WO2018150448A1

WO2018150448A1 - Rotating electric machine and method for manufacturing same

Info

Publication number: WO2018150448A1
Application number: PCT/JP2017/005279
Authority: WO
Inventors: 大野　正明; 金光　憲太郎; 辰哉岩崎
Original assignee: デンソートリム株式会社
Priority date: 2017-02-14
Filing date: 2017-02-14
Publication date: 2018-08-23
Also published as: CN110291698A; CN112968563A; CN110291698B

Abstract

A stator 31 of a rotating electric machine has a connection portion 50 on the stator 31, said connection portion 50 connecting a coil end 33a and a terminal 71. The stator 31 has a wall member 62 providing a wall for enclosing the coil end 33a and the terminal 71. The coil end 33a and the terminal 71 are covered with a protection resin in the wall member 62. In another embodiment, the coil end of the rotating electric machine is pressed into a narrow positioning portion from a wide entrance portion. A guide portion allows the coil end to move, thereby preventing the coil end from slipping on the terminal.

Description

Rotating electric machine and manufacturing method thereof

Cross-reference of related applications

This application is based on Patent Application No. 2015-187203 filed in Japan on September 24, 2015 and Patent Application No. 2015-197150 filed in Japan on October 2, 2015. The contents of this application are incorporated by reference in their entirety.

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

Patent Documents 1 to 5 disclose rotating electrical machines. Furthermore, patent document 4 and patent document 5 disclose the connection part for a rotary electric machine in detail. The rotating electrical machine disclosed in Patent Document 4 includes a resin that wraps a joint between an aluminum wire and a metal terminal. However, it is difficult to cure the applied resin into a desired shape. The rotating electrical machine disclosed in Patent Document 5 includes a low bank (112B) that prevents the resin enveloping the joint from flowing out.

Patent Documents 1 to 5 disclose a rotating electrical machine and a manufacturing method thereof. In this technique, an insulator (bobbin) provided in the stator is provided with a guide groove (112C) for guiding a coil end. The coil end is disposed in the guide groove. The guide groove positions the coil end in the vicinity of the terminal.

The 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 2013-233030 A JP 2013-27252 A Patent No. 5064279 JP 2013-188048 A JP2015-130785A

In the technique of Patent Document 5, the resin may exceed the bank. In this case, the joint may not be sufficiently wrapped. In addition, the spilled resin may adhere to undesired sites.

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

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

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

One object disclosed herein is to provide a rotating electrical machine in which terminals are reliably protected and a method for manufacturing the same.

Another object disclosed herein is to provide a rotating electrical machine in which a resin for protecting a terminal is held around the terminal and a method for manufacturing the same.

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

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

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 in this section indicate the correspondence with the portions of the embodiments described later, and do not limit the technical scope.

The rotating electrical machine disclosed in this specification has a connection part (50) for connecting the coil end (33a) and the terminal (71). The rotating electrical machine includes a wall member (62) that forms a surrounding wall that surrounds the coil end and the terminal, and a protective resin (61) that is stored in a storage tank that is defined by the surrounding wall and that surrounds the coil end and the terminal. .

According to this rotating electric machine, the surrounding wall is provided by the wall member. Furthermore, the surrounding wall defines the storage tank. Since the protective resin is disposed in the storage tank, the protective resin can be stored in the storage tank. Thereby, a coil end and a terminal are reliably protected by protective resin. Further, the wall member suppresses the outflow of the protective resin.

This specification discloses a method of manufacturing a rotating electrical machine (10) having a connection portion (50) for connecting a coil end (33a) and a terminal (71). The manufacturing method includes a step of connecting a coil end and a terminal. The manufacturing method includes disposing the wall member (62) so as to form an enclosing wall surrounding the coil end and the terminal after the coil end and the terminal are connected. The manufacturing method includes the step of wrapping the coil end and the terminal with the protective resin by pouring the protective resin (61) into the storage tank defined by the surrounding wall.

According to the manufacturing method of the rotating electrical machine, the wall member is disposed after the coil end and the terminal are connected. Therefore, the connection work is not hindered by the wall member. Since the protective resin is poured into the storage tank, the wall member suppresses the protective resin from flowing out. Since the protective resin is stored thick in the storage tank, the coil ends and the terminals are reliably protected by the protective resin.

According to one aspect, a rotating electrical machine is disclosed. The rotating electrical machine includes a coil end (33a) that is an end of the stator coil (33), a terminal (71) to which the coil end is connected, and a groove that guides the coil end toward the terminal by accommodating the coil end. And a guide part (35c) for partitioning (43). The guide portion is provided at a predetermined position of the coil end in the groove, and is positioned at the position of the positioning portion (47) deformed by contact with the coil end. And an inlet part (46, B46, C46, D46) having a width (WW) larger than the width (WN) of the positioning part.

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

According to one aspect, a method for manufacturing a rotating electrical machine is disclosed. The rotating electrical machine includes a coil end (33a) that is an end of the stator coil (33), a terminal (71) to which the coil end is connected, and a groove that guides the coil end toward the terminal by accommodating the coil end. And a guide part (35c) for partitioning (43). A method of manufacturing a rotating electrical machine includes loosely positioning a coil end at an inlet portion (46, B46, C46, D46) provided at an entrance of a groove and having a width (WW) larger than a diameter (DC) of the coil end. The guide end is deformed by moving the end of the coil through the inlet portion toward the positioning portion (47) provided at a predetermined position of the end of the coil, and bringing the end of the coil into contact with the guide at the positioning portion. The coil end is firmly positioned, and the coil end and the terminal are connected in a state where the coil end is positioned by the positioning portion.

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

According to one aspect, a method for manufacturing a rotating electrical machine is disclosed. The rotating electrical machine includes a coil end (33a) that is an end of the stator coil (33), a terminal (71) to which the coil end is connected, and a groove that guides the coil end toward the terminal by accommodating the coil end. And a guide part (35c) for partitioning (43). In the manufacturing method of the rotating electrical machine, the coil end is inserted into the groove, the coil end is brought into contact with the guide portion, the guide portion is deformed to firmly position the coil end, and the coil end is positioned by the groove. When the coil end and the terminal are sandwiched between the welding electrodes (81, 82), the coil end and the terminal are welded, and when the coil end and the terminal are sandwiched by the welding electrode, the guide portion is moved by the movement of the coil end. It further includes allowing the coil end to move by deforming.

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

According to one aspect, a method for manufacturing a rotating electrical machine is disclosed. The rotating electrical machine includes a coil end (33a) that is an end of the stator coil (33), a terminal (71) to which the coil end is connected, and a groove that guides the coil end toward the terminal by accommodating the coil end. And a guide part (35c) for partitioning (43). A method of manufacturing a rotating electrical machine includes inserting a coil end into a groove, bringing the coil end into contact with the guide portion, deforming the guide portion and positioning the coil end firmly, and the coil end on the terminal, The coil end is bent so that the coil end is arranged so as to be away from the terminal toward the tip of the end, and the coil end and the terminal are sandwiched by the welding electrodes (81, 82) in a state where the coil end is positioned by the groove. Welding the ends and the terminals.

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

According to one aspect, a method for manufacturing a rotating electrical machine is disclosed. The rotating electrical machine includes a coil end (33a) that is an end of the stator coil (33), a terminal (71) to which the coil end is connected, and a groove that guides the coil end toward the terminal by accommodating the coil end. And a guide part (35c) for partitioning (43). A method of manufacturing a rotating electrical machine includes inserting a coil end into a groove to bring the coil end into contact with the guide portion, deforming the guide portion and positioning the coil end firmly, and spanning between the guide portion and the terminal. The coil end is bent so as to form a slack in the suspended portion of the coil end passed, and the coil end and the terminal are sandwiched by the welding electrodes (81, 82) while the coil end is positioned by the groove. Welding the terminal and the terminal, and when the coil end pivots along the terminal, the slack is deformed.

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

It is sectional drawing of the rotary electric machine which concerns on 1st Embodiment. It is a top view of the stator of a 1st embodiment. It is a perspective view of the stator of 1st Embodiment. It is sectional drawing modeled of the stator of 1st Embodiment. It is a top view which does not have protective resin of the stator of 1st Embodiment. It is a perspective view which does not have protective resin of the stator of 1st Embodiment. It is a disassembled perspective view of the stator of 1st Embodiment. It is a perspective view which shows the wall member of 1st Embodiment. It is the perspective view seen along the arrow IX in FIG. It is the top view seen along the arrow X in FIG. It is the bottom view seen along arrow XI in FIG. It is an expansion perspective view of the part shown by arrow XII in FIG. FIG. 8 is an enlarged perspective view of a portion indicated by an arrow XIII in FIG. 7. It is a perspective view of the stator of 2nd Embodiment. It is sectional drawing modeled of the stator of 2nd Embodiment. It is a disassembled perspective view of the stator of 2nd Embodiment. It is a perspective view which shows the wall member of 2nd Embodiment. It is a top view which shows the wall member of 2nd Embodiment. It is a perspective view which shows the wall member of 3rd Embodiment. It is a top view which shows the wall member of 3rd Embodiment. It is a perspective view which shows the wall member of 4th Embodiment. It is a perspective view which shows the wall member of 5th Embodiment. It is a perspective view which shows the wall member of 6th Embodiment. It is a perspective view which shows the wall member of 7th Embodiment. It is a top view of the stator of an 8th embodiment. It is the elements on larger scale of the stator of 8th Embodiment. It is the elements on larger scale of the stator of 8th Embodiment. It is the elements on larger scale of the stator of 8th Embodiment. It is the elements on larger scale of the stator of 8th Embodiment. It is the elements on larger scale of the stator of 8th Embodiment. It is the elements on larger scale of the stator of 8th Embodiment. It is a fragmentary perspective view of the stator of 9th Embodiment. It is a fragmentary perspective view of the stator of 9th Embodiment. It is the elements on larger scale of the stator of 9th Embodiment. It is the elements on larger scale of the stator of 9th Embodiment. It is the elements on larger scale of the stator of 9th Embodiment. It is the elements on larger scale of the stator of 10th Embodiment. It is the elements on larger scale of the stator of 10th Embodiment. It is the elements on larger scale of the stator of 11th Embodiment. It is the elements on larger scale of the stator of 12th Embodiment. It is the elements on larger scale of the stator of 13th Embodiment. It is sectional drawing modeled of the stator of 14th Embodiment. It is sectional drawing modeled of the stator of 15th 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 for ignition control supplied from the rotating electrical machine 10. The electric circuit 11 may provide an ignition controller that performs ignition 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 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, a stator 31, and a sensor unit 41. In the following description, the term “axial direction” refers to a direction along the central axis when the rotor 21, the stator 31, or the stator core 32 is regarded as a cylinder. The term “radial direction” refers to a radial direction when the rotor 21, the stator 31, or the stator core 32 is regarded as a cylinder.

The rotor 21 is a field element. The stator 31 is an armature. The entire rotor 21 is cup-shaped. The rotor 21 is connected to the end of the rotating shaft 14. The rotor 21 rotates together with the rotating shaft 14. The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 provides a yoke for a permanent magnet described later. The rotor core 22 is made of a magnetic metal. The rotor 21 has a permanent magnet 23 disposed on the inner surface of the rotor core 22. The rotor 21 provides a field by a permanent magnet 23. 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 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 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 electric wires. The wire harness 15 includes a signal line for external connection that connects the sensor unit 41 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 and 3, the stator 31 is an outer salient pole type stator. The stator core 32 has a plurality of magnetic poles 32a. An insulator 35 is disposed between the stator core 32 and the stator coil 33. The insulator 35 is made of an electrically insulating resin. The insulator 35 is provided on the stator 31. The insulator 35 is also called a bobbin. A portion of the insulator 35 is positioned adjacent to the magnetic pole 32a to provide a bobbin flange. A part of the insulator 35 is disposed on both sides in the axial direction of the magnetic pole 32a. In the following description, in many cases, the insulator 35 includes an annular inner flange portion disposed in the central annular portion of the stator core 32 and an electrode support portion that extends so as to cover a part of the axial surface of the central annular portion. Point to.

Sensor unit 41 provides a rotational position detection device for an internal combustion engine. The sensor unit 41 is fixed to one end surface of the stator core 32. The sensor unit 41 is disposed between the stator core 32 and the body 13. The sensor unit 41 detects the rotational position of the rotor 21 by detecting the magnetic flux supplied by the permanent magnet 23, and outputs an electrical signal indicating the rotational position. The sensor unit 41 has a plurality of rotational position sensors. The rotational position sensor is provided by a hall sensor, an MRE sensor, or the like. The sensor unit 41 has one sensor for ignition control and three sensors for motor control. Details relating to the permanent magnet 23 for ignition control and motor control and details relating to the sensor unit 41 are disclosed in Japanese Patent Application Laid-Open No. 2013-233030, Japanese Patent Application Laid-Open No. 2013-27252, or Japanese Patent The contents described in No. 5064279 are incorporated by reference.

The stator 31 has a connection portion 50 for connecting a coil end 33a which is an end portion of the stator coil 33 so as to form an electric circuit. The connection unit 50 connects the coil end 33 a and the terminal 71. The connection unit 50 is used to connect the stator coil 33 to a predetermined multiphase winding or to connect the stator coil 33 to a power line. In the illustrated example, the stator 31 has two connection portions 51 and 52. The connection unit 51 is used for neutral point connection for star connection. The connection part 52 is used for connecting the stator coil 33 to the power line.

The stator core 32 has a plurality of bolt holes for fixing the stator core 32 to the body 13. The connecting portion 51 is disposed between two bolt holes adjacent in the circumferential direction. The connecting portion 52 is disposed between the other two bolt holes.

The connection part 50 has the protective resin 61 which wraps the terminal to which the coil end 33a and the coil end 33a are connected. The protective resin 61 is an electrically insulating resin. The protective resin 61 is closely attached to the coil end 33a and the surface of the coil end 33a. The protective resin 61 is applied or dropped in an uncured state and cured. The protective resin 61 is also called potting resin or sealing resin.

The connecting part 50 has a wall member 62 that surrounds the connecting part 50 on the end face of the stator 31. The wall member 62 is made of an electrically insulating resin. The wall member 62 forms an enclosing wall that surrounds the coil end 33 a and the terminal 71. The surrounding wall is formed by the wall member 62 and the insulator 35. A storage tank for storing the protective resin 61 is partitioned by the surrounding wall. The wall member 62 is disposed on the insulator 35 so as to surround the coil end 33 a and the terminal 71. The wall member 62 partitions the storage tank on the end surface of the stator 31. Specifically, the wall member 62 defines a storage tank on the insulator 35.

The wall member 62 is used to limit the range to which the protective resin 61 is applied. The wall member 62 is used to hold the protective resin 61 having a predetermined thickness. The wall member 62 is formed to mesh with the components of the stator 31 so as to suppress the outflow of the protective resin 61. The wall member 62 is connected to the insulator 35 so that the outflow of the protective resin 61 can be suppressed. The wall member 62 receives the coil end 33a so that the outflow of the protective resin 61 can be suppressed.

FIG. 4 shows a modeled cross section of the stator 31. A terminal 71 to which the coil end 33a is connected is disposed in the connection portion 50. The terminal 71 has a shape suitable for welding. For example, the terminal 71 has a convex portion having a ridge line intersecting with the coil end 33a. The terminal 71 is made of metal suitable for welding with the coil end 33a made of aluminum metal. The terminal 71 is also called a welding terminal. The terminal 71 is supported by the insulator 35. The terminal 71 is supported so as to extend along the axial direction of the stator 31. The terminal 71 is plate-shaped. The terminal 71 is disposed so that its surface intersects the radial direction. In other words, the terminal 71 is disposed so as to be sandwiched between a pair of welding electrodes for welding that are opened and closed in the radial direction. The terminal 71 and the coil end 33a are welded by electrical resistance welding or spot welding, and are electrically and mechanically joined. Therefore, the terminal 71 and the coil end 33a arranged in the connecting portion 50 have a surface where the metal is exposed.

A plurality of terminals 71 are arranged in the connection portion 51. A coil end 33 a is connected to each terminal 71. A plurality of terminals 71 arranged in the connecting portion 51 are formed on a common electrode 72. The electrode 72 is supported by the insulator 35 by being insert-molded or inserted into the insulator 35. The electrode 72 is also called a bus bar. Electrode 72 provides a neutral point connection for stator coil 33. The electrode 72 is also called a multi-head electrode or a neutral point electrode. The electrode 72 is disposed on one end face of the stator 31. The electrode 72 does not penetrate the stator core 32. The electrode 72 is also called a non-penetrating electrode.

A plurality of terminals 71 are arranged in the connection portion 52. A coil end 33 a is connected to each terminal 71. The plurality of terminals 71 arranged in the connection part 52 are electrically insulated from each other. One terminal 71 is formed on the electrode 73. The electrode 73 is supported by the insulator 35 by being insert-molded or inserted into the insulator 35. The electrode 73 is also called a bus bar. The electrode 73 is disposed so as to protrude from both end faces of the stator 31. The electrode 73 is disposed through the stator core 32. The electrode 73 is also called a through electrode.

The electrode 73 has a terminal 71 at one end and a terminal 74 at the other end. The terminal 74 is used for connection with a power line. The electrode 73 provides a connection between the output end of the stator coil 33 and the power line of the wire harness 15. The terminal 74 has a shape suitable for connection with a power line. In the illustrated example, the terminal 74 has an arm for embedding a multi-core electric wire. The terminal 74 has a shape suitable for soldering.

5 and 6 show the stator 31 before the protective resin 61 is applied. In the connection portion 50, the wall member 62 is disposed so as to surround the plurality of terminals 71. The wall member 62 defines a cylindrical portion extending in the axial direction from the end face of the stator 31. The cylindrical portion is used as a storage tank. The wall member 62 extends higher in the axial direction than the terminal 71. As a result, the terminal 71 and the coil end 33a are completely accommodated in the storage tank formed by the wall member 62 in the axial direction.

The connection unit 51 has three terminals 71 positioned therein. Three coil ends 33 a are drawn into the connection portion 51. The three terminals 71 and the three coil ends 33a are arranged along the circumferential direction. Three terminals 71 are positioned in the connection portion 52. Three coil ends 33 a are drawn into the connection portion 52. The three terminals 71 and the three coil ends 33a are arranged along the circumferential direction.

FIG. 7 shows a state in which the wall member 62 is separated from the insulator 35. The insulator 35 has a stepped portion 36. The step portion 36 is formed so as to provide a fit between the wall member 62 and the insulator 35. The step portion 36 is used as a mark for indicating a predetermined position of the wall member 62. The step part 36 is used as a guide part for guiding the wall member 62 to a specified position. The step portion 36 is used as a fixed portion that suppresses the movement of the wall member 62. Further, the step portion 36 provides a connecting portion for preliminarily connecting the insulator 35 and the wall member 62 in the method of manufacturing the rotating electrical machine. The stepped portion 36 and the wall member 62 are coupled so as not to easily fall off in the manufacturing method step by utilizing the elasticity of the resin. The step portion 36 provides temporary fixing of the wall member 62 in the process before the protective resin 61 is applied. The step part 36 extends so as to surround the connection part 50.

8, 9, 10, and 11 show the wall member 62. FIG. One wall member 62 is provided by one cylindrical member 63. The cylindrical member 63 is formed so as to surround the plurality of terminals 71. The cylindrical member 63 has a shape that can be called an arc shape or a fan shape. The cylindrical member 63 has an outer wall 64 disposed on the radially outer side in the stator 31 shape. The outer wall 64 is an arc-shaped wall. The outer wall 64 is disposed on the radially inner side of the stator coil 33. The cylindrical member 63 has an inner wall 65 disposed on the radially inner side of the outer wall 64. A storage tank is defined by the outer wall 64 and the inner wall 65.

The outer wall 64 is provided with a notch 66. The notch 66 is formed so as to extend in the axial direction from the edge on the insulator 35 side. The notch 66 is used to arrange the coil end 33 a so as to penetrate the tubular member 63. The coil end 33 a is drawn from the outside to the inside of the cylindrical member 63 through the notch 66. In this embodiment, one cylindrical member 63 has three notches 66.

Returning to FIG. 7, the insulator 35 has a positioning portion 37. The positioning portion 37 is used for positioning the coil end 33a at a predetermined position. The positioning portion 37 is formed as a pair of convex portions extending in the axial direction from the insulator 35. The positioning unit 37 positions the coil end 33a at a predetermined position in the circumferential direction by receiving the coil end 33a between the pair of convex portions. The positioning part 37 can also be used as a part for holding or fixing the coil end 33a. In the illustrated example, six positioning portions 37 are provided.

FIG. 12 is a perspective view of the notch 66 as viewed from below. FIG. 13 shows a fitting portion between the notch 66 and the insulator 35. The cutout portion 66 is formed so as to be fitted with the positioning portion 37. The notch 66 is formed so as to be covered by the positioning portion 37 by receiving the positioning portion 37. The notch portion 66 and the positioning portion 37 are fitted to each other to suppress the outflow of the protective resin 61. The notch portion 66 has a receiving groove 66a that receives the positioning portion 37 along the axial direction. The notch portion 66 has a rib 66b that fixes the positioning portion 37 using the elasticity of the resin. By the rib 66b, the notch portion 66 and the positioning portion 37 are tightly fitted. The notch 66 has a convex portion 66 c that covers the slit 38 by being inserted into the slit 38 between the two convex portions of the positioning portion 37. The convex portion 66c reduces the gap around the coil end 33a. The convex portion 66c can be formed so as to be in contact with the coil end 33a.

11, a stepped portion 67 is provided on the end surface of the tubular member 63 on the insulator 35 side. The stepped portion 67 is provided on the end surface of the cylindrical member 63 except for the notched portion 66. The stepped portion 67 is formed so as to provide a fit between the wall member 62 and the insulator 35. The step portion 67 is used as a guide portion for guiding the wall member 62 to a predetermined position on the insulator 35. The stepped portion 67 is used as a fixed portion that suppresses the movement of the wall member 62. Further, the stepped portion 67 provides a connecting portion for preliminarily connecting the insulator 35 and the wall member 62 in the method of manufacturing a rotating electrical machine. The stepped portion 67 and the insulator 35 are coupled so as not to easily fall off in the manufacturing method step by utilizing the elasticity of the resin. The step portion 67 provides temporary fixing of the wall member 62 in the step before the protective resin 61 is applied. The stepped portion 67 extends so as to surround the connecting portion 50.

The step portion 36 is a step that is concave in the axial direction toward the stator core 32 in the connection portion 50. The step portion 67 is a step that is convex in the axial direction from the stator core 32 in the connection portion 50. The step portion 67 is formed so as to mesh with the step portion 36. The wall member 62 and the insulator 35 are opposed to each other in a plane perpendicular to the axial direction. Furthermore, by providing the stepped portion 36 and the stepped portion 67, the wall member 62 and the insulator 35 are opposed to each other even on an elongated surface that extends in the axial direction and extends along the edge of the tubular member 63. The stepped portion 36 and the stepped portion 67 are fitted together to connect the insulator 35 and the wall member 62. The stepped portion 36 and the stepped portion 67 are fitted together to suppress the outflow of the protective resin 61.

In this embodiment, the wall member 62 and the insulator 35 have a plurality of connecting portions that connect the wall member 62 and the insulator 35. One of the connecting portions is provided by the step portion 36 and the step portion 67. Another one of the connecting parts is provided by the positioning part 37 and the notch part 66.

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

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

electrodes

72 and 73 are fixed on the stator 31. In this step, the coil end 33a and the terminal 71 are arranged at regular positions. The regular position is a position immediately before the coil end 33 a is welded to the terminal 71.

The step of manufacturing the stator 31 includes a step of electrically connecting the coil end 33a and the terminal 71. This step includes a step of sandwiching the coil end 33a and the terminal 71 between the pair of welding electrodes, a step of welding the coil end 33a and the terminal 71 by energizing the welding electrode, and a step of removing the welding electrode. This step may include a step of inspecting the welding state between the coil end 33a and the terminal 71.

The process of manufacturing the stator 31 includes a process of mounting the wall member 62 after the welding process. The wall member 62 is disposed so as to form an enclosing wall surrounding the coil end 33a and the terminal 71 after the coil end 33a and the terminal 71 are connected. As shown in FIG. 7, the wall member 62 is mounted on the insulator 35 along the axial direction of the stator 31. The wall member 62 is mounted so as to be connected to the insulator 35. At this time, the stepped portion 36 and the stepped portion 67 position the wall member 62 at a predetermined position.

The step of manufacturing the stator 31 includes a step of applying the protective resin 61 after the wall member 62 is mounted. The protective resin 61 is poured into a storage tank defined by the surrounding wall. The coil end 33a and the terminal 71 are wrapped by the protective resin 61. The protective resin 61 is poured so as to completely cover the exposed metal surfaces of the coil end 33 a and the terminal 71 disposed in the connection portion 50. The protective resin 61 covers at least the metal surface exposed by removing the protective film of the coil end 33 a and the exposed metal surface of the terminal 71. The protective resin 61 is poured into the wall member 62 in an uncured state. Thereafter, the protective resin 61 is cured. The step portion 36 and the step portion 67 suppress the outflow of the protective resin 61. Further, the positioning part 37 and the notch part 66 suppress the outflow of the protective resin 61.

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

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

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

The step of manufacturing the stator 31 includes a step of connecting the terminal 74 and the power line. The terminal 74 and the power line are connected at any stage after the electrode 73 is fixed on the stator 31.

According to the embodiment described above, the surrounding wall is provided by the insulator 35 and the wall member 62. Furthermore, the surrounding wall defines the storage tank. Protective resin can be stored in the storage tank. Thereby, the coil end 33a and the terminal 71 are reliably protected by the protective resin 61. Further, the wall member 62 suppresses the outflow of the protective resin 61.

The coil end 33a and the terminal 71 arranged in the connection part 50 are reliably protected. The wall member 62 is mounted after the coil end 33a and the terminal 71 are welded. For this reason, the wall member 62 does not interfere with the welding operation. The protective resin 61 is held in the connection portion 50, that is, around the coil end 33 a and the terminal 71. Thereby, adhesion of the protective resin 61 to an undesired location is suppressed. Furthermore, since the outflow of the protective resin 61 is suppressed by the wall member 62, the protective resin 61 having a viscosity suitable for wrapping the coil end 33a and the terminal 71 can be used. Thereby, formation of the cavity in the protective resin 61 is suppressed.

The wall member 62 is higher in the axial direction than the coil end 33a and the terminal 71 to be protected. Since the wall member 62 protects the coil end 33a and the terminal 71, the electrical connection is maintained. Further, the surface of the protective resin 61 is lower than the front end surface of the wall member 62 in the axial direction. Since the wall member 62 protects the protective resin 61, breakage and tearing of the protective resin 61 are suppressed.

(Second Embodiment)
This embodiment is a modification based on the preceding embodiment. In the preceding embodiment, a common electrode 72 and a penetrating electrode 73 are used. Further, a cylindrical member 63 surrounding the plurality of terminals 71 is used. Instead, in this embodiment, an independent electrode 272 and a non-penetrating electrode 273 are used. Moreover, in this embodiment, the wall member 62 which forms a some storage tank is used.

14 and 15, also in this embodiment, two connecting portions 50 are provided. The connection unit 51 provides a neutral point connection. The connection unit 51 includes a plurality of electrodes 272 and a common electrode 276. The plurality of electrodes 272 are provided on the insulator 35 electrically independent from each other. Each electrode 272 has a terminal 71 connected to the coil end 33 a and a terminal 275 connected to the electrode 276. The electrode 272 has a fixed portion to the insulator 35 at one end and a terminal 275 at the other end. The terminal 71 is provided at the center in the length direction of the electrode 272. The electrode 272 is an I-shaped plate. The plurality of electrodes 272 are arranged so that the surfaces thereof extend substantially in the radial direction. The plurality of electrodes 272 are arranged so as to be sandwiched between welding electrodes that can be opened and closed along the circumferential direction of the stator 31.

The electrode 276 is a common electrode connected to the plurality of electrodes 272. The electrode 276 can be provided by a conductor piece or an electric wire. The electrode 272 and the electrode 276 are electrically and mechanically connected by soldering.

The connection unit 52 provides a connection between the stator coil 33 and the power line. The connection part 52 has a plurality of electrodes 273. The plurality of electrodes 273 are provided in the insulator 35 electrically independently from each other. Each electrode 273 has a terminal 71 connected to the coil end 33a and a terminal 274 connected to the power line. The electrode 273 has a fixed portion to the insulator 35 at one end and a terminal 274 at the other end. The electrode 273 is an L-shaped plate. The plurality of electrodes 273 are arranged so that the surfaces thereof extend in the radial direction. The plurality of electrodes 273 are arranged so as to be sandwiched by welding electrodes that can be opened and closed along the circumferential direction of the stator 31.

FIG. 14 does not show the electrode 276 in order to show the terminal 275. As shown in FIG. 15, the protective resin 61 surrounds the coil end 33 a and the terminal 71. However, the protective resin 61 does not enclose the terminal 275 and the electrode 276.

The wall member 62 for the connecting portion 51 defines a plurality of storage tanks corresponding to each of the plurality of electrodes 272. The wall member 62 for the connecting portion 52 defines a plurality of storage tanks corresponding to each of the plurality of electrodes 273. The storage tank in which the wall member 62 and the insulator 35 are partitioned is filled with the protective resin 61. The height of the wall member 62 in the axial direction is at least higher than the height of the coil end 33 a and the terminal 71. Thereby, the protective resin 61 can wrap the coil end 33 a and the terminal 71.

As shown in FIG. 16, one wall member 62 has three half-cylinder members 263. The plurality of half-cylinder members 263 are connected to each other. The plurality of half-cylinder members 263 are integrally formed of a resin material. The insulator 35 has a cylindrical wall 35 a along the radially inner edge of the stator coil 33. The wall 35 a extends in the axial direction of the stator 31. The wall 35a is located on the outer side in the radial direction from the fixing portion of the plurality of

electrodes

272 and 273 to the insulator 35. The insulator 35 has a stepped portion 36 corresponding to the shape of the wall member 62.

17 and 18, the half-cylinder member 263 includes an arm portion 264 positioned on the radially outer side and a U-shaped inner wall 265 positioned on the radially inner side. The half cylinder member 263 has a notch 266 provided on the outer side in the radial direction. The half cylinder member 263 has a connecting portion 268 that connects two half cylinder members 263 adjacent in the circumferential direction. The wall member 62 has three half-cylinder members 263 connected in a row.

The half-cylinder member 263 is attached to the stator 31 so that the notch 266 is closed by the wall 35a. The half cylinder member 263 is positioned at a predetermined position by the step portion 36. The arm portion 264 extends along the circumferential direction from the edge of the inner wall 265 to the center in the circumferential direction of the cutout portion 266, and further extends along the axial direction. The arm portion 264 has a convex portion 266c that extends so as to be in contact with the coil end 33a at the tip portion thereof. The convex portion 266c extends so as to cover a slit for passing the coil end 33a formed on the wall 35a. As a result, the wall 35a and the semi-cylindrical member 263 define a cylindrical storage tank.

According to this embodiment, the coil end 33 a and the terminal 71 can be protected by the protective resin 61 and the wall member 62. Further, the plurality of half-cylinder members 263 contribute to reducing the amount of the protective resin 61 used.

(Third embodiment)
This embodiment is a modification based on the preceding embodiment. In the preceding embodiment, a plurality of U-shaped half-cylinder members 263 are used to form a plurality of storage tanks. Instead, in this embodiment, a plurality of cylindrical members 363 are used to form a plurality of storage tanks.

19 and FIG. 20, the wall member 62 has a plurality of cylindrical members 363. As shown in FIG. The tubular member 363 has an inner wall 364, an outer wall 365, a notch 366, and a connecting portion 368. Furthermore, the cylindrical member 363 has a convex portion 366c. Also in this embodiment, the same effect as the preceding embodiment can be obtained.

(Fourth embodiment)
This embodiment is a modification based on the preceding embodiment. In the preceding embodiment, the wall member 62 has

notches

66, 266, and 366 for allowing the coil end 33a to pass therethrough. Instead, in this embodiment, the coil end 33 a is introduced from the bottom opening of the wall member 62 into the internal cavity of the wall member 62.

21, the coil end 33a is drawn into the cavity in the wall member 62 via a groove formed in the insulator 35. The wall member 62 is provided by a cylindrical member 463 that does not have a notch. According to this embodiment, the same effect as the preceding embodiment can be obtained. Furthermore, according to this embodiment, the clearance gap between the insulator 35 and the wall member 62 is suppressed. For this reason, the outflow of the protective resin 61 is suppressed. The configuration for laying the coil end 33a in this embodiment can also be applied to the preceding embodiment.

(Fifth embodiment)
This embodiment is a modification based on the preceding embodiment. In the preceding embodiment, the wall member 62 provides an axially extending wall. Instead, in this embodiment, the wall member 62 provides a wall having a step in the axial direction.

22, the wall member 62 has a cylindrical member 563. The cylindrical member 563 has a small inner diameter portion on the insulator 35 side. The cylindrical member 563 has a large inner diameter portion on the outer side in the axial direction. As a result, a step portion 569 is formed on the inner wall of the cylindrical member 563. The inside of the cylindrical member 563 is filled with the protective resin 61. The protective resin 61 meshes with the complicated shapes of the coil end 33 a and the terminal 71. The step portion 569 provides a connection between the protective resin 61 and the tubular member 563. As a result, the cylindrical member 563 is prevented from falling off in the axial direction. The step portion 569 may be provided by a concave portion provided on the inner surface of the tubular member 563. According to this embodiment, the same effect as the preceding embodiment can be obtained. Furthermore, according to this embodiment, the dropout of the wall member 62 is suppressed. The step portion 569 in this embodiment can also be applied to the preceding embodiment.

(Sixth embodiment)
This embodiment is a modification based on the preceding embodiment. In the preceding embodiment, the coil end 33 a is positioned at a predetermined position by the insulator 35. Instead of this, the wall member 62 may have a positioning portion that positions the coil end 33a at a specified position.

23, the cylindrical member 663 has a slit-like thin notch 666. The notch 666 is formed so as to extend in the axial direction from the contact surface with the insulator 35. The notch 666 has a narrow width corresponding to the diameter of the coil end 33a. The notch 666 allows the coil end 33 a to be received inside the wall member 62 while suppressing the outflow of the protective resin 61. The notch 666 may be formed so as to be elastically deformed when receiving the coil end 33a and to become narrow again after receiving the coil end 33a. Further, the insulator 35 may be provided with a convex portion that closes the notch 666. According to this embodiment, the same effect as the preceding embodiment can be obtained.

(Seventh embodiment)
This embodiment is a modification based on the preceding embodiment. Some preceding embodiments have a wall member 62 to which a plurality of tubular members are connected. Instead of this, a plurality of independent cylindrical members may be employed.

24, the wall member 62 is provided by an independent cylindrical member 763. A plurality of wall members 62, that is, a plurality of cylindrical members 763 are attached to one stator 31. The cylindrical member 763 has an inner wall 764, an outer wall 765, and a notch 766. The cylindrical member 763 has a convex portion 766c. Further, the cylindrical member 763 has a step portion 769. According to this embodiment, the same effect as the preceding embodiment can be obtained. Furthermore, according to this embodiment, the freedom degree of arrangement | positioning of the terminal 71 on the stator 31 is raised.

(Eighth embodiment)
This embodiment is a modification based on the preceding embodiment. The rotating electrical machine 10 is a generator. The rotating electrical machine 10 is electrically connected to an electric circuit 11 including a rectifier circuit (AC / DC). The electric circuit 11 provides a single-phase power conversion circuit.

25, the stator 31 is an outer salient pole type stator. The magnetic pole 32a is a part also called a tooth.

In the illustrated example, the stator 31 has two connection portions 50. One connecting portion 50 provides connection between one coil wire and one electrode on one end face of the stator 31. One electrode is connected to the power line at the other end face of the stator 31. The other electrode is connected to the coil end of another coil wire on the other end face of the stator 31. In this embodiment, the electrode provides a connection portion separated on one end surface and the other end surface of the stator 31.

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

The connection part 50 has the protective resin 61 which wraps the terminal 71 to which the coil end 33a and the coil end 33a are connected. In the drawing, in order to show the coil end 33a and the terminal 71, the range covered with the protective resin 61 is indicated by a broken line.

FIG. 26 is an enlarged view showing a part of the stator 31, particularly the connection portion 50 in an enlarged manner. In the drawing, the state after the coil end 33a and the terminal 71 are joined is shown. In order to illustrate the coil end 33a and the terminal 71, the protective resin 61 is not illustrated. The application range of the protective resin 61 is indicated by a broken line.

The insulator 35 has a wall 35 a for suppressing the outflow of the protective resin 61. The range in which the protective resin 61 flows is limited by the wall 35a. The axial height of the wall 35 a is lower than that of the terminal 71. The protective resin 61 is thickly applied around the coil end 33a and the terminal 71 by the wall 35a. The insulator 35 has a bobbin portion 35b. The bobbin portion 35 b is disposed between the magnetic pole 32 a and the stator coil 33. The bobbin portion 35b has a cylindrical shape surrounding the magnetic pole 32a. In the drawing, the stator coil 33 is not shown.

The insulator 35 has a guide part 35c. The guide part 35c is used for arranging the coil end 33a for the connection part 50 in a prescribed shape. Moreover, the guide part 35c is utilized in order to hold | maintain the coil end 33a in a regular position. The guide portion 35 c is formed as a protrusion extending in the axial direction on the end surface of the stator 31. The guide part 35 c and the wall 35 a are arranged so as to surround the connection part 50. The axial height of the wall 35a is lower than that of the guide portion 35c.

The coil end 33a is disposed so as to extend inward from the radially outer side. The coil end 33a is disposed so as to be adjacent to the terminal 71 from the stator coil 33 via the guide portion 35c. The coil end 33a is slightly curved. The coil end 33 a is bent along the surface of the terminal 71. The coil end 33 a has a portion that extends along the circumferential direction of the stator 31, a portion that bends along the radial direction of the stator 31, and a portion that extends along the surface of the terminal 71.

The guide part 35c divides and forms the groove | channel 43 which guides the coil end 33a toward the terminal 71 by accommodating the coil end 33a. The guide part 35 c has a first protrusion 841 and a second protrusion 842. The first protrusion 841 and the second protrusion 842 define a groove 43 that can receive the coil end 33a therebetween. The first projecting portion 841 and the second projecting portion 842 may be provided by an elongated wall extending along the circumferential direction of the stator 31.

The first protrusion 841 is located inside the bending end 33b, that is, the bending of the coil end 33a. The 1st protrusion 841 restrict | limits the movement to the inner side of the bending shape of the coil end 33a. The first protrusion 841 defines the bending shape of the coil end 33a. The first protrusion 841 is also referred to as an inner protrusion. The first protrusion 841 provides a wall surface 41a that faces the coil end 33a. The wall surface 41a has a curved surface that defines the curved shape of the coil end 33a.

The second protrusion 842 is located on the outside of the bending end 33b, that is, the bending end 33b. The 2nd protrusion 842 restrict | limits the movement to the outer side of the bending shape of the coil end 33a. The second protrusion 842 is also called an outer protrusion. The second protrusion 842 has a thin plate portion 44 that faces the coil end 33a and contacts the coil end 33a. The thin plate portion 44 is formed in a plate shape that is thinner than other portions of the second protrusion 842. The thin plate portion 44 is formed only on the second protrusion 842. The second protrusion 842 is not provided at the entrance of the groove 43, but is provided only at the back in the axial direction of the groove 43. The thin plate portion 44 holds the coil end 33a by contacting the coil end 33a from the outside of the bent shape of the coil end 33a.

A deformed portion 45 is formed at the tip of the thin plate portion 44, that is, the contact portion with the coil end 33a. The deformable portion 45 is provided on the second protrusion 842. The deformation part 45 is provided in a positioning part 47 described later. The deformation part 45 is formed by the resin material being deformed by contact with the coil end 33a. The deformation part 45 is formed by elastic deformation and / or plastic deformation of a resin material. The deforming portion 45 prevents excessive movement of the coil end 33a while allowing movement of the coil end 33a. For example, the thin plate portion 44 is formed to be deformed by the movement of the coil end 33a in a normal manufacturing method. On the other hand, the other part of the 2nd protrusion 842 is formed so that it may not deform | transform greatly by the movement of the coil end 33a in a normal manufacturing method. For this reason, the thin plate portion 44 is formed thinner or narrower than other portions of the second protrusion 842. The size of the deforming portion 45 changes due to an error in the shape of each portion, a shift in the arrangement position, and the like. The deformable portion 45 may not be formed.

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

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

The terminal 71 has a shape suitable for welding. For example, the terminal 71 has a protrusion 77 having a ridge line intersecting with the coil end 33a. The protrusion 77 is a protrusion extending along the axial direction. The terminal 71 is made of metal suitable for welding with the coil end 33a made of aluminum metal. The terminal 71 is also called a welding terminal. The terminal 71 is supported by the insulator 35. The terminal 71 is supported so as to extend along the axial direction of the stator 31.

The coil end 33a and the terminal 71 are welded by electrical resistance welding or spot welding, and are electrically and mechanically joined. Between the coil end 33a and the terminal 71, there is formed a welded portion 55 formed by melting and re-hardening these metals once. The weld 55 is also called a welding mark. The terminal 71 and the coil end 33a arranged in the connection part 50 have a surface with exposed metal.

The cross-sectional shape of the coil end 33a before welding is a circle. The cross-sectional shape of the coil end 33a after welding is a slightly flat shape. In the welding process, the coil end 33a and the terminal 71 are sandwiched between electrodes for welding. The coil end 33a and the terminal 71 are slightly deformed due to compression for welding and melting accompanying welding. The coil end 33a may have a flat surface portion that is a contact mark with the welding electrode. The coil end 33 a is deformed so as to follow the protrusion 77 at the contact portion with the terminal 71. The protrusion 77 is also deformed. The cross-sectional shape of the coil end 33 a is an ellipse or an ellipse having a long axis in the axial direction of the stator 31. The coil end 33 a is positioned along the plate-like surface of the terminal 71. The coil end 33 a is arranged such that its longitudinal direction intersects the longitudinal direction of the protrusion 77. The coil end 33 a is disposed such that the surface thereof is in contact with the top of the projection 77, both slopes of the projection 77, and the flat portion of the terminal 71. Thereby, the coil end 33a and the terminal 71 are firmly joined.

FIG. 27 shows the guide part 35c. In the drawing, the broken line and the alternate long and short dash line indicate the coil end 33a. A thick solid arrow indicates a moving path of the coil end 33a in the manufacturing method.

The groove 43 provides various functions. The groove 43 provides a guide groove for guiding the coil end 33a toward a specified position in the manufacturing method. The groove 43 provides a holding groove for holding the coil end 33a at a predetermined position before the coil end 33a and the terminal 71 are welded in the manufacturing method. In the manufacturing method, the groove 43 allows a slight movement of the coil end 33a to allow the coil end 33a and the terminal 71 to be desirably welded while positioning the coil end 33a within a specified position range. I will provide a. The function as the welding support portion is provided by the deformation of the groove 43, that is, the deformation of the first protrusion 841 and the second protrusion 842 that define the groove 43. More specifically, the function as the welding support part is provided by deformation of the thin plate part 44. The groove 43 provides a movement suppressing unit that suppresses excessive movement of the coil end 33 a after being manufactured as the rotating electrical machine 10. The manufacturing method of the rotating electrical machine 10 may include a step of bonding and fixing the stator coil 33 and the coil end 33a with an adhesive, that is, a resin. In this case, the groove 43 also functions as a function of accumulating the adhesive and a portion that holds the adhesive so as to prevent excessive spread of the adhesive. In this case, the loose holding by the groove 43 and the thin plate portion 44 and the deforming portion 45 therein is firmly fixed by cooperation with the adhesive.

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

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

The positioning portion 47 has a width WN that can receive the coil end 33a when the first protrusion 841 and the second protrusion 842 are deformed. The width WN of the positioning portion 47 is smaller than the diameter DC of the coil end 33a. The width WN of the positioning portion 47 may be set to be equal to or smaller than the diameter DC of the coil end 33a. The width WN of the positioning portion 47 is smaller than the width WW of the inlet portion 46. The positioning portion 47 receives the coil end 33a operated along the axial direction of the stator 31 while the first protrusion 841 and the second protrusion 842 are deformed. The positioning portion 47 is deformed by being in contact with the coil end 33a. It can be said that the coil end 33 a is press-fitted into the positioning portion 47. The deformation is mainly deformation of the thin plate portion 44. The positioning part 47 is also called a bottom part or a narrow part.

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

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

The manufacturing method of the rotating electrical machine 10 includes the steps of the preceding embodiment. As shown in FIGS. 27, 28, and 29, the coil end 33 a is inserted into the groove 43 and bent so as to contact the terminal 71. The operation of the coil end 33a is provided by manual operation by an operator or mechanized tool movement by an assembly machine.

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

Furthermore, the coil end 33a is pushed from the position PS1 indicated by the broken line to the position PS2. Thereby, a step of moving the coil end 33 a toward the positioning portion 47 via the inlet portion 46 is provided. At this time, the thin plate portion 44 is at least elastically deformed. In this embodiment, a part of the thin plate portion 44 is plastically deformed. As a result, the coil end 33a is firmly held in the groove 43 using the elasticity of the resin material. Tight holding is also a tight tightening. Thereby, by bringing the coil end 33a and the guide portion 35c into contact with each other in the positioning portion 47, a step of deforming the guide portion 35c and firmly positioning the coil end 33a is provided. However, the thin plate portion 44 is formed thin in the direction in which the coil end 33a extends, that is, in the radial direction. Therefore, the thin plate portion 44 is more easily deformed than other portions of the first protrusion 841 and the second protrusion 842. Further, since the contact area between the coil end 33 a and the thin plate portion 44 is small, the frictional force provided by the thin plate portion 44 is adjusted to be smaller than the frictional force due to the thickness of the second protrusion 842.

27, the coil end 33a is operated so as to move from the top of the terminal 71 toward the surface of the terminal 71 outside the groove 43, as indicated by arrows P2 and P3. The tip end of the coil end 33a extends from the groove 43, and the tip end portion is positioned at a position PS3 illustrated by a one-dot chain line. The coil end 33 a is operated so as to be in contact with the protrusion 77 via the terminal 71. At this time, the coil end 33a is bent.

In FIG. 28, a state in which the coil end 33a is disposed in the groove 43 by the operation indicated by the arrow P1 is indicated by a solid line. The coil end 33a is disposed in the groove 43 as indicated by an arrow P1 from above the groove 43.

The portion of the coil end 33a extending from the groove 43 is operated as indicated by the arrow P2. That is, the coil end 33 a is bent via the terminal 71. At this time, the coil end 33a is bent with the first protrusion 841 as an inner mold. Instead, the coil end 33a may be bent with a member different from the first protrusion 841 as an inner mold. The coil end 33a is bent as indicated by a broken line. A bent portion 33b is formed at the coil end 33a. The bent portion 33 b is bent so that the coil end 33 a is along the terminal 71.

Next, the coil end 33a is operated so as to be pushed in along the axial direction of the stator 31 so as to be in contact with the top of the protrusion 77 with respect to the protrusion direction of the protrusion 77, as indicated by an arrow tail P3. . As a result, the coil end 33 a is positioned on the surface of the terminal 71, that is, on the side of the protrusion 77 with respect to the axial direction of the stator 31.

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

FIG. 29 shows a state where the coil end 33a is positioned at a normal position. This state is a state before welding. The coil end 33 a is firmly held between the first protrusion 841 and the thin plate portion 44. The coil end 33a extends straight from the bent portion 33b. The outer peripheral surface of the coil end 33 a is in contact with the protrusion 77. The coil end 33a is held at a predetermined position by the holding by the guide portion 35c and the elasticity of the coil end 33a itself.

The step of manufacturing the stator 31 is a step of connecting the coil end 33a and the terminal 71 in a state where the coil end 33a is positioned by the positioning portion 47. This step is also a step of sandwiching the coil end 33a and the terminal 71 between the

welding electrodes

81 and 82 and welding the coil end 33a and the terminal 71. This process is called a joining process or a welding process.

FIG. 30 shows an initial stage in which the coil end 33a and the terminal 71 are sandwiched between the

welding electrodes

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

For example, as shown in the figure, the corner of the welding electrode 82 comes into contact with the suspended portion of the coil end 33 a that is spanned between the guide portion 35 c and the protrusion 77. In this embodiment, both the shape of the guide 35c and the step of bending the coil end 33a are set to provide the shape of the illustrated coil end 33a. The coil end 33a is arranged and bent so that the suspended portion thereof is not positioned on the terminal 71 side beyond the virtual plane PP. The virtual plane PP is a plane that is parallel to the surface of the terminal 71 and is in contact with the top in the protruding direction of the protrusion 77. The virtual plane PP is also parallel to the surfaces of the

welding electrodes

81 and 82 that attempt to sandwich the terminal 71.

The guide part 35c is formed so that the coil end 33a is arranged in the shape shown in the figure. That is, both of the

edges

41c and 42c of the groove 43 on the radially inner side of the stator 31 are positioned on the side opposite to the terminal 71 with respect to the virtual plane PP. In other words, of the

edges

41c and 42c on the radially inner side of the groove 43, the edge 42c positioned outside the bending of the coil end 33a is in contact with the virtual plane PP or closer to the welding electrode 82 than the virtual plane PP. It is positioned. Note that the edge 41c is provided by the first protrusion 841. The edge 42c is provided by the second protrusion 842. As a result, the coil end 33 a extends from the

edges

41 c and 42 c so as to approach the terminal 71 and the virtual plane PP, and reaches the terminal 71. In the step of bending the coil end 33 a, the coil end 33 a is bent so as to extend straight from the

edges

41 c and 42 c toward the terminal 71.

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

At this time, the coil end 33a may move undesirably in order to form a proper weld. For example, since one end of the suspended portion of the coil end 33 a is held by the guide portion 35 c, the coil end 33 a may move so as to slide on the protrusion 77. Such movement may result in movement of the melted part in the welding process and may hinder the proper amount of melting. In addition, the melted portion may protrude from the proper position.

FIG. 31 shows the movement of the coil end 33 a by the welding electrode 82. The welding electrode 82 is operated as indicated by an arrow P6. The coil end 33a and the terminal 71 sandwiched between the pair of

welding electrodes

81 and 82 form a welded portion 55 as welding progresses.

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

Further, the force component indicated by the arrow P7 deforms the thin plate portion 44 to form a deformed portion 45. Since the deformable portion 45 is formed at the contact portion with the coil end 33a, the thin plate portion 44 continues to hold the coil end 33a in the axial direction. As a result, the coil end 33a is separated from the first protrusion 841 and a gap 48 is formed. Such deformation of the thin plate portion 44 also allows the movement of the coil end 33a. In this step, when the coil end 33a and the terminal 71 are sandwiched between the

welding electrodes

81 and 82, the guide portion 35c is further deformed by the movement of the coil end 33a, thereby allowing the movement of the coil end 33a.

The first protrusion 841 and the second protrusion 842 suppress excessive movement of the coil end 33a in the circumferential direction and the axial direction of the stator 31 even after the coil end 33a is drawn along the arrow P7. The first protrusion 841 and the second protrusion 842 suppress excessive movement of the coil end 33a in the circumferential direction and the axial direction of the stator 31 even after the thin plate portion 44 is deformed.

Thus, the guide portion 35c, particularly the thin plate portion 44, holds the coil end 33a firmly until the initial stage of the welding process. The thin plate portion 44 allows the coil end 33a to move during the process for welding. As a result, the coil end 33a moves to the illustrated welding state without moving so as to be dragged over the terminal 71. The coil end 33 a is welded to the terminal 71 on the protrusion 77 without shifting in the length direction of the coil end 33 a.

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

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

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

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

The positioning portion 47 holds the coil end 33a in the deformed portion 45 deformed in the welding process. Therefore, the positioning part 47 holds the coil end 33a firmly before the deformation part 45 is formed, and holds the coil end 33a loosely after the deformation part 45 is formed. Thereby, in the process which welds them by pinching the coil end 33a and the terminal 71, the positioning part 47 can accept | permit the movement of the coil end 33a.

(Ninth embodiment)
This embodiment is a modification based on the preceding embodiment. In the above embodiment, the positioning portion 47 can be deformed so as to hold the coil end 33a loosely. Instead, in this embodiment, the guide portion 35c that provides the positioning portion 47 continues to hold the coil end 33a firmly.

32 and 33 are perspective views showing the guide portion 35c in this embodiment. 34, 35, and 36 show a process of electrically connecting the coil end 33a and the terminal 71 in this embodiment.

Also in this embodiment, the guide portion 35c has a first protrusion 841 and a second protrusion 942. The second protrusion 242 does not include the thin plate portion 44 and the deformation portion 45 in the preceding embodiment. The second protrusion 942 is in contact with the coil end 33a over almost the entire thickness in the radial direction. Also in this embodiment, the first protrusion 841 and the second protrusion 942 define the groove 43. The groove 43 has an inlet portion 46 and a positioning portion 47. The positioning portion 47 holds the coil end 33a with substantially the entire thickness of the second protrusion 942.

FIG. 34 shows the initial stage of the welding process. In this embodiment, the coil end 33 a is firmly held in the groove 43. In addition, the coil end 33a is firmly held in the groove 43 both before and after the joining step.

The

welding electrodes

81 and 82 are respectively operated so as to contact the coil end 33a and the terminal 71. At this time, in this embodiment, a free end portion of the coil end 33 a that protrudes radially inward from the protrusion 77 is in contact with the welding electrode 82. The welding electrode 82 first contacts the contact portion 933c. The contact part 933c is located in the free end part which the coil end 33a protrudes.

In this embodiment, the coil end 33a is bent so that the contact portion 933c is located at the free end portion. From another viewpoint, the shape of the guide portion 35c and the position of the protrusion 77 are set so that the contact portion 933c is located at the free end portion. The coil end 33a is arranged on the terminal 71 so as to be away from the terminal 71 toward the tip of the coil end 33a.

In this embodiment, both the shape of the guide portion 35c and the step of bending the coil end 33a are set so as to provide the shape of the coil end 33a illustrated. The coil end 33a is arranged and bent so that a part of the suspended portion is located on the terminal 71 side beyond the virtual plane PP.

The guide part 35c is formed so that the coil end 33a is arranged in the shape shown in the figure. That is, the edge 42c is positioned on the terminal 71 side with respect to the virtual plane PP. In other words, of the

edges

41c and 42c on the radially inner side of the groove 43, the edge 42c located outside the bend of the coil end 33a is positioned closer to the terminal 71 than the virtual plane PP. As a result, the coil end 33 a extends from the

edges

41 c and 42 c so as to return to the top of the protrusion 77 after passing through the terminal 71 side beyond the virtual plane PP. In the step of bending the coil end 33a, the coil end 33a is bent from the

edges

41c and 42c so as to pass through the terminal 71 side beyond the virtual plane PP.

In this embodiment, a step of bending the coil end 33a is adopted so as to provide this arrangement. Such arrangement of the coil end 33a makes it possible to form the contact portion 933c at the free end portion.

FIG. 35 shows a stage where the welding electrode 82 is gradually pressed. The coil end 33 a is gradually deformed along the terminal 71. The coil end 33a is gradually deformed from its free end portion, that is, from the tip. Therefore, the coil end 33a contacts the terminal 71 while maintaining contact with the protrusion 77 at a certain portion.

FIG. 36 shows the final stage of the welding process. The welding electrode 82 is pressed to a specified end position. The coil end 33 a is welded to the terminal 71.

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

The guide part 35c holds the coil end 33a firmly. Moreover, the coil end 33a and the welding electrode 82 are arranged so that the welding electrode 82 contacts the free end portion of the coil end 33a. The welding electrode 82 and the coil end 33a first contact each other at a portion near the tip of the coil end 33a. In other words, it is avoided that the contact portion 33c is formed on the suspended portion of the coil end 33a. Thereby, it is suppressed that the coil end 33a moves on the terminal 71 so that it may slide on the receiving part of the protrusion 77 in particular. As compared with the case where the suspension portion is pushed, the coil end 33a is prevented from moving so as to slide on the terminal 71. Thereby, a desirable connection state is formed between the coil end 33a and the terminal 71.

(10th Embodiment)
This embodiment is a modification based on the preceding embodiment. In this embodiment, the bent portion 33b of the coil end 33a is used so as to suppress the movement of the coil end 33a on the terminal 71.

37 and 38 show a process of electrically connecting the coil end 33a and the terminal 71 in this embodiment. Also in this embodiment, the coil end 33a is guided and held by the guide portion 35c. The coil end 33a is pushed between the first protrusion 841 and the second protrusion A42 and is held firmly. The second protrusion A42 is formed so as not to be deformed by a force acting on the coil end 33a in the manufacturing process. Also in this embodiment, the groove 43 is formed between the first protrusion 841 and the second protrusion 342. The groove 43 has an inlet portion 46 and a positioning portion 47.

The coil end 33a has an S-shaped bent portion A33d including a bent portion 33b at a portion extending from the guide portion 35c toward the terminal 71. Here, an S-shaped word is defined as including an inverted S-shape. The bent portion A33d slightly detours the coil end 33a in a direction approaching the terminal 71. The bent portion A33d enables the coil end 33a to be arranged so as to have a desired positional relationship with respect to the terminal 71. The coil end 33a is arranged on the terminal 71 so as to be away from the terminal 71 toward the tip of the coil end 33a. Such an arrangement of open ends is provided by the bent portion A33d. As with the second embodiment, the arrangement of the open ends enables the contact portion 933c to be positioned at the free end portion of the coil end 33a.

From another viewpoint, the bent portion A33d is formed as a portion that is easily bent in the coil end 33a. The bent portion A33d is used to make the coil end 33a easier to bend than the case where only the bent portion 33b is formed in the suspended portion of the coil end 33a spanned between the guide portion 35c and the protrusion 77. It is formed as a part. The bending portion A33d allows the coil end 33a ahead of the bending portion A33d to rotate along the terminal 71 by deformation of the bending portion A33d itself. In other words, the bending portion A33d is prevented from moving so that the coil end 33a slides on the protrusion 77 by being deformed itself.

The bent portion A33d can also be referred to as a slack portion formed by loosening the coil end 33a between the guide portion 35c and the protrusion 77. In this embodiment, a step of bending the coil end 33a so as to form a slack in a suspended portion of the coil end 33a between the guide portion 35c and the terminal 71 is employed.

In this embodiment, both the shape of the guide portion 35c and the step of bending the coil end 33a are set so as to provide the shape of the coil end 33a illustrated. The coil end 33a is arranged and bent so that a part of the suspended portion thereof, that is, a part of the bent portion A33d is located on the terminal 71 side beyond the virtual plane PP.

The guide part 35c is formed so that the coil end 33a is arranged in the shape shown in the figure. The edge 42c is positioned on the welding electrode 82 side with respect to the virtual plane PP, that is, on the side in the protruding direction of the protrusion 77 with respect to the virtual plane PP. In other words, both of the radially

inner edges

41c and 42c of the groove 43 are positioned on the side opposite to the terminal 71 with respect to the virtual plane PP. Further, the guide portion 35 c is formed so as to be separated from the terminal 71 radially outward of the stator 31 so as to provide a space necessary for forming the bent portion A 33 d between the guide portion 35 c and the terminal 71. ing. In the step of bending the coil end 33a, the coil end 33a is bent from the

edges

41c and 42c so as to pass through the terminal 71 side beyond the virtual plane PP. In other words, the coil end 33a is bent so as to meander from the

edges

41c and 42c.

Also in this embodiment, the welding electrode 82 first contacts the contact portion 233c of the free end portion. The welding electrode 82 presses the coil end 33 a toward the terminal 71. As a result, the coil end 33 a is deformed along the terminal 71. At this time, the bending portion 333 d allows the coil end 33 a on the distal end side from the bending portion A 33 d to rotate so as to follow the terminal 71. The bent portion A33d functions as a hinge portion in the coil end 33a. Also in this embodiment, the welding electrode 82 does not contact only the suspended portion of the coil end 33a spanned between the protrusion 77 and the guide portion 35c. Compared with the case where the suspended portion of the coil end 33 a spanned between the guide portion 35 c and the terminal 71 is pushed, the coil end 33 a is restrained from sliding on the terminal 71. Thereby, a desirable weld is formed.

According to this embodiment, the coil end 33a is firmly positioned before welding. A slack is formed in the suspended portion of the coil end spanned between the guide portion 35c and the terminal 71. In the welding process, the coil end 33 a is pushed by the

welding electrodes

81 and 82. Therefore, the coil end 33 a tends to rotate along the terminal 71. At this time, the slack is deformed. Due to the deformation of the slack, the coil end 33a is prevented from moving so as to slide on the terminal 71. Thereby, a desirable weld is formed.

(Eleventh embodiment)
This embodiment is a modification based on the preceding embodiment. Instead of the preceding embodiment, various shapes of grooves 43 can be employed. FIG. 39 shows the groove 43 of this embodiment. The groove 43 has a quadrangular inlet B46 defined by a pair of edges parallel to the axial direction of the stator 31. Also in this embodiment, the coil end 33a can be guided by the inlet B46.

(Twelfth embodiment)
This embodiment is a modification based on the preceding embodiment. FIG. 40 shows the groove 43 of this embodiment. The groove 43 has an inlet portion 546 which can be called a triangle or a trapezoid defined by a pair of edges inclined with respect to the axial direction of the stator 31. Also in this embodiment, the coil end 33a can be guided by the inlet portion C46.

(13th Embodiment)
This embodiment is a modification based on the preceding embodiment. FIG. 41 shows the groove 43 of this embodiment. The groove 43 has an inlet portion D46 defined by one edge parallel to the axial direction and one edge inclined with respect to the axial direction. Also in this embodiment, the coil end 33a can be guided by the inlet portion D46.

(14th Embodiment)
This embodiment is a modification based on the preceding embodiment. In the preceding embodiment, an electrode 73 for a single phase coil is illustrated. Instead of this, the configuration of the guide portion 35c employed in the preceding embodiment can be applied to electrodes for various purposes.

FIG. 42 is a cross-sectional view modeling the stator 31 of this embodiment. In this embodiment,

electrodes

72, 73 for a three-phase coil are shown. The plurality of

electrodes

72 and 73 are arranged so that their surfaces extend in a substantially circumferential direction. The plurality of

electrodes

72 and 73 are arranged so as to be sandwiched by welding electrodes that can be opened and closed along the radial direction of the stator 31.

The electrode 73 connects the coil end 33 a and the power line of the wire harness 15. The electrode 73 has a terminal 71 and a terminal 74. The electrode 73 is a through electrode that penetrates the stator 31 in the axial direction. The electrode 73 has

terminals

71 and 74 that are separated from each other on both surfaces of the stator 31.

Electrode 72 provides a neutral point connection for a three-phase coil. The electrode 72 has a plurality of terminals 71. The electrode 72 is an E-shaped multi-head electrode. Also in this embodiment, the guide part 35c can employ the same structure as the preceding embodiment.

(Fifteenth embodiment)
This embodiment is a modification based on the preceding embodiment. In this embodiment,

other electrodes

272 and 273 are illustrated.

FIG. 43 is a cross-sectional view modeling the stator 31 of this embodiment. In this embodiment,

electrodes

272, 273 for a three-phase coil are shown. The plurality of

electrodes

272 and 273 are arranged so that the surfaces thereof extend substantially in the radial direction. The plurality of

electrodes

272 and 273 are arranged so as to be sandwiched between welding electrodes that can be opened and closed along the circumferential direction of the stator 31.

The electrode 872 connects the coil end 33 a and the power line of the wire harness 15. The electrode 273 is an L-shaped plate. The electrode 273 includes a terminal 71 and a terminal 274. The electrode 723 is a non-penetrating electrode that does not penetrate the stator 31. The electrode 273 has a fixing portion to the insulator 35 at one end thereof. The electrode 273 has a terminal 274 connected to the power line at the other end. The electrode 273 has a terminal 71 between the terminal 274 and the fixed portion.

A plurality of electrodes 272 provide a neutral point connection for the three-phase coil. Also in this embodiment, the guide part 35c can employ the same structure as the preceding embodiment.

(Other embodiments)
The disclosure in this specification is not limited to the illustrated embodiments. The disclosure encompasses the illustrated embodiments and variations by those skilled in the art based thereon. For example, the disclosure is not limited to the combinations of parts and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure may have additional parts that can be added to the embodiments. The disclosure includes those in which parts and / or elements of the embodiments are omitted. The disclosure encompasses the replacement or combination of parts and / or elements between one embodiment and another. The technical scope disclosed is not limited to the description of the embodiments. Some technical scope disclosed is 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, the height of the wall provided by the wall member 62 is set higher in the axial direction than the height of the coil end 33a and the terminal 71 disposed in the connecting portion 50. Instead of this, the height of the wall provided by the wall member 62 may be set slightly lower than or the same as the height of the coil end 33a and the terminal 71 disposed in the connecting portion 50. Even in this case, the coil end 33a and the terminal 71 arranged in the connecting portion 50 can be completely wrapped by the viscosity and surface tension of the protective resin 61.

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

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

10 rotating electrical machines, 11 electrical circuits, 12 internal combustion engines, 13 bodies,
14 rotating shaft, 15 wire harness, 21 rotor,
22 rotor core, 23 permanent magnet, 31 stator,
32 stator core, 32a magnetic pole, 33 stator coil,
33a coil end, 33b, 933b bent part,
33c, 933c contact part, A33d bent part,
35 insulator, 35a wall, 35b bobbin, 35c guide part,
36 steps, 37 positioning parts, 38 slits,
41 sensor unit,
841 1st protrusion, 842, 942, A42 2nd protrusion, 43 groove,
44 Thin plate part, 45 Deformation part, 46, B46, C46, D46 Inlet part,
47 Positioning part, 48 Clearance,
50, 51, 52 connection, 55 weld,
61 protective resin, 62 wall member,
63, 363, 463, 563, 663, 763 tubular member,
263 half cylinder member, 64 outer wall, 65 inner wall,
66, 266, 366, 666, 766 Notch, 67 Step,
569 Stepped portion, 769 Stepped portion,
71 terminals, 72, 272 electrodes, 73, 273 electrodes,
74, 274 terminals, 275 terminals, 276 electrodes, 77 protrusions,
81, 82 Welding electrodes.

Claims

In the rotating electrical machine (10) having the connection portion (50) for connecting the coil end (33a) and the terminal (71),
A wall member (62) forming an enclosure wall surrounding the coil end and the terminal;
A rotating electrical machine comprising a protective resin (61) which is stored in a storage tank defined by the surrounding wall and encloses the coil end and the terminal.
A rotor (21) connected to the rotating shaft (14) of the internal combustion engine;
A stator (31) disposed opposite the rotor;
An electrically insulating insulator (35) provided on the stator,
The coil end is an end of a stator coil (33) provided in the stator,
The terminal is supported by the insulator so as to extend along the axial direction of the stator,
The rotating electrical machine according to claim 1, wherein the wall member is disposed on the insulator so as to surround the coil end and the terminal.
The rotating electrical machine according to claim 2, wherein the wall member and the insulator have a connecting portion (36, 67, 37, 66) for connecting the wall member and the insulator.
The insulator has a wall (35a) extending in the axial direction of the stator,
The rotating electrical machine according to claim 2, wherein the surrounding wall is formed by the wall member and the wall.
The rotating electric machine according to any one of claims 2 to 4, wherein the terminal is provided on a part of an electrode (72, 272), and the electrode provides a neutral point connection of the stator coil.
The said terminal is provided in a part of electrode (73, 273), The said electrode has the other terminal (74, 274) connected with a power line in any one of Claims 2-4. Rotating electric machine.
A plurality of terminals (71) including the terminals;
The rotating electrical machine according to claim 1, wherein the wall member is disposed so as to surround the plurality of terminals.
The rotating electrical machine according to any one of claims 1 to 7, wherein the wall member has a notch (66, 266, 366, 666, 766) for allowing the coil end to pass therethrough.
The rotating electrical machine according to any one of claims 1 to 8, wherein the surrounding wall provided by the wall member is higher than the coil end and the terminal.
The rotating electric machine according to any one of claims 1 to 9, wherein the wall member has step portions (569, 769) for connection with the protective resin.
In the manufacturing method of the rotating electrical machine (10) having the connection part (50) for connecting the coil end (33a) and the terminal (71)
Connecting the coil end and the terminal;
After the coil end and the terminal are connected, a wall member (62) is arranged so as to form an enclosing wall surrounding the coil end and the terminal,
A method of manufacturing a rotating electrical machine in which the coil end and the terminal are wrapped with the protective resin by pouring protective resin (61) into a storage tank defined by the surrounding wall.
A rotor (21) connected to the rotating shaft (14) of the internal combustion engine;
A stator (31) disposed opposite the rotor;
An electrically insulating insulator (35) provided on the stator,
The coil end is an end of a stator coil (33) provided in the stator,
The terminal is supported by the insulator so as to extend along the axial direction of the stator,
The method for manufacturing a rotating electrical machine according to claim 11, wherein the wall member is mounted on the insulator along an axial direction of the stator.
The method for manufacturing a rotating electrical machine according to claim 12, wherein the wall member is mounted so as to be connected to the insulator.
A coil end (33a) which is an end of the stator coil (33);
A terminal (71) to which the coil end is connected;
A guide part (35c) for defining and forming a groove (43) for guiding the coil end toward the terminal by accommodating the coil end;
The guide part is
A positioning portion (47) provided at a predetermined position of the coil end in the groove and deformed by contact with the coil end;
An inlet portion (46, B46, C46, D46) provided at the inlet of the groove and having a width (WW) larger than a diameter (DC) of the coil end and larger than a width (WN) of the positioning portion. Rotating electric machine.
A rotor (21) connected to the rotating shaft (14) of the internal combustion engine;
A stator (31) disposed opposite the rotor;
An electrically insulating insulator (35) provided on the stator,
The stator coil is provided on the stator,
The terminal is supported by the insulator so as to extend along the axial direction of the stator,
The rotating electrical machine according to claim 14, wherein the guide portion includes a first protrusion (841) and a second protrusion (842, 942, A42) provided in the insulator and defining the groove.
The coil end has a bent portion (33b, A33d) that is a portion protruding from the guide portion and bent along the terminal,
The first protrusion is located inside the bent portion,
The second protrusion is located outside the bent portion,
The rotating electrical machine according to claim 15, wherein the second protrusion has a deforming portion (45) provided on the positioning portion and deformed by contacting with the coil end.
The rotating electrical machine according to claim 16, wherein the second protrusion is formed in a thin plate shape and has a thin plate portion (44) that forms the deformed portion by contacting the coil end.
The positioning part is
A portion that is deformed by contact with the coil end at a position where the coil end is positioned to provide a width equal to or greater than the diameter (DC) of the coil end;
The rotating electrical machine according to any one of claims 14 to 17, further comprising a portion having a width (WN) smaller than a diameter (DC) of the coil end.
A coil end (33a) which is an end of the stator coil (33);
A terminal (71) to which the coil end is connected;
In a method of manufacturing a rotating electrical machine, comprising a guide portion (35c) that defines a groove (43) that guides the coil end toward the terminal by accommodating the coil end,
Loosely positioning the coil end in an inlet portion (46, B46, C46, D46) provided at the entrance of the groove and having a width (WW) greater than the diameter (DC) of the coil end;
Moving the coil end via the inlet portion toward a positioning portion (47) provided at a predetermined position of the coil end in the groove;
In the positioning unit, the coil end and the guide unit are brought into contact with each other, the guide unit is deformed to position the coil end firmly, and the coil end is positioned by the positioning unit, A method of manufacturing a rotating electrical machine including connecting a terminal.
The connection is provided by sandwiching the coil end and the terminal by welding electrodes (81, 82) and welding the coil end and the terminal with the coil end positioned by the positioning portion. And
further,
The rotation according to claim 19, further comprising allowing the movement of the coil end by further deforming the guide portion due to the movement of the coil end when the coil end and the terminal are sandwiched by the welding electrode. Electric manufacturing method.
further,
21. The rotation according to claim 20, comprising bending the coil end before the welding so that the coil end is arranged on the terminal so as to be away from the terminal toward the tip of the coil end. Electric manufacturing method.
further,
The method of manufacturing a rotating electrical machine according to claim 20 or 21, further comprising bending the coil end so as to form a sag at the coil end between the guide portion and the terminal before the welding.
The method for manufacturing a rotating electrical machine according to claim 21 or 22, wherein the coil end is bent into an S shape.
A coil end (33a) which is an end of the stator coil (33);
A terminal (71) to which the coil end is connected;
In a method of manufacturing a rotating electrical machine, comprising a guide portion (35c) that defines a groove (43) that guides the coil end toward the terminal by accommodating the coil end,
Inserting the coil end into the groove to bring the coil end into contact with the guide part, deforming the guide part, and firmly positioning the coil end;
In a state where the coil end is positioned by the groove, the coil end and the terminal are sandwiched by welding electrodes (81, 82), and the coil end and the terminal are welded. A method of manufacturing a rotating electrical machine including allowing the coil end to move when the guide end is further deformed by the movement of the coil end when the terminal is sandwiched between the terminal and the terminal.
A coil end (33a) which is an end of the stator coil (33);
A terminal (71) to which the coil end is connected;
In a method of manufacturing a rotating electrical machine, comprising a guide portion (35c) that defines a groove (43) that guides the coil end toward the terminal by accommodating the coil end,
Inserting the coil end into the groove to bring the coil end into contact with the guide part, deforming the guide part, and firmly positioning the coil end;
Bending the coil end so that the coil end is arranged on the terminal so as to be away from the terminal toward the tip of the coil end, and welding the coil end in a state where the coil end is positioned by the groove. A method of manufacturing a rotating electrical machine, comprising sandwiching the coil end and the terminal between electrodes (81, 82) and welding the coil end and the terminal.
A coil end (33a) which is an end of the stator coil (33);
A terminal (71) to which the coil end is connected;
In a method of manufacturing a rotating electrical machine, comprising a guide portion (35c) that defines a groove (43) that guides the coil end toward the terminal by accommodating the coil end,
Inserting the coil end into the groove to bring the coil end into contact with the guide part, deforming the guide part, and firmly positioning the coil end;
Bending the coil end to form a slack in a suspended portion of the coil end spanned between the guide portion and the terminal;
With the coil end positioned by the groove, the coil end and the terminal are sandwiched by welding electrodes (81, 82), the coil end and the terminal are welded, and the coil end is connected to the terminal A method for manufacturing a rotating electrical machine, comprising the step of deforming the sag when rotating along.