CN114902535A

CN114902535A - Stator for rotating electric machine, method for manufacturing stator for rotating electric machine, and method for manufacturing rotating electric machine

Info

Publication number: CN114902535A
Application number: CN202080091582.2A
Authority: CN
Inventors: 横手雄哉
Original assignee: Mitsubishi Electric Corp
Current assignee: Mitsubishi Electric Corp
Priority date: 2020-01-08
Filing date: 2020-10-05
Publication date: 2022-08-12
Also published as: WO2021140714A1; JPWO2021140714A1; JP7297102B2

Abstract

The fourth bobbin (54) as an insulating part is provided with a second tooth end surface covering part (54c) which covers the other end surface in the axial direction of the part of the tooth part (11b) on which the coil (7) is wound, and a second outer collar (54a) which is connected with the end part on the radial outer side of the second tooth end surface covering part (54c) and covers the other end surface in the axial direction of the yoke part (11a) and protrudes upward in the axial direction, the second outer collar (54a) is provided with a bundling part (54k) which protrudes upward in the axial direction and fixes the winding end part of each coil (7), and the plurality of coils (7) are formed by continuous coil wires (70).

Description

Stator for rotating electric machine, method for manufacturing stator for rotating electric machine, and method for manufacturing rotating electric machine

Technical Field

The present application relates to a stator of a rotating electric machine, a method for manufacturing a stator of a rotating electric machine, and a method for manufacturing a rotating electric machine.

Background

Conventionally, a stator used in a rotating electric machine such as a motor or a generator is configured by a stator core and a coil, and the coil is housed and attached in a slot formed between teeth of the stator core. The coil wires forming the coil are covered with insulation, and the coil is electrically insulated from the stator core. However, in the stator of the rotating electric machine, in order to ensure sufficient insulation between the coil and the stator core, an insulating portion is further provided in a portion where the stator core and the coil are in contact.

As a conventional stator, a technique of simultaneously winding a coil wire around 3 consecutive teeth has been proposed (for example, see patent document 1).

Prior art documents

Patent document

Patent document 1: japanese patent laid-open publication No. 9-191588

Disclosure of Invention

Problems to be solved by the invention

In general, in manufacturing a stator of a rotating electrical machine, it is important to prevent coil collapse and to make coils uniform by preventing a jumper wire between coils from loosening in order to ensure product quality.

In the stator described in patent document 1, 3 winding nozzles are used to simultaneously wind the 6-tooth stator core with 3 teeth at a time. First, coils of 3 teeth are simultaneously formed, and a jumper wire is formed between each of the teeth separated by 2 teeth, and further, the coils are continuously wound on the next 3 teeth simultaneously.

In this document, since the winding end wire of 3 coils wound simultaneously is directly led as a jumper wire to a tooth to be wound next and 3 coils are continuously wound, the coil wire is not fixed in the middle, and there is a problem as follows: when the jumper is loosened, a coil collapse may occur in the wound coil or the coil during winding.

The present application discloses a technique for solving the above-described problem, and an object thereof is to provide a stator of a rotating electric machine, a method for manufacturing a stator of a rotating electric machine, and a method for manufacturing a rotating electric machine, which are capable of preventing each coil from collapsing.

Means for solving the problems

The stator of a rotating electric machine disclosed in the present application includes:

a stator core in which a plurality of core portions are annularly combined, the core portions including a yoke portion and tooth portions formed so as to protrude radially inward from a circumferential center portion of an inner circumferential surface of the yoke portion;

a coil formed by winding a coil wire around each of the plurality of teeth; and

an insulating portion disposed between the core portion and the coil and insulating the stator core and the coil,

the first bobbin as the insulating portion includes: a first tooth end surface covering portion that covers an axial end surface of a portion of the tooth portion around which the coil is wound; and a first outer collar connected to a radially outer end of the first tooth end surface covering portion and protruding upward in the axial direction while covering an axial end surface of the yoke portion,

the fourth bobbin as the insulating portion includes: a second tooth end surface covering portion that covers the other end surface of the tooth portion in the axial direction of the portion around which the coil is wound; and a second outer collar connected to a radially outer end of the second end face covering portion and protruding upward in the axial direction while covering the other axial end face of the yoke portion,

the second outer collar includes a binding portion that protrudes upward in the axial direction from a central portion in the circumferential direction and binds winding end portions of the coils,

the plurality of coils are formed by continuous coil wires.

Further, the rotating electric machine disclosed in the present application, wherein,

the rotating electric machine includes:

a stator of the above-described rotating electrical machine; and

and a rotor disposed to face an inner side of the stator with a gap therebetween.

In addition, the present application discloses a method for manufacturing a stator of a rotating electric machine,

the method for manufacturing the stator of the rotating electric machine comprises the following steps:

a winding step of deforming the yoke portions of the plurality of core portions into a linear shape and winding the coil wire around the tooth portions by using a winding nozzle to form the coil;

a binding step of binding the coil wire to the binding portion; and

and a clamping step of fixing the coil wire between the bundling part and the clamping part.

In addition, the present application discloses a method for manufacturing a rotating electric machine, wherein,

the rotor is disposed to face the inside of the stator manufactured by the above-described method for manufacturing a stator of a rotating electrical machine with a gap therebetween.

ADVANTAGEOUS EFFECTS OF INVENTION

According to the stator of a rotating electric machine, the method for manufacturing the stator of the rotating electric machine, and the method for manufacturing the rotating electric machine disclosed in the present application, it is possible to provide the stator of a rotating electric machine, the method for manufacturing the stator of the rotating electric machine, and the method for manufacturing the rotating electric machine, which can prevent each coil from collapsing.

Drawings

Fig. 1 is a cross-sectional view perpendicular to the axial direction of a rotary electric machine according to embodiment 1.

Fig. 2 is a cross-sectional view of the rotating electric machine according to embodiment 1 taken on a plane passing through the axis center of the rotating shaft.

Fig. 3 is a rear view showing a state in which a stator of the rotating electric machine according to embodiment 1 is cut and deformed into a straight line.

Fig. 4 is a perspective view of the stator shown in fig. 3, and is a view in which the back side of fig. 3, i.e., the inside of the stator, is visible.

Fig. 5 is a perspective view showing the configuration of 2 core pieces constituting the stator core of the stator shown in fig. 3.

Fig. 6 is a perspective view showing the configuration of a stator core according to embodiment 1.

Fig. 7 is a plan view of a core according to embodiment 1.

Fig. 8 is a perspective view showing the configuration of the first bobbin according to embodiment 1.

Fig. 9 is a perspective view showing the configuration of a fourth bobbin according to embodiment 1.

Fig. 10 is a perspective view showing a state in which a first bobbin and a fourth bobbin are attached to a core according to embodiment 1.

Fig. 11 is a view of the first core section viewed in the direction of arrow a in fig. 10.

Fig. 12 is a view of the first core section viewed in the arrow B direction of fig. 10.

Fig. 13A is a view of the first core section viewed in the arrow C direction of fig. 10.

Fig. 13B is a view of the first core section viewed in the arrow D direction of fig. 10.

Fig. 14 is a perspective view of a second bobbin according to embodiment 1.

Fig. 15 is a view of the second core section to which the second bobbin and the fourth bobbin are attached according to embodiment 1, as viewed from the outer side X1 in the radial direction X.

Fig. 16 is a perspective view of a third bobbin according to embodiment 1.

Fig. 17 is a view of the third core section to which the third bobbin and the fourth bobbin are attached according to embodiment 1, as viewed from the outer side X1 in the radial direction X.

Fig. 18 is a flowchart illustrating a manufacturing process of the rotating electric machine according to embodiment 1.

Fig. 19 is a flowchart showing a manufacturing process of the coil according to embodiment 1.

Fig. 20 is a development view of the stator in the coil forming process according to embodiment 1.

Fig. 21 is a view showing an action of a wire winding nozzle of the wire winding machine according to embodiment 1.

Fig. 22 is a perspective view showing the operation of each winding nozzle in the bundling process according to embodiment 1.

Fig. 23 is a perspective view showing a state of the core at the end of the binding process according to embodiment 1.

Fig. 24 is a diagram showing the behavior of the mouths N1, N2, N3 after the coil formation of the first, second, and third core sections according to embodiment 1.

Fig. 25 is a conceptual diagram illustrating another winding method according to embodiment 1.

Fig. 26 is a perspective view showing a state in which a first bobbin, a second bobbin, a third bobbin, a fourth bobbin, and a film portion are attached to a stator core according to embodiment 2.

Fig. 27 is an exploded perspective view of the respective members of fig. 26.

Fig. 28 is a perspective view showing the configuration of the thin film portion according to embodiment 2.

Fig. 29A is a perspective view showing the configuration of the first bobbin according to embodiment 2.

Fig. 29B is a perspective view of the first bobbin shown in fig. 29A viewed from the opposite side in the axial direction Y.

Fig. 30 is a perspective view showing the configuration of a fourth bobbin according to embodiment 2.

Fig. 31 is a perspective view of a stator core according to embodiment 3.

Fig. 32 is an enlarged top view of a main portion of a stator core according to embodiment 3.

Fig. 33 is a perspective view of a core according to embodiment 4.

Fig. 34 is a perspective view showing a state after winding of a stator according to embodiment 4.

Detailed Description

Embodiment 1.

Hereinafter, a stator of a rotating electric machine, a method for manufacturing the stator of the rotating electric machine, and a method for manufacturing the rotating electric machine according to embodiment 1 will be described with reference to the drawings.

Fig. 1 is a cross-sectional view perpendicular to the axial direction of the rotating electric machine 100.

Fig. 2 is a cross-sectional view of rotor 20 of rotating electric machine 100 taken along a plane passing through the axial center of rotating shaft 21.

The rotating electric machine 100 includes: a cylindrical frame 101; a bracket 103 for closing openings at both ends of the frame 101 in the axial direction; a stator 10 fitted inside the frame 101; and a rotor 20 rotatably supported at the center of each of the 2 brackets 103 via a bearing not shown, the rotor 20 being disposed such that an outer peripheral surface thereof faces an inner peripheral surface of the stator 10. A gap 107 exists between the outer peripheral surface of the rotor 20 and the inner peripheral surface of the stator 10.

The permanent magnets 105 are embedded in a V-shape in the rotor core 22 fixed to the outer periphery of the rotating shaft 21, but the permanent magnets may be arranged in a straight line or in another shape. The permanent magnets may be disposed so as to face the inner circumferential surface of the stator 10 by being bonded to the outer circumferential surface of the rotor core 22 without being embedded.

In the following description, the outer sides X1 and the inner sides X2 of the circumferential direction Z, the axial direction Y, the radial direction X, and the radial direction X are respectively shown with respect to each direction of the stator 10 of the rotating electrical machine 100, with reference to a state in which the yoke portions 11a of the plurality of core portions 60 are annularly arranged and combined. Therefore, in the stator 10, when the yoke portion 11a of each core portion 60 of the stator 10 is rotationally deformed into a linear shape, or when a reverse-turning shape is formed in which the protruding direction of each tooth portion 11b is reversed even if the inside and the outside of the stator 10 are reversed, the respective directions will be described with reference to the direction in which the yoke portion 11a of the stator 10 is in a product state, that is, in a state of being arranged in a ring shape, as shown in the drawings.

In addition, unless otherwise specified, when "up" and "down" are referred to, a surface side perpendicular to the axial direction Y of the stator 10 and passing through the center of the stator 10 is referred to as "down" and an opposite surface thereof is referred to as "up" at a reference portion. When the heights are relatively high, the comparison is performed based on the distance from the plane perpendicular to the axial direction Y of the stator 10 and passing through the center of the stator 10.

The stator 10 includes: a stator core 11A in which a plurality of core portions 60 are annularly combined, the core portions 60 including a yoke portion 11A and tooth portions 11b formed so as to protrude from a central portion in a circumferential direction Z of an inner circumferential surface of the yoke portion 11A toward an inner side X2 in a radial direction X; a coil 7 formed by winding a coil wire around each of the plurality of tooth portions 11 b; and an insulating portion disposed between each of the core portions 60 and the coil 7, for insulating the core portions 60 and the coil 7. The stator core 11A is formed by joining and combining 9 core portions 60.

Fig. 3 is a rear view showing a state where the stator 10 of the rotary electric machine 100, which is originally annular, is cut and deformed into a straight line, and is a view of the stator 10 viewed from the outer peripheral side.

In the following description, the respective core portions 60 are denoted by reference numerals 61 to 69 and described as first to ninth core portions 61 to 69.

Fig. 4 is a perspective view of the stator 10 shown in fig. 3, and is a view in which the back side of fig. 3, i.e., the inside of the stator 10, is visible.

Fig. 5 is a perspective view showing the configuration of 2 core piece groups 11k1, 11k2 constituting stator core 11A of stator 10 shown in fig. 3.

Fig. 6 is a perspective view showing a configuration of a stator core 11A formed by alternately stacking a plurality of core groups 11k1 and 11k2 shown in fig. 5 in the axial direction Y.

Fig. 7 is a plan view of the core 60.

As shown in fig. 3 and 4, the stator 10 includes: a stator core 11A constituted by a plurality of core portions 60; a coil 7; the first bobbin 51, the second bobbin 52, the third bobbin 53, and the fourth bobbin 54 on the upper side of the drawing are disposed as insulating portions for insulating the stator core 11A and the coil 7. As shown in fig. 6, the core portions 60 arranged in the circumferential direction Z are set as a first core portion 61, a second core portion 62, a third core portion 63, a fourth core portion 64, a fifth core portion 65, a sixth core portion 66, a seventh core portion 67, an eighth core portion 68, and a ninth core portion 69 from the winding start side of the first coil wire 71. The first bobbin 51 is used for the first core portion 61, the fourth core portion 64, and the seventh core portion 67, i.e., the core portion 60 constituting the U-phase. The second bobbin 52 is used for the second core portion 62, the fifth core portion 65, and the eighth core portion 68, that is, the core portion 60 constituting the V-phase. The third bobbin 53 is used for the third core 63, the sixth core 66, and the ninth core 69, which constitute the W-phase core 60, and the differences will be described later in detail.

As shown in fig. 6, the stator core 11A is formed by alternately stacking a plurality of sets 11k1, 11k2 shown in fig. 5 in the axial direction Y, and the plurality of sets 11k1, 11k2 are formed by punching thin magnetic steel plates in a die not shown. Thus, the stator core 11A is formed by coupling the yoke portions 11A of the first to ninth core portions 61 to 69 with the coupling portions 111 provided at the ends in the circumferential direction Z. In fig. 6, stator core 11A is configured by linearly coupling 9 core portions, i.e., first to ninth core portions 61 to 69, by coupling portions 111.

In the coupling portion 111, the yoke portions 11a of the adjacent core portions 60 are freely rotatable. Thereby, the stator core 11A can be rotated linearly or in a reverse-turn shape in which the direction of the tooth portion 11b protruding in the radial direction X is reversed.

The stator coil is formed of three phases, i.e., U-phase, V-phase, and W-phase, and has a junction structure in which star-junction wires of different phases are arranged for each core portion 60 connected in the circumferential direction Z. The first core 61 is wound with a coil of the U phase (U1), the second core 62 is wound with a coil of the V phase (V1), the third core 63 is wound with a coil of the W phase (W1), the fourth core 64 is wound with a coil of the U phase (U2), the fifth core 65 is wound with a coil of the V phase (V2), the sixth core 66 is wound with a coil of the W phase (W2), the seventh core 67 is wound with a coil of the U phase (U3), the eighth core 68 is wound with a coil of the V phase (V3), and the ninth core 69 is wound with a coil 7 of the W phase (W3).

When the order of the first to ninth core sections 61 to 69 is not required to be described, the first to ninth core sections 61 to 69 will be collectively referred to as the core section 60. The core portions 60 are provided with the coil 7 and the first bobbin 51, the second bobbin 52, the third bobbin 53, and the fourth bobbin 54, which are upper side insulating portions, respectively. The description is applied to the first to ninth core sections 61 to 69 regardless of the state in which the coil 7, the first bobbin 51, the second bobbin 52, the third bobbin 53, and the fourth bobbin 54 on the upper side of the paper surface of fig. 4 as the insulating section are provided in the respective core sections 60 or the state in which these members are not provided.

Next, the structure of each part of the core 60 will be described with reference to fig. 7. A surface along the axial direction Y of the outer side X1 in the radial direction X of the yoke portion 11a is defined as a yoke outer circumferential surface 113. A first recess 114 extending in the axial direction Y is formed in the yoke outer peripheral surface 113 at a central portion in the circumferential direction Z. The first recess 114 is used for positioning when the stator core 11A is mounted on a winding machine that forms the coil 7. The tooth portion 11b is provided with shoes 11c projecting in the circumferential direction Z from the tips of the inner sides X2 in the radial direction X. A surface along the axial direction Y of the inner side X2 in the radial direction X of the yoke portion 11a is defined as a yoke inner circumferential surface 112.

Both surfaces along the axial direction Y of both ends in the circumferential direction Z of the tooth portion 11b are tooth side surfaces 121, and a surface along the axial direction Y of the tip of the inner side X2 in the radial direction X of the tooth portion 11b is a tooth inner circumferential surface 122. A surface along the axial direction Y of the outer side X1 in the radial direction X of the shoe 11c is defined as a shoe outer circumferential surface 131. The region surrounded by the yoke inner circumferential surface 112, the tooth side surfaces 121, and the shoe outer circumferential surfaces 131 is a groove 14 in which the coil wire 70 is wound to form the coil 7.

Next, the first bobbin 51, the second bobbin 52, the third bobbin 53 on the upper side of the drawing sheet of fig. 4, and the fourth bobbin 54 on the lower side of the drawing sheet will be described as the insulating portion.

The first bobbin 51 is a bobbin attached to the first core 61, the fourth core 64, and the seventh core 67. The first bobbin 51 is attached to the tooth 11b and the yoke 11 a.

The second bobbin 52 is a bobbin attached to the second core 62, the fifth core 65, and the eighth core 68. The second bobbin 52 is attached to the tooth 11b and the yoke 11 a.

The third bobbin 53 is a bobbin attached to the third core 63, the sixth core 66, and the ninth core 69. The third bobbin 53 is attached to the tooth portion 11b and the yoke portion 11 a.

Fig. 8 is a perspective view showing a structure of the first bobbin 51 used in the stator 10 shown in fig. 3 and 4.

The first bobbin 51 includes a tooth end surface covering portion 51c (first tooth end surface covering portion), an outer collar 51a (first outer collar), an inner collar 51b (first inner collar), and a groove side surface covering portion 51d (first groove side surface covering portion), which are integrally formed.

The tooth end surface covering portion 51c covers one end surface in the axial direction Y of the portion of the tooth portion 11b around which the coil 7 is wound. The outer collar 51a is connected to an end of the outer side X1 in the radial direction X of the gear end surface covering portion 51c, covers one end surface in the axial direction Y of the yoke portion 11a, and protrudes upward in the axial direction Y.

The inner collar 51b is connected to an end of the inner side X2 in the radial direction X of the tooth end surface covering portion 51c, covers an inner end portion of one end surface in the axial direction Y of the tooth portion 11b and one end surface in the axial direction Y of the shoe portion 11c, and protrudes upward in the axial direction Y.

The groove side surface covering portion 51d covers the tooth side surfaces 121 of the tooth 11b, the yoke inner circumferential surface 112 of the yoke 11a, and the shoe outer circumferential surface 131 of the shoe 11 c. The groove side surface covering portion 51d protrudes downward from the tooth end surface covering portion 51c, the outer collar 51a, and the inner collar 51 b. Actually, the groove-side covering portion 51d covers half of each surface constituting the groove 14 in the axial direction Y.

Fig. 9 is a perspective view showing a structure of the fourth bobbin 54 used in the stator 10 shown in fig. 3 and 4. The fourth bobbin 54 is an insulating member on the lower side of the sheet of the stator 10 shown in fig. 3.

The fourth bracket 54 includes a tooth end surface covering portion 54c (second tooth end surface covering portion), an outer blade 54a (second outer blade), an inner blade 54b (second inner blade), and a groove side surface covering portion 54d (second groove end surface covering portion), which are integrally formed.

The tooth end surface covering portion 54c covers the other end surface of the tooth portion 11b in the axial direction Y of the portion around which the coil 7 is wound. The outer collar 54a is connected to an end portion of the outer side X1 in the radial direction X of the gear end surface covering portion 54c, covers the other end surface in the axial direction Y of the yoke portion 11a, and protrudes upward in the axial direction Y.

The inner collar 54b is connected to an end portion of the inner side X2 in the radial direction X of the tooth end surface covering portion 54c, covers an inner end portion of the other end surface in the axial direction Y of the tooth portion 11b and the other end surface in the axial direction Y of the shoe portion 11c, and protrudes upward in the axial direction Y. As shown in fig. 11 and 13, the outer collar 54a has a binding portion 54k projecting upward in the axial direction Y from a central portion in the circumferential direction Z. The protrusions 54t protrude from the upper end of the bundling portion 54k in the axial direction Y toward both sides in the circumferential direction Z.

The outer collar 54a includes a hook-shaped engaging portion 54f that protrudes outward X1 in the radial direction X from an upper end portion in the axial direction Y of the outer peripheral surface 54aout and a circumferential center portion, and extends parallel to the binding portion 54k upward in the axial direction Y. The width of the gap 54r between the bundling portion 54k and the locking portion 54f in the radial direction X is slightly smaller than the wire diameter of the coil wire 70.

The bundling section 54k is used to bundle and fix the coil wire 70 as a winding end after the coils 7 are wound and before a jumper wire described later is guided. The protrusion 54t is provided to prevent the coil wire 70 from falling off from the bundling unit 54k during the bundling operation to the bundling unit 54 k. The engaging portion 54f engages the bundling portion 54k with the coil wire 70 interposed therebetween.

The groove side surface covering portion 54d covers the tooth side surfaces 121 of the tooth 11b, the yoke inner circumferential surface 112 of the yoke 11a, and the shoe outer circumferential surface 131 of the shoe 11 c. The groove side surface covering portion 54d protrudes downward from the tooth end surface covering portion 54c, the outer collar 54a, and the inner collar 54 b. Actually, the groove side surface covering portion 54d covers half of each surface constituting the groove 14 in the axial direction Y. Therefore, the entire side surfaces constituting the slot 14 can be covered with the slot-side covering portion 51d of the first bobbin and the slot-side covering portion 54d of the fourth bobbin 54.

The first bobbin 51 and the fourth bobbin 54 are attached so as to be fitted to the inner circumferential surface of the groove 14 from both axial sides with respect to each core portion 60. The first bobbin 51 and the fourth bobbin 54 electrically insulate the coil 7 from the respective core portions 60. The first bobbin 51 and the fourth bobbin 54 are formed by, for example, extrusion molding of an insulating resin.

In embodiment 1, the example in which the lengths in the axial direction Y of the groove side surface covering portion 51d of the first bobbin 51 and the groove side surface covering portion 54d of the fourth bobbin 54 are formed to be substantially the same is shown, but the present invention is not limited thereto, and the respective lengths in the axial direction Y may be appropriately changed as long as all the side surfaces constituting the groove 14 can be covered.

Next, the configuration of the rightmost first core portion 61 in fig. 3, which is one of the core portions 60, will be described with reference to the drawings. The first core 61 is attached with the first bobbin 51 on the upper side of the drawing and the fourth bobbin 54 on the lower side of the drawing.

Fig. 10 is a perspective view showing a state in which the first bobbin 51 and the fourth bobbin 54 are attached to the first core 61.

Fig. 11 is a view of the first core 61 shown in fig. 10, to which the first bobbin 51 and the fourth bobbin 54 are attached, as viewed from an outer side X1 in the radial direction X, that is, a view of the first core 61 as viewed in the direction of arrow a in fig. 10.

Fig. 12 is a view of the first core 61 shown in fig. 10, to which the first bobbin 51 and the fourth bobbin 54 are attached, as viewed from the inner side X2 in the radial direction X, that is, a view of the first core 61 as viewed in the direction of arrow B in fig. 10.

Fig. 13A is a view of the first core 61 shown in fig. 10, to which the first bobbin 51 and the fourth bobbin 54 are attached, as viewed from the circumferential direction Z, that is, a view of the first core 61 as viewed in the direction of arrow C in fig. 10.

Fig. 13B is a view of the first core 61 shown in fig. 10 with the first bobbin 51 and the fourth bobbin 54 attached, viewed from the axial direction Y, that is, a view of the first core 61 viewed in the direction of arrow D in fig. 10.

As shown in fig. 10, 11, and 13A, a groove portion M extending in the circumferential direction Z is formed in a plurality of stages in the axial direction Y on the outer peripheral surface of the outer side X1 of the outer collar 51a in the radial direction X. Here, the groove portion M is formed in three stages of a first groove portion M1, a second groove portion M2, and a third groove portion M3 from the upper side away from the core portion 60 in the axial direction Y. That is, the first groove portion M1, the second groove portion M2, and the third groove portion M3 are arranged parallel to the circumferential direction Z and in the axial direction Y, and are formed to have different heights. The first groove portion M1 is formed between the first guide portion G1 and the second guide portion G2 provided in the circumferential direction Z on the outer peripheral surface of the outer collar 51 a. Similarly, the second groove portion M2 is formed between the second guide portion G2 and the third guide portion G3 provided in the circumferential direction Z on the outer peripheral surface of the outer collar 51 a. The third groove portion M3 is formed between the third guide portion G3 and the fourth guide portion G4 provided in the circumferential direction Z on the outer peripheral surface of the outer collar 51 a. Therefore, the first guide portion G1 to the fourth guide portion G4 are also arranged parallel to the circumferential direction Z and in the axial direction Y, and are formed to have different heights. As shown in fig. 11, in actuality, the first guide portions G1 are provided only on both sides in the circumferential direction Z of the later-described lead-out groove portion 51out (first lead-out groove portion) and only in the vicinity of one edge in the circumferential direction Z of the later-described lead-in groove portion 51in (first lead-in groove portion), and therefore the first groove portion M1 is formed only in the vicinity of both sides in the circumferential direction Z of the lead-out groove portion 51out and only in the vicinity of one edge in the circumferential direction Z of the lead-in groove portion 51 in. The second groove portion M2 and the third groove portion M3 extend intermittently in the circumferential direction Z.

The first, second, and third groove portions M1, M2, and M3 hold a plurality of jumper wires 70J that connect the coils 7 of different tooth portions 11b to each other in parallel with the circumferential direction. The jumper line 70J is a continuous line of the coils 7. The introduction groove portion 51in formed in the axial direction Y of the outer collar 51A is an inlet for introducing the coil wire 70 from the outer side X1 in the radial direction X of the stator core 11A to the inner side X2 in the radial direction X in order to wind the coil 7 around the tooth portion 11 b.

The lead-out groove portion 51out formed in the axial direction Y of the outer collar 51A is an outlet through which the coil wire 70 wound around the tooth portion 11b to form the coil 7 is led out from the inner side X2 in the radial direction X of the stator core 11A to the outer side X1 in the radial direction X. The lead-out groove 51out is inclined such that the lower end of the jumper line 70J on the jumper direction side is positioned closer to the jumper direction side than the upper end of the jumper line 70J.

As shown in fig. 11, the lead-out groove portion 51out formed in the outer collar 51a of the first bobbin 51 is set such that the lower portion thereof is continuous with the first groove portion M1 provided on the left side of the lead-out groove portion 51out in the circumferential direction Z, and the height of the lower portion of the lead-out groove portion 51out is equal to the height of the upper surface of the second guide portion G2 constituting the lower surface of the first groove portion M1. That is, the lower portion of the lead-out groove 51out is connected to the upper surface of the second guide portion G2 uniformly.

Fig. 14 is a perspective view of the second bobbin 52.

Fig. 15 is a view of the second core 62 to which the second bobbin 52 and the fourth bobbin 54 are attached, as viewed from the outer side X1 in the radial direction X.

Since the basic configuration of the second bobbin 52 is the same as that of the first bobbin 51, only the different portions will be described.

First, in the outer collar 52a of the second bobbin 52, the second guide portions G2 intermittently provided in the circumferential direction Z in the outer collar 51a of the first bobbin 51 are provided only at the central portion in the circumferential direction Z of the outer collar 52a, and are not provided at both end portions in the circumferential direction Z. Therefore, the second guide portions G2 are not present on both sides of the lead-out groove portion 52out (second lead-out groove portion) in the circumferential direction Z, and the first groove portion M1 and the second groove portion M2 in the first bobbin 51 are integrated. The same applies to the outer side in the circumferential direction Z of the introduction groove portion 52in (second introduction groove portion). Therefore, the groove portion that can fix the jumper line 70J in the axial direction is the third groove portion M3 and the second groove portion M2 at the center portion in the circumferential direction Z.

As shown in fig. 15, the lead-out groove portion 52out formed in the outer collar 52a of the second bobbin 52 is set to the same height as the upper surface of the third guide portion G3. That is, the lower portion of the lead-out groove portion 52out is connected to the upper surface of the third guide portion G3 flush therewith.

Fig. 16 is a perspective view of the third carriage 53.

Fig. 17 is a view of the third core 63 to which the third bobbin 53 and the fourth bobbin 54 are attached, as viewed from the outer side X1 in the radial direction X.

Since the basic configuration of the third bobbin 53 is the same as that of the first bobbin 51, only the different portions will be described.

First, the second guide portions G2 and the third guide portions G3 provided intermittently in the circumferential direction Z in the outer collar 53a of the third collar 53, the outer collar 51a of the first collar 51 are provided only in the central portion in the circumferential direction Z of the outer collar 52a, and these guide portions are not provided at both end portions in the circumferential direction Z. Therefore, the second groove M2 and the third groove M3 are not present on both sides of the lead-out groove 53out (third lead-out groove) in the circumferential direction Z, and the first groove M1, the second groove M2, and the third groove M3 in the first bobbin 51 are integrally formed. The same applies to the outer side in the circumferential direction Z of the introduction groove portion 53in (third introduction groove portion).

As shown in fig. 17, the lead-out groove portion 53out formed in the outer collar 53a of the third bobbin 53 is set so that the lower portion thereof has the same height as the upper surface of the fourth guide portion G4. That is, the lower portion of the lead-out groove portion 53out is connected to the upper surface of the fourth guide portion G4 flush therewith.

Next, the coil wire 70 will be described with reference to fig. 3 and 4. The coil wire 70 is a wire for forming the coil 7. Here, three coil wires 70, i.e., a first coil wire 71, a second coil wire 72, and a third coil wire 73, are used. Among the first coil wire 71, the second coil wire 72, and the third coil wire 73, the portions of the coil 7 where winding starts are the first winding-start wire 711, the second winding-start wire 721, and the third winding-start wire 731.

The first winding start wire 711, the second winding start wire 721, and the third winding start wire 731 are moved from the outer side X1 to the inner side X2 in the radial direction X of the stator core 11A, and when used as power supply lines, the respective portions become the first power supply line 713, the second power supply line 723, and the third power supply line 733.

Among the first coil wire 71, the second coil wire 72, and the third coil wire 73, the portions pulled out after the winding of the coil 7 are a first winding end wire harness 712, a second winding end wire harness 722, and a third winding end wire harness 732. The first, second, and third winding

end wires

712, 722, 732 are connected to form the neutral point 700. The first coil wire 71, the second coil wire 72, and the third coil wire 73 are each a continuous single wire. Note that, when it is not necessary to describe the portions of the coil wire 70 by using names, the portions are collectively referred to as the coil wire 70.

Next, the jumper line 70J will be described with reference to fig. 3. The jumper line 70J is formed as a part of the coil line 70. Among the jumpers 70J, there are a first jumper 70J1, a second jumper 70J2, a third jumper 70J3, a fourth jumper 70J4, a fifth jumper 70J5, and a sixth jumper 70J 6. The first crossover line 70J1 connects the coil 7 of the first core section 61 with the coil 7 of the fourth core section 64 that is separated by 3 core sections in the circumferential direction Z. The second jumper wire 70J2 connects the coil 7 of the second core 62 with the coil 7 of the fifth core 65 separated by 3 cores in the circumferential direction Z. The third crossover line 70J3 connects the coil 7 of the third core 63 with the coil 7 of the sixth core 66 that is separated by 3 cores in the circumferential direction Z.

The fourth crossover line 70J4 connects the coil 7 of the fourth core 64 with the coil 7 of the seventh core 67 that is separated by 3 cores in the circumferential direction Z. The fifth jumper wire 70J5 connects the coil 7 of the fifth core 65 with the coil 7 of the eighth core 68 that is separated by 3 cores in the circumferential direction Z. The sixth jumper wire 70J6 connects the coil 7 of the sixth core 66 with the coil 7 of the ninth core 69 that is 3 cores apart in the circumferential direction Z.

Note that, when the first jumper line 70J1 to the sixth jumper line 70J6 are not described separately, they will be collectively referred to as a jumper line 70J.

Next, a manufacturing process of the rotating electric machine 100 will be described.

Fig. 18 is a flowchart illustrating a manufacturing process of the rotating electric machine 100.

Fig. 19 is a flowchart showing a manufacturing process of the coil 7.

Fig. 20 is a developed view of the stator 10 in the coil forming step, is a rear view showing a state where the stator 10 is rotated (deformed) to be linear, and is a view of the stator 10 viewed from the outer peripheral side.

Fig. 21 is a diagram illustrating an operation of a winding nozzle of the winding machine.

First, while 2 core pieces 11k1 and 11k2 are alternately punched out of a magnetic steel plate, a plurality of core portions 11A are stacked in the axial direction Y, and adjacent core portions 60 are connected by a connecting portion 111 of a yoke portion 11A to form a stator core 11A (ST 1: stator core manufacturing process).

Next, the slot side surface covering portion 51d of the first bobbin 51 is fitted into the slots 14 on both sides in the circumferential direction Z of the first core portion 61, the fourth core portion 64, and the seventh core portion 67 from one end side in the axial direction Y, and the slot side surface covering portion 54d of the fourth bobbin 54 is fitted into the slots from the other end side. Similarly, the second bobbin 52 and the fourth bobbin 54 are attached to the second core 62, the fifth core 65, and the eighth core 68, and the third bobbin 53 and the fourth bobbin 54 are attached to the third core 63, the sixth core 66, and the ninth core 69 (ST 2: bobbin attaching step). Thus, three types of bobbins are attached to one end side of the 9 core portions 60, and the same fourth bobbin 54 is attached to the other end side.

Next, a coil forming step (ST3) of forming the coil 7 will be described with reference to fig. 19, 20, 21, 11, 15, and 17.

First, the first coil wire 71 is introduced from the outer side X1 toward the inner side X2 in the radial direction X using the introduction groove portion 51in of the first core portion 61. At this time, the second coil wire 72 and the third coil wire 73 are introduced from the outer side X1 toward the inner side X2 in the radial direction X, similarly using the introduction grooves 52in and 53in of the second core portion 62 and the third core portion 63, respectively (ST 31: introduction step in fig. 19).

As shown in fig. 21, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are wound around the tooth 11b of each of the first core 61, the second core 62, and the third core 63 simultaneously as indicated by arrows N11, N21, and N31 using 3 first winding nozzles N1, second winding nozzles N2, and third winding nozzles N3 of a winding machine (not shown in detail) (ST 32: winding process, fig. 19).

Fig. 22 is a perspective view showing the operation of each winding nozzle in the bundling step. The first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 all perform the same operation simultaneously.

Fig. 23 is a perspective view showing a state of the core portion 60 at the end of the binding process.

After the coils 7 are wound around the teeth 11b of the first core 61, the second core 62, and the third core 63, the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are moved as shown in the positions P1 to P5 of fig. 22, and the first coil wire 71 to the third coil wire 73 are fed out while the first coil wire 71, the second coil wire 72, and the third coil wire 73 are simultaneously bound to the binding portion 54k of the fourth bobbin 54 of the first core 61, the second core 62, and the third core 63 (fig. 19, ST 32B: binding step), whereby the coils 7 that have just been wound are prevented from loosening. At this time, the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are moved from the position P3 to the position P4, whereby the first coil wire 71, the second coil wire 72, and the third coil wire 73 are guided to the gap 54r between the engaging portion 54f and the binding portion 54k, and are further moved to the position P5, and are fixed to the bottom of the gap 54r (ST 32C: engaging step).

As shown in fig. 23, when the bundling process is completed, the coil wire 70 is wound around the bundling portion 54k once, and the coil wire 70 crosses the bundling portion 54k inside, so that the anti-loosening effect is exhibited at the portion where the coil wires 70 overlap. Further, the coil wire 70 can be prevented from falling off from the bundling portion 54k by the protrusion portion 54t in the bundling step.

Fig. 24 is a view showing the operation of the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 after the first coil wire 71 to the third coil wire 73 of the first core portion 61, the second core portion 62, and the third core portion 63 are bundled in the bundling portions 54 k.

After the coils 7 are formed on the tooth portions 11b of the first core portion 61, the second core portion 62, and the third core portion 63 as described above, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are bound to the binding portions 54k of the first core portion 61, the second core portion 62, and the third core portion 63, and are fixed so as to be sandwiched between the binding portions 54k and the binding portions 54f to prevent the coil wire 70 from loosening, and are held in the lead-out groove portions 51out, 52out, and 53out to prevent loosening, and are led out from the inner side X2 to the outer side X1 in the radial direction X (see fig. 20). Then, in order to perform the next winding process (step ST33 — no), the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are respectively fed with the first coil wire 71, the second coil wire 72, and the third coil wire 73 in the direction of the arrow E, and the first winding nozzle N1 is moved to the position of the fourth core portion 64 by 3 teeth, the second winding nozzle N2 is moved to the position of the fifth core portion 65, and the third winding nozzle N3 is moved to the position of the sixth core portion 66 (fig. 19, ST 34: nozzle moving process).

At this time, the first crossover wire 70J1 connecting the coil 7 of the first core 61 and the coil 7 of the fourth core 64 is held in fig. 11 of the first core 61 from the bottom of the lead-out groove portion 51out inclined such that the lower end portion of the side surface on the crossover direction side is positioned on the crossover direction side of the first crossover wire 70J1 with respect to the upper end portion, the first groove portion M1 provided on the left side in the circumferential direction of the lead-out groove portion 51out in fig. 20 is guided by the first groove portion M1 held by the second core portion 62 further contacting in the circumferential direction Z, and the first groove portion M1 provided on the right side in the circumferential direction of the lead-in groove portion 51in fig. 11 and 20 held by the fourth core portion 64 further contacting in the circumferential direction Z is introduced from the outer side X1 in the radial direction X of the fourth core portion 64 toward the inner side X2 from the lead-in groove portion 51in, while being guided along the upper surface of the second guide portion G2 and the lower surface of the first guide portion G1 of the third core portion 63 further contacting in the circumferential direction Z.

Further, the second jumper wire 70J2 connecting the coil 7 of the second core portion 62 and the coil 7 of the fifth core portion 65 is introduced from the bottom of the lead-out groove portion 52out inclined so that the lower end portion of the side surface on the jumper direction side is positioned on the jumper direction side of the second jumper wire 70J2 with respect to the upper end portion, along the upper surface of the third guide portion G3 of the second core portion 62 shown in fig. 15, the second groove portion M2 held in the third core portion 63 in contact in the circumferential direction Z, the second groove portion M2 held in the fourth core portion 64 in contact in the circumferential direction Z, along the upper surface of the third guide portion G3 of the fifth core portion 65 in contact in the circumferential direction Z, and from the lead-in groove portion 52in toward the inner side X2 from the outer side X1 in the radial direction X of the fifth core portion 65.

Similarly, the third crossover wire 70J3 connecting the coil 7 of the third core 63 and the coil 7 of the sixth core 66 is introduced from the bottom of the lead-out groove portion 53out inclined so that the lower end portion of the side surface on the crossover direction side is positioned on the crossover direction side of the third crossover wire 70J3 than the upper end portion, along the upper surface of the fourth guide portion G4 of the third core 63 shown in fig. 17, the third groove portion M3 held in the fourth core 64 in contact in the circumferential direction Z, the third groove portion M3 held in the fifth core 65 in contact in the circumferential direction Z, along the upper surface of the fourth guide portion G4 of the sixth core 66 in contact in the circumferential direction Z, and from the lead-in groove portion 53in toward the inner side X2 from the outer side X1 in the radial direction X of the sixth core 66.

Similarly to the first to third cores 61 to 63, the first, second, and

third coil wires

71, 72, and 73 are wound around the tooth portions 11b of the fourth, fifth, and

sixth cores

64, 65, and 66 at the same time as indicated by arrows N11, N21, and N31 using the first, second, and third winding nozzles N1, N2, and N3, respectively.

After the coils 7 are wound around the teeth 11b of the fourth core 64, the fifth core 65, and the sixth core 66, the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are moved as shown in the positions P1 to P5 of fig. 22, whereby the first coil wire 71 to the third coil wire 73 are fed out while simultaneously binding the first coil wire 71, the second coil wire 72, and the third coil wire 73 to the binding portions 54k of the fourth bobbins 54 of the fourth core 64, the fifth core 65, and the sixth core 66 (fig. 19, ST 32B: binding process), thereby preventing the coils 7 that have just been wound from loosening. At this time, the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are moved from the position P3 to the position P4, whereby the first coil wire 71, the second coil wire 72, and the third coil wire 73 are guided to the gap 54r between the engaging portion 54f and the bundling portion 54k, and are further moved to the position P5, and are fixed to the bottom of the gap 54r (ST 32C: engaging step).

After the coils 7 are formed on the tooth portions 11b of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66 in this way, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are bound to the binding portions 54k of the fourth core portion 64, the fifth core portion 65, and the sixth core portion 66, and fixed so as to be sandwiched between the binding portions 54k and the locking portions 54f, thereby preventing the coil wire 70 from loosening, and further, the lead-out groove portions 51out are held so as to prevent loosening, and are led out from the inner side X2 to the outer side X1 in the radial direction X (see fig. 20). Then, in order to perform the next winding process, the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are respectively caused to discharge the first coil wire 71, the second coil wire 72, and the third coil wire 73 in the direction of the arrow E, while the first winding nozzle N1 is caused to move to the position of the seventh core portion 67, the second winding nozzle N2 is caused to move to the position of the eighth core portion 68, and the third winding nozzle N3 is caused to move to the position of the ninth core portion 69.

At this time, the fourth crossover wire 70J4 connecting the coil 7 of the fourth core 64 and the coil 7 of the seventh core 67 is held in fig. 11 of the fourth core 64 from the bottom of the lead-out groove 51out inclined so that the lower end of the crossover-direction-side surface is positioned closer to the crossover-direction side of the fourth crossover wire 70J4 than the upper end, the first groove portion M1 provided on the left side in the circumferential direction of the lead-out groove portion 51out in fig. 20 is guided along the first groove portion M1 of the fifth core portion 65 that is further adjacent in the circumferential direction Z, along the upper surface of the second guide portion G2 of the sixth core portion 66 that is further adjacent in the circumferential direction Z and the lower surface of the first guide portion G1, and the first groove portion M1 provided on the right side in the circumferential direction of the lead-in groove portion 51in fig. 11 and 20 that is held on the seventh core portion 67 that is further adjacent in the circumferential direction Z is led from the lead-in groove portion 51in toward the inner side X2 from the outer side X1 in the radial direction X of the seventh core portion 67.

Further, the fifth jumper wire 70J5 connecting the coil 7 of the fifth core portion 65 and the coil 7 of the eighth core portion 68 is introduced from the bottom of the lead-out groove portion 52out inclined so that the lower end portion of the side surface on the jumper direction side is positioned on the jumper direction side of the fifth jumper wire 70J5 than the upper end portion, along the upper surface of the third guide portion G3 of the fifth core portion 65 shown in fig. 15, the second groove portion M2 held in the sixth core portion 66 in contact in the circumferential direction Z, the second groove portion M2 held in the seventh core portion 67 in contact in the circumferential direction Z, along the upper surface of the third guide portion G3 of the eighth core portion 68 in contact in the circumferential direction Z, and from the lead-in groove portion 52in toward the inner side X2 from the outer side X1 in the radial direction X of the eighth core portion 68.

Similarly, the sixth jumper wire 70J6 connecting the coil 7 of the sixth core portion 66 and the coil 7 of the ninth core portion 69 is introduced from the bottom of the lead-out groove portion 53out inclined so that the lower end portion of the side surface on the jumper direction side is positioned on the jumper direction side of the sixth jumper wire 70J6 with respect to the upper end portion, along the upper surface of the fourth guide portion G4 of the sixth core portion 66 shown in fig. 17, the third groove portion M3 held in the seventh core portion 67 that meets in the circumferential direction Z, the third groove portion M3 held in the eighth core portion 68 that meets in the circumferential direction Z, along the upper surface of the fourth guide portion G4 of the ninth core portion 69 that meets in the circumferential direction Z, and from the lead-in groove portion 53in, toward the inner side X2 from the outer side X1 of the radial direction X of the ninth core portion 69.

Similarly to the fourth to sixth cores 64 to 66, the first, second, and

third coil wires

71, 72, and 73 are wound around the tooth portions 11b of the seventh, eighth, and

ninth cores

67, 68, and 69 at the same time as indicated by arrows N11, N21, and N31 using the first, second, and third winding nozzles N1, N2, and N3.

After the coil 7 is wound around the tooth 11b of each of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69, the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are moved as shown by positions P1 to P5 in fig. 22, whereby the first coil wire 71 to the third coil wire 73 are fed out, and the first coil wire 71, the second coil wire 72, and the third coil wire 73 are simultaneously bound to the binding portion 54k of the fourth bobbin 54 of each of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69 (ST 32B: binding step in fig. 19), thereby preventing the coil 7 that has just been wound from loosening. At this time, the first winding nozzle N1, the second winding nozzle N2, and the third winding nozzle N3 are moved from the position P3 to the position P4, whereby the first coil wire 71, the second coil wire 72, and the third coil wire 73 are guided to the gap 54r between the engaging portion 54f and the binding portion 54k, and are further moved to the position P5, and are fixed to the bottom of the gap 54r (ST 32C: engaging step).

After the coil 7 is formed in the tooth portion 11b of each of the seventh core portion 67, the eighth core portion 68, and the ninth core portion 69, the first coil wire 71, the second coil wire 72, and the third coil wire 73 are cut to form a first winding harness 712, a second winding harness 722, and a third winding harness 732. Then, the first winding harness 712, the second winding harness 722, and the third winding harness 732 are collectively crimped to form a neutral point 700 of the star-shaped tie (see fig. 3). As a method of the wiring, a wire connection process such as caulking, soldering or soldering by a terminal can be used (ST 35: wire connection and wiring process in ST 33-FIG. 19).

In this way, the lower portion of the lead-out groove portion 51out of the first bobbin 51 is connected flush with the upper surface of the second guide portion G2, the lower portion of the lead-out groove portion 52out of the second bobbin 52 is connected flush with the upper surface of the third guide portion G3, the lower portion of the lead-out groove portion 53out of the third bobbin 53 is connected flush with the upper surface of the fourth guide portion G4, and further, the lower end portions of the crossover-direction-side respective side surfaces of the crossover-line 70J of the lead-out groove portions 51out, 52out, 53out are inclined so as to be positioned closer to the crossover-direction side of the crossover-line 70J than the upper end portions, and therefore, by actually moving the respective bobbins, the crossover-lines 70J constituting the respective phases are held in the first to third groove portions M1 to M3 at axially different heights while the respective crossover-lines 70J are fixed to the lower portions of the lead-out groove portions 51out to 53 out.

As shown in fig. 3, the first coil wire 71 thus formed serves as a connection wire without being cut in the middle thereof, and serves as a first winding start wire 711, the coil 7 of the first core portion 61, the first crossover wire 70J1, the coil 7 of the fourth core portion 64, the fourth crossover wire 70J4, the coil 7 of the seventh core portion 67, and a first winding end wire 712. Similarly, the second coil wire 72 serves as a connection wire without being cut halfway, and serves as a second winding start wire 721, the coil 7 of the second core portion 62, the second jumper wire 70J2, the coil 7 of the fifth core portion 65, the fifth jumper wire 70J5, the coil 7 of the eighth core portion 68, and a second winding end wire 722. Similarly, the third coil wire 73 serves as a connection wire without being cut halfway, and includes the third winding start wire 731, the coil 7 of the third core portion 63, the third jumper wire 70J3, the coil 7 of the sixth core portion 66, the sixth jumper wire 70J6, the coil 7 of the ninth core portion 69, and the third winding end wire 732.

Next, a process of using the first winding-start line 711, the second winding-start line 721, and the third winding-start line 731 as power supply lines is performed. The 3 first, second, and third winding

start wires

711, 721, and 731 are required to be arranged on the inner side X2 in the radial direction X of the stator 10 when the stator 10 is formed into an annular shape, but in a state where the winding of the coil 7 is completed, the first, second, and third winding

start wires

711, 721, and 731 are on the outer side X1 side in the radial direction X of the stator 10 as shown by the solid lines in fig. 3.

However, even if all the coils 7 are formed, the second groove portion M2, the third groove portion M3, and the third groove portion M3 of the first core portion 61 and the second core portion 62 are not used for holding the jumper wire 70J.

Therefore, as shown by the broken line in fig. 1, the first winding start line 711, the second winding start line 721, and the third winding start line 731 are folded back as shown by the broken line in fig. 3, passed through the unused second groove portion M2 and the third groove portion M3, and further, passed through the notch K formed continuously in the circumferential direction Z with the introduction groove portion 51in of the first core portion 61, and arranged on the inner side X2 in the radial direction X of the stator 10. The first power line 713, the second power line 723, and the third power line 733 are covered with an insulating tube on the inner side X2 in the radial direction X to ensure insulation, and wiring processing is performed (ST 35: wiring step in fig. 19).

Next, the respective core portions 60 are rotationally deformed into an annular shape, and the ends of the stator core 11A are fixed to each other by welding or the like to form the stator 10 (ST 4: stator forming step, fig. 18). Then, the outer peripheral surface of the stator 10 is fixed to the inner peripheral surface of the frame 101 (ST 5: stator fixing step in FIG. 18). Next, the rotor 20 is rotatably supported by the bracket 103 via a bearing (not shown), and the rotor 20 is disposed to face the stator 10 with a gap therebetween (ST 6: rotor disposing step in fig. 18). Through these steps, the rotating electric machine 100 is formed.

In the above description, the coil 7 is formed by rotating the plurality of yoke portions 11A of the stator core 11A into a linear shape and winding the coil wire 70 around the tooth portions 11b, but the present invention is not limited thereto. As another method, the following coil forming method will be explained: the plurality of yoke portions 11A of the stator core 11A are rotated by the coupling portion into a reverse-turning shape in which the direction of the teeth protruding in the radial direction X is opposite to the product state.

Fig. 25 is a conceptual diagram illustrating another winding method. The stator 10 is manufactured identically, with only the winding machine. The winding machine 400 has a hexagonal chucking mechanism 40. The jig mechanism 40 includes

jigs

41, 42, 43, 44, 45, and 46.

In fig. 25, the first winding nozzle NB1, the second winding nozzle NB2, and the third winding nozzle NB3 around which the coil wire 70 is wound are provided at positions facing the

jigs

41, 42, and 43. The first, second, and third winding nozzles NB1, NB2, and NB3 rotate about the rotation axes RB1, RB2, and RB3, and the coil wire 70 is wound around each tooth portion 11 b. However, fig. 25 is different from fig. 3in that the axial direction Y is reversed. That is, fig. 25 is a view showing a state in which the fourth bobbin 54 of each core 60 is visible. Further, since the chuck mechanism 40 rotates in the arrow R direction, the positions of the chucks 41 to 46 change.

First, as shown in fig. 25, the first core portion 61, the second core portion 62, and the third core portion 63 are fixed to the

jigs

41, 42, and 43, respectively. The first winding tip NB1, the second winding tip NB2, and the third winding tip NB3 are rotated about the rotation axes RB1, RB2, and RB3, and the coil wire 70 is wound around each tooth 11b to form the coil 7.

After the coils 7 are wound around the teeth 11b of the first, second, and

third core portions

61, 62, and 63, the first, second, and third winding mouths NB1, NB2, and NB3 are moved as shown in positions P1 to P5 of fig. 22, whereby the first, second, and third coil wires 71 to 73 are simultaneously bound to the binding portions 54k of the fourth bobbins 54 of the first, second, and

third core portions

61, 62, and 63 while the first to third coil wires 71 to 73 are being fed out (ST 32B binding step of fig. 19), and the first, second, and

third coil wires

71, 72, and 73 are fixed between the

binding portions

54f and 54k (ST32C binding step), respectively, thereby preventing the coils 7 that have just been wound from loosening.

After the 1 st coil binding process is completed, the first winding tap NB1, the second winding tap NB2, and the third winding tap NB3 are moved up and down in the front-rear direction, and the fixture mechanism 40 is rotated, whereby the jumper wire 70J is bridged between the predetermined core portions 60, as in the case of the fields described so far.

At this time, the chucking mechanism 40 is rotated 3 times at 60 ° intervals. That is, the rotation at 60 ° intervals is repeated 3 times until the fourth core portion 64 shown in fig. 25 comes to a position where the first core portion 61 is fixed in the 1 st coil winding step (moves by 3 core portions 60). At this time, all the other core portions 60 are simultaneously moved (a core portion moving step instead of the nozzle moving step). Further, since the core portions 60 are sequentially discharged from the position of the jig 46 shown in fig. 25, the stator core 11A is not fixed to the jig mechanism 40 at the position of the jig 45 shown in fig. 25.

According to this method, the coil wire 70 can be wound around the tooth portions 11b to form the coil 7 while securing a wide space between the adjacent tooth portions 11b in the circumferential direction Z. That is, as shown in fig. 25, the rotation axes of the first winding tip NB1, the second winding tip NB2, and the third winding tip NB3 can be wound so as to be directed to the tooth 11b side at all times. Therefore, the coil wire 70 can be wound at a high speed with respect to the tooth portions 11b, and the winding cycle of the coil wire 70 can be shortened.

Note that the method for manufacturing a stator of a rotating electric machine described in embodiment 1 can be similarly performed in the following embodiments, and therefore, the description thereof is appropriately omitted.

In embodiment 1, three types of bobbins, i.e., the first bobbin 51, the second bobbin 52, and the third bobbin 53, are used on one end side of each core portion 60, but only the first bobbin 51 may be used.

In the present embodiment, the first to third groove portions M1 to M3 are provided parallel to the circumferential direction Z, but the first to third groove portions M1 to M3 may be provided obliquely.

Although embodiment 1 shows an example in which the insulating portion is formed of a plurality of members, the insulating portion may be integrally formed with each core portion 60. For example, after the core portions 60 are laminated, an insulating portion having a shape in which the first bobbin 51 and the fourth bobbin 54 are combined may be integrally resin-molded thereon.

Further, it is sufficient to provide a bobbin capable of forming the coil 7 on the insulator even when a stator core without the shoe portion 11c is used.

According to the stator of the rotating electric machine of embodiment 1 configured as described above,

the stator includes:

a stator core in which a plurality of core portions having a yoke portion and a tooth portion formed to protrude radially inward from a circumferential central portion of an inner circumferential surface of the yoke portion are annularly combined;

a coil formed by winding a coil wire around each of the plurality of teeth; and

the fourth bobbin as the insulating portion includes: a second tooth end surface covering portion that covers the other end surface of the tooth portion in the axial direction of the portion around which the coil is wound; and a second outer collar connected to a radially outer end portion of the second tooth end surface covering portion so as to cover the other axial end surface of the yoke portion and project upward in the axial direction,

since the plurality of coils are formed by the continuous coil wire, the coils can be prevented from collapsing.

In addition, the following stator of the rotating electric machine may be provided: the interference of jumper wires of a stator can be prevented, the number of turns of coils of teeth is the same, the directions of a winding start wire and a winding finish wire can be commonly used, and electrical problems such as pulsation or vibration can be reduced. In addition, the number of wire connecting members can be reduced, and the manufacturing time can be shortened to improve the productivity.

Further, since the bundling portion has the protruding portions protruding from the upper end in the axial direction toward both sides in the circumferential direction, the coil wire can be prevented from falling off from the bundling portion in the bundling step.

Further, the second outer collar includes a hook-shaped engaging portion which protrudes radially outward from an axially upper end portion and a circumferentially central portion of the outer peripheral surface and extends axially upward in parallel with the binding portion, and a gap between the binding portion and the engaging portion has a radial width smaller than a wire diameter of the coil wire.

Further, the first outer collar includes a plurality of guide portions extending in the circumferential direction and arranged in the axial direction, and the plurality of guide portions form a plurality of groove portions for holding a plurality of jumper wires connecting coils of different tooth portions to each other, respectively.

Further, since the yoke portion of the core portion is formed so as to be able to linearly deform the yoke portion of each of the plurality of core portions, a method of manufacturing a stator of a rotating electric machine using:

a winding step of deforming the yoke portion of the stator core into a linear shape and winding the coil wire around the tooth portion by a winding nozzle to form the coil;

a binding step of binding the coil wire to the binding portion; and

and a locking step of fixing the coil wire between the bundling portion and the locking portion, and winding the coil wire around the tooth portion to form a coil, and fixing the wound wire between the bundling portion and the locking portion after bundling the wound wire in the bundling portion. This prevents coil collapse and loosening of jumper wires.

Further, since the yoke portion is formed in a reverse-turned shape that is deformable so that the direction in which the plurality of tooth portions protrude in the radial direction is reversed, the following method of manufacturing a stator of a rotating electric machine is used:

a winding step of deforming the yoke portion of the stator core into a reverse-turning shape and winding the coil wire around the tooth portion by a winding nozzle to form the coil;

a binding step of binding the coil wire to the binding portion; and

and a locking step of fixing the coil wire between the bundling portion and the locking portion, and winding the coil wire around the tooth portion to form a coil, and fixing the wound wire between the bundling portion and the locking portion after bundling the wound wire in the bundling portion. This prevents coil collapse and loosening of the jumper wire.

Embodiment 2.

Hereinafter, a stator of a rotating electric machine, a method of manufacturing a stator of a rotating electric machine, and a method of manufacturing a rotating electric machine according to embodiment 2 will be described mainly focusing on differences from embodiment 1 with reference to the drawings.

Fig. 26 is a perspective view showing a state in which the first bobbin 251, the second bobbin 252, the third bobbin 253, the fourth bobbin 254, and the film part 230 are attached to each core part 60. The following states are shown: the yoke portion 11a of each core portion 60 is linearly deformed, and the first bobbin 251, the second bobbin 252, the third bobbin 253, the fourth bobbin 254 on the upper side of the paper plane, and the thin film portion 230, which are insulating portions, are attached to each slot 14.

Fig. 27 is a perspective view in which the respective members of fig. 26 are exploded.

Fig. 28 is a perspective view showing the structure of the thin film part 230 shown in fig. 26.

Fig. 29A is a perspective view showing the structure of the first bobbin 251 shown in fig. 27.

Fig. 29B is a perspective view of the first bobbin 251 shown in fig. 29A viewed from the opposite side in the axial direction Y.

Fig. 30 is a perspective view showing the configuration of the fourth bobbin 254.

As shown in the drawings, the stator 10 according to embodiment 2 is different from the respective bobbins according to embodiment 1in the configurations of the first bobbin 251, the second bobbin 252, the third bobbin 253, and the fourth bobbin 254, which are insulating portions for insulating the plurality of core portions 60 from the coil 7. In embodiment 2, the insulating portion is configured by the 4 types of bobbins and the film portion 230 (slot side surface covering portion) having an electrical insulating property that covers the side surface of the slot 14 in order to insulate the plurality of core portions 60 from the coil 7.

The first bobbin 251, the second bobbin 252, the third bobbin 253, and the fourth bobbin 254 do not have a slot side surface covering portion provided in each bobbin in embodiment 1. That is, as shown in fig. 29A, the first bobbin 251 includes a gear end surface covering portion 251c, an outer collar 251a, and an inner collar 251b, which are integrally formed. The tooth end surface covering portion 251c covers one end surface in the axial direction Y of the portion of the tooth portion 11b around which the coil 7 is wound. The outer collar 251a is connected to an end portion of the outer side X1 in the radial direction X of the gear end surface covering portion 251c, covers one end surface in the axial direction Y of the yoke portion 11a, and protrudes upward in the axial direction Y.

The inner collar 251b is connected to an end portion of the inner side X2 in the radial direction X of the tooth end surface covering portion 251c, covers an inner end portion of one end surface of the tooth portion 11b and one end surface of the shoe portion 11c, and protrudes upward in the axial direction Y.

The configuration of the bobbin described below is common to the first bobbin 251, the second bobbin 252, and the third bobbin 253, and therefore, the first bobbin 251 is used for description.

The first bobbin 251 includes claw portions bt1, bt2, and at1 for fixing a film portion 230 described later. Claw portions bt1, bt2 among the 3 claw portions are provided on the outer side X1 in the radial direction X at both end portions in the circumferential direction Z of the inner blade 251 b. The remaining claw portions at1 are provided on the side surface of the tooth end surface covering portion 251c on the circumferential direction Z at the end portion on the outer blade edge 251a side where the lead-out groove portion 251out is present. The claw portions bt1, bt2, at1 project downward in the axial direction Y. Further, no claw portion is provided in a portion opposite to the side where the claw portion at1 is provided in the circumferential direction Z. Since the introduction groove portion 251in for the coil wire 70 is provided on the outer side X1 side in the radial direction X of this portion, interference with the introduction wire is avoided.

As shown in fig. 30, the fourth bobbin 254 includes 4 claws bt3, bt4, at3, and at 4. Since the fourth bobbin 254 does not interfere with the lead-in wire, a claw portion at4 is provided at a portion corresponding to the omitted portion of the first bobbin 251.

As shown in fig. 29B, a convex portion 251e protruding downward in the axial direction Y is provided on the lower surface of the first bobbin 251. As shown in fig. 30, a projection 254e projecting downward in the axial direction Y is provided on the lower surface of the fourth bobbin 254. The

protrusions

251e and 254e are used to position the first bobbin 251 and the fourth bobbin 254 at the respective end surfaces in the axial direction Y of the core 60. The convex portion 251e is fitted into the second concave portion 11r provided on one end surface of the core portion 60 in the axial direction Y, and the convex portion 254e is fitted into the second concave portion 11r provided on the other end surface of the core portion 60 in the axial direction Y.

The thin film part 230 is formed of a thin insulating thin film material, and for example, a thin film material having a thickness of 0.125mm can be considered. Then, a plurality of folding lines are provided on the film material in a shape as shown in fig. 28. The film portion 230 is formed by this folding line so as to be continuously provided with a first yoke inner peripheral surface covering portion 231 covering the yoke inner peripheral surface 112 which is one side surface in the axial direction Y of the inner side X2 in the radial direction X of the yoke portion 11a of the first core portion 61, a first side surface covering portion 232 covering one side surface in the circumferential direction Z of the tooth portion 11b and the outer peripheral surface of one shoe portion 11c, and a continuous portion 233 which bypasses the inner side X2 in the radial direction X of the tooth portion 11b of the first core portion 61 and is continuous with a second side surface covering portion 232b covering the outer peripheral surface of the other shoe portion 11c and the side surface of the other tooth portion 11b, the second side surface covering portion 232b and the second yoke inner peripheral surface covering portion 231b continuously covering the other yoke inner peripheral surface 112 of the first core portion 61 and the one yoke inner peripheral surface 112 of the second core portion 62 are repeatedly provided until the ninth core portion 69 is covered therewith.

Further, since the film portion 230 is interposed between each core portion 60 and the claw portions bt1, bt2, at1, bt1 to bt4 provided on the first bobbin 251, the second bobbin 252, the third bobbin 253, and the fourth bobbin 254, each core portion 60 can be completely insulated from the coil 7. In addition, the continuous portion 233 and the second yoke inner peripheral surface covering portion are cut after the coil 7 is wound.

According to the stator of the rotating electric machine, the method for manufacturing the stator of the rotating electric machine, and the method for manufacturing the rotating electric machine of embodiment 2,

a stator of a rotating electric machine is provided with:

a coil formed by winding a coil wire around each of the plurality of teeth; and

a binding step of binding the coil wire to the binding portion; and

a method for manufacturing a stator of a rotating electric machine includes:

a binding step of binding the coil wire to the binding portion; and

Embodiment 3.

Hereinafter, a stator of a rotating electric machine, a method of manufacturing a stator of a rotating electric machine, and a method of manufacturing a rotating electric machine according to embodiment 3 will be described mainly focusing on differences from embodiment 1 with reference to the drawings.

The stator of the present embodiment is the same as the stator 10 of embodiment 1, except that the stator core 311A used for the stator has a different configuration.

Fig. 31 is a perspective view of the stator core 311A.

Fig. 32 is a main portion enlarged plan view of the stator core 311A.

The stator core 11A of embodiment 1 differs from the stator core 311A of embodiment 3in that: adjacent core portions 60 constituting a stator core 11A of embodiment 1 are coupled to each other by a rotatable coupling portion 111 formed at an end portion in the circumferential direction Z of a yoke portion 11A; in contrast, adjacent core portions 360 constituting stator core 311A in embodiment 3 are coupled to each other by bendable coupling portions 111B formed at the end portions of yoke portion 311A in circumferential direction Z.

In the stator core 11A of embodiment 1, the coupling portion 111 is formed by alternately stacking 2 core pieces 11k1 and 11k2 formed by punching thin magnetic steel plates in the axial direction Y, whereas in embodiment 3, a plurality of 1 type of core pieces 311k formed by punching thin magnetic steel plates are stacked in the axial direction Y.

The core plates 311k are formed such that portions laminated to the yoke portions 311a are linearly arranged, that is, portions to be the tooth portions 311b are arranged in parallel, and portions to be the adjacent yoke portions 311a are connected to each other with a thin wall without being physically separated. Therefore, by simply stacking a plurality of 1 type of core plates 311k in the axial direction Y, thin connecting portions 111B can be formed between adjacent core portions 360.

In a state where a plurality of core plates 311k are stacked in the axial direction Y, the yoke portions 311a of the respective core portions 360 are held in a linearly arranged state. The stator of embodiment 3 also includes an insulating member similar to the insulating member used in embodiment 1 or embodiment 2.

After the winding of each tooth 311B is completed, the coupling portion 111B is plastically deformed and bent so that the yoke portions 311a are arranged in a circular ring shape. At this time, the positional relationship between the yoke portions 311a and the tooth portions 311b is the same as the positional relationship between the yoke portions 11a and the tooth portions 11b in embodiment 1.

The stator according to the present embodiment is also the same as the stator of embodiment 1 except for the configuration of the coupling portion of the stator core,

a stator of a rotating electric machine is provided with:

a coil formed by winding a coil wire around each of the plurality of teeth; and

the first bobbin as the insulating portion includes: a first tooth end surface covering portion that covers an axial end surface of a portion of the tooth portion around which the coil is wound; and a first outer collar connected to a radially outer end of the first tooth end surface covering portion so as to cover an axial end surface of the yoke portion and project upward in an axial direction,

a method for manufacturing a stator of a rotating electric machine includes:

a binding step of binding the coil wire to the binding portion; and

and a locking step of fixing the coil wire between the bundling portion and the locking portion, and winding the coil wire around the tooth portion to form a coil, and fixing the wound wire between the bundling portion and the locking portion after bundling the wound wire in the bundling portion. This prevents coil collapse and loosening of the jumper wire. Further, since each yoke portion is held in a linear shape by the rigidity of the thin-walled coupling portion without using a jig, the fixing jig at the time of winding can be simplified.

Embodiment 4.

Hereinafter, a stator of a rotating electric machine, a method for manufacturing a stator of a rotating electric machine, and a method for manufacturing a rotating electric machine according to embodiment 4 will be described mainly focusing on differences from embodiment 1 with reference to the drawings.

The stator of the present embodiment is the same as the stator 10 of embodiment 1, except that the stator core used in the stator has a different configuration.

Fig. 33 is a perspective view of the core 460.

The core 460 includes a yoke 411a and a tooth 411b similar to the core 60 of embodiment 1.

Fig. 34 is a perspective view showing a state after winding of the stator 410.

The stator core 11A of embodiment 1 differs from the stator core 411A of embodiment 4 in that: adjacent core portions 60 constituting a stator core 11A of embodiment 1 are coupled to each other by a rotatable coupling portion 111 formed at an end portion in the circumferential direction Z of a yoke portion 11A; in contrast, the adjacent core portions 460 constituting the stator core 411A according to embodiment 4 are independent of each other without a connecting portion.

The core portion 460 is also formed by stacking a plurality of core pieces 411k formed by punching thin magnetic steel plates in the axial direction Y.

In stator core 11A of embodiment 1, 2 core pieces 11k1 and 11k2 formed by punching thin magnetic steel plates are alternately stacked in axial direction Y to form connection portion 111, whereas in embodiment 4, core portion 460 is formed by stacking a plurality of 1 type of core pieces 411k formed by punching thin magnetic steel plates in axial direction Y. As described above, the stator 410 according to embodiment 4 is configured by 9 independent core portions 460. The stator 410 according to embodiment 4 also includes an insulating member similar to the insulating member used in embodiment 1 or embodiment 2.

The same winding as in embodiment 1 is continuously performed on the windings on the respective core portions 460 by arranging and holding all the core portions 460 in the core fixing jig 80 so that the yoke portions 411a are linearly arranged. Then, the core fixing jigs 80 are removed and combined so that the yoke portions 411a of the respective core portions 460 are in an annular shape, and the adjacent core portions 460 are fixed to each other, thereby forming the stator 410. The fixing method is welding, hot sleeve and the like.

The stator according to the present embodiment is also the same as the stator of embodiment 1 except that the stator core does not have the coupling portion,

a stator of a rotating electric machine is provided with:

a coil formed by winding a coil wire around each of the plurality of teeth; and

the first bobbin as the insulating portion includes: a first tooth end surface covering portion that covers one end surface in an axial direction of a portion of the tooth portion around which the coil is wound; and a first outer collar connected to a radially outer end of the first tooth end surface covering portion and protruding upward in the axial direction while covering an axial end surface of the yoke portion,

Further, the second outer flange includes a hook-shaped engaging portion which protrudes radially outward from an axially upper end portion and a circumferentially central portion of the outer peripheral surface and extends axially upward in parallel with the binding portion, and a radial width of a gap between the binding portion and the engaging portion is smaller than a wire diameter of the coil wire.

Further, since the yoke portion of the core portion is formed so as to be able to hold the yoke portion of each of the plurality of core portions in a linear shape, the following method of manufacturing a stator of a rotating electric machine is used:

a method for manufacturing a stator of a rotating electric machine includes:

a winding step of forming the coil by winding the coil wire around the tooth portion by a winding nozzle;

a binding step of binding the coil wire to the binding portion; and

and a locking step of fixing the coil wire between the bundling portion and the locking portion, and winding the coil wire around the tooth portion to form a coil, and fixing the wound wire between the bundling portion and the locking portion after bundling the wound wire in the bundling portion. This prevents coil collapse and loosening of the jumper wire. Further, since the core portion has no connecting portion, the die of the chip constituting the core portion can be downsized.

The number of magnetic poles generated by the permanent magnets of the rotor is not limited to 6 poles, and may be a number corresponding to the number of teeth of the

stator

10 or 410. For example, in the present case (UVWUVW …) in which jumper wires need to be provided to teeth spanning 2 teeth, when the number of teeth is 3 · N (N is an integer of 2 or more), the number of magnetic poles may be ((3 ± 1) · N). In the case of the method of winding the adjacent teeth in a 3-tooth continuous manner (UU ' UVV ' VWW ' W …), it is necessary to perform winding in a manner opposite to the 1 st tooth and the 3 rd tooth when winding the 2 nd tooth, and when the number of teeth is 9 · N (N is an integer of 1 or more), the number of magnetic poles may be ((9 ± 1) · N). In the case where the number of teeth is set to 6 · N (N is an integer of 1 or more) in the case of the method (UU ' VV ' WW ' …) in which the adjacent teeth are wound in a 2-tooth continuous manner, the number of magnetic poles may be ((6 ± 1) · N).

When the number of magnetic poles is ((9 ± 1) · N), if N is 2 or more, after winding in a 3-tooth continuous form, winding needs to be performed to the next tooth portion separated by 6 teeth, and thus, a jumper wire guiding operation separated by 6 teeth needs to be performed. When the number of magnetic poles is ((6 ± 1) · N), if N is 2 or more, after 2-tooth continuous winding, the next tooth separated by 4 teeth needs to be wound, and therefore, the jumper wire separated by 4 teeth needs to be guided.

Various exemplary embodiments and examples are described in the present application, but the various features, aspects, and functions described in one or more embodiments are not limited to the application to a specific embodiment, and may be applied to the embodiments individually or in various combinations.

Therefore, numerous modifications not illustrated can be conceived within the technical scope disclosed in the present application. For example, the case where at least one component is modified, added, or omitted, or the case where at least one component is extracted and combined with the components of the other embodiments is included.

Description of reference numerals

100 rotary electric machine, 10, 410 stator, 11A, 311A, 411A stator core, 11A, 311A, 411A yoke portion, 11b, 311b, 411b tooth portion, 11c shoe portion, 11r second recess portion, 11k1, 11k2 chip set, 311k core plate, 411k chip, 14 slot, 20 rotor, 21 rotation shaft, 22 rotor core, 51, 251 first bobbin, 51A, 52a, 53a, 54a, 251A outer flange, 51b, 54b, 251b inner flange, 51c, 54c, 251c tooth end face covering portion, 51d, 54d slot side covering portion, 51in, 52in, 53in, 251in introduction slot portion, 51out, 52out, 53out, 251out slot portion, 52, 252 second bobbin, 53, 253, third bobbin, 54, 254 fourth bobbin, 54k binding portion, 54t protrusion portion, 54f locking portion, 54r gap, 60, 360, 460 core portion, 63 core portion, 64 fourth core portion, 65 fifth core portion, 66 sixth core portion, 67 seventh core portion, 68 eighth core portion, 69 ninth core portion, 70 coil wire, 71 first coil wire, 72 second coil wire, 73 third coil wire, 70J jumper wire, 70J1 first jumper wire, 70J2 second jumper wire, 70J3 third jumper wire, 70J4 fourth jumper wire, 70J5 fifth jumper wire, 70J6 sixth jumper wire, G1 first guide portion, G2 second guide portion, G3 third guide portion, G4 fourth guide portion, M1 first groove portion, M2 second groove portion, M3 third groove portion, N1 first winding mouth, N2 second winding mouth, N3 third winding mouth, 80 core portion fixing jig, 101 bracket frame, 103, 105 permanent magnet, 107, 111B coupling portion, 112 yoke inner peripheral face, 113 tooth portion, first tooth portion, tooth portion 122 tooth portion, film yoke portion, film portion, inner peripheral face portion, 121, film portion side face portion, and outer peripheral face portion, 231 first yoke inner peripheral surface covering portion, 231b second yoke inner peripheral surface covering portion, 232 first side surface covering portion, 232b second side surface covering portion, 233 continuous portion, 251e and 254e convex portions, 400 winding machine, 40 clamp mechanism, 41 to 46 clamps, 700 neutral point, 711 first winding starting line, 712 first winding ending line, 713 first power line, 721 second winding starting line, 722 second winding ending line, 723 second power line, 731 third winding starting line, 732 third winding ending line, 733 third power line, NB1 first winding nozzle, NB2 second winding nozzle, NB3 third winding nozzle, RB1, RB2, RB3 rotation axis, at1, at4, bt1, bt3 claw portions.

Claims

1. A stator of a rotating electric machine, comprising:

a coil formed by winding a coil wire around each of the plurality of teeth; and

the second outer collar includes a binding portion which protrudes upward in the axial direction from a central portion in the circumferential direction and binds winding end portions of the coils,

the plurality of coils are formed by continuous coil wires.

2. The stator of a rotating electric machine according to claim 1,

the binding portion includes a protruding portion protruding from an axially upward end toward both sides in the circumferential direction.

3. The stator of a rotating electric machine according to claim 1 or 2,

the second outer collar includes a hook-shaped engaging portion protruding radially outward from an axially upper end portion and a circumferentially central portion of the outer peripheral surface, the engaging portion extending axially upward in parallel with the binding portion, and a radial width of a gap between the binding portion and the engaging portion is smaller than a wire diameter of the coil wire.

4. The stator of a rotating electric machine according to claim 3,

the yoke portion of the core portion includes a coupling portion that is capable of rotating the yoke portion of each of the plurality of core portions linearly or in a reverse-turned shape in which a direction in which the plurality of tooth portions protrude in the radial direction is reversed.

5. The stator of a rotating electric machine according to claim 3,

circumferential ends of adjacent ones of the yokes are connected to each other with a thin wall.

6. The stator of a rotating electric machine according to any one of claims 1 to 5,

the first outer collar includes a plurality of guide portions extending in a circumferential direction and arranged in an axial direction, and the plurality of guide portions form a plurality of groove portions that respectively hold a plurality of jumper wires that connect coils of different tooth portions to each other.

7. A rotating electric machine, wherein,

the rotating electric machine includes:

a stator of a rotating electric machine according to any one of claims 1 to 6; and

8. A method of manufacturing a stator of a rotating electric machine according to claim 4,

a winding step of deforming the yoke portions of the plurality of core portions into a linear shape and winding the coil wire around the tooth portions by a winding nozzle to form the coil;

a binding step of binding the coil wire to the binding portion; and

9. A method of manufacturing a stator of a rotating electric machine according to claim 4,

a winding step of deforming the yoke portions of the plurality of core portions into a reverse-turning shape and winding the coil wire around the tooth portions by a winding nozzle to form the coil;

a binding step of binding the coil wire to the binding portion; and

10. A method of manufacturing a rotating electric machine, wherein,

the rotor is disposed to face the inside of the stator manufactured by the method for manufacturing a stator of a rotating electric machine according to claim 8 or 9 with a gap therebetween.