WO2018012612A1 - Dynamo-electric machine, stator for same, and method of manufacture therefor - Google Patents

Abstract

Provided is a dynamo-electric machine stator of which an outside surface can be installed on a circumferential surface. The stator 31 includes a coil assembly 31a. The stator 31 includes a stator core 32, a stator coil 33, a magnetic pole portion 34, an attachment portion 35 and an insulator 36. A radial direction gap is provided between the magnetic pole portion 34 and the attachment portion 35. The gap suppresses stress. The coil assembly 31a is a linked body comprising a plurality of unit stators 38. Each unit stator 38 includes a unit core 37 and a unit coil 33a. The plurality of unit stators 38 are linked at linking portions 39. There are gaps in the circumferential direction between the linking portions 39. The circumferential direction gaps make it possible for an outside surface 34d to be disposed on a circumferential surface.

Description

Rotating electric machine, stator thereof, and manufacturing method thereof Cross-reference of related applications

This application is based on Japanese Patent Application No. 2016-140615 filed on July 15, 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 and its stator. Furthermore, the disclosure extends to a method for manufacturing a rotating electrical machine and a method for manufacturing a stator thereof.

Patent Document 1 discloses a stator having a core that provides a plurality of teeth. The core is divided into a plurality of tooth portions. One teeth part has one tooth and one coil. In the manufacturing stage, the plurality of teeth are connected like a chain. The plurality of teeth are arranged in an annular shape so as to wind a chain. The core fixed in a cylindrical shape is accommodated in the housing.

The description of the prior art documents listed as the prior art is incorporated by reference as an explanation of the technical elements in this specification.

JP 2012-65546 A

In one aspect, the teeth portion is required to have high dimensional accuracy. An error in the size of the tooth portion reduces the roundness of the outer surface of the core. In another aspect, the error in the teeth portion makes it difficult to achieve high roundness on both the inner surface and the outer surface. For example, an error in the size of the tooth portion causes interference between the plurality of tooth portions, and makes it difficult to adjust the outer surface and / or the inner surface. In yet another aspect, in the prior art, the core may be pressed into the housing, which may cause undesirable stress on the core.

In the above-mentioned viewpoints or other viewpoints not mentioned, further improvements are required for the rotating electrical machine, the stator thereof, and the manufacturing method thereof.

One disclosed object is to provide a rotating electrical machine in which an outer surface can be disposed on a circumferential surface, a stator thereof, and a manufacturing method thereof.

The stator of the rotating electrical machine disclosed herein includes a plurality of teeth (34a) projecting radially outward, and a magnetic pole portion (34) having a yoke (34b) connecting the plurality of teeth radially inward, A stator coil (33) attached to a plurality of teeth, and a mounting part (35) that is a separate part from the magnetic pole part and is provided on the radially inner side of the yoke for mounting to a mounting object. Prepare. A stator of a rotating electrical machine has a plurality of unit stators (38) arranged and connected along a circumferential direction to provide a magnetic pole part and a stator coil. The unit stator includes one tooth (34a), a stator. A unit coil (33a) mounted on one tooth and a part yoke (34c) which is a part of the coil and is arranged in the circumferential direction to form a yoke by being connected to each other. have. The plurality of partial yokes have a meshing portion (39a) that meshes the partial yokes adjacent to each other in the circumferential direction, and the plurality of partial yokes are circumferentially spaced apart from each other in the meshing portion. A gap (G39a) is formed, and the mounting portion has an outer diameter (D35b) smaller than the inner diameter (D34e) of the yoke.

According to the disclosure, the plurality of partial yokes are arranged with a circumferential gap between them. Therefore, interference between the partial yokes resulting from the processing accuracy of the plurality of unit cores can be avoided, and the outer surfaces of the plurality of teeth can be arranged on the circumferential surface. Therefore, the roundness of the outer surface is high. Moreover, the outer diameter of the mounting portion is smaller than the inner diameter of the yoke. Further, the outer surfaces of the plurality of teeth and the attachment portion can be adjusted coaxially. Therefore, even if the mounting portion is mounted on the inside in the radial direction of the yoke, the stress that the yoke receives from the mounting portion in the radial direction is suppressed. Thereby, damage and breakage of the outer salient pole type stator core formed by connecting a plurality of partial cores are suppressed.

The rotating electrical machine disclosed herein includes the stator (31) and a rotor (21) having a plurality of permanent magnets (23) arranged to face the stator.

In the method of manufacturing a stator for a rotating electrical machine disclosed herein, the rotating electrical machine includes a plurality of teeth (34a) protruding outward in the radial direction and a yoke (34b) connecting the plurality of teeth on the radially inner side. The magnetic pole part (34), the stator coil (33) attached to the plurality of teeth, and the magnetic pole part are separate parts, and are provided on the radially inner side of the yoke for attachment to an attachment object. And an attachment portion (35). The stator manufacturing method of the rotating electrical machine includes one tooth (34a), a part of the stator coil, the unit coil (33a) mounted on one tooth, a part of the yoke, and the circumferential direction. Assembling a plurality of unit stators having partial yokes (34c) that are arranged and connected to each other to form a yoke (152), and arranging the plurality of unit stators along the circumferential direction, and adjacent portions in the circumferential direction The step of engaging the yokes with each other at the meshing portion (153), and forming the circumferential gap (G39a) separating the adjacent partial yokes in the circumferential direction at the meshing portion while forming the outer surface (34d) of the plurality of teeth into a circle. Arranging and positioning on the peripheral surface (41a), (154), fixing the plurality of partial yokes to each other in the positioned state (15) ), And radially inside the fixed yoke, comprising the step (156) for mounting the mounting portion has an inner diameter of the yoke (D34e) smaller than the outer diameter (D35b).

According to the disclosure, the outer surfaces of the plurality of teeth are arranged on the circumferential surface while forming a circumferential clearance between the plurality of partial yokes. Therefore, the outer surface can be brought close to a perfect circle without being restricted by the dimension error of the partial yoke. That is, the outer surfaces of the plurality of teeth can be disposed on the circumferential surface while avoiding interference between the partial yokes due to the processing accuracy of the plurality of unit cores. Therefore, the roundness of the outer surface is high. Moreover, the outer diameter of the mounting portion is smaller than the inner diameter of the yoke. Therefore, even if the attachment portion is mounted on the inside in the radial direction of the yoke, the stress that the yoke receives is suppressed. Thereby, damage and breakage of the outer salient pole type stator core formed by connecting a plurality of partial cores are suppressed.

The manufacturing method of the rotating electrical machine disclosed herein includes a step of pressing the yoke of the stator (31) manufactured by the above manufacturing method toward the mounting object in the axial direction by the outer flange provided at the mounting portion.

The plurality of aspects disclosed in this specification adopt different technical means to achieve each purpose. The reference numerals in parentheses described in the claims and 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 disassembled perspective view of a stator. It is a top view which shows one unit core. It is a fragmentary sectional view of a stator. It is a top view which shows a clearance gap. It is an expanded view which shows the internal peripheral surface of a several unit core. It is process drawing which shows the manufacturing method of 1st Embodiment. It is a perspective view which shows the positioning process of an outer surface. It is a top view which shows the crevice of the core concerning a 2nd embodiment. It is an expanded view which shows the internal peripheral surface of the several unit core which concerns on 3rd Embodiment. It is a perspective view which shows the cyclic | annular arrangement | positioning process which concerns on 4th Embodiment. It is an expanded view which shows the outer peripheral surface of the stator which concerns on 5th Embodiment. It is a perspective view of the stator which concerns on 6th Embodiment. It is a top view of a stator. It is a side view of a stator. It is a bottom view of a stator. It is a disassembled perspective view of a stator. It is a bottom perspective view of the stator excluding the mounting portion. It is a fragmentary sectional view of a stator. It is a fragmentary sectional view of a stator. It is a fragmentary sectional view of a stator. It is process drawing which shows the manufacturing method of 6th Embodiment. It is a fragmentary sectional view of the stator concerning a 7th 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.

1st Embodiment In FIG. 1, the rotary electric machine 10 for internal combustion engines (henceforth the rotary electric 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 single-phase or multi-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 electric circuit 11 has an electric load including a battery mounted on the vehicle. The electric circuit 11 provides a rectifier circuit that rectifies the output AC power and supplies the electric load to the electric load when the rotating electrical machine 10 functions as a generator. 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 rotating electrical machine 10 is attached to an internal combustion engine 12 that is an attachment target. 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 term “circumferential direction” refers to a circumferential 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 entire rotor 21 is cup-shaped. The rotor 21 is connected to the end of the rotating shaft 14. The rotor 21 is connected to the rotating shaft 14. The rotor 21 rotates together with the rotating shaft 14. The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 provides an outer 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 armature. The stator 31 is an outer salient pole type stator. The stator 31 is fixed to the body 13, that is, the internal combustion engine 12 by bolts 16. The stator 31 is an annular member. The stator 31 is disposed so as to face the rotor 21.

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

The stator core 32 has a magnetic pole part 34 and an attachment part 35. The magnetic pole portion 34 occupies a radially outer portion of the stator core 32. The magnetic pole portion 34 is a magnetic path member that provides a magnetic path for passing a magnetic flux for the rotating electrical machine 10 to function. The magnetic pole portion 34 is also called an outer core that occupies the radially outer portion of the stator core 32. The magnetic pole portion 34 includes a plurality of teeth portions around which the stator coil 33 is wound, and an inner yoke portion that magnetically connects the plurality of teeth portions. The magnetic pole part 34 is provided by a laminated body of magnetic metals such as electromagnetic steel plates.

The attachment part 35 is a member for fixing the magnetic pole part 34 to the body 13. The attachment part 35 is cylindrical. The attachment portion 35 is a separate component from the magnetic pole portion 34. The mounting portion 35 is disposed on the inner side in the radial direction of the magnetic pole portion 34, that is, the yoke 34b. The attachment portion 35 has a core connection mechanism for being connected to the magnetic pole portion 34 and a fixing mechanism for being fixed to the body 13. This fixing mechanism includes a through hole provided in the center of the attachment portion 35. The fixing mechanism has a protrusion provided on the body 13. The fixing of the attachment portion 35 to the body 13 is provided by fitting the through hole with the protrusion. The fixing mechanism is also called in-row connection. The attachment portion 35 is a member for fixing the magnetic pole portion 34 to the body 13. The attachment portion 35 is also called an inner core that occupies the radially inner portion of the stator core 32. The attachment portion 35 is made of a massive metal.

The fixing mechanism positions the attachment portion 35 in the radial direction by a protrusion provided on the body 13. The fixing mechanism positions the attachment portion 35 in the axial direction by a seat portion provided on the body 13. Thus, the mounting seat provided on the body 13 positions the mounting portion 35, which is a half of the fixing mechanism, in the radial direction and the axial direction. The body 13 is fixed coaxially with the rotating shaft 14. The rotation shaft 14 and the rotor 21 are arranged coaxially with respect to the rotation shaft 14. With the rotation shaft 14 as a reference, the outer diameters of the rotation shaft 14, the body 13, the attachment portion 35, and the magnetic pole portion 34 are arranged coaxially. The body 13 has a main body and a cover that is in-row connected to the main body. Therefore, the entire body 13 is positioned with respect to the rotating shaft 14. As a result, the rotor 21 and the stator 31 are arranged coaxially around the rotation shaft 14.

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 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.

2, the stator 31 includes a coil assembly 31a including a stator coil 33, a magnetic pole portion 34, and an insulator 36. The coil assembly 31a and the attachment portion 35 are formed so that the attachment portion 35 can be attached to the coil assembly 31a after the assembly process of assembling the coil assembly 31a.

The magnetic pole part 34 has a plurality of teeth 34a. The teeth 34a are also called salient poles or magnetic poles. The plurality of teeth 34a extend radially. One tooth 34 a has one outer magnetic pole surface facing the rotor 21.

The magnetic pole part 34 has a cylindrical yoke 34b. The yoke 34b provides a magnetic flux path between the plurality of teeth 34a. A plurality of teeth 34a are provided on the radially outer side of the yoke 34b. The plurality of teeth 34a extends radially outward from the yoke 34b. The yoke 34 b has an inner diameter that can receive the attachment portion 35. The yoke 34b is an aggregate of a plurality of partial yokes 34c. One partial yoke 34c is a partial cylindrical member. The partial yokes 34c are arranged in the circumferential direction and are connected to each other to provide one yoke 34b. As shown in the figure, the partial yoke 34c has two types of shapes.

The magnetic pole part 34 has a plurality of unit cores 37. The plurality of unit cores 37 may include several types of unit cores having slightly different shapes. In the illustrated example, two types of shapes of the partial yoke 34 c characterize the type of the unit core 37. The plurality of unit cores 37 are formed so as to form one magnetic pole portion 34 by being connected to each other. The shapes of the plurality of unit cores 37 are planned and set so as to form one magnetic pole portion 34. One unit core 37 has one tooth 34a and a partial yoke 34c.

As shown in FIG. 3, one unit core 37 has a tooth 34a and a partial yoke 34c. The unit core 37 is a laminate of magnetic metals such as electromagnetic steel plates. The teeth 34 a provide the outer surface 34 d of the stator core 32. A plurality of outer surfaces 34d are provided by the plurality of teeth 34a. The partial yoke 34 c provides the inner side surface 34 e of the stator core 32. Since the yoke 34b is provided by an assembly of the plurality of partial yokes 34c, the inner side surface 34e is a cylindrical inner surface.

Teeth 34a has a width WTH in the circumferential direction. The yoke 34b has a width WYK in the radial direction. The width WTH is larger than the width WYK (WTH> WYK). The relatively small width WYK contributes to the suppression of the usage amount of expensive electrical steel sheets. The attachment part 35 may also function as a magnetic flux path.

Referring back to FIG. 2, the stator coil 33 is attached to a plurality of teeth 34a. The stator coil 33 has a plurality of unit coils 33a. One unit coil 33a is attached to one tooth 34a. One unit coil 33a is wound on one tooth 34a. Each of the plurality of unit coils 33a has an extended portion of a coil wire extending from the unit coil 33a.

The stator coil 33 has a connecting member 33b. The connection member 33b electrically connects the plurality of unit coils 33a. For example, the connection member 33b connects the plurality of unit coils 33a so as to form a three-phase star circuit or a three-phase delta circuit.

A part or all of the connecting member 33 b can be provided by a coil wire forming the stator coil 33. The connection member 33b may be provided by a conductive member separate from the coil wire, for example, a bus bar. The connecting member 33b may have a plurality of joints such as soldering or welding. When the connection member 33b is provided by a coil wire, some or all of the plurality of unit coils 33a may be connected by a coil wire that passes through the connection member 33b. The connection member 33 b includes an external connection lead wire for the stator coil 33.

The mounting portion 35 is exclusively planned and designed as a member for fixing the magnetic pole portion 34. The attachment portion 35 is made of, for example, a metal such as aluminum or iron, or a resin. The material of the attachment portion 35 may be selected from materials that can contribute to weight reduction of the stator 31. The attachment part 35 has a cylindrical main body 35a. The main body 35a is inserted and disposed inside the yoke 34b. The main body 35a has an outer surface 35b.

The mounting portion 35 has an outer flange 35c that protrudes radially outward from one axial end of the main body 35a. The outer flange 35c is formed and positioned so as to overlap the yoke 34b in the axial direction. The outer flange 35 c holds the magnetic pole part 34. The outer flange 35c can be used for pressing the magnetic pole portion 34 in the axial direction.

The attachment part 35 has a through hole 35d in the center. The attachment portion 35 has a plurality of recesses 35e for receiving a head portion of the bolt 16 and providing a seat portion for receiving the head portion of the bolt 16. The recess 35e is recessed in the axial direction from one end where the outer flange 35c is provided. Further, the attachment portion 35 has a through hole 35 f for arranging the bolt 16. When the bolt 16 is tightened, the attachment portion 35 is tightened toward the body 13. This tightening force acts to press the magnetic pole portion 34 toward the body 13 via the outer flange 35c.

An insulator 36 is disposed between the stator core 32 and the stator coil 33. The insulator 36 is made of an electrically insulating resin. The insulator 36 is also a bobbin for winding the stator coil 33. A part of the insulator 36 is positioned at the radially outer end and the radially inner end of the tooth 34a to provide a flange portion of the bobbin.

The coil assembly 31 a has a plurality of unit stators 38. The plurality of unit stators 38 are arranged in an annular shape and connected to another adjacent unit stator 38 to provide the coil assembly 31a. One unit stator 38 is connected to another unit stator 38 at least in the partial yoke 34c. One unit stator 38 may be connected to another unit stator 38 in the stator coil 33 and / or in the insulator 36. The plurality of unit stators 38 are magnetically coupled between the plurality of partial yokes 34c so that a magnetic flux required as a rotating electrical machine passes. The plurality of unit stators 38 are mechanically coupled between the plurality of partial yokes 34c so as not to be separated from each other. The plurality of unit stators 38 are electrically connected between the plurality of unit coils 33a.

One unit stator 38 has one unit coil 33 a, one unit core 37, and a part of the insulator 36 belonging to the unit core 37. One unit stator 38 has one tooth 34a and one partial yoke 34c. In one unit stator 38, a part of the insulator 36 is attached to one unit core 37 so as not to be separated. In one unit stator 38, one unit coil 33a is attached to one unit core 37 in a non-separable manner.

4, a plurality of metal plates 34 f forming the magnetic pole part 34 are illustrated. The plurality of metal plates 34f provide teeth 34a. Therefore, the plurality of metal plates 34f provide an outer side surface 34d and an inner side surface 34e. The magnetic pole part 34 has an end plate 34g. The end plate 34g is provided at the end of the yoke 34b. The end plate 34g is joined to the metal plate 34f. In this embodiment, the attachment portion 35 presses the yoke 34b in the axial direction by the outer flange 35c. In this embodiment, the attachment portion 35 is a part belonging to the rotating electrical machine 10 for the internal combustion engine, and is used in the manufacturing method thereof. The attachment portion 35 sandwiches the yoke 34b in the axial direction between the end plate 34g and the outer flange 35c. The end plate 34g and the outer flange 35c can be called two plates that sandwich the yoke 34b. In this case, the attachment portion 35 is a part belonging to the stator 31 and is used in the manufacturing method thereof. The end plate 34g may be coupled to the attachment portion 35. In this case, the end plate 34g and the outer flange 35c can be called not only the yoke 34b but also two plates that are fixedly sandwiched.

4 and 5, a gap G32 is provided between the main body 35a of the attachment portion 35 and the yoke 34b of the magnetic pole portion 34. The gap G32 is formed between the inner side surface 34e and the outer side surface 35b. The yoke 34b and the mounting portion 35 form a gap G32 between the yoke 34b and the mounting portion 35 on the entire circumference in the circumferential direction. The main body 35a defines an outer diameter D35b by the outer side surface 35b. An inner diameter D34e of the inner side surface 34e is larger than an outer diameter D35b of the outer side surface 35b. The difference between the inner diameter D34e and the outer diameter D35b is set so that the gap G32 is formed even if possible thermal expansion and contraction of the magnetic pole part 34 and the attachment part 35 occur.

The gap G32 allows adjustment of the radial position of the plurality of unit stators 38. The gap G32 allows the position adjustment in the radial direction of the plurality of unit stators 38 to align the plurality of outer surfaces 34d on the cylindrical surface. In other words, the gap G32 is set to a size that can absorb a dimensional error of the plurality of unit stators 38, particularly the plurality of unit cores 37. The gap G32 forms a loose fit between the coil assembly 31a and the attachment portion 35. The loose fitting avoids press-fitting between the coil assembly 31a and the mounting portion 35. The loose fit contributes to suppressing the deformation of the yoke 34b, that is, the deformation of the magnetic pole portion 34. In addition, the loose fit contributes to suppressing damage to the structure connecting the plurality of unit stators 38. For example, breakage of the fixing portion that fixes the plurality of unit stators 38 to each other is suppressed. The gap G32 is also called a radial gap.

Between the magnetic pole part 34 and the attachment part 35, that is, between the main body 35a and the yoke 34b, a core connection part for connecting and fixing the coil assembly 31a and the attachment part 35 is provided. The core connecting portion can be formed by an adhesive applied to the gap G32. The core connecting portion may be provided by a caulking connecting portion or a bolt connecting portion provided partially between the magnetic pole portion 34 and the attachment portion 35. The core connecting portion connects the magnetic pole portion 34 and the mounting portion 35 in the axial direction and the circumferential direction. The core connecting part is not shown in the drawing.

Referring back to FIG. 2, a connecting portion 39 is provided between two partial yokes 34c adjacent in the circumferential direction. The connecting portion 39 connects two partial yokes 34c adjacent in the circumferential direction to each other. The connecting portion 39 is a mechanical connecting portion that connects the plurality of partial yokes 34c as a series of yokes 34b. The connecting portion 39 is also a magnetic connecting portion that provides a low magnetic resistance required as a rotating electric machine.

FIG. 6 shows the inner surface of the magnetic pole part 34. A plurality of connecting portions 39 are provided to connect the plurality of partial yokes 34c. One partial yoke 34c has connecting portions 39 on both sides in the circumferential direction. One connecting portion 39 connects two partial yokes 34c adjacent in the circumferential direction. All partial yokes 34c have connecting portions 39 on both sides. As a result, the plurality of partial yokes 34 c arranged along the circumferential direction are coupled to each other in a ring shape that can be mechanically called a ring in the plurality of coupling portions 39. The plurality of partial yokes 34 c arranged along the circumferential direction provide magnetically tight coupling at the plurality of connecting portions 39.

The connecting part 39 has a meshing part 39a. The meshing portion 39a meshes two partial yokes 34c adjacent in the circumferential direction with each other. The meshing part 39a is provided by an uneven end. The meshing part 39a can be called an uneven part, a tooth part, or a rectangular wave end part. The meshing part 39a is provided at the circumferential end of the partial yoke 34c, and has a plurality of convex parts protruding in the circumferential direction and a plurality of concave parts arranged adjacent to the convex parts.

One partial yoke 34c has an uneven portion for the engaging portion 39a at both ends in the circumferential direction. These end portions are provided by a convex portion provided by several metal plates 34f and a concave portion provided by several other metal plates 34f.

The end portion has a first end face 39b that extends along the axial direction and faces in the circumferential direction or the tangential direction. The end surfaces of the plurality of metal plates 34f are exposed at the first end surface 39b. The first end surface 39b corresponds to the top surface and the bottom surface of the uneven portion. The end portion has a second end surface 39c that extends in the circumferential direction and faces the axial direction. The second end surface 39c corresponds to the side surface of the uneven portion. The second end surface 39c is provided by a wide main surface of the metal plate 34f.

The plurality of first end faces 39b and the plurality of second end faces 39c are alternately arranged to form an uneven portion. The uneven portion provided in one partial yoke 34c is formed so as to mesh with another uneven portion provided in another adjacent partial yoke 34c. The uneven portion and the other uneven portion are meshed along the circumferential direction. Engagement of the two concavo-convex portions allows the two partial yokes 34c to approach and separate while maintaining the meshed state along the circumferential direction. Engagement of the two uneven portions allows the two partial yokes 34c, that is, the two unit cores 37, to move relatively in the radial direction.

The two first end faces 39b belonging to the two adjacent partial yokes 34c face each other in the circumferential direction. These two first end faces 39b form a gap G39a. The gap G39a makes it possible to adjust the positions of the plurality of unit stators 38 at least in the radial direction. The gap G39a makes it possible to adjust the positions of the plurality of unit stators 38 in the circumferential direction. The gap G39a allows position adjustment in the radial direction of the plurality of unit stators 38 so that the plurality of outer surfaces 34d are aligned on the cylindrical surface. In other words, the gap G39a is set to a size capable of absorbing a dimensional error of the plurality of unit stators 38, particularly the plurality of unit cores 37. The gap G39a is also called a circumferential gap.

The two second end faces 39c belonging to the two adjacent partial yokes 34c face each other in the axial direction. These two second end surfaces 39c are in contact with each other with respect to the axial direction, or are opposed to each other through a minute gap. Many magnetic fluxes pass through these two second end faces 39c.

The axial arrangement of the irregularities requires at least one complete convex portion or one complete concave portion to be disposed on one end face of one unit stator 38. In other words, it is necessary to completely fit the uneven portion between the adjacent unit stators 38. L-shaped combinations are not desirable. That is, the axial thickness of the convex portion or the concave portion is 1/3 or less of the axial thickness of the unit stator 38.

On the other hand, considering the output characteristics of the product, for example, the torque generated by the motor and the electromotive force of the generator, it is preferable to alternately combine the metal plates 34f one by one. However, the axial thickness of the metal plate 34f is usually 1 mm or less, and it is difficult to press-fit at many points in processing. It is preferable that at least two or more metal plates 34f form a concave portion or a convex portion and mesh with each other.

The yoke 34b is an assembly of two types of partial yokes 34c. The first type partial yoke 34c has a convex portion occupying an angle RD1 and a concave portion occupying an angle RD2 on a series of circumferences. The first type partial yoke 34c has convex portions at both ends in the axial direction. The second type partial yoke 34c has a convex portion with an angle RD1 and a concave portion with an angle RD2 in the circumferential direction. The second type partial yoke 34c has concave portions at both ends in the axial direction.

FIG. 3 shows the angles RD1 and RD2 of the first type partial yoke 34c. The angle RD1 and the angle RD2 can be understood by replacing the length in the circumferential direction.

Referring back to FIG. 6, the angles RD1 and RD2 are set so as to provide the gap G39a. That is, the angle RD1 and the angle RD2 are set so that the sum of the angle RD1, the angle RD2, and the gap G39a is in the circumferential range (360 °). In the case of the stator 31 having 2n poles (n: natural number), n × RD1 + n × RD2 + 2n × G39a = 360. In other words, the plurality of partial yokes 34c are formed such that the total angle range (n × RD1 + n × RD2) occupied by the plurality of partial yokes 34c in the circumferential direction is smaller than the circumferential range (360 °). The size of the gap G39a is set such that the gap G39a is formed on the inner surface of the yoke 34b under a machining accuracy that can be economically employed for machining the partial yoke 34c. The gap G39a is usually 1 mm or less, and preferably 0.5 mm or less in terms of product characteristics. However, the gap G39a is larger than 0 (G39a> 0).

Thus, the meshing portion 39a is formed so that one partial yoke 34c and another partial yoke 34c overlap with each other in the axial direction and face each other with the gap G39a in the circumferential direction. In other words, the plurality of unit cores 37 have gaps in the circumferential direction such that one partial yoke 34c and the other partial yoke 34c overlap in the axial direction at the circumferential ends of the multiple partial yokes 34c. It is formed and arranged so as to form G39a. Moreover, the one partial yoke 34c and the other partial yoke 34c are placed in a close positional relationship for allowing the magnetic flux to pass in the overlapping portion in the axial direction.

The connecting part 39 has a fixing part 39d. The fixing portion 39d fixes the plurality of unit cores 37 to each other. The fixed portion 39d joins the plurality of unit cores 37 to each other. The fixing portion 39d can be provided by a welded portion that welds the plurality of unit cores 37. The fixing portion 39d is a welding mark formed so as to pass over the two partial yokes 34c in the meshing portion 39a. The fixed portion 39d is a laser welded portion that passes over the two partial yokes 34c. The laser welded portion extends straight above the meshing portion 39a. The laser welded portion extends along the stacking direction of the plurality of metal plates 34f. The laser welded portion joins a plurality of metal plates 34f.

The fixing portion 39d may be provided by an adhesive that fixes the plurality of unit cores 37. For example, the plurality of unit cores 37 can be fixed by an adhesive applied to the stator core 32. The adhesive may be provided by a coating layer applied to the surfaces of the plurality of unit cores 37 or an adhesive layer impregnated between the plurality of metal plates 34f.

FIG. 7 shows a manufacturing method 150 of the rotating electrical machine 10. Of the manufacturing method of the rotating electrical machine 10, the manufacturing method of the stator 31 is mainly shown. Step 151 is a unit core assembly stage for assembling a plurality of unit cores 37. In step 151, a plurality of metal plates 34f are manufactured by press working, and a plurality of unit cores 37 are assembled by stacking the plurality of metal plates 34f. The plurality of unit cores 37 are separated from each other and are independent.

In step 152, the insulator 36 and the unit coil 33a are attached to the unit core 37. As a result, the unit stator 38 is assembled. Step 152 is a unit stator assembly stage in which the plurality of unit stators 38 are assembled. The plurality of unit stators 38 are independent from each other. The plurality of unit stators 38 may be connected like a chain so as to form one or a plurality of groups.

In step 152, the unit coil 33a is attached to the independent unit core 37. Therefore, the winding operation is easier than in the case of winding on the outer salient pole type stator core. For this reason, the strand which is comparatively difficult to wind can be wound. Alternatively, a wire having a large number of turns can be wound. For example, a thick aluminum wire can be wound with a high space factor. Step 152 provides a step of assembling a plurality of unit stators 38.

Steps 153-157 are steps for assembling the coil assembly 31a. At this stage, the plurality of unit stators 38 are annularly combined. After the plurality of unit stators 38 are combined in an annular shape, the position is adjusted with respect to the radial direction and the circumferential direction so that the outer surface 34d is positioned along the circumferential surface. The plurality of unit stators 38 are fixed to each other after the position adjustment.

In step 153, the plurality of unit stators 38 are arranged in an annular shape. In step 153, the plurality of unit stators 38 are connected by the meshing portion 39a. The plurality of unit stators 38 are assembled so that the plurality of partial yokes 34c are connected at the meshing portion 39a. In step 153, the plurality of meshing portions 39a are brought into a meshed state. The plurality of unit stators 38 are placed so that their positions can be adjusted in the radial direction and the circumferential direction.

The plurality of unit stators 38 are arranged so that the plurality of partial yokes 34c are positioned radially inside and the plurality of magnetic pole surfaces, that is, the plurality of outer surfaces 34d, are positioned radially outside. The plurality of partial yokes 34c are disposed adjacent to each other on the radially inner side, and meshed with each other at the meshing portion 39a. On the radially outer side, the plurality of outer surfaces 34d are arranged away from each other so as to form a magnetic interpole gap therebetween. Step 153 provides a step of arranging the plurality of unit stators 38 along the circumferential direction and further meshing the two partial yokes 34c adjacent in the circumferential direction with each other at the meshing portion 39a.

In step 154, the positions of the plurality of unit stators 38 are adjusted so that the plurality of outer surfaces 34d are positioned on the circumferential surface. Here, the meshing state in the meshing part 39a is shifted. For example, one unit stator 38 is shifted toward the radially outer side. At this time, the meshing portions 39a on both sides allow movement. Step 154 is a step of positioning the plurality of unit stators 38 at predetermined positions. Step 154 is also a step of shifting the meshing portion 39a. Step 154 is also a step of changing the gap G39a. The plurality of unit stators 38 are positioned at predetermined positions by changing the gap G39a. The plurality of unit stators 38 are still independent from each other in step 154. In step 154, a jig for positioning the plurality of outer surfaces 34d at predetermined positions can be used.

As shown in FIG. 8, the jig 41 is a cylindrical member that can accommodate the coil assembly 31a. The jig 41 has an inner peripheral surface 41a that defines a circumferential surface for defining the positions of the plurality of outer surfaces 34d. Step 154 includes a step 154a of placing the coil assembly 31a in the jig 41 and a step 154b of bringing the plurality of outer surfaces 34d into contact with the inner peripheral surface 41a. By step 154, the plurality of outer surfaces 34d are aligned on the circumferential surface.

Step 154 is a stage in which the outer surfaces 34d of the plurality of teeth 34a are arranged and positioned on the circumferential surface. Step 154 is also a step of forming a gap G39a that separates two adjacent partial yokes 34c in the circumferential direction in the meshing portion 39a. Step 154 is also a step of positioning the outer surface 34d while forming the gap G39a. Step 154 includes a step of mounting the plurality of unit stators 38 on the jig 41 that defines the circumferential surface, and a step of positioning the plurality of outer surfaces 34d on the circumferential surface while being mounted on the jig 41. And provide.

Returning to FIG. 7, in step 155, the plurality of unit stators 38 are fixed to each other. In this embodiment, the plurality of unit stators 38 are fixed by a fixing portion 39d. Step 155 is a step of forming the fixing portion 39d. Step 155 is a step of finally fixing the plurality of unit stators 38. The plurality of unit stators 38 become a series of integral parts at step 155. Step 155 is also a stage for preventing the shift at the meshing portion 39a. Step 155 provides a step of fixing the plurality of partial yokes 34c to each other with the plurality of outer surfaces 34d positioned. Step 155 provides a step of fixing the plurality of partial yokes 34 c while being mounted on the jig 41.

In step 156, the jig 41 is removed. In step 156, the attachment portion 35 is mounted inside the coil assembly 31a. The mounting portion 35 is mounted after the plurality of unit stators 38 are connected to each other and fixed. The attachment portion 35 is inserted into a cavity defined by the inner side surface 34e. Since the outer diameter D35b is smaller than the inner diameter D34e, the attachment portion 35 is loosely attached without being strongly pressed against the inner side surface 34e. Step 156 provides a step of mounting the mounting portion 35 having an outer diameter D35b smaller than the inner diameter D34e of the yoke 34b on the radially inner side of the yoke 34b fixed by the previous step. The attachment portion 35 is attached to the coil assembly 31a so that the axis of a virtual circle formed by the plurality of outer surfaces 34d and the axis of the attachment portion 35 are coaxial. Since the outer diameter D35b of the mounting portion 35 is smaller than the inner diameter D34e of the yoke 34b, the plurality of outer side surfaces 34d and the mounting portion 35 can be adjusted coaxially. Step 156 suppresses the stress applied to the coil assembly 31 a, that is, the magnetic pole part 34. As a result, damage to the fixing portion 39d is suppressed. Further, the deviation of the outer surface 34d is suppressed.

Step 156 provides a step of fixing the coil assembly 31a and the mounting portion 35. At the same time, the step 156 is also an adjustment stage for achieving a coaxial relationship between the circumference of the coil assembly 31a, i.e., the circumference defined by the plurality of outer surfaces 34d, and the fixing mechanism provided by the mounting portion 35, i.e. is there. The outer diameter D35b and the inner diameter D34e are set so that this adjustment can be achieved. The outer diameter D35b and the inner diameter D34e are set so that inevitable manufacturing errors can be absorbed by the gap G32.

In step 157, the connecting member 33b is formed. Thereby, the stator 31 is completed. In step 158, the rotor 21 and the stator 31 are mounted on the internal combustion engine 12. Step 158 provides a step of pressing the yoke 34 b toward the internal combustion engine 12 in the axial direction by the outer flange 35 c provided in the mounting portion 35. Thereby, the rotary electric machine 10 is completed.

According to the embodiment described above, the stator 31 as an assembly of a plurality of unit stators 38 is provided. Therefore, the winding work can be facilitated. From another point of view, a gap G32 is provided between the magnetic pole part 34 and the attachment part 35. Thereby, the deformation | transformation and damage of the magnetic pole part 34 are suppressed. For example, the stress applied to the fixing portion 39d that fixes the plurality of unit cores 37 is suppressed. As a result, high roundness is obtained on the outer peripheral surface defined by the plurality of outer surfaces 34 d provided by the magnetic pole portion 34. From another viewpoint, a gap G39a is provided between the plurality of unit cores 37. The plurality of unit cores 37 are positioned at predetermined positions without depending on the dimensional accuracy of the meshing portion 39a in the partial yoke 34c. Therefore, high roundness of the outer peripheral surface can be obtained. Such a structure is suitable for the outer rotor type rotating electrical machine 10 in which the yoke 34b is disposed on the radially inner side.

Second Embodiment This embodiment is a modified example based on the preceding embodiment. In the above embodiment, as shown in FIG. 5, the inner side surface 34e and the outer side surface 35b are arranged concentrically. Instead, the inner side surface 34e and the outer side surface 35b may be arranged eccentrically.

As illustrated in FIG. 9, the inner side surface 34e and the outer side surface 35b may be in contact with each other at the contact portion CP. In other words, the yoke 34b and the attachment portion 35 are in contact with each other at one contact portion CP in the circumferential direction. A gap G232 is formed between the inner side surface 34e and the outer side surface 35b. The yoke 34b and the attachment part 35 form a gap G232 between the yoke 34b and the attachment part 35 at the remaining part other than the contact part CP. Even in this configuration, since the outer diameter D35b is smaller than the inner diameter D34e, the stress applied to the magnetic pole portion 34 is suppressed.

Third Embodiment This embodiment is a modification in which the preceding embodiment is a basic form. In the above-described embodiment, the symmetrical engagement portion 39a illustrated in FIG. 6 is employed. As a result, the plurality of partial yokes 34c have two types of shapes. Instead of this, the shape of the meshing portion may be set so that the plurality of partial yokes 34c have the same shape.

As shown in FIG. 10, one partial yoke 34c has a meshing portion 339 that is convex at one end and concave at the other end. According to this embodiment, the magnetic pole part 34 can be formed by one type of unit core 37. A stator having 2n + 1 poles (n: natural number) is applicable according to this embodiment.

Fourth Embodiment This embodiment is a modified example based on the preceding embodiment. In the above embodiment, the plurality of unit stators 38 are independent from each other. Instead, the plurality of unit stators 38 may be connected like a chain at least in the manufacturing process.

FIG. 11 shows a plurality of unit stators 38 in step 153. A hinge-like connecting portion 445 provided by the insulator 36 is provided between the plurality of unit stators 38. The connecting portion 445 connects two adjacent unit stators 38. All of the plurality of unit stators 38 for forming one coil assembly 31 a are connected as a series of members by a plurality of connecting portions 445.

The connecting portion 445 can include a connecting member that connects the plurality of unit coils 33a. The connecting member is also called a crossover. The connecting member is provided by a coil wire that forms the stator coil 33. The connecting member gives a chain-like flexibility to a connecting body in which a plurality of unit stators 38 are connected by its own plastic deformation. The connecting member is located on the radially outer side of the stator 31. The radially outer connecting member enables winding work from the radially inner side of the stator 31. Further, the radially outer connection member suppresses the electric wire from being caught in the meshing portion 39a.

The connecting portion 445 can be provided by a deformable resin piece or a bearing mechanism provided by a shaft and a bearing. The connecting portion 445 is provided on the radially outer side of the coil assembly 31a. The connecting portion 445 is provided at both ends in the axial direction of the coil assembly 31a. The connecting portion 445 is disposed between the two outer surfaces 34d as outer magnetic pole surfaces. The connecting portion 445 is disposed in the inter-electrode gap G445 to be formed between the two outer surfaces 34d. The connecting portion 445 also contributes to form a gap G445 having a predetermined dimension. Therefore, the connecting portion 445 is also a spacer for defining the inter-electrode gap G445.

The connecting portion 445 connects the plurality of unit stators 38 so as to form a gap G34c. The gap G34c is formed between the two adjacent partial yokes 34c during step 152. The gap G34c allows two adjacent partial yokes 34c to be completely separated without any contact. The gap G34c is used for mounting the unit coil 33a. The outer surface 34 d connected by the connecting portion 445, that is, the outer end is called a connecting end of the unit stator 38 or the unit core 37. On the other hand, the plurality of unit cores 37 or the plurality of unit stators 38 can rotate about the connecting portion 445 as a rotation axis. Therefore, the plurality of partial yokes 34 c are referred to as the free ends of the unit core 37 or the unit stator 38. The gap G34c is also called a free end gap.

In step 152, the plurality of unit stators 38 are manufactured to include a plurality of connecting portions 445. In other words, step 152 provides a step of connecting the plurality of unit stators 38 by the connecting portion 445.

In step 153, the plurality of unit stators 38 are wound like a chain while being connected by the connecting portion 445, and assembled in an annular shape. In the winding process, the plurality of partial yokes 34c are brought close to each other so as to close the gap G34c. In this process, the meshing portion 39a is meshed. Therefore, a step of meshing the meshing portion 39a while winding the plurality of unit stators 38 is provided. The gap G34c is closed in step 153. The plurality of unit stators 38 are meshed on the inside while being connected on the outside. Therefore, the connecting portion 445 does not become an obstacle to the meshing at the meshing portion 39a. For this reason, the connection part 445 is given a shape suitable for connection. The meshing part 39a is given a shape suitable for meshing. Further, the connecting portion 445 forms an inter-electrode gap G445. Therefore, the step of forming the magnetic inter-pole gap G445 between the two outer surfaces 34d by providing the connecting portion 445 between the two outer surfaces 34d adjacent in the circumferential direction is provided.

In step 154, the connecting portion 445 enables the plurality of outer surfaces 34d to be disposed on the circumferential surface. When the connecting portion 445 is provided by a resin piece, the connecting portion 445 can be formed to be slightly deformable in the circumferential direction. For example, the resin piece is formed to be elastically deformable or plastically deformable. Large play is provided when the articulation 445 is provided by a shaft and a bearing hole. For example, a large bearing hole that allows play of the shaft along the circumferential direction is provided.

This embodiment also provides a rotating electrical machine that can suppress the stress applied to the stator core while arranging the outer surface 34d with high roundness. In addition, a rotating electrical machine with excellent productivity is provided. A manufacturing method for manufacturing the stator 31 from a plurality of unit stators 38 connected in a chain shape is also provided.

Fifth Embodiment This embodiment is a modified example based on the preceding embodiment. In the above embodiment, the connecting portion 445 is provided. The connecting portion 445 may include an electric wire that connects the plurality of unit coils 33a.

In FIG. 12, the outer peripheral surface of the stator 31 of this embodiment is shown expanded. A plurality of teeth 34a and a plurality of outer peripheral surfaces 34d are arranged. A part of the insulator 36 is visible above and below each tooth 34a. A sensor unit 547 including a plurality of magnetic sensors is disposed between the plurality of teeth 34a. The sensor unit 547 includes a magnetic sensor for detecting the reference position and a plurality of magnetic sensors for detecting the rotational position. Each magnetic sensor is provided between adjacent teeth 34a. Each magnetic sensor detects the magnetic flux of the rotor 21.

The insulator 36 is provided with a connecting portion 545. The connecting portion 545 is provided in a part of the coil assembly 31a in the axial direction. The connecting portion 545 is disposed so as to avoid buffering with the sensor unit 547. The connecting portion 545 is shifted to one side in the axial direction of the coil assembly 31a where the sensor unit 547 is not arranged, and is arranged only on one side. The connecting portion 545 is disposed only on the lower side of the coil assembly 31a in the drawing.

The unit coil 33a is located behind the insulator 36. Further, a connection member 533b is disposed behind the connecting portion 545. Connection member 533b includes a coil wire and its connection material. The connection member 533b is located on the radially outer side of the stator 31. The connecting member 533b enables winding work from the radially inner side of the stator 31. Further, the connecting member 533b suppresses the electric wire from being caught in the meshing portion 39a. The connection member 533b is disposed only on the lower side in the axial direction of the coil assembly 31a. Therefore, buffering with the sensor unit 547 arranged on the opposite side is avoided.

According to this embodiment, a rotating electrical machine that can be employed in a rotating electrical machine having the sensor unit 547, a stator thereof, and a method for manufacturing the same are provided. The description in Japanese Patent Application Laid-Open No. 2016-1111917 or Japanese Patent Application Laid-Open No. 2016-77081 can be referred to as an explanation of the sensor unit, and these descriptions are incorporated by reference as disclosure of this specification regarding the sensor unit.

Sixth Embodiment This embodiment is a modification in which the preceding embodiment is a basic form. In the above embodiment, the massive attachment portion 35 is used. Instead, in this embodiment, the attachment portion 35 is provided by the plate- like plates 635m and 635n. Further, the plurality of unit cores 37 have inner protrusions 632a, 632b, 632c sandwiched between plates 635m, 635n.

In FIG. 13, the stator 31 has a plurality of unit stators 38. A broken line shows the unit coil 33a which belongs to one unit stator 38, and the partial yoke 34c. The plurality of unit stators 38 are connected and further fixed at the partial yoke 34c as in the above-described embodiment.

The mounting portion 35 includes a first plate 635m and a second plate 635n. The first plate 635m is an annular plate. The second plate 635n is an annular plate and has a cylindrical portion 635p inside. The second plate 635n is disposed on the pedestal side to which the stator 31 is fixed. The cylindrical portion 635p provides a cylindrical surface for in-lobe coupling with the pedestal.

Both plates 635m, 635n have rivet holes 635r and bolt holes 635s. The rivet hole 635r is a through hole with a seat for placing a rivet 635t for connecting both plates 635m and 635n. The bolt holes 635 s are through holes for arranging the bolts 16.

The stator core 32 is formed by arranging a plurality of unit cores 37 in an annular shape. The inner surface of the stator core 32 has a plurality of inner protrusions 632a, 632b, and 632c.

The thickness of the plurality of inner protrusions 632a, 632b, 632c is smaller than the thickness of the stator core 32. The plurality of inner protrusions 632a, 632b, 632c protrude radially inward from only a part including the thickness direction of the stator core 32, that is, the center in the axial direction. Therefore, the stator core 32 does not have the inner protrusions 632a, 632b, and 632c at both ends in the axial direction. The stator core 32 includes an inner circle portion having no inner protrusions 632a, 632b, and 632c, an inner uneven portion having inner protrusion portions 632a, 632b, and 632c, and an inner circle portion having no inner protrusions 632a, 632b, and 632c. It is a laminated body of three groups. Each group is a laminated body of magnetic metals.

One unit core 37 has one inner protrusion. One inner protrusion is any one of the plurality of inner protrusions 632a, 632b, and 632c. For example, the stator core 32 has 18 unit cores 37. The three unit cores 37 have first inner protrusions 632a. The three unit cores 37 have second inner protrusions 632b. The remaining unit cores 37 (12 unit cores 37) have a third inner protrusion 632c. The plurality of unit cores 37 are arranged such that a plurality of inner protrusions 632a, 632b, 632c are arranged in a predetermined order. For example, the three first inner protrusions 632a are arranged at equal intervals in the circumferential direction. The three second inner protrusions 632b are arranged at equal intervals in the circumferential direction. The twelve third inner protrusions 632c are disposed in the remaining part.

The plurality of inner protrusions 632a, 632b, 632c are in contact with both plates 635m, 635n in the axial direction. The plurality of inner protrusions 632a, 632b, 632c have three types of uses. The plurality of inner protrusions 632a, 632b, 632c have three types of shapes. The first inner protrusion 632a is an inner protrusion for making contact with both the plates 635m and 635n in the axial direction and receiving the bolt 16. The second inner protrusion 632b is an inner protrusion for making contact with both plates 635m and 635n in the axial direction and receiving the rivet 635t. The third inner protrusion 632c is an inner protrusion for making contact with both plates 635m and 635n in the axial direction.

As shown in FIGS. 14, 15, and 16, the plates 635m and 635n are fixed by a plurality of rivets 635t. The head of the rivet 635t is formed so as not to protrude from the plates 635m and 635n.

17, the positional relationship between the plurality of inner protrusions 632a, 632b, 632c and the plates 635m, 635n is illustrated. The three types of inner protrusions 632a, 632b, 632c have different shapes.

The first inner protrusion 632a has a bolt hole 632d positioned on the extension of the bolt hole 635s. The bolt hole 632d receives the bolt 16. The second inner protrusion 632b has a rivet hole 632e located on the extension of the rivet hole 635r. The rivet hole 632e receives the rivet 635t. The third inner protrusion 632c extends so as to contact the plates 635m and 635n in the axial direction.

These inner protrusions 632a, 632b, 632c provide a surface that contacts the plate 635m and a surface that contacts the plate 635n at both ends in the axial direction. The plurality of surfaces are aligned at the same position in the axial direction. In other words, these surfaces are provided by a common magnetic metal plate. The surface in contact with the plate 635m is directed to the rotor 21 with respect to the axial direction. The surface in contact with the plate 635n is directed to a member that indicates the stator 31 in the axial direction.

FIG. 18 is a perspective view seen from the back surface of the stator 31 excluding the plates 635m and 635n as the attachment portion 35. FIG. One inner protruding portion is provided inside one unit core 37. In other words, one unit stator 38 has one inner protrusion. As a result, each of the plurality of unit stators 38 comes into contact with the plates 635m and 635n to provide a reliable connection relationship.

FIG. 19 shows a radial cross section of the stator 31 at a portion where the inner protrusion 632a is provided. One inner projecting portion 632 a is a part of one unit core 37. A bolt 16 is disposed at this portion.

The plates 635m and 635n that provide the attachment portion 35 compress a part of the magnetic metal laminate belonging to one unit core 37 in the thickness direction, that is, in the axial direction. The plate 635n provides an axial reference plane AXR for fixing the stator 31. The inner surface of the cylindrical portion 635p provides a radial reference surface RDR for fixing the stator 31.

The outer diameters of the plates 635m and 635n are set so as to avoid the press fitting of the mounting portion 35 into the yoke and to provide a loose fit. A gap is formed between the radially outer surfaces of the plates 635m and 635n and the inner surface of the yoke. A gap is also formed between the outer surface of the cylindrical portion 635p and the inner surface of the inner protrusion 632a. The outer surface of the cylindrical portion 635p provides an outer diameter D35b. The inner protrusion 632 a is a part of the yoke 34. Therefore, the outer diameter D35b of the cylindrical portion 635p is smaller than the inner diameter D34e of the yoke 34.

FIG. 20 shows a radial cross section of the stator 31 at a portion where the inner protrusion 632b is provided. One inner protrusion 632 b is a part of one unit core 37. The rivet 635t fixes the plate 635m and the plate 635n with respect to the axial direction. As a result, the inner protrusions 632a, 632b, 632c are tightened between the plates 635m and 635n.

FIG. 21 shows a radial cross section of the stator 31 at a portion where the inner protrusion 632c is provided. One inner protrusion 632 c is a part of one unit core 37. The inner protrusion 632c protrudes radially inward from the partial yoke 34c so as to contact both the plate 635m and the plate 635n.

In FIG. 22, the manufacturing method 650 of this embodiment is illustrated. The manufacturing method 650 is based on the manufacturing method of the preceding embodiment, and some steps are the same.

In this embodiment, a connecting portion extending from the insulator 36 is used to connect the adjacent unit stators 38. The connecting part has a hinge shape. The connecting portion is formed by a front male hinge and a rear female hinge. One unit stator 38 has a front male hinge and a rear female hinge. The male hinge of one unit stator 38 is connected to the female hinge of another unit stator 38 located on the front side. The female hinge of one unit stator 38 is connected to the male hinge of another unit stator 38 located on the rear side. The hinges are connectable to each other and connect two adjacent unit stators 38 so as to be swingable.

Step 652a is a step of attaching the insulator 36 with the connecting portion to the plurality of unit cores 37. In this step, the plurality of unit cores 37 are independent from each other.

Step 652b is a step of connecting a plurality of unit cores 37 by connecting portions. A plurality of unit cores 37 necessary for one stator 31 have a plurality of types of inner protrusions 632a, 632b, and 632c. The plurality of unit cores 37 are connected by connecting portions such that a plurality of types of inner protrusions 632a, 632b, 632c are arranged in a predetermined order. By step 652b, the plurality of unit cores 37 are loosely connected as if a series of chains meander. The connecting portion facilitates handling of the plurality of unit cores 37 and the plurality of unit stators 38 over the period in which they exist.

Step 652c is a step of attaching the unit coil 33a to the plurality of unit cores 37 after being connected. Here, a unit coil 33 a is wound around the insulator 36. The winding is performed by arranging a plurality of unit cores 37 in a predetermined shape. The winding operation is sequentially performed on the plurality of unit cores 37. The plurality of unit coils 33a may be provided by strands that are independent of each other. The plurality of unit coils 33a belonging to one phase may be provided by a series of strands. In this embodiment, after the plurality of unit coils 33a are mounted, the process proceeds to step 153.

Step 652d is a step of removing the connecting portion. The removal of the connecting part can be realized by various methods such as excision of the connecting part, abrasion of the connecting part, and dissolution of the connecting part. The connecting portion is used to facilitate the handling of the plurality of unit cores 37 or the plurality of unit stators 38 in a predetermined period of the manufacturing method.

After the connection part has finished its purpose, the connection part may become an undesired protruding part or an obstacle to the air flow. Step 652d suppresses a problem caused by the connecting portion. The connecting portion is used to facilitate handling of the plurality of unit cores 37 or the plurality of unit stators 38 in the winding process. For this reason, the removal of the connecting portion is executed after step 153. Thus, step 652d provides a step of removing the connecting portion after the engaging portion is engaged. The connecting portion may be an obstacle in step 154 for positioning the outer surfaces of the plurality of unit stators 38. Thus, step 652d is executed before step 154. Note that the connecting portion may be removed after being maintained for another period.

Step 656 is a process of mounting the mounting portion 35 provided by the plates 653m and 653n. Step 656 is executed after all the unit stators 38 are connected. Here, the two plates 653m and 653n are arranged in contact with all the inner protrusions 632a, 632b, and 632c. Further, by deforming the head of the rivet 632t, all the inner protrusions 632a, 632b, 632c are sandwiched between the two plates 635m, 635n. Step 656 provides a step of placing a plurality of inner protrusions 632a, 632b, 632c, which are part of the yoke 34, between the two plates 635m, 635n and sandwiching them in the axial direction.

In this embodiment, the attachment portion 35 has two plates 635m and 635n as flange portions sandwiching the yoke 34 in the axial direction. The attachment portion 35 is provided by the plates 635m and 635n. For this reason, the lightweight attachment part 35 can be provided. Furthermore, when a cavity is left between the two plates 635m and 635n and the cavity is opened, it contributes to heat dissipation.

The yoke 34 protrudes inward in the radial direction from the partial yoke 34c and has a plurality of inner protrusions 632a, 632b, 632c sandwiched between two plates 635m, 635n. The plates 635m and 635n fasten the plurality of inner protrusions 632a, 632b, and 632c in the axial direction. Each of all the unit stators 38 has one inner protrusion 632a, 632b, 632c. For this reason, all the unit cores 37 and the unit stators 38 are securely fixed. The plurality of inner protrusions 632a, 632b, and 632c are limited to the minimum required size according to each application. For this reason, it contributes to suppressing the weight of the stator 31 and suppressing the amount of material used.

According to this embodiment, the connecting portion supports the handling of the plurality of unit cores 37 or the plurality of unit stators 38 in the manufacturing method. Moreover, the connecting portion is removed in the manufacturing method after the role is finished. For this reason, the disadvantage resulting from a connection part can be suppressed.

Seventh Embodiment This embodiment is a modified example based on the preceding embodiment. In the said embodiment, the thickness of the internal protrusion part 632a, 632b, 632c is smaller than the thickness of the teeth 34a. Instead, the plurality of inner protrusions may have the same thickness as the teeth 34a. According to this embodiment, the same effect as the preceding embodiment can be obtained.

FIG. 23 illustrates a thick inner protrusion 732a. The thickness of the inner protrusion 732a is thinner than the thickness of the thin inner protrusion 632a which is a corresponding element. The stator 31 also has a thick inner protrusion corresponding to the inner protrusion 632b and the inner protrusion 632c. The thickness of the inner protrusion 732a is the same as the thickness of the teeth 34a.

The plates 635m and 635n that provide the attachment portions compress all the magnetic metal laminates belonging to one unit core in the thickness direction, that is, in the axial direction. The plate 635m and the plate 635n are connected by a fixing member such as a rivet 635t. The thickness of the attachment provided by the plates 635m, 635n is greater than the thickness of the teeth 34a. In other words, the amount of protrusion from the axial reference surface AXR is large. For this reason, longer bolts 16 are used than in the preceding embodiment.

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.

The disclosure covers a rotating electric 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. The stator core 32 is not limited to a structure in which a plurality of teeth 34a are arranged at an equal pitch. The plurality of teeth 34a may be arranged at unequal pitches by adjusting the angles RD1 and RD2, for example, by including several types of unit cores 37 having different types of angles RD1 and RD2.

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 plate 635n has a cylindrical portion 635p for fitting with the body 13. However, the cylindrical portion 635p may be omitted when the plate 635n has a sufficient thickness for fitting and can provide a ground contact area with the pedestal at the inner end face of the plate 635n. Moreover, the cylindrical part 635p may be provided by the plate 635m.

10 rotating electrical machines, 11 electrical circuits, 12 internal combustion engines,
13 body, 14 rotating shaft, 15 wire harness,
16 bolts, 21 rotors, 22 rotor cores,
23 permanent magnets, 31 stators, 32 stator cores,
33 stator coil, 33a unit coil, 34 magnetic pole part,
34a teeth, 34b yoke, 34c partial yoke,
34d outer surface, 34e inner surface, 35 mounting part,
36 insulators, 37 unit core, 38 unit stator,
39, 339 connecting portion, 39a meshing portion, 39b first end surface,
39c second end face, 39d fixing part, 41 jig,
41a inner peripheral surface, D34e outer diameter, D35b inner diameter,
G32, G232 gap (radial gap),
G34c clearance (free end clearance), G39a clearance (circumferential clearance),
445, 545 articulated part, 632a, 632b, 632c internal protrusion,
635m, 635n plate, 635p cylindrical part,
635t rivets.

Claims (20)

1. A plurality of teeth (34a) projecting radially outward, and a magnetic pole portion (34) having a yoke (34b) connecting the plurality of teeth radially inward;
   A stator coil (33) mounted on the plurality of teeth;
   In the stator of the rotating electrical machine, which is a separate component from the magnetic pole part, and includes a mounting part (35) provided on the radially inner side of the yoke for mounting to a mounting target,
   A plurality of unit stators (38) arranged and connected along a circumferential direction to provide the magnetic pole part and the stator coil;
   The unit stator is
   One of the teeth (34a);
   A unit coil (33a) which is a part of the stator coil and attached to one of the teeth;
   A partial yoke (34c) which is a part of the yoke and is arranged and connected in the circumferential direction to form the yoke;
   The plurality of partial yokes have meshing portions (39a) that mesh the circumferentially adjacent partial yokes with each other,
   The plurality of partial yokes form a circumferential gap (G39a) that separates the adjacent partial yokes in the circumferential direction in the meshing portion,
   The mounting portion is a stator of a rotating electrical machine having an outer diameter (D35b) smaller than an inner diameter (D34e) of the yoke.
2. The stator of a rotating electrical machine according to claim 1, further comprising a fixing portion (39d) for fixing the partial yoke adjacent in the circumferential direction.
3. The rotation according to claim 1 or 2, wherein an inner diameter of the yoke and an outer diameter of the mounting portion are set so as to avoid press fitting of the mounting portion into the yoke and to provide a loose fit. Electric stator.
4. The meshing portion is provided at a circumferential end of the partial yoke, and has a plurality of convex portions protruding in the circumferential direction and a plurality of concave portions arranged adjacent to the convex portions,
   The convex portion and the concave portion are formed such that one partial yoke and another partial yoke overlap with each other in the axial direction and face each other with the gap in the circumferential direction. The stator of the rotary electric machine according to any one of claims 1 to 3.
5. The mounting portion is
   A main body (35a) that is inserted inside the yoke and defines the outer diameter, and an outer flange (35c) that protrudes radially outward from the main body and overlaps the yoke in the axial direction. Item 5. A stator for a rotating electrical machine according to any one of Items 4 to 5.
6. The stator of the rotating electrical machine according to any one of claims 1 to 4, wherein the mounting portion includes two plates (34g, 35c, 635m, 635n) sandwiching the yoke in the axial direction.
7. The stator of a rotating electrical machine according to claim 6, wherein the yoke has a plurality of inner protrusions (632a, 632b, 632c) protruding radially inward from the partial yoke and sandwiched between the two plates.
8. The stator of a rotating electrical machine according to claim 7, wherein each of all the unit stators has one inner projecting portion.
9. 9. The rotating electrical machine according to claim 1, wherein a circumferential width (WTH) of the teeth is larger than a radial width (WYK) of the partial yoke (WTH> WYK). Stator.
10. The rotating electrical machine according to any one of claims 1 to 9, wherein the yoke and the mounting portion form a radial gap (G32) between the yoke and the mounting portion in the entire circumference in the circumferential direction. Stator.
11. The yoke and the attachment portion are in contact with each other at one contact portion (CP) in the circumferential direction, and a radial gap (G232) is formed between the yoke and the attachment portion in the remaining portion. The stator of the rotary electric machine according to claim 10.
12. The stator of a rotating electrical machine according to any one of claims 1 to 11, wherein the plurality of unit stators have a plurality of connecting portions (445) connecting the unit stators adjacent in the circumferential direction.
13. A stator (31) of a rotating electrical machine according to any one of claims 1 to 12,
    A rotating electrical machine comprising: a rotor (21) having a plurality of permanent magnets (23) arranged to face the stator.
14. A plurality of teeth (34a) projecting radially outward, and a magnetic pole portion (34) having a yoke (34b) connecting the plurality of teeth radially inward;
    A stator coil (33) mounted on the plurality of teeth;
    In the method of manufacturing a stator for a rotating electrical machine, the component being a separate component from the magnetic pole portion, and including a mounting portion (35) provided on the radially inner side of the yoke for mounting to a mounting target,
    One of the teeth (34a), a part of the stator coil, the unit coil (33a) mounted on one of the teeth, and a part of the yoke, which are arranged and connected in the circumferential direction. Assembling a plurality of unit stators having a partial yoke (34c) forming the yoke,
    Disposing a plurality of the unit stators along the circumferential direction and meshing the partial yokes adjacent in the circumferential direction with each other at a meshing portion (153);
    The outer side surfaces (34d) of the plurality of teeth are arranged on the circumferential surface (41a) while forming a circumferential gap (G39a) separating the adjacent partial yokes in the circumferential direction at the meshing portion. Positioning (154),
    In the positioned state, a plurality of the partial yokes are fixed to each other (155), and the outer diameter (D35b) smaller than the inner diameter (D34e) of the yoke is provided on the radially inner side of the fixed yoke. A method of manufacturing a stator for a rotating electrical machine, comprising the step (156) of mounting the mounting portion.
15. Furthermore, the step of mounting a plurality of unit stators on a jig (41) that defines the circumferential surface,
    Positioning the outer surface on the circumferential surface in a state of being mounted on the jig,
    The method for manufacturing a stator for a rotating electrical machine according to claim 14, wherein the plurality of partial yokes are fixed in a state of being mounted on the jig.
16. And a step of connecting the plurality of unit stators by a plurality of connecting portions (445, 545);
    The method of manufacturing a stator for a rotating electrical machine according to claim 14 or 15, wherein the meshing portions are meshed while winding the plurality of unit stators.
17. The method further comprises forming a magnetic inter-pole gap (G445) between the two outer surfaces by disposing the connecting portion between the two outer surfaces adjacent in the circumferential direction. The manufacturing method of the stator of the rotary electric machine described.
18. The method for manufacturing a stator of a rotating electrical machine according to claim 16 or 17, further comprising the step of removing the connecting portion after the engaging portion is engaged.
19. The method of manufacturing a stator for a rotating electrical machine according to any one of claims 14 to 18, further comprising a step of disposing the yoke between two plates (34g, 35c, 635m, 635n) and sandwiching the yoke in the axial direction.
20. The attachment object in the axial direction of the yoke of the stator (31) manufactured by the method for manufacturing a stator for a rotating electrical machine according to any one of claims 14 to 18 with respect to an axial direction by an outer flange provided on the mounting portion. A method of manufacturing a rotating electrical machine comprising a step of pressing toward an object.
    
    

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