WO2018221565A1 - Rotary electric machine and method for manufacturing rotary electric machine - Google Patents

Abstract

According to the present invention, a sensor unit (41) accommodates a sensor (43) which detects a rotation position by detecting the magnetic flux of a rotor. The sensor is disposed in a sensor gap between two neighboring magnetic poles (32a). The sensor unit, by means of a cover (53), extends in the axial direction from an end surface (SD1) side on one side of a stator into the sensor gap. A coil wire (33d) facing the sensor unit is disposed on the end surface side while being spaced apart from the magnetic poles in the radial direction. Accordingly, interference between the sensor unit and the coil wire is suppressed. Consequently, a reduction in the accuracy of detecting the rotation position caused by interference between the sensor unit and the coil wire is suppressed.

Description

Rotating electric machine and method of manufacturing rotating electric machine Cross-reference of related applications

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

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

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

JP 2017-34732 A JP 2013-233030 A JP 2013-27252 A Patent No. 5064279

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

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

One object disclosed is to provide a rotating electrical machine with high rotational position detection accuracy and a method of manufacturing the rotating electrical machine.

Another object of the present disclosure is to provide a rotating electrical machine and a method of manufacturing the rotating electrical machine in which a shift of a sensor element that detects a rotational position is suppressed.

Yet another object of the present invention is to provide a rotating electrical machine and a rotating electrical machine in which a coil element wire can be accurately arranged on a bobbin and displacement of a sensor element due to interference between the coil element wire and a sensor unit is suppressed. It is to provide a manufacturing method.

Yet another object disclosed is that the coil strands can be placed on the bobbin accurately and at high speed, making it suitable for mass production and suppressing displacement of the sensor elements due to interference between the coil strands and the sensor unit. And providing a method of manufacturing the rotating electric machine.

According to this disclosure, a rotating electrical machine is provided. The rotating electrical machine is provided with a rotor (21) that provides a magnetic field, and a plurality of magnetic poles that are provided at the ends of a plurality of teeth portions extending in the radial direction so as to be separated from each other along the circumferential direction. The stator core (32) having (32a) and the stator (31) having the stator coil (33) attached to the tooth portion, and the sensor magnetic flux (38b) between two adjacent magnetic poles, the magnetic flux of the rotor A sensor unit (41) that accommodates a sensor (43) for detecting the sensor, and the sensor unit extends into the sensor gap along the axial direction from one end surface (SD1) side in the axial direction of the stator, The coil wire (33d) of the stator coil facing the sensor unit is arranged on the one end face side away from the magnetic pole in the radial direction.

According to the disclosed rotating electrical machine, the coil wire of the stator coil facing the sensor unit is arranged radially away from the magnetic pole on one end face side. For this reason, interference with a sensor unit and a coil strand is suppressed. As a result, a decrease in detection accuracy of the rotational position due to interference between the sensor unit and the coil wire is suppressed.

According to this disclosure, a method of manufacturing a rotating electrical machine is provided. The rotating electrical machine manufacturing method is adjacent to a winding step in which a stator coil (33) is wound around the outer periphery of a plurality of bobbin portions (36) attached to a plurality of tooth portions (32c) having magnetic poles (32a) at the tips. An insertion step of inserting the sensor (43) from one end face (SD1) of the stator (31) in the gap between the two magnetic poles, and the winding step includes the coil wire (33d) of the stator coil, On one end face side, the coil wire is wound so as to be arranged radially away from the magnetic pole.

According to the disclosed rotating electrical machine, a coil shape that does not easily interfere with the sensor is provided when the sensor is inserted. As a result, a decrease in detection accuracy of the rotational position due to interference between the sensor and the coil wire is suppressed.

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

It is sectional drawing modeled of the rotary electric machine which concerns on 1st Embodiment. It is a top view of a stator. It is a perspective view of a stator. It is a top view of an insulator. It is a perspective view of an insulator. It is a side view which shows the magnetic pole and insulator in the direction of the VI arrow of FIG. It is a top view in the VII arrow of FIG. FIG. 7 is a cross-sectional view taken along the line VIII-VIII in FIG. 6. It is a partial perspective view of an insulator. It is a partial perspective view of an insulator. It is a top view of a sensor unit. It is a perspective view of a sensor unit. It is a side view of the radial inside of a sensor unit. It is a perspective view of a sensor unit. It is the modeled perspective view of a cover. It is sectional drawing of a cover. It is a side view which shows a stator core and a sensor unit. It is a side view which shows a part of one pole in a cross section. It is sectional drawing which shows the relationship between a cover and a coil. It is a side view which shows a part of one pole of 2nd Embodiment in a cross section. It is a partial perspective view of the insulator of 3rd Embodiment. It is a partial perspective view of the insulator of a 4th embodiment. It is a partial perspective view of the insulator of a 5th embodiment. It is a partial perspective view of the insulator of 6th Embodiment. It is a partial perspective view of the insulator of a 7th embodiment. It is a partial perspective view of the insulator of 8th Embodiment. It is a side view which shows a part of one pole of 9th Embodiment in a cross section. It is an external view of the bare core in one pole of a 10th embodiment. It is an external view which shows one pole after an inner layer was mounted | worn. It is an external view which shows one pole after the outermost layer was mounted | worn. It is sectional drawing which shows a winding apparatus. It is a diagram which shows the movement process of a shaping | molding machine. It is a diagram which shows the movement process of a shaping | molding machine.

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 of an internal combustion engine 12 for a vehicle. The vehicle is a vehicle, a ship, or an aircraft, and a typical example is a saddle type vehicle.

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 shaft 14 rotates when the internal combustion engine 12 is operated.

The rotating shaft 14 rotates the rotating electrical machine 10 so that the rotating electrical machine 10 functions as a generator. The rotating shaft 14 is a rotating shaft that can start the internal combustion engine 12 by the rotation of the rotating electrical machine 10 when the rotating electrical machine 10 functions as an electric motor. The rotating shaft 14 is a rotating shaft that can assist (assist) the rotation of the internal combustion engine 12 by the rotation of the rotating electrical machine 10 when the rotating electrical machine 10 functions as an electric motor.

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 AD means the direction of the central axis when the stator 31 is regarded as a cylindrical body. The term “radial direction RD” means a radial direction when the stator 31 is regarded as a cylindrical body.

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

The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 is connected to the rotating shaft 14 of the internal combustion engine 12. The rotor core 22 has an inner cylinder fixed to the rotating shaft 14, an outer cylinder positioned on the radially outer side of the inner cylinder, and an annular bottom plate extending between the inner cylinder and the outer cylinder. The rotor core 22 provides a yoke for a permanent magnet 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 permanent magnet 23 is fixed inside the outer cylinder. The permanent magnet 23 is fixed with respect to the axial direction AD and the radial direction RD by a holding cup 24 arranged on the radially inner side. The holding cup 24 is made of a thin nonmagnetic metal. The holding cup 24 is fixed to the rotor core 22.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The case 51 has a tightening portion 54. The tightening portion 54 is provided radially inward of the container 52 with respect to the radial direction RD of the rotating electrical machine 10. A connecting portion 55 is provided between the container 52 and the tightening portion 54 to connect them. The fixing bolt 44 is disposed through the stator core 32 from the surface of the stator core 32 opposite to the body 13. The front end portion of the fixing bolt 44 protruding from the stator core 32 is screwed into the female thread portion of the tightening portion 54. Thereby, the sensor unit 41 is fixed to the stator core 32. The inside of the container 52 is filled with a protective sealing resin 56. The sealing resin 56 is a potting resin for protecting the electric circuit component 42.

The sensor unit 41 has a wiring 11a for external connection for taking out signals output from one or a plurality of sensors 43 to the outside. The wiring 11a can transmit an ignition signal indicating a reference position and / or a rotation position signal indicating a rotation angle. The rotating electrical machine 10 includes a plurality of power lines 11 b that connect the stator coil 33 and the electric circuit 11. The electric power line 11b 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 electric power line 11 b supplies electric 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 annular member. The stator 31 has a through hole that can receive the rotating shaft 14 and the inner cylinder of the rotor core 22. The stator core 32 defines a through hole for receiving the inner shaft of the rotary shaft 14 and the rotor core 22. Further, the stator core 32 has a plurality of through holes for receiving a plurality of fixing bolts 34. These through holes contribute to defining the position of the stator core 32 in the circumferential direction. The stator core 32 has a through hole for receiving a fixing bolt 44 for fixing the sensor unit 41.

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

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

The stator coil 33 provides a multi-phase armature winding. The stator coil 33 is attached to the plurality of tooth portions 32c. The stator 31 is a three-phase multipolar stator having a plurality of magnetic poles 32a and a plurality of three-phase windings. The stator coil 33 has a plurality of single coils 33s. The single coil 33s is a coil attached to one magnetic pole 32a and one tooth portion 32c. The single coil 33s is concentratedly wound around one tooth portion 32c. The plurality of single coils 33s provide one phase coil. A multi-phase armature winding is provided by a plurality of phase coils.

The insulator 35 has two halves 35a and 35b that sandwich the stator core 32 in the axial direction. The half body 35a is located on one end surface SD1 side of the stator 31 in the axial direction. The sensor unit 41 is disposed on the one end surface SD1. The half body 35 a is located on the other end face SD <b> 2 side in the axial direction of the stator 31. The other end surface SD2 is an end surface opposite to the end surface on which the sensor unit 41 is disposed. A coil wire 33d, which will be described later, is disposed on the halved body 35a so as to be separated from the magnetic pole 32a in the radial direction. The half body 35a includes a protruding portion 37e described later. The half body 35b does not include the protruding portion 37e.

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

The insulator 35 has guide fins 35d for guiding the jumper wire 33j on the central portion 35c. The guide fins 35d are positioned on the fixed portion. The guide fin 35d is a plate-like member. The guide fins 35d extend in the radial direction. The guide fins 35d extend in the axial direction. The guide fins 35d are integrally formed of a material continuous with the insulator 35. The guide fin 35d has an edge extending in the axial direction on the radially outer side. The guide fin 35d has an edge on the radially inner side that is inclined so as to be separated from the stator core 32 toward the radially outer side. The guide fins 35 d are part of the end surface of the stator 31 and protrude from the end surface of the stator core 32 in the axial direction. The insulator 35 includes a plurality of guide fins 35d. The plurality of guide fins 35d are separated from each other along the circumferential direction. The plurality of guide fins 35d are arranged radially.

The manufacturing method of the rotating electrical machine 10 includes a wiring step of arranging the jumper wire 33j in the annular range where the stator coil 33 is installed. The at least one guide fin 35d suppresses the jumper wire 33j from entering inward in the radial direction in the manufacturing process of the rotating electrical machine 10. Further, at least one guide fin 35d suppresses the intrusion of the jumper wire 33j in the radial direction in the finished product. In other words, the guide fin 35d guides the coil element wire so as to suppress the penetration of the coil element wire into the fixed portion. By preventing the jumper wire 33j from entering inward in the radial direction, damage to the jumper wire 33j is suppressed. The guide fin 35d guides the jumper wire 33j without occupying a wide range above the fixed portion. The guide fin 35d does not hinder the arrangement of the tightening portion 54 and the arrangement of the fixing bolt 34 in the annular portion 32b.

The insulator 35 has a bobbin portion 36 that covers the tooth portion 32c. The bobbin portion 36 is disposed between the tooth portion 32 c and the stator coil 33. The insulator 35 has a flange portion 37 that is located at the radially outer end and extends along the edge of the magnetic pole 32a. The flange portion 37 is disposed between the magnetic pole 32 a and the stator coil 33.

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

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

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

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

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

The insulator 35 has a plurality of bobbin portions 36. The plurality of bobbin portions 36 includes a plurality of normal bobbin portions 36a located on both sides of the normal gap 38a and a plurality of sensor bobbin portions 36b located on both sides of the sensor gap 38b where the cover 53 is disposed. A normal bobbin portion 36a and a sensor bobbin portion 36b are positioned on both sides of the two normal gaps 38a located on both sides of the four sensor gaps 38b. Among the four sensor gaps 38b, sensor bobbin portions 36b are positioned on both sides of the endmost sensor gap 38b. The sensor bobbin portion 36b has an uneven portion corresponding to a coil guide portion described later.

The insulator 35 has a plurality of flange portions 37. The flange portion 37 is provided at the distal end of the bobbin portion 36 in the radial direction. The plurality of flange portions 37 include a first flange portion 37a, a second flange portion 37b, and a third flange portion 37c. The first flange portion 37a, the second flange portion 37b, and the third flange portion 37c correspond to the first magnetic pole 32aw, the second magnetic pole 32am, and the third magnetic pole 32as, respectively. The second flange portion 37b and the third flange portion 37c are disposed on the second magnetic pole 32am and the third magnetic pole 32as that form the sensor gap 38b. Since the second flange portion 37b and the third flange portion 37c are related to the cover 53, they can also be called sensor flange portions. The sensor flange portion has a guide portion corresponding to a coil guide portion described later.

The normal bobbin portion 36a and the first flange portion 37a provide a normal insulator portion corresponding to the magnetic pole 32a that forms the normal gap 38a. The sensor bobbin portion 36b and the second flange portion 37b provide a sensor insulator portion corresponding to the magnetic pole 32a that forms the sensor gap 38b. The sensor bobbin portion 36b and the third flange portion 37c provide a sensor insulator portion corresponding to the magnetic pole 32a that forms the sensor gap 38b. A coil guide described later is provided only in the sensor insulator portion. Thereby, the coil wire 33d of the stator coil 33 facing the sensor unit 41 is disposed away from the magnetic pole 32a in the radial direction on the one end face SD1 side.

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

The surface 36e and the plurality of fins 36f provide an uneven portion on the surface of the sensor bobbin portion 36b. The uneven portion holds the coil wire of the stator coil 33 at a predetermined position. The uneven part restricts the movement of the coil wire in the sensor bobbin portion 36b. The uneven portion is one of coil guide portions that radially separate the stator coil 33 from the third magnetic pole 32as on the one end face SD1 side.

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

Returning to FIG. 6 and FIG. 7, the halved body 35a has a third flange portion 37c. The third flange portion 37c has a protruding portion 37e. The protruding portion 37e protrudes on one end surface SD1 side. The protruding portion 37e protrudes from the flange portion toward the inner stator coil 33 in the radial direction along the tooth portion 32c. The radially inner surface of the projecting portion 37e is away from the field of the rotor 21. The surface of the protruding portion 37e protrudes toward the inside in the radial direction. The surface of the protruding portion 37e protrudes toward the root of the tooth portion 32c. Of the flange portion 37 extending around the entire circumference of the tooth portion 32c, only a portion close to one end surface SD1 protrudes as a protruding portion 37e. The protruding portion 37e protrudes more than the base flange surface 37d. The base flange surface 37d is a surface facing the stator coil 33 of the flange portion 37 on the other end surface SD2 side of the stator 31. In other words, the foundation flange surface 37d is an inner surface of the flange portion 37 provided in the half body 35b.

The protruding portion 37e separates the stator coil 33 from the third magnetic pole 32as in the radial direction. The projecting portion 37e is one of coil guide portions that radially separate the stator coil 33 from the third magnetic pole 32as on one end face side.

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

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

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

Similarly to FIG. 9, the sensor insulator portion for the second magnetic pole 32am also has a surface 36e and a plurality of fins 36f for providing the uneven portion on the sensor bobbin portion 36b. Similarly to FIG. 9, the sensor insulator portion for the second magnetic pole 32am also has a protruding portion 37e on the third flange portion 37c. The uneven portion and the protruding portion 37e provide a coil guide portion that causes the stator coil 33 to be separated from the second magnetic pole 32am in the radial direction.

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

Referring back to FIG. 9, the projecting portion 37e separates the stator coil 33 radially inward and defines its position. The stator coil 33 is separated in the radial direction so as to avoid the cover 53 only at a position where the cover 53 enters. It is desirable that the distance that the stator coil 33 is separated in the radial direction is kept to the minimum necessary for stably arranging the cover 53. As will be described later, the winding process that proceeds from the inner layer to the outer layer contributes to reducing the distance. Further, the uneven portion in the sensor bobbin portion 36b also contributes to accurately control the distance.

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

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

11 and 12, the case 51 has a container 52 and a cavity 58. The container 52 accommodates the electric circuit component 42 and is sealed with an electrically insulating sealing resin 56. On the other hand, the cavity 58 is not sealed with a sealing resin. The cavity 58 provides a cavity. The cavity 58 is divided into a plurality of partitions. The cavity 58 has three cavities 58a, 58b, and 58c. The cavity 58 is provided at the radially inner edge of the container 52. The hollow portion 58 provides high rigidity against the warp deformation of the case 51 by the partition wall. The cavity 58 reduces the weight of the case 51. The cavity 58 suppresses the usage amount of the sealing resin 56. The cavity 58 contributes to suppress warping deformation of the case 51.

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

14, the direction label indicates the circumferential direction CD and the radial direction RD in the cover 53d. The cover 53d has a width WT along the circumferential direction CD, a length LG along the axial direction AD, and a thickness TH along the radial direction RD. The cover 53 d extends from the bottom plate of the container 52 toward the outside of the container 52. The cover 53d has a proximal end portion on the container 52 side and a distal end portion on the opposite side.

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

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

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

The cover 53d is radially inward and has relief portions 53m and 53n on both sides of the circumferential direction CD. The escape portions 53m and 53n face the coil. The escape portions 53m and 53n extend between the tip portion 53e, the side portion 53f, and the inner portion 53i. The escape portions 53m and 53n are flat surfaces or curved surfaces. The escape portions 53m and 53n are wide at the distal end portion 53e and narrow at the proximal end portion. In other words, the clearances 53m and 53n are wide at the distal end of the cover 53d and narrow at the proximal end of the cover 53d. The escape portions 53m and 53n suppress contact between the coil and the cover 53d. In the distal end portion 53e, a predetermined distance 53p remains between the escape portion 53m and the escape portion 53n.

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

Referring back to FIG. 14, the plurality of covers 53 have a shape similar to the cover 53d. However, the cover 53a is longer than the other covers 53b, 53c, 53d. The cover 53a has escape portions 53m and 53n wider than the other covers 53b, 53c and 53d. The distance 53p in the cover 53d is larger than the distance 53p in the cover 53a. The distance 53p in the cover 53a may be 0 (zero) mm.

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

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

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

The coil wire has shifted from the inner layer 33a to the outermost layer 33b on the surface opposite to the illustrated single coil 33s. The coil wire 33c forming the final turn of the inner layer 33a circulates around the bobbin portion 36. The coil wire 33d forming the first turn of the outermost layer 33b rides on the inner layer 33a at a portion adjacent to the magnetic pole 32a, and moves to the outermost layer 33b.

The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is radially inward from the magnetic pole 32a toward the one end surface SD1 side from the other end surface SD2 side in the axial direction of the stator 31 at the back of the page. Inclined to leave. Furthermore, the coil wire 33d is inclined so as to approach the magnetic pole 32a in the radial direction from one end surface SD1 side in the axial direction of the stator 31 toward the other end surface SD2 side before the paper surface. The coil wire 33d of the outermost layer 33b is positioned farther from the magnetic pole 32a than the other part only on the one end face SD1 side. The coil wire 33d of the outermost layer 33b is positioned near the magnetic pole 32a on the other end face SD2 side. The coil wire 33d of the outermost layer 33b is positioned so as to be farther from the magnetic pole 32a on the one end face SD1 side than the central portion in the axial direction. As a result, when the sensor unit 41 is arranged so that the cover 53 extends from one end surface SD1 as indicated by a broken line, the coil strand 33d is positioned away from the cover 53. Interference between 33d and the cover 53 is suppressed.

The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is positioned on a recess formed between the plurality of coil wires 33c of the inner layer 33a. Thus, the coil wire 33d is disposed away from the magnetic pole 32a radially inward on the one end face SD1 side. Such an aligned arrangement of the coil wires enables the coil wire 33d of the outermost layer 33b to be arranged at a target position. In particular, the single coil 33s has a circumferential width smaller than the axial length. For this reason, the coil strand 33d is wound so as to bend the coil strand 33d on the one end face SD1 side in the winding step. For this reason, the coil wire 33d is easily disposed on the concave portion on the one end face SD1 side.

The insulator 35 has a bobbin portion 36 disposed between the tooth portion 32 c and the stator coil 33. As described above, the bobbin portion 36 has an uneven portion that defines the position of the coil wire on the bobbin portion 36. The uneven portion is provided by the surface 36e and the plurality of fins 36f. The concavo-convex portion allows the inner layer 33a and the outermost layer 33b to be wound in an aligned state. This uneven portion is also referred to as a coil guide portion that radially separates the stator coil 33 from the magnetic pole 32a on one end surface SD1 side.

The insulator 35 has a flange portion 37 disposed between the magnetic pole 32 a and the stator coil 33. The flange portion 37 has a protruding portion 37e that protrudes from the flange portion 37 along the tooth portion 32c toward the stator coil 33. The protruding portion 37e protrudes from the foundation flange surface 37d. The protruding portion 37e separates the stator coil 33 from the magnetic pole 32a in the radial direction on the one end surface SD1 side. Therefore, the protrusion part 37e is also a coil guide part. The coil wire 33d is arranged away from the magnetic pole 32a in the radial direction only on the one end face SD1 side.

The plurality of magnetic poles 32a define a normal gap 38a where the sensor unit 41 is not arranged and a sensor gap 38b where the sensor unit 41 is arranged. The coil element wire 33d is arranged on the one end face SD1 side so as to be separated in the radial direction from only the magnetic pole 32a forming the sensor gap 38b. In other words, the protruding portion 37e is provided only on the flange portion 37 provided on the magnetic pole 32a that defines the sensor gap 38b.

The amount by which the coil wire 33d of the outermost layer 33b moves radially inward on the one end face SD1 side depends on the protruding amount of the protruding portion 37e from the basic flange surface 37d. The protruding amount can be about ½ of the diameter of the coil wire 33c. The protruding amount is set in consideration of the accuracy of the winding machine so that the coil wire 33d is positioned on the recess formed by the coil wire 33c. As a result, the coil wire 33d is positioned radially inward from the basic flange surface 37d by the diameter of the coil wire 33d.

The configuration in which the stator coil 33 is separated from the magnetic pole 32a only in a part of the stator core 32 simplifies the winding process. The manufacturing method of the rotating electrical machine 10 includes a winding step of attaching a coil wire to the plurality of tooth portions 32c. In this winding process, if the coil wires are aligned using the concavo-convex portion, the winding process may be extended in time. However, in this embodiment, unevenness is provided only on the sensor bobbin portion 36b. For this reason, a high-speed winding can be realized in the normal bobbin portion 36a.

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

FIG. 19 shows two magnetic poles 32a and one cover 53 viewed from one end face SD1 side. The cover 53 is shown as a cross section. The coil wire 33d is separated from the magnetic pole 32a radially inward on the one end face SD1 side. Thereby, interference with the cover 53 and the coil strand 33d is suppressed.

The manufacturing method of the rotating electrical machine 10 includes a winding process and an insertion process after the winding process. In the winding process, the stator coil 33 is wound around the outer periphery of the plurality of bobbin portions 36 attached to the plurality of tooth portions 32c having the magnetic poles 32a at the tips. The winding process is performed by a winding machine. The winding process includes a high-speed process that is normally performed on the bobbin part 36a and a low-speed part that is executed on the sensor bobbin part 36b. The low-speed part is also called a high-accuracy process in which the coil wire is arranged at a predetermined position with higher accuracy than the high-speed process.

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

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

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

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

Thus, in this embodiment, the coil wire 33 d is arranged so as to be away from the cover 53. Thereby, insertion of the cover 53 becomes easy. Further, since a gap is formed between the cover 53 and the coil element wire 33d, the coil can be easily cooled. Further, the gap between the cover 53 and the coil wire 33d facilitates the change of the stator coil 33. For example, the length, diameter, number of turns, material, thickness of the insulating layer, etc. of the coil wire can be changed. For example, two sensor units 41 having the same shape can be used with a coil metal wire made of copper metal and a coil wire made of aluminum metal.

Second Embodiment This embodiment is a modified example based on the preceding embodiment. In the above embodiment, the protruding portion 37e is employed. Instead, in this embodiment, a protruding portion 237e that is longer in the axial direction than the protruding portion 37e is employed.

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

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

Third Embodiment This embodiment is a modification in which the preceding embodiment is a basic form. In this embodiment, a protruding portion 337e is employed.

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

Fourth Embodiment This embodiment is a modified example based on the preceding embodiment. In this embodiment, the protruding portion 437e is employed.

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

Fifth Embodiment This embodiment is a modified example based on the preceding embodiment. In this embodiment, a protruding portion 537e is employed.

23, the third flange portion 37c has two protruding portions 537e. The protruding portions 537e are disposed on both sides in the circumferential direction of the third flange portion 37c. The protruding portion 537e has a cylindrical shape. The protruding portion 537e protrudes radially inward from the radially inner surface of the third flange portion 37c. The protruding portion 537e is provided only in part with respect to the axial direction. When the protruding portion 537e is provided in the second flange portion 37b, it may be provided only in a portion adjacent to the sensor gap 38b. In the vicinity of the cover 53, the protruding portion 537e arranges the coil wire away from the basic flange surface 37d inward in the axial direction.

Sixth Embodiment This embodiment is a modification in which the preceding embodiment is a basic form. In this embodiment, the protruding portion 637e is employed.

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

Seventh Embodiment This embodiment is a modified example based on the preceding embodiment. In this embodiment, a protruding portion 737e is employed.

25, the third flange portion 37c has a plurality of protruding portions 737e. The plurality of protruding portions 737e are arranged away from each other in the circumferential direction. Between the plurality of protruding portions 737e, the base flange surface 37d is exposed in a groove shape. The groove forms a gap between the third flange portion 37c and the coil wire. The gap may contribute to improve the heat dissipation of the coil wire through air as a cooling medium. In this embodiment, the same operation and effect as the preceding embodiment can be obtained.

Eighth Embodiment This embodiment is a modification example based on the preceding embodiment. In this embodiment, a protruding portion 837e is employed.

26, both the half body 35a and the half body 35b have a protruding portion 837e. The protruding portion 837e protrudes in the radial direction from the base flange surface 37d as it goes from the other end surface SD2 to the one end surface SD1. As a result, the coil wires 33c and 33d are inclined over a wider range. In this embodiment, the same operation and effect as the preceding embodiment can be obtained.

Ninth Embodiment This embodiment is a modification example based on the preceding embodiment. In the above embodiment, a coil guide is employed. Instead, in this embodiment, the coil wire 33d of the outermost layer 33b is arranged so as to be separated from the magnetic pole 32a without the coil guide portion.

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

The coil wire 33d of the outermost layer 33b rides on the inner layer 33a at a portion adjacent to the magnetic pole 32a and moves to the outermost layer 33b. The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is inclined so as to be separated from the magnetic pole 32a in the radial direction from the other end surface SD2 side in the axial direction of the stator 31 toward the one end surface SD1 side. Yes. The coil strands 33d of the outermost layer 33b facing the sensor unit 41 are positioned on the recesses formed between the plurality of coil strands 33c of the inner layer 33a, so that the one end face SD1 side is separated from the magnetic pole 32a. They are spaced apart in the radial direction. The coil wire 33d rides on the inner layer 33a at a portion adjacent to the magnetic pole 32a and moves to the outermost layer 33b. The coil wire 33c and the coil wire 33d pass through the riding position 33r. At the riding position 33r, the coil wire 33c and the coil wire 33d overlap in the circumferential direction. The riding position 33r is located on the side surface of the tooth portion 32c facing in the circumferential direction. At the riding position 33r, the coil wire 33d bulges outside the tooth portion 32c.

27, the sensor unit 41 and the cover 53 are indicated by broken lines. The riding position 33r is located on the other end surface CD2 side than the tip of the cover 53. For this reason, interference with the coil strand 33d and the cover 53 is suppressed. Such a shape of the coil wire is realized on at least the plurality of sensor bobbin portions 36b. Such a shape of the coil wire is not usually realized on the bobbin portion 36a. For this reason, the winding process can be carried out for other purposes on the normal bobbin portion 36a. For example, the speed of the winding process can be more important than the arrangement of the coil wires. However, such a shape of the coil wire may be realized on all the bobbin portions 36.

According to this embodiment, the coil element wire 33d of the stator coil 33 facing the sensor unit 41 can be arranged away from the magnetic pole 32a in the radial direction on the one end face SD1 side without the coil guide portion. For this reason, interference with a coil strand and the cover 53 can be suppressed.

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

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

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

The plurality of fins A36f are arranged at equal intervals along the length direction. The plurality of intervals Pt between the plurality of fins A36f correspond to the diameter of the coil wire. The interval Pt may be smaller than the diameter of the coil wire. The interval Pt can be made larger than the diameter of the coil wire, but it is not preferable in order to accurately position the coil wire. Therefore, the interval Pt can be adjusted so that the coil wire can be positioned, and the word “equivalent” indicates a range in which this object can be achieved. The interval Pt is also called a pitch. The initial distance between the base flange surface 37d and the first fin A 36f corresponds to the diameter of the coil wire. The initial spacing allows the coil wire 33c to be positioned adjacent to the base flange surface 37d. In the preferred form, the initial spacing allows contact between the coil strand 33c and the foundation flange surface 37d.

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

The plurality of fins A36f are positioned in alignment with each other in the circumferential direction on the outer periphery of the core. A plurality of virtual circumferential trajectories can be assumed on the outer periphery of the core. In the figure, two typical virtual circumferential trajectories RI and RO are shown. The plurality of virtual circumferential trajectories are perpendicular to the central axis of the tooth portion 32c. One virtual circumferential trajectory goes around the core. The plurality of virtual orbits are parallel to each other. Four fins A36f are positioned on one virtual circumferential track. In other words, the four fins A36f arranged in the circumferential direction of the core define one virtual circumferential trajectory. When the bobbin portion 36 includes the plurality of fins A36f, the outer peripheral shape of the bobbin portion 36 includes irregularities with a predetermined pitch. Moreover, the bobbin portion 36 is characterized by irregularities that are equally spaced in the length direction.

The inner surface of the flange portion A37c is planar. The inner surface of the flange portion A37c is defined by a base flange surface 37d. The distance between the outermost virtual circumferential track RO in the radial direction and the base flange surface 37d corresponds to the diameter of one coil wire 33c. The distance between the innermost virtual circumferential trajectory RI in the radial direction and the central portion 35c is not constant in order to position the coil wire 33c at the beginning of winding. The central portion 35c can include a positioning portion 36s for positioning the coil wire 33c at the beginning of winding.

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

As shown in the front side surface S1, the coil wire 33c has a start end ST at the start of winding. The start end ST is provided at the base of the teeth. The start end ST is provided at the opposite end in the protruding direction (length direction) of the magnetic pole. The coil wire 33c is not disconnected at the start end ST. The coil wire 33c is drawn on the bobbin portion 36 from the outside of the bobbin portion 36 as indicated by a broken line. The coil strand 33c has a return end RN for changing the winding direction. The coil wire 33c is not disconnected at the return end RN. The coil wire 33c is continuous as indicated by a broken line. The return end RN is disposed so as to contact the base flange surface 37d.

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

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

The inner layer 33a terminates at a return end RN located on the back side S3. In front of the return end RN, the coil wire 33c is arranged so as to be in contact with the foundation flange surface 37d from the right side surface S4. Note that the return end RN is an end set for explanation, and the coil wire is continuous at the return end RN.

The inner layer 33a including a plurality of turns can be wound with the start end ST positioned on one of the four side surfaces. The front side surface S1 where the start end ST is positioned can be referred to as a first side surface. Side surfaces following the first side surface can be referred to as a second side surface, a third side surface, and a fourth side surface in this order. The skew portion 33ff is positioned on one of the remaining three side surfaces. The skew portion 33ff can be positioned on the second side surface, the third side surface, or the fourth side surface. The skew portion 33ff is preferably positioned on a wide side surface among the four side surfaces.

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

As illustrated in the front side surface S1, the outermost layer 33b is wound over only a part of the bobbin portion 36 in the length direction. The inner layer 33a and the outermost layer 33b have the same winding direction. The inner layer 33a and the outermost layer 33b are reverse in the direction of winding. The traveling direction of the inner layer 33a is a direction from the central portion 35c toward the flange portion A37c. The traveling direction of the outermost layer 33b is a direction from the flange portion A37c toward the central portion 35c. The traveling direction of the outermost layer 33b is also called a return direction.

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

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

The outermost layer 33b has a skew portion 33fs. The skew portion 33fs may be a transition portion from the inner layer 33a to the outermost layer 33b. The skew portion 33fs is the first skew portion in the outermost layer 33b. The oblique portion 33fs has a circumferential length ADfs. The skew portion 33fs provides rewinding with a pitch of 1/2 Pt with respect to the length direction. The pitch of the skew portion 33fs is ½ of the pitch of the skew portion 33ss. The oblique portion 33fs shifts to a recess between two adjacent coil wires 33c after riding on the inner layer 33a. The coil wire 33d gets over the coil wire 33c of the inner layer 33a in the skewed portion 33fs. After the coil strand 33d rides on the coil strand 33c, the coil strand 33d moves along a recess between two adjacent coil strands 33c.

Furthermore, the outermost layer 33b has a skewed portion 33ss. The skewed portion 33 ss has a circumferential length ADs. The skew portion 33ss provides rewinding of the pitch Pt with respect to the length direction. The length ADs is longer than the length ADfs (ADfs <ADs).

The skew portion 33fs and the skew portion 33ss are shifted with respect to the circumferential direction. The skew portion 33fs is positioned at a position preceding the skew portion 33ss in the winding direction. The internal angle formed by the skewed portion 33fs and the virtual circumferential track is larger than the internal angle formed by the skewed portion 33ss and the virtual circumferential track. The skew portion 33fs provides the first winding advance in the outermost layer 33b. The skew portion 33ss provides a plurality of remaining winding advances in the outermost layer 33b. The arrangement of the skew portion 33fs and the skew portion 33ss causes the outermost layer 33b to move away from the flange portion A37c while suppressing mutual interference. The outermost layer 33b transitions away from the flange portion A37c. Therefore, the cover portion 53 of the sensor unit 41 is installed avoiding strong interference with the coil wire 33d.

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

Cross section C1 shows a cross section taken along line C1-C1. Since the insulator 35 provides a thin cross section, the cross section is not hatched. The illustrated coil wire 33e is in the process of moving from the inner layer 33a to the outermost layer 33b while interfering with the skewed portion 33ff of the inner layer 33a.

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

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

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

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

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

FIG. 31 is a cross-sectional view showing the winding device 61. The winding device 61 is used in a method for manufacturing a stator in a rotating electrical machine. The winding device 61 executes a winding process for the stator 31. The winding device 61 includes a flyer 62 for winding a coil, and a feeder 63 that supplies a coil wire 63a. The winding device 61 has a forming device 64 for adjusting the position of the coil wire 63 a on the bobbin portion 36. The shaper 64 can move along the bobbin portion 36. The molding device 64 guides the coil wire 63a. The molding device 64 is a member that molds the coil wire 63a. The winding device 1 may include an auxiliary molding device 65 that faces the molding device 64. The flyer 62 winds the coil wire 63 a around the outer periphery of the bobbin portion 36. The coil wire 63 a is arranged at a predetermined position on the bobbin portion 36 by the molding device 64. At this time, the plurality of fins A36f stabilize the position of the coil wire 63a. The winding device 61 includes a control device 66 (CNT) that controls the movement position of the molding device 64.

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

The thin solid line CMP indicates the movement of the molding machine of the comparative form. The molding machine of the comparative form moves at a constant speed. Therefore, the coil wire is disposed obliquely on all side surfaces. In this comparative embodiment, the crossing angle between the inner coil element wire and the outermost coil element wire is small. For this reason, the position of the outermost coil wire is not stable. As a result, the outermost coil may collapse.

The thick solid line EMB indicates the movement of the molding device 64 of this embodiment. When the coil wire 63a is positioned at the start end ST, the flyer 62 rotates. The flyer 62 winds the coil wire 63 around the core. At the same time, the former 64 moves as the winding process proceeds. The molding machine 64 is controlled to advance intermittently. The movement amount of the molding device 64 on the front side surface S1, the left side surface S2, and the back side surface S3 is smaller than the movement amount of the molding device 64 on the right side surface S4. The molding device 64 advances more than the remaining side surface only on one of the side surfaces. Moreover, the one side surface on which the molding machine 64 moves greatly is the same in the inner layer 33a and the outer layer 33b. For this reason, the skewed portion 33ff of the inner layer 33a and the skewed portions 33fs, 33ss of the outer layer 33b intersect each other. Moreover, a relatively large crossing angle can be obtained. As a result, the collapse of the outermost layer 33b is suppressed.

In this embodiment, the amount of movement of the molding device 64 on the front side S1, the left side S2, and the back side S3 is zero (0). The amount of movement of the molding device 64 on the right side surface S4 is the pitch Pt. The molding device 64 is fixed on 3/4 of the four side surfaces. The molder 64 advances only on 1/4 side. As a result, the coil wire 63a is arranged straight on 3/4 side surfaces. The coil wire 63a is arranged so as to form the skewed portion 33ff only on the ¼ side surface.

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

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

The flyer 62 rotates even during the return process. The flyer 62 continuously winds the coil wire 63a from the return end RN. The coil wire 63a gradually runs on the inner layer 33a from the return end RN. Soon, on the right side S4, the coil wire 63a reaches the inner layer 33a.

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

In this embodiment, the amount of movement of the molding device 64 on the front side S1, the left side S2, and the back side S3 is zero (0). The movement amount of the molding device 64 on the right side surface S4 is 1/2 Pt or Pt. The molding machine 64 is fixed in the circumferential direction on 3/4 of the four side surfaces. The former 64 returns only on the 1/4 side. As a result, the coil wire 63a is arranged straight on 3/4 side surfaces. The coil wire 63a is arranged so as to form the skewed portion 33fs on only ¼ side surfaces.

The molding machine 64 moves backward by 1/2 Pt on the first right side S4. Thereby, the skew portion 33fs is formed. In the behavior of the molding device 64, the coil wire 63a is arranged so as to get over the coil wire 33c of the inner layer 33a. Thereby, one intersection is formed. The intersection between the skew portion 33ff and the skew portion 33fs provides a relatively large intersection angle. Therefore, the positional deviation of the coil wire 63a is suppressed.

The molding machine 64 moves backward by Pt on the next right side surface S4. Thereby, the skew portion 33ss is formed. In the behavior of the molding device 64, the coil wire 63a is arranged so as to get over the coil wire 33c of the inner layer 33a. Thereby, one intersection is formed. The intersection of the skew portion 33ff and the skew portion 33ss provides a relatively large intersection angle. Therefore, the positional deviation of the coil wire 63a is suppressed.

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

The winding process of this embodiment includes a step of arranging the coil wire 33c of the inner layer 33a and a step of arranging the coil wire 33d of the outermost layer 33b outside the inner layer 33a. In the step of disposing the outermost layer 33b, the outermost layer oblique portions 33fs and 33ss that are inclined away from the magnetic poles are formed only on one specific side surface S4 other than the one side surface S1 that is one end surface SD1. The step includes arranging the coil wire 33d. The step of disposing the outermost layer 33b includes a step of straightly arranging the coil wire 33d along the circumferential direction on the remaining side surface other than the specific side surface S4.

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

The step of arranging the inner layer 33a includes the step of arranging the coil wire 33c so as to form the inner layer skew portion 33ff that is inclined toward the magnetic pole only on the specific side surface S4. The step of arranging the inner layer 33a includes the step of arranging the coil wire 33c straight along the circumferential direction on the remaining side surface other than the specific side surface S4. Further, in the step of disposing the outermost layer 33b, the outermost layer oblique portions 33fs and 33ss are disposed so as to intersect with the inner layer oblique portion 33ff.

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

In this embodiment, the coil wire 63a can be positioned at a predetermined position by the molding device 64. For this reason, a well-shaped coil is obtained. Further, the coil wire can be arranged so as to avoid strong interference with the cover portion 53 of the sensor unit 41. In addition, since the skew portions 33fs and 33ss of the outermost layer 33b intersect with the skew portion 33ff of the inner layer 33a, a large intersection angle is provided. Thereby, the position shift of a coil strand can be suppressed. Further, the stator manufacturing method is suitable for mass production because the coil strands 33c and 33d can be accurately and rapidly arranged on the bobbin portion 36.

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

In the above-described embodiment, the protruding portion 37e is provided only on one end surface SD1 side and next to the sensor gap. Instead of this, the protruding portion 37e may be provided at any other position. In the said embodiment, both the uneven | corrugated | grooved part and the protrusion part 37e were provided only in the sensor insulator part. Instead of this, only the protruding portion 37e may be provided only in the sensor insulator portion. For example, the uneven portions may be provided on all bobbin portions 36.

In the above embodiment, the uneven portion in the bobbin portion 36 is provided by the surface 36e and the fins 36f. Instead, the uneven portion can be provided in various shapes. For example, the uneven portion may be provided by the surface 36e and a groove.

In the above embodiment, the single coil 33ss has a series of coil wires. It may replace with this and may arrange a plurality of coil strands on one teeth part 32c. In this case, the plurality of coil wires provide the single coil 33ss. For example, two groups of coil wires for providing two coils having different numbers of turns may be arranged on one tooth portion. Moreover, in the said embodiment, although the stator coil 33 is concentrated winding, you may be formed by distributed winding, for example, wave winding, or distributed winding.

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

In the above embodiment, the electric circuit component 42 including the substrate is accommodated in the container 52. Alternatively, the cover 53 may have a substrate for electrical wiring. The substrate may be a lead frame.

In the above embodiment, one sensor 43 is arranged in one cover 53. Instead of this, a plurality of sensors may be arranged. Some sensors may be disposed in the container 52. Thereby, the bad influence by interference with a coil and the cover 53, for example, damage, is suppressed. Further, the sensor unit 41 including one cover 53 may be employed. For example, a rotating electrical machine as a generator including only the ignition control sensor 43 may be provided.

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

In the above embodiment, the plurality of fins 36f and A36f are provided at equal intervals. Alternatively, the plurality of fins 36f and A36f may be provided only in both end ranges in the length direction. In this case, the central range of the bobbin portion 36 provides a flat cylindrical portion having no fins 36f and A36f. The fins 36f and A36f in the both end ranges suppress the positional deviation of the coil wire 33c at the start of winding. The fins 36f and A36f in the both end ranges suppress the displacement of the coil wire 33c in the winding direction change portion after contacting the base flange surfaces 36f and 37d.

10 rotating electrical machines, 12 internal combustion engines, 13 bodies, 21 rotors,
22 rotor core, 23 permanent magnet, 31 stator,
32 stator core, 32a magnetic pole, 32c teeth portion,
33 Stator coil, 33a inner layer, 33b outermost layer,
33c coil wire, 33d coil wire, 33j jumper wire,
33s single coil, 33r riding position,
33ff inner layer skewed portion, 33fs, 33ss outermost layer skewed portion,
35 insulator, 35d guide fin,
36 bobbin part, 36a normal bobbin part,
36b sensor bobbin portion, 36e surface (uneven portion, coil guide portion),
36f, A36f fins (concavo-convex part, coil guide part),
37 flange part,
37e, 237e, 337e, 437e protruding portion (coil guide portion),
537e, 637e, 737e, 837e projecting part (coil guide part),
38a normal gap, 38b sensor gap, 41 sensor unit,
43 sensors, 51 cases, 52 containers,
53 cover, 57 projecting part, 58 cavity,
SD1 One end face, SD2 The other end face.

Claims (20)

1. A rotor (21) providing a field;
   A stator core (32) having a plurality of magnetic poles (32a) arranged to receive the field at end portions of a plurality of teeth portions extending in the radial direction and spaced apart from each other along the circumferential direction, and the teeth portions A stator (31) having a stator coil (33) mounted on;
   A sensor unit (41) disposed in a sensor gap (38b) between two adjacent magnetic poles and containing a sensor (43) for detecting the magnetic flux of the rotor;
   The sensor unit extends into the sensor gap along the axial direction from one axial end surface (SD1) side of the stator,
   A rotating electrical machine in which the coil wire (33d) of the stator coil facing the sensor unit is arranged radially away from the magnetic pole on the one end face side.
2. The stator coil has a multilayer coil disposed outside the teeth portion,
   The coil wire (33d) runs on the inner layer at a portion adjacent to the magnetic pole and moves to the outermost layer,
   The outermost coil wire (33d) facing the sensor unit is inclined from the other end surface side in the axial direction of the stator toward the one end surface so as to be separated from the magnetic pole in the radial direction. The rotating electrical machine according to claim 1.
3. The riding position (33r) where the coil wires of the outermost layer and the coil wires of the inner layer are stacked in the circumferential direction is located closer to the other end surface (SD2) of the stator than the sensor unit. The rotating electrical machine according to claim 2.
4. The outermost coil wire (33d) facing the sensor unit is positioned on a recess formed between a plurality of coil wires in the inner layer, so that the diameter from the magnetic pole on the one end surface side is increased. The rotating electrical machine according to any one of claims 1 to 3, wherein the rotating electrical machine is disposed apart in a direction.
5. 5. The coil element wire according to claim 1, wherein the coil wire is disposed on the one end surface side in a radial direction away from the magnetic pole than the other end surface (SD2) side of the stator. Rotating electric machine.
6. Between the stator core and the stator coil, a resin insulator (35) is disposed,
   The insulator has coil guide portions (36e, 36f, 37e, 237e, 337e, 437e, 537e, 637e, 737e, 837e, A36f) for radially separating the stator coil from the magnetic poles on the one end face side. The rotating electrical machine according to any one of claims 1 to 5.
7. The insulator has a bobbin portion (36) disposed between the teeth portion and the stator coil;
   The rotating electrical machine according to claim 6, wherein the coil guide portion is an uneven portion (36e, 36f, A36f) that defines a position of the coil wire on the bobbin portion.
8. The insulator has a flange portion (37) disposed between the magnetic pole and the stator coil,
   The said coil guide part is a protrusion part (37e, 237e, 337e, 437e, 537e, 637e, 737e, 837e) which protrudes toward the said stator coil along the said teeth part from the said flange part. Item 8. The rotating electrical machine according to Item 7.
9. The plurality of magnetic poles are
   A normal gap (38a) in which the sensor unit is not disposed;
   The sensor gap (38b) in which the sensor unit is disposed is partitioned and formed,
   The insulator is
   A normal insulator portion corresponding to the magnetic pole forming the normal gap;
   A sensor insulator portion corresponding to the magnetic pole forming the sensor gap,
   The rotating electrical machine according to any one of claims 6 to 8, wherein the coil guide portion is provided only in the sensor insulator portion.
10. The stator core has a fixing portion for fixing the stator core,
    The insulator is positioned on the fixing portion and has a plate shape extending in the radial direction, extending in the axial direction, and the fixing portion of a jumper wire (33j) for connecting a plurality of coils included in the stator coil The rotating electrical machine according to any one of claims 6 to 9, further comprising guide fins (35d) for guiding the jumper wire so as to suppress intrusion into the wire.
11. The sensor unit is
    A case (51) disposed on one end surface of the stator in the axial direction;
    A cover (53) extending from the case into the sensor gap,
    The rotating electrical machine according to any one of claims 1 to 10, further comprising projecting portions (57) provided on both sides in a circumferential direction of the case and projecting from the case.
12. The sensor unit is
    A case (51) disposed on one end surface of the stator in the axial direction;
    A cover (53) extending from the case into the sensor gap,
    The case contains an electrical component and is sealed with a resin material (52);
    The rotating electrical machine according to any one of claims 1 to 11, further comprising a hollow portion (58) not sealed with the resin material.
13. The sensor unit is
    A case (51) disposed on one end surface of the stator in the axial direction;
    A cover (53) extending from the case into the sensor gap,
    The rotary electric machine according to any one of claims 1 to 12, wherein a cross-sectional area perpendicular to the axial direction of the cover gradually decreases from the case toward a tip portion.
14. The stator coil includes a coil wire (33c) of an inner layer (33a) and a coil wire (33d) of an outermost layer (33b) disposed outside the inner layer,
    The outermost coil wire (33d) is:
    The outermost layer oblique portion (33fs, 33ss) is disposed only on one specific side surface (S2, S3, S4) other than the one side surface (S1) which is the one end surface (SD1), and is inclined so as to be away from the magnetic pole. )When,
    The rotating electrical machine according to any one of claims 1 to 13, further comprising: a portion disposed on a remaining side surface other than the specific side surface and extending straight along a circumferential direction.
15. The coil wire (33c) of the inner layer is
    An inner layer skew portion (33ff) that is disposed only on the specific side surface (S2, S3, S4) and is inclined so as to approach the magnetic pole;
    Including a portion that is disposed on a remaining side surface other than the specific side surface and extends straight along a circumferential direction,
    The rotating electrical machine according to claim 14, wherein the outermost layer skew portion is disposed so as to intersect with the inner layer skew portion.
16. A winding step in which a stator coil (33) is wound around the outer periphery of a plurality of bobbin portions (36) attached to a plurality of teeth portions (32c) having magnetic poles (32a) at their tips;
    An insertion step of inserting a sensor (43) from one end face (SD1) of the stator (31) into a gap between two adjacent magnetic poles,
    In the winding step, a method of manufacturing a rotating electrical machine in which the coil wire is wound so that the coil wire (33d) of the stator coil is disposed radially away from the magnetic pole on the one end face side. .
17. The insertion step is a step of inserting the sensor only into the sensor gap (38b) among the plurality of normal gaps (38a) and sensor gaps (38b) formed by the plurality of magnetic poles,
    In the winding step, only in the sensor bobbin portion (36b) located next to the sensor gap (38b), the coil wire (33d) of the stator coil is radially formed from the magnetic pole on the one end face side. The method of manufacturing a rotating electrical machine according to claim 16, which is a step of winding the coil wire so as to be spaced apart.
18. The winding step is performed such that the coil wire (33d) of the stator coil is arranged radially away from the magnetic pole on the one end face side from the other end face (SD2) of the stator. The method for manufacturing a rotating electrical machine according to claim 16 or 17, which is a step of winding a coil wire.
19. The winding process includes
    Arranging the coil wire (33c) of the inner layer (33a);
    Arranging the coil wire (33d) of the outermost layer (33b) outside the inner layer,
    Arranging the outermost layer comprises:
    Only on one specific side surface (S2, S3, S4) other than one side surface (S1) which is the one end surface (SD1), outermost layer oblique portions (33fs, 33ss) which incline away from the magnetic poles. Arranging the coil strands to form,
    The method for manufacturing a rotating electrical machine according to any one of claims 16 to 18, further comprising a step of arranging the coil wire (33d) straight along a circumferential direction on a remaining side surface other than the specific side surface.
20. Arranging the inner layer comprises:
    Arranging the coil wires so as to form an inner layer oblique portion (33ff) that is inclined so as to approach the magnetic pole only on the specific side surfaces (S2, S3, S4);
    Placing the coil wire (33c) straight along the circumferential direction on the remaining side surface other than the specific side surface,
    The method for manufacturing a rotating electrical machine according to claim 19, wherein in the step of disposing the outermost layer, the outermost layer oblique portion is disposed so as to intersect with the inner layer oblique portion.
    
    

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