WO2017154466A1 - Dynamo-electric machine - Google Patents

Abstract

Provided is a dynamo-electric machine capable of realizing high-quality joining at a plurality of joining parts. A stator 31 of the dynamo-electric machine has an electrode 50 to which a plurality of coil ends 33a are connected. The electrode 50 has a plurality of terminals 51, 52. The electrode 50 provides the terminals 51, 52 by using a plurality of tabs arranged in the form of a bracket. The plurality of terminals 51, 52 are positioned at a distance from each other in the dynamo-electric machine. The plurality of joining surfaces provided by the plurality of terminals 51, 52 are hidden from each other. The plurality of coil ends 33a and the plurality of terminals 51, 52 are joined one-to-one so that one coil end 33a is joined to one terminal. High-quality joining is realized at a plurality of joining parts. Adverse effects from the preceding joining step to the subsequent joining step, such as adverse effects due to heat and/or scattered matter, for example, are suppressed.

Description

Rotating electric machine Cross-reference of related applications

This application is based on Japanese Patent Application No. 2016-047392 filed on March 10, 2016, and the disclosure of the basic application is incorporated into this application by reference.

The disclosure in this specification relates to a rotating electrical machine.

Patent Document 1 discloses a rotating electrical machine for an internal combustion engine and its electrodes. The electrode is used to connect a coil for a rotating electrical machine and a wire harness. The electrode includes a terminal for soldering and a terminal for projection welding. Patent Document 2 discloses a terminal for heat caulking. Patent Document 3 discloses a rotating electrical machine in which a plurality of coil ends are projection welded onto one protruding portion.

JP2015-130785A JP 2013-222586 A JP2015-39283A

In the technique of Patent Document 1 or Patent Document 2, one electrode and one coil end are connected. In this case, it is necessary to arrange a large number of electrodes on the rotating electrical machine, and it is difficult to provide a compact rotating electrical machine.

In the technique of Patent Document 3, since one continuous protruding portion is used, a large terminal is required to form a long protruding portion. In addition, since the long protruding portion extends long on the end face of the rotating electrical machine, it occupies a wide range on the rotating electrical machine. From another viewpoint, one continuous protruding portion causes a problem when joining operations are sequentially performed at a plurality of coil ends. A plurality of joining operations executed in sequence on one continuous protruding portion gradually change the joining conditions. For example, the temperature in the subsequent bonding operation may be higher than the temperature in the previous bonding operation. In addition, scattered matter in the previous joining operation may affect the subsequent joining operation.

In the above-mentioned viewpoints or other viewpoints not mentioned, further improvements are demanded for rotating electrical machines.

One object disclosed is to provide a rotating electrical machine including an electrode that can be connected to a plurality of coil ends.

Another object of the disclosure is to provide a rotating electrical machine including an electrode that can realize high-quality bonding at a plurality of bonding portions.

The rotating electrical machine disclosed herein has a plurality of coil ends (33a) that are ends of a coil (33) of the rotating electrical machine, and a plurality of terminals (51, 52, 54) joined to the plurality of coil ends. Electrodes (50, 250, 350, 450, 550, 650, 750, 850, 950, A50, C50), and a plurality of terminals are positioned apart from each other in the rotating electrical machine, and a plurality of coil ends The plurality of terminals are joined one-on-one so that one coil end is joined to one terminal.

According to the disclosed rotating electrical machine, a plurality of coil ends are electrically connected via electrodes. Since the terminals are arranged apart from each other and one coil end is joined to one terminal, a high-quality joint can be obtained.

The plurality of modes disclosed in this specification adopt different technical means to achieve each purpose. The reference numerals in parentheses described in the claims and this section exemplify the correspondence with the embodiments described later, and are not intended to limit the technical scope. The objects, features, and advantages disclosed in this specification will become more apparent with reference to the following detailed description and accompanying drawings.

It is sectional drawing of the rotary electric machine for internal combustion engines which concerns on 1st Embodiment. It is a top view of the stator of a 1st embodiment. It is a circuit diagram which shows the connection of the stator coil of 1st Embodiment. FIG. 4 is a partial sectional view taken along line IV-IV in FIG. 2. It is a top view which shows the electrode of 1st Embodiment. It is a side view in the arrow VI of FIG. FIG. 7 is an end view taken along arrow VII in FIG. 5. It is a top view of the stator of a 2nd embodiment. It is a top view which shows the electrode of 2nd Embodiment. It is a side view which shows the electrode of 2nd Embodiment. It is an end elevation which shows the electrode of 2nd Embodiment. It is a top view which shows the electrode of 3rd Embodiment. It is a side view which shows the electrode of 3rd Embodiment. It is an end view which shows the electrode of 3rd Embodiment. It is a top view which shows the electrode of 4th Embodiment. It is a side view which shows the electrode of 4th Embodiment. It is an end elevation which shows the electrode of 4th Embodiment. It is a top view which shows the electrode of 5th Embodiment. It is a side view which shows the electrode of 5th Embodiment. It is an end view which shows the electrode of 5th Embodiment. It is a top view which shows the electrode of 6th Embodiment. It is a side view which shows the electrode of 6th Embodiment. It is an end view which shows the electrode of 6th Embodiment. It is a top view which shows the electrode of 7th Embodiment. It is a side view which shows the electrode of 7th Embodiment. It is an end view which shows the electrode of 7th Embodiment. It is a top view which shows the electrode of 8th Embodiment. It is a side view which shows the electrode of 8th Embodiment. It is an end view which shows the electrode of 8th Embodiment. It is a top view which shows the electrode of 9th Embodiment. It is a side view which shows the electrode of 10th Embodiment. It is a circuit diagram which shows the connection of the stator coil of 11th Embodiment. It is a top view which shows the electrode of 12th Embodiment. It is a side view which shows the electrode of 12th Embodiment. It is an end view which shows the electrode of 12th Embodiment.

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

First Embodiment In FIG. 1, a rotating electrical machine for an internal combustion engine (hereinafter simply referred to as a rotating electrical machine 10) is also called a generator motor or an AC generator starter. The rotating electrical 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 rotating electrical machine 10 is a generator motor connected to an internal combustion engine 12 for a vehicle. The rotating electrical machine 10 can be used for a motorcycle, for example.

The electrical circuit 11 provides a rectifier circuit that rectifies the AC power that is output when the rotating electrical machine 10 functions as a generator and supplies power to an electrical load including a battery. The electric circuit 11 provides a signal processing circuit that receives a reference position signal supplied from the rotating electrical machine 10. The reference position signal is used for ignition timing control and / or fuel injection timing control. The electric circuit 11 may provide a controller that performs engine control including ignition timing control and / or fuel injection timing control. The electric circuit 11 provides a drive circuit that causes the rotating electrical machine 10 to function as an electric motor. The electrical circuit 11 receives from the rotating electrical machine 10 a rotational position signal for causing the rotating electrical machine 10 to function as an electric motor. The electrical circuit 11 causes the rotating electrical machine 10 to function as an electric motor by controlling energization to the rotating electrical machine 10 according to the detected rotational position. The electrical circuit 11 can include a battery and / or an electrical load.

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

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

The rotor 21 is a field element. The stator 31 is an armature. The entire rotor 21 is cup-shaped. The rotor 21 is connected to the end of the rotating shaft 14. The rotor 21 rotates together with the rotating shaft 14. A gap is formed between the rotor 21 and the stator 31 in the radial direction and the axial direction. In order to make the rotary electric machine 10 compact, it is desirable that the gap related to the stator 31 is small. The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 provides a yoke for a permanent magnet described later. The rotor core 22 is made of a magnetic metal. The rotor 21 has a permanent magnet 23 disposed on the inner surface of the rotor core 22. The rotor 21 provides a field by a permanent magnet 23. Furthermore, the permanent magnet 23 provides a partial special magnetic pole for providing a reference position signal for ignition control.

The stator 31 is an annular member. The stator 31 is disposed so as to face the rotor 21. The stator 31 has a stator core 32. The stator core 32 is provided by a laminate of magnetic metals such as electromagnetic steel plates. The stator core 32 is fixed to the body 13 of the internal combustion engine 12. The stator 31 has a stator coil 33 wound around a stator core 32. The stator coil 33 provides an armature winding. The stator coil 33 is a single-phase winding or a multi-phase winding. The stator coil 33 can selectively function the rotor 21 and the stator 31 as a generator or an electric motor. The coil wire is a single wire conductor covered with an insulating coating. The coil wire is made of an aluminum-based metal such as aluminum or an aluminum alloy.

The rotating electrical machine 10 has a wire harness 15 that provides an electrical connection between the rotating electrical machine 10 and the electric circuit 11. The wire harness 15 is an electric wire that is more flexible than the coil wire. The wire harness 15 includes a plurality of electric wires. Each electric wire is a coated conductor in which a bundle of a plurality of thin wires is covered with a resin coating. Each thin wire is made of copper-based metal or aluminum-based metal.

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

In FIG. 2, the stator 31 is an outer salient pole type stator. The stator core 32 has a plurality of magnetic poles 32a. One single coil is mounted on one magnetic pole 32a. The stator coil 33 is provided by a plurality of single coils. The magnetic pole 32a is also called a salient pole or a tooth. The stator core 32 has a central annular portion 32b. A plurality of magnetic poles 32a are provided on the radially outer side of the central annular portion 32b. A through hole 32c is defined in the central portion of the central annular portion 32b. The through hole 32 c is used for fitting with the body 12. For example, the end portion of the through hole 32c and the body 12 are inlay-fitted. The through hole 32 c is used to avoid interference with the boss portion of the rotor 21. The function required for the through hole 32c mainly limits the inner diameter of the central annular portion 32b. Further, the outer diameter of the central annular portion 32b is limited by the magnetic pole 32a. For this reason, the size of the central annular portion 32b is limited. The stator core 32 has a plurality of bolt holes 32 d for fixing the stator core 32 to the body 13. The plurality of bolt holes 32d are also one of the factors that limit the width of the central annular portion 32b. In many cases, the plurality of bolt holes 32d can provide an electrode installation range that the central annular portion 32b can provide in a fan shape.

An insulator 35 is disposed between the stator core 32 and the stator coil 33. The insulator 35 is made of an electrically insulating resin. The insulator 35 is provided on the stator 31. The insulator 35 is also called a bobbin. A portion of the insulator 35 is positioned adjacent to the magnetic pole 32a to provide a bobbin flange. A part of the insulator 35 is disposed on both sides in the axial direction of the magnetic pole 32a. A part of the insulator 35 has an annular inner flange portion disposed in the central annular portion 32b and an electrode support portion that extends so as to cover a part of the axial surface of the central annular portion 32b. In the following description, the term insulator 35 often refers to an electrode support.

The stator 31 has a plurality of electrodes 50. A plurality of coil ends 33 a that are end portions of the stator coil 33 are connected to the electrode 50. The plurality of electrodes 50 may provide an internal connection member for connecting the stator coil 33 so as to form a predetermined circuit. The plurality of electrodes 50 may provide an external connection member for electrically connecting the stator coil 33 and the wire harness 15. In the illustrated example, the plurality of electrodes 50 connect the stator coil 33 and the wire harness 15 while connecting the stator coil 33 in three phases.

FIG. 3 is a circuit diagram showing the connection of the stator coil 33. The stator coil 33 is a three-phase winding. Stator coil 33 is a star connection having a neutral point NT. One phase is provided by a parallel circuit of a plurality of coils. In this example, one phase is provided by the parallel connection of two coils. For example, the U phase is provided by the parallel connection of the coil U1 and the coil U2. The stator coil 33 has a plurality of coils. Each coil has two coil ends 33a. Therefore, the stator coil 33 has a plurality of coil ends 33a.

The coil U1 may be formed from a single coil. Instead of this, the coil U1 may be formed of a coil group in which a plurality of coils are connected in series. For example, when one single coil is attached to one magnetic pole 32a, one coil U1 can be provided by a group of a plurality of single coils arranged in series. For example, consider a case where there are a total of 18 magnetic poles 32 a of the stator 31. In this case, there are six coils (single coils) belonging to the U phase. A coil group in which three coils are connected in series is associated with each of the coil U1 and the coil U2. In this case, the coil U1 is provided by one coil group including three single coils connected in series. For example, the coil U1 has a total of two coil ends, one at the start and end of winding of the coil. That is, when viewed as a whole of the U phase obtained by adding the coil U1 and the coil U2, one U phase has four coil terminals.

The electrode 50 can be used for various connections for the stator coil 33. In the illustrated example, one electrode 50 provides an output end in one phase when the rotating electrical machine 10 functions as a generator. A plurality of coil ends 33 a are connected to one electrode 50. In the illustrated example, two coil ends 33 a are connected to one electrode 50. The electrode 50 is connected to the end of one power line included in the wire harness 15. Therefore, one electrode connects the plurality of coil ends 33 a and one end of the wire harness 15. Electrode 50 may be utilized to provide a connection at neutral point NT of stator coil 33.

2, the plurality of electrodes 50 are fixed to the stator 31. The plurality of electrodes 50 are fixed to the central annular portion 32b. The plurality of electrodes 50 are disposed between two bolt holes 32d adjacent in the circumferential direction. One electrode 50 has a plurality of terminals 51 and 52. The plurality of terminals 51 and 52 provided by one electrode 50 are positioned away from each other in the rotating electrical machine 10, that is, on the end surface of the stator 31. The terminals 51 and 52 are joined to the coil end 33 a of the stator coil 33. One terminal 51 is joined to one coil end 33a. One terminal 52 is joined to one coil end 33a. The plurality of coil ends 33a and the plurality of terminals 51 and 52 are joined one-on-one so that one coil end 33a is joined to one terminal.

The plurality of coil ends 33 a are arranged so as to extend radially inward from the stator coil 33. The plurality of coil ends 33a reach the center annular portion 32b from the radially outer annular region where the stator coil 33 is disposed. The plurality of coil ends 33a are arranged so as to extend approximately along the radial direction.

Each of the plurality of coil ends 33a has a predetermined shape necessary to reach the corresponding terminal. The plurality of coil ends 33a can have various shapes. For example, the coil end 33 a can have an L-shape that extends from above the magnetic pole 32 a onto the terminal 51 and is disposed along the terminals 51 and 52. As shown on the terminal 51 in the drawing, the coil end 33a can have a shape that wraps around the outer periphery of the terminal 51 from above the magnetic pole 32a or a shape that wraps around. The coil end 33a can have a shape that approaches the terminal 52 from above the magnetic pole 32a, as on the terminal 52 in the drawing.

In the method for manufacturing the stator 31, the plurality of coil ends 33a are processed to have the predetermined shape after the step of winding the stator coil 33 around the stator core 32. The plurality of coil ends 33a are bent and arranged to have the predetermined shape. The insulator 35 can include a guide member such as a groove or a column for guiding the coil end 33a.

The stator 31 has a protective member 61 for protecting the joint between the electrode 50 and the coil end 33a. The protection member 61 covers at least the joint. As shown in the figure, the protective member 61 covers the entire protruding portion of the electrode 50 on the stator 31 and covers the coil end 33 a located in the vicinity of the electrode 50. The protective member 61 suppresses corrosion of the joint portion by being in close contact with the electrode 50 and the coil end 33a. The protection member 61 is an electrically insulating resin material.

FIG. 4 shows a partial cross section near the electrode 50. As illustrated, the insulator 35 includes a first portion 35 a disposed on one end surface in the axial direction of the stator core 32 and a second portion 35 b disposed on the other end surface in the axial direction of the stator core 32. One end face is an end face for connecting the stator coil 33. The other end surface is an end surface for arranging the wire harness 15. The insulator 35 has a through portion 35 c arranged so as to penetrate the stator core 32. The through portion 35 c is disposed in a through hole 32 e defined by the stator core 32. The through portion 35 c is exposed on both surfaces of the stator core 32. The through portion 35c accommodates and holds the electrode 50. The through part 35c is also an electrode holding part. The through portion 35 c electrically insulates the stator core 32 and the electrode 50. The insulator 35 has a plurality of through portions 35 c that is the number corresponding to the plurality of electrodes 50. In the illustrated example, since the stator 31 includes three electrodes 50, the insulator 35 includes three through portions 35c.

The plurality of electrodes 50 are arranged so as to penetrate the stator 31 in the axial direction. The terminals 51 and 52 are disposed on one end surface of the stator 31. The terminals 51 and 52 are joined to the coil end 33a. One terminal 51 and one coil end 33a are joined. One terminal 52 and one coil end 33a are joined. The two terminals 51 and 52 are continuously formed of a metal material that forms the electrode 50.

The terminals 51 and 52 and the coil end 33a are joined by melting one or both of them or by metallurgically diffusing one or both of them. Specifically, the coil end 33a and the terminals 51 and 52 are welded by a welding technique called electric resistance welding or projection welding. Between the terminals 51 and 52 and the coil end 33a, the coil end 33a is mainly deformed along the terminals 51 and 52, and a joint portion in which the coil end 33a and the terminals 51 and 52 are in close contact with each other is formed.

The protective member 61 covers a part of the coil end 33a and the terminals 51 and 52. The protection member 61 is also in contact with the insulator 35 and is in close contact therewith. Thereby, the coil end 33a, the terminals 51 and 52, and the joint portion between them are protected from corrosion. Further, the protective member 61 fills a gap between the coil end 33 a, the terminals 51 and 52, and a joint portion between them, and the insulator 35. Thereby, the mechanical strength of the coil end 33a and the terminals 51 and 52 is enhanced.

The electrode 50 further has a terminal 53. The terminal 53 is a terminal for providing electrical connection with the wire harness 15. The terminal 53 is disposed on the other end surface of the stator 31. The terminal 53 is joined to the conductor 15 a that provides the wire harness 15 and the solder 62. The terminal 53 has a shape suitable for receiving the conductor 15a and holding them. The terminal 53 has a pair of claws arranged in a U shape for receiving and holding the conductor 15a. The terminal 53 has a material and a shape suitable for soldering.

The electrode 50 has a body portion 55. The body part 55 electrically connects the plurality of terminals 51, 52, 53. Thereby, the electrode 50 electrically connects a plurality of coils included in the stator coil 33. Further, the electrode 50 electrically connects the stator coil 33 to the wire harness 15. The body part 55 is arrange | positioned in the penetration part 35c. The body part 55 is fixed to the insulator 35, that is, the through part 35c. The body portion 55 is fixed to the stator 31, that is, the rotating electrical machine 10. The body part 55 is a main member of the electrode 50. The plurality of terminals 51, 52, 53 and the body portion 55 are formed of a continuous conductor material. In this embodiment, the electrode 50 is made of an iron-based metal such as iron or an iron alloy. A tin plating layer is formed on the surface of the electrode 50. In the method for manufacturing the stator 31, the body part 55 is press-fitted into the through part 35c. The body part 55 may be insert-molded so as to be wrapped by the resin material forming the through part 35c.

Since the terminals 51 and 52 are used for connection with the coil end 33a, they are also called coil terminals. Further, since the terminals 51 and 52 are used for welding, they are also called welding terminals. The terminals 51 and 52 are also called first terminals. Therefore, one electrode has a plurality of first terminals. The plurality of first terminals are different from each other in at least one aspect.

The plurality of first terminals are arranged apart from each other. Between the plurality of first terminals, a thermal barrier portion that inhibits direct heat conduction is provided. The plurality of first terminals are respectively disposed on different surfaces. The plurality of first terminals are respectively disposed on a plurality of surfaces having different directivity directions. The plurality of first terminals are respectively disposed on the plurality of surfaces. The plurality of surfaces extend so as to intersect each other on their extensions. The plurality of first terminals have different positions on the stator 31. The plurality of first terminals have different directing directions on the stator 31. The plurality of first terminals have different positions on the electrode 50. The plurality of first terminals have different shapes on the electrode 50. The positions of the plurality of first terminals with respect to the body portion 55 are different.

The terminal 53 is connected to the wire harness 15 for connecting the stator coil 33 to the outside. The terminal 53 is also called a wire harness terminal. Since the terminal 53 is used for soldering, it is also called a soldering terminal. The terminal 53 is also called a second terminal.

The shape of the first terminal is different from the shape of the second terminal. The joining method used at the first terminal is different from the joining method used at the second terminal.

The at least one first terminal is disposed on one end surface on the stator 31. In the illustrated example, all of the plurality of first terminals are arranged on one end surface on the stator 31. At least one first terminal is disposed on one end face of the stator 31, and the second terminal is disposed on the other end face of the stator 31. In other words, at least one of the first terminal and the second terminal is disposed on the opposite end surfaces of the stator 31. In the illustrated example, the first terminal is not disposed on the other end surface of the stator 31. Such a configuration suppresses the influence between the first terminal and the second terminal. For example, the influence of scattering components such as spatter due to welding on soldering is suppressed. From another viewpoint, the influence of scattering components such as evaporation flux caused by soldering on welding is suppressed.

5, 6, and 7, the electrode 50 is illustrated in detail. The body part 55 has an elongated plate shape. The body part 55 has engagement parts 55a and 55b for strengthening the coupling with the through part 35c. The engaging portions 55a and 55b provide meshing between the body portion 55 and the through portion 35c. The electrode 50 has a plurality of tabs 56, 57, 58 and 59. The tabs 56, 57, 58, and 59 are plate-like pieces that extend directly or indirectly from the body portion 55. The tabs 56, 57, and 58 are quadrilateral flat plates. A plurality of tabs 56, 57, and 58 are provided at one end of the body portion 55. A tab 59 is provided at the other end of the body portion 55.

The tab 56 is a plate-like portion that extends on the same plane as the body portion 55. The tab 56 is larger than the body portion 55 with respect to the width direction WD. The tab 56 may have the same width as the body portion 55. The tab 56 protrudes from the body portion 55 to both sides in the width direction WD. The tab 56 has an upper end surface 56 a on the extension of the body portion 55. The tab 56 has a lower end surface 56b on the side opposite to the end surface 56a. The lower end surface 56 b is positioned on the insulator 35. The upper end surface 56a provides a pressing surface for pressing the electrode 50 in the step of press-fitting the electrode 50 into the through portion 35c. The lower end surface 56b can be used to set the press-fitting amount of the electrode 50 by contacting the insulator 35. The lower end surface 56b is also called a stopper surface during press-fitting. Note that the end surface 56 b may be partially inserted into the insulator 35. However, the insulator 35 is positioned between the end face 56b and the stator core 32, and electrical insulation is ensured. The tab 56 is also called a first tab. The tab 56 is also called a support tab for supporting the other tabs 57 and 58.

The tab 57 extends from one side of the tab 56. The tab 57 extends from the tab 56 in the height direction HD. The tab 56 and the tab 57 are perpendicular to each other. The tab 57 extends so as to intersect the body portion 55. The tab 57 is also called a second tab. Terminal 51 is provided by a tab 57. The terminal 51 is a part of the tab 57. The tab 57 is also referred to as a first terminal tab for providing the terminal 51.

The tab 58 extends from the other side of the tab 56. The tab 58 extends from the tab 56 in the height direction HD. The tab 56 and the tab 58 are perpendicular to each other. The tab 58 extends so as to intersect the body portion 55. The tab 58 is also called a third tab. Terminal 52 is provided by tab 58. The terminal 51 is a part of the tab 58. The tab 58 is also referred to as a second terminal tab for providing the terminal 52.

The plurality of tabs 56, 57, and 58 are arranged so that the cross section has a bracket shape. In other words, the plurality of tabs 56, 57, 58 are arranged such that the planes they provide intersect each other. In another aspect, the plurality of tabs 56, 57, 58 are arranged such that the planes they provide are oriented in different directions. The tab 56 is arranged in the center. The tabs 57 and 58 are arranged so as to be located on both sides of the tab 56. The tabs 57 and 58 extend from each of two opposite sides on the tab 56. Curved curved portions are provided between the tab 56 and the tab 57 and between the tab 56 and the tab 58. With respect to the length direction LD, the tabs 56, 57, and 58 are positioned within a range overlapping each other. The tab 56 is disposed between the two tabs 57 and 58, thereby providing a thermal barrier portion that suppresses heat conduction between the two tabs 57 and 58.

The tab 57 and the tab 58 are positioned so as to be parallel to each other and to face each other. The tab 57 and the tab 58 are connected via the tab 56 only. Therefore, the terminal 51 and the terminal 52 are connected via the tab 56 only. The tab 57 and the tab 58 are positioned away from each other in the width direction WD. A cavity is defined between the tab 57 and the tab 58. Therefore, there is a cavity between the terminal 51 and the terminal 52. The terminal 51 and the terminal 52 are not directly continuous and are not directly adjacent to each other. The terminal 51 and the terminal 52 are positioned spatially apart.

The terminals 51 and 52 have a shape suitable for joining them and the coil end 33a. The terminals 51 and 52 have protrusions 51a and 52a for projection welding. The protrusions 51a and 52a protrude in the width direction WD. The protrusions 51a and 52a protrude toward the outside of the tabs 57 and 58 in the width direction WD. The protrusions 51a and 52a protrude toward the coil end 33a. The protrusions 51a and 52a are protrusions having ridges extending along the length direction LD. The protrusions 51a and 52a are protrusions that form ridges that extend across the coil end 33a positioned thereon. The protrusions 51a and 52a are semi-cylindrical protrusions. The plurality of protrusions 51a and 52a provided on one electrode 50 are separated from each other. The coil end 33a and the protrusions 51a and 52a form a welded portion having a trace shape after being welded.

The surfaces of the terminals 51 and 52 in the direction in which the protrusions 51a and 52a protrude are the bonding surfaces 51b and 52b. The coil end 33a is positioned on the protrusions 51a and 52a. The coil end 33a is positioned so as to intersect with the peaks provided by the protrusions 51a and 52a. The coil end 33a has a shape that encloses the protrusions 51a and 52a.

The terminal 51 is provided on a tab 57 extending from the body portion 55 in a direction different from the length direction LD, that is, in the width direction WD and / or the height direction HD. The terminal 52 is provided by a tab 58 extending from the body portion 55 in a direction different from the length direction LD, that is, in the width direction WD and / or the height direction HD. The electrode 50 has at least one terminal 51, 52 that extends from the body portion 55 and the tab 56 in the width direction WD and / or the height direction HD. This structure promotes heat radiation from the terminals 51 and 52 and suppresses heat conduction from the terminals 51 and 52 to the body portion 55. This structure makes it possible to provide a space for joining operations at the terminals 51 and 52.

The plurality of terminals 51 and 52 are provided by plate-like members. The plurality of terminals 51 and 52 have a plurality of joint surfaces 51b and 52b to which the coil end 33a and the terminal are joined. The plurality of bonding surfaces 51b and 52b provided by one electrode 50 are arranged on different surfaces provided by the plate-like member. The electrode 50 has a plurality of tabs 56, 57, and 58 which are plate-like members. Tabs 57 and 58 extend from other tabs 56. Each of the plurality of bonding surfaces 51b and 52b is disposed on each of the plurality of tabs 57 and 58. The plurality of tabs 57, 58 are arranged to provide a plurality of surfaces that are separated from each other or a plurality of surfaces that intersect each other. The plurality of tabs 56, 57, 58 are defined by corners formed therebetween. Since the corner is formed by bending the material, it is also called a bent portion. Two of the plurality of tabs 56, 57, 58 are defined by at least one corner located between them.

The tab 59 is a plate-like portion that extends on the same plane as the body portion 55. The width of the body portion 55 in the width direction WD and the width of the tab 59 are equal. Terminal 53 is provided by a tab 59. The terminal 53 is a part of the tab 59.

The tab 59 is positioned away from the tabs 57 and 58 with respect to the length direction LD. The tab 59 and the tabs 57 and 58 are disposed on both end surfaces of the stator core 32 so as to be isolated from each other. The tab 59 is positioned spatially separated from at least one of the plurality of tabs 57 and 58. Such an arrangement contributes to suppressing undesirable effects between the joining operation at the tabs 57, 58 and the joining operation at the tab 59.

4 to 7, the plurality of tabs 56, 57, 58 for providing the plurality of terminals 51, 52 are arranged so as to protrude from the insulator 35. A tab 59 for providing the terminal 53 is also arranged so as to protrude from the insulator 35.

As shown in the drawing, the plurality of tabs 57 and 58 for providing the plurality of terminals 51 and 52 are arranged so as to spread along the radial direction of the stator 31. The plurality of terminals 51 and 52 and the plurality of tabs 57 and 58 are arranged radially. The protrusions 51 a and 52 a protrude toward the circumferential direction or tangential direction of the stator 31. Moreover, the protruding directions of the two protrusions 51a and 52a in one electrode 50 are different directions. The protruding directions of the two protruding portions 51 a and 52 a are opposite to the circumferential direction or tangential direction of the stator 31. The peaks of all the protrusions 51 a and 52 a extend along the axial direction of the stator 31. Thereby, the coil end 33a can cross | intersect the protrusion parts 51a and 52a by arrange | positioning along the end surface of the stator 31. FIG.

The shapes of the plurality of tabs 56, 57, 58 and the plurality of terminals 51, 52 provided by them are set so as to suppress the amount of axial protrusion of the joined part including the electrode 50 and the coil end 33 a on the end face of the stator 31. Has been. The suppression of the protruding amount of the joining component in the axial direction may make it possible to reduce the gap between the rotor 21 and the stator 31. The suppression of the protruding amount of the joining component in the axial direction may make it possible to reduce the gap between the stator 31 and the body 13. Therefore, the suppression of the axial protrusion amount of the joining component contributes to the miniaturization of the rotating electrical machine 10 including the rotor 21 and the stator 31. In addition, the suppression of the protruding amount in the axial direction of the joining component contributes to the downsizing of the portion of the internal combustion engine 12 where the rotating electrical machine 10 is disposed, for example, the portion including the body 13.

The two terminals 51 and 52 provided on one electrode 50 provide two joint surfaces 51b and 52b. These two joint surfaces 51b and 52b face in different directions. In other words, the surface direction of the joint surfaces 51b and 52b, that is, the direction in which the joint surfaces 51b and 52b face is directed in the opposite direction with respect to the circumferential direction or tangential direction of the stator 31. The two joint surfaces 51b and 52b are oriented in the opposite direction of the width direction WD. The other bonding surface 52b is located behind or behind the at least one tab 57, 58 with respect to one bonding surface 51b. The other bonding surface 51b is located behind or behind the at least one tab 57, 58 with respect to one bonding surface 52b. In the state where the plurality of tabs 56, 57, 58 are developed on the plane, that is, before the bending process, the joining surface 51b and the joining surface 52b are located on the same plane and in the same direction. Is oriented.

The body portion 55 and the tab 56 are arranged so as to extend along the circumferential direction or the tangential direction of the stator 31. The tabs 57 and 58 extend from the body portion 55 and the tab 56 along the radial direction of the stator 31. The tabs 57 and 58 are positioned inside the body portion 55 and the tab 56 with respect to the radial direction of the stator 31.

The method for manufacturing the rotating electrical machine 10 includes a process of manufacturing the rotor 21 and a process of manufacturing the stator 31. The method for manufacturing the rotating electrical machine 10 includes a step of combining the rotor 21 and the stator 31 on the internal combustion engine 12. The process of manufacturing the rotor 21 includes a process of manufacturing the rotor core 22 by a process such as pressing or cutting, and a process of fixing the permanent magnet 23 in the rotor core 22.

The process of manufacturing the stator 31 includes a process of forming a stator core 32 by laminating electromagnetic steel sheets press-formed into a predetermined shape, a process of mounting an insulator 35 on the stator core 32, and a process of mounting a stator coil 33 on the stator core 32. Including the step of.

The process of manufacturing the stator 31 includes a process of manufacturing a plurality of electrodes 50. The electrode 50 is manufactured by a step of forming a metal plate material into a predetermined shape by pressing. This step includes a step of cutting the material into a predetermined shape and a step of bending the material. The bending step can be performed before, after, or simultaneously with the cutting step. The step of bending includes a step of forming the protrusions 51a and 52a. The step of bending includes a step of bending the plurality of tabs 56, 57, 58 into a bracket shape. Thereby, each of the plurality of terminals 51 and 52 is arranged on a different surface.

The step of manufacturing the stator 31 includes a step of attaching the plurality of electrodes 50 to the insulator 35. This step is executed before the insulator 35 is attached to the stator core 32 or after the insulator 35 is attached to the stator core 32.

The step of manufacturing the stator 31 includes a step of joining each of the plurality of coil ends 33 a to the corresponding terminals 51 and 52. In this step, the coil end 33a and the terminals 51 and 52 are joined by welding. Here, the welding process in the terminal 51 will be described. A similar process is performed at the terminal 52. First, one coil end 33a is positioned on one protrusion 51a. The coil end 33a is positioned so as to intersect the longitudinal direction of the protrusion 51a.

Next, the welding electrodes 65 and 66 are positioned on both sides of the coil end 33 a and the terminal 51. The welding electrodes 65 and 66 are tightened by a tightening device so as to press the coil end 33a and the terminal 51 together. By the welding electrodes 65 and 66, the protrusion 51a bites into the coil end 33a and deforms the coil end 33a. The coil end 33a receives the protrusion 51a and deforms along the joint surface 51b. As a result, the coil end 33a and the terminal 51 are in contact with each other over a wide area. At this time, even if there is an insulating film such as an oxide film on the surface of the coil end 33a, the insulating film is broken by the deformation of the coil end 33a, and a contact between the fresh surface of the aluminum-based metal and the bonding surface 51b may be obtained. is there.

The coil end 33 a is given a shape that wraps the protrusions 51 a and 52 a in the process in which the welding electrodes 65 and 66 tighten the coil end 33 a and the terminal 51. Even after the coil end 33a is welded, the coil end 33a maintains a shape for enveloping the protrusions 51a and 52a.

The welding power is supplied to the welding electrodes 65 and 66 in at least a part of the process in which the welding electrodes 65 and 66 are tightened. A current flows through the coil end 33a and the terminal 51, and a contact portion between the coil end 33a and the terminal 51 generates heat. As a result, the coil end 33a and the terminal 51 are joined by at least metallurgical diffusion. When sufficient heat generation is obtained, a part of the coil end 33a is melted. Next, the welding electrodes 65 and 66 are removed. Contact marks with the welding electrodes 65 and 66 are left on the surface of the relatively soft coil end 33a. A welding mark is left at the joint between the coil end 33a and the terminal 51.

When one coil end 33a and one terminal 51, 52 are joined, foreign matter due to high temperature such as spatter and smoke may be generated. For example, the spatter is scattered along the bonding surfaces 51b and 52b, in other words, along the gap between the welding electrodes 65 and 66. In addition, foreign matters such as smoke and volatile components generated due to high temperature also spread and scatter along the joint surfaces of the terminals 51 and 52, in other words, along the gap between the welding electrodes 65 and 66.

In this embodiment, after the joining process at one terminal 51, the joining process at another terminal 52 is executed. After the joining process at the terminal 52, the joining process at the terminal 51 may be performed.

The terminal 51, that is, the tab 57 extends along the radial direction of the stator 31. On the other hand, the terminal 52, that is, the tab 58 also extends along the radial direction of the stator 31. Therefore, the joining surfaces 51b and 52b on which the joining process is performed later are not positioned on the extension of the joining surfaces 51b and 52b on which the joining process is performed first. For this reason, the scattered matter generated in the previous joining step is unlikely to reach the joining surfaces 51b and 52b that are the targets of the subsequent joining step. For this reason, the deterioration of the joining state resulting from the scattered material in the preceding joining process is suppressed.

The tab 56 is provided between the tab 57 and the tab 58. The heat generated in the joining process on the tab 57, that is, in the terminal 51 reaches the tab 58 through the tab 56. However, since the tab 56 extends in the width direction WD, heat conduction is suppressed. Therefore, the temperature rise of the terminal 52 due to the heat generated in the terminal 51 is suppressed. As a result, it is possible to suppress a difference between the parameter in the joining process at the terminal 51 and the parameter in the joining process at the terminal 52. For example, the same process parameters can be used for the bonding process at the terminal 51 and the bonding process at the terminal 52. For example, it is possible to reduce differences in tightening pressure, tightening time, energization amount, and the like due to the welding electrodes 65 and 66. From another viewpoint, since the temperature difference between the two terminals 51 and 52 is suppressed, the difference in quality of the joint is suppressed.

In this embodiment, all the terminals 51 and 52 shown in the figure are spread radially on the stator 31. In other words, all the terminals 51 and 52 are arranged radially. Therefore, the welding electrodes 65 and 66 can be welded by opening and closing operations in the circumferential direction or tangential direction at all the terminals 51 and 52. Further, by moving the stator 31 or the welding electrodes 65 and 66 along the circumferential direction of the stator 31, it is possible to join the plurality of terminals 51 and 52.

The step of manufacturing the stator 31 includes a step of connecting the wire harness 15 to the terminal 53. In this step, the conductor 15 a of the wire harness 15 is disposed between the pair of claws of the terminal 53. Next, molten solder 62 is applied to the conductor 15 a and the terminal 53. When the solder 62 is solidified, a lump of the solder 62 is formed. This completes the soldering of the wire harness 15 and the terminal 53. Before applying the solder 62, the pair of claws may be deformed so as to tighten the conductor 15a, and the conductor 15a may be temporarily fixed. The process at the terminal 53 can be performed before or after the bonding process at the terminals 51 and 52.

The step of manufacturing the stator 31 includes a step of applying the protective member 61 after the joining step of the terminals 51 and 52. The protective member 61 is provided on the terminals 51 and 52 by applying or dropping a resin in a flowable state. The protection member 61 is formed by curing a resin. Further, a resin material such as a varnish for covering the stator coil 33 may be provided so as to cover the coil end 33 a and the terminals 51 and 52.

According to the embodiment described above, it is possible to provide the rotating electrical machine electrode 50, the rotating electrical machine 10, and the manufacturing method of the rotating electrical machine 10 that occupy a small area on the rotating electrical machine 10. Moreover, from another viewpoint, the influence on the joining operation at one other terminal is suppressed from the joining operation at one terminal.

Second Embodiment This embodiment is a modified example based on the preceding embodiment. Instead of the arrangement of the terminals 51 and 52 in the above embodiment, various arrangements can be adopted.

As shown in FIG. 8, the stator 31 has three electrodes 250. One electrode has two terminals 51 and 52 arranged in a shape that can be called L-shaped or V-shaped. The insulator 35 has a container 35 d for suppressing the flow of the protection member 61. The container 35d has a shallow dish shape. The side walls characterizing the container 35d are lower than the terminals 51,52. The side wall has a height for restricting the flow of the resin material forming the protection member 61. The plurality of electrodes 250 are disposed in the container 35d.

The electrode 250 is arranged so that the two terminals 51 and 52 are V-shaped and open toward the outside in the radial direction of the stator 31. The two joint surfaces 51b and 52b face the outside of the cavity defined by the two terminals 51 and 52, that is, the tabs 56 and 57 arranged in an L shape or a V shape. Further, the joint surfaces 51 b and 52 b face radially inward on the stator 31. The two joint surfaces 51b and 52b are located behind or behind the tabs 56 and 57, respectively.

The coil end 33a is disposed so as to extend from the radially outer side of the stator 31 toward the radially inner side. The coil end 33 a is disposed so as to be wound around the terminals 51 and 52.

9, FIG. 10, and FIG. 11 are diagrams corresponding to FIG. 5, FIG. 6, and FIG. The electrode 250 has a terminal 52 on a tab 56. Therefore, the two tabs 56 and 57 and the two terminals 51 and 52 are arranged to form a shape that can be called an L-shape or a V-shape.

The electrode 250 has a recess 56 c between the terminal 51 and the terminal 52, in other words, between the tab 56 and the tab 57. A portion connecting the tab 56 and the tab 57 is left. The recess 56c extends along the length direction LD from the distal end side in the axial direction of the terminals 51 and 52. The recess 56 c separates the terminal 51 and the terminal 52. The recess 56c provides a thermal barrier portion that suppresses heat conduction between the terminal 51 and the terminal 52. The recess 56c is located between the plurality of bonding surfaces 51b and 52b. The recess 56c suppresses a cross-sectional area that contributes to heat conduction. By the recess 56c, the terminal 51 provides a single terminal protruding independently in the length direction LD. Terminal 52 also provides a single terminal.

Also in this embodiment, an electrode 250 for a rotating electrical machine that occupies a small area on the rotating electrical machine 10 is provided. Also in this embodiment, the adverse effect between the joining operations at the two terminals 51 and 52 provided by one electrode 250 is suppressed.

Third Embodiment This embodiment is a modification in which the preceding embodiment is a basic form. 12, FIG. 13, and FIG. 14 correspond to FIG. 5, FIG. 6, and FIG.

The electrode 350 has protrusions 51a and 52a and bonding surfaces 51b and 52b. The joint surface 52b faces the inside of the cavity defined by the two terminals 51 and 52. The bonding surface 51b and the bonding surface 52b face different directions on the electrode 350. When the electrode 350 is disposed on the stator 31, the joint surface 51 b and the joint surface 52 b are directed in different directions on the end surface of the stator 31. The joint surface 51b is located behind or behind the tab 57 with respect to the joint surface 52b. The joint surface 52b is located behind or behind the tab 57 with respect to the joint surface 51b.

Also in this embodiment, an electrode 350 for a rotating electrical machine that occupies a small area on the rotating electrical machine 10 is provided. In this embodiment as well, adverse effects between bonding operations at the two terminals 51 and 52 provided by one electrode 350 are suppressed.

Fourth Embodiment This embodiment is a modified example based on the preceding embodiment. 15, FIG. 16, and FIG. 17 are diagrams corresponding to FIG. 5, FIG. 6, and FIG.

The electrode 450 has protrusions 51a and 52a and bonding surfaces 51b and 52b. The joint surfaces 51b and 52b face the inside of the cavity defined by the two terminals 51 and 52. The bonding surface 51b and the bonding surface 52b face different directions on the electrode 450. When the electrode 450 is disposed on the stator 31, the joint surface 51 b and the joint surface 52 b are directed in different directions on the end surface of the stator 31.

The tab 57 extends in the height direction HD slightly longer than the preceding embodiment. At the same time, the recess 56c extends slightly wider along the height direction HD. Thereby, the heat conduction between the terminal 51 and the terminal 52 is suppressed.

Also in this embodiment, an electrode 450 for a rotating electrical machine that occupies a small area on the rotating electrical machine 10 is provided. Also in this embodiment, the adverse effect between the joining operations at the two terminals 51 and 52 provided by one electrode 450 is suppressed.

Fifth Embodiment This embodiment is a modified example based on the preceding embodiment. 18, 19, and 20 correspond to FIGS. 5, 6, and 7. FIG.

The electrode 550 has a protrusion 51a. The protrusion 51a has a peak extending along the height direction HD. The protrusion 51a extends long along the direction intersecting the length direction LD. The peak of the protrusion 51a and the peak of the protrusion 52a extend in different directions.

When the electrode 550 is disposed on the stator 31, the peak of the protrusion 51 a extends in parallel with the end surface of the stator 31. The coil end 33a is disposed along the axial direction of the stator 31 so as to intersect the protrusion 51a.

Also in this embodiment, an electrode 550 for a rotating electrical machine that occupies a small area on the rotating electrical machine 10 is provided. Also in this embodiment, the adverse effect between the joining operations at the two terminals 51 and 52 provided by one electrode 550 is suppressed.

Sixth Embodiment This embodiment is a modification in which the preceding embodiment is a basic form. 21, FIG. 22, and FIG. 23 correspond to FIG. 5, FIG. 6, and FIG.

In the electrode 650, the tab 56 and the tab 57 are plate-like portions extending on the same plane. The tab 57 protrudes to one side of the tab 56 in the width direction WD. The electrode 650 has an asymmetric shape with respect to the width direction WD, which can be called L-shaped.

A terminal 52 is provided on the tab 56. A terminal 51 is provided on the tab 57. The protrusion 51a and the protrusion 52a protrude in the opposite direction in the height direction HD. Therefore, the joint surface 51b and the joint surface 52b face in opposite directions with respect to the height direction HD. Each of the plurality of bonding surfaces 51b and 52b is disposed on each of the front and back surfaces of the plate-like member.

In the manufacturing method of the rotating electrical machine 10, the welding electrodes 65 and 66 are positioned and sandwiched between the two coil ends 33 a and 33 a and the electrode 650. The two coil ends 33a and 33a positioned diagonally are pressed against the joint surfaces 51a and 52a, respectively. The welding current flows diagonally. According to this manufacturing method, the joining at the two terminals 51 and 52 can be provided by a series of joining steps. In addition, the joining process in the terminal 51 and the joining process in the terminal 52 may be performed in order.

Also in this embodiment, an electrode 650 for a rotating electrical machine that occupies a small area on the rotating electrical machine 10 is provided. Also in this embodiment, adverse effects between the joining operations at the two terminals 51 and 52 provided by one electrode 650 are suppressed.

Seventh Embodiment This embodiment is a modified example based on the preceding embodiment. 24, 25, and 26 correspond to FIGS. 5, 6, and 7. FIG.

The electrode 750 has a protrusion 52 a formed on the tab 56 and a protrusion 51 a formed on the tab 57. The protrusions 51a and 52a protrude in the same direction with respect to the height direction HD. The joint surface 51b and the joint surface 52b face in the same direction with respect to the height direction HD.

A flat plate-like portion spreads between the plurality of protrusions 51a and 52a. The plurality of protrusions 51a and 52a are separated from each other. The plurality of protrusions 51 a and 52 a are also positioned apart on the stator 31. Also in this embodiment, one coil end 33a is joined to one terminal, that is, one protrusion. Moreover, the plurality of protrusions 51a and 52a are independent.

In the manufacturing method of the rotating electrical machine 10, common welding electrodes 65 and 66 extending over the plurality of terminals 51 and 52 are used. Even in this manufacturing method, the joining at the two terminals 51 and 52 can be provided by a series of joining steps. Instead of at least one of the welding electrodes 65 and 66, a welding electrode associated with only one terminal may be used. In this case, the joining process at the terminal 51 and the joining process at the terminal 52 are performed in order.

Also in this embodiment, an electrode 650 for a rotating electrical machine that occupies a small area on the rotating electrical machine 10 is provided. Therefore, a plurality of joints in one electrode 750 can be formed with high quality.

Eighth Embodiment This embodiment is a modification example based on the preceding embodiment. 27, 28, and 29 are diagrams corresponding to FIG. 5, FIG. 6, and FIG.

The electrode 850 has a terminal 52 at one end of the body portion 55 and a terminal 51 at the other end of the body portion 55. The electrode 850 has a terminal 53 at one end of the body portion 55. The terminal 53 is disposed on the tab 57. The terminal 51 is disposed on the tab 59. The protrusion 51a and the protrusion 52a protrude in the same direction in the height direction HD. Therefore, the joint surface 51b and the joint surface 52b face in the same direction.

In this embodiment, the terminal 51 and the terminal 52 are disposed on both end surfaces of the stator 31 so as to be isolated from each other. Thereby, the bad influence of the joining work in the terminal 51 and the joining work in the terminal 52 is suppressed. Since the terminal 53 is formed on the tab 57 which is not on the extension of the joining surface 52b, the influence received from the joining work on the terminal 52 is suppressed.

Also in this embodiment, an electrode 850 for a rotating electrical machine that occupies a small area on the rotating electrical machine 10 is provided. This embodiment also provides an electrode 850 capable of forming a plurality of high quality joints.

Ninth Embodiment This embodiment is a modification example based on the preceding embodiment. FIG. 30 corresponds to FIG. In the drawing, the surface of the insulator 35 is indicated by a broken line.

The electrode 950 has a tab 56 embedded in the insulator 35. A part of the tab 58 is also embedded in the insulator 35. As a result, the tab 57 that provides the terminal 51 and a part of the tab 58 that provides the terminal 52 protrude from the insulator 35.

Also in this embodiment, an electrode 950 for a rotating electrical machine that occupies a small area on the rotating electrical machine 10 is provided. This embodiment also provides an electrode 950 capable of forming a plurality of high quality joints.

Tenth Embodiment This embodiment is a modified example based on the preceding embodiment. FIG. 31 corresponds to FIG. In the drawing, the surface of the insulator 35 is indicated by a broken line.

The electrode A50 has three welding terminals 51, 52, and 54. The terminal 54 has a protrusion 54a. The peak of the protrusion 54a extends along the length direction LD. The electrode A50 can be used for the neutral point NT of the three-phase star connection.

Also in this embodiment, an electrode A50 for a rotating electrical machine that occupies a small area on the rotating electrical machine 10 is provided. This embodiment also provides an electrode A50 that can form a plurality of high-quality joints.

Eleventh Embodiment This embodiment is a modified example based on the preceding embodiment. FIG. 32 shows the stator coil 33 of this embodiment. The phase coils U1, V2, V3, V4 shown in the figure are exemplary. The stator coil 33 is delta-connected. The electrodes disclosed herein can also be used for delta connections. The electrode disclosed here can also be used as an intermediate tap in the stator coil 33. The electrode disclosed here is also applicable to the stator coil 33 in which a plurality of phase coils U1, V2, V3, and V4 having different electrical angles are included in one phase coil group.

For example, the electrode 50 can be used at the output end of the delta connection. The electrode A50 can be used as an intermediate tap that connects the three phase coils included in the stator coil 33 and provides external connection.

Twelfth Embodiment This embodiment is a modified example based on the preceding embodiment. 33, 34, and 35 correspond to FIGS. 5, 6, and 7. FIG.

The electrode C50 has tabs 57 and 58 at both ends of the tab 56. The tab 56 is plate-shaped. A tab 57 extends from one side of the tab 56 in a perpendicular direction. A tab 58 extends from the other surface of the tab 56 in a perpendicular direction. The two tabs 57 and 58 protrude away from the central tab 56. The two tabs 57 and 58 protrude from the central tab 56 in the opposite direction. The tab 57 has a terminal 51. The tab 58 has a terminal 52. Therefore, the three tabs 56, 57, and 58 are arranged to form a shape that can be called a crank shape.

The terminals 51 and 52 have protrusions 51a and 52a and joint surfaces 51b and 52b. The protrusions 51a and 52a extend across both ends of the tabs 57 and 58 in the length direction LD. The two protrusions 51a and 52a protrude outward. The two protrusions 51a and 52a protrude away from the central tab 56.

35, the crank- type tabs 56, 57, 58 enable the two terminals 51, 52 to be separated from each other. The crank-shaped tabs 56, 57, 58 provide a space for placing the welding electrodes 65, 66. The crank- type tabs 56, 57, 58 contribute to an easy welding operation. Crank- type tabs 56, 57, 58 allow various terminal arrangements on the stator. Also in this embodiment, an electrode C50 for a rotating electrical machine that occupies a small area on the rotating electrical machine 10 is provided. Also in this embodiment, adverse effects between the joining operations at the two terminals 51 and 52 provided by one electrode C50 are suppressed.

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

In the above embodiment, a rotating electrical machine for an internal combustion engine is exemplified as the rotating electrical machine. However, this disclosure is not limited to the rotating electrical machine for the internal combustion engine. This disclosure can be applied to various electric motors such as a blower motor. This disclosure can be applied to various generators such as hydraulic power and wind power. Furthermore, the motor generator is illustrated in the said embodiment. Alternatively, the disclosure is applicable to electric motors or generators. When used in a generator, the electric circuit 11 may include a rectifier circuit provided by a bridge circuit including a plurality of rectifier elements, for example, diodes, and / or a regulator circuit that adjusts an output voltage to a predetermined voltage. Moreover, in the said embodiment, the electrode is utilized for the connection of a stator coil. Alternatively, the electrode may be used for connecting the rotor coil. For example, the present invention can be applied to an electrical connection portion between a commutator and a conducting wire in a rotating electrical machine having a brush.

As exemplified in the above embodiment, this disclosure is applicable to a rotating electrical machine having a single-phase or multi-phase stator coil 33. For example, this disclosure can be applied to various connection shapes such as a star connection and a delta connection. In addition, the present disclosure can be applied to a rotating electric machine including a plurality of coils having different electrical angles in one phase. For example, FIG. 3 illustrates a star connection in which two coil elements are connected in parallel in the same phase. Instead of this, three coil elements may be connected in parallel. In this case, for example, a configuration in which a terminal, that is, a projection is provided on the tab 56 in FIGS. 4 to 6, and a configuration in which the coil end of the third coil element is connected thereto can be employed.

In the above embodiment, the coil wire forming the stator coil 33 is an aluminum-based metal. Alternatively, the coil wire can be formed from a variety of conductor materials. For example, the coil wire may be made of copper or a copper alloy. Further, a part of the coil wire forming the stator coil 33 may be made of aluminum metal, and the other part may be made of copper metal.

In the above embodiment, the electrodes 50 to A50 are made of iron-based metal with tin plating. Instead, the electrodes 50 to A50 can be formed of various materials. For example, the electrodes 50 to A50 may be made of copper, aluminum, copper, or an alloy containing aluminum as a main component. Various surface treatment layers such as a nickel layer and a silver plating layer can be provided on the surfaces of the electrodes 50 to A50.

In the above embodiment, the terminals 51, 52, and 54, which are coil terminals, are connected to the coil end 33a by projection welding which is one of electric resistance welding. Instead, for joining the coil terminal and the coil end 33a, welding (TIG, laser, ultrasonic wave, friction stirring, etc.), solid phase joining (heat staking, etc.), cold pressure welding, brazing, or Various joints such as soldering can be used. Also in these configurations, the joining method employed in the coil terminal and the joining employed in the wire harness terminal can be different joining methods.

In the above-described embodiment, the terminals 51, 52, and 54 have elongated protrusions 51a, 52a, and 54a having peaks. Instead of this, a plurality of dot-like protrusions arranged may be used. Further, the protrusion can have various cross-sectional shapes such as a hemisphere, a triangle, and a trapezoid. In the above-described embodiment, the protrusions 51a, 52a, and 54a are formed by causing a part of the flat plate-like material to protrude. Instead of this, a recess may be formed in a part of a flat plate-like material, and the remaining corner may be used as a protrusion. For example, a pair of corners extending along both sides of the groove may be used as two protrusions.

In the above embodiment, the body portion 55 and the tabs 56, 57, 58, 59 are flat. Instead, materials having various cross-sectional shapes can be used. For example, the body portion 55 and the tabs 56, 57, 58, 59 can be provided by members having various shapes such as a cylindrical shape, a semi-cylindrical shape, a polygonal shape, and a semi-polygonal shape.

In the above embodiment, the electrodes 50, 250, 350, 450, 550, 650, 750, 850, 950, A50 have two or three welding terminals 51, 52, 54. Alternatively, the electrode may have four or more terminals. The electrode may have a plurality of metal members joined by welding or the like.

In the above embodiment, the body portion 55 is disposed through the stator 31. Instead, the body portion 55 may have a shape that does not penetrate the stator 31. In this case, the tab 59 and the terminal 53 are disposed together with the terminals 51 and 52 on one end face on the stator 31.

In the above embodiment, the protective member 61 is employed. Instead, various techniques can be employed to protect the joint. For example, as a technique for removing a corrosion factor in the joint, a case structure in which a room for housing the joint is sealed, or a structure in which the case is filled with oil or an inert gas can be employed. These approaches reduce or prevent direct exposure of the joint to corrosion factors such as water and oxygen.

10 rotating electrical machines, 11 electrical circuits, 12 internal combustion engines,
13 body, 14 rotating shaft, 15 wire harness,
21 rotor, 22 rotor core, 23 permanent magnet,
31 Stator, 32 Stator core, 33 Stator coil,
35 insulator, 35c penetration part,
50, 250, 350, 450, 550 electrodes,
650, 750, 850, 950, A50, C50 electrode,
51, 52, 53, 54 terminals,
51a, 52a, 54a protrusion, 51b, 52b joint surface,
55 body part, 56, 57, 58, 59 tab,
61 Protection member, 62 Solder, 65, 66 Welding electrode.

Claims (12)

1. A plurality of coil ends (33a) which are ends of the coil (33) of the rotating electrical machine;
   And electrodes (50, 250, 350, 450, 550, 650, 750, 850, 950, A50, C50) having a plurality of terminals (51, 52, 54) joined to the coil ends. ,
   The plurality of terminals are positioned away from each other in the rotating electrical machine,
   The plurality of coil ends and the plurality of terminals are connected to one another so that one coil end is joined to one terminal.
2. Each of the plurality of terminals has a protrusion (51a, 52a) protruding toward the coil end,
   The plurality of protrusions are separated from each other,
   The rotating electrical machine according to claim 1, wherein the coil end and the protrusion form a weld.
3. 3. The rotating electrical machine according to claim 2, wherein the protrusion is a protrusion that forms a peak extending across the coil end.
4. The plurality of terminals are provided by a plate-shaped member,
   The plurality of terminals have a plurality of joint surfaces (51b, 52b) to which the coil ends and the terminals are joined,
   The rotating electrical machine according to any one of claims 1 to 3, wherein the plurality of joining surfaces are arranged on different surfaces provided by the plate-like member.
5. The electrode has a plurality of tabs (56, 57, 58, 59) which are plate-shaped members,
   The rotating electrical machine according to claim 4, wherein each of the plurality of joining surfaces is disposed on each of the plurality of tabs.
6. The rotating electric machine according to claim 5, wherein the plurality of tabs are arranged to provide a plurality of surfaces that are separated from each other or a plurality of surfaces that intersect each other.
7. The rotary electric machine according to claim 5 or 6, wherein one of the tabs (57, 58) extends from the other tab (56).
8. 5. The rotating electrical machine according to claim 4, wherein each of the plurality of joint surfaces is disposed on each of the front and back surfaces of the plate-like member.
9. The rotating electrical machine according to any one of claims 4 to 8, wherein a recess (56c) for suppressing a cross-sectional area contributing to heat conduction is provided between the plurality of joint surfaces.
10. Furthermore, a body part (55) fixed to the rotating electrical machine,
    The rotating electrical machine according to any one of claims 1 to 9, comprising a wire harness (15) for connecting the coil to the outside and a wire harness terminal (53) connected to the coil.
11. The coil is a stator coil (33) provided on the stator (31),
    The body part (55) is disposed through the stator,
    The terminals (51, 52, 54) for the coils connected to the coil ends are arranged so as to protrude from one end of the stator,
    The rotating electrical machine according to claim 10, wherein the terminal (53) for the wire harness is disposed so as to protrude from the other end of the stator.
12. The rotating electrical machine according to any one of claims 1 to 11, wherein the coil is made of aluminum or an aluminum alloy.
    
    

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