, the rotating shaft 14 is a rotating shaft capable of assisting the rotation of the internal combustion engine 12 by the rotation of the rotating electric machine 10 when the rotating electric machine 10 functions as an electric motor.

The rotary electric machine 10 has a rotor 21, a stator 31, and a sensor unit 41. In the following description, the term axial AD means the direction of the central axis when the stator 31 is regarded as a cylinder. The term RD in the radial direction means the radial direction when the stator 31 is regarded as a cylindrical body.

The rotor 21 is a field magnet. The stator 31 is an armature. The rotor 21 has a cup shape as a whole. The rotor 21 is positioned with its open end facing the body 13. The rotor 21 is fixed to the end of the rotating shaft 14. The rotor 21 and the rotating shaft 14 are connected via a positioning mechanism in the rotational direction such as key fitting. The rotor 21 is fixed by being tightened to the rotating shaft 14 by the fixing bolt 25. The rotor 21 rotates together with the rotating shaft 14. The rotor 21 provides a field, that is, a rotating field, by means of a permanent magnet.

The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 is connected to the rotating shaft 14 of the internal combustion engine 12. The rotor core 22 has an inner cylinder fixed to the rotating shaft 14, an outer cylinder located radially outside the inner cylinder, and an annular bottom plate extending between the inner cylinder and the outer cylinder. The rotor core 22 provides a yoke for a permanent magnet, which will be described later. The rotor core 22 is made of magnetic metal.

The rotor 21 has a permanent magnet 23 arranged on the inner surface of the rotor core 22. The permanent magnet 23 is fixed to the inside of the outer cylinder. The permanent magnet 23 is fixed with respect to the axial AD and the radial RD by the holding cup 24 arranged inside in the radial direction. The holding cup 24 is made of a thin non-magnetic metal. The holding cup 24 is fixed to the rotor core 22.

The permanent magnet 23 has a plurality of segments. Each segment is partially cylindrical. The permanent magnet 23 provides a plurality of N poles and a plurality of S poles inside the permanent magnet 23. The permanent magnet 23 provides at least a field magnet. The permanent magnet 23 provides a field of 6 pairs of N and S poles, that is, 12 poles by 12 segments. The number of magnetic poles may be another number. The permanent magnet 23 provides a partial special magnetic pole to provide a reference position signal for ignition control. The special magnetic poles are provided by partial magnetic poles that are different from the magnetic pole arrangement for the field.

The stator 31 and the body 13 are connected via fixing bolts 34. The stator 31 is fixed by being tightened to the body 13 by a plurality of fixing bolts 34. The stator 31 is arranged between the rotor 21 and the body 13. The stator 31 has an outer peripheral surface that faces the inner surface of the rotor 21 via a gap. The stator 31 is fixed to the body 13.

The stator 31 has a stator core 32. The stator core 32 is arranged inside the rotor 21 by being fixed to the body 13 of the internal combustion engine 12. The stator core 32 has a plurality of tooth portions. One tooth portion provides one magnetic pole. The stator core 32 provides an outer salient pole type iron core.

The stator 31 has a stator coil 33 wound around a stator core 32. The stator coil 33 provides an armature winding. An electrically insulating resin insulator 35 is arranged between the stator core 32 and the stator coil 33. The stator coil 33 is a three-phase winding. The stator coil 33 can selectively function the rotor 21 and the stator 31 as a generator or an electric motor.

The sensor unit 41 provides a rotation position detecting device for an internal combustion engine. The sensor unit 41 is provided in the rotary electric machine 10 linked to the internal combustion engine 12. The sensor unit 41 is provided on the stator core 32 of the rotary electric machine 10. The sensor unit 41 outputs an electric signal indicating the rotation position of the rotor 21 by detecting the magnetic flux of the permanent magnet 23 provided in the rotor 21.

The sensor unit 41 is fixed to the stator 31. The sensor unit 41 is arranged between the stator core 32 and the body 13. The sensor unit 41 is fixed to the end face SD1 of the stator core 32. Although the sensor unit 41 is also fixed to the body 13, it may be fixed only to the stator core 32. The sensor unit 41 detects the rotational position of the rotor 21 by detecting the magnetic flux supplied by the permanent magnet 23 provided in the rotor 21. The sensor unit 41 has a plurality of sensors 43. The plurality of sensors 43 are arranged between two adjacent magnetic poles 32a. It can be said that the plurality of sensors 43 are arranged between two adjacent coils. The plurality of sensors 43 detect the rotational position of the rotor 21 by detecting the change in the magnetic flux of the permanent magnet 23. The plurality of sensors 43 are arranged apart from each other in the circumferential direction with respect to the rotation axis of the rotor 21.

The position of the special magnetic pole provided by the permanent magnet 23 indicates a reference position for ignition control. The rotation position of the rotor 21 is also the rotation position of the rotation shaft 14. Therefore, by detecting the rotation position of the rotor 21, a reference position signal for ignition control can be obtained. At least one of the plurality of sensors 43 outputs a signal for ignition control by reacting with a special magnetic pole. In this embodiment, one sensor 43 provides a sensor for ignition control. As a result, the stator 31 includes a sensor for outputting a signal for ignition control when the rotor 21 is in a predetermined rotational position.

The rotational position of the rotor 21 is indicated by the position in the rotational direction of the field provided by the permanent magnet 23. Therefore, the rotary electric machine 10 can function as an electric motor by detecting the rotational position of the rotor 21 and controlling the energization of the armature winding according to the detected rotational position. At least one of the plurality of sensors 43 detects the rotational position of the rotor 21 for causing the rotary electric machine 10 to function as at least an electric motor. The rotary electric machine 10 can function as a generator and an electric motor, and is selectively functioned as any of them.

The sensor unit 41 accommodates the electric circuit component 42. The electric circuit component 42 includes a substrate, an electric element mounted on the substrate, an electric wire, and the like. The sensor unit 41 accommodates the sensor 43. The sensor unit 41 has a case 51.

The case 51 is made of a resin material. The case 51 can have a partially metal portion. The case 51 accommodates and holds the electric circuit component 42 and the sensor 43. The sensor 43 is connected to the electric circuit component 42. The case 51 has a shape corresponding to the cross section of a polygonal cylinder, for example, a trapezoidal cylinder, and has an outer edge extending substantially corresponding to the radial outer edge of the stator 31. The case 51 has a container 52 for accommodating the electric circuit component 42. The container 52 is made of a resin material. The container 52 has a box shape with an open surface facing the body 13. The container 52 has a bottom surface facing the stator core 32 side, an opening facing the body 13, and a side wall surrounding the bottom surface and the opening. The electric circuit component 42 is housed and fixed in the container 52.

The case 51 has at least one cover 53 for accommodating and supporting at least one sensor 43. The sensor 43 is fixed in the cover 53. The cover 53 is a bottomed tubular member formed so as to extend from the bottom surface of the container 52. The cover 53 is provided on the outer side in the radial direction. The cover 53 is inserted into the gap between the two magnetic poles 32a.

The cover 53 has a base portion provided on the bottom surface of the case 51 and a main body portion extending from the base portion. The main body is thinner than the base. The base has a width wider than the gap. A step portion is formed between the base portion and the main body portion. The step portion comes into contact with one end surface SD1 of the stator core 32. As a result, the amount of the main body inserted into the gap is defined.

The inside of the cover 53 communicates with the inside of the container 52. The sensor unit 41 has a plurality of covers 53. The cover 53 has a shape that can be called a finger shape or a tongue shape that extends from the container 52. The cover 53 can also be referred to as a sheath for the sensor 43. The plurality of covers 53 include one cover 53 for the sensor for reference position detection for ignition control and three covers 53 for the sensor for motor control.

One sensor 43 is housed in each cover 53. The sensor 43 detects the magnetic flux supplied by the permanent magnet 23. The sensor 43 is provided by a Hall sensor, an MRE sensor, or the like. This embodiment has one sensor for ignition control and three sensors for motor control. The sensor 43 is electrically connected to the electric circuit component 42 by a sensor terminal arranged in a cavity in the cover 53.

For the details related to the permanent magnet 23 for ignition control and motor control in this embodiment and the details related to the plurality of sensors 43, the contents described in the documents listed as patent documents can be incorporated. The content of the description is quoted by reference.

The case 51 has a tightening portion 54. The tightening portion 54 is provided radially inside the container 52 with respect to the radial RD of the rotary electric machine 10. A connecting portion 55 for connecting between the container 52 and the tightening portion 54 is provided. The fixing bolt 44 is arranged so as to penetrate the stator core 32 from the surface of the stator core 32 opposite to the body 13. The tip of the fixing bolt 44 protruding from the stator core 32 is screwed into the female threaded portion of the tightening portion 54. As a result, the sensor unit 41 is fixed to the stator core 32. The inside of the container 52 is filled with a protective sealing resin 56. The sealing resin 56 is a potting resin for protecting the electric circuit component 42.

The sensor unit 41 has wiring 11a for external connection for taking out signals output from one or more sensors 43 to the outside. The wiring 11a can transmit an ignition signal indicating a reference position and / or a rotation position signal indicating a rotation angle. The rotary electric machine 10 has a plurality of power lines 11b that connect the stator coil 33 and the electric circuit 11. The power line 11b supplies the electric power induced in the stator coil 33 to the electric circuit 11 when the rotary electric machine 10 functions as a generator. The power line 11b supplies electric power for exciting the stator coil 33 from the electric circuit 11 to the stator coil 33 when the rotary electric machine 10 functions as an electric motor.

In FIGS. 2 and 3, the stator 31 is an annular member. The stator 31 has a through hole capable of receiving the rotating shaft 14 and the inner cylinder of the rotor core 22. The stator core 32 forms a through hole for receiving the inner cylinder of the rotating shaft 14 and the rotor core 22. Further, the stator core 32 has a plurality of through holes for receiving the plurality of fixing bolts 34. These through holes contribute to defining the position of the stator core 32 in the circumferential direction. The stator core 32 has a through hole for receiving a fixing bolt 44 for fixing the sensor unit 41.

A plurality of magnetic poles 32a are arranged on the outer peripheral surface of the stator 31. The plurality of magnetic poles 32a are arranged apart from each other along the circumferential direction. The plurality of magnetic poles 32a are provided so as to receive the field of the rotor 21 at the ends of the plurality of tooth portions 32c extending in the radial direction. The stator 31 has, for example, 18 magnetic poles 32a. The number of magnetic poles 32a may be another number. These magnetic poles 32a are arranged so as to face the field of the rotor 21. The stator core 32 forms a plurality of magnetic poles 32a facing the permanent magnet 23 on the outer side in the radial direction. The stator core 32 is formed by laminating magnetic steel plates (electrical steel sheets) formed into a predetermined shape so as to form a plurality of magnetic poles 32a.

In FIGS. 2 and 3, the insulator 35 and the stator core 32 hidden by the stator coil 33 by the broken line are drawn in the lower left portion. The stator core 32 has an annular portion 32b positioned radially inward. The annular portion 32b has the above-mentioned through hole and is a fixing portion for fixing the stator core 32. The stator core 32 has a plurality of teeth portions 32c extending in the radial direction. One tooth portion 32c connects the annular portion 32b and one magnetic pole 32a.

The stator coil 33 provides a polyphase armature winding. The stator coil 33 is mounted on a plurality of tooth portions 32c. The stator 31 is a three-phase multi-pole stator having a plurality of magnetic poles 32a and a plurality of three-phase windings. The stator coil 33 has a plurality of single coils 33s. The single coil 33s is a coil mounted on one magnetic pole 32a and one tooth portion 32c. The single coil 33s is centrally wound around one tooth portion 32c. The plurality of single coils 33s provide one phase coil. A multi-phase coil provides a multi-phase armature winding.

The insulator 35 has two halves 35a and 35b that sandwich the stator core 32 in the axial direction. The half-split body 35a is located on one end surface SD1 side in the axial direction of the stator 31. The sensor unit 41 is arranged on one of the end faces SD1. The half-split body 35b is located on the SD2 side of the other end surface of the stator 31 in the axial direction. The other end face SD2 is an end face opposite to the end face on which the sensor unit 41 is arranged. The coil strand 33d, which will be described later, is arranged on the half-split body 35a at a distance from the magnetic pole 32a in the radial direction. The half-split body 35a includes a protruding portion 37e described later. The half-split body 35b does not include a protruding portion 37e.

The insulator 35 has a central portion 35c arranged so as to cover the radial outer portion of the annular portion 32b. The stator coil 33 has a plurality of jumper wires 33j arranged so as to extend along the circumferential direction on the stator 31 in order to connect the plurality of single coils 33s. The jumper wire 33j is a coil wire for forming the stator coil 33. In FIGS. 2 and 3, some jumper lines 33j are shown by broken lines.

The insulator 35 has a guide fin 35d for guiding the jumper wire 33j on the central portion 35c. The guide fin 35d is positioned at the fixed portion. The guide fin 35d is a plate-shaped member. The guide fin 35d extends in the radial direction. The guide fin 35d extends in the axial direction. The guide fin 35d is integrally molded with a material continuous with the insulator 35. The guide fin 35d has an axially extending edge outward in the radial direction. The guide fin 35d has an edge inside the radial direction that is inclined away from the stator core 32 toward the outside in the radial direction. The guide fin 35d is a part of the end surface of the stator 31, and projects axially from the end surface of the stator core 32. The insulator 35 includes a plurality of guide fins 35d. The plurality of guide fins 35d are separated from each other along the circumferential direction. The plurality of guide fins 35d are arranged radially.

The method of manufacturing the rotary electric machine 10 includes a wiring step of arranging the jumper wire 33j in the annular range in which the stator coil 33 is installed. At least one guide fin 35d suppresses the intrusion of the jumper wire 33j in the radial direction in the manufacturing process of the rotary electric machine 10. Further, at least one guide fin 35d suppresses the invasion of the jumper wire 33j inward in the radial direction in the finished product. In other words, the guide fin 35d guides the coil wire so as to suppress the invasion of the coil wire into the fixed portion. Damage to the jumper wire 33j is suppressed by suppressing the invasion of the jumper wire 33j inward in the radial direction. The guide fin 35d guides the jumper wire 33j without occupying a wide area above the fixed portion. The guide fin 35d does not hinder the arrangement of the tightening portion 54 and the arrangement of the fixing bolt 34 in the annular portion 32b.

The insulator 35 has a bobbin portion 36 that covers the teeth portion 32c. The bobbin portion 36 is arranged between the teeth portion 32c and the stator coil 33. The insulator 35 has a flange portion 37 located at the outer end in the radial direction and extending along the edge of the magnetic pole 32a. The flange portion 37 is arranged between the magnetic pole 32a and the stator coil 33.

The stator 31 has a plurality of gaps 38. The gap 38 is formed between two adjacent magnetic poles 32a. The plurality of gaps 38 usually have a gap 38a and a sensor gap 38b. The sensor gap 38b is used to arrange the cover 53. The stator core 32 has 18 gaps 38. In this embodiment, the sensor unit 41 has four covers 53. Therefore, the stator 31 has four sensor gaps 38b. Therefore, it has 14 normal gaps 38a and 4 sensor gaps 38b. Instead of this, when the sensor unit 41 has one sensor 43, one sensor gap 38b is provided. When the sensor unit 41 has three sensors 43, three sensor gaps 38b are provided.

The normal gap 38a has a width in a predetermined circumferential direction. The sensor gap 38b usually has a width in the circumferential direction wider than the gap 38a. The plurality of magnetic poles 32a have a first magnetic pole 32aw, a second magnetic pole 32am, and a third magnetic pole 32as. The plurality of magnetic poles 32a have different circumferential widths so as to provide a normal gap 38a and a sensor gap 38b. The plurality of magnetic poles 32a extend to both sides in the circumferential direction. The first magnetic pole 32aw, the second magnetic pole 32am, and the third magnetic pole 32as have different amounts of protrusion in the circumferential direction.

The first magnetic pole 32aw has a width in a predetermined circumferential direction. The first magnetic pole 32aw extends equally from the tip of the tooth portion 32c to both sides in the circumferential direction. The stator core 32 has a plurality of first magnetic poles 32aw. The two adjacent first magnetic poles 32aw usually form a gap 38a between them. The first magnetic pole 32aw extends greatly so as to form a normal gap 38a between them.

The second magnetic pole 32am and the third magnetic pole 32as have a circumferential width smaller than that of the first magnetic pole aw. The third magnetic pole 32as has a width in the circumferential direction smaller than that of the second magnetic pole 32am. The stator core 32 has three third magnetic poles 32as. The third magnetic pole 32as extends from the tip of the tooth portion 32c to both sides in the circumferential direction. The third magnetic pole 32as is located between the sensor gap 38b and the sensor gap 38b. The third magnetic pole 32as extends smaller than the first magnetic pole 32aw so as to form a sensor gap 38b between them. The spread of the third magnetic pole 32as on both sides in the circumferential direction is smaller than that of the first magnetic pole 32aw. The spread of the third magnetic pole 32as on both sides in the circumferential direction is equal. The stator core 32 has at least two second magnetic poles 32 am. The second magnetic poles 32am are located at both ends of the group of the plurality of sensor gaps 38b. The second magnetic pole 32am is usually located between the gap 38a and the sensor gap 38b. The second magnetic pole 32am usually extends to the side of the gap 38a by the same amount as the first magnetic pole 32aw. The second magnetic pole 32am extends to the side of the sensor gap 38b by the same amount as the third magnetic pole 32as.

In FIGS. 4 and 5, the insulator 35 has a shape that covers the surface excluding the magnetic pole 32a and the annular portion 32b. 4 and 5 show a half-split body 35a arranged between the stator core 32 and the sensor unit 41. The half-split body 35a has a protruding portion described later, but the half-split body 35b does not have a protruding portion. The guide fins 35d project radially inward from the central portion 35c as shown. As a result, the guide fin 35d guides the jumper line 33j.

The insulator 35 has a plurality of bobbin portions 36. The plurality of bobbin portions 36 have a plurality of normal bobbin portions 36a located on both sides of the normal gap 38a, and a plurality of sensor bobbin portions 36b located on both sides of the sensor gap 38b in which the cover 53 is arranged. The normal bobbin portion 36a and the sensor bobbin portion 36b are positioned on both sides of the two normal gaps 38a located on both sides of the four sensor gaps 38b. Of the four sensor gaps 38b, sensor bobbin portions 36b are positioned on both sides of the sensor gap 38b at the end. The sensor bobbin portion 36b has an uneven portion corresponding to a coil guide portion described later.

The insulator 35 has a plurality of flange portions 37. The flange portion 37 is provided at the radial tip of the bobbin portion 36. The plurality of flange portions 37 have a first flange portion 37a, a second flange portion 37b, and a third flange portion 37c. The first flange portion 37a, the second flange portion 37b, and the third flange portion 37c correspond to the first magnetic pole 32aw, the second magnetic pole 32am, and the third magnetic pole 32as, respectively. The second flange portion 37b and the third flange portion 37c are arranged on the second magnetic pole 32am and the third magnetic pole 32as forming the sensor gap 38b. Since the second flange portion 37b and the third flange portion 37c are related to the cover 53, they can also be referred to as a sensor flange portion. The sensor flange portion has a guide portion corresponding to a coil guide portion described later.

The normal bobbin portion 36a and the first flange portion 37a provide a normal insulator portion corresponding to the magnetic pole 32a forming the normal gap 38a. The sensor bobbin portion 36b and the second flange portion 37b provide a sensor insulator portion corresponding to the magnetic pole 32a forming the sensor gap 38b. The sensor bobbin portion 36b and the third flange portion 37c provide a sensor insulator portion corresponding to the magnetic pole 32a forming the sensor gap 38b. The coil guide portion described later is provided only in the sensor insulator portion. As a result, the coil strand 33d of the stator coil 33 facing the sensor unit 41 is arranged radially away from the magnetic pole 32a on one end surface SD1 side.

6 and 7 show a state in which the half-split bodies 35a and 35b are mounted on the stator core 32. FIG. 6 shows a side view seen from the direction of the VI arrow in FIG. The sensor insulator portion for the third magnetic pole 32as has a sensor bobbin portion 36b and a third flange portion 37c. The sensor bobbin portion 36b has a quadrangular surface 36e with rounded corners and a plurality of fins 36f. FIG. 8 shows a cross section of the tooth portion 32c and the insulator 35. The stator core 32 including the tooth portion 32c is a laminated body in which a plurality of magnetic plates are laminated. The plurality of fins 36f extend radially outward of the tooth portion 32c only at the corners of the surface 36e, which can also be called a quadrilateral.

The surface 36e and the plurality of fins 36f provide an uneven portion on the surface of the sensor bobbin portion 36b. This uneven portion holds the coil strand of the stator coil 33 at a predetermined position. The uneven portion regulates the movement of the coil strand in the sensor bobbin portion 36b. The uneven portion is one of the coil guide portions that separates the stator coil 33 from the third magnetic pole 32as in the radial direction on one end surface SD1 side.

The sensor insulator portion for the second magnetic pole 32am has a sensor bobbin portion 36b and a second flange portion 37b. The sensor insulator portion for the second magnetic pole 32am also has an uneven portion on the sensor bobbin portion 36b, as in FIGS. 6 and 7.

Returning to FIGS. 6 and 7, the half-split body 35a has a third flange portion 37c. The third flange portion 37c has a protruding portion 37e. The protruding portion 37e protrudes on one end face SD1 side. The protruding portion 37e protrudes from the flange portion along the teeth portion 32c toward the inner stator coil 33 in the radial direction. The radial inner surface of the protruding portion 37e is separated from the field of the rotor 21. The surface of the protruding portion 37e is raised inward in the radial direction. The surface of the protruding portion 37e protrudes toward the root of the tooth portion 32c. Of the flange portions 37 extending over the entire circumference of the teeth portion 32c, only the portion close to one end face SD1 protrudes as the protruding portion 37e. The protruding portion 37e protrudes from the base flange surface 37d. The base flange surface 37d is a surface of the flange portion 37 on the other end surface SD2 side of the stator 31 that faces the stator coil 33. In other words, the foundation flange surface 37d is the inner surface of the flange portion 37 provided on the half-split body 35b.

The protruding portion 37e causes the stator coil 33 to be radially separated from the third magnetic pole 32as. The protruding portion 37e is one of the coil guide portions that separates the stator coil 33 from the third magnetic pole 32as in the radial direction on one end surface side.

The sensor insulator portion for the second magnetic pole 32am has a sensor bobbin portion 36b and a second flange portion 37b. The sensor insulator portion for the second magnetic pole 32am also has a protruding portion 37e on the second flange portion 37b, as in FIGS. 6 and 7.

FIG. 9 is a perspective view showing a sensor insulator portion for the third magnetic pole 32as. The sensor insulator portion has a surface 36e and a plurality of fins 36f that provide uneven portions on the sensor bobbin portion 36b. The sensor insulator portion has a protruding portion 37e on the third flange portion 37c. The uneven portion and the protruding portion 37e provide a coil guide portion that separates the stator coil 33 from the third magnetic pole 32as in the radial direction.

The protruding portion 37e projects from the other end face side of the stator 31 toward one end face side so as to gradually increase. The protruding portion 37e has a slope portion at a position overlapping the sensor bobbin portion 36b with respect to the axial direction AD. The protruding portion 37e protrudes at a position axially separated from the end face of the axial AD of the sensor bobbin portion 36b. The protruding portion 37e separates the stator coil 33 from the third magnetic pole 32as toward the inside of the radial RD. The protruding portion 37e protrudes in the range on both sides of the circumferential CD at the end of the axial AD of the sensor bobbin portion 36b. The protruding portion 37e separates the stator coil 33 from the third magnetic pole 32as inward in the radial direction on both sides of the third magnetic pole 32as on which the cover 53 is arranged.

The sensor insulator portion for the second magnetic pole 32am also has a surface 36e and a plurality of fins 36f that provide uneven portions on the sensor bobbin portion 36b, as in FIG. The sensor insulator portion for the second magnetic pole 32am also has a protruding portion 37e on the third flange portion 37c, as in FIG. The uneven portion and the protruding portion 37e provide a coil guide portion that separates the stator coil 33 from the second magnetic pole 32am in the radial direction.

FIG. 10 is a perspective view showing a normal insulator portion for the first magnetic pole 32aw. The normal insulator portion usually does not have an uneven portion on the bobbin portion 36a. Normally, the insulator portion does not have a protruding portion on the first flange portion 37a. In other words, the coil guide portion is not usually provided in the insulator portion. The coil guide portion is provided only in the sensor insulator portion.

Returning to FIG. 9, the protruding portion 37e separates the stator coil 33 inward in the radial direction and defines the position thereof. The stator coils 33 are radially separated so as to avoid the cover 53 only at the position where the cover 53 is inserted. It is desirable that the distance that the stator coil 33 is separated in the radial direction is kept to the minimum necessary for the cover 53 to be stably arranged. As will be described later, the winding process from the inner layer to the outer layer contributes to reducing the above distance. Further, the uneven portion in the sensor bobbin portion 36b also contributes to accurately control the distance.

11, FIG. 12, FIG. 13, and FIG. 14 show the sensor unit 41. The sensor unit 41 has a case 51. The case 51 is arranged on one end surface of the stator 31 in the axial direction. The sensor unit 41 has a plurality of covers 53 extending from the case 51 into the sensor gap 38b. The plurality of covers 53 are arranged apart from each other along the plurality of magnetic poles 32a.

The case 51 has a protruding portion 57 at the end of the circumferential CD. The protruding portions 57 are provided on both sides of the case 51 in the circumferential direction. The protruding portion 57 protrudes from the container 52. The protruding portion 57 provides an operating portion for operating the sensor unit 41 in the method of manufacturing a rotary electric machine. The two protruding portions 57 enable the sensor unit 41 to be operated stably. For example, in the process of assembling the sensor unit 41 to the stator 31, the operator or the work machine can insert the plurality of covers 53 straight into the plurality of sensor gaps 38b by pushing the two protruding portions 57.

In FIGS. 11 and 12, the case 51 has a container 52 and a cavity 58. The container 52 houses the electric circuit component 42 and is sealed with an electrically insulating sealing resin 56. On the other hand, the cavity 58 is not sealed with the sealing resin. The cavity 58 provides a cavity. The cavity 58 is divided into a plurality of portions by a partition wall. The cavity 58 has three cavities 58a, 58b and 58c. The cavity 58 is provided on the radial inner edge of the container 52. The cavity 58 provides high rigidity against warpage deformation of the case 51 due to its partition wall. The cavity 58 reduces the weight of the case 51. The cavity 58 suppresses the amount of the sealing resin 56 used. The cavity 58 contributes to suppress the warp deformation of the case 51.

In FIGS. 12, 13, and 14, the plurality of covers 53 have a tapered shape in which the base portion connected to the container 52 is thick and the tip portion is thinner than the base portion. The cover 53 maintains its width in the circumferential direction with respect to the length direction. The cross-sectional area of the cover 53 perpendicular to the axial direction gradually decreases from the container 52 toward the tip of the cover 53. The plurality of covers 53 is four. One cover 53a is longer than the other covers 53b, 53c, 53d to accommodate the sensor 43 to indicate the reference position. The plurality of covers 53b, 53c, 53d accommodate a sensor 43 for detecting the rotation angle. The plurality of covers 53 are polygonal columns flat in the circumferential direction. The plurality of covers 53 have different lengths but similar shapes. As a typical example, the cover 53d will be described in detail.

In FIG. 14, the directional label indicates the circumferential CD and the radial RD on the cover 53d. The cover 53d has a width WT along the circumferential CD, a length LG along the axial AD, and a thickness TH along the radial RD. The cover 53d extends from the bottom plate of the container 52 toward the outside of the container 52. The cover 53d has a base end on the container 52 side and a tip on the opposite side.

FIG. 15 models and shows the shape of the cover 53d. The cover 53d has a tip portion 53e. The tip portion 53e is also the top portion of the cover 53d. The cover 53d has side portions 53f on both sides of the circumferential CD. The side portion 53f extends longer in the axial direction AD than in the radial direction RD. The side portion 53f provides a flat or curved side surface. The cover 53d has axial grooves 53g and 53h for fitting with the adjacent magnetic poles 32a. Axial grooves 53g and 53h are provided on both sides of the cover 53d. Axial grooves 53g and 53h are provided in the side portion 53f. The axial grooves 53g and 53h extend along the axial AD. Axial grooves 53g and 53h guide the cover 53d. The axial grooves 53g and 53h fix the cover 53d to the magnetic poles 32a on both sides.

The cover 53d has an inner portion 53i. The inner portion 53i provides an inner surface of a flat or curved surface. The inner portion 53i is connected to the reinforcing rib 53j. The reinforcing rib 53j extends between the inner portion 53i and the bottom plate of the container 52. The reinforcing rib 53j reinforces the cover 53d in the radial direction by bridging between the inner portion 53i and the bottom plate of the container 52. All of the plurality of covers 53 have reinforcing ribs. As a result, even if one of the covers 53 interferes with the coil, the cover 53 is provided with a strength capable of pushing and deforming the coil. Even if the cover 53 interferes with the coil, the cover 53 is arranged at a predetermined position between the two magnetic poles 32a by deforming the coil.

The cover 53d has an outer portion 53k. The outer portion 53k extends so as to bridge between two adjacent magnetic poles 32a. The outer portion 53k provides a flat or curved outer surface.

The cover 53d is inside in the radial direction and has relief portions 53m and 53n on both sides of the circumferential CD. The relief portions 53m and 53n face the coil. The relief portions 53m and 53n extend between the tip portion 53e, the side portion 53f, and the inner portion 53i. The relief portions 53m and 53n are flat surfaces or curved surfaces. The relief portions 53m and 53n have a wide width at the tip portion 53e and a narrow width at the base end portion. In other words, the widths of the relief portions 53m and 53n are wide at the tip of the cover 53d and narrow at the base end of the cover 53d. The relief portions 53m and 53n suppress the contact between the coil and the cover 53d. At the tip portion 53e, a predetermined distance 53p is left between the relief portion 53m and the relief portion 53n.

FIG. 16 shows a cross section of the cover 53d perpendicular to the axial AD. The cover 53d has an inner surface 53r to form a cavity for accommodating the sensor 43. The relief portions 53m and 53n gradually expand toward the tip portion 53e. When the cavity defined by the inner surface 53r gradually becomes smaller toward the tip portion 53e, the relief portions 53m and 53n contribute to maintain the thickness of the material forming the cover 53d. As a result, a cover 53d having a uniform or uniform thickness is provided. The axially perpendicular cross-sectional area of the cover 53d includes a cavity. The cross-sectional area perpendicular to the axial direction of the cover 53d gradually decreases from the container 52 toward the tip portion 53e. Such a gradually changing cross-sectional area is provided exclusively by changes in the relief portions 53m, 53n.

Returning to FIG. 14, the plurality of covers 53 have a shape similar to that of the cover 53d. However, the cover 53a is longer than the other covers 53b, 53c, 53d. The cover 53a has reliefs 53m, 53n wider than the other covers 53b, 53c, 53d. The distance 53p on the cover 53d is greater than the distance 53p on the cover 53a. The distance 53p on the cover 53a may be 0 (zero) mm.

As described above, the shapes of the relief portions 53m and 53n depend on the length of the cover 53. The longest cover 53a is longer than the other short covers and has wide reliefs 53m, 53n. The shortest cover 53a is shorter than the other long covers and has narrow reliefs 53m, 53n. The relationship shows a positive correlation. The plurality of covers 53 have relief portions 53m and 53n having a width corresponding to the length.

In FIG. 17, the positional relationship between the stator core 32 and the sensor unit 41 is modeled and illustrated. The sensor unit 41 is mounted and fixed on one end surface SD1 of the stator 31 or the stator core 32. The method for manufacturing the rotary electric machine 10 includes a step of forming a plurality of sensor gaps 38b between a plurality of magnetic poles 32a of the stator core 32. This step is a step of forming the stator core 32. The method for manufacturing the rotary electric machine 10 includes a step of inserting the plurality of covers 53 into the plurality of sensor gaps 38b from one end face SD1 side. As a result, the cover 53 of the sensor unit 41 extends from one end surface SD1 side in the axial direction of the stator 31 into the sensor gap 38b along the axial direction AD. The sensor 43 that detects the magnetic flux of the rotor 21 is arranged in the sensor gap 38b between two adjacent magnetic poles 32a. The sensor unit 41 houses the sensor 43.

In FIG. 18, the stator coil 33 has a multi-layered single coil 33s arranged outside the teeth portion 32c. The single coil 33s has an inner layer 33a and an outermost layer 33b. The inner layer 33a is one layer inside the outermost layer 33b. The inner layer 33a is also the innermost layer. The inner layer 33a is formed by winding a coil wire around the bobbin portion 36. The inner layer 33a is formed by winding a coil wire in the radial direction along the bobbin portion 36. Therefore, the coil wire is transferred from the inner layer 33a to the outermost layer 33b at a position adjacent to the flange portion 37.

The coil wire is transferred from the inner layer 33a to the outermost layer 33b on the surface opposite to the single coil 33s shown in the drawing. The coil wire 33c forming the final turn of the inner layer 33a orbits the bobbin portion 36. The coil wire 33d forming the first turn of the outermost layer 33b rides on the inner layer 33a at a portion adjacent to the magnetic pole 32a and migrates to the outermost layer 33b.

The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is radially inward from the magnetic pole 32a from the other end surface SD2 side in the axial direction of the stator 31 toward the one end surface SD1 side in the depth of the paper surface. It is tilted away. Further, the coil strand 33d is inclined in front of the paper surface from one end surface SD1 side in the axial direction of the stator 31 toward the other end surface SD2 side so as to approach the magnetic pole 32a in the radial direction. The coil wire 33d of the outermost layer 33b is positioned only on one end surface SD1 side and away from the magnetic pole 32a than the other portion. The coil wire 33d of the outermost layer 33b is positioned near the magnetic pole 32a on the other end surface SD2 side. The coil strand 33d of the outermost layer 33b is positioned so as to be separated from the magnetic pole 32a on one end surface SD1 side of the central portion in the axial direction. As a result, when the sensor unit 41 is arranged so that the cover 53 extends from one end surface SD1 as shown by the broken line, the coil wire 33d is positioned so as to be separated from the cover 53. The interference between the 33d and the cover 53 is suppressed.

The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is located above a recess formed between the plurality of coil wires 33c of the inner layer 33a. As a result, the coil strand 33d is arranged on one end surface SD1 side apart from the magnetic pole 32a inward in the radial direction. Such an alignment arrangement of the coil strands makes it possible to arrange the coil strands 33d of the outermost layer 33b at a target position. In particular, the width of the single coil 33s in the circumferential direction is smaller than the length in the axial direction. Therefore, the coil wire 33d is wound so as to bend the coil wire 33d on one end surface SD1 side in the winding process. Therefore, the coil wire 33d is likely to be arranged on the recess on one end surface SD1 side.

The insulator 35 has a bobbin portion 36 arranged between the tooth portion 32c and the stator coil 33. As described above, above the bobbin portion 36, there is an uneven portion that defines the position of the coil strand on the bobbin portion 36. The uneven portion is provided by the surface 36e and the plurality of fins 36f. The uneven portion makes it possible to wind the inner layer 33a and the outermost layer 33b in an aligned state. This uneven portion is also called a coil guide portion that separates the stator coil 33 from the magnetic pole 32a in the radial direction on one end surface SD1 side.

The insulator 35 has a flange portion 37 arranged between the magnetic pole 32a and the stator coil 33. The flange portion 37 has a protruding portion 37e that protrudes from the flange portion 37 along the teeth portion 32c toward the stator coil 33. The protruding portion 37e protrudes from the base flange surface 37d. The protruding portion 37e causes the stator coil 33 to be radially separated from the magnetic pole 32a on one end surface SD1 side. Therefore, the protruding portion 37e is also a coil guide portion. The coil strand 33d is arranged radially away from the magnetic pole 32a only on one end surface SD1 side.

The plurality of magnetic poles 32a partition the normal gap 38a in which the sensor unit 41 is not arranged and the sensor gap 38b in which the sensor unit 41 is arranged. The coil strand 33d is arranged on one end surface SD1 side in the radial direction from only the magnetic pole 32a forming the sensor gap 38b. In other words, the protruding portion 37e is provided only on the flange portion 37 provided on the magnetic pole 32a that partitions the sensor gap 38b.

The amount of the coil wire 33d of the outermost layer 33b moving inward in the radial direction on one end surface SD1 side depends on the amount of protrusion of the protruding portion 37e from the base flange surface 37d. The amount of protrusion can be about 1/2 of the diameter of the coil wire 33c. The protrusion amount is set in consideration of the accuracy of the winding machine and the like so that the coil wire 33d is located above the recess formed by the coil wire 33c. As a result, the coil wire 33d is positioned radially inward by the diameter of the coil wire 33d with respect to the base flange surface 37d.

The configuration in which the stator coil 33 is separated from the magnetic pole 32a only in a part of the stator core 32 simplifies the winding process. The manufacturing method of the rotary electric machine 10 includes a winding step of mounting coil strands on a plurality of tooth portions 32c. In this winding process, if the coil strands are aligned using the uneven portion, the winding process may be extended in time. However, in this embodiment, unevenness is provided only on the sensor bobbin portion 36b. Therefore, high-speed winding can be realized in the bobbin portion 36a.

Further, since the protruding portion 37e bends the coil wire, the winding process may be extended in time. However, in this embodiment, the protruding portion 37e is provided only on the second flange portion 37b and the third flange portion 37c. Therefore, high-speed winding can be realized in the first flange portion 37a.

FIG. 19 shows two magnetic poles 32a and one cover 53 as seen from one end surface SD1 side. The cover 53 is shown as a cross section. The coil strand 33d is separated from the magnetic pole 32a in the radial direction on one end surface SD1 side. As a result, the interference between the cover 53 and the coil wire 33d is suppressed.

The method for manufacturing the rotary electric machine 10 includes a winding step and an insertion step after the winding step. In the winding step, the stator coil 33 is wound around the outer periphery of the plurality of bobbin portions 36 mounted on the plurality of tooth portions 32c having the magnetic poles 32a at the tip. The winding process is carried out by a winding machine. The winding process usually has a high-speed process executed for the bobbin portion 36a and a low-speed portion executed for the sensor bobbin portion 36b. The low-speed portion is also called a high-precision process in which the coil strands are arranged at a predetermined position with higher accuracy than in the high-speed process.

In the insertion step, the sensor 43 is inserted from one end surface SD1 of the stator 31 into the gap 38 between two adjacent magnetic poles 32a. The insertion step is executed by arranging the sensor 43 in the sensor unit 41.

In the winding step, the coil wire is wound so that the coil wire 33d of the stator coil 33 is arranged radially away from the magnetic pole 32a on one end surface SD1 side. The coil wire 33d is wound so as to be radially separated from the magnetic pole 32a on one end surface SD1 side rather than the other end surface SD1 side. As a result, a coil shape in which the sensor 43 can be easily inserted can be obtained. The insertion step is a step of inserting the sensor 43 only into the sensor gap 38b among the plurality of normal gaps 38a and the sensor gap 38b formed by the plurality of magnetic poles 32a. That is, the insertion step is executed for a part of the circumferential range of the stator 31.

In the winding process, the coil strand 33d of the stator coil 33 is arranged radially away from the magnetic pole 32a on one end surface SD1 side only in the sensor bobbin portion 36b located next to the sensor gap 38b. This is the process of winding the coil wire. That is, in the winding process, the coil having the above shape is formed only in the sensor bobbin portion 36b among the plurality of bobbin portions 36. Of the plurality of bobbin portions 36, in the normal bobbin portion 36a that is not adjacent to the sensor gap 38b, the position of the coil strand is controlled with low accuracy. Therefore, high-speed winding is possible in the plurality of normal bobbin portions 36a.

The winding step is a step of winding the coil wire so that the coil wire 33d of the stator coil 33 is arranged radially away from the magnetic pole 32a on one end face SD1 side of the other end face SD2 of the stator 31. Is. The winding process provides a coil shape suitable for inserting the sensor 43 on one end face SD1 side while obtaining a cross-sectional area available for the coil on the other end face SD2 side.

As described above, in this embodiment, the coil strand 33d is arranged so as to be separated from the cover 53. This facilitates the insertion of the cover 53. Further, since a gap is formed between the cover 53 and the coil wire 33d, the coil can be easily cooled. Further, a gap between the cover 53 and the coil wire 33d facilitates the change of the stator coil 33. For example, the length, diameter, number of turns, material, thickness of the insulating layer, and the like of the coil wire can be changed. For example, two sensor units 41 having the same shape can be used with a coil wire made of copper-based metal and a coil wire made of aluminum-based metal.

Second Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In the above embodiment, the protruding portion 37e is adopted. Instead of this, in this embodiment, a protruding portion 237e that is axially longer than the protruding portion 37e is adopted.

As shown in FIG. 20, the flange portion 37 has a protruding portion 237e protruding from the base flange surface 37d. The length of the axial AD of the protruding portion 237e is longer than the length of the axial AD of the protruding portion 37e. The protruding portion 237e is formed over the entire flange portion 37 provided by the half-split body 35a.

Such a long protruding portion 237e can be used for the flange portion 37 adjacent to the sensor gap 38b into which the cover 53a is inserted. Further, all the protruding portions 37e may be replaced with the protruding portions 237e.

Third Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In this embodiment, the protruding portion 337e is adopted.

As shown in FIG. 21, the protruding portion 337e is arranged along the outer edge of the third flange portion 37c provided on the half-split body 35a. The protruding portion 337e protrudes inward in the radial direction so as to be separated from the magnetic pole 32a from the base flange surface 37d. Even in this shape, the coil wire of the outermost layer is separated from the magnetic pole inward in the radial direction. The coil wire of the inner layer is housed inside the protruding portion 337e. Such a configuration is effective for separating the outermost layer radially inward without depending on the inner layer. Further, since the coil wire of the inner layer is wound up to the base flange surface 37d, a decrease in the coil winding amount (number of turns) is suppressed. The sensor bobbin portion 36b may or may not have the unevenness of the preceding embodiment, as shown in the drawing.

Fourth Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In this embodiment, the protruding portion 437e is adopted.

As shown in FIG. 22, the protruding portion 437e is provided only on one end surface SD1 side of the third flange portion 37c. The protruding portion 437e has the same circumferential width as the sensor bobbin portion 36d. Even in this protruding portion 437e, the coil strands of the outermost layer are arranged radially inward from the base flange surface 37d. Since the coil wire is gradually inclined from that position, interference between the cover 53 and the coil on one end surface SD1 side is suppressed.

Fifth Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In this embodiment, the protruding portion 537e is adopted.

As illustrated in FIG. 23, the third flange portion 37c has two protruding portions 537e. The protruding portions 537e are arranged on both sides of the third flange portion 37c in the circumferential direction. The protruding portion 537e is columnar. The protruding portion 537e protrudes inward in the radial direction from the radial inner surface of the third flange portion 37c. The protruding portion 537e is provided only partially in the axial direction. When the protruding portion 537e is provided on the second flange portion 37b, it may be provided only on the portion adjacent to the sensor gap 38b. The protruding portion 537e is arranged near the cover 53 so that the coil strand is axially inward from the base flange surface 37d.

Sixth Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In this embodiment, the protruding portion 637e is adopted.

As illustrated in FIG. 24, the third flange portion 37c has two protruding portions 637e. The protruding portions 637e are arranged on both sides of the third flange portion 37c in the circumferential direction. The protruding portion 637e is prismatic. The protruding portion 637e protrudes inward in the radial direction from the radial inner surface of the third flange portion 37c. The protruding portion 637e is provided only in a range corresponding to the magnetic pole 32a in the axial direction. When the protruding portion 637e is provided on the second flange portion 37b, it may be provided only on the portion adjacent to the sensor gap 38b. The protruding portion 637e is arranged near the cover 53 so that the coil strand is axially inward from the base flange surface 37d.

Seventh Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In this embodiment, the protruding portion 737e is adopted.

As illustrated in FIG. 25, the third flange portion 37c has a plurality of protruding portions 737e. The plurality of projecting portions 737e are arranged apart from each other in the circumferential direction. The foundation flange surface 37d is exposed in a groove shape between the plurality of protruding portions 737e. The groove forms a gap between the third flange portion 37c and the coil wire. The gap allows air as a cooling medium to pass through and may contribute to improving heat dissipation of the coil strands. Also in this embodiment, the same actions and effects as those in the preceding embodiment can be obtained.

Eighth Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In this embodiment, the protruding portion 837e is adopted.

As illustrated in FIG. 26, both the half-split body 35a and the half-split body 35b have a protruding portion 837e. The protruding portion 837e protrudes radially from the base flange surface 37d toward the one end surface SD1 from the other end surface SD2. As a result, the coil strands 33c and 33d are inclined over a wider range. Also in this embodiment, the same actions and effects as those in the preceding embodiment can be obtained.

Ninth Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In the above embodiment, the coil guide unit is adopted. Instead, in this embodiment, the coil strand 33d of the outermost layer 33b is arranged away from the magnetic pole 32a without the coil guide.

As shown in FIG. 27, the flange portion 937c has a flat plate shape. The plurality of flange portions 937c are all flat. The manufacturing method of the rotary electric machine 10 includes a winding step. In the winding process, the coil wire is wound from the innermost layer to the outermost layer. In the innermost layer 33a, the coil wire 33c is wound from the radially inner side to the radial outer side of the tooth portion 32c. When the coil wire 33c reaches the flange portion 937c, it moves to the outer layer. At this time, the traveling direction of the coil is reversed. In the outermost layer 33b, the coil wire 33d is wound from the radial outer side to the radial inner side of the tooth portion 32c. After reaching the flange portion 937c, the coil wire 33c rides on the coil wire 33c of the inner layer and becomes the outermost layer 33b. In the outermost layer 33b, the coil wire 33d is positioned above the recess formed between the coil wires 33c in the inner layer.

The coil strand 33d of the outermost layer 33b rides on the inner layer 33a at a portion adjacent to the magnetic pole 32a and migrates to the outermost layer 33b. The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is inclined so as to be radially away from the magnetic pole 32a from the other end surface SD2 side in the axial direction of the stator 31 toward one end surface SD1 side. There is. The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is located on the recess formed between the plurality of coil wires 33c of the inner layer 33a, so that the coil wire 33d on one end surface SD1 side is formed from the magnetic pole 32a. They are arranged apart in the radial direction. The coil wire 33d rides on the inner layer 33a at a portion adjacent to the magnetic pole 32a and moves to the outermost layer 33b. The coil wire 33c and the coil wire 33d pass through the riding position 33r. At the riding position 33r, the coil strands 33c and the coil strands 33d overlap in the circumferential direction. The riding position 33r is located on the side surface of the teeth portion 32c facing the circumferential direction. At this riding position 33r, the coil wire 33d swells to the outside of the tooth portion 32c.

In FIG. 27, the sensor unit 41 and the cover 53 are shown by broken lines. The riding position 33r is located on the other end face CD2 side of the tip of the cover 53. Therefore, the interference between the coil wire 33d and the cover 53 is suppressed. The shape of such a coil wire is realized on at least a plurality of sensor bobbin portions 36b. Such a shape of the coil wire is not usually realized on the bobbin portion 36a. Therefore, the winding process can be carried out for other purposes on the bobbin portion 36a. For example, the speed of the winding process can be emphasized rather than the arrangement of the coil strands. However, such a shape of the coil wire may be realized on all the bobbin portions 36.

According to this embodiment, the coil strand 33d of the stator coil 33 facing the sensor unit 41 can be arranged radially away from the magnetic pole 32a on one end surface SD1 side without the coil guide portion. Therefore, interference between the coil wire and the cover 53 can be suppressed.

Tenth Embodiment This embodiment is a modification based on the preceding embodiment as a basic embodiment. In the above embodiment, the coil guide unit is adopted. Instead, in this embodiment, the coil strand 33d of the outermost layer 33b is arranged away from the magnetic pole 32a without the coil guide. In the following description, the portion including the teeth portion 32c and the bobbin 36 is referred to as a core. Also in this embodiment, the coil wire is made of an aluminum-based metal. The coil wire may be made of copper-based metal.

FIG. 28 is an appearance showing a bare core before the stator coil 33 is mounted. FIG. 28 shows the four sides of the bare core. The four side surfaces are referred to as a front side surface S1, a left side surface S2, a back side surface S3, and a right side surface S4. The left side surface S2 and the right side surface S4 are wider than the front side surface S1 and the back side surface S3. Therefore, the left side surface S2 and the right side surface S4 provide a wide side surface. Each of the four aspects is given the hierarchical relationship shown in the left column to help understand the alignment state of the plurality of fins A36f described later. Therefore, the right side surface S4 is shown in an inverted state. In this description, the left-right direction in the figure, that is, the radial direction of the stator 31, is called the length direction of one pole. The direction that orbits the outer circumference of one core is called the circumferential direction. A magnetic pole 32a is exposed at the tip of the tooth portion 32c. The insulator 35 provides a bobbin portion 36 and a flange portion A37c.

The bobbin portion 36 has a plurality of fins A36f. The plurality of fins A36f are arranged at the corners of the core. The plurality of fins A36f are provided intermittently in the left-right direction, that is, the length direction in the figure. Further, the plurality of fins A36f are provided intermittently in the vertical direction, that is, the circumferential direction in the figure. In other words, the plurality of fins A36f are provided only at the four corners. For example, on the front side surface S1, the two fins A36f separated at the top and bottom in the drawing are positioned at the same position in the length direction. The plurality of fins A36f arranged intermittently in the circumferential direction enable an oblique portion of the coil strand in the length direction. The skew portion allows the coil wire to be wound and rewound.

The plurality of fins A36f are arranged at equal intervals along the length direction. The plurality of spacing Pts between the plurality of fins A36f correspond to the diameter of the coil strand. The interval Pt may be smaller than the diameter of the coil strand. The interval Pt can be made larger than the diameter of the coil wire, but it is not preferable in order to accurately position the coil wire. Therefore, the spacing Pt can be adjusted so that the coil strands can be positioned, and the term "equivalent" indicates a range in which this object can be achieved. The interval Pt is also called the pitch. The first distance between the base flange surface 37d and the first fin A36f corresponds to the diameter of the coil strand. The initial spacing allows the coil strands 33c to be placed adjacent to the base flange surface 37d. In the preferred embodiment, the initial spacing allows contact between the coil strand 33c and the foundation flange surface 37d.

The plurality of fins A36f are arranged in a row along the length direction at the four corners of the core. As a result, the plurality of fins A36f are arranged so as to form four rows at the four corners of the core.

The plurality of fins A36f are positioned on the outer circumference of the core so as to be aligned with each other in the circumferential direction. A plurality of virtual circumferential orbits can be assumed on the outer circumference of the core. In the figure, two typical virtual circumferential orbits RI and RO are shown. The plurality of virtual circumferential orbits are perpendicular to the central axis of the teeth portion 32c. One virtual circumferential orbit orbits the core. The plurality of virtual orbits are parallel to each other. Four fins A36f are positioned on one virtual circumferential orbit. In other words, the four fins A36f arranged in the circumferential direction of the core define one virtual circumferential orbit. Since the bobbin portion 36 includes the plurality of fins A36f, the outer peripheral shape of the bobbin portion 36 has irregularities of a predetermined pitch. Moreover, the bobbin portion 36 is characterized by irregularities at equal intervals in the length direction.

The inner surface of the flange portion A37c is flat. The inner surface of the flange portion A37c is defined by the foundation flange surface 37d. The distance between the outermost virtual circumferential orbit RO in the radial direction and the foundation flange surface 37d corresponds to the diameter of one coil wire 33c. The distance between the innermost virtual circumferential orbit RI in the radial direction and the central portion 35c is not constant in order to position the coil strand 33c at the beginning of winding. The central portion 35c may be provided with a positioning portion 36s for positioning the coil wire 33c at the start of winding.

FIG. 29 shows the pole after the inner layer 33a is attached. The inner layer 33a is also called the first layer. The inner layer 33a has a coil wire 33c. The inner layer 33a is wound around the outer circumference of the bobbin portion 36. The inner layer 33a is wound over the entire length direction of the bobbin portion 36.

As shown on the front side surface S1, the coil wire 33c has a start end ST at the start of winding. The starting end ST is provided at the base of the teeth. It is provided at the start end ST and the opposite end in the protruding direction (length direction) of the magnetic pole. The coil wire 33c is not broken at the start end ST. The coil wire 33c is drawn onto the bobbin portion 36 from the outside of the bobbin portion 36 as shown by the broken line. The coil wire 33c has a return end RN for changing the winding direction. The coil wire 33c is not interrupted at the return end RN. The coil strands 33c are continuous as shown by the broken line. The return end RN is arranged so as to come into contact with the base flange surface 37d.

The coil wire 33c is wound so as to return to the front side surface S1 again from the front side surface S1, passing through the left side surface S2, the back side surface S3, and the right side surface S4 in this order. The coiled wire 33c wound in a coil shape has a plurality of skewed portions 33ff. The coil wire 33c is straight in the circumferential direction in a portion other than the oblique portion 33ff. The plurality of skewed portions 33ff are positioned on only one of the four side surfaces. In that one aspect, only a portion of the coil strand 33c provides the skew portion 33ff. On that one aspect, the rest of the coil strand 33c provides a straight portion along the circumferential direction. In other words, on the one side surface, the coil strand 33c provides an oblique portion 33ff and portions located on both sides thereof that are straight in the circumferential direction. On the remaining three sides, the coil strand 33c is straight along the circumferential direction.

As shown on the right side surface S4, the oblique portion 33ff extends over the length ADf in the circumferential direction. The length ADf is shorter than the circumferential gap between the fins A36f on the right side surface S4. The skew portion 33ff causes winding of the pitch Pt in the length direction. In other words, the skew portion 33ff is defined by the circumferential length ADf and the pitch Pt.

The inner layer 33a is terminated at the return end RN located on the dorsal side surface S3. In front of the return end RN, the coil wire 33c is arranged so as to be in contact with the base flange surface 37d from the right side surface S4. The return end RN is an end portion set for explanation, and the coil strands are continuous even at the return end RN.

The inner layer 33a containing a plurality of turns can be wound by positioning the start end ST on one of the four side surfaces. The front side surface S1 in which the start end ST is positioned can be referred to as a first side surface. The side surfaces following the first side surface can be referred to as a second side surface, a third side surface, and a fourth side surface in order. The skew portion 33ff is positioned on one of the remaining three sides. The skew portion 33ff can be positioned on the second side surface, the third side surface, or the fourth side surface. It is desirable that the oblique portion 33ff is positioned on the wide side surface among the four side surfaces.

FIG. 30 shows the poles after the outermost layer 33b is mounted. The inner layer 33a is the first layer. The outermost layer 33b is the second layer. The outermost layer 33b extends to the end end ED. The coil wire 33d is not broken at the end end ED. The coil wire 33d continuously extends from the end end ED.

As shown on the front surface S1, the outermost layer 33b is wound over only a part of the bobbin portion 36 in the length direction. The inner layer 33a and the outermost layer 33b have the same winding direction. The winding traveling directions of the inner layer 33a and the outermost layer 33b are opposite to each other. The traveling direction of the inner layer 33a is a direction from the central portion 35c toward the flange portion A37c. The traveling direction of the outermost layer 33b is a direction from the flange portion A37c toward the central portion 35c. The traveling direction of the outermost layer 33b is also called a returning direction.

The cross section C4 shows a cross section on the C4-C4 line. The start end ST is shown as a surface for illustration purposes. The coil wire 33c positioned on the left side surface S2 extends straight along the circumferential direction as shown by the broken line.

As shown in the right side surface S4, the coil wire 33e extending from the return end RN gradually rides on the inner layer 33a. The coil wire 33e is also a transition range from the inner layer 33a to the outermost layer 33b. In this description, the coil strand 33e is described as part of the outermost layer 33b.

The outermost layer 33b has an oblique portion 33fs. The skew portion 33fs may be a transition portion from the inner layer 33a to the outermost layer 33b. The skew portion 33fs is the first skew portion in the outermost layer 33b. The skewed portion 33fs has a circumferential length ADfs. The skew portion 33fs provides unwinding with a pitch of 1 / 2Pt in the longitudinal direction. The pitch of the skew portion 33fs is 1/2 of the pitch of the skew portion 33ss. The skew portion 33fs rides on the inner layer 33a and then moves to the recess between the two adjacent coil strands 33c. The coil wire 33d gets over the coil wire 33c of the inner layer 33a at the skew portion 33fs. After riding on the coil wire 33c, the coil wire 33d moves along the recess between the two adjacent coil wires 33c.

Further, the outermost layer 33b has an oblique portion 33ss. The skewed portion 33ss has length ADs in the circumferential direction. The skew portion 33ss provides rewinding of pitch Pt in the longitudinal direction. The length ADs are longer than the length ADfs (ADfs <ADs).

The oblique portion 33fs and the oblique portion 33ss are deviated from each other in the circumferential direction. The oblique portion 33fs is positioned ahead of the oblique portion 33ss in the winding direction. The internal angle formed by the oblique portion 33fs and the virtual circumferential orbit is larger than the internal angle formed by the oblique portion 33ss and the virtual circumferential orbit. The skew portion 33fs provides the first winding lead in the outermost layer 33b. The skew portion 33ss provides a plurality of remaining winding leads in the outermost layer 33b. The arrangement of the oblique portion 33fs and the oblique portion 33ss causes the outermost layer 33b to move away from the flange portion A37c while suppressing mutual interference. The outermost layer 33b has been moved away from the flange portion A37c. Therefore, the cover portion 53 of the sensor unit 41 is installed while avoiding strong interference with the coil strand 33d.

The oblique portion 33ff is also referred to as an inner layer oblique portion in the inner layer 33a. Since the skew portion 33fs is the first skew portion after the transition from the inner layer 33a to the outer layer 33b, it is also called an intermediate skew portion. The oblique portion 33ss is also referred to as an outer layer oblique portion in the outer layer 33b. The plurality of oblique portions 33ff, 33fs, 33ss are provided on the right side surface S4, which is one side surface of the plurality of side surfaces. The plurality of oblique portions 33ff, 33fs, 33ss are arranged so as to intersect each other on one and the same side surface. The winding direction of the skewed portion 33ff and the rewinding direction of the skewed portions 33fs and 33ss are opposite to each other. Therefore, the skewed portion 33ff and the skewed portion 33fs intersect with each other. At the same time, the oblique portion 33ff and the oblique portion 33ss intersect with each other. As a result, a large crossing angle is formed between the skewed portion 33ff and the skewed portions 33fs and 33ss. Specifically, the crossing angle when the skewed portions 33fs and 33ss pass over the skewed portion 33ff is the case where the skewed portions 33fs and 33ss pass over the coil strands 33c straight in the circumferential direction. Larger than the intersection angle.

The cross section C1 shows a cross section on the C1-C1 line. Since the insulator 35 provides a thin cross section, the cross section is not hatched. The illustrated coil strand 33e is in the process of migrating from the inner layer 33a to the outermost layer 33b while interfering with the oblique portion 33ff of the inner layer 33a.

According to this embodiment, the coil strand 33d facing the sensor unit 41 is arranged radially inward from the magnetic pole 32a on the side of one end surface SD1. The coil strand 33d of the outermost layer 33b facing the sensor unit 41 is obliquely inclined inward from the magnetic pole 32a from the other end surface SD2 side in the axial direction of the stator 31 toward one end surface SD1 side. It is inclined by the portions 33fs and 33ss. The riding position 33r on which the coil wire 33d of the outermost layer 33b and the coil wire 33c of the inner layer 33a are stacked in the circumferential direction is located closer to the other end surface SD2 side of the stator 31 than the sensor unit 41. The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is located above a recess formed between the plurality of coil wires 33c of the inner layer 33a. As a result, the coil element 33d is arranged radially inward from the magnetic pole 32a on one end surface SD1 side. The coil strand 33d is arranged radially inward from the magnetic pole 32a with respect to the other end surface SD2 side of the stator 31 only on one end surface SD1 side. In this embodiment, the slip of the coil wire 33d with respect to the coil wire 33c is suppressed. As a result, the coil strands 33c and 33d can be arranged accurately and at high speed on the bobbin 36, which is suitable for mass production.

The stator coil 32 of this embodiment includes a coil wire 33c of the inner layer 33a and a coil wire 33d of the outermost layer 33b arranged outside the inner layer 33a. The coil wire 33d of the outermost layer 33b includes outermost layer oblique portions 33fs and 33ss arranged only on one specific side surface S4 other than one side surface S1 which is one end surface SD1. The coil wire 33d of the outermost layer 33b is arranged on the remaining side surface other than the specific side surface S1, and includes a portion extending straight along the circumferential direction. The outermost layer oblique portions 33fs and 33ss are inclined so as to be separated from the magnetic poles. The specific side surface is any one of the side surfaces S2, S3, and S4.

In this embodiment, the oblique portions 33fs and 33ss of the coil strand 33d of the outermost layer 33b are concentrated on the specific side surface S4. Therefore, the angle of intersection between the coil wire 33c of the inner layer 33a and the coil wire 33d of the outermost layer 33b is large. As a result, the slip of the coil wire 33d with respect to the coil wire 33c is suppressed.

The coil strand 33c of the inner layer 33a includes an inner layer oblique portion 33ff which is arranged only on the specific side surface S4 and is inclined so as to approach the magnetic pole. The coil wire 33c is arranged on the remaining side surface other than the specific side surface S4, and includes a portion extending straight along the circumferential direction. Further, the outermost layer oblique portions 33fs and 33ss are arranged so as to intersect the inner layer oblique portion 33ff.

In this embodiment, the inclination direction of the inner layer oblique portion 33ff and the inclination direction of the outermost layer oblique portions 33fs and 33ss are opposite to each other. Therefore, the crossing angle between the coil wire 33c and the coil wire 33d is large. As a result, the slip of the coil wire 33d with respect to the coil wire 33c is further suppressed.

FIG. 31 is a cross-sectional view showing the winding device 61. The winding device 61 is used in a method for manufacturing a stator in a rotary electric machine. The winding device 61 executes a winding process for the stator 31. The winding device 61 includes a flyer 62 for winding the coil and a feeder 63 for supplying the coil wire 63a. The winding device 61 has a molding device 64 for adjusting the position of the coil wire 63a on the bobbin portion 36. The molder 64 can move along the bobbin portion 36. The molding machine 64 guides the coil wire 63a. The molding machine 64 is a member for molding the coil wire 63a. The winding device 1 may include an auxiliary molding machine 65 facing the molding machine 64. The flyer 62 winds a coil wire 63a around the outer circumference of the bobbin portion 36. The coil wire 63a is arranged at a specified position on the bobbin portion 36 by the molding machine 64. At this time, the plurality of fins A36f stabilize the position of the coil strand 63a. The winding device 61 includes a control device 66 (CNT) that controls the moving position of the molding machine 64.

FIG. 32 shows the progress process of the position control of the molding machine 64. The horizontal axis SN indicates the length (mm) in the circumferential direction. The horizontal axis SN corresponds to a plurality of side surfaces S1, S2, S3, and S4. The vertical axis LG indicates the length (mm) in the length direction. The pitch Pt corresponds to the diameter of the coil wire 63a. The pitch Pt corresponds to the distance between two adjacent fins A36f. The behavior of the molding machine 64 shown in the figure is a behavior for forming the inner layer 33a.

The thin solid line CMP shows the movement of the molder in comparative form. The molding machine of the comparative form moves at a constant speed. Therefore, the coil strands are arranged diagonally on all sides. In this comparative form, the angle of intersection between the coil strands in the inner layer and the coil strands in the outermost layer is small. Therefore, the position of the coil wire of the outermost layer is not stable. As a result, the coil of the outermost layer may collapse.

The thick solid EMB shows the movement of the molding machine 64 of this embodiment. When the coil wire 63a is positioned at the start end ST, the flyer 62 rotates. The flyer 62 winds the coil wire 63 around the core. At the same time, the molding machine 64 moves as the winding process progresses. The molder 64 is controlled to move forward intermittently. The amount of movement of the molding machine 64 on the front side surface S1, the left side surface S2, and the back side surface S3 is smaller than the amount of movement of the molding machine 64 on the right side surface S4. The molding machine 64 advances more than the remaining side surface only on one side of the plurality of sides. Moreover, one side surface on which the molding machine 64 moves significantly is the same in the inner layer 33a and the outer layer 33b. Therefore, the oblique portion 33ff of the inner layer 33a and the oblique portions 33fs and 33ss of the outer layer 33b intersect. Moreover, a relatively large crossing angle can be obtained. As a result, the collapse of the outermost layer 33b is suppressed.

In this embodiment, the amount of movement of the molding machine 64 on the front side surface S1, the left side surface S2, and the back side surface S3 is zero (0). The amount of movement of the molding machine 64 on the right side surface S4 is the pitch Pt. The molding machine 64 is fixed on 3/4 of the four side surfaces. The molder 64 advances only on one quarter side surface. As a result, the coil strands 63a are arranged straight on the 3/4 side surfaces. The coil strand 63a is arranged so as to form the skew portion 33ff only on the 1/4 side surface.

The coil wire 63a is wound from the start end ST. The molder 64 is intermittently driven from the position for the start end ST. The molder 54 is repeatedly driven to form a plurality of turns. The coil wire 63a is wound up to the return end RN. The molder 64 ends the process for the inner layer 33a at the return end RN.

FIG. 33 shows the return process of the position control of the molding machine 64. The behavior of the molding machine 64 shown in the figure is a behavior for forming the outermost layer 33b. The broken line indicates the inner layer 33a. The solid line shows the outermost layer 33b.

The flyer 62 also rotates during the return process. The flyer 62 continuously winds the coil wire 63a from the return end RN. The coil wire 63a gradually rides on the inner layer 33a from the return end RN. Eventually, on the right side surface S4, the coil wire 63a reaches above the inner layer 33a.

At the same time, the molding machine 64 moves as the winding process progresses. The molding machine 64 is controlled so as to retreat intermittently even in the return process. The amount of movement of the molding machine 64 on the front side surface S1, the left side surface S2, and the back side surface S3 is smaller than the amount of movement of the molding machine 64 on the right side surface S4. The molding machine 64 advances more than the remaining side surface only on one side of the plurality of sides.

In this embodiment, the amount of movement of the molding machine 64 on the front side surface S1, the left side surface S2, and the back side surface S3 is zero (0). The amount of movement of the molding machine 64 on the right side surface S4 is 1 / 2Pt or Pt. The molding machine 64 is fixed in the circumferential direction on 3/4 of the four side surfaces. The molder 64 returns on only 1/4 side surface. As a result, the coil strands 63a are arranged straight on the 3/4 side surfaces. The coil strand 63a is arranged so as to form the skew portion 33fs only on the 1/4 side surface.

The molding machine 64 retracts by 1 / 2Pt on the first right side surface S4. As a result, the skew portion 33fs is formed. The behavior of the molding machine 64 is to arrange the coil wire 63a so as to get over the coil wire 33c of the inner layer 33a. As a result, one intersection is formed. The intersection of the skew portion 33ff and the skew portion 33fs provides a relatively large intersection angle. Therefore, the misalignment of the coil wire 63a is suppressed.

The molding machine 64 retracts by Pt on the next right side surface S4. As a result, the skew portion 33ss is formed. The behavior of the molding machine 64 is to arrange the coil wire 63a so as to get over the coil wire 33c of the inner layer 33a. As a result, one intersection is formed. The intersection of the skew portion 33ff and the skew portion 33ss provides a relatively large intersection angle. Therefore, the misalignment of the coil wire 63a is suppressed.

The molding machine 64 repeats the above behavior. Eventually, when the coil wire 63a reaches the end end ED, the driving of the molding machine 64 is completed. By going through these steps, the coil shown in FIG. 30 is formed.

The winding step of this embodiment includes a step of arranging the coil wire 33c of the inner layer 33a and a step of arranging the coil wire 33d of the outermost layer 33b outside the inner layer 33a. At the stage of arranging the outermost layer 33b, only one specific side surface S4 other than one side surface S1 which is one end surface SD1 forms the outermost layer oblique portions 33fs and 33ss which are inclined away from the magnetic poles. The step of arranging the coil wire 33d is included. The step of arranging the outermost layer 33b includes a step of arranging the coil strand 33d straight along the circumferential direction on the remaining side surface other than the specific side surface S4.

In this embodiment, the oblique portions 33fs and 33ss of the coil strand 33d of the outermost layer 33b are concentrated on the specific side surface S4. Therefore, the angle of intersection between the coil wire 33c of the inner layer 33a and the coil wire 33d of the outermost layer 33b is large. As a result, the slip of the coil wire 33d with respect to the coil wire 33c is suppressed.

The step of arranging the inner layer 33a includes a step of arranging the coil strand 33c so as to form the inner layer oblique portion 33ff which is inclined so as to approach the magnetic pole only on the specific side surface S4. The step of arranging the inner layer 33a includes a step of arranging the coil strand 33c straight along the circumferential direction on the remaining side surface other than the specific side surface S4. Further, at the stage of arranging the outermost layer 33b, the outermost layer oblique portions 33fs and 33ss are arranged so as to intersect the inner layer oblique portion 33ff.

In this embodiment, the inclination direction of the inner layer oblique portion 33ff and the inclination direction of the outermost layer oblique portions 33fs and 33ss are opposite to each other. Therefore, the crossing angle between the coil wire 33c and the coil wire 33d is large. As a result, the slip of the coil wire 33d with respect to the coil wire 33c is further suppressed.

In this embodiment, the coil wire 63a can be positioned at a predetermined position by the molding machine 64. Therefore, a coil having a well-formed shape can be obtained. Further, the coil strands can be arranged so as to avoid strong interference with the cover portion 53 of the sensor unit 41. In addition, since the oblique portions 33fs and 33ss of the outermost layer 33b intersect with the oblique portion 33ff of the inner layer 33a, a large intersection angle is provided. As a result, the misalignment of the coil strands can be suppressed. Further, the method of manufacturing the stator is suitable for mass production because the coil strands 33c and 33d can be arranged accurately and at high speed on the bobbin portion 36.

Other Embodiments The disclosure herein is not limited to the exemplified embodiments. The disclosure includes exemplary embodiments and modifications by those skilled in the art based on them. For example, disclosure is not limited to the parts and / or element combinations shown in the embodiments. Disclosure can be carried out in various combinations. The disclosure can have additional parts that can be added to the embodiment. The disclosure includes the parts and / or elements of the embodiment omitted. Disclosures include 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 scopes disclosed are indicated by the claims description and should be understood to include all modifications within the meaning and scope equivalent to the claims statement.

In the above embodiment, the protruding portion 37e is provided only on one end surface SD1 side and only next to the sensor gap. Alternatively, the protruding portion 37e may be provided at any other position. In the above embodiment, both the uneven portion and the protruding portion 37e are provided only on the sensor insulator portion. Instead of this, only the protruding portion 37e may be provided only on the sensor insulator portion. For example, the uneven portion may be provided on all the bobbin portions 36.

In the above embodiment, the uneven portion of the bobbin portion 36 is provided by the surface 36e and the fin 36f. Instead, the concavo-convex portion can be provided in a variety of shapes. For example, the uneven portion may be provided by the surface 36e and the groove.

In the above embodiment, the single coil 33ss has a series of coil strands. Instead of this, a plurality of coil strands may be arranged on one tooth portion 32c. In this case, the plurality of coil strands provide a single coil 33ss. For example, two groups of coil strands for providing two coils with different numbers of turns may be placed on one tooth portion. Further, in the above embodiment, the stator coil 33 is centrally wound, but may be formed by distributed winding, for example, wave winding or distributed winding.

In the above embodiment, the container 52 and the cover 53 are integrally formed of a continuous resin material. Alternatively, the case 51 may be provided by a plurality of components. For example, the container 52 and the plurality of covers 53 may be different parts.

In the above embodiment, the electric circuit component 42 including the substrate is housed in the container 52. Instead of this, a substrate for electrical wiring may be provided in the cover 53. Further, the substrate may be a lead frame.

In the above embodiment, one sensor 43 is arranged in one cover 53. Instead of this, a plurality of sensors may be arranged. Further, some sensors may be arranged in the container 52. As a result, adverse effects due to interference between the coil and the cover 53, for example, damage are suppressed. Further, the sensor unit 41 including one cover 53 may be adopted. For example, a rotary electric machine as a generator including only the sensor 43 for ignition control may be provided.

In the above embodiment, the inner layer 33a and the outermost layer 33b are provided by the two-layer single coil 33ss. Instead of this, a single coil 33ss having three or more layers may be used. Even in those cases, the inner layer 33a and the outermost layer 33b are provided.

In the above embodiment, the plurality of fins 36f and A36f are provided at equal intervals. Alternatively, the plurality of fins 36f, A36f may be provided only in the range of both ends in the length direction. In this case, the central range of the bobbin portion 36 provides a flat tubular portion without fins 36f, A36f. The fins 36f and A36f in both ends range suppress the misalignment of the coil strand 33c at the start of winding. The fins 36f and A36f in both ends range suppress the misalignment of the coil strand 33c at the turning direction change portion after contacting the base flange surfaces 36f and 37d.

10 rotary electric machine, 12 internal combustion engine, 13 body, 21 rotor,
22 rotor core, 23 permanent magnet, 31 stator,
32 stator core, 32a magnetic pole, 32c teeth part,
33 stator coil, 33a inner layer, 33b outermost layer,
33c coil wire, 33d coil wire, 33j jumper wire,
33s single coil, 33r riding position,
33ff inner layer skew part, 33fs, 33ss outer layer skew part,
35 insulator, 35d guide fin,
36 bobbin part, 36a normal bobbin part,
36b sensor bobbin part, 36e surface (concavo-convex part, coil guide part),
36f, A36f fins (concavo-convex part, coil guide part),
37 Flange part,
37e, 237e, 337e, 437e Protruding part (coil guide part),
537e, 637e, 737e, 837e Protruding part (coil guide part),
38a normal gap, 38b sensor gap, 41 sensor unit,
43 sensors, 51 cases, 52 containers,
53 cover, 57 protruding part, 58 cavity,
SD1 one end face, SD2 the other end face.

Claims (4)

A winding process in which a stator coil (33) is wound around the outer circumference of a plurality of bobbin portions (36) mounted on a plurality of teeth portions (32c) having magnetic poles (32a) at the tip thereof.
An insertion step of inserting the sensor (43) from one end surface (SD1) of the stator (31) is provided in the gap between the two adjacent magnetic poles.
In the winding step, the coil wire is wound so that the coil wire (33d) of the stator coil is arranged radially away from the magnetic pole on one end surface side .
The insertion step is a step of inserting the sensor only in the sensor gap (38b) among the plurality of normal gaps (38a) and the sensor gap (38b) formed by the plurality of magnetic poles.
In the winding step, only in the sensor bobbin portion (36b) located next to the sensor gap (38b), the coil strand (33d) of the stator coil is radially from the magnetic pole on one end face side. as will be spaced apart, the manufacturing method of the rotary electric machine is a step of winding the coil wire. In the winding step, the coil wire (33d) of the stator coil is arranged radially away from the magnetic pole on the one end surface side of the other end surface (SD2) of the stator. method of manufacturing a rotary electric machine according to claim 1 step Ru der winding the coil wire. The winding process
At the stage of arranging the coil wire (33c) of the inner layer (33a),
A step of arranging the coil wire (33d) of the outermost layer (33b) on the outside of the inner layer is provided.
The stage of arranging the outermost layer is
On only one specific side surface (S2, S3, S4) other than one side surface (S1) which is the one end surface (SD1), the outermost layer oblique portion (33fs, 33ss) inclined away from the magnetic pole is provided. At the stage of arranging the coil strands so as to form,
The method for manufacturing a rotary electric machine according to claim 1 or 2, which includes a step of arranging the coil strand (33d) straight along the circumferential direction on the remaining side surface other than the specific side surface. The stage of arranging the inner layer is
A step of arranging the coil strands so as to form an inner layer oblique portion (33 ff) inclined so as to approach the magnetic pole only on the specific side surfaces (S2, S3, S4).
Including the step of arranging the coil strand (33c) straight along the circumferential direction on the remaining side surface other than the specific side surface.
The method for manufacturing a rotary electric machine according to claim 3 , wherein the step of arranging the outermost layer is to arrange the outermost layer oblique portion so as to intersect the inner layer oblique portion.

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