WO2016194347A1 - Dynamo-electric machine for internal combustion engine, and stator of said machine - Google Patents

Dynamo-electric machine for internal combustion engine, and stator of said machine Download PDF

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Publication number
WO2016194347A1
WO2016194347A1 PCT/JP2016/002561 JP2016002561W WO2016194347A1 WO 2016194347 A1 WO2016194347 A1 WO 2016194347A1 JP 2016002561 W JP2016002561 W JP 2016002561W WO 2016194347 A1 WO2016194347 A1 WO 2016194347A1
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WO
WIPO (PCT)
Prior art keywords
stator
coil end
coil
internal combustion
combustion engine
Prior art date
Application number
PCT/JP2016/002561
Other languages
French (fr)
Japanese (ja)
Inventor
義則 倉谷
金光　憲太郎
優一 水元
辰哉 岩崎
正尚 道明
Original Assignee
デンソートリム株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by デンソートリム株式会社 filed Critical デンソートリム株式会社
Priority to JP2016571772A priority Critical patent/JP6124493B1/en
Publication of WO2016194347A1 publication Critical patent/WO2016194347A1/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/52—Fastening salient pole windings or connections thereto

Definitions

  • the disclosure in this specification relates to a rotating electrical machine for an internal combustion engine and its stator.
  • Patent Document 1 and Patent Document 2 disclose rotating electrical machines for internal combustion engines.
  • a rotating electrical machine for an internal combustion engine has a multiphase winding.
  • a terminal for connection may be provided on the stator in some cases.
  • the prior art uses soldering to connect the end of the coil and the terminal. Furthermore, before soldering, the end of the coil is preliminarily fixed by a process (caulking) of bending a part of the terminal. The bending process fixes a bundle of end portions of a plurality of coils.
  • One object is to provide an improved rotating electrical machine for an internal combustion engine and its stator.
  • Another object is to provide a rotating electrical machine for an internal combustion engine in which a plurality of coil ends can be connected by projection welding and its stator.
  • Yet another object is to provide a stator for a rotating electrical machine for an internal combustion engine and a rotating electrical machine for an internal combustion engine that can provide a small connection structure between a coil end and a terminal.
  • a stator for a rotating electrical machine for an internal combustion engine including a stator core (32), an insulator (35) attached to the stator core, and a stator coil (33) attached to the stator core.
  • a stator of a rotating electrical machine for an internal combustion engine includes a terminal (51) fixed to an insulator on one end face of the stator, and a plurality of coil ends (37) extending from the stator coil and connected to the terminal.
  • a terminal is arrange
  • the plurality of coil end portions are distributed and associated with the plurality of connection portions.
  • Each of the plurality of connecting portions has a protrusion (55) extending along the axial direction of the stator.
  • Each of the plurality of connecting portions is connected by projection welding to a coil end portion corresponding to the connecting end portion and disposed at a top portion of the ridge, which is arranged to intersect the ridge.
  • the stator of the rotating electrical machine for an internal combustion engine since the coil end portion is disposed so as to intersect the protrusion, contact suitable for projection welding can be obtained between the coil end portion and the protrusion. . Since the plurality of connecting portions are arranged along the circumferential direction of the stator, the work space for projection welding is arranged in a distributed manner along the circumferential direction. Therefore, a plurality of coil ends can be connected to each other using projection welding using the end face of the stator.
  • a stator for a rotating electrical machine for an internal combustion engine including a stator core (32), an insulator (35) attached to the stator core, and a stator coil (33) attached to the stator core.
  • a stator of a rotating electrical machine for an internal combustion engine includes a terminal (51) fixed to an insulator on one end face of the stator, and a plurality of coil ends (37) extending from the stator coil and connected to the terminal.
  • connection portion has a connecting portion (52, 352) disposed so as to protrude from the end face (42) of the insulator, and the connecting portion has a protrusion (55) extending along the axial direction of the stator,
  • the connection portion is connected by projection welding at a plurality of coil end portions arranged so as to intersect with the ridge and the top of the ridge.
  • the stator of the rotating electrical machine for an internal combustion engine since the plurality of coil end portions are arranged so as to intersect with the ridges, it is suitable for projection welding between the plurality of coil end portions and the ridges. Contact is obtained. Therefore, a plurality of coil ends can be connected to each other using projection welding.
  • a rotating electrical machine for an internal combustion engine including the stator is provided.
  • a rotating electrical machine for an internal combustion engine having a small connection structure for a coil end can be provided.
  • FIG. 1st Embodiment It is a circuit diagram of a stator coil. It is a perspective view of a stator. It is a perspective view which expands and shows a part of FIG. It is a top view which expands and shows a part of stator. It is a perspective view of a terminal. It is a flowchart which shows a manufacturing method. It is a perspective view which shows the terminal which concerns on 2nd Embodiment. It is a perspective view which shows the terminal which concerns on 3rd Embodiment. It is a perspective view which shows the terminal which concerns on 4th Embodiment. It is a top view which expands and shows some stators concerning a 5th embodiment. It is a perspective view of a terminal. It is a perspective view which shows the coil end part after a connection.
  • FIG. 1 is a cross-sectional view of a rotating electrical machine 10 for an internal combustion engine (hereinafter simply referred to as a rotating electrical machine).
  • the rotating electrical machine 10 is electrically connected to an electrical load (LOAD) 11.
  • the load 11 may include an electric circuit and a battery.
  • LOAD electrical load
  • An example of the use of the rotating electrical machine 10 is a generator driven by an internal combustion engine 12 for a vehicle.
  • the rotating electrical machine 10 can be used for a motorcycle, for example.
  • the rotating electrical machine 10 is assembled to the internal combustion engine 12.
  • the internal combustion engine 12 includes a body 13 and a rotary shaft 14 that is rotatably supported by the body 13 and rotates in conjunction with the internal combustion engine 12.
  • the rotating electrical machine 10 is assembled to the body 13 and the rotating shaft 14.
  • the body 13 is a structure such as a crankcase or a transmission case of the internal combustion engine 12.
  • the rotating shaft 14 is a crankshaft of the internal combustion engine 12 or a rotating shaft interlocking with the crankshaft. The rotating shaft 14 rotates when the internal combustion engine 12 is operated, and drives the rotating electrical machine 10 to function as a generator.
  • the rotating electrical machine 10 includes a rotor 21 and a stator 31.
  • the rotor 21 is a field element.
  • the stator 31 is an armature.
  • the entire rotor 21 is cup-shaped.
  • the rotor 21 is positioned with its open end facing the body 13.
  • the rotor 21 is fixed to the end of the rotating shaft 14.
  • the rotor 21 and the rotating shaft 14 are connected via a positioning mechanism in the rotational direction such as key fitting.
  • the rotor 21 is fixed by being fastened to the rotary shaft 14 by a fixing bolt 25.
  • the rotor 21 rotates together with the rotating shaft 14.
  • the rotor 21 provides a field by a permanent magnet.
  • the rotor 21 has a cup-shaped rotor core 22.
  • the rotor core 22 is connected to the rotating shaft 14 of the internal combustion engine 12.
  • the rotor core 22 has an inner cylinder fixed to the rotating shaft 14, an outer cylinder positioned on the radially outer side of the inner cylinder, and an annular bottom plate extending between the inner cylinder and the outer cylinder.
  • the rotor core 22 provides a yoke for a permanent magnet described later.
  • the rotor core 22 is made of a magnetic metal.
  • the rotor 21 has a permanent magnet 23 disposed on the inner surface of the rotor core 22.
  • the permanent magnet 23 is fixed inside the outer cylinder.
  • the permanent magnet 23 is fixed with respect to the axial direction and the radial direction by a holding cup 24 arranged on the radially inner side.
  • the holding cup 24 is made of a thin nonmagnetic metal. The holding cup 24 is fixed to the rotor core 22.
  • the permanent magnet 23 has a plurality of segments. Each segment is partially cylindrical.
  • the permanent magnet 23 provides a plurality of N poles and a plurality of S poles inside thereof.
  • the permanent magnet 23 provides at least a field.
  • the permanent magnet 23 provides six pairs of N poles and S poles, that is, a 12 pole field by 12 segments. The number of segments and / or the number of magnetic poles may be other numbers.
  • the stator 31 is an annular member.
  • the stator 31 is disposed between the rotor 21 and the body 13.
  • the stator 31 has a through hole that can receive the rotating shaft 14 and the inner cylinder of the rotor core 22.
  • the stator 31 has an outer peripheral surface that faces the inner surface of the rotor 21 via a gap.
  • a plurality of magnetic poles are arranged on the outer peripheral surface.
  • the stator 31 has, for example, 18 magnetic poles. The number of magnetic poles may be other numbers. These magnetic poles are arranged opposite to the field of the rotor 21.
  • the stator 31 has an armature winding.
  • the stator 31 has multiphase armature windings.
  • the stator 31 is fixed to the body 13.
  • the stator 31 is a three-phase multipolar stator having a plurality of magnetic poles and a plurality of three-phase windings.
  • the stator 31 has a stator core 32.
  • the stator core 32 is disposed inside the rotor 21 by being fixed to the body 13 of the internal combustion engine 12.
  • the stator core 32 forms a plurality of magnetic poles facing the inner surface of the permanent magnet 23 on the radially outer side.
  • the stator core 32 is formed by laminating magnetic materials such as electromagnetic steel plates or steel plates formed into a predetermined shape so as to form a plurality of magnetic poles.
  • the stator 31 has a stator coil 33 wound around a stator core 32.
  • the stator coil 33 provides an armature winding.
  • the stator 31 and the body 13 are connected via a fixing bolt 34.
  • the stator 31 is fixed by being fastened to the body 13 by a plurality of fixing bolts 34.
  • the stator 31 is fixed to a boss portion 13 a extending from the body 13.
  • the boss part 13a is a cylindrical part.
  • the boss portion 13 a is a metal member that is integral with the body 13.
  • An insulator 35 made of an insulating material is disposed between the stator core 32 and the stator coil 33.
  • the insulator 35 is made of resin.
  • the insulator 35 is also called a bobbin.
  • a portion of the insulator 35 is positioned adjacent to the magnetic pole to provide a bobbin flange.
  • Part of the insulator 35 is disposed on both sides in the axial direction of the magnetic pole.
  • the insulator 35 is also exposed at the radially inner portion of the stator core 32.
  • the insulator 35 provides a cylindrical portion at a radially inner portion of the stator core 32. In the following description, the insulator 35 often refers to a cylindrical portion.
  • the stator coil 33 is a multiphase winding.
  • the stator coil 33 is a three-phase winding.
  • the stator coil 33 is star-connected.
  • the stator coil 33 includes a plurality of phase coils u1, u2, v1, v2, w1, and w2.
  • a plurality of electrically in-phase phase coils u1, u2 are connected in parallel.
  • a plurality of phase coils v1, v2 are also connected in parallel.
  • a plurality of phase coils w1, w2 are also connected in parallel.
  • the plurality of phase coils u1, u2, v1, v2, w1, w2 are connected to form a set of three-phase windings (u1, u2)-(v1, v2)-(w1, w2). . Therefore, the stator coil 33 has three output ends PT and one neutral point NT. The neutral point NT connects six coil ends.
  • the plurality of phase coils u1, u2, v1, v2, w1, w2 may be connected to form two sets of three-phase windings u1-v1-w1, u2-v2-w2.
  • the neutral point NT is provided by a plurality of coil end portions 37, a terminal block 41, and a terminal 51.
  • the coil is a single wire conductor covered with an insulating coating.
  • the conducting wire forming the coil is made of aluminum or aluminum alloy.
  • the coil end portion 37 is an end portion of a conducting wire forming a coil. At the neutral point NT, the six coil end portions 37 are electrically connected.
  • the terminal block 41 is provided on the insulator 35.
  • the terminal block 41 is formed integrally with the insulator 35 by a resin material that forms the insulator 35.
  • the terminal block 41 is made of an electrically insulating resin material.
  • the terminal block 41 is formed on the cylindrical portion of the insulator 35.
  • the terminal block 41 is formed so as to protrude inward in the radial direction of the cylindrical portion.
  • the terminal block 41 extends in a range surrounded by a partial arc of the cylindrical portion and a string corresponding to the arc.
  • the terminal block 41 provides a base for fixing the terminal 51.
  • the terminal block 41 is also called a fixing part for fixing and holding the terminal 51.
  • the terminal block 41 protrudes from the end surface of the stator core 32 in the axial direction.
  • the terminal block 41 protrudes at substantially the same height as the end face of the stator coil 33.
  • the terminal block 41 receives a coil end 37 extending from the stator coil 33.
  • the terminal block 41 is given a height capable of receiving the coil end portion 37 along the radial direction from the height of the axial end surface of the stator coil 33.
  • the terminal block 41 has an end face 42 facing the axial direction on the stator 31.
  • the end surface 42 extends along an arc having a circumference of 1/3 or less on the end surface of the stator 31.
  • the end face 42 has an arcuate shape surrounded by an arc and a string.
  • the circumferential range in which the terminal block 41 extends may be a wider range.
  • the terminal block 41 may extend in a range of 1 ⁇ 2 circumference or less.
  • the terminal block 41 has side walls 43 and 44 surrounding the end face 42.
  • the side walls 43 and 44 extend from the end face 42 in the axial direction of the stator 31.
  • the side walls 43 and 44 define a concave portion that is recessed in the axial direction from one end of the stator 31 in the axial direction.
  • the side walls 43 and 44 include a side wall 43 extending along the string and a side wall 44 extending along the arc.
  • the side wall 43 provides a radially inner edge of the insulator 35.
  • Side wall 44 provides a bobbin inner flange for stator coil 33.
  • the side wall 43 is an inner wall of the terminal block 41.
  • the side wall 44 is an outer wall of the terminal block 41.
  • the end surface 42 provides the bottom surface of the recess.
  • the top of the side wall 44 is substantially the same height as the axial end surface of the stator coil 33 to receive the coil end portion 37 from the stator coil 33 substantially parallel to the radial end surface of the stator coil 33 and along the radial direction. Is positioned. The height of the side walls 43 and 44 from the end face 42 is set so that the protective material can be prevented from flowing out.
  • the terminal block 41 has a slit 45 for receiving the terminal 51.
  • the slit 45 opens in the end face 42.
  • the slit 45 extends approximately along the circumferential direction of the stator core 32.
  • the slit 45 is bent in a somewhat multi-step manner corresponding to the shape of the terminal 51 and extends along the circumferential direction.
  • the slit 45 has a predetermined depth in the axial direction in order to receive the terminal 51.
  • the axial depth of the slit 45 is set so that the connecting portion 52 of the terminal 51 protrudes from the end face 42.
  • the terminal block 41 has holding portions 47 and 48 for holding the coil end portion 37.
  • the holding portions 47 and 48 hold the coil end portion 37 between the stator coil 33 and the connection portion 52.
  • the holding portions 47 and 48 are also guide portions that guide the coil end portion 37.
  • the holding portions 47 and 48 are also winding portions around which the coil end portion 37 is wound along the surface thereof.
  • the holding portions 47 and 48 are also members that define and form a long and narrow gap into which the coil end portion 37 is inserted.
  • the holding portions 47 and 48 are disposed on the radially outer side of the terminal block 41.
  • the holding part 47 and the holding part 48 are arranged side by side along the circumferential direction of the stator core 32.
  • the holding portions 47 and 48 are provided on the side wall 44.
  • the holding parts 47 and 48 extend from the end face 42 to the axial direction higher than the side wall 44.
  • the holding portions 47 and 48 are formed as columnar members extending in the axial direction.
  • the holding portions 47 and 48 are columnar shapes with rounded corners so that the coil end portion 37 is gently bent.
  • a gap that can receive the coil end portion 37 is defined between the holding portion 47 and the holding portion 48.
  • the gap has a circumferential width that can receive the coil end portion 37.
  • the width of the gap is set so as to receive the coil end portion 37 while slightly deforming the holding portions 47 and 48.
  • the gap has an axial depth that can be received in a state in which at least two coil ends 37 are stacked in the axial direction.
  • the holding part 47 is thicker than the holding part 48.
  • the holding portion 47 is located on the inner side with respect to the bending of the coil end portion 37.
  • the holding portion 47 is used as a core for bending the coil end portion 37.
  • the holding portion 47 contributes to maintain the shape of the bent coil end portion 37 against the elastic force of the bent coil end portion 37.
  • the holding portion 48 is located outside with respect to the bending of the coil end portion 37.
  • the holding portion 48 functions as a member that provides an outer wall that holds the coil end portion 37 on the holding portion 47.
  • the holding portion 48 contributes to maintain the shape of the bent coil end portion 37 against the elastic force of the bent coil end portion 37.
  • the terminal block 41 has a plurality of sets of holding portions 47 and 48. In the illustrated example, the terminal block 41 has three sets of holding portions 47 and 48. One holding portion 47, 48 holds the two coil end portions 37.
  • the terminal 51 is made of conductive metal.
  • the terminal 51 can be provided by aluminum, aluminum alloy, iron-based alloy, copper, brass, or the like.
  • the material of the terminal 51 is selected according to the conductive wire connected thereto, for example, the material of the coil end portion 37.
  • the material of the terminal 51 is selected so as to suppress corrosion caused by the combination with the coil end portion 37.
  • the terminal 51 is made of aluminum, an aluminum alloy, or an iron-based alloy.
  • the terminal 51 may be provided by an iron-based alloy.
  • the terminal 51 has a plurality of connection parts 52. In the illustrated example, the terminal 51 has three connection parts 52. One connection portion 52 is electrically connected to at least one coil end portion 37. One connection portion 52 is electrically connected to the plurality of coil end portions 37. In the illustrated example, one connection portion 52 is electrically connected to the two coil end portions 37.
  • One connecting portion 52 has a plate shape.
  • the connecting portion 52 extends from the end face 42 along the axial direction of the stator 31.
  • the connecting portion 52 extends along the circumferential direction or tangential direction of the stator 31.
  • the connecting portion 52 has a base portion 53.
  • the base portion 53 has a flat plate shape.
  • the base portion 53 may be formed in a slightly curved plate shape.
  • connection part 52 has a projection part protruding toward the radial direction of the stator 31.
  • the projection part is formed as a curved part in a part of the connection part 52.
  • the projection portion is provided adjacent to the base portion 53.
  • Base portions 53 are provided on both sides of the projection portion in the circumferential direction.
  • the projection portion protrudes in the direction in which the coil end portion 37 is disposed.
  • the projection part extends long along the axial direction.
  • the projection part is formed by a groove 54 and a ridge 55.
  • the concave groove 54 and the protrusion 55 are formed by pressing.
  • the recessed groove 54 is recessed from the radially inner side toward the radially outer side.
  • the concave groove 54 extends along the axial direction of the stator 31.
  • the protrusion 55 protrudes from the radially inner side toward the radially outer side.
  • the protrusion 55 extends along the axial direction of the stator 31. Projections are provided by the ridges 55.
  • the connecting portion 52 has a tip edge 56 at the tip in the axial direction.
  • the leading edge 56 is formed as a rounded edge so as to reduce sharp corners.
  • the tip edge 56 appears as a round shoulder at the tip of the base portion 53.
  • the plurality of connection portions 52 are arranged along the circumferential direction of the stator 31.
  • the plurality of connection portions 52 are arranged so that the top portions of the plurality of protrusions 55 are positioned along the circumferential direction of the stator 31.
  • the tops of the plurality of protrusions 55 are positioned on a circumference CP concentric with the stator 31.
  • the protruding direction of each of the plurality of protrusions 55 is directed in the radially outward direction of the circumference CP.
  • connection unit 52 is associated with a set of holding units 47 and 48.
  • the connecting portion 52 is disposed on the radially inner side from the holding portions 47 and 48.
  • the connecting portion 52 is disposed radially inward from the associated holding portions 47 and 48 via a gap.
  • the gap has a size that allows the coil end portion 37 to be disposed.
  • a radial gap RG is defined between the radially inner edge of the holding portion 47 and the radially outer edge of the connecting portion 52, that is, the top of the protrusion 55.
  • the radial gap RG has such a size that the coil end portion 37 can be disposed.
  • the connecting portion 52 is disposed at a position shifted in the circumferential direction on the radially inner side of the associated holding portions 47 and 48.
  • the position of the connecting portion 52 in the circumferential direction and the positions of the holding portions 47 and 48 associated therewith are such that the coil end portion 37 can be disposed between the holding portions 47 and 48 along the radial direction.
  • the position of the connection portion 52 in the circumferential direction and the positions of the holding portions 47 and 48 associated therewith are such that the coil end portion 37 that has passed between the holding portions 47 and 48 is placed on the radially outer surface of the connection portion 52. It is set so that it can be contacted.
  • the position of the connecting portion 52 in the circumferential direction and the positions of the holding portions 47 and 48 associated therewith are set so that the connecting portion 52 and the holding portions 47 and 48 do not overlap in the radial direction. Yes.
  • the terminal 51 has a connecting portion 57.
  • the connecting portion 57 connects the plurality of connecting portions 52.
  • the connecting portion 57 is accommodated in the slit 45.
  • the end surface of the connecting portion 57 is positioned at the opening end of the slit 45.
  • the terminal 51 is inserted and fixed in the slit 45 so that the connection part 52 is exposed.
  • the terminal 51 is press-fitted into the slit 45.
  • the terminal 51 is fixed to the terminal block 41 by press-fitting the connecting portion 57 into the slit 45.
  • the connection part 52 protrudes and extends from the connection part 57.
  • the plurality of connecting portions 52 are positioned away from each other.
  • the connecting portion 52 is given an independent shape that can also be called a connecting piece.
  • the coil end 37 is disposed radially inward from the stator coil 33.
  • the coil end portion 37 is disposed so as to protrude from the radially outer side through the holding portions 47 and 48 to the radially inner side.
  • the coil end portion 37 is disposed so as to extend along the end surface of the stator 31 on the radially inner side of the holding portions 47 and 48.
  • the coil end portion 37 is bent approximately 90 degrees by being wound around the outer surface of the holding portion 47 over about 1 ⁇ 4 circumference.
  • the coil end portion 37 has a bent portion along the holding portion 47.
  • the coil end portion 37 is disposed so as to extend along the circumferential direction of the stator 31 before the bent portion.
  • the coil end portion 37 is disposed so as to pass through a gap between the holding portion 47 and the connection portion 52.
  • the coil end portion 37 is bent in an L shape before and after the holding portions 47 and 48.
  • the coil end portion 37 is bent toward the radially outer side of the connecting portion 52 after passing between the holding portions 47 and 48.
  • the coil end portion 37 is disposed so as to contact the holding portion 47 and the connection portion 52.
  • the coil end portion 37 has a strip portion 38 having an insulating coating peeled off at a tip portion thereof, particularly in a predetermined range in contact with the connection portion 52.
  • the strip portion 38 is positioned on the radially outer side of the connecting portion 52.
  • the strip portion 38 is positioned radially inward of the holding portions 47 and 48.
  • the strip portion 38 is electrically connected to the connection portion 52.
  • the strip portion 38 and the connection portion 52 are welded by projection welding.
  • the strip portion 38 is welded to the top of the projection portion of the connection portion 52.
  • a plurality of coil end portions 37 and 37 are arranged between the holding portions 47 and 48.
  • the plurality of coil end portions 37 and 37 are disposed between the holding portions 47 and 48 in a state of being stacked in the axial direction of the stator 31.
  • two coil end portions 37 and 37 are arranged in parallel.
  • the plurality of coil ends 37, 37 are given the same shape.
  • the plurality of coil end portions 37 and 37 are disposed so as to be laminated in the axial direction of the stator 31 on the radially outer side of the connection portion 52.
  • the longitudinal direction of the projection portion extends in the axial direction of the stator 31.
  • the plurality of coil end portions 37 and 37 are arranged so as to be aligned along the longitudinal direction of the projection portion.
  • the plurality of coil end portions 37 and 37 are connected to a common connection portion 52.
  • connection structure includes a plurality of coil end portions 37, holding portions 47 and 48, and one connection portion 52.
  • the plurality of connection structures are arranged on the end surface of the stator 31 along the circumferential direction of the stator 31.
  • the three connection structures shown provide a neutral point NT.
  • connection structure is covered with a protective material 59.
  • the protective material 59 is imparted to the connection structure in a fluid state and cured.
  • the protective material 59 covers at least the strip portion 38 and the connection portion 52.
  • the protective material 59 covers three connection structures.
  • the protective material 59 reaches the end surface 42.
  • a part of the protective material 59 extends also on the end face 42.
  • a part of the protective material 59 reaches the side walls 43 and 44.
  • the side walls 43 and 44 prevent the protective material 59 from flowing out.
  • the side walls 43 and 44 hold the protective material 59 on the terminal block 41.
  • the side walls 43 and 44 define a container portion for storing the protective material 59 on the terminal block 41.
  • the round shape of the leading edge 56 prevents the protective material 59 from becoming too thin.
  • FIG. 5 shows a part of a manufacturing apparatus for manufacturing the rotating electrical machine 10.
  • the manufacturing apparatus includes a welding machine (WELD) 61 for projection welding.
  • the welding machine 61 includes a pair of electrodes 62 and 63.
  • the electrodes 62 and 63 include an outer electrode 62 positioned on the radially outer side of the connection structure and an inner electrode 63 positioned on the radial inner side of the connection structure.
  • the electrodes 62 and 63 are used to sandwich and contact the coil end portion 37 and the connection portion 52 that are the welding objects.
  • the electrodes 62 and 63 are also used to energize and weld the coil end portion 37 and the connection portion 52.
  • the process of moving the electrodes 62 and 63 in the manufacturing method is shown by broken lines.
  • the manufacturing apparatus includes electrodes 62 and 63 and a moving device (INDEX) 65 for the terminal 51.
  • the moving device 65 moves the electrodes 62 and 63 between the standby position and the illustrated work position. In the working position, the moving device 65 moves the electrodes 62 and 63 between the illustrated closed position and the open position. In the figure, the opening and closing direction is indicated by a radial arrow.
  • the moving device 65 changes the relative positional relationship between the electrodes 62 and 63 and the terminal 51. For example, the moving device 65 sequentially moves the electrodes 62 and 63 on the plurality of connection structures by rotating the stator 31. In the figure, the relative rotational movement is indicated by circumferential arrows.
  • the moving device 65 can be provided by various devices such as a robot arm that supports the electrodes 62 and 63 and an index table that rotates the stator 31.
  • the electrodes 62 and 63 are moved so as to approach each other along the radial direction of the stator 31, and the coil end portion 37 and the connection portion 52 are tightened.
  • the electrodes 62 and 63 are moved away from each other along the radial direction of the stator 31, and are separated from the coil end portion 37 and the connection portion 52.
  • the electrodes 62 and 63 are separated to a position where they can move in the circumferential direction of the stator 31 without interfering with the portion of the stator 31.
  • the portion closest to the stator 31 is located higher than the axial surface of the stator 31.
  • the surface of the coil end portion 37 closest to the stator 31 is located higher than the axial surface of the stator coil 33.
  • the connecting portion 52 extends so as to be separated from the surface of the stator 31 in the axial direction. In other words, the connecting portion 52 is located higher than the axial surface of the stator coil 33.
  • the stator 31 is configured to suppress the protruding height of the coil end portion 37 and the connection portion 52 from the stator 31.
  • the stator coil 33 is thick on the radially outer side and wound thin on the radially inner side.
  • the stator coil 33 may be concentratedly wound around one magnetic pole.
  • the stator coil 33 is wound around a single magnetic pole so as to form a plurality of layers.
  • the stator coil 33 is wound such that the number of radially inner layers is smaller than the number of radially outer layers.
  • the axial thickness on the radially inner side of the stator coil 33 is smaller than the axial thickness on the radially outer side.
  • This configuration enables the radially inner height of one end face of the stator 31 to be lower than the radially outer height. Since the terminal 51 is disposed radially inward of the stator 31, particularly radially inward of the stator coil 33, the terminal 51 is provided at a relatively low position on the end surface of the stator 31. Thereby, the height of the connection part 52 on the end surface of the stator 31 is suppressed. Further, a narrow portion on the radially inner side of the stator coil 33, in other words, a low portion is also a portion where the electrode 62 is positioned. Therefore, the shape of the stator coil 33 contributes to enable projection welding while suppressing the height of the connection portion 52.
  • the manufacturing apparatus sequentially performs connection operations in a plurality of connection structures by opening and closing movement of the electrodes 62 and 63 and movement in the relative rotation direction of the electrodes 62 and 63 and the stator 31.
  • FIG. 7 is a flowchart showing a method for manufacturing the rotating electrical machine 10.
  • the manufacturing method 180 is also a method for manufacturing the stator 31.
  • Step 181 is a process for manufacturing a component. In this step, the stator core 32, the insulator 35, and the terminal 51 are manufactured.
  • Step 182 is a process of fixing the terminal 51 to the insulator 35.
  • the terminal 51 is inserted into the slit 45 of the insulator 35 and fixed after the insulator 35 is attached to the stator core 32 or before the insulator 35 is attached to the stator core 32.
  • Step 183 is a step of winding the stator coil 33. Prior to this step, the insulator 35 is attached to the stator core 32. The stator coil 33 is wound on the insulator 35.
  • the terminal 51 may be fixed to the insulator 35 after this winding step.
  • Step 184 is a step of forming the strip portion 38 at the coil end portion 37.
  • Step 185 is a step of arranging the coil end portion 37 in the shape shown in the drawing. This step is also called a preliminary step of preliminarily positioning the coil end portion 37 so as to be adjacent to the connection portion 52. This configuration is also called a temporary fastening process in which the coil end portion 37 is positioned at a predetermined position by the holding portions 47 and 48 and the connection portion 52.
  • step 185 the coil end portion 37 is first disposed so as to pass between the holding portions 47 and 48 from the stator coil 33. Two coil end portions 37 are arranged between the holding portions 47 and 48. Next, the coil end portion 37 is bent into an L shape along the holding portion 47. In this bending step, the coil end portion 37 is positioned on the radially outer side of the connection portion 52. At this time, the coil end portion 37 is positioned on the radially outer side of the connection portion 52 while being elastically deformed. As a result, the coil end portion 37 is pressed toward the connection portion 52 by its own elasticity. Further, the coil end portion 37 is positioned at a predetermined position between the holding portions 47 and 48 and the connection portion 52 by its own elasticity. Step 185 is performed in each of the three connection structures.
  • Step 186 is a moving process for moving the electrodes 62 and 63 from the standby position to the working position.
  • the electrodes 62 and 63 are positioned at specified working positions by the robot arm.
  • the electrodes 62, 63 are in the open position.
  • the electrodes 62 and 63 are arranged on both sides in the radial direction of one connection structure in which a connection operation is to be performed.
  • Step 187 is a process of closing the electrodes 62 and 63.
  • Step 188 is a step of executing projection welding by causing a current for projection welding to flow through the electrodes 62 and 63.
  • the plurality of coil end portions 37 and the connection portion 52 are welded.
  • a plurality of coil end portions 37 are welded onto one connection portion 52 by one projection welding, that is, energization.
  • Step 189 is a process of opening the electrodes 62 and 63.
  • the electrodes 62 and 63 are opened to a position where they do not interfere with the components of the stator 31 even when the stator 31 is rotated.
  • Step 190 is a step of determining whether or not n times of welding corresponding to the number of connection structures have been completed. Step 190 provides a determination unit that determines whether or not the welding operation has been completed for all connection structures. If the welding work for all the connection structures has not been completed, the process branches to NO and proceeds to step 191. If the welding work for all connections is completed, the process branches to YES and proceeds to step 192.
  • Step 191 is a process of relatively rotating the electrodes 62 and 63 and the stator 31.
  • the relative rotation amount is set so that the electrodes 62 and 63 are moved radially outside and inside of the other connection structures. Thereby, the electrodes 62 and 63 move to the radially outer side and the inner side of other connection structures.
  • step 187 is executed again. Steps 187-191 are repeated for all connection structures. As a result, welding operations in a plurality of connection structures are executed in order. In addition, welding operations for a plurality of connection structures are performed by opening and closing the electrodes 62 and 63 and relative rotation between the electrodes 62 and 63 and the stator 31 (terminal 51).
  • Step 192 is a process of moving the electrodes 62 and 63 from the work position to the standby position.
  • the electrical connection work for the neutral point NT is executed by the processes of Steps 186-192.
  • Steps 186-192 provide a welding process for the neutral point NT.
  • Step 193 is a step of applying the protective material 59 to the connection structure.
  • the protective material 59 is provided so as to cover the charging portions of the plurality of connection structures.
  • the protective material 59 is a resin material that has a relatively low viscosity at the time of application and is cured after application. For example, the protective material 59 is dripped from the axial direction front-end
  • the protective material 59 flows so as to cover at least the surfaces of the strip portion 38 and the connection portion 52 in the connection structure, and forms an insulating film thereon. A part of the protective material 59 reaches the end face 42. Excess protective material 59 is blocked by side walls 43 and 44.
  • a stator for a rotating electrical machine for an internal combustion engine including a stator core 32, an insulator 35 attached to the stator core 32, and a stator coil 33 attached to the stator core 32.
  • the stator 31 of the rotating electrical machine for the internal combustion engine includes a terminal 51 fixed to the insulator 35 on one end surface of the stator 31 and a plurality of coil end portions 37 extending from the stator coil 33 and connected to the terminal 51.
  • the terminal 51 is disposed so as to protrude from the end face 42 of the insulator 35, and has a plurality of connection portions 52 disposed along the circumferential direction.
  • the plurality of coil end portions 37 are distributed and associated with the plurality of connection portions 52.
  • Each of the plurality of connection portions 52 has a protrusion 55 extending along the axial direction of the stator 31.
  • Each of the plurality of connection portions 52 is connected to the coil end portion 37 corresponding to the plurality of connection portions 52, which is arranged so as to intersect the protrusion 55, at the top of the protrusion 55 by projection welding. ing.
  • the coil end portion 37 is disposed so as to intersect with the protrusion 55, contact suitable for projection welding can be obtained between the coil end 37 and the protrusion 55. Since the plurality of connecting portions 52 are arranged along the circumferential direction of the stator 31, work spaces for projection welding are arranged in a distributed manner along the circumferential direction. Therefore, a plurality of coil end portions 37 can be connected to each other using projection welding using the end face of the stator 31.
  • connection structure 37 and the terminal 51 are connected by projection welding.
  • Projection welding allows a small connection structure compared to soldering. Soldering may require cleaning for flux application and flux removal. For this reason, when soldering is employed, a large space for work is required around the connection structure.
  • the connection structure can be arranged in a narrow space by using projection welding.
  • a plurality of coil end portions 37 that is, a plurality of coil strands, are connected to one connection portion 52. Since the plurality of coil end portions 37 are connected at one place, a small connection structure is provided.
  • the plurality of coil end portions 37 are stacked in the axial direction. In other words, the plurality of coil end portions 37 are arranged vertically with respect to the axial direction. Moreover, the plurality of coil end portions 37 are in contact with the connection portion 52 while being arranged in the axial direction. Such an arrangement also contributes to the miniaturization of the connection structure.
  • the connecting portion 52 includes a protrusion 55 having a longitudinal direction in the axial direction.
  • the protrusion 55 contacts the plurality of coil end portions 37.
  • the ridge 55 is used for projection welding. As a result, electrical connection with a plurality of coil end portions 37 is provided in a narrow range on the stator 31.
  • the plurality of coil end portions 37 are guided by holding portions 47 and 48.
  • the plurality of coil end portions 37 are held at a predetermined position and a predetermined shape by the holding portions 47 and 48. Thereby, the operation
  • the plurality of coil end portions 37 are also arranged in the axial direction in the holding portions 47 and 48, a small connection structure is provided.
  • the coil end portion 37 is bent into an L shape using the holding portion 47. For this reason, the coil end part 37 can be processed into a defined shape. Furthermore, the coil end portion 37 extends along the circumferential direction of the stator 31 by bending the coil end portion 37 into an L shape. As a result, the contact portion between the coil end portion 37 and the connection portion 52 is disposed at a radially outer portion on the stator 31.
  • the protruding shaft of the protrusion 55 extends along the radial direction of the stator 31. Further, the plurality of connection structures are arranged in a distributed manner along the circumferential direction of the stator 31. Thereby, the moving direction of the electrodes 62 and 63 for projection welding can be set to a radial direction. Thereby, the connection operation
  • a plurality of connection parts 52 are provided on one terminal 51. This configuration enables connection to a plurality of coil end portions 37. Further, since the plurality of coil end portions 37 are connected to one connection portion 52, the connection between the many coil end portions 37 can be provided by the terminal 51. More specifically, a small neutral point NT can be provided in the stator coil 33 including a plurality of in-phase coils.
  • the side walls 43 and 44 provided in the insulator 35 provide a container portion for suppressing the excessive spread of the protective material 59. Therefore, reliable insulation protection of the charged portion is provided while suppressing the excessive spread of the protective material 59.
  • the connecting portion 57 is press-fitted into the insulator 35.
  • the terminal 51 has an insertion piece 258.
  • the insertion piece 258 extends from the coupling portion 57 to the side opposite to the connection portion 52.
  • the insertion piece 258 is inserted into the insulator 35.
  • the insertion piece 258 strengthens the connection between the terminal 51 and the insulator 35.
  • the stator core 32 can include a recess for receiving the insulator 35 and the insertion piece 258.
  • connection part 52 is provided so that it may mutually separate regarding the circumferential direction.
  • a plurality of connecting portions 352 are provided in a continuous plate-like portion. In this shape, the plurality of connecting portions 352 are provided so as to be connected to each other in the circumferential direction. Even in this shape, it can be said that the plurality of connecting portions 352 are arranged along the circumferential direction.
  • This embodiment is a modification based on the preceding embodiment.
  • the said embodiment is the neutral point NT.
  • electrical connections for other applications may be provided.
  • the terminal 51 provides a connection between the plurality of coil ends 37 and also provides a connection with one power line 411a.
  • the terminal 51 has a plurality of connecting portions 52.
  • the terminal 51 has two connection parts 52.
  • a plurality of coil end portions 37 are connected to one connection portion 52 by projection welding.
  • Two coil end portions 37 are connected to one connection portion 52 by projection welding.
  • connection part 452 is a connection part to which another welding method different from projection welding is applied.
  • the connection part 452 is a connection part for caulking, fusing, and / or soldering.
  • the connection unit 452 is provided for connection to the power line 411a.
  • the power line 411a is a stranded wire including a plurality of conducting wires.
  • the connection portion 452 can also be referred to as a connection portion suitable for connection with a stranded wire.
  • the connection part 52 can also be called a connection part suitable for the connection with the coil end part 37 which is a single wire.
  • the plurality of connecting portions 52 and 452 are mechanically and electrically connected by a connecting portion 57.
  • the plurality of coil end portions 37 are electrically connected by one connection portion 52.
  • the plurality of coil end portions 37 are electrically connected by the plurality of connecting portions 52 and the connecting portion 57.
  • the plurality of coil end portions 37 and at least one power line 411a are electrically connected by a connection portion 52 suitable for them. At least one of the functions and effects described in the above embodiment can be obtained.
  • the terminal 51 of this embodiment can be used for the output terminal PT, for example.
  • it can be used for an output end in delta connection.
  • the connecting portion 57 of the above embodiment is a plate that is bent along the circumferential direction of the stator 31.
  • the connecting portion can have various shapes such as a flat plate or a curved plate.
  • the terminal 51 includes a flat connecting portion 557.
  • the terminal 51 has a connecting portion 557.
  • FIG. 12 shows the state before or during the welding process.
  • the connection part 557 is a flat plate.
  • the connecting portion 557 extends along a string with respect to the circumferential direction of the stator 31.
  • the plurality of connecting portions 52 are arranged along the strings.
  • the plurality of connection parts 52 are arranged on a common plane.
  • the plurality of base portions 53 are arranged on a straight line.
  • the plurality of connecting portions 52 have a similar shape or the same shape.
  • the protrusion 55 protrudes from the surface of the terminal 51 facing the radially inner side of the stator 31.
  • the protrusion 55 protrudes from the radially inner surface of the corresponding base portion 53 in a direction perpendicular to the base portion 53.
  • the protrusion 55 protrudes from the inner side surface of the corresponding connection portion 52.
  • the protrusion 55 protrudes inward of the stator 31 along a diameter line of the stator 31 or a parallel line parallel to the diameter line.
  • the base portion 53 of the central connection 52 is orthogonal to the diameter line passing therethrough.
  • the protrusion 55 provided in the central connection portion 52 protrudes inward in the radial direction of the stator 31 along the diameter line.
  • the base portions 53 of the connecting portions 52 at both ends are inclined with respect to the diameter line passing therethrough.
  • the ridges 55 provided on the connection portions 52 at both ends protrude inward of the stator 31 along a parallel line parallel to the diameter line.
  • the protrusion 55 protrudes inward of the stator 31 with respect to the tangent line of the stator 31 at the position where the protrusion 55 is provided.
  • the surface from which the protrusion 55 protrudes can be referred to as a first surface
  • the surface on which the concave groove 54 is formed can be referred to as a second surface.
  • the terminal 51 is positioned with the first surface directed toward the center side of the tangential direction of the stator 31.
  • the terminal 51 is positioned with the first surface facing the radially inner side of the stator 31 and the second surface facing the radially outer side of the stator 31.
  • the coil end portion 37 is disposed so as to extend radially inward from the stator coil 33.
  • the coil end portion 37 is disposed on the end face of the stator 31 so as to pass through the side of the corresponding connecting portion 52.
  • the coil end portions 37 are arranged so as to go from the corresponding connection portion 52 to the radially inner side of the stator 31 from the corresponding connection portion 52 from the radially outer side of the stator 31.
  • the coil end portion 37 reaches the corresponding protrusion 55.
  • the coil end portion 37 is disposed so as to wind around the connection portion 52.
  • the coil end portion 37 is disposed so as to be hooked on the connection portion 52.
  • the coil end portion 37 has a held portion 37 a held by holding portions 47 and 48.
  • the coil end portion 37 is positioned at a predetermined position at least in the circumferential direction by the holding portions 47 and 48.
  • the held portion 37a extends between the pair of holding portions 47 and 48 relatively longer and straighter than a crank portion 37b described later.
  • the holding portions 47 and 48 are arranged on the outer side in the radial direction than the corresponding connection portion 52. The holding portions 47 and 48 allow the coil end portion 37 to move in the axial direction, that is, the radial direction of the stator 31.
  • the coil end portion 37 has a crank portion 37b.
  • the crank portion 37 b is a bent portion formed by bending the coil end portion 37.
  • the crank portion 37b provides a bend of approximately 90 degrees.
  • the crank portion 37b can also be referred to as an L-shaped portion.
  • the crank part 37 b is located between the holding parts 47 and 48 and the connection part 52.
  • the crank portion 37 b is located on the radially inner side with respect to the holding portions 47 and 48.
  • many portions of the crank portion 37 b are located on the radially inner side of the stator 31 with respect to the plane defined by the terminal 51.
  • a part of the crank portion 37 b is located beside the connection portion 52.
  • a part less than half of the crank portion 37 b may be located on the radially outer side from the connecting portion 52.
  • the at least one crank part 37b is disposed through the outside of the end connection part 52. At least one crank portion 37 b is disposed between the two connection portions 52.
  • a gap large enough to arrange the coil end portion 37 is provided between the two connection portions 52.
  • the coil end portion 37 passes through the holding portions 47 and 48 and further passes through the gap and reaches the ridge 55.
  • the gap can also be referred to as a notch provided in the terminal 51.
  • the gap provides a passage cavity for arranging the coil end portion 37 along the end surface of the stator 31 between the holding portions 47 and 48 and the protrusion 55.
  • the gap is open in the axial direction of the stator 31, and the coil end portion 37 is pushed into the gap along the axial direction and is positioned at a predetermined position.
  • the coil end portion 37 has a tip end portion 37c.
  • the distal end portion 37 c is positioned radially inward from the holding portions 47 and 48.
  • the distal end portion 37 c is positioned on the radially inner side with respect to the connection portion 52.
  • the coil end portion 37 is formed so as to pass through the side of the connecting portion 52 and further through the top of the protrusion 55.
  • the coil end portion 37 is formed so that the tip end portion 37 c approaches the connection portion 52 again after passing through the top of the protrusion 55.
  • the coil end portion 37 is slightly curved along the first surface of the connection portion 52. This curvature is such that the coil end portion 37 is wound around the connection portion 52.
  • the coil end portion 37 is disposed as illustrated in FIG.
  • the shape of the coil end 37 has several features that contribute to forming a high quality weld. These features can be used in combination as in the embodiment. These features can also be used alone.
  • One feature is a plurality of connecting portions 52 arranged in a straight line.
  • This shape is provided by a straight connection 557.
  • This shape enables the plurality of connecting portions 52 to be stably positioned at a predetermined position on the stator 31.
  • the connecting portion 557 does not have a bent shape, it is difficult to cause an error in positioning of the connecting portions 52 at both ends.
  • the two of the coil end portion 37 and the connection portion 52 can be surely positioned at the prescribed positions.
  • the three of the coil end portion 37, the connection portion 52, and the electrodes 62 and 63 can be surely positioned at specified positions. Therefore, a high quality weld can be stably formed.
  • Another feature is a shape in which a relatively long coil end portion 37 is disposed radially inward from the holding portions 47 and 48. This shape is made possible by the protrusion 55 provided on the first surface of the terminal 51. This shape is made possible by arranging the coil end portion 37 so as to wrap around the connection portion 52.
  • the long coil end 37 enables easy bending.
  • the coil end portion 37 can be processed into a shape suitable for projection welding. Therefore, a high quality weld can be stably formed.
  • the coil end portion 37 is bent so as to be wound around the connection portion 52 at the crank portion 37b.
  • the coil end portion 37 can hook the coil end portion 37 to the connection portion 52 by using its own elastic force. This manufacturing method makes it possible to stably position the coil end portion 37 on the protrusion 55. Therefore, a high quality weld can be stably formed.
  • the long coil end 37 allows the coil end 37 to sag.
  • the long coil end portion 37 allows a dimensional error of the coil end portion 37 or a change in sag due to deformation.
  • the long coil end 37 provides a long slack allowance.
  • the coil end portion 37 is disposed relatively straight over a relatively long distance between the held portion 37a and the crank portion 37b.
  • the relatively straight coil end portion 37 allows the coil end portion 37 to move smoothly with respect to the holding portions 47 and 48. Such movement facilitates movement of the coil end 37 in the welding process.
  • the relatively long straight portion provided between the held portion 37a and the crank portion 37b enables the coil end portion 37 to smoothly slide.
  • the coil end portion 37 is welded to the connection portion 52.
  • the welding electrodes 62 and 63 include an electrode 62 that contacts the second surface of the connection portion 52 and an electrode 63 that contacts the coil end portion 37.
  • the electrode 62 is also called a back electrode, a support electrode, or an outer electrode.
  • the electrode 63 is also called a front electrode, a working electrode, or an inner electrode.
  • the second surface of the connecting portion 52 and the electrode 52 are formed so as to provide a stable contact state, that is, an energized state.
  • the welding electrodes 62 and 63 are positioned and driven so as to clamp the coil end portion 37 and the connection portion 52.
  • the stator 31 and the electrodes 62 and 63 are relatively rotated.
  • the stator 31 and the electrodes 62 and 63 are relatively translated.
  • a plurality of connection operations are executed in order.
  • the electrodes 62 and 63 clamp the coil end portion 37 and the connection portion 52
  • the coil end portion 37 moves toward the connection portion 52.
  • a portion between the crank portion 37 b and the tip portion 37 c moves in parallel toward the connecting portion 52. That is, the strip portion 38 translates toward the connection portion 52.
  • the crank portion 37b also translates radially outward.
  • the long coil end portion 37 between the holding portions 47 and 48 and the tip end portion 37c provides a slack that allows the strip portion 38 to move.
  • the long coil end portion 37 can be deformed while suppressing the tension. For this reason, the position correction of the coil end part 37 is easily performed.
  • the held portion 37 a and the holding portions 47 and 48 allow the coil end portion 37 to move between the holding portions 47 and 48 while sliding. For this reason, the position correction of the coil end part 37 is easily performed.
  • the long coil end 37 described above allows the above movement by “sag” and “slip”.
  • the above movement provides correction of the position of the coil end 37 in the welding process.
  • a desirable contact state can be formed between the coil end portion 37 and the connection portion 52.
  • the desired contact state also contributes to the formation of the desired weld state. Only one of “sag” and “slip” may be used. For example, even if the holding portions 47 and 48 and the held portion 37a are firmly engaged with each other, the position of the coil end portion 37 can be corrected only by “sag”.
  • the width WD1 of the connecting portion 52 is set smaller than the width WD2 of the electrode 62 (WD1 ⁇ WD2).
  • the width WD3 of the notch between the two connecting portions 52 is set so that the width WD1 of the connecting portion 52 is smaller than the width WD2 of the electrode 62.
  • the width WD3 is set so that the coil end portion 37 can be disposed.
  • the electrode 62 and the electrode 63 can have the same width.
  • the electrode 62 and the electrode 63 may have different widths.
  • the electrode 63 may have a width smaller than the width WD2, but larger than the width of the protrusion 55.
  • FIG. 13 shows the coil end portion 37 and the connection portion 52 after welding.
  • the crank portion 37b provides a bending angle DG1.
  • the bending angle DG ⁇ b> 1 is an angle between the central axis AX ⁇ b> 1 of the coil end 37 next to the connecting portion 52 and the central axis AX ⁇ b> 2 of the coil end 37 parallel to the connecting portion 52.
  • the bending angle DG ⁇ b> 1 gives the coil end portion 37 a shape in which the coil end portion 37 is wound around the connection portion 52. The winding shape can be realized by less than 1/4 turn.
  • the tip portion 37 c is bent so as to approach the connection portion 52 again after exceeding the protrusion 55.
  • the tip portion 37c provides a bending angle DG2.
  • the bending angle DG2 is an angle between the central axis AX2 and the central axis AX3 of the tip surface of the coil end portion 37.
  • a contact mark 37 d is formed in a portion of the coil end portion 37 that is in contact with the electrode 63.
  • the contact mark 37 d is a surface corresponding to the surface shape of the electrode 63.
  • the contact mark 37d is a flat surface.
  • the contact mark 37 d is formed on the strip portion 38.
  • the coil end portion 37 is deformed along the protrusion 55 around the contact mark 37d.
  • the coil end portion 37 provides a wide portion that extends along the extending direction of the protrusion 55.
  • the wide portion forms a wide contact area between the coil end portion 37 and the protrusion 55.
  • the disclosure of this specification is not limited to the illustrated embodiments.
  • the disclosure encompasses the illustrated embodiments and variations by those skilled in the art based thereon.
  • the disclosure is not limited to the combinations of parts and / or elements shown in the embodiments.
  • the disclosure can be implemented in various combinations.
  • the disclosure may have additional parts that can be added to the embodiments.
  • the disclosure includes those in which parts and / or elements of the embodiments are omitted.
  • the disclosure encompasses the replacement or combination of parts and / or elements between one embodiment and another.
  • the technical scope disclosed is not limited to the description of the embodiments. Some technical scope disclosed is shown by the description of the scope of claims, and should be understood to include all modifications within the meaning and scope equivalent to the description of the scope of claims.
  • the protrusion 55 is formed by press working for forming the groove 54.
  • the protrusion 55 may be formed without the concave groove 54.
  • the protrusion 55 can employ various cross-sectional shapes such as a semicircular cross-section, a triangular cross-section, and a trapezoidal cross-section.
  • the coil end portion 37 is disposed outside the connecting portion 52 in the radial direction.
  • the coil end portion 37 may be disposed on the radially inner side of the connecting portion 52.
  • the protrusion 55 is given a shape that protrudes radially inward.
  • the protruding shaft of the protrusion is in the radial direction.
  • the conductive wire forming the coil is made of aluminum. Instead of this, a copper conducting wire may be used.
  • two coils are arranged in the same phase.
  • three or more coils may be arranged in the same phase.
  • all the coils are integrated in one three-phase connection. Instead of this, a plurality of three-phase connections may be formed.
  • two coil end portions 37 are connected to one connection portion 52.
  • one connecting portion 52 and one coil end portion 37 may be connected.
  • one connecting portion 52 and three or more coil end portions 37 may be connected.
  • connection portion 52 has a plate shape facing the radial direction.
  • the connecting portion 52 may be twisted 90 degrees.
  • the connecting portion has a plate shape facing the circumferential direction.
  • the plurality of connecting portions are arranged along the circumferential direction.
  • the connection part 52 is flat form.
  • the connecting portion 52 may be a curved plate.
  • the entire terminal 51 may be curved along the circumferential direction of the stator 31.
  • the terminal 51 is provided on the end surface of the stator 31 on the body 13 side.
  • the terminal 51 can be provided on one end surface or both surfaces of the stator 31.
  • the terminal 51 may be provided on an end surface facing the rotor 21.
  • the strip portion 38 is formed at the tip of the coil end portion 37.
  • the coil end portion 37 and the connection portion 52 may be projection welded without forming the strip portion 38 and with the insulating film attached.
  • the insulating film can be broken by projection welding.
  • the coil end portion 37 is L-shaped on the stator 31.
  • the coil end portion 37 may be L-shaped in the reverse direction.
  • the plurality of coil end portions 37 are L-shaped in the same direction.
  • at least one coil end 37 may be L-shaped, and the remaining coil end 37 may be L-shaped in the reverse direction.
  • Such a shape of the coil end portion 37 enables various arrangements of the coil end portion 37 and the connection portion 52. For example, it is possible to arrange the coil end portion 37 that avoids other components on the stator 31.
  • the terminal 51 is electrically connected to the plurality of coil end portions 37 and the power line 411a.
  • the terminal 51 may be electrically connected to other members.
  • the terminal 51 is electrically connected to the stator core 32.
  • Terminal 51 and stator core 32 are electrically connected by direct contact and / or via an electric wire or the like.
  • the terminal 51 is fixed by press-fitting the terminal 51 into the insulator 35.
  • the terminal 51 may be insert-molded in the step of resin-molding the insulator 35.
  • the stator core 32 and the insulator 35 are separate parts. Instead of this, the stator core 32 and the insulator 35 may be integrated. For example, the stator core 32 may be insert-molded in the insulator 35. In the above embodiment, the insulator 35 that provides the terminal block 41 provides a bobbin for the stator coil 33. Instead of this, the insulator that provides the terminal block 41 and the insulator that provides the bobbin may be separate components. For example, only the portion of the terminal block 41 may be configured as a separate part so that it can be mounted on the stator 31.
  • the rotor 21 has a cup shape that covers the body 13 from the end of the rotating shaft 14. Instead, a cup-shaped rotor opened toward the end of the rotating shaft may be used.
  • the stator 31 may be attached to a cover member as the body 13.
  • the rotating electrical machine 10 is a so-called outer rotor type. Instead of this, the rotating electrical machine 10 may be an inner rotor type. Even in the inner rotor type, the terminal 51 can be used.
  • the rotating electrical machine 10 provides a generator.
  • the rotating electrical machine 10 may be configured as an AC generator starter disclosed in Patent Document 2.
  • the rotating electrical machine 10 is configured as an AC generator starter, the contents described in Patent Document 2 can be incorporated, and the contents described therein are cited by reference.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

Provided is a dynamo-electric machine for an internal combustion engine, it being possible for said machine to be connected to a coil end part by projection welding. A stator 31 of the dynamo-electric machine for an internal combustion engine has a terminal 51 secured to an insulator 35. The terminal 51 includes a plurality of connection parts 52. The connection parts 52 have ridges 55 extending along the axial direction of the stator 31. The insulator 35 has holding parts 47, 48 for holding a plurality of coil end parts 37. The plurality of coil end parts 37 are disposed so as to span the space between the holding parts 47, 48, and are bent in an L-shape. The plurality of coil end parts 37 are provisionally fixed in a preliminary manner so as to contact the connection parts 52. The plurality of coil end parts 37 and the ridges 55 are connected by projection welding. Because the terminal 51 has the plurality of connection parts 52, the terminal 51 electrically connects the plurality of coil end parts 37. Fig. 4 is the selected drawing.

Description

内燃機関用回転電機およびそのステータRotating electric machine for internal combustion engine and stator thereof 関連出願の相互参照Cross-reference of related applications
　この出願は、２０１５年６月５日に出願された日本特許出願２０１５－１１４９０５号を基礎出願とするものであり、基礎出願の開示内容は参照によってこの出願に組み込まれている。 This application is based on Japanese Patent Application No. 2015-114905 filed on June 5, 2015, and the disclosure of the basic application is incorporated into this application by reference.
　この明細書における開示は、内燃機関用回転電機およびそのステータに関する。 The disclosure in this specification relates to a rotating electrical machine for an internal combustion engine and its stator.
　特許文献１および特許文献２は、内燃機関用回転電機を開示する。内燃機関用回転電機は、多相巻線を有する。特許文献１に記載されるように、ステータの上に、結線のための端子が設けられる場合がある。従来技術は、コイルの端部と、端子との接続に、はんだ付けを用いる。さらに、はんだ付けの前に、端子の一部を曲げる加工（かしめ）によって、コイルの端部を予備的に固定している。曲げ加工は、複数のコイルの端部の束を固定する。 Patent Document 1 and Patent Document 2 disclose rotating electrical machines for internal combustion engines. A rotating electrical machine for an internal combustion engine has a multiphase winding. As described in Patent Document 1, a terminal for connection may be provided on the stator in some cases. The prior art uses soldering to connect the end of the coil and the terminal. Furthermore, before soldering, the end of the coil is preliminarily fixed by a process (caulking) of bending a part of the terminal. The bending process fixes a bundle of end portions of a plurality of coils.
特開２０１０－６３２３３号公報JP 2010-63233 A 特開２０１３－２７２５２号公報JP 2013-27252 A
　従来技術の曲げ加工では、複数のコイルの端部を、安定的に固定することが困難である。別の観点では、従来技術の曲げ加工では、端子が変形するから、インシュレータへの端子の固定が不安定になる場合がある。さらに、別の観点では、端子の設置と、接続作業とのために、接続構造の体格が大型化する場合がある。上述の観点において、または言及されていない他の観点において、内燃機関用回転電機およびそのステータにはさらなる改良が求められている。 In the conventional bending process, it is difficult to stably fix the ends of the plurality of coils. From another viewpoint, since the terminal is deformed in the conventional bending process, the fixing of the terminal to the insulator may become unstable. Furthermore, from another viewpoint, the physique of the connection structure may increase in size due to terminal installation and connection work. In the above-mentioned viewpoints or other aspects not mentioned, further improvement is required for the rotating electrical machine for internal combustion engines and its stator.
　ひとつの目的は、改良された内燃機関用回転電機およびそのステータを提供することである。 One object is to provide an improved rotating electrical machine for an internal combustion engine and its stator.
　他のひとつの目的は、プロジェクション溶接によって複数のコイル端部を接続可能な内燃機関用回転電機およびそのステータを提供することである。 Another object is to provide a rotating electrical machine for an internal combustion engine in which a plurality of coil ends can be connected by projection welding and its stator.
　さらに他のひとつの目的は、コイル端部と端子との間における小型の接続構造を提供することができる内燃機関用回転電機のステータ、および内燃機関用回転電機を提供することである。 Yet another object is to provide a stator for a rotating electrical machine for an internal combustion engine and a rotating electrical machine for an internal combustion engine that can provide a small connection structure between a coil end and a terminal.
　この明細書に開示された複数の態様は、それぞれの目的を達成するために、互いに異なる技術的手段を採用する。請求の範囲およびこの項に記載した括弧内の符号は、後述する実施形態の部分との対応関係を示すものであって、技術的範囲を限定するものではない。 The plurality of aspects disclosed in this specification adopt different technical means to achieve each purpose. The reference numerals in parentheses described in the claims and in this section indicate the correspondence with the portions of the embodiments described later, and do not limit the technical scope.
　ひとつの態様により、ステータコア（３２）、ステータコアに装着されたインシュレータ（３５）、およびステータコアに装着されたステータコイル（３３）を備える内燃機関用回転電機のステータが提供される。内燃機関用回転電機のステータは、ステータの一方の端面においてインシュレータに固定された端子（５１）と、ステータコイルから延び出し、端子に接続される複数のコイル端部（３７）とを備える。端子は、インシュレータの端面（４２）から突出するように配置され、周方向に沿って配置された複数の接続部（５２、３５２）を有する。複数のコイル端部は、複数の接続部に分配されて対応付けられている。複数の接続部のそれぞれは、ステータの軸方向に沿って延びる突条（５５）を有している。複数の接続部のそれぞれは、それに対応付けられたコイル端部であって突条と交差するように配置されたコイル端部と、突条の頂部において、プロジェクション溶接によって接続されている。 According to one aspect, there is provided a stator for a rotating electrical machine for an internal combustion engine including a stator core (32), an insulator (35) attached to the stator core, and a stator coil (33) attached to the stator core. A stator of a rotating electrical machine for an internal combustion engine includes a terminal (51) fixed to an insulator on one end face of the stator, and a plurality of coil ends (37) extending from the stator coil and connected to the terminal. A terminal is arrange | positioned so that it may protrude from the end surface (42) of an insulator, and has a some connection part (52,352) arrange | positioned along the circumferential direction. The plurality of coil end portions are distributed and associated with the plurality of connection portions. Each of the plurality of connecting portions has a protrusion (55) extending along the axial direction of the stator. Each of the plurality of connecting portions is connected by projection welding to a coil end portion corresponding to the connecting end portion and disposed at a top portion of the ridge, which is arranged to intersect the ridge.
　この内燃機関用回転電機のステータによると、コイル端部は、突条と交差するように配置されているから、コイル端部と、突条との間に、プロジェクション溶接に適した接触が得られる。複数の接続部は、ステータの周方向に沿って配置されているから、プロジェクション溶接のための作業空間が周方向に沿って分散的に配置される。よって、ステータの端面を利用して、複数のコイル端部をプロジェクション溶接を利用して互いに接続することができる。 According to the stator of the rotating electrical machine for an internal combustion engine, since the coil end portion is disposed so as to intersect the protrusion, contact suitable for projection welding can be obtained between the coil end portion and the protrusion. . Since the plurality of connecting portions are arranged along the circumferential direction of the stator, the work space for projection welding is arranged in a distributed manner along the circumferential direction. Therefore, a plurality of coil ends can be connected to each other using projection welding using the end face of the stator.
　ひとつの態様により、ステータコア（３２）、ステータコアに装着されたインシュレータ（３５）、およびステータコアに装着されたステータコイル（３３）を備える内燃機関用回転電機のステータが提供される。内燃機関用回転電機のステータは、ステータの一方の端面においてインシュレータに固定された端子（５１）と、ステータコイルから延び出し、端子に接続される複数のコイル端部（３７）とを備え、端子は、インシュレータの端面（４２）から突出するように配置された接続部（５２、３５２）を有し、接続部は、ステータの軸方向に沿って延びる突条（５５）を有しており、接続部は、突条と交差するように配置された複数のコイル端部と、突条の頂部において、プロジェクション溶接によって接続されている。 According to one aspect, there is provided a stator for a rotating electrical machine for an internal combustion engine including a stator core (32), an insulator (35) attached to the stator core, and a stator coil (33) attached to the stator core. A stator of a rotating electrical machine for an internal combustion engine includes a terminal (51) fixed to an insulator on one end face of the stator, and a plurality of coil ends (37) extending from the stator coil and connected to the terminal. Has a connecting portion (52, 352) disposed so as to protrude from the end face (42) of the insulator, and the connecting portion has a protrusion (55) extending along the axial direction of the stator, The connection portion is connected by projection welding at a plurality of coil end portions arranged so as to intersect with the ridge and the top of the ridge.
　この内燃機関用回転電機のステータによると、複数のコイル端部は、突条と交差するように配置されているから、複数のコイル端部と、突条との間に、プロジェクション溶接に適した接触が得られる。よって、複数のコイル端部をプロジェクション溶接を利用して互いに接続することができる。 According to the stator of the rotating electrical machine for an internal combustion engine, since the plurality of coil end portions are arranged so as to intersect with the ridges, it is suitable for projection welding between the plurality of coil end portions and the ridges. Contact is obtained. Therefore, a plurality of coil ends can be connected to each other using projection welding.
　ひとつの態様により、上記ステータを備える内燃機関用回転電機が提供される。コイル端部のための小型の接続構造を有する内燃機関用回転電機を提供することができる。 According to one aspect, a rotating electrical machine for an internal combustion engine including the stator is provided. A rotating electrical machine for an internal combustion engine having a small connection structure for a coil end can be provided.
第１実施形態に係る内燃機関用回転電機の断面図である。It is sectional drawing of the rotary electric machine for internal combustion engines which concerns on 1st Embodiment. ステータコイルの回路図である。It is a circuit diagram of a stator coil. ステータの斜視図である。It is a perspective view of a stator. 図３の一部を拡大して示す斜視図である。It is a perspective view which expands and shows a part of FIG. ステータの一部を拡大して示す平面図である。It is a top view which expands and shows a part of stator. 端子の斜視図である。It is a perspective view of a terminal. 製造方法を示すフローチャートである。It is a flowchart which shows a manufacturing method. 第２実施形態に係る端子を示す斜視図である。It is a perspective view which shows the terminal which concerns on 2nd Embodiment. 第３実施形態に係る端子を示す斜視図である。It is a perspective view which shows the terminal which concerns on 3rd Embodiment. 第４実施形態に係る端子を示す斜視図である。It is a perspective view which shows the terminal which concerns on 4th Embodiment. 第５実施形態に係るステータの一部を拡大して示す平面図である。It is a top view which expands and shows some stators concerning a 5th embodiment. 端子の斜視図である。It is a perspective view of a terminal. 接続後のコイル端部を示す斜視図である。It is a perspective view which shows the coil end part after a connection.
　図面を参照しながら、複数の実施形態を説明する。複数の実施形態において、機能的におよび／または構造的に対応する部分および／または関連付けられる部分には同一の参照符号、または百以上の位が異なる参照符号が付される場合がある。対応する部分および／または関連付けられる部分については、他の実施形態の説明を参照することができる。 A plurality of embodiments will be described with reference to the drawings. In embodiments, functionally and / or structurally corresponding parts and / or associated parts may be assigned the same reference signs or reference signs that differ by more than a hundred. For the corresponding parts and / or associated parts, the description of other embodiments can be referred to.
　（第１実施形態）
　図１は、内燃機関用回転電機１０（以下、単に回転電機という）の断面図である。回転電機１０は、電気的な負荷（ＬＯＡＤ）１１と電気的に接続されている。負荷１１は、電気回路と、バッテリとを含む場合がある。回転電機１０と負荷１１との間には、両者を電気的に接続する電力線１１ａが設けられている。回転電機１０の用途の一例は、車両用の内燃機関１２によって駆動される発電機である。回転電機１０は、例えば、二輪車に利用することができる。 (First embodiment)
FIG. 1 is a cross-sectional view of a rotating electrical machine 10 for an internal combustion engine (hereinafter simply referred to as a rotating electrical machine). The rotating electrical machine 10 is electrically connected to an electrical load (LOAD) 11. The load 11 may include an electric circuit and a battery. Between the rotating electrical machine 10 and the load 11, a power line 11 a that electrically connects both is provided. An example of the use of the rotating electrical machine 10 is a generator driven by an internal combustion engine 12 for a vehicle. The rotating electrical machine 10 can be used for a motorcycle, for example.
　回転電機１０は、内燃機関１２に組み付けられている。内燃機関１２は、ボディ１３と、ボディ１３に回転可能に支持され、内燃機関１２と連動して回転する回転軸１４とを有する。回転電機１０は、ボディ１３と回転軸１４とに組み付けられている。ボディ１３は、内燃機関１２のクランクケース、ミッションケースなどの構造体である。回転軸１４は、内燃機関１２のクランク軸、またはクランク軸と連動する回転軸である。回転軸１４は、内燃機関１２が運転されることによって回転し、回転電機１０を発電機として機能させるように駆動する。 The rotating electrical machine 10 is assembled to the internal combustion engine 12. The internal combustion engine 12 includes a body 13 and a rotary shaft 14 that is rotatably supported by the body 13 and rotates in conjunction with the internal combustion engine 12. The rotating electrical machine 10 is assembled to the body 13 and the rotating shaft 14. The body 13 is a structure such as a crankcase or a transmission case of the internal combustion engine 12. The rotating shaft 14 is a crankshaft of the internal combustion engine 12 or a rotating shaft interlocking with the crankshaft. The rotating shaft 14 rotates when the internal combustion engine 12 is operated, and drives the rotating electrical machine 10 to function as a generator.
　回転電機１０は、ロータ２１と、ステータ３１とを有する。ロータ２１は、界磁子である。ステータ３１は、電機子である。ロータ２１は、全体がカップ状である。ロータ２１は、その開口端をボディ１３に向けて位置付けられる。ロータ２１は、回転軸１４の端部に固定される。ロータ２１と回転軸１４とは、キー嵌合などの回転方向の位置決め機構を介して連結されている。ロータ２１は、固定ボルト２５によって回転軸１４に締め付けられることによって固定されている。ロータ２１は、回転軸１４とともに回転する。ロータ２１は、永久磁石によって界磁を提供する。 The rotating electrical machine 10 includes a rotor 21 and a stator 31. The rotor 21 is a field element. The stator 31 is an armature. The entire rotor 21 is cup-shaped. The rotor 21 is positioned with its open end facing the body 13. The rotor 21 is fixed to the end of the rotating shaft 14. The rotor 21 and the rotating shaft 14 are connected via a positioning mechanism in the rotational direction such as key fitting. The rotor 21 is fixed by being fastened to the rotary shaft 14 by a fixing bolt 25. The rotor 21 rotates together with the rotating shaft 14. The rotor 21 provides a field by a permanent magnet.
　ロータ２１は、カップ状のロータコア２２を有する。ロータコア２２は、内燃機関１２の回転軸１４に連結される。ロータコア２２は、回転軸１４に固定される内筒と、内筒の径方向外側に位置する外筒と、内筒と外筒との間に拡がる環状の底板とを有する。ロータコア２２は、後述する永久磁石のためのヨークを提供する。ロータコア２２は、磁性金属製である。 The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 is connected to the rotating shaft 14 of the internal combustion engine 12. The rotor core 22 has an inner cylinder fixed to the rotating shaft 14, an outer cylinder positioned on the radially outer side of the inner cylinder, and an annular bottom plate extending between the inner cylinder and the outer cylinder. The rotor core 22 provides a yoke for a permanent magnet described later. The rotor core 22 is made of a magnetic metal.
　ロータ２１は、ロータコア２２の内面に配置された永久磁石２３を有する。永久磁石２３は、外筒の内側に固定されている。永久磁石２３は、径方向内側に配置された保持カップ２４によって軸方向および径方向に関して固定されている。保持カップ２４は、薄い非磁性金属製である。保持カップ２４は、ロータコア２２に固定されている。 The rotor 21 has a permanent magnet 23 disposed on the inner surface of the rotor core 22. The permanent magnet 23 is fixed inside the outer cylinder. The permanent magnet 23 is fixed with respect to the axial direction and the radial direction by a holding cup 24 arranged on the radially inner side. The holding cup 24 is made of a thin nonmagnetic metal. The holding cup 24 is fixed to the rotor core 22.
　永久磁石２３は、複数のセグメントを有する。それぞれのセグメントは、部分円筒状である。永久磁石２３は、その内側に、複数のＮ極と複数のＳ極とを提供する。永久磁石２３は、少なくとも界磁を提供する。永久磁石２３は、１２個のセグメントによって、６対のＮ極とＳ極、すなわち１２極の界磁を提供する。セグメントの数、および／または磁極の数は、他の数でもよい。 The permanent magnet 23 has a plurality of segments. Each segment is partially cylindrical. The permanent magnet 23 provides a plurality of N poles and a plurality of S poles inside thereof. The permanent magnet 23 provides at least a field. The permanent magnet 23 provides six pairs of N poles and S poles, that is, a 12 pole field by 12 segments. The number of segments and / or the number of magnetic poles may be other numbers.
　ステータ３１は、環状の部材である。ステータ３１は、ロータ２１とボディ１３との間に配置されている。ステータ３１は、回転軸１４とロータコア２２の内筒とを受け入れることができる貫通穴を有する。ステータ３１は、ロータ２１の内面とギャップを介して対向する外周面を有する。外周面には、複数の磁極が配置されている。ステータ３１は、例えば、１８個の磁極を有する。磁極の数は、他の数でもよい。これら磁極は、ロータ２１の界磁と対向して配置されている。ステータ３１は、電機子巻線を有する。ステータ３１は、多相の電機子巻線を有する。ステータ３１は、ボディ１３に固定される。ステータ３１は、複数の磁極と、複数の三相巻線とを有する三相多極ステータである。 The stator 31 is an annular member. The stator 31 is disposed between the rotor 21 and the body 13. The stator 31 has a through hole that can receive the rotating shaft 14 and the inner cylinder of the rotor core 22. The stator 31 has an outer peripheral surface that faces the inner surface of the rotor 21 via a gap. A plurality of magnetic poles are arranged on the outer peripheral surface. The stator 31 has, for example, 18 magnetic poles. The number of magnetic poles may be other numbers. These magnetic poles are arranged opposite to the field of the rotor 21. The stator 31 has an armature winding. The stator 31 has multiphase armature windings. The stator 31 is fixed to the body 13. The stator 31 is a three-phase multipolar stator having a plurality of magnetic poles and a plurality of three-phase windings.
　ステータ３１は、ステータコア３２を有する。ステータコア３２は、内燃機関１２のボディ１３に固定されることによってロータ２１の内側に配置される。ステータコア３２は、永久磁石２３の内面と対向する複数の磁極を径方向外側に形成する。ステータコア３２は、複数の磁極を形成するように所定の形状に成形された電磁鋼板または鋼板などの磁性材料を積層することにより形成されている。 The stator 31 has a stator core 32. The stator core 32 is disposed inside the rotor 21 by being fixed to the body 13 of the internal combustion engine 12. The stator core 32 forms a plurality of magnetic poles facing the inner surface of the permanent magnet 23 on the radially outer side. The stator core 32 is formed by laminating magnetic materials such as electromagnetic steel plates or steel plates formed into a predetermined shape so as to form a plurality of magnetic poles.
　ステータ３１は、ステータコア３２に巻回されたステータコイル３３を有する。ステータコイル３３は、電機子巻線を提供する。 The stator 31 has a stator coil 33 wound around a stator core 32. The stator coil 33 provides an armature winding.
　ステータ３１とボディ１３とは、固定ボルト３４を介して連結されている。ステータ３１は、複数の固定ボルト３４によってボディ１３に締め付けられることによって固定されている。ステータ３１は、ボディ１３から延び出すボス部１３ａに固定されている。ボス部１３ａは、筒状の部分である。ボス部１３ａは、ボディ１３と一体の金属製の部材である。 The stator 31 and the body 13 are connected via a fixing bolt 34. The stator 31 is fixed by being fastened to the body 13 by a plurality of fixing bolts 34. The stator 31 is fixed to a boss portion 13 a extending from the body 13. The boss part 13a is a cylindrical part. The boss portion 13 a is a metal member that is integral with the body 13.
　ステータコア３２とステータコイル３３との間には絶縁材料製のインシュレータ３５が配置されている。インシュレータ３５は、樹脂製である。インシュレータ３５は、ボビンとも呼ばれる。インシュレータ３５の一部は、磁極に隣接して位置づけられることによって、ボビンのフランジ部を提供する。インシュレータ３５の一部は、磁極の軸方向における両側に配置されている。インシュレータ３５は、ステータコア３２の径方向内側の部位にも露出している。インシュレータ３５は、ステータコア３２の径方向内側の部位において、筒状部分を提供している。以下の説明では、多くの場合、インシュレータ３５は、筒状部分を指す。 An insulator 35 made of an insulating material is disposed between the stator core 32 and the stator coil 33. The insulator 35 is made of resin. The insulator 35 is also called a bobbin. A portion of the insulator 35 is positioned adjacent to the magnetic pole to provide a bobbin flange. Part of the insulator 35 is disposed on both sides in the axial direction of the magnetic pole. The insulator 35 is also exposed at the radially inner portion of the stator core 32. The insulator 35 provides a cylindrical portion at a radially inner portion of the stator core 32. In the following description, the insulator 35 often refers to a cylindrical portion.
　図２において、ステータコイル３３は、多相巻線である。ステータコイル３３は、三相巻線である。ステータコイル３３は、スター結線されている。ステータコイル３３は、複数の相コイルｕ１、ｕ２、ｖ１、ｖ２、ｗ１、ｗ２を有する。電気的に同相の複数の相コイルｕ１、ｕ２は並列接続されている。複数の相コイルｖ１、ｖ２も並列接続されている。複数の相コイルｗ１、ｗ２も並列接続されている。複数の相コイルｕ１、ｕ２、ｖ１、ｖ２、ｗ１、ｗ２は、一組の三相巻線（ｕ１、ｕ２）－（ｖ１、ｖ２）－（ｗ１、ｗ２）を形成するように接続されている。よって、ステータコイル３３は、３つの出力端ＰＴと、ひとつの中性点ＮＴとを有する。中性点ＮＴは、６つのコイル端部を接続する。なお、複数の相コイルｕ１、ｕ２、ｖ１、ｖ２、ｗ１、ｗ２は、二組の三相巻線ｕ１－ｖ１－ｗ１、ｕ２－ｖ２－ｗ２を形成するように接続されてもよい。 In FIG. 2, the stator coil 33 is a multiphase winding. The stator coil 33 is a three-phase winding. The stator coil 33 is star-connected. The stator coil 33 includes a plurality of phase coils u1, u2, v1, v2, w1, and w2. A plurality of electrically in-phase phase coils u1, u2 are connected in parallel. A plurality of phase coils v1, v2 are also connected in parallel. A plurality of phase coils w1, w2 are also connected in parallel. The plurality of phase coils u1, u2, v1, v2, w1, w2 are connected to form a set of three-phase windings (u1, u2)-(v1, v2)-(w1, w2). . Therefore, the stator coil 33 has three output ends PT and one neutral point NT. The neutral point NT connects six coil ends. The plurality of phase coils u1, u2, v1, v2, w1, w2 may be connected to form two sets of three-phase windings u1-v1-w1, u2-v2-w2.
　図３において、中性点ＮＴは、複数のコイル端部３７と、端子台４１と、端子５１とによって提供されている。コイルは絶縁被覆によって被覆された単線導体である。コイルを形成する導線は、アルミニウム製またはアルミニウム合金製である。コイル端部３７は、コイルを形成する導線の端部である。中性点ＮＴでは、６本のコイル端部３７が電気的に接続される。 In FIG. 3, the neutral point NT is provided by a plurality of coil end portions 37, a terminal block 41, and a terminal 51. The coil is a single wire conductor covered with an insulating coating. The conducting wire forming the coil is made of aluminum or aluminum alloy. The coil end portion 37 is an end portion of a conducting wire forming a coil. At the neutral point NT, the six coil end portions 37 are electrically connected.
　端子台４１は、インシュレータ３５の上に設けられている。端子台４１は、インシュレータ３５を形成する樹脂材料によって、インシュレータ３５と一体的に成形されている。端子台４１は、電気絶縁性の樹脂材料によって形成されている。端子台４１は、インシュレータ３５の筒状部分に形成されている。端子台４１は、筒状部分の径方向内側に突出するように形成されている。端子台４１は、筒状部分の一部の弧と、この弧に対応する弦とで囲まれる範囲に広がっている。 The terminal block 41 is provided on the insulator 35. The terminal block 41 is formed integrally with the insulator 35 by a resin material that forms the insulator 35. The terminal block 41 is made of an electrically insulating resin material. The terminal block 41 is formed on the cylindrical portion of the insulator 35. The terminal block 41 is formed so as to protrude inward in the radial direction of the cylindrical portion. The terminal block 41 extends in a range surrounded by a partial arc of the cylindrical portion and a string corresponding to the arc.
　端子台４１は、端子５１を固定するための基台を提供する。端子台４１は、端子５１を固定し、保持するための固定部とも呼ばれる。端子台４１は、ステータコア３２の端面から、軸方向に突出している。端子台４１は、ステータコイル３３の端面とほぼ同じ高さに突出している。端子台４１は、ステータコイル３３から延び出すコイル端部３７を受け入れる。端子台４１は、ステータコイル３３の軸方向端面の高さから、径方向に沿って、コイル端部３７を受け入れることができる高さを与えられている。 The terminal block 41 provides a base for fixing the terminal 51. The terminal block 41 is also called a fixing part for fixing and holding the terminal 51. The terminal block 41 protrudes from the end surface of the stator core 32 in the axial direction. The terminal block 41 protrudes at substantially the same height as the end face of the stator coil 33. The terminal block 41 receives a coil end 37 extending from the stator coil 33. The terminal block 41 is given a height capable of receiving the coil end portion 37 along the radial direction from the height of the axial end surface of the stator coil 33.
　図４および図５において、端子台４１は、ステータ３１の上において軸方向に面する端面４２を有する。端面４２は、ステータ３１の端面上において、１／３円周以下の円弧に沿って広がっている。端面４２は、弧と弦とで囲まれた弓形である。なお、端子台４１が広がる周方向の範囲は、より広い範囲でもよい。例えば、端子台４１は、１／２円周以下の範囲に広がっていてもよい。 4 and 5, the terminal block 41 has an end face 42 facing the axial direction on the stator 31. The end surface 42 extends along an arc having a circumference of 1/3 or less on the end surface of the stator 31. The end face 42 has an arcuate shape surrounded by an arc and a string. The circumferential range in which the terminal block 41 extends may be a wider range. For example, the terminal block 41 may extend in a range of ½ circumference or less.
　端子台４１は、端面４２を囲む側壁４３、４４を有する。側壁４３、４４は、端面４２からステータ３１の軸方向に延び出している。側壁４３、４４は、ステータ３１の軸方向の一端から、軸方向に凹む凹部を区画形成する。側壁４３、４４は、弦に沿って延びる側壁４３と、弧に沿って延びる側壁４４とを有する。側壁４３は、インシュレータ３５の径方向内側の縁を提供する。側壁４４は、ステータコイル３３のためのボビンの内側のフランジを提供する。側壁４３は、端子台４１の内壁である。側壁４４は、端子台４１の外壁である。端面４２は、凹部の底面を提供している。 The terminal block 41 has side walls 43 and 44 surrounding the end face 42. The side walls 43 and 44 extend from the end face 42 in the axial direction of the stator 31. The side walls 43 and 44 define a concave portion that is recessed in the axial direction from one end of the stator 31 in the axial direction. The side walls 43 and 44 include a side wall 43 extending along the string and a side wall 44 extending along the arc. The side wall 43 provides a radially inner edge of the insulator 35. Side wall 44 provides a bobbin inner flange for stator coil 33. The side wall 43 is an inner wall of the terminal block 41. The side wall 44 is an outer wall of the terminal block 41. The end surface 42 provides the bottom surface of the recess.
　側壁４４の頂は、ステータコイル３３から、ステータコイル３３の軸方向端面とほぼ平行に、かつ径方向に沿って、コイル端部３７を受け入れるために、ステータコイル３３の軸方向端面とほぼ同じ高さに位置づけられている。端面４２からの側壁４３、４４の高さは、保護材の流出を阻止できるように設定されている。 The top of the side wall 44 is substantially the same height as the axial end surface of the stator coil 33 to receive the coil end portion 37 from the stator coil 33 substantially parallel to the radial end surface of the stator coil 33 and along the radial direction. Is positioned. The height of the side walls 43 and 44 from the end face 42 is set so that the protective material can be prevented from flowing out.
　端子台４１は、端子５１を受け入れるスリット４５を有する。スリット４５は、端面４２に開口している。スリット４５は、ステータコア３２の周方向におおよそ沿って延びている。スリット４５は、端子５１の形状に対応して、やや多段に折れ曲がった形状で、周方向に沿って延びている。スリット４５は、端子５１を受け入れるために、軸方向に所定の深さを有する。スリット４５の軸方向深さは、端子５１の接続部５２を端面４２から突出させるように設定されている。 The terminal block 41 has a slit 45 for receiving the terminal 51. The slit 45 opens in the end face 42. The slit 45 extends approximately along the circumferential direction of the stator core 32. The slit 45 is bent in a somewhat multi-step manner corresponding to the shape of the terminal 51 and extends along the circumferential direction. The slit 45 has a predetermined depth in the axial direction in order to receive the terminal 51. The axial depth of the slit 45 is set so that the connecting portion 52 of the terminal 51 protrudes from the end face 42.
　端子台４１は、コイル端部３７を保持する保持部４７、４８を有する。保持部４７、４８は、ステータコイル３３と接続部５２との間において、コイル端部３７を保持する。保持部４７、４８は、コイル端部３７を案内する案内部でもある。保持部４７、４８は、その表面に沿ってコイル端部３７が巻き付けられる巻き付け部でもある。また、保持部４７、４８は、コイル端部３７が挿入される細長い隙間を区画形成する部材でもある。 The terminal block 41 has holding portions 47 and 48 for holding the coil end portion 37. The holding portions 47 and 48 hold the coil end portion 37 between the stator coil 33 and the connection portion 52. The holding portions 47 and 48 are also guide portions that guide the coil end portion 37. The holding portions 47 and 48 are also winding portions around which the coil end portion 37 is wound along the surface thereof. The holding portions 47 and 48 are also members that define and form a long and narrow gap into which the coil end portion 37 is inserted.
　保持部４７、４８は、端子台４１の径方向外側に配置されている。保持部４７と保持部４８とは、ステータコア３２の周方向に沿って並んで配置されている。保持部４７、４８は、側壁４４の上に設けられている。保持部４７、４８は、端面４２から側壁４４より高く軸方向に延び出している。保持部４７、４８は、軸方向に延びる柱状の部材として形成されている。保持部４７、４８は、コイル端部３７を緩やかに曲げるように、角が丸い柱状である。保持部４７と、保持部４８との間には、コイル端部３７を受け入れ可能な隙間が区画形成されている。隙間は、コイル端部３７を受け入れ可能な周方向幅を有する。隙間の幅は、保持部４７、４８をやや変形させながら、コイル端部３７を受け入れるように設定されている。隙間は、少なくとも２本のコイル端部３７、３７を軸方向に積層した状態で受け入れ可能な軸方向深さを有する。 The holding portions 47 and 48 are disposed on the radially outer side of the terminal block 41. The holding part 47 and the holding part 48 are arranged side by side along the circumferential direction of the stator core 32. The holding portions 47 and 48 are provided on the side wall 44. The holding parts 47 and 48 extend from the end face 42 to the axial direction higher than the side wall 44. The holding portions 47 and 48 are formed as columnar members extending in the axial direction. The holding portions 47 and 48 are columnar shapes with rounded corners so that the coil end portion 37 is gently bent. A gap that can receive the coil end portion 37 is defined between the holding portion 47 and the holding portion 48. The gap has a circumferential width that can receive the coil end portion 37. The width of the gap is set so as to receive the coil end portion 37 while slightly deforming the holding portions 47 and 48. The gap has an axial depth that can be received in a state in which at least two coil ends 37 are stacked in the axial direction.
　保持部４７は、保持部４８より太い。保持部４７は、コイル端部３７の曲げに関して内側に位置している。保持部４７は、コイル端部３７を曲げるためのコアとして利用される。保持部４７は、曲げられたコイル端部３７の弾性力に抗して、曲げられたコイル端部３７の形状を維持するために貢献する。保持部４８は、コイル端部３７の曲げに関して外側に位置している。保持部４８は、コイル端部３７を保持部４７の上に保持する外壁を提供する部材として機能する。保持部４８は、曲げられたコイル端部３７の弾性力に抗して、曲げられたコイル端部３７の形状を維持するために貢献する。 The holding part 47 is thicker than the holding part 48. The holding portion 47 is located on the inner side with respect to the bending of the coil end portion 37. The holding portion 47 is used as a core for bending the coil end portion 37. The holding portion 47 contributes to maintain the shape of the bent coil end portion 37 against the elastic force of the bent coil end portion 37. The holding portion 48 is located outside with respect to the bending of the coil end portion 37. The holding portion 48 functions as a member that provides an outer wall that holds the coil end portion 37 on the holding portion 47. The holding portion 48 contributes to maintain the shape of the bent coil end portion 37 against the elastic force of the bent coil end portion 37.
　端子台４１は、複数組の保持部４７、４８を有する。図示の例では、端子台４１は、三組の保持部４７、４８を有する。ひとつの保持部４７、４８が２本のコイル端部３７を保持する。 The terminal block 41 has a plurality of sets of holding portions 47 and 48. In the illustrated example, the terminal block 41 has three sets of holding portions 47 and 48. One holding portion 47, 48 holds the two coil end portions 37.
　端子５１は、導電性の金属製である。端子５１は、アルミニウム、アルミニウム合金、鉄系合金、銅、黄銅などによって提供することができる。端子５１の材料は、そこに接続される導線、例えば、コイル端部３７の材料に応じて選定される。例えば、端子５１の材料は、コイル端部３７との組み合わせに起因する腐食を抑制するように選定される。コイル端部３７がアルミニウムまたはアルミニウム合金である場合、端子５１には、アルミニウム、アルミニウム合金、または鉄系合金が用いられる。端子５１にアルミニウムまたはルミニウム合金と、銅とが接続される場合、端子５１は鉄系合金によって提供される場合がある。 The terminal 51 is made of conductive metal. The terminal 51 can be provided by aluminum, aluminum alloy, iron-based alloy, copper, brass, or the like. The material of the terminal 51 is selected according to the conductive wire connected thereto, for example, the material of the coil end portion 37. For example, the material of the terminal 51 is selected so as to suppress corrosion caused by the combination with the coil end portion 37. When the coil end portion 37 is made of aluminum or an aluminum alloy, the terminal 51 is made of aluminum, an aluminum alloy, or an iron-based alloy. When aluminum or a rumium alloy and copper are connected to the terminal 51, the terminal 51 may be provided by an iron-based alloy.
　端子５１は、複数の接続部５２を有する。図示の例では、端子５１は、３つの接続部５２を有する。ひとつの接続部５２は、少なくともひとつのコイル端部３７と電気的に接続されている。ひとつの接続部５２は、複数のコイル端部３７と電気的に接続されている。図示の例では、ひとつの接続部５２は、２つのコイル端部３７と電気的に接続されている。 The terminal 51 has a plurality of connection parts 52. In the illustrated example, the terminal 51 has three connection parts 52. One connection portion 52 is electrically connected to at least one coil end portion 37. One connection portion 52 is electrically connected to the plurality of coil end portions 37. In the illustrated example, one connection portion 52 is electrically connected to the two coil end portions 37.
　ひとつの接続部５２は、板状である。接続部５２は、ステータ３１の軸方向に沿って端面４２から延び出している。接続部５２は、ステータ３１の周方向または接線方向に沿って広がっている。接続部５２は、ベース部分５３を有する。ベース部分５３は、平板状である。ベース部分５３は、やや湾曲した板状に形成されてもよい。 One connecting portion 52 has a plate shape. The connecting portion 52 extends from the end face 42 along the axial direction of the stator 31. The connecting portion 52 extends along the circumferential direction or tangential direction of the stator 31. The connecting portion 52 has a base portion 53. The base portion 53 has a flat plate shape. The base portion 53 may be formed in a slightly curved plate shape.
　接続部５２は、ステータ３１の径方向に向けて突出したプロジェクション部分を有する。プロジェクション部分は、接続部５２の一部に湾曲部分として形成されている。プロジェクション部分は、ベース部分５３と隣接して設けられている。プロジェクション部分の周方向の両側にベース部分５３が設けられている。プロジェクション部分は、コイル端部３７が配置される方向へ突出している。プロジェクション部分は、軸方向に沿って長く延びている。 The connection part 52 has a projection part protruding toward the radial direction of the stator 31. The projection part is formed as a curved part in a part of the connection part 52. The projection portion is provided adjacent to the base portion 53. Base portions 53 are provided on both sides of the projection portion in the circumferential direction. The projection portion protrudes in the direction in which the coil end portion 37 is disposed. The projection part extends long along the axial direction.
　プロジェクション部分は、凹溝５４と、突条５５とによって形成されている。凹溝５４および突条５５は、プレス加工によって形成されている。凹溝５４は、径方向内側から径方向外側に向けて凹んでいる。凹溝５４は、ステータ３１の軸方向に沿って延びている。突条５５は、径方向内側から径方向外側に向けて突出している。突条５５は、ステータ３１の軸方向に沿って延びている。突条５５によってプロジェクション部分が提供されている。 The projection part is formed by a groove 54 and a ridge 55. The concave groove 54 and the protrusion 55 are formed by pressing. The recessed groove 54 is recessed from the radially inner side toward the radially outer side. The concave groove 54 extends along the axial direction of the stator 31. The protrusion 55 protrudes from the radially inner side toward the radially outer side. The protrusion 55 extends along the axial direction of the stator 31. Projections are provided by the ridges 55.
　接続部５２は、軸方向の先端に先端縁５６を有する。先端縁５６は、鋭い角部を減らすように丸い縁として形成されている。先端縁５６は、ベース部分５３の先端において、丸い肩部としてあらわれている。 The connecting portion 52 has a tip edge 56 at the tip in the axial direction. The leading edge 56 is formed as a rounded edge so as to reduce sharp corners. The tip edge 56 appears as a round shoulder at the tip of the base portion 53.
　複数の接続部５２は、ステータ３１の周方向に沿って配置されている。複数の接続部５２は、複数の突条５５の頂部を、ステータ３１の周方向に沿って位置づけるように配置されている。複数の突条５５の頂部は、ステータ３１と同心の円周ＣＰの上に位置づけられている。複数の突条５５のそれぞれの突出方向は、円周ＣＰの径外方向を指向している。 The plurality of connection portions 52 are arranged along the circumferential direction of the stator 31. The plurality of connection portions 52 are arranged so that the top portions of the plurality of protrusions 55 are positioned along the circumferential direction of the stator 31. The tops of the plurality of protrusions 55 are positioned on a circumference CP concentric with the stator 31. The protruding direction of each of the plurality of protrusions 55 is directed in the radially outward direction of the circumference CP.
　ひとつの接続部５２は、一組の保持部４７、４８と、対応付けられている。接続部５２は、保持部４７、４８より径方向内側に配置されている。接続部５２は、対応付けられた保持部４７、４８から、隙間を介して、径方向内側に配置されている。この隙間は、コイル端部３７を配置することができる大きさを有する。図示の例では、保持部４７の径方向内側縁と、接続部５２の径方向外側縁、すなわち突条５５の頂部との間に、径方向隙間ＲＧが区画形成されている。径方向隙間ＲＧは、コイル端部３７を配置可能な大きさである。 One connection unit 52 is associated with a set of holding units 47 and 48. The connecting portion 52 is disposed on the radially inner side from the holding portions 47 and 48. The connecting portion 52 is disposed radially inward from the associated holding portions 47 and 48 via a gap. The gap has a size that allows the coil end portion 37 to be disposed. In the illustrated example, a radial gap RG is defined between the radially inner edge of the holding portion 47 and the radially outer edge of the connecting portion 52, that is, the top of the protrusion 55. The radial gap RG has such a size that the coil end portion 37 can be disposed.
　接続部５２は、対応付けられた保持部４７、４８の径方向内側において、周方向にずれた位置に配置されている。周方向に関する接続部５２の位置と、これに対応付けられた保持部４７、４８の位置とは、保持部４７、４８の間に径方向に沿ってコイル端部３７を配置することができるように、周方向に関してずれている。周方向に関する接続部５２の位置と、これに対応付けられた保持部４７、４８の位置とは、保持部４７、４８の間を通過したコイル端部３７を接続部５２の径方向外側面に接触させることができるように設定されている。周方向に関する接続部５２の位置と、これに対応付けられた保持部４７、４８の位置とは、径方向に関して接続部５２と保持部４７、４８とが重複することがないように設定されている。 The connecting portion 52 is disposed at a position shifted in the circumferential direction on the radially inner side of the associated holding portions 47 and 48. The position of the connecting portion 52 in the circumferential direction and the positions of the holding portions 47 and 48 associated therewith are such that the coil end portion 37 can be disposed between the holding portions 47 and 48 along the radial direction. In addition, there is a deviation in the circumferential direction. The position of the connection portion 52 in the circumferential direction and the positions of the holding portions 47 and 48 associated therewith are such that the coil end portion 37 that has passed between the holding portions 47 and 48 is placed on the radially outer surface of the connection portion 52. It is set so that it can be contacted. The position of the connecting portion 52 in the circumferential direction and the positions of the holding portions 47 and 48 associated therewith are set so that the connecting portion 52 and the holding portions 47 and 48 do not overlap in the radial direction. Yes.
　図６において、端子５１は、連結部５７を有する。連結部５７は、複数の接続部５２を連結する。連結部５７は、スリット４５内に収容されている。連結部５７の端面は、スリット４５の開口端に位置づけられている。端子５１は、接続部５２を露出させるように、スリット４５内に挿入され、固定されている。端子５１は、スリット４５内に圧入されている。図示の例では、連結部５７がスリット４５内に圧入されることによって、端子５１は端子台４１に固定されている。接続部５２は、連結部５７から突出して延び出している。複数の接続部５２は、互いに離れて位置づけられている。接続部５２は、接続片とも呼びうる独立した形状を与えられている。 In FIG. 6, the terminal 51 has a connecting portion 57. The connecting portion 57 connects the plurality of connecting portions 52. The connecting portion 57 is accommodated in the slit 45. The end surface of the connecting portion 57 is positioned at the opening end of the slit 45. The terminal 51 is inserted and fixed in the slit 45 so that the connection part 52 is exposed. The terminal 51 is press-fitted into the slit 45. In the illustrated example, the terminal 51 is fixed to the terminal block 41 by press-fitting the connecting portion 57 into the slit 45. The connection part 52 protrudes and extends from the connection part 57. The plurality of connecting portions 52 are positioned away from each other. The connecting portion 52 is given an independent shape that can also be called a connecting piece.
　図４および図５に戻り、コイル端部３７は、ステータコイル３３から径方向内側に向けて配置されている。コイル端部３７は、径方向外側から、保持部４７、４８の間を通り、径方向内側へ突出するように配置されている。コイル端部３７は、保持部４７、４８より径方向内側において、ステータ３１の端面に沿って延びるように配置されている。コイル端部３７は、保持部４７の外面におよそ１／４周にわたって巻き付けられることによって、ほぼ９０度曲げられている。コイル端部３７は、保持部４７に沿って曲げ部を有している。コイル端部３７は、曲げ部より先において、ステータ３１の周方向に沿って延びるように配置されている。コイル端部３７は、保持部４７と接続部５２との間の隙間を通るように配置されている。コイル端部３７は、保持部４７、４８の前後において、Ｌ字型に曲げられている。コイル端部３７は、保持部４７、４８の間を通過した後に、接続部５２の径方向外側に向けて曲げられている。コイル端部３７は、保持部４７と接続部５２とに接触するように配置されている。 4 and 5, the coil end 37 is disposed radially inward from the stator coil 33. The coil end portion 37 is disposed so as to protrude from the radially outer side through the holding portions 47 and 48 to the radially inner side. The coil end portion 37 is disposed so as to extend along the end surface of the stator 31 on the radially inner side of the holding portions 47 and 48. The coil end portion 37 is bent approximately 90 degrees by being wound around the outer surface of the holding portion 47 over about ¼ circumference. The coil end portion 37 has a bent portion along the holding portion 47. The coil end portion 37 is disposed so as to extend along the circumferential direction of the stator 31 before the bent portion. The coil end portion 37 is disposed so as to pass through a gap between the holding portion 47 and the connection portion 52. The coil end portion 37 is bent in an L shape before and after the holding portions 47 and 48. The coil end portion 37 is bent toward the radially outer side of the connecting portion 52 after passing between the holding portions 47 and 48. The coil end portion 37 is disposed so as to contact the holding portion 47 and the connection portion 52.
　コイル端部３７は、その先端部分に、特に接続部５２と接触する所定範囲に、絶縁被覆が剥かれたストリップ部分３８を有する。ストリップ部分３８は、接続部５２の径方向外側に位置づけられている。ストリップ部分３８は、保持部４７、４８よりも径方向内側に位置づけられている。ストリップ部分３８は、接続部５２に電気的に接続されている。ストリップ部分３８と接続部５２とは、プロジェクション溶接によって溶接されている。ストリップ部分３８は、接続部５２のプロジェクション部分の頂部に溶接されている。 The coil end portion 37 has a strip portion 38 having an insulating coating peeled off at a tip portion thereof, particularly in a predetermined range in contact with the connection portion 52. The strip portion 38 is positioned on the radially outer side of the connecting portion 52. The strip portion 38 is positioned radially inward of the holding portions 47 and 48. The strip portion 38 is electrically connected to the connection portion 52. The strip portion 38 and the connection portion 52 are welded by projection welding. The strip portion 38 is welded to the top of the projection portion of the connection portion 52.
　保持部４７、４８の間には、複数のコイル端部３７、３７が配置されている。複数のコイル端部３７、３７は、保持部４７、４８の間において、ステータ３１の軸方向に積層された状態で配置されている。図示の例では、２本のコイル端部３７、３７が平行に配置されている。複数のコイル端部３７、３７は、同じ形状を与えられている。複数のコイル端部３７、３７は、接続部５２の径方向外側において、ステータ３１の軸方向に積層されるように配置される。プロジェクション部分の長手方向は、ステータ３１の軸方向に延びている。複数のコイル端部３７、３７は、プロジェクション部分の長手方向に沿って並ぶように配置される。複数のコイル端部３７、３７は、共通の接続部５２に接続されている。 A plurality of coil end portions 37 and 37 are arranged between the holding portions 47 and 48. The plurality of coil end portions 37 and 37 are disposed between the holding portions 47 and 48 in a state of being stacked in the axial direction of the stator 31. In the illustrated example, two coil end portions 37 and 37 are arranged in parallel. The plurality of coil ends 37, 37 are given the same shape. The plurality of coil end portions 37 and 37 are disposed so as to be laminated in the axial direction of the stator 31 on the radially outer side of the connection portion 52. The longitudinal direction of the projection portion extends in the axial direction of the stator 31. The plurality of coil end portions 37 and 37 are arranged so as to be aligned along the longitudinal direction of the projection portion. The plurality of coil end portions 37 and 37 are connected to a common connection portion 52.
　図中には、複数の接続構造が図示されている。ひとつの接続構造は、複数のコイル端部３７と、保持部４７、４８と、ひとつの接続部５２とを有する。複数の接続構造は、ステータ３１の端面の上に、ステータ３１の周方向に沿って配置されている。図示される３つの接続構造によって中性点ＮＴが提供される。 In the figure, a plurality of connection structures are shown. One connection structure includes a plurality of coil end portions 37, holding portions 47 and 48, and one connection portion 52. The plurality of connection structures are arranged on the end surface of the stator 31 along the circumferential direction of the stator 31. The three connection structures shown provide a neutral point NT.
　それぞれの接続構造は、保護材５９によって覆われている。保護材５９は、流動性がある状態で接続構造に付与され、硬化されている。保護材５９は、少なくともストリップ部分３８および接続部５２を覆う。図示の例では、保護材５９は、３つの接続構造を覆っている。保護材５９は、端面４２の上に到達している。保護材５９の一部は、端面４２の上にも広がっている。保護材５９の一部は、側壁４３、４４に到達している。側壁４３、４４は、保護材５９の流出を阻止する。側壁４３、４４は、保護材５９を端子台４１の上に保持する。側壁４３、４４は、端子台４１の上に保護材５９を溜める容器部分を区画形成している。先端縁５６の丸い形状は、保護材５９の厚さが薄くなりすぎることを阻止する。 Each connection structure is covered with a protective material 59. The protective material 59 is imparted to the connection structure in a fluid state and cured. The protective material 59 covers at least the strip portion 38 and the connection portion 52. In the illustrated example, the protective material 59 covers three connection structures. The protective material 59 reaches the end surface 42. A part of the protective material 59 extends also on the end face 42. A part of the protective material 59 reaches the side walls 43 and 44. The side walls 43 and 44 prevent the protective material 59 from flowing out. The side walls 43 and 44 hold the protective material 59 on the terminal block 41. The side walls 43 and 44 define a container portion for storing the protective material 59 on the terminal block 41. The round shape of the leading edge 56 prevents the protective material 59 from becoming too thin.
　図５には、回転電機１０を製造するための製造装置の一部が図示されている。製造装置は、プロジェクション溶接のための溶接機（ＷＥＬＤ）６１を備える。溶接機６１は、一対の電極６２、６３を備える。電極６２、６３は、接続構造の径方向外側に位置づけられる外側の電極６２と、接続構造の径方向内側に位置づけられる内側の電極６３とを含む。電極６２、６３は、溶接対象物であるコイル端部３７と接続部５２とを挟み、接触させるために利用される。電極６２、６３は、コイル端部３７と接続部５２とに通電し、溶接するためにも利用される。図中には、製造方法の中における電極６２、６３の移動の過程が破線によって図示されている。 FIG. 5 shows a part of a manufacturing apparatus for manufacturing the rotating electrical machine 10. The manufacturing apparatus includes a welding machine (WELD) 61 for projection welding. The welding machine 61 includes a pair of electrodes 62 and 63. The electrodes 62 and 63 include an outer electrode 62 positioned on the radially outer side of the connection structure and an inner electrode 63 positioned on the radial inner side of the connection structure. The electrodes 62 and 63 are used to sandwich and contact the coil end portion 37 and the connection portion 52 that are the welding objects. The electrodes 62 and 63 are also used to energize and weld the coil end portion 37 and the connection portion 52. In the drawing, the process of moving the electrodes 62 and 63 in the manufacturing method is shown by broken lines.
　製造装置は、電極６２、６３、および端子５１のための移動装置（ＩＮＤＥＸ）６５を備える。移動装置６５は、電極６２、６３を、待機位置と、図示される作業位置との間で移動させる。作業位置において、移動装置６５は、電極６２、６３を、図示される閉位置と、開位置との間で移動させる。図中には、開閉方向が径方向の矢印によって示されている。移動装置６５は、電極６２、６３と端子５１との間の相対的な位置関係を変化させる。例えば、移動装置６５は、ステータ３１を回転させることによって、電極６２、６３を、複数の接続構造の上に順に移動させる。図中には、相対的な回転移動が、周方向の矢印によって示されている。移動装置６５は、電極６２、６３を支持するロボットアーム、およびステータ３１を回転させるインデックステーブルなど多様な機器によって提供することができる。 The manufacturing apparatus includes electrodes 62 and 63 and a moving device (INDEX) 65 for the terminal 51. The moving device 65 moves the electrodes 62 and 63 between the standby position and the illustrated work position. In the working position, the moving device 65 moves the electrodes 62 and 63 between the illustrated closed position and the open position. In the figure, the opening and closing direction is indicated by a radial arrow. The moving device 65 changes the relative positional relationship between the electrodes 62 and 63 and the terminal 51. For example, the moving device 65 sequentially moves the electrodes 62 and 63 on the plurality of connection structures by rotating the stator 31. In the figure, the relative rotational movement is indicated by circumferential arrows. The moving device 65 can be provided by various devices such as a robot arm that supports the electrodes 62 and 63 and an index table that rotates the stator 31.
　閉位置において、電極６２、６３は、ステータ３１の径方向に沿って互いに接近するように移動され、コイル端部３７と接続部５２とを締め付ける。開位置において、電極６２、６３は、ステータ３１の径方向に沿って互いに離れるように移動され、コイル端部３７および接続部５２から離れる。電極６２、６３は、ステータ３１の部分と干渉することなくステータ３１の周方向に移動できる位置まで離される。 In the closed position, the electrodes 62 and 63 are moved so as to approach each other along the radial direction of the stator 31, and the coil end portion 37 and the connection portion 52 are tightened. In the open position, the electrodes 62 and 63 are moved away from each other along the radial direction of the stator 31, and are separated from the coil end portion 37 and the connection portion 52. The electrodes 62 and 63 are separated to a position where they can move in the circumferential direction of the stator 31 without interfering with the portion of the stator 31.
　複数のコイル端部３７のうち、最もステータ３１に近い部分は、ステータ３１の軸方向の表面よりも高く離れて位置している。言い換えると、コイル端部３７のステータ３１に最も近い面は、ステータコイル３３の軸方向表面よりも高く離れて位置している。さらに、接続部５２は、ステータ３１の軸方向の表面よりも高く離れるように延び出している。言い換えると、接続部５２は、ステータコイル３３の軸方向表面よりも高く離れて位置している。このような配置は、電極６２、６３とステータ３１との干渉を回避するために貢献している。 Among the plurality of coil end portions 37, the portion closest to the stator 31 is located higher than the axial surface of the stator 31. In other words, the surface of the coil end portion 37 closest to the stator 31 is located higher than the axial surface of the stator coil 33. Further, the connecting portion 52 extends so as to be separated from the surface of the stator 31 in the axial direction. In other words, the connecting portion 52 is located higher than the axial surface of the stator coil 33. Such an arrangement contributes to avoid interference between the electrodes 62 and 63 and the stator 31.
　一方で、ボディ１３またはロータ２１との干渉を避けるために、接続部５２の突出量は小さいことが望ましい。ステータ３１は、コイル端部３７および接続部５２のステータ３１からの突出高さを抑制するように構成されている。ステータコイル３３は、径方向外側において太く、径方向内側において細く巻かれている。ステータコイル３３は、ひとつの磁極の周囲において、集中巻きされる場合がある。ステータコイル３３は、ひとつの磁極の周囲に、複数の層をなすように巻かれている。ステータコイル３３は、径方向内側の層数が、径方向外側の層数より少なくなるように巻かれている。この結果、ステータコイル３３の径方向内側における軸方向の厚さは、径方向外側における軸方向の厚さより小さい。この構成は、ステータ３１の一方の端面において、径方向内側の高さを径方向外側の高さより低くすることを可能とする。端子５１は、ステータ３１の径方向内側、特にステータコイル３３より径方向内側に配置されているから、ステータ３１の端面の上における比較的低い位置に設けられる。これにより、ステータ３１の端面上における接続部５２の高さが抑制される。さらに、ステータコイル３３の径方向内側における細い部分、言い換えると低い部分は、電極６２が位置づけられる部分でもある。よって、ステータコイル３３の形状は、接続部５２の高さを抑制しながら、プロジェクション溶接を可能とするために貢献する。 On the other hand, in order to avoid interference with the body 13 or the rotor 21, it is desirable that the protruding amount of the connecting portion 52 is small. The stator 31 is configured to suppress the protruding height of the coil end portion 37 and the connection portion 52 from the stator 31. The stator coil 33 is thick on the radially outer side and wound thin on the radially inner side. The stator coil 33 may be concentratedly wound around one magnetic pole. The stator coil 33 is wound around a single magnetic pole so as to form a plurality of layers. The stator coil 33 is wound such that the number of radially inner layers is smaller than the number of radially outer layers. As a result, the axial thickness on the radially inner side of the stator coil 33 is smaller than the axial thickness on the radially outer side. This configuration enables the radially inner height of one end face of the stator 31 to be lower than the radially outer height. Since the terminal 51 is disposed radially inward of the stator 31, particularly radially inward of the stator coil 33, the terminal 51 is provided at a relatively low position on the end surface of the stator 31. Thereby, the height of the connection part 52 on the end surface of the stator 31 is suppressed. Further, a narrow portion on the radially inner side of the stator coil 33, in other words, a low portion is also a portion where the electrode 62 is positioned. Therefore, the shape of the stator coil 33 contributes to enable projection welding while suppressing the height of the connection portion 52.
　製造装置は、電極６２、６３の開閉移動と、電極６２、６３とステータ３１との相対的な回転方向の移動とによって、複数の接続構造における接続作業を順に遂行する。 The manufacturing apparatus sequentially performs connection operations in a plurality of connection structures by opening and closing movement of the electrodes 62 and 63 and movement in the relative rotation direction of the electrodes 62 and 63 and the stator 31.
　図７は、回転電機１０の製造方法を示すフローチャートである。製造方法１８０は、ステータ３１の製造方法でもある。ステップ１８１は、部品を製造する工程である。このステップでは、ステータコア３２、インシュレータ３５、および端子５１が製造される。 FIG. 7 is a flowchart showing a method for manufacturing the rotating electrical machine 10. The manufacturing method 180 is also a method for manufacturing the stator 31. Step 181 is a process for manufacturing a component. In this step, the stator core 32, the insulator 35, and the terminal 51 are manufactured.
　ステップ１８２は、端子５１をインシュレータ３５に固定する工程である。端子５１は、インシュレータ３５がステータコア３２に装着された後に、またはインシュレータ３５がステータコア３２に装着される前に、インシュレータ３５のスリット４５に挿入され、固定される。ステップ１８３は、ステータコイル３３を巻く工程である。この工程の前に、ステータコア３２にインシュレータ３５が装着される。ステータコイル３３は、インシュレータ３５の上に巻き付けられる。端子５１は、この巻線工程の後にインシュレータ３５に固定されてもよい。 Step 182 is a process of fixing the terminal 51 to the insulator 35. The terminal 51 is inserted into the slit 45 of the insulator 35 and fixed after the insulator 35 is attached to the stator core 32 or before the insulator 35 is attached to the stator core 32. Step 183 is a step of winding the stator coil 33. Prior to this step, the insulator 35 is attached to the stator core 32. The stator coil 33 is wound on the insulator 35. The terminal 51 may be fixed to the insulator 35 after this winding step.
　ステップ１８４は、コイル端部３７にストリップ部分３８を形成する工程である。ステップ１８５は、コイル端部３７を図示される形状に配置する工程である。この工程は、コイル端部３７を接続部５２に隣接するように予備的に位置づける予備工程とも呼ばれる。この構成は、保持部４７、４８と接続部５２とによって、コイル端部３７を規定の位置に位置づける仮留め工程とも呼ばれる。 Step 184 is a step of forming the strip portion 38 at the coil end portion 37. Step 185 is a step of arranging the coil end portion 37 in the shape shown in the drawing. This step is also called a preliminary step of preliminarily positioning the coil end portion 37 so as to be adjacent to the connection portion 52. This configuration is also called a temporary fastening process in which the coil end portion 37 is positioned at a predetermined position by the holding portions 47 and 48 and the connection portion 52.
　ステップ１８５において、コイル端部３７は、まず、ステータコイル３３から、保持部４７、４８の間を通るように配置される。保持部４７、４８の間には、２本のコイル端部３７が配置される。次に、コイル端部３７は、保持部４７に沿ってＬ字型に曲げられる。この曲げ工程において、コイル端部３７は、接続部５２の径方向外側に位置づけられる。このとき、コイル端部３７は、弾性変形しながら接続部５２の径方向外側に位置づけられる。この結果、コイル端部３７は、自らの弾性によって接続部５２に向けて押し付けられる。また、コイル端部３７は、自らの弾性によって、保持部４７、４８と接続部５２との間において、規定の位置に位置付けられる。ステップ１８５は、３つの接続構造のそれぞれにおいて実行される。 In step 185, the coil end portion 37 is first disposed so as to pass between the holding portions 47 and 48 from the stator coil 33. Two coil end portions 37 are arranged between the holding portions 47 and 48. Next, the coil end portion 37 is bent into an L shape along the holding portion 47. In this bending step, the coil end portion 37 is positioned on the radially outer side of the connection portion 52. At this time, the coil end portion 37 is positioned on the radially outer side of the connection portion 52 while being elastically deformed. As a result, the coil end portion 37 is pressed toward the connection portion 52 by its own elasticity. Further, the coil end portion 37 is positioned at a predetermined position between the holding portions 47 and 48 and the connection portion 52 by its own elasticity. Step 185 is performed in each of the three connection structures.
　ステップ１８６は、電極６２、６３を待機位置から作業位置に移動させる移動工程である。例えば、電極６２、６３は、ロボットアームによって規定の作業位置に位置付けられる。ステップ１８６では、電極６２、６３は、開位置にある。電極６２、６３は、接続作業が実行されるべきひとつの接続構造の径方向両側に配置される。 Step 186 is a moving process for moving the electrodes 62 and 63 from the standby position to the working position. For example, the electrodes 62 and 63 are positioned at specified working positions by the robot arm. In step 186, the electrodes 62, 63 are in the open position. The electrodes 62 and 63 are arranged on both sides in the radial direction of one connection structure in which a connection operation is to be performed.
　ステップ１８７は、電極６２、６３を閉じる工程である。電極６２、６３が閉じられることにより、接続作業の対象となっている複数のコイル端部３７と接続部５２とが電極６２、６３の間において締め付けられる。 Step 187 is a process of closing the electrodes 62 and 63. By closing the electrodes 62 and 63, the plurality of coil end portions 37 and the connection portions 52 that are the objects of connection work are tightened between the electrodes 62 and 63.
　ステップ１８８は、電極６２、６３にプロジェクション溶接のための電流を流すことによりプロジェクション溶接を実行する工程である。ステップ１８８により、複数のコイル端部３７と接続部５２とが溶接される。ここでは、１回のプロジェクション溶接、すなわち通電によって複数のコイル端部３７がひとつの接続部５２の上に溶接される。 Step 188 is a step of executing projection welding by causing a current for projection welding to flow through the electrodes 62 and 63. In step 188, the plurality of coil end portions 37 and the connection portion 52 are welded. Here, a plurality of coil end portions 37 are welded onto one connection portion 52 by one projection welding, that is, energization.
　ステップ１８９は、電極６２、６３を開く工程である。電極６２、６３は、ステータ３１が回転されても、ステータ３１の部品に干渉しない位置まで開かれる。 Step 189 is a process of opening the electrodes 62 and 63. The electrodes 62 and 63 are opened to a position where they do not interfere with the components of the stator 31 even when the stator 31 is rotated.
　ステップ１９０は、接続構造の数に対応するｎ回の溶接が完了したか否かを判定する工程である。ステップ１９０は、すべての接続構造における溶接作業が完了したか否かを判定する判定部を提供する。すべての接続構造における溶接作業が完了していない場合、ＮＯに分岐し、ステップ１９１へ進む。すべての接続における溶接作業が完了した場合、ＹＥＳに分岐しステップ１９２へ進む。 Step 190 is a step of determining whether or not n times of welding corresponding to the number of connection structures have been completed. Step 190 provides a determination unit that determines whether or not the welding operation has been completed for all connection structures. If the welding work for all the connection structures has not been completed, the process branches to NO and proceeds to step 191. If the welding work for all connections is completed, the process branches to YES and proceeds to step 192.
　ステップ１９１は、電極６２、６３と、ステータ３１とを相対的に回転させる工程である。ここでは、電極６２、６３を、他の接続構造の径方向外側および内側に移動させるように、相対的な回転量が設定されている。これにより、電極６２、６３は、他の接続構造の径方向外側と内側とに移動する。ステップ１９１の後、再びステップ１８７が実行される。ステップ１８７－１９１の工程がすべての接続構造に対して繰り返される。この結果、複数の接続構造における溶接作業が順に実行される。しかも、電極６２、６３の開閉と、電極６２、６３およびステータ３１（端子５１）の間の相対回転とによって、複数の接続構造に対する溶接作業が実行される。 Step 191 is a process of relatively rotating the electrodes 62 and 63 and the stator 31. Here, the relative rotation amount is set so that the electrodes 62 and 63 are moved radially outside and inside of the other connection structures. Thereby, the electrodes 62 and 63 move to the radially outer side and the inner side of other connection structures. After step 191, step 187 is executed again. Steps 187-191 are repeated for all connection structures. As a result, welding operations in a plurality of connection structures are executed in order. In addition, welding operations for a plurality of connection structures are performed by opening and closing the electrodes 62 and 63 and relative rotation between the electrodes 62 and 63 and the stator 31 (terminal 51).
　ステップ１９２は、電極６２、６３を作業位置から待機位置へ移動させる工程である。ステップ１８６－１９２の工程により、中性点ＮＴのための電気的な接続作業が実行される。ステップ１８６－１９２は、中性点ＮＴのための溶接工程を提供する。 Step 192 is a process of moving the electrodes 62 and 63 from the work position to the standby position. The electrical connection work for the neutral point NT is executed by the processes of Steps 186-192. Steps 186-192 provide a welding process for the neutral point NT.
　ステップ１９３は、接続構造に保護材５９を付与する工程である。保護材５９は、複数の接続構造の帯電部を覆うように付与される。保護材５９は、付与時には比較的低粘度であり、付与後に硬化する樹脂材料である。例えば、保護材５９は、接続構造の軸方向先端から滴下される。保護材５９は、接続構造における、少なくともストリップ部分３８および接続部５２の表面を覆うように流れ、それらの上に絶縁皮膜を形成する。保護材５９の一部は、端面４２の上に到達する。余剰の保護材５９は、側壁４３、４４によって堰き止められる。 Step 193 is a step of applying the protective material 59 to the connection structure. The protective material 59 is provided so as to cover the charging portions of the plurality of connection structures. The protective material 59 is a resin material that has a relatively low viscosity at the time of application and is cured after application. For example, the protective material 59 is dripped from the axial direction front-end | tip of a connection structure. The protective material 59 flows so as to cover at least the surfaces of the strip portion 38 and the connection portion 52 in the connection structure, and forms an insulating film thereon. A part of the protective material 59 reaches the end face 42. Excess protective material 59 is blocked by side walls 43 and 44.
　以上に述べた実施形態によると、ステータコア３２、ステータコア３２に装着されたインシュレータ３５、およびステータコア３２に装着されたステータコイル３３を備える内燃機関用回転電機のステータが提供される。内燃機関用回転電機のステータ３１は、ステータ３１の一方の端面においてインシュレータ３５に固定された端子５１と、ステータコイル３３から延び出し、端子５１に接続される複数のコイル端部３７とを備える。端子５１は、インシュレータ３５の端面４２から突出するように配置され、周方向に沿って配置された複数の接続部５２を有する。複数のコイル端部３７は、複数の接続部５２に分配されて対応付けられている。複数の接続部５２のそれぞれは、ステータ３１の軸方向に沿って延びる突条５５を有している。複数の接続部５２のそれぞれは、それに対応付けられたコイル端部３７であって突条５５と交差するように配置されたコイル端部３７と、突条５５の頂部において、プロジェクション溶接によって接続されている。 According to the embodiment described above, there is provided a stator for a rotating electrical machine for an internal combustion engine including a stator core 32, an insulator 35 attached to the stator core 32, and a stator coil 33 attached to the stator core 32. The stator 31 of the rotating electrical machine for the internal combustion engine includes a terminal 51 fixed to the insulator 35 on one end surface of the stator 31 and a plurality of coil end portions 37 extending from the stator coil 33 and connected to the terminal 51. The terminal 51 is disposed so as to protrude from the end face 42 of the insulator 35, and has a plurality of connection portions 52 disposed along the circumferential direction. The plurality of coil end portions 37 are distributed and associated with the plurality of connection portions 52. Each of the plurality of connection portions 52 has a protrusion 55 extending along the axial direction of the stator 31. Each of the plurality of connection portions 52 is connected to the coil end portion 37 corresponding to the plurality of connection portions 52, which is arranged so as to intersect the protrusion 55, at the top of the protrusion 55 by projection welding. ing.
　コイル端部３７は、突条５５と交差するように配置されているから、コイル端部３７と、突条５５との間にプロジェクション溶接に適した接触が得られる。複数の接続部５２は、ステータ３１の周方向に沿って配置されているから、プロジェクション溶接のための作業空間が周方向に沿って分散的に配置される。よって、ステータ３１の端面を利用して、複数のコイル端部３７をプロジェクション溶接を利用して互いに接続することができる。 Since the coil end portion 37 is disposed so as to intersect with the protrusion 55, contact suitable for projection welding can be obtained between the coil end 37 and the protrusion 55. Since the plurality of connecting portions 52 are arranged along the circumferential direction of the stator 31, work spaces for projection welding are arranged in a distributed manner along the circumferential direction. Therefore, a plurality of coil end portions 37 can be connected to each other using projection welding using the end face of the stator 31.
　コイル端部３７と端子５１とは、プロジェクション溶接によって接続される。プロジェクション溶接は、はんだ付けに比べると、小型の接続構造を可能とする。はんだ付けは、フラックスの塗布、フラックスの除去のための洗浄を必要とする場合がある。このため、はんだ付けが採用される場合、接続構造の周囲には、作業のための広く空間が必要となる。これに対して、プロジェクション溶接を用いることにより、狭い空間に接続構造を配置することができる。 The coil end portion 37 and the terminal 51 are connected by projection welding. Projection welding allows a small connection structure compared to soldering. Soldering may require cleaning for flux application and flux removal. For this reason, when soldering is employed, a large space for work is required around the connection structure. On the other hand, the connection structure can be arranged in a narrow space by using projection welding.
　複数のコイル端部３７、すなわち複数のコイル素線が、ひとつの接続部５２に接続される。複数のコイル端部３７が一箇所で接続されるから、小型の接続構造が提供される。複数のコイル端部３７は、軸方向に積層して配置される。言い換えると、複数のコイル端部３７は、軸方向に関して上下に配置される。しかも、複数のコイル端部３７は、軸方向に配置されたまま、接続部５２に接触する。このような配置も、接続構造の小型化に貢献する。 A plurality of coil end portions 37, that is, a plurality of coil strands, are connected to one connection portion 52. Since the plurality of coil end portions 37 are connected at one place, a small connection structure is provided. The plurality of coil end portions 37 are stacked in the axial direction. In other words, the plurality of coil end portions 37 are arranged vertically with respect to the axial direction. Moreover, the plurality of coil end portions 37 are in contact with the connection portion 52 while being arranged in the axial direction. Such an arrangement also contributes to the miniaturization of the connection structure.
　接続部５２は、軸方向に長手方向をもつ突条５５を備える。突条５５は、複数のコイル端部３７と接触する。突条５５は、プロジェクション溶接のために利用される。この結果、ステータ３１上の狭い範囲において複数のコイル端部３７との電気的な接続が提供される。 The connecting portion 52 includes a protrusion 55 having a longitudinal direction in the axial direction. The protrusion 55 contacts the plurality of coil end portions 37. The ridge 55 is used for projection welding. As a result, electrical connection with a plurality of coil end portions 37 is provided in a narrow range on the stator 31.
　複数のコイル端部３７は、保持部４７、４８によって案内される。複数のコイル端部３７は、保持部４７、４８によって規定の位置、および規定の形状に保持される。これにより、コイル端部３７を仮留めする作業を正確に実行できる。しかも、保持部４７、４８においても、複数のコイル端部３７が軸方向に配置されるから、小型の接続構造が提供される。 The plurality of coil end portions 37 are guided by holding portions 47 and 48. The plurality of coil end portions 37 are held at a predetermined position and a predetermined shape by the holding portions 47 and 48. Thereby, the operation | work which temporarily fixes the coil edge part 37 can be performed correctly. Moreover, since the plurality of coil end portions 37 are also arranged in the axial direction in the holding portions 47 and 48, a small connection structure is provided.
　コイル端部３７は、保持部４７を利用して、Ｌ字型に曲げられる。このため、コイル端部３７を規定の形状に加工することができる。さらに、コイル端部３７がＬ字型に曲げられることにより、コイル端部３７は、ステータ３１の周方向に沿って延びる。この結果、コイル端部３７と接続部５２との接触部分は、ステータ３１上の径方向外側の部位に配置される。 The coil end portion 37 is bent into an L shape using the holding portion 47. For this reason, the coil end part 37 can be processed into a defined shape. Furthermore, the coil end portion 37 extends along the circumferential direction of the stator 31 by bending the coil end portion 37 into an L shape. As a result, the contact portion between the coil end portion 37 and the connection portion 52 is disposed at a radially outer portion on the stator 31.
　突条５５の突出軸は、ステータ３１の径方向に沿って延びている。また、複数の接続構造は、ステータ３１の周方向に沿って分散的に配置されている。これにより、プロジェクション溶接のための電極６２、６３の移動方向を径方向に設定することができる。これにより、電極６２、６３の開閉と、相対的な回転移動とによって、複数の接続構造における接続作業を順に実行することができる。しかも、突条５５は、径方向外側に向けて突出しており、コイル端部３７は、接続部５２の径方向外側に配置される。この配置も、径方向外側における広い空間の利用を可能とする。 The protruding shaft of the protrusion 55 extends along the radial direction of the stator 31. Further, the plurality of connection structures are arranged in a distributed manner along the circumferential direction of the stator 31. Thereby, the moving direction of the electrodes 62 and 63 for projection welding can be set to a radial direction. Thereby, the connection operation | work in a some connection structure can be performed in order by opening and closing of the electrodes 62 and 63 and relative rotational movement. Moreover, the protrusion 55 protrudes outward in the radial direction, and the coil end portion 37 is disposed on the outer side in the radial direction of the connection portion 52. This arrangement also enables use of a wide space on the radially outer side.
　ひとつの端子５１の上に、複数の接続部５２が設けられる。この構成は、複数のコイル端部３７との接続を可能とする。さらに、ひとつの接続部５２に複数のコイル端部３７が接続されるから、多数のコイル端部３７の間の接続を端子５１によって提供することができる。より具体的には、複数の同相のコイルを備えるステータコイル３３において、小型の中性点ＮＴを提供することができる。 A plurality of connection parts 52 are provided on one terminal 51. This configuration enables connection to a plurality of coil end portions 37. Further, since the plurality of coil end portions 37 are connected to one connection portion 52, the connection between the many coil end portions 37 can be provided by the terminal 51. More specifically, a small neutral point NT can be provided in the stator coil 33 including a plurality of in-phase coils.
　インシュレータ３５に設けられた側壁４３、４４は、保護材５９の過剰な広がりを抑制するための容器部分を提供する。よって、保護材５９の過剰な広がりを抑制しながら、帯電部分の確実な絶縁保護が提供される。 The side walls 43 and 44 provided in the insulator 35 provide a container portion for suppressing the excessive spread of the protective material 59. Therefore, reliable insulation protection of the charged portion is provided while suppressing the excessive spread of the protective material 59.
　（第２実施形態）
　この実施形態は、先行する実施形態を基礎的形態とする変形例である。上記実施形態では、連結部５７がインシュレータ３５に圧入される。これに加えて、この実施形態では、図８に図示されるように、端子５１は、挿入片２５８を有する。挿入片２５８は、連結部５７から、接続部５２とは反対側に延び出している。挿入片２５８は、インシュレータ３５の中に挿入される。挿入片２５８は、端子５１とインシュレータ３５との連結を強化する。ステータコア３２は、インシュレータ３５と挿入片２５８とを受け入れるための凹部を備えることができる。 (Second Embodiment)
This embodiment is a modification based on the preceding embodiment. In the above embodiment, the connecting portion 57 is press-fitted into the insulator 35. In addition, in this embodiment, as shown in FIG. 8, the terminal 51 has an insertion piece 258. The insertion piece 258 extends from the coupling portion 57 to the side opposite to the connection portion 52. The insertion piece 258 is inserted into the insulator 35. The insertion piece 258 strengthens the connection between the terminal 51 and the insulator 35. The stator core 32 can include a recess for receiving the insulator 35 and the insertion piece 258.
　（第３実施形態）
　この実施形態は、先行する実施形態を基礎的形態とする変形例である。上記実施形態では、複数の接続部５２が周方向に関して互いに離れるように設けられている。これに代えて、この実施形態では、図９に図示されるように、連続した板状部分に、複数の接続部３５２が設けられている。この形状では、複数の接続部３５２は周方向に互いに連接して設けられている。この形状でも、複数の接続部３５２は、周方向に沿って配置されているといえる。 (Third embodiment)
This embodiment is a modification based on the preceding embodiment. In the said embodiment, the some connection part 52 is provided so that it may mutually separate regarding the circumferential direction. Instead, in this embodiment, as shown in FIG. 9, a plurality of connecting portions 352 are provided in a continuous plate-like portion. In this shape, the plurality of connecting portions 352 are provided so as to be connected to each other in the circumferential direction. Even in this shape, it can be said that the plurality of connecting portions 352 are arranged along the circumferential direction.
　（第４実施形態）
　この実施形態は、先行する実施形態を基礎的形態とする変形例である。上記実施形態は、中性点ＮＴである。これに代えて、他の用途の電気的な接続を提供してもよい。この実施形態では、端子５１は、複数のコイル端部３７の間の接続を提供するとともに、さらに、ひとつの電力線４１１ａとの接続を提供する。 (Fourth embodiment)
This embodiment is a modification based on the preceding embodiment. The said embodiment is the neutral point NT. Alternatively, electrical connections for other applications may be provided. In this embodiment, the terminal 51 provides a connection between the plurality of coil ends 37 and also provides a connection with one power line 411a.
　図１０において、端子５１は、複数の接続部５２を有する。端子５１は、２つの接続部５２を有する。ひとつの接続部５２には、複数のコイル端部３７がプロジェクション溶接によって接続されている。ひとつの接続部５２には、２つのコイル端部３７がプロジェクション溶接によって接続されている。 In FIG. 10, the terminal 51 has a plurality of connecting portions 52. The terminal 51 has two connection parts 52. A plurality of coil end portions 37 are connected to one connection portion 52 by projection welding. Two coil end portions 37 are connected to one connection portion 52 by projection welding.
　さらに、端子５１は、接続部４５２を有する。接続部４５２は、プロジェクション溶接とは異なる他の溶接手法が適用される接続部である。接続部４５２は、かしめ、フュージング、および／または、はんだ付けのための接続部である。接続部４５２は、電力線４１１ａとの接続のために提供されている。電力線４１１ａは、複数の導線を含む撚り線である。接続部４５２は、撚り線との接続に適した接続部とも呼ぶことができる。一方で、接続部５２は、単線であるコイル端部３７との接続に適した接続部とも呼ぶことができる。 Furthermore, the terminal 51 has a connection part 452. The connection part 452 is a connection part to which another welding method different from projection welding is applied. The connection part 452 is a connection part for caulking, fusing, and / or soldering. The connection unit 452 is provided for connection to the power line 411a. The power line 411a is a stranded wire including a plurality of conducting wires. The connection portion 452 can also be referred to as a connection portion suitable for connection with a stranded wire. On the other hand, the connection part 52 can also be called a connection part suitable for the connection with the coil end part 37 which is a single wire.
　複数の接続部５２、４５２は、連結部５７によって機械的に、かつ、電気的に接続されている。この構成では、複数のコイル端部３７がひとつの接続部５２によって電気的に接続される。この構成では、複数のコイル端部３７が複数の接続部５２と連結部５７とによって電気的に接続される。この構成では、複数のコイル端部３７と、少なくともひとつの電力線４１１ａとが、それらに適した接続部５２によって電気的に接続される。上記実施形態において説明した作用効果のうちの対応する少なくともひとつを得ることができる。 The plurality of connecting portions 52 and 452 are mechanically and electrically connected by a connecting portion 57. In this configuration, the plurality of coil end portions 37 are electrically connected by one connection portion 52. In this configuration, the plurality of coil end portions 37 are electrically connected by the plurality of connecting portions 52 and the connecting portion 57. In this configuration, the plurality of coil end portions 37 and at least one power line 411a are electrically connected by a connection portion 52 suitable for them. At least one of the functions and effects described in the above embodiment can be obtained.
　この実施形態の端子５１は、例えば、出力端ＰＴに利用することができる。例えば、デルタ結線における出力端に利用することができる。 The terminal 51 of this embodiment can be used for the output terminal PT, for example. For example, it can be used for an output end in delta connection.
　（第５実施形態）
　この実施形態は、先行する実施形態を基礎的形態とする変形例である。上記実施形態の連結部５７は、ステータ３１の周方向に沿って曲がっている板である。これに代えて、連結部は平板、または曲面板など多様な形状をもつことができる。この実施形態では、端子５１は、平板状の連結部５５７を備える。 (Fifth embodiment)
This embodiment is a modification based on the preceding embodiment. The connecting portion 57 of the above embodiment is a plate that is bent along the circumferential direction of the stator 31. Alternatively, the connecting portion can have various shapes such as a flat plate or a curved plate. In this embodiment, the terminal 51 includes a flat connecting portion 557.
　図１１および図１２において、端子５１は、連結部５５７を有する。図１２は、溶接工程の前、または溶接工程の間の状態を示している。連結部５５７は、平板である。連結部５５７は、ステータ３１の周方向に対する弦に沿って延在している。この結果、複数の接続部５２は、弦に沿って配置されている。複数の接続部５２は、共通の平面上に配置されている。複数のベース部分５３は、一直線上に配置されている。複数の接続部５２は相似形または同じ形状である。 11 and 12, the terminal 51 has a connecting portion 557. FIG. 12 shows the state before or during the welding process. The connection part 557 is a flat plate. The connecting portion 557 extends along a string with respect to the circumferential direction of the stator 31. As a result, the plurality of connecting portions 52 are arranged along the strings. The plurality of connection parts 52 are arranged on a common plane. The plurality of base portions 53 are arranged on a straight line. The plurality of connecting portions 52 have a similar shape or the same shape.
　突条５５は、端子５１の両面のうち、ステータ３１の径方向内側に面する面から突出している。突条５５は、対応するベース部分５３の径方向内側の面から、ベース部分５３に垂直な方向へ向けて突出している。突条５５は、対応する接続部５２の内側面から突出している。 The protrusion 55 protrudes from the surface of the terminal 51 facing the radially inner side of the stator 31. The protrusion 55 protrudes from the radially inner surface of the corresponding base portion 53 in a direction perpendicular to the base portion 53. The protrusion 55 protrudes from the inner side surface of the corresponding connection portion 52.
　突条５５は、ステータ３１の直径線または直径線と平行な平行線に沿って、ステータ３１の内方向へ突出している。３つの接続部５２を有する図示される例では、中央の接続部５２のベース部分５３は、そこを通る直径線と直交している。中央の接続部５２に設けられた突条５５は、上記直径線に沿って、ステータ３１の径方向内側へ向けて突出している。両端の接続部５２のベース部分５３は、そこを通る直径線に対して傾斜している。両端の接続部５２に設けられた突条５５は、上記直径線と平行な平行線に沿って、ステータ３１の内方向へ突出している。言い換えると、突条５５は、その突条５５が設けられた位置におけるステータ３１の接線に対して、ステータ３１の内方向に突出している。 The protrusion 55 protrudes inward of the stator 31 along a diameter line of the stator 31 or a parallel line parallel to the diameter line. In the illustrated example having three connections 52, the base portion 53 of the central connection 52 is orthogonal to the diameter line passing therethrough. The protrusion 55 provided in the central connection portion 52 protrudes inward in the radial direction of the stator 31 along the diameter line. The base portions 53 of the connecting portions 52 at both ends are inclined with respect to the diameter line passing therethrough. The ridges 55 provided on the connection portions 52 at both ends protrude inward of the stator 31 along a parallel line parallel to the diameter line. In other words, the protrusion 55 protrudes inward of the stator 31 with respect to the tangent line of the stator 31 at the position where the protrusion 55 is provided.
　接続部５２の両面のうち、突条５５が突出する面を第１面と呼び、凹溝５４が形成された面を第２面と呼ぶことができる。端子５１は、第１面をステータ３１の接線方向よりも中心側に向けて位置付けられている。端子５１は、第１面をステータ３１の径方向内側に向け、第２面をステータ３１の径方向外側に向けて位置づけられている。 Of the two surfaces of the connecting portion 52, the surface from which the protrusion 55 protrudes can be referred to as a first surface, and the surface on which the concave groove 54 is formed can be referred to as a second surface. The terminal 51 is positioned with the first surface directed toward the center side of the tangential direction of the stator 31. The terminal 51 is positioned with the first surface facing the radially inner side of the stator 31 and the second surface facing the radially outer side of the stator 31.
　コイル端部３７は、ステータコイル３３から径方向内側に向けて延びるように配置されている。コイル端部３７は、ステータ３１の端面上において、対応する接続部５２の横側を通るように配置されている。コイル端部３７は、対応する接続部５２よりもステータ３１の径方向外側から、対応する接続部５２よりもステータ３１の径方向内側へ回り込むように配置されている。コイル端部３７は、対応する突条５５の上に到達している。コイル端部３７は、接続部５２に巻き付くように配置されている。コイル端部３７は、接続部５２に引っ掛けられるように配置されている。 The coil end portion 37 is disposed so as to extend radially inward from the stator coil 33. The coil end portion 37 is disposed on the end face of the stator 31 so as to pass through the side of the corresponding connecting portion 52. The coil end portions 37 are arranged so as to go from the corresponding connection portion 52 to the radially inner side of the stator 31 from the corresponding connection portion 52 from the radially outer side of the stator 31. The coil end portion 37 reaches the corresponding protrusion 55. The coil end portion 37 is disposed so as to wind around the connection portion 52. The coil end portion 37 is disposed so as to be hooked on the connection portion 52.
　コイル端部３７は、保持部４７、４８によって保持された被保持部３７ａを有する。コイル端部３７は、保持部４７、４８によって、少なくとも周方向に関して規定の位置に位置づけられている。被保持部３７ａは、一組の保持部４７、４８の間において、後述するクランク部３７ｂよりも比較的まっすぐに長く延びている。保持部４７、４８は、対応する接続部５２よりも径方向外側に配置されている。保持部４７、４８は、コイル端部３７が、その軸方向、すなわちステータ３１の径方向に関して移動することを許容する。 The coil end portion 37 has a held portion 37 a held by holding portions 47 and 48. The coil end portion 37 is positioned at a predetermined position at least in the circumferential direction by the holding portions 47 and 48. The held portion 37a extends between the pair of holding portions 47 and 48 relatively longer and straighter than a crank portion 37b described later. The holding portions 47 and 48 are arranged on the outer side in the radial direction than the corresponding connection portion 52. The holding portions 47 and 48 allow the coil end portion 37 to move in the axial direction, that is, the radial direction of the stator 31.
　コイル端部３７は、クランク部３７ｂを有している。クランク部３７ｂは、コイル端部３７を曲げることによって形成された曲がり部である。クランク部３７ｂは、ほぼ９０度の曲がりを提供している。クランク部３７ｂは、Ｌ字型部分とも呼ぶことができる。 The coil end portion 37 has a crank portion 37b. The crank portion 37 b is a bent portion formed by bending the coil end portion 37. The crank portion 37b provides a bend of approximately 90 degrees. The crank portion 37b can also be referred to as an L-shaped portion.
　クランク部３７ｂは、保持部４７、４８と接続部５２との間に位置している。クランク部３７ｂは、保持部４７、４８より径方向内側に位置している。図示の例では、クランク部３７ｂの多くの部分は、端子５１が規定する平面よりもステータ３１の径方向内側に位置している。クランク部３７ｂの一部は、接続部５２の横に位置している。クランク部３７ｂの半分未満の一部が、接続部５２より径方向外側に位置していてもよい。 The crank part 37 b is located between the holding parts 47 and 48 and the connection part 52. The crank portion 37 b is located on the radially inner side with respect to the holding portions 47 and 48. In the illustrated example, many portions of the crank portion 37 b are located on the radially inner side of the stator 31 with respect to the plane defined by the terminal 51. A part of the crank portion 37 b is located beside the connection portion 52. A part less than half of the crank portion 37 b may be located on the radially outer side from the connecting portion 52.
　少なくともひとつのクランク部３７ｂは、端の接続部５２の外側を通って配置されている。少なくともひとつのクランク部３７ｂは、２つの接続部５２の間を通って配置されている。２つの接続部５２の間には、コイル端部３７を配置するために十分な大きさの隙間が設けられている。コイル端部３７は、保持部４７、４８を通り、さらに、隙間を通って、突条５５の上に到達している。隙間は、端子５１に設けられた切欠部とも呼ぶことができる。隙間は、保持部４７、４８と突条５５との間において、コイル端部３７をステータ３１の端面に沿って配置するための通路空洞を提供する。隙間は、ステータ３１の軸方向に向けて開いており、この軸方向に沿って、コイル端部３７は隙間の中に押し込まれ、規定の位置に位置付けられる。 The at least one crank part 37b is disposed through the outside of the end connection part 52. At least one crank portion 37 b is disposed between the two connection portions 52. A gap large enough to arrange the coil end portion 37 is provided between the two connection portions 52. The coil end portion 37 passes through the holding portions 47 and 48 and further passes through the gap and reaches the ridge 55. The gap can also be referred to as a notch provided in the terminal 51. The gap provides a passage cavity for arranging the coil end portion 37 along the end surface of the stator 31 between the holding portions 47 and 48 and the protrusion 55. The gap is open in the axial direction of the stator 31, and the coil end portion 37 is pushed into the gap along the axial direction and is positioned at a predetermined position.
　コイル端部３７は、先端部３７ｃを有する。先端部３７ｃは、保持部４７、４８より径方向内側に位置づけられている。先端部３７ｃは、接続部５２よりも径方向内側に位置づけられている。コイル端部３７は、接続部５２の横を経由し、さらに突条５５の頂きを経由するように形成されている。コイル端部３７は、突条５５の頂きを経由した後に、先端部３７ｃが再び接続部５２に向けて接近するように形成されている。言い換えると、コイル端部３７は、接続部５２の第１面の上に沿って、やや湾曲している。この湾曲は、コイル端部３７が接続部５２に巻き付くような湾曲である。 The coil end portion 37 has a tip end portion 37c. The distal end portion 37 c is positioned radially inward from the holding portions 47 and 48. The distal end portion 37 c is positioned on the radially inner side with respect to the connection portion 52. The coil end portion 37 is formed so as to pass through the side of the connecting portion 52 and further through the top of the protrusion 55. The coil end portion 37 is formed so that the tip end portion 37 c approaches the connection portion 52 again after passing through the top of the protrusion 55. In other words, the coil end portion 37 is slightly curved along the first surface of the connection portion 52. This curvature is such that the coil end portion 37 is wound around the connection portion 52.
　回転電機１０の製造方法において、コイル端部３７は、図１１に図示されるように配置される。コイル端部３７の形状は、高品質の溶接部を形成するために貢献する複数の特徴を有している。これらの特徴は、実施形態のように組み合わせて利用することができる。また、これらの特徴は、単独でも利用することができる。 In the manufacturing method of the rotating electrical machine 10, the coil end portion 37 is disposed as illustrated in FIG. The shape of the coil end 37 has several features that contribute to forming a high quality weld. These features can be used in combination as in the embodiment. These features can also be used alone.
　ひとつの特徴は、真っ直ぐに配置された複数の接続部５２である。この形状は、真っ直ぐの連結部５５７によって提供される。この形状は、複数の接続部５２をステータ３１上の規定の位置に安定的に位置づけることを可能とする。この形状は、連結部５５７に曲げ形状を有しないから、特に両端の連結部５２の位置決めに誤差を生じ難い。この結果、コイル端部３７と接続部５２との二者を確実に規定の位置に位置付けることができる。また、溶接工程において、コイル端部３７と接続部５２と電極６２、６３との三者を確実に規定の位置に位置付けることができる。よって、高品質の溶接部を安定的に形成することができる。 One feature is a plurality of connecting portions 52 arranged in a straight line. This shape is provided by a straight connection 557. This shape enables the plurality of connecting portions 52 to be stably positioned at a predetermined position on the stator 31. In this shape, since the connecting portion 557 does not have a bent shape, it is difficult to cause an error in positioning of the connecting portions 52 at both ends. As a result, the two of the coil end portion 37 and the connection portion 52 can be surely positioned at the prescribed positions. Further, in the welding process, the three of the coil end portion 37, the connection portion 52, and the electrodes 62 and 63 can be surely positioned at specified positions. Therefore, a high quality weld can be stably formed.
　他のひとつの特徴は、保持部４７、４８より径方向内側に比較的長いコイル端部３７が配置される形状である。この形状は、端子５１の第１面に設けられた突条５５によって可能とされている。この形状は、コイル端部３７が接続部５２に回りこむように配置されることで可能とされている。 Another feature is a shape in which a relatively long coil end portion 37 is disposed radially inward from the holding portions 47 and 48. This shape is made possible by the protrusion 55 provided on the first surface of the terminal 51. This shape is made possible by arranging the coil end portion 37 so as to wrap around the connection portion 52.
　ひとつの観点において、長いコイル端部３７は、容易な曲げ加工を可能とする。コイル端部３７は、プロジェクション溶接に適した形状に加工することができる。よって、高品質の溶接部を安定的に形成することができる。 In one aspect, the long coil end 37 enables easy bending. The coil end portion 37 can be processed into a shape suitable for projection welding. Therefore, a high quality weld can be stably formed.
　別の観点において、コイル端部３７は、クランク部３７ｂにおいて、接続部５２に巻き付くように曲げられる。コイル端部３７は、それ自身の弾性力を利用して、コイル端部３７を接続部５２に引っ掛けることができる。この製造方法は、コイル端部３７を突条５５の上に安定的に位置づけることを可能とする。よって、高品質の溶接部を安定的に形成することができる。 In another viewpoint, the coil end portion 37 is bent so as to be wound around the connection portion 52 at the crank portion 37b. The coil end portion 37 can hook the coil end portion 37 to the connection portion 52 by using its own elastic force. This manufacturing method makes it possible to stably position the coil end portion 37 on the protrusion 55. Therefore, a high quality weld can be stably formed.
　さらに別の観点において、長いコイル端部３７は、コイル端部３７自身のたるみを許容する。また、長いコイル端部３７は、コイル端部３７の寸法誤差、または変形に起因するたるみの変化を許容する。言い換えると、長いコイル端部３７は、長いたるみ代を提供する。 In yet another aspect, the long coil end 37 allows the coil end 37 to sag. In addition, the long coil end portion 37 allows a dimensional error of the coil end portion 37 or a change in sag due to deformation. In other words, the long coil end 37 provides a long slack allowance.
　さらに別の観点において、コイル端部３７は、被保持部３７ａとクランク部３７ｂとの間において、比較的長い距離にわたって比較的真っ直ぐに配置される。比較的真っ直ぐのコイル端部３７は、保持部４７、４８に対してコイル端部３７が滑らかに移動することを許容する。このような移動は、溶接工程におけるコイル端部３７の移動を容易にする。しかも、被保持部３７ａとクランク部３７ｂとの間に設けられた比較的長い真っ直ぐの部分は、コイル端部３７の滑らかな滑りを可能とする。 In yet another aspect, the coil end portion 37 is disposed relatively straight over a relatively long distance between the held portion 37a and the crank portion 37b. The relatively straight coil end portion 37 allows the coil end portion 37 to move smoothly with respect to the holding portions 47 and 48. Such movement facilitates movement of the coil end 37 in the welding process. Moreover, the relatively long straight portion provided between the held portion 37a and the crank portion 37b enables the coil end portion 37 to smoothly slide.
　回転電機１０の製造方法において、コイル端部３７は、接続部５２に溶接される。溶接用の電極６２、６３は、接続部５２の第２面と接触する電極６２と、コイル端部３７と接触する電極６３とを有する。電極６２は、背面電極、支持電極、または外側電極とも呼ばれる。電極６３は、正面電極、作用電極、または内側電極とも呼ばれる。接続部５２の第２面と電極５２とは、安定した接触状態、すなわち通電状態を提供するように形成されている。 In the manufacturing method of the rotating electrical machine 10, the coil end portion 37 is welded to the connection portion 52. The welding electrodes 62 and 63 include an electrode 62 that contacts the second surface of the connection portion 52 and an electrode 63 that contacts the coil end portion 37. The electrode 62 is also called a back electrode, a support electrode, or an outer electrode. The electrode 63 is also called a front electrode, a working electrode, or an inner electrode. The second surface of the connecting portion 52 and the electrode 52 are formed so as to provide a stable contact state, that is, an energized state.
　溶接用の電極６２、６３は、コイル端部３７と接続部５２とをクランプするように位置づけられ、駆動される。先行する実施形態では、ステップ１９１において、ステータ３１と電極６２、６３とが相対回転されるが、この実施形態では、ステータ３１と電極６２、６３とが相対的に平行移動される。これにより、複数の接続作業が順に実行される。溶接工程において、電極６２、６３がコイル端部３７と接続部５２とをクランプすると、コイル端部３７が接続部５２に向けて移動する。クランク部３７ｂと先端部３７ｃとの間の部位は、接続部５２に向けて平行移動する。すなわち、ストリップ部分３８は、接続部５２に向けて平行移動する。これにより、ストリップ部分３８は突条５５に強く押し付けられ、望ましい接触状態が提供される。同時に、クランク部３７ｂも径方向外側へ平行移動する。 The welding electrodes 62 and 63 are positioned and driven so as to clamp the coil end portion 37 and the connection portion 52. In the preceding embodiment, in step 191, the stator 31 and the electrodes 62 and 63 are relatively rotated. In this embodiment, the stator 31 and the electrodes 62 and 63 are relatively translated. Thereby, a plurality of connection operations are executed in order. In the welding process, when the electrodes 62 and 63 clamp the coil end portion 37 and the connection portion 52, the coil end portion 37 moves toward the connection portion 52. A portion between the crank portion 37 b and the tip portion 37 c moves in parallel toward the connecting portion 52. That is, the strip portion 38 translates toward the connection portion 52. As a result, the strip portion 38 is strongly pressed against the protrusion 55, and a desired contact state is provided. At the same time, the crank portion 37b also translates radially outward.
　このとき、保持部４７、４８と先端部３７ｃとの間の長いコイル端部３７は、ストリップ部３８の移動を許容するたるみを提供する。長いコイル端部３７は、突っ張りを抑制しながら、変形することができる。このため、コイル端部３７の位置修正が容易に行われる。同時に、被保持部３７ａと保持部４７、４８とは、コイル端部３７が保持部４７、４８の間を滑りながら移動することを許容する。このため、コイル端部３７の位置修正が容易に行われる。 At this time, the long coil end portion 37 between the holding portions 47 and 48 and the tip end portion 37c provides a slack that allows the strip portion 38 to move. The long coil end portion 37 can be deformed while suppressing the tension. For this reason, the position correction of the coil end part 37 is easily performed. At the same time, the held portion 37 a and the holding portions 47 and 48 allow the coil end portion 37 to move between the holding portions 47 and 48 while sliding. For this reason, the position correction of the coil end part 37 is easily performed.
　上述の長いコイル端部３７は、「たるみ」と「滑り」とによって、上記移動を許容する。上記移動は、溶接工程におけるコイル端部３７の位置修正を提供する。この結果、コイル端部３７と接続部５２との間に望ましい接触状態を形成することができる。さらに、望ましい接触状態は、望ましい溶接状態の形成にも貢献する。なお、「たるみ」と「滑り」とは、いずれか一方のみが利用されてもよい。例えば、保持部４７、４８と被保持部３７ａとが強固に噛み合っていても、「たるみ」だけでコイル端部３７の位置修正が可能である。 The long coil end 37 described above allows the above movement by “sag” and “slip”. The above movement provides correction of the position of the coil end 37 in the welding process. As a result, a desirable contact state can be formed between the coil end portion 37 and the connection portion 52. Furthermore, the desired contact state also contributes to the formation of the desired weld state. Only one of “sag” and “slip” may be used. For example, even if the holding portions 47 and 48 and the held portion 37a are firmly engaged with each other, the position of the coil end portion 37 can be corrected only by “sag”.
　接続部５２の幅ＷＤ１は、電極６２の幅ＷＤ２より小さく設定されている（ＷＤ１＜ＷＤ２）。２つの接続部５２の間の切欠部の幅ＷＤ３は、接続部５２の幅ＷＤ１を電極６２の幅ＷＤ２より小さくするように設定されている。切欠部が設けられることにより、溶接工程において、接続部５２と電極６２、６３との間の安定的な接触状態が提供される。例えば、接続部５２と電極６２とが規定の位置からわずかにずれても、接続部５２と電極６２との間に規定の接触面積が安定的に提供される。この結果、高品質の溶接部を安定的に形成することができる。さらに、切欠部には、コイル端部３７が配置されるから、幅ＷＤ３は、コイル端部３７の配置を可能とするように設定されている。電極６２と電極６３とは、同じ幅を有することができる。また、電極６２と電極６３とは、異なる幅を有していてもよい。例えば、電極６３は、幅ＷＤ２より小さいが、突条５５の幅より大きい幅を有していてもよい。 The width WD1 of the connecting portion 52 is set smaller than the width WD2 of the electrode 62 (WD1 <WD2). The width WD3 of the notch between the two connecting portions 52 is set so that the width WD1 of the connecting portion 52 is smaller than the width WD2 of the electrode 62. By providing the notch portion, a stable contact state between the connection portion 52 and the electrodes 62 and 63 is provided in the welding process. For example, even if the connection part 52 and the electrode 62 are slightly shifted from the specified position, a specified contact area is stably provided between the connection part 52 and the electrode 62. As a result, a high quality weld can be stably formed. Furthermore, since the coil end portion 37 is disposed in the notch portion, the width WD3 is set so that the coil end portion 37 can be disposed. The electrode 62 and the electrode 63 can have the same width. Moreover, the electrode 62 and the electrode 63 may have different widths. For example, the electrode 63 may have a width smaller than the width WD2, but larger than the width of the protrusion 55.
　図１３は、溶接後のコイル端部３７と接続部５２を示している。クランク部３７ｂは、曲げ角ＤＧ１を提供する。曲げ角ＤＧ１は、接続部５２の横におけるコイル端部３７の中心軸ＡＸ１と接続部５２と平行なコイル端部３７の中心軸ＡＸ２との間の角度である。曲げ角ＤＧ１は、コイル端部３７が接続部５２に巻き付く形状をコイル端部３７に与える。巻き付く形状は、１／４周回未満によって実現可能である。先端部３７ｃは、突条５５を越えた後に再び接続部５２に接近するように曲がっている。先端部３７ｃは、曲げ角ＤＧ２を提供する。曲げ角ＤＧ２は、中心軸ＡＸ２とコイル端部３７の先端面の中心軸ＡＸ３との間の角度である。 FIG. 13 shows the coil end portion 37 and the connection portion 52 after welding. The crank portion 37b provides a bending angle DG1. The bending angle DG <b> 1 is an angle between the central axis AX <b> 1 of the coil end 37 next to the connecting portion 52 and the central axis AX <b> 2 of the coil end 37 parallel to the connecting portion 52. The bending angle DG <b> 1 gives the coil end portion 37 a shape in which the coil end portion 37 is wound around the connection portion 52. The winding shape can be realized by less than 1/4 turn. The tip portion 37 c is bent so as to approach the connection portion 52 again after exceeding the protrusion 55. The tip portion 37c provides a bending angle DG2. The bending angle DG2 is an angle between the central axis AX2 and the central axis AX3 of the tip surface of the coil end portion 37.
　コイル端部３７のうち、電極６３と接触した部分には、接触痕３７ｄが形成されている。接触痕３７ｄは、電極６３の表面形状に対応した面である。図示の例では、接触痕３７ｄは、平面である。接触痕３７ｄは、ストリップ部分３８の上に形成されている。コイル端部３７と突条５５とが望ましい接触状態であるとき、ストリップ部分３８の延在方向と、突条５５の延在方向とは直交する。この望ましい接触状態が実現される場合、接触痕３７ｄの形状は、コイル端部３７の延在方向と、突条５５の延在方向とに延びる十字形または菱形である。コイル端部３７は、接触痕３７ｄの周囲において突条５５に沿うように変形している。コイル端部３７は、突条５５の延在方向に沿って延び出す幅広部を提供する。幅広部は、コイル端部３７と突条５５との間に広い接触面積を形成する。 A contact mark 37 d is formed in a portion of the coil end portion 37 that is in contact with the electrode 63. The contact mark 37 d is a surface corresponding to the surface shape of the electrode 63. In the illustrated example, the contact mark 37d is a flat surface. The contact mark 37 d is formed on the strip portion 38. When the coil end portion 37 and the protrusion 55 are in a desirable contact state, the extending direction of the strip portion 38 and the extending direction of the protrusion 55 are orthogonal to each other. When this desirable contact state is realized, the shape of the contact mark 37d is a cross or rhombus extending in the extending direction of the coil end portion 37 and the extending direction of the protrusion 55. The coil end portion 37 is deformed along the protrusion 55 around the contact mark 37d. The coil end portion 37 provides a wide portion that extends along the extending direction of the protrusion 55. The wide portion forms a wide contact area between the coil end portion 37 and the protrusion 55.
　（他の実施形態）
　この明細書の開示は、例示された実施形態に制限されない。開示は、例示された実施形態と、それらに基づく当業者による変形態様を包含する。例えば、開示は、実施形態において示された部品および／または要素の組み合わせに限定されない。開示は、多様な組み合わせによって実施可能である。開示は、実施形態に追加可能な追加的な部分をもつことができる。開示は、実施形態の部品および／または要素が省略されたものを包含する。開示は、ひとつの実施形態と他の実施形態との間における部品および／または要素の置き換え、または組み合わせを包含する。開示される技術的範囲は、実施形態の記載に限定されない。開示されるいくつかの技術的範囲は、請求の範囲の記載によって示され、さらに請求の範囲の記載と均等の意味及び範囲内での全ての変更を含むものと解されるべきである。 (Other embodiments)
The disclosure of this specification is not limited to the illustrated embodiments. The disclosure encompasses the illustrated embodiments and variations by those skilled in the art based thereon. For example, the disclosure is not limited to the combinations of parts and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure may have additional parts that can be added to the embodiments. The disclosure includes those in which parts and / or elements of the embodiments are omitted. The disclosure encompasses the replacement or combination of parts and / or elements between one embodiment and another. The technical scope disclosed is not limited to the description of the embodiments. Some technical scope disclosed is shown by the description of the scope of claims, and should be understood to include all modifications within the meaning and scope equivalent to the description of the scope of claims.
　例えば、上記実施形態では、突条５５は、凹溝５４を形成するプレス加工によって形成されている。これに代えて、凹溝５４なしで突条５５を形成してもよい。また、突条５５は、半円断面、三角断面、台形断面など多様な断面形状を採用することができる。 For example, in the above-described embodiment, the protrusion 55 is formed by press working for forming the groove 54. Instead, the protrusion 55 may be formed without the concave groove 54. The protrusion 55 can employ various cross-sectional shapes such as a semicircular cross-section, a triangular cross-section, and a trapezoidal cross-section.
　上記実施形態では、接続部５２の径方向外側にコイル端部３７を配置した。これに代えて、接続部５２の径方向内側にコイル端部３７を配置してもよい。この場合、突条５５は、径方向内側に向けて突出する形状を与えられる。この場合も、突条の突出軸は、径方向である。 In the above embodiment, the coil end portion 37 is disposed outside the connecting portion 52 in the radial direction. Instead of this, the coil end portion 37 may be disposed on the radially inner side of the connecting portion 52. In this case, the protrusion 55 is given a shape that protrudes radially inward. Also in this case, the protruding shaft of the protrusion is in the radial direction.
　上記実施形態では、コイルを形成する導線はアルミ製である。これに代えて、銅製の導線を使用してもよい。 In the above embodiment, the conductive wire forming the coil is made of aluminum. Instead of this, a copper conducting wire may be used.
　上記実施形態では、同じ相に２つのコイルを配置した。これに代えて、同じ相に３つ以上のコイルを配置してもよい。さらに、上記実施形態では、すべてのコイルをひとつの三相結線に組み込んでいる。これに代えて、複数の三相結線を形成してもよい。 In the above embodiment, two coils are arranged in the same phase. Alternatively, three or more coils may be arranged in the same phase. Furthermore, in the said embodiment, all the coils are integrated in one three-phase connection. Instead of this, a plurality of three-phase connections may be formed.
　上記実施形態では、ひとつの接続部５２に２つのコイル端部３７を接続している。これに代えて、ひとつの接続部５２とひとつのコイル端部３７とを接続してもよい。また、ひとつの接続部５２と３つ以上のコイル端部３７とを接続してもよい。 In the above embodiment, two coil end portions 37 are connected to one connection portion 52. Instead of this, one connecting portion 52 and one coil end portion 37 may be connected. Further, one connecting portion 52 and three or more coil end portions 37 may be connected.
　上記実施形態では、接続部５２は、径方向に面する板状である。これに代えて、接続部５２を９０度ひねってもよい。この場合、接続部は、周方向に面する板状である。この場合でも、複数の接続部は、周方向に沿って配置される。上記実施形態では、接続部５２は平板状である。これに代えて、接続部５２は、湾曲した板でもよい。さらに、端子５１の全体が、ステータ３１の周方向に沿って湾曲していてもよい。 In the above embodiment, the connection portion 52 has a plate shape facing the radial direction. Instead, the connecting portion 52 may be twisted 90 degrees. In this case, the connecting portion has a plate shape facing the circumferential direction. Even in this case, the plurality of connecting portions are arranged along the circumferential direction. In the said embodiment, the connection part 52 is flat form. Alternatively, the connecting portion 52 may be a curved plate. Further, the entire terminal 51 may be curved along the circumferential direction of the stator 31.
　上記実施形態では、ステータ３１のボディ１３側の端面に端子５１を設けている。端子５１は、ステータ３１のどちらか一方の端面または両面に設けることができる。例えば、端子５１は、ロータ２１に面する端面に設けられてもよい。 In the above embodiment, the terminal 51 is provided on the end surface of the stator 31 on the body 13 side. The terminal 51 can be provided on one end surface or both surfaces of the stator 31. For example, the terminal 51 may be provided on an end surface facing the rotor 21.
　上記実施形態では、コイル端部３７の先端にストリップ部分３８を形成した。これに代えて、ストリップ部分３８を形成することなく、絶縁皮膜を付けたままで、コイル端部３７と接続部５２とをプロジェクション溶接してもよい。この場合、プロジェクション溶接によって絶縁皮膜を破ることができる。 In the above embodiment, the strip portion 38 is formed at the tip of the coil end portion 37. Alternatively, the coil end portion 37 and the connection portion 52 may be projection welded without forming the strip portion 38 and with the insulating film attached. In this case, the insulating film can be broken by projection welding.
　上記実施形態では、コイル端部３７は、ステータ３１上においてＬ字型である。コイル端部３７は、逆方向を指向するＬ字型でもよい。また、複数のコイル端部３７は、同方向のＬ字型である。これに代えて、例えば、少なくともひとつのコイル端部３７をＬ字型とし、残るコイル端部３７を逆方向のＬ字型としてもよい。このようなコイル端部３７の形状は、コイル端部３７と接続部５２との多様な配置を可能とする。例えば、ステータ３１上における他の部品を避けるコイル端部３７の配置を可能とする。 In the above embodiment, the coil end portion 37 is L-shaped on the stator 31. The coil end portion 37 may be L-shaped in the reverse direction. The plurality of coil end portions 37 are L-shaped in the same direction. Alternatively, for example, at least one coil end 37 may be L-shaped, and the remaining coil end 37 may be L-shaped in the reverse direction. Such a shape of the coil end portion 37 enables various arrangements of the coil end portion 37 and the connection portion 52. For example, it is possible to arrange the coil end portion 37 that avoids other components on the stator 31.
　上記実施形態では、端子５１は、複数のコイル端部３７および電力線４１１ａと電気的に接続されている。これに加えて、端子５１は、他の部材と電気的に接続されてもよい。例えば、中性点ＮＴを地絡する場合、端子５１はステータコア３２と電気的に接続される。端子５１とステータコア３２とは、直接的な接触により、および／または電線などを介して電気的に接続される。 In the above embodiment, the terminal 51 is electrically connected to the plurality of coil end portions 37 and the power line 411a. In addition to this, the terminal 51 may be electrically connected to other members. For example, when grounding the neutral point NT, the terminal 51 is electrically connected to the stator core 32. Terminal 51 and stator core 32 are electrically connected by direct contact and / or via an electric wire or the like.
　上記実施形態では、インシュレータ３５に端子５１を圧入することによって端子５１を固定している。これに代えて、インシュレータ３５を樹脂成形する工程において、端子５１をインサート成形してもよい。 In the above embodiment, the terminal 51 is fixed by press-fitting the terminal 51 into the insulator 35. Instead of this, the terminal 51 may be insert-molded in the step of resin-molding the insulator 35.
　上記実施形態では、ステータコア３２とインシュレータ３５とは別体の部品である。これに代えて、ステータコア３２とインシュレータ３５とを一体化してもよい。例えば、ステータコア３２をインシュレータ３５の中にインサート成形してもよい。また、上記実施形態では、端子台４１を提供するインシュレータ３５は、ステータコイル３３のためのボビンを提供している。これに代えて、端子台４１を提供するインシュレータと、ボビンを提供するインシュレータとを別部品としてもよい。例えば、端子台４１の部分だけを別部品として、ステータ３１上に装着可能に構成してもよい。 In the above embodiment, the stator core 32 and the insulator 35 are separate parts. Instead of this, the stator core 32 and the insulator 35 may be integrated. For example, the stator core 32 may be insert-molded in the insulator 35. In the above embodiment, the insulator 35 that provides the terminal block 41 provides a bobbin for the stator coil 33. Instead of this, the insulator that provides the terminal block 41 and the insulator that provides the bobbin may be separate components. For example, only the portion of the terminal block 41 may be configured as a separate part so that it can be mounted on the stator 31.
　上記実施形態では、ロータ２１は、回転軸１４の端部からボディ１３側に覆いかぶさるようなカップ形状である。これに代えて、回転軸の端部に向けて開いたカップ形状のロータを用いてもよい。この場合、ステータ３１は、ボディ１３としてのカバー部材に装着される場合がある。上記実施形態では、回転電機１０は、いわゆるアウタロータ型である。これに代えて、回転電機１０は、インナロータ型であってもよい。インナロータ型であっても、端子５１を利用することができる。 In the above embodiment, the rotor 21 has a cup shape that covers the body 13 from the end of the rotating shaft 14. Instead, a cup-shaped rotor opened toward the end of the rotating shaft may be used. In this case, the stator 31 may be attached to a cover member as the body 13. In the above embodiment, the rotating electrical machine 10 is a so-called outer rotor type. Instead of this, the rotating electrical machine 10 may be an inner rotor type. Even in the inner rotor type, the terminal 51 can be used.
　上記実施形態では、回転電機１０は、発電機を提供する。これに代えて、回転電機１０は、特許文献２に開示される交流発電機スタータ（AC Generator Starter）として構成されてもよい。回転電機１０が交流発電機スタータとして構成される場合、特許文献２に記載の内容を援用することができ、同記載の内容は参照により引用される。 In the above embodiment, the rotating electrical machine 10 provides a generator. Instead of this, the rotating electrical machine 10 may be configured as an AC generator starter disclosed in Patent Document 2. When the rotating electrical machine 10 is configured as an AC generator starter, the contents described in Patent Document 2 can be incorporated, and the contents described therein are cited by reference.
　１０　内燃機関用回転電機、１１　負荷、１１ａ　電力線、
　１２　内燃機関、１３　ボディ、１４　回転軸、
　２１　ロータ、２２　ロータコア、２３　永久磁石、２４　保持カップ、
　３１　ステータ、３２　ステータコア、３３　ステータコイル、
　３５　インシュレータ、３７　コイル端部、３８　ストリップ部分、
　４１　端子台、４２　端面、４３　側壁、４４　側壁、４５　スリット、
　４７　保持部、４８　保持部、
　５１　端子、５２、３５２　接続部、５３　ベース部分、
　５４　凹溝、５５　突条、５６　先端縁、５７、５５７　連結部、
　２５８　挿入片、５９　保護材、
　６１　溶接機、６２　電極、６３　電極、６５　移動装置。 10 rotating electrical machine for internal combustion engine, 11 load, 11a power line,
12 internal combustion engine, 13 body, 14 rotating shaft,
21 rotor, 22 rotor core, 23 permanent magnet, 24 holding cup,
31 Stator, 32 Stator core, 33 Stator coil,
35 insulator, 37 coil end, 38 strip part,
41 terminal block, 42 end face, 43 side wall, 44 side wall, 45 slit,
47 holding part, 48 holding part,
51 terminal, 52, 352 connection part, 53 base part,
54 concave groove, 55 ridge, 56 tip edge, 57, 557 connecting portion,
258 insert piece, 59 protective material,
61 welding machine, 62 electrodes, 63 electrodes, 65 moving device.

Claims (18)

  1. 　ステータコア（３２）、前記ステータコアに装着されたインシュレータ（３５）、および前記ステータコアに装着されたステータコイル（３３）を備える内燃機関用回転電機のステータにおいて、
    　前記ステータの一方の端面において前記インシュレータに固定された端子（５１）と、
    　前記ステータコイルから延び出し、前記端子に接続される複数のコイル端部（３７）とを備え、
    　前記端子は、前記インシュレータの端面（４２）から突出するように配置され、周方向に沿って配置された複数の接続部（５２、３５２）を有し、
    　複数の前記コイル端部は、複数の前記接続部に分配されて対応付けられており、
    　複数の前記接続部のそれぞれは、前記ステータの軸方向に沿って延びる突条（５５）を有しており、
    　複数の前記接続部のそれぞれは、それに対応付けられた前記コイル端部であって前記突条と交差するように配置された前記コイル端部と、前記突条の頂部において、プロジェクション溶接によって接続されている内燃機関用回転電機のステータ。     In a stator of a rotating electrical machine for an internal combustion engine comprising a stator core (32), an insulator (35) attached to the stator core, and a stator coil (33) attached to the stator core,
    A terminal (51) fixed to the insulator at one end face of the stator;
    A plurality of coil ends (37) extending from the stator coil and connected to the terminals;
    The terminal is disposed so as to protrude from the end face (42) of the insulator, and has a plurality of connecting portions (52, 352) disposed along the circumferential direction,
    The plurality of coil end portions are distributed and associated with the plurality of connection portions,
    Each of the plurality of connection portions has a protrusion (55) extending along the axial direction of the stator,
    Each of the plurality of connection portions is connected by projection welding at the coil end portion corresponding to the coil end portion, which is disposed so as to intersect the protrusions, and at the top of the protrusions. A stator of a rotating electrical machine for an internal combustion engine.
  2. 　複数の前記接続部のそれぞれは、それに対応付けられた２つ以上の前記コイル端部と接続されている請求項１に記載の内燃機関用回転電機のステータ。 2. The stator of a rotating electrical machine for an internal combustion engine according to claim 1, wherein each of the plurality of connection portions is connected to two or more coil end portions associated with the connection portions.
  3. 　ステータコア（３２）、前記ステータコアに装着されたインシュレータ（３５）、および前記ステータコアに装着されたステータコイル（３３）を備える内燃機関用回転電機のステータにおいて、
    　前記ステータの一方の端面において前記インシュレータに固定された端子（５１）と、
    　前記ステータコイルから延び出し、前記端子に接続される複数のコイル端部（３７）とを備え、
    　前記端子は、前記インシュレータの端面（４２）から突出するように配置された接続部（５２、３５２）を有し、
    　前記接続部は、前記ステータの軸方向に沿って延びる突条（５５）を有しており、
    　前記接続部は、前記突条と交差するように配置された複数の前記コイル端部と、前記突条の頂部において、プロジェクション溶接によって接続されている内燃機関用回転電機のステータ。     In a stator of a rotating electrical machine for an internal combustion engine comprising a stator core (32), an insulator (35) attached to the stator core, and a stator coil (33) attached to the stator core,
    A terminal (51) fixed to the insulator at one end face of the stator;
    A plurality of coil ends (37) extending from the stator coil and connected to the terminals;
    The terminal has a connecting portion (52, 352) arranged so as to protrude from the end face (42) of the insulator,
    The connection portion has a ridge (55) extending along the axial direction of the stator,
    The connection part is a stator of a rotating electrical machine for an internal combustion engine, which is connected by projection welding at a plurality of the coil end parts arranged so as to intersect the protrusions and at the top part of the protrusions.
  4. 　ひとつの前記接続部に接続される複数の前記コイル端部は、前記ステータの軸方向に沿って積層して配置されている請求項２または請求項３に記載の内燃機関用回転電機のステータ。 The stator of the rotating electrical machine for an internal combustion engine according to claim 2 or 3, wherein a plurality of the coil end portions connected to the one connection portion are stacked along the axial direction of the stator.
  5. 　前記端子は、複数の前記接続部を接続しており、前記インシュレータに収容された連結部（５７、５５７）を備える請求項１から請求項４のいずれかに記載の内燃機関用回転電機のステータ。 The stator of the rotating electrical machine for an internal combustion engine according to any one of claims 1 to 4, wherein the terminal is connected to a plurality of the connecting portions and includes connecting portions (57, 557) accommodated in the insulator. .
  6. 　前記連結部（５７）は、前記ステータの周方向に沿って曲がっている板である請求項５に記載の内燃機関用回転電機のステータ。 The stator of a rotating electrical machine for an internal combustion engine according to claim 5, wherein the connecting portion (57) is a plate bent along the circumferential direction of the stator.
  7. 　前記連結部（５５７）は、前記ステータの周方向に対する弦に沿って広がっている平板である請求項５に記載の内燃機関用回転電機のステータ。 The stator of a rotating electrical machine for an internal combustion engine according to claim 5, wherein the connecting portion (557) is a flat plate extending along a string with respect to a circumferential direction of the stator.
  8. 　前記接続部と前記コイル端部とを含む複数の接続構造が、前記ステータの端面の上に、前記ステータの周方向に沿って配置されている請求項１から請求項７のいずれかに記載の内燃機関用回転電機のステータ。 The several connection structure containing the said connection part and the said coil edge part is arrange | positioned along the circumferential direction of the said stator on the end surface of the said stator. A stator of a rotating electrical machine for an internal combustion engine.
  9. 　前記コイル端部は、前記接続部の径方向外側に配置されている請求項１から請求項８のいずれかに記載の内燃機関用回転電機のステータ。 The stator of the rotating electrical machine for an internal combustion engine according to any one of claims 1 to 8, wherein the coil end portion is disposed on a radially outer side of the connection portion.
  10. 　前記コイル端部は、前記接続部に巻き付くように配置されている請求項１から請求項９のいずれかに記載の内燃機関用回転電機のステータ。 The stator of the rotating electrical machine for an internal combustion engine according to any one of claims 1 to 9, wherein the coil end portion is disposed so as to be wound around the connection portion.
  11. 　前記インシュレータは、前記ステータコイルと前記接続部との間において、前記コイル端部を保持する保持部（４７、４８）を備える請求項１から請求項１０のいずれかに記載の内燃機関用回転電機のステータ。 The rotating electrical machine for an internal combustion engine according to any one of claims 1 to 10, wherein the insulator includes a holding portion (47, 48) that holds the coil end portion between the stator coil and the connection portion. Stator.
  12. 　前記コイル端部は、前記保持部においてＬ字型に曲げられている請求項１１に記載の内燃機関用回転電機のステータ。 The stator of a rotating electrical machine for an internal combustion engine according to claim 11, wherein the coil end portion is bent in an L shape at the holding portion.
  13. 　前記インシュレータは、前記端面を囲む側壁（４３、４４）を有する端子台（４１）を備える請求項１から請求項１２のいずれかに記載の内燃機関用回転電機のステータ。 The stator for a rotating electrical machine for an internal combustion engine according to any one of claims 1 to 12, wherein the insulator includes a terminal block (41) having side walls (43, 44) surrounding the end face.
  14. 　さらに、前記接続部および前記コイル端部の少なくとも一部を覆い、前記接続部および前記コイル端部の一部を保護する保護材（５９）を備える請求項１から請求項１３のいずれかに記載の内燃機関用回転電機のステータ。 Furthermore, the protective part (59) which covers at least one part of the said connection part and the said coil edge part, and protects a part of the said connection part and the said coil edge part is provided in any one of Claims 1-13. Of a rotating electrical machine for an internal combustion engine.
  15. 　前記接続部は、前記ステータの径方向に面する板状である請求項１から請求項１４のいずれかに記載の内燃機関用回転電機のステータ。 The stator of a rotating electrical machine for an internal combustion engine according to any one of claims 1 to 14, wherein the connection portion has a plate shape facing the radial direction of the stator.
  16. 　複数の前記コイル端部および前記端子は、前記ステータコイルの中性点（ＮＴ）を提供する請求項１から請求項１５のいずれかに記載の内燃機関用回転電機のステータ。 The stator of the rotating electrical machine for an internal combustion engine according to any one of claims 1 to 15, wherein the plurality of coil end portions and the terminals provide a neutral point (NT) of the stator coil.
  17. 　前記コイル端部はアルミニウム製またはアルミニウム合金製である請求項１から請求項１６のいずれかに記載の内燃機関用回転電機のステータ。 The stator of a rotating electrical machine for an internal combustion engine according to any one of claims 1 to 16, wherein the coil end portion is made of aluminum or aluminum alloy.
  18. 　請求項１から請求項１７のいずれかに記載の内燃機関用回転電機のステータと、
    　前記ステータと対向して配置されたロータとを備える内燃機関用回転電機。     A stator of a rotating electrical machine for an internal combustion engine according to any one of claims 1 to 17,
    A rotating electrical machine for an internal combustion engine comprising a rotor disposed opposite to the stator.
PCT/JP2016/002561 2015-06-05 2016-05-27 Dynamo-electric machine for internal combustion engine, and stator of said machine WO2016194347A1 (en)

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