JP6733682B2 - Rotating electric machine, manufacturing method of rotating electric machine, coil unit - Google Patents

Description

The disclosed embodiments relate to a rotary electric machine, a method for manufacturing a rotary electric machine, and a coil unit.

Non-Patent Document 1 and Non-Patent Document 2 describe a technique of suppressing the occurrence of partial discharge by increasing the thickness of the coil coating to ensure the insulation of the coil.

Daisuke Muto, 3 others, "Study on Partial Discharge Phenomena of Winding", Furukawa Electric Jikkan, Furukawa Electric Co., Ltd., February 2014, No. 133, p. 11-18 Satoshi Takasaki and 5 others, "Development of Motor Stator for Small Hybrid Vehicles", Pre-Academic Lecture Collection, Automotive Engineering Society, May 2012, No. 58-12, p. 5-8

In the above-mentioned conventional technique, the coil coating is thickened, so that the space factor of the conductor is reduced.

The present invention has been made in view of these problems, and an object thereof is to provide a rotating electric machine, a method for manufacturing a rotating electric machine, and a coil unit that can suppress the occurrence of partial discharge without lowering the conductor space factor. And

In order to solve the above problems, according to one aspect of the present invention, a stator core including a tooth portion, a coil unit that is mounted on the tooth portion, and includes a conductor and a resin portion, and The coil unit is a rotary electric machine in which at least one surface of the plurality of surfaces facing the teeth portion is composed of the resin portion and the conductive wire, and the coil unit faces the teeth portion of the coil unit. The conductor wire forming at least one surface has two adjacent flat portions, and the at least one surface facing the teeth portion has the resin portion interposed between the two flat portions. A rotary electric machine having the above-described structure and having a flat surface of the intervening resin portion and the flat portion are substantially flush with each other is applied.

According to another aspect of the present invention, the cross-sectional shape of the conductive wire is deformed by pressurization to form the outer shape of the air-core coil into a predetermined shape, and a plurality of surfaces on the inner peripheral side of the air-core coil are formed. At least one of the surfaces is composed of a resin portion and the conductive wire, and the conductive wire forming the at least one surface on the inner peripheral side has two flat portions adjacent to each other. The at least one surface on the side is configured such that the resin portion is interposed between the two flat portions, and the flat surface of the interposed resin portion and the flat portion are substantially flush with each other. to so that is formed to be, the air has a forming a coil unit core coil hardened with a resin, and the method comprising mounting the coil unit to the tooth portions of the stator core, a manufacturing method of a rotating electric machine Is applied.

Further, according to still another aspect of the present invention, it has a conductor wire wound in an annular shape, and an annular resin portion obtained by hardening the conductor wire, and at least one surface among a plurality of inner peripheral surfaces. Is composed of the resin portion and the conductive wire, and the conductive wire forming the at least one surface on the inner peripheral side has two flat portions adjacent to each other, and at least the inner peripheral surface side. One surface is configured such that the resin portion is interposed between the two flat portions, and the flat surface of the resin portion that is interposed is substantially flush with the flat portion. The coil unit is applied.

Further, according to still another aspect of the present invention, a stator core including a tooth portion, a coil unit mounted on the tooth portion and provided with a conductor and a resin portion, and the tooth portion of the coil unit facing each other. A rotating electrical machine having at least one of a plurality of surfaces formed by the resin portion and the means configured by the conductive wire is applied.

According to the rotating electric machine and the like of the present invention, the occurrence of partial discharge can be suppressed without lowering the conductor space factor.

It is an axial sectional view showing an example of the whole composition of the rotary electric machine of a 1st embodiment. It is a radial direction sectional drawing by the AA cross section in FIG. It is a perspective view showing an example of the external appearance composition of a coil unit. It is a flowchart showing an example of a manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the 1st process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the 2nd process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the 2nd process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the 2nd process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the 2nd process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the 2nd process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the insulator mounting process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the coil unit arrangement|sequence process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the connection process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the load bracket mounting process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the split core mounting process of the manufacturing method of a rotary electric machine. It is explanatory drawing showing an example of the frame mounting process of the manufacturing method of a rotary electric machine. It is explanatory drawing which shows and compares the partial discharge starting voltage of the coil unit of 1st Embodiment, and the coil of a comparative example. It is a perspective view showing an example of the appearance composition of the annular coil body in the modification which carries out resin molding of a plurality of air core coil parts. It is a perspective view showing an example of appearance composition of a coil unit in a modification which constitutes a resin part with two kinds of resin. It is an axial sectional view showing an example of the whole composition of a rotary electric machine and the composition of a coil unit in the modification which arranges a coil unit by a distributed winding method. It is an axial sectional view showing an example of the whole composition of the rotary electric machine of a 2nd embodiment. It is explanatory drawing showing an example of the cover member mounting process of the manufacturing method of a rotary electric machine. FIG. 11 is an axial cross-sectional view showing an example of the overall configuration of a rotating electric machine in a modification in which the cover member contacts the load side bracket and the frame.

<1. First Embodiment>
Hereinafter, the first embodiment will be described with reference to the drawings. In the following, for convenience of description of the configuration of the rotary electric machine or the like, directions such as up, down, left, and right may be used as appropriate, but the positional relationship of each configuration of the rotary electric machine or the like is not limited.

(1-1. Example of overall configuration of rotating electric machine)
First, an example of the overall configuration of the rotary electric machine according to the first embodiment will be described with reference to FIGS. 1 and 2.

The rotary electric machine 1 is used as a rotary motor or a generator. As shown in FIGS. 1 and 2, a rotary electric machine 1 includes a rotor 2 including a shaft 10, a stator 3, a frame 5, a load side bracket 6 (corresponding to an example of a bracket), and a load side bearing. 7, a counter-load side bracket 8, and a counter-load side bearing 9.

In the present specification, the direction along the rotation axis AX of the shaft 10 (rotor 2) (the left-right direction in FIG. 1) is the “axial direction”, and the radial direction around the rotation axis AX is the “radial direction”. The direction along the circumference centered on the rotation axis AX is referred to as “circumferential direction”. Further, in the present specification, the “load side” refers to the side on which the load is attached to the rotating electric machine 1, that is, the side where the shaft 10 projects (the right side in FIG. 1) in this example, and the “anti-load side”. Means the side opposite to the load side (left side in FIG. 1).

The frame 5 has a substantially cylindrical shape, and the stator 3 is fixed to the inner peripheral portion 5a. The load-side bracket 6 is provided at the load-side end of the frame 5 (corresponding to an example of the axial end). The counter-load side bracket 8 is provided at the counter-load side end of the frame 5. The anti-load side bracket 8 and the frame 5 are fixed to the load side bracket 6 by bolts (not shown).

The load side bearing 7 is provided on the load side bracket 6. The anti-load side bearing 9 is provided on the anti-load side bracket 8. The shaft 10 is supported by a load side bearing 7 and an anti-load side bearing 9 so as to be rotatable around a rotation axis AX. An encoder 12 that detects the rotational position of the rotor 2 is provided on the counter load side of the shaft 10. The load side bracket 6 is provided with a dust seal 11 on the load side of the load side bearing 7 in order to prevent foreign matter from entering the inside of the rotary electric machine 1.

The rotor 2 is fixed to the outer circumference of the shaft 10. The rotor 2 has a substantially cylindrical rotor core 14 having an inner peripheral portion 13, and a plurality of (10 poles in this example) permanent magnets 15 embedded in the rotor core 14 in a V-shape for each pole. And. The shaft 10 is fitted to the inner peripheral portion 13 of the rotor core 14.

The stator 3 is fixed to the inner peripheral portion 5a of the frame 5 so as to surround the outer side of the rotor 2 in the radial direction with a magnetic gap. The stator 3 has a substantially annular stator core 22 in which a plurality of slots 12 (12 in this example) are arranged over the entire circumference in the circumferential direction, and a plurality of slots 21 housed in the slots 21 in a concentrated winding manner (this In the example, the coil unit 30 of 12) is included. On the anti-load side of the stator 3, there is arranged a connecting portion 16 in which the end portions 31a and 31b of the plurality of coil units 30 (see FIG. 3, which will be described later, details will be described later) are connected in a predetermined connecting pattern. ing. An external power source (not shown) is connected to the connection portion 16 via a lead wire (not shown), and power is supplied from the external power source to the coil unit 30 via the lead wire and the connection portion 16.

In the stator core 22, a plurality of (12 in this example) split cores (also referred to as “iron core pieces”) 23 are arranged along the inner peripheral portion 5a of the frame 5 over the entire circumference in the circumferential direction, It is formed in a ring shape. Each of the split cores 23 has a substantially T-shaped radial cross-sectional shape in this example, and includes a tooth portion 24 having a substantially rectangular radial cross-sectional shape inside the radial direction. The slot 21 is formed between the tooth portions 24, 24 of the split cores 23, 23 adjacent to each other in the circumferential direction. The circumferential dimension of each tooth portion 24 is substantially equal along the radial direction in this example, and each slot 21 is open toward the inner circumferential side in this example. Therefore, the coil unit 30 can be provided with a large occupied area up to the inner peripheral surface substantially the same as the stator core 22, and the resistance can be reduced by using the thicker conductive wire 31 (details will be described later) to reduce heat generation. .. In this example, each slot 21 has a substantially trapezoidal radial cross-sectional shape that narrows inward in the radial direction, and includes one region 21a on one side in the circumferential direction and another region 21b on the other side in the circumferential direction.

Each of the coil units 30 is housed in the slot 21 so that the coil unit 30 is mounted on the tooth portion 24. Specifically, each coil unit 30 includes one of the slots 21 and 21 adjacent to each other in the circumferential direction, the other side region 21b of the slot 21 located on one side in the circumferential direction and one of the slots 21 located on the other side in the circumferential direction. It is mounted on one tooth portion 24 by being accommodated across the side region 21a. That is, the plurality of coil units 30 are individually mounted for each tooth portion 24. Each coil unit 30 has an insulator 18 (of an insulating material) made of an appropriate insulating material (for example, polyester) in order to ensure insulation between the surface of the coil unit 30 and the contact portion of the split core 23 that contacts the surface. Equivalent to an example) is installed. It should be noted that the insulator 18 is not shown in FIG. 1.

By fitting the load-side coil end portions 38a (details will be described later) of the plurality of coil units 30 into the substantially conical recess 6b inside the annular mounting portion 6a provided on the load-side bracket 6, The coil unit 30 is attached to the load side bracket 6. At this time, the axially outer surface 38a2 (details will be described later) of the load-side coil end portions 38a of the plurality of coil units 30 are provided with the recesses via the insulator 19 made of an appropriate insulating material (for example, polyester). It is in close contact with the inner wall surface 6b1 of 6b. That is, the insulator 19 is interposed between the load side coil end portions 38 a of the plurality of coil units 30 and the load side bracket 6. The axially outer surface 38a2 of the load-side coil end portions 38a of the plurality of coil units 30 may be directly attached to the inner wall surface 6b1 of the recess 6b. By closely contacting the load-side coil end portion 38a of the coil unit 30 with the load-side bracket 6, heat conduction from the load-side coil end portion 38a of the coil unit 30 to the load-side bracket 6 can be improved. As a result, it becomes possible to flow a larger load current with respect to the allowable temperature of the coil unit 30, and the rated output can be improved.

Note that the above is an example, and the configuration of the rotary electric machine 1 is not limited to the examples shown in FIGS. 1 and 2. For example, in the rotor 2, the permanent magnets 15 may be radially embedded in the rotor core 14, or the permanent magnets 15 may be fixed to the outer peripheral surface of the rotor core 14. Further, the teeth portion 24 of the stator 3 may have an inner peripheral side tip end connected in a cylindrical shape. In addition, the stator core 22 may be integrally configured instead of being composed of a plurality of split cores. Further, the slot 21 may have a radial cross-sectional shape with circumferentially substantially equal dimensions in the radial direction. Further, the rotary electric machine 1 may be a slot combination other than the 10 poles and 12 slots shown in FIG.

(1-2. Example of configuration of coil unit)
Generally, in a coil used in a rotating electric machine, partial discharge occurs in a gap between conductors, which causes a dielectric breakdown. Therefore, it is preferable to raise the partial discharge start voltage as high as possible according to the required breakdown voltage. Temporarily, it is possible to increase the partial discharge inception voltage by thickening the film of the conducting wire, but in this case, the conductor space factor decreases, which causes an increase in winding resistance. In addition, there is a possibility that the heat dissipation may be reduced and the cost of the conductive wire may be increased.

Therefore, in the present embodiment, the coil unit 30 is configured to fill the voids between the conductors with resin to reduce the voids. Hereinafter, an example of a detailed configuration of the coil unit 30 will be described with reference to FIGS. 2 and 3.

As shown in FIGS. 2 and 3, in this example, the coil unit 30 is formed in a substantially rectangular frame shape, and has a hollow portion 30a into which the tooth portion 24 is inserted, two coil side portions 37a and 37b, and a load. A side coil end portion 38a and an anti-load side coil end portion 38b are provided. The coil side portion 37a is housed in the other side region 21b of the slot 21 which extends along the axial direction and is located on one circumferential side of the adjacent slots 21 and 21. The coil side portion 37b is accommodated in the one side region 21a of the slot 21 extending along the axial direction and located on the other circumferential side of the adjacent slots 21 and 21. The load side coil end portion 38a extends between the coil side portions 37a and 37b so as to connect the load side end portions of the coil side portions 37a and 37b on the load side with respect to the stator core 22. The anti-load side coil end portion 38b extends between the coil side portions 37a, 37b so as to connect the anti-load side end portions of the coil side portions 37a, 37b on the anti-load side of the stator core 22.

The coil unit 30 includes a substantially annular air-core coil portion 35 (corresponding to an example of an air-core coil) formed by a conductive wire 31 having a substantially circular cross section (round wire) before pressure molding, and an air core. And a substantially annular resin portion 36 obtained by solidifying and molding the coil portion 35. The coil unit is also called a molded coil. The conductive wire 31 is insulated from a linear conductor 32 made of an appropriate conductive material (eg, copper) and an insulating film 33 made of an appropriate insulating material (eg, enamel) that covers the conductor 32. And a fusible coating 34 made of an appropriate fusible material (for example, nylon) for covering the coating (see enlarged view in FIG. 5 described later). One end (for example, the winding start side) of the conductor 31 and the other end (for example, the end of the winding) 31b project from the anti-load side coil end portion 38b to the anti-load side.

In the air-core coil portion 35, the conductive wire 31 is wound in a substantially annular shape a plurality of times, and is pressure-molded so that the outer shape has a predetermined shape. The cross-sectional shape of each conducting wire 31 is plastically deformed into an arbitrary shape (for example, a substantially quadrangular shape, a substantially pentagonal shape, a substantially hexagonal shape, a substantially circular shape, etc.) by applying pressure. The air-core coil portion 35 is formed by melting the fusion coating 34 of the conductive wire 31 and adhering the adjacent conductors 32 to each other from the insulating coating 33 by fusion of the fusion coating 34. The outer shape of the portion of the air-core coil portion 35 corresponding to the coil side portion 37a is formed into a shape that substantially matches the inner shape of the other side region 21b, and the outer shape of the portion corresponding to the coil side portion 37b is formed. It is formed in a shape that substantially matches the inner shape of the one side region 21a. Further, the outer shape of the portion corresponding to the load side coil end portion 38a is formed in a shape that substantially matches the inner shape of the recess 6b of the load side bracket 6.

Of the surface of the coil unit 30, two circumferentially inner surfaces 37a1 and 37b1 circumferentially opposed to the teeth portion 24 inserted into the hollow portion 30a are composed of a resin portion 36 and a conductor wire 31. There is. Specifically, the conductors 31 forming the surfaces 37a1 and 37b1 on the inner side in the circumferential direction are flattened by the above-mentioned pressing of the conductors 31 (8 layers in the illustrated example) laminated on the inner side in the circumferential direction of the air-core coil portion 35. The flat portion 310 is plastically deformed. The flat portion 310 of the conductive wire 31 is not limited to the case where the entire surface exposed from the resin portion 36 is flat, and includes the case where at least a part of the exposed surface is flat. That is, on the circumferentially inner surfaces 37a1 and 37b1, the flat portions 310 of the conducting wire 31 are exposed at a plurality of locations, and the resin portion 36 is interposed between two adjacent flat portions 310. Surfaces 37a1 and 37b1 on the inner side in the circumferential direction are opposed surfaces on the inner peripheral side of the coil side portions 37a and 37b. Note that, as shown in the figure, the flat portion 310 of the conductor wire 31 (8 layers in the illustrated example) laminated on the inner side in the circumferential direction of the air-core coil portion 35 is not entirely exposed, but may be partially exposed. Good. Further, one of the surfaces 37a1 and 37b1 on the inner side in the circumferential direction may be composed of only the resin portion 36.

The flat portion 310 of the conductive wire 31 is formed not only on the surface of the coil unit 30 but also inside the coil unit 30 by pressure molding. That is, inside the coil unit 30, the flat portions 310 of the adjacent conductors 31 face (contact) each other.

On the other hand, of the surface of the coil unit 30, the two axially inner surfaces 38a1 and 38b1 axially opposed to the teeth portion 24 inserted into the hollow portion 30a are composed of only the resin portion 36. That is, on the axially inner surfaces 38a1 and 38b1, the flat portion 310 of the conductive wire 31 laminated on the axially inner side of the air-core coil portion 35 is not exposed. The surfaces 38a1 and 38b1 on the inner side in the axial direction are opposed surfaces on the inner peripheral side of the coil end portions 38a and 38b. In addition to or instead of at least one of the circumferentially inner surfaces 37a1 and 37b1, at least one of the axially inner surfaces 38a1 and 38b1 is configured by the resin portion 36 and the flat portion 310 of the conductor 31. You may.

Further, of the surface of the coil unit 30, the radially inner surface 30b1 is a flat portion of the resin portion 36 and the conductor wire 31 (two layers in the illustrated example) laminated on the radially inner side of the air-core coil portion 35. And 310. That is, on the radially inner surface 30b1, the flat portions 310 of the conducting wire 31 are exposed at a plurality of locations, and the resin portion 36 is interposed between two adjacent flat portions 310. The radially inner surface 30b1 is composed of the radially inner surfaces of the coil side portions 37a and 37b and the radially inner surfaces of the coil end portions 38a and 38b. Note that, as shown in the drawing, the flat portion 310 of the conductor wire 31 (two layers in the illustrated example) laminated on the inner side in the radial direction of the air-core coil portion 35 is not exposed, but may be partially exposed. Good. Further, all or part of the radially inner surface 30b1 may be configured by only the resin portion 36.

Similarly, of the surfaces of the coil unit 30, the radially outer surface 30b2 of the conductor portion 31 (four layers in the illustrated example) laminated on the resin portion 36 and the air core coil portion 35 on the radially outer side. And a flat portion 310. That is, on the radially outer surface 30b2, the flat portions 310 of the conductive wire 31 are exposed at a plurality of locations, and the resin portion 36 is interposed between two adjacent flat portions 310. The radially outer surface 30b2 is composed of the radially outer surfaces of the coil side portions 37a and 37b and the radially outer surfaces of the coil end portions 38a and 38b. It should be noted that, as shown in the figure, the flat portion 310 of the conductor wire 31 (four layers in the example shown in the figure) laminated on the outside in the radial direction of the air-core coil portion 35 is not entirely exposed, but may be partially exposed. Good. In addition, all or part of the radially outer surface 30b2 may be configured by only the resin portion 36.

Further, of the surfaces of the coil unit 30, the two outer circumferential surfaces 37a2 and 37b2 are composed of only the resin portion 36. That is, on the two circumferentially outer surfaces 37a2 and 37b2, the flat portion 310 of the conductive wire 31 laminated on the circumferentially outer side of the air-core coil portion 35 is not exposed. The two circumferentially outer surfaces 37a2, 37b2 are circumferentially outer surfaces of the coil side portions 37a, 37b. Note that at least one of the two circumferentially outer surfaces 37a2, 37b2 may be configured by the resin portion 36 and the flat portion 310 of the conducting wire 31.

Similarly, of the surfaces of the coil unit 30, the two axially outer surfaces 38a2 and 38b2 are composed of only the resin portion 36. That is, in the two axially outer surfaces 38a2 and 38b2, the flat portion 310 of the conductive wire 31 laminated on the axially outer side of the air-core coil portion 35 is not exposed. The two axially outer surfaces 38a2, 38b2 are the axially outer surfaces of the coil end portions 38a, 38b. Note that at least one of the two axially outer surfaces 38a2, 38b2 may be configured by the resin portion 36 and the flat portion 310 of the conducting wire 31.

Of the surface of the coil unit 30, the surface formed by the resin portion 36 and the flat portion 310 of the conductive wire 31 is formed such that the flat surface of the resin portion 36 and the flat portion 310 of the conductive wire 31 are substantially flush with each other. Has been done. Further, the surface of the resin portion 36 and the flat portion 310 of the conductive wire 31 are substantially flat or curved along the end face shapes of the core pin 40, the die 41, the upper punch 44 and the like, which will be described later, used in the pressure molding. It is formed in a row. In other words, on the surfaces 37a1 and 37b1 on the inner side in the circumferential direction of the coil unit 30, the surface of the resin portion 36 and the flat portion 310 of the conductive wire 31 are formed in a substantially planar shape along the surface of the tooth portion 24 facing each other. ing.

Of the surfaces of the coil unit 30, the insulator 18 covers the circumferentially inner surfaces 37a1 and 37b1, the axially inner surfaces 38a1 and 38b1, the radially inner surface 30b1, and the radially outer surface 30b2. , Is attached to the coil unit 30. The insulator 18 is arranged between the circumferentially inner surfaces 37a1 and 37b1, the axially inner surfaces 38a1 and 38b1, the radially inner surface 30b1 and the radially outer surface 30b2, and the split core 23. It The surface of the coil unit 30 covered by the insulator 18 is not limited to the above surface.

Between the adjacent coil units 30 and 30, the resin portion 36 forming the circumferentially outer surface 37b2 of the coil side portion 37b of the one coil unit 30 housed in the one side region 21a of the slot 21 and the slot. The resin portion 36 constituting the circumferentially outer surface 37a2 of the coil side portion 37a of the other coil unit 30 housed in the other side region 21b of 21 directly contacts. An appropriate insulating material may be interposed between the adjacent coil units 30, 30 so that the coil units 30, 30 do not come into direct contact with each other. In this case, the surfaces 37a2, 37b2 on the outer side in the circumferential direction of the coil unit 30 may also be configured by the resin portion 36 and the flat portion 310 of the conducting wire 31.

Since the surface of the coil unit 30 is configured as described above, the outer dimensions of the coil unit 30 are substantially equal to the outer dimensions of the air-core coil portion 35 excluding the resin portion 36. It should be noted that, of the surfaces of the coil unit 30, which surface is constituted by the resin portion 36 and the flat portion 310 of the conducting wire 31 can be selectively changed according to required specifications.

In the inside of the coil unit 30, the flat portions 310 of the adjacent conductive wires 31 face (contact) with each other as described above, but the conductive wires 31 are not completely in close contact with each other and a gap exists. .. The resin portion 36 is also filled in the gap between the adjacent conductors 31 inside the coil unit 30. As the resin forming the resin portion 36, a resin having a high impregnating property (for example, varnish) is preferable.

The above is an example, and the configuration of the coil unit 30 is not limited to the examples shown in FIGS. 2 and 3.

(1-3. Example of manufacturing method of rotating electric machine)
Next, an example of a method for manufacturing the rotary electric machine 1 will be described with reference to FIGS. 4 to 15.

As shown in FIG. 4, the manufacturing process of the rotary electric machine 1 includes the manufacturing process of the coil unit 30. In the coil unit 30, roughly, the first step of winding the conductive wire 31 to form the air-core coil portion 35 and the outer shape of the wound air-core coil portion 35 are pressure-molded. And a third step of adhering and solidifying the conductors 32 of the air core coil portion 35 whose outer shape is pressure-molded, and a resin molding of the air core coil portion 35 of which the conductors 32 are adhered and solidified. And a fourth step of forming the coil unit 30.

(1-3-1. First step)
First, as the first step, the conducting wire 31 which is a round wire is wound around a winding jig to form the air-core coil portion 35. Specifically, as shown in FIG. 5, the winding upper spacer 42 and the winding lower spacer 43 are fixed to the core pin 40, which is a winding jig that also serves as a pressure molding jig, with a predetermined gap. After that, the core pin 40 is inserted and fixed in a die 41 which is a molding jig, and the conductive wire 31 is wound around the core pin 40 in a substantially annular shape between the winding upper spacer 42 and the winding lower spacer 43, The air core coil portion 35 is formed.

In addition, FIG. 5 also shows the winding sequence and position of the conductive wire 31 when the cross section orthogonal to the axial direction when the coil unit 30 is mounted on the teeth portion 24 is viewed from the anti-load side. The upper side of FIG. 5 corresponds to the radially outer side of the air-core coil portion 35, and the lower side thereof corresponds to the radially inner side of the air-core coil portion 35. The X mark shown on the conducting wire 31 wound around the core pin 40 indicates the conducting wire 31 wound from the anti-load side to the load side, and the numeral shown on the conducting wire 31 indicates the load side to the anti-load side. The winding order of the conducting wire 31 to be wound is shown. In this example, the conducting wire 31 is wound such that the number of turns of the outer layer is smaller than that of the inner layer by one turn or more. In the range other than the end portion on the non-load side, the conductor wire 31 is wound in a perfectly aligned winding, and all intersections of the conductor wire 31 are performed on the end portion on the non-load side. Then, as described above, the end portions 31a and 31b of the conductive wire 31 are provided at the end portions on the anti-load side. By doing so, the conductive wire 31 can be wound into an aligned winding at a high speed, and the air-core coil portion 35 can be formed. The winding mode of the conductive wire 31 shown in FIG. 5 is an example, and the present invention is not limited to this.

(1-3-2. Second step)
Next, as a second step, the end surface of the air-core coil portion 35 formed by being wound is pressed by a pressing jig. Specifically, the inner and outer end surfaces of the air-core coil portion 35 in the radial direction are pressed by a curved press jig that forms a part of a cylindrical shape, and both sides of the air-core coil portion 35 in the circumferential direction and the shaft are pressed. The end faces on both sides in the direction are pressed by a flat press jig. Hereinafter, an example of pressure molding of the outer shape of the air-core coil portion 35 will be described with reference to FIGS. 6 to 9.

First, as shown in FIGS. 6 and 7, the winding upper spacer 42 and the winding lower spacer 43 are removed from the core pin 40. Then, the core pin 40 in which the conducting wire 31 is wound in an annular shape and the air-core coil portion 35 is formed is attached to the upper punch 44 and set in the forming hole 50 of the die 41 that receives the upper punch 44.

The forming hole 50 is a bottomed hole that is open on the front side and the rear side corresponding to both axial sides of the air-core coil portion 35. The forming hole 50 has a substantially trapezoidal shape corresponding to the shape of the slot 21. That is, the forming hole 50 has a forming surface 50a for the radially inner side that forms the outer shape on the radially inner side of the air-core coil portion 35, and a circumferential direction that forms the outer shape on both sides in the circumferential direction of the air-core coil portion 35. And a pair of molding surfaces 50b. The molding surface 50a is a curved surface forming a part of a cylindrical shape, and is specifically a curved wall surface curved with a predetermined curvature corresponding to the outer shape of the air-core coil portion 35 on the radially inner side. The pair of molding surfaces 50b are planar, and specifically, the inclined wall surfaces that rise outward from the left and right sides of the molding surface 50a at an inclination corresponding to the outer shape of the air core coil portion 35 on both sides in the circumferential direction. Is.

The upper punch 44 has a molding surface 53a for molding the outer shape of the air core coil portion 35 on the outer side in the radial direction. The molding surface 53a is a curved surface forming a part of a cylindrical shape, and is specifically a curved wall surface curved with a predetermined curvature corresponding to the outer shape of the air-core coil portion 35 on the radially outer side.

When the air-core coil portion 35 is set in the forming hole 50 of the die 41, the upper punch 44 is lowered by a predetermined amount with respect to the die 41 as shown by the white arrow in FIGS. 6 and 7. As the upper punch 44 descends, as shown in FIG. 8A, the upper punch 44 and the die 41 press the end surfaces of the air-core coil portion 35 on both sides in the radial direction, and the cross-sectional shape of the conductive wire 31 is plastically deformed. The outer shapes of the core coil portion 35 on both sides in the radial direction are pressure-molded. Further, the end faces on both sides in the circumferential direction of the air-core coil portion 35 are pressed, the cross-sectional shape of the conducting wire 31 is plastically deformed, and the outer shapes on both sides in the circumferential direction of the air-core coil portion 35 are pressure-molded. Then, when the upper punch 44 descends to reach the predetermined outline S shown in FIG. 7, as shown in FIG. 8B, the outer shapes of the four end surfaces of the air-core coil portion 35 on both the radial direction side and the circumferential side both sides are added. After the pressure forming is completed, the outer shapes of the four end surfaces of the air-core coil portion 35 on both sides in the radial direction and both sides in the circumferential direction are formed into a shape that substantially matches the shape of the slot 21.

Next, as shown in FIG. 9, of the pair of openings 55 formed on the front and rear sides between the upper punch 44 and the die 41, the openings 55 on the load side where the end portions 31a and 31b do not project are compared with the openings 55 on the load side. Then, the horizontal punch 54 is inserted as shown by the white arrow in FIG. The lateral punch 54 has a wall surface that comes into contact with the load-side end surface of the air-core coil portion 35, and is formed into a partially conical shaped surface corresponding to the inner wall surface 6b1 of the recess 6b of the load-side bracket 6.

When the horizontal punch 54 inserted into the opening 55 of the die 41 is advanced by a predetermined amount, the load-side end surface of the air-core coil portion 35 is pressed. As a result, the cross-sectional shape of the conducting wire 31 is plastically deformed, and the outer shape of the air-core coil portion 35 on the load side is pressed so as to be an end surface having a shape corresponding to the inner wall surface 6b1 of the recess 6b of the load-side bracket 6. Molded. Thereby, the outer shape of the air-core coil portion 35 matches the inner shape of the slot 21, and the outer shape of the load-side end portion of the air-core coil portion 35 can be in close contact with the inner wall surface 6b1 of the recess 6b of the load-side bracket 6. It is formed in a shape having various end faces. In this way, pressure molding of the outer shape of the air-core coil portion 35 is completed.

(1-3-3. Third step)
Next, in a third step, the air-core coil portion 35 whose outer shape has been pressure-molded is heated in a pressurized state, and the fusion coating 34 is melted. That is, for example, under pressure while still mounted on the above-mentioned molding jig, the conductor 32 of the conductor wire 31 is energized from the end portions 31a and 31b protruding from the end portion on the anti-load side of the air-core coil portion 35. As a result, the fusion coating 34 is melted by the heat generation of the conductor 32, and the adjacent conductors 32 are adhered and solidified from the insulating coating 33 by the thermal fusion of the fusion coating 34. In addition, the conductors 32 may be bonded and solidified by using the conductive wire 31 that does not have the fusion coating 34, for example, by adding a thermosetting adhesive and heating.

(1-3-4. Fourth step)
Next, in a fourth step, the air-core coil portion 35 in which the conductors 32 are bonded and solidified is solidified with resin and molded to form the coil unit 30 shown in FIG. At this time, of the surfaces of the coil unit 30, the circumferentially inner surfaces 37a1 and 37b1, the radially inner surface 30b1 and the radially outer surface 30b2 are the resin portion 36 and the flat portion 310 of the conductor 31. Composed. In addition, the other surface is composed only of the resin portion 36, and the resin portion 36 is filled in the gap between the adjacent conductive wires 31 inside the coil unit 30. At this time, a resin having a high impregnating property (for example, varnish) is used as the resin, and the voids inside the coil unit 30 are filled with the resin by, for example, vacuuming, and then the resin is cured (for example, heat-cured). As a result, the resin portion 36 is formed. The jig used in the pressurizing step may be used as it is in the molding step in order to mold the press-molded outer shape, or a part of the jig used in the pressurizing step may be cured in the molding step. You may use it as an ingredient.

The ratio of the resin portion 36 to the conductive wire 31 in the coil unit 30 manufactured as described above is as follows. That is, for example, when the conductor space factor in the slot 21 of the coil unit 30 is designed to be 90% or more and the conductor space factor in the coil end portion is designed to be 80% or more, the coil side portion which is a portion to be mounted in the slot 21 is designed. In the cross-sectional shapes of 37a and 37b, the area ratio of the total area of the resin portion 36 to the total area of the conductive wire 31 is 10% or less. Further, in the cross-sectional shape of the coil end portions 38a and 38b, the area ratio of the total area of the resin portion 36 to the total area of the conductive wire 31 is 20% or less. The above area ratio is an example, and is a value according to the design value of the conductor space factor of the coil unit 30.

(1-3-5. Subsequent process)
Then, as shown in FIGS. 4 and 10, the insulator 18 is mounted on the coil unit 30. That is, the insulator 18 covers the surfaces 37a1 and 37b1 on the inner side in the circumferential direction, the surfaces 38a1 and 38b1 on the inner side in the axial direction, the surface 30b1 on the inner side in the radial direction, and the surface 30b2 on the outer side in the radial direction among the surfaces of the coil unit 30. Then, the coil unit 30 is mounted. In the example shown in FIG. 10, the insulator 18 is composed of an insulator 18a mounted inside the coil unit 30 in the radial direction and an insulator 18b mounted outside the coil unit 30 in the radial direction. The insulator 18 may be integrated. At this time, the surfaces 37a1 and 37b1 on the inner side in the circumferential direction and the surfaces 38a1 and 38b1 on the inner side in the axial direction of the coil unit 30 and the insulator 18 are bonded to each other with an adhesive.

After that, as shown in FIGS. 4 and 11, the plurality of coil units 30 to which the insulators 18 are respectively mounted are arranged in a substantially annular shape (a substantially cylindrical shape). At this time, for example, when high insulation reliability is required, an appropriate insulating material may be installed between the adjacent coil units 30, and in this case, high insulation reliability according to the request may be obtained. Can be established.

Then, as shown in FIGS. 4 and 12, the end portions of the plurality of coil units 30 are provided on the axially outer surface 38b2 of the anti-load side coil end portions 38b of the plurality of coil units 30 arranged in a substantially annular shape. A substantially disk-shaped wiring board 16A having a plurality of lead-out holes (not shown) for inserting the shafts 31a and 31b in the substantially axial direction is attached. The wiring board 16A is formed by connecting the end portions 31a and 31b so as to form a predetermined wiring pattern. The step may be performed after the teeth portions 24 of the plurality of split cores 23 are attached to the plurality of coil units 30.

Thereafter, as shown in FIGS. 4 and 13, the load-side coil end portions 38a of the plurality of coil units 30 in which the connection portions 16 are formed are fitted into the recesses 6b of the mounting portion 6a of the load-side bracket 6. The plurality of coil units 30 are mounted on the load side bracket 6. At this time, the axially outer surface 38a2 of the load-side coil end portion 38a of the coil unit 30 is brought into close contact with the inner wall surface 6b1 of the recess 6b via the insulator 19 (see FIG. 1). At this time, when an insulator having high thermal conductivity (eg, aluminum nitride or alumina) is used as the insulator 19, the thermal conductivity from the coil unit 30 to the load side bracket 6 can be improved. The axially outer surface 38a2 of the load-side coil end portion 38a of the coil unit 30 may be directly adhered to the inner wall surface 6b1 of the recess 6b. The step may be performed after the teeth portions 24 of the plurality of split cores 23 are attached to the plurality of coil units 30.

Then, as shown in FIG. 4 and FIG. 14, the tooth portions 24 of the plurality of split cores 23 are respectively inserted from the outside in the radial direction into the hollow portions 30a of the plurality of coil units 30 attached to the load side bracket 6. It As a result, the plurality of split cores 23, that is, the plurality of teeth portions 24 of the stator core 22 are attached to the plurality of coil units 30. In other words, it can be said that the plurality of coil units 30 are mounted on the plurality of teeth portions 24 of the stator core 22. At this time, the insulator 18 and the teeth portion 24 which are mounted on the coil unit 30 and adhered by the adhesive agent are adhered by the adhesive agent. As a result, the surfaces 37a1 and 37b1 on the inner side in the circumferential direction and the surfaces 38a1 and 38b1 on the inner side in the axial direction of the coil unit 30 are bonded to the teeth portion 24.

After that, as shown in FIGS. 4 and 15, a plurality of coil units 30 to which the stator cores 22 are attached are inserted into the inner peripheral portion 5a of the frame 5 from the load side, and the frame 5 is attached to the load side bracket 6 It is attached to the attachment portion 6a of. Then, the shaft 10, the rotor 2 and the like are inserted and fixed inside the stator core 22. Thereafter, the anti-load side bracket 8 is attached to the anti-load side end of the frame 5, and the anti-load side bracket 8 and the frame 5 are fastened to the load side bracket 6 with bolts. With the above, the rotary electric machine 1 is completed.

It should be noted that the above is an example, and the manufacturing method of the rotary electric machine 1 is not limited to the steps performed in time series according to the above order, but is not necessarily performed in time series, but is performed in parallel or individually. It also includes a step to be performed. In addition, even in the steps performed in time series, the order can be appropriately changed depending on the case.

(1-4. Example of effect of first embodiment)
The rotary electric machine 1 of the present embodiment described above has the following effects.

In the rotating electric machine 1, at least one of the plurality of surfaces 37a1, 37b1, 38a1, 38b1 facing the teeth portion 24 of the coil unit 30 mounted on the teeth portion 24 of the stator core 22 (in the above-described example, the circumferential direction). The inner surfaces 37a1 and 37b1) are composed of the resin portion 36 and the conductive wire 31. In the coil unit 30 having such a configuration, it is possible to fill the space between the conductive wires 31 with resin to reduce the voids. As a result, the partial discharge inception voltage can be increased without increasing the thickness of the conductive wire 31.

FIG. 16 shows the partial discharge inception voltages of the coil unit 30 of the present embodiment and the coil of the comparative example (for example, the air-core coil formed only of the unmolded conductor 31) in comparison. In the example shown in FIG. 16, the partial discharge inception voltages of the 10 coil units 30 of the present embodiment and the 10 coils of the comparative example are shown in comparison with each other. The partial discharge starting voltage of the coil unit 30 is significantly higher than that of the coil of the comparative example.

As described above, according to the present embodiment, the partial discharge inception voltage can be increased without thickening the film of the conductive wire 31, so that the occurrence of partial discharge can be suppressed without reducing the conductor space factor. Further, the heat dissipation can be improved and the cost of the conductive wire 31 can be reduced as compared with the case where the coating film of the conductive wire 31 is thickened.

Further, particularly in the present embodiment, the conductive wire 31 forming the at least one surface of the coil unit 30 (the surfaces 37a1 and 37b1 on the inner side in the circumferential direction in the above example) has two flat portions 310 adjacent to each other. The at least one surface of the coil unit 30 is configured such that the resin portion 36 is interposed between the two flat portions 310. Such a coil unit 30 is obtained by molding the air-core coil portion 35, which is formed by deforming the cross-sectional shape of the conducting wire 31 by pressurizing and has a predetermined outer shape, with a resin. This is because even when the outer shape of the air-core coil portion 35 is pressure-molded, the flat portions 310 of the conductive wire 31 do not completely adhere to each other, and the resin enters the gap. Therefore, the coil unit 30 having a high space factor can be realized.

Further, particularly in the present embodiment, the surfaces 37a1 and 37b1 on the inner side in the circumferential direction are configured by the resin portion 36 and the flat portion 310 of the conducting wire 31. This makes it possible to make the internal dimensions of the coil unit 30 substantially the same as the air core coil portion 35 before molding. As a result, the coil unit 30 can be replaced according to the required specifications without changing the dimensions of the unmolded coil and the teeth portion 24, and the insulator 18 can be shared.

Further, particularly in the present embodiment, the resin portion 36 is filled in the gap between the conductive wires 31 inside the coil unit 30. As a result, the resin can be filled in the gaps between the conductors 31 inside the coil unit 30 to reduce the gaps. As a result, the occurrence of partial discharge can be suppressed without lowering the conductor space factor. Further, the heat dissipation can be improved and the cost of the conductive wire 31 can be reduced as compared with the case where the coating film of the conductive wire 31 is thickened.

Further, particularly in the present embodiment, the insulator 18 is provided between the teeth portion 24 and the plurality of surfaces 37 a 1, 37 b 1, 38 a 1, 38 b 1 facing the teeth portion 24 of the coil unit 30. As a result, the surface facing the teeth portion 24 is configured by the resin portion 36 and the flat portion 310 of the conductive wire 31, so that the insulation of the coil unit 30 can be secured even when the conductive wire 31 is exposed from the resin portion 36.

Further, particularly in the present embodiment, the coil unit 30 is individually attached to each tooth portion 24. As a result, in the rotary electric machine 1 in which the coil unit 30 is arranged in the concentrated winding method, it is possible to realize the rotary electric machine 1 in which the occurrence of partial discharge can be suppressed without reducing the conductor space factor.

Further, particularly in the present embodiment, the outer dimensions of the coil unit 30 are substantially equal to the outer dimensions of the air-core coil portion 35 formed by winding the conductive wire 31 in an annular shape. As a result, the coil unit 30 can be replaced with an air core coil without a mold according to the required specifications, so that the rotary electric machine 1 that can flexibly meet the required specifications can be realized.

Further, in the rotary electric machine 1 manufactured by the manufacturing method of the present embodiment, the cross-sectional shape of the conductive wire 31 is deformed by pressurization to form the outer shape of the air-core coil portion 35 into a predetermined shape, so that the space factor is high. The coil unit 30 can be realized.

Further, in the rotary electric machine 1 of the present embodiment, the air core coil portion 35 is fixed to the teeth portion 24 with resin after the air core coil portion 35 is attached to the teeth portion 24, and the air core coil portion 35 is fixed with resin to form the coil unit 30. After that, the teeth portion 24 is mounted. Therefore, a gap may be formed between the coil unit 30 and the tooth portion 24, and rattling may occur.

Therefore, particularly in the manufacturing method of the present embodiment, since the coil unit 30 is adhered to the teeth portion 24 with an adhesive, it is possible to prevent the coil unit 30 from coming off from the teeth portion 24 and being displaced, and to prevent noise and vibration due to rattling. It can be prevented.

Further, particularly in the manufacturing method of the present embodiment, the ends 31a and 31b of the lead wires 31 of the plurality of coil units 30 are connected so as to have a predetermined connection pattern. Since the ends 31a and 31b of the conductor 31 are connected after the plurality of coil units 30 are mounted on the teeth portion 24 of the stator core 22, it is possible to perform connection work with the position of the coil unit 30 fixed. Workability can be improved.

(1-5. Modifications, etc.)
The first embodiment is not limited to the above contents, and various modifications can be made without departing from the spirit and technical idea of the first embodiment. Hereinafter, such a modified example will be described.

(1-5-1. When molding a plurality of air-core coil parts with resin)
As shown in FIG. 17, in the present modified example, the plurality of air-core coil portions 35 are fixed with resin and molded in a state of being arranged in a substantially annular shape (substantially cylindrical shape), so that a plurality of coil unit portions are formed. 30' (corresponding to an example of a coil unit) is integrally formed as an annular coil body 60 connected in a substantially annular shape (substantially cylindrical shape) by a resin portion 36'.

The annular coil body 60 includes the hollow portion 30a in which the one tooth portion 24 is inserted from the outside in the radial direction, at the molding position of the air-core coil portion 35. The annular coil body 60 axially faces the molding position of the air-core coil portion 35 on the inner circumferential surfaces 37a1 and 37b1 facing the one tooth portion 24 in the circumferential direction and the one tooth portion 24 in the axial direction. The surfaces 38a1 and 38b1 on the inner side in the axial direction are provided. That is, in the annular coil body 60, the surfaces 37a1 and 37b1 on the inner side in the circumferential direction and the surfaces 38a1 and 38b1 on the inner side in the axial direction are set as one set, and the surfaces 37a1 and 37b1 on the inner side in the circumferential direction and the surfaces 38a1 and 38b1 on the inner side in the axial direction, Each tooth portion 24 has a plurality of sets in the circumferential direction. In the annular coil body 60, the inner circumferential surfaces 37a1 and 37b1 of each set are composed of the resin portion 36' and the flat portion 310 of the conductor 31, and the inner axial surfaces 38a1 and 38b1 of each set are made of resin. It is composed of only the portion 36'. Note that in FIG. 17, the flat portion 310 of the conductor wire 31 exposed on the circumferentially inner surfaces 37a1 and 37b1 of each set is omitted.

According to this modification, the following effects are achieved. That is, in the rotary electric machine 1, a case where a plurality of coil units 30 are formed by resin molding for each air-core coil section 35 as in the first embodiment, and a case where a plurality of coil unit sections 30 ′ are resin sections are used. It may be formed as an integral annular coil body 60 by being connected in an annular shape by 36'. In the present modification, when the annular coil body 60 is provided, the rotating electric machine 1 that can suppress the occurrence of partial discharge without reducing the conductor space factor can be realized.

(1-5-2. When the resin portion is composed of two kinds of resin)
As shown in FIG. 18, the coil unit 30″ of the present modified example has a first resin portion 36a and a second resin portion 36b as a resin portion 36″ obtained by hardening the air-core coil portion 35. The first resin portion 36a is provided so as to cover the axially outer surface of the load side coil end portion 38a″ which is a direct or indirect contact portion with the load side bracket 6 of the coil unit 30″. The first resin portion 36a may be provided on a portion of the coil unit 30″ other than the contact portion with the load side bracket 6. The second resin portion 36b is the first resin portion 36a of the resin portion 36″. It constitutes the part other than. The first resin portion 36a is made of a resin having higher thermal conductivity than the second resin portion 36b (hereinafter appropriately referred to as "first resin"). As the resin forming the second resin portion 36b (hereinafter appropriately referred to as "second resin"), a resin having a high impregnating property (for example, varnish) is preferable.

In the manufacturing process of the coil unit 30″, the first resin is applied to the portion corresponding to the load side coil end portion 38a″ of the air-core coil portion 35 in which the conductors 32 are bonded and solidified as described above. (Or it may be filled in the mold in advance). Then, after the air-core coil portion 35 is mounted on the mold, the second resin is vacuum-molded and the air-core coil portion 35 is solidified and molded with the first resin and the second resin. A coil unit 30" shown in Fig. 18 is formed. That is, of the surface of the coil unit 30", the portions 37a1 and 37b1 on the inner side in the circumferential direction and the surface 30b1 on the radially inner side excluding the load side coil end portion 38a". , And a portion of the radially outer surface 30b2 excluding the load-side coil end portion 38a″ is composed of the second resin portion 36b and the flat portion 310 of the conductive wire 31. Further, on the other surface, the portion corresponding to the load side coil end portion 38a″ is configured by only the first resin portion 36a, and the portion other than the portion corresponding to the load side coil end portion 38a″ is configured by only the second resin portion 36b. To be done. In addition, the second resin portion 36b is filled in the gap between the adjacent conductive wires 31 inside the coil unit 30″.

According to this modification, the resin portion 36″ of the coil unit 30″ is configured by two types of resin portions, that is, the first resin portion 36a and the second resin portion 36b, so that the resin portion 36″ has a function of suppressing partial discharge. Other functions (for example, heat dissipation function) can be enhanced.

In addition, in this modification, the first resin portion 36a is made of a resin having higher thermal conductivity than the second resin portion 36b. Thereby, the heat of the coil unit 30″ can be efficiently transferred to the load-side bracket 6 via the first resin portion 36a, so that the heat dissipation can be further improved.

(1-5-3. When arranging coil unit by distributed winding method)
As shown in FIG. 19, the rotary electric machine 110 of the present modified example includes a stator 130 and a rotor 120. The stator 130 is provided on the inner circumference of the frame 111. The rotor 120 is arranged on the inner circumference side of the stator 130 and is provided on the outer circumference of the shaft 116. A load side bracket 112 (corresponding to an example of a bracket) is provided on the load side of the frame 111. An anti-load side bracket (not shown) is provided on the anti-load side of the frame 111.

The rotor 120 includes a rotor core 122 radially opposed to the inner peripheral surface of the stator 130 via a magnetic gap, and a plurality of poles embedded in the rotor core 122 in a V shape for each pole. (8 poles in this example). An inner peripheral portion 121 is formed on the rotor core 122, and the rotor iron core 122 is fixed to the outer peripheral surface of the shaft 116 by fitting the inner peripheral portion 121 with the shaft 116.

The stator 130 has a plurality of (48 in this example) slots 131 arranged in a substantially annular stator core 132 in which the slots 131 are arranged over the entire circumference in the circumferential direction around the rotation axis AX1 of the rotor 120. A plurality of (48 in this example) coil units 141 accommodated in a distributed winding method (two-layer lap winding method in this example). On the anti-load side of the stator 130, there is a connecting portion (not shown) in which one and the other ends (not shown) of the conductors 31 of the plurality of coil units 141 are connected in a predetermined connecting pattern. It is arranged. The load side coil end portions (not shown) of the plurality of coil units 141 are attached to the load side bracket 112.

The stator core 132 is formed in a substantially annular shape by arranging a plurality (48 in this example) of split cores 133 along the inner circumference of the frame 111 over the entire circumference in the circumferential direction. Each of the split cores 133 has a substantially T-shaped radial cross-sectional shape in this example, and includes a tooth portion 134 having a substantially rectangular radial cross-sectional shape inside the radial direction. The slot 131 is formed between the tooth portions 134 and 134 of the split cores 133 and 133 that are adjacent to each other in the circumferential direction. The circumferential dimension of each tooth portion 134 is substantially equal in the radial direction in this example, and each slot 131 is open toward the inner circumferential side in this example. In this example, each slot 131 has a substantially trapezoidal radial cross-sectional shape that narrows inward in the radial direction, and includes an inner region 131a on the radially inner side and an outer region 131b on the radially outer side.

Each coil unit 141 is attached to the tooth portion 134 by being accommodated in the slot 131. Specifically, each coil unit 141 has a plurality of (six in this example) circumferentially spaced slots 131, 131, and an inner region 131a of the slot 131 located on one circumferential side and the other circumferential side. And the outer region 131b of the slot 131 located at. Thereby, each coil unit 141 is mounted across a plurality of (five in this example) tooth portions 134. Each coil unit 141 has an insulator 18A (of an insulating material) made of an appropriate insulating material (for example, polyester) in order to ensure insulation between the surface of the coil unit 141 and the portion of the stator core 132 that contacts the surface. Equivalent to an example) is installed.

The coil unit 141 includes two coil side portions 150 and 151, a load side coil end portion (not shown), and an anti-load side coil end portion (not shown). The coil side portion 150 extends in the axial direction and is housed in the inner region 131a of the slot 131 located on one side in the circumferential direction of the six slots 131, 131 separated from each other. The coil side portion 151 extends along the axial direction at a position that is separated from the coil side portion 150 by a predetermined distance X in the substantially circumferential direction, and is located on the other side in the circumferential direction of the slots 131 and 131 that are separated by six. The slot 131 is accommodated in the outer region 131b. The load side coil end portion extends between the coil side portions 150 and 151 so as to connect the load side end portions of the coil side portions 150 and 151 on the load side with respect to the stator core 132. The anti-load side coil end portion extends between the coil side portions 150, 151 so as to connect the anti-load side end portions of the coil side portions 150, 151 on the anti-load side of the stator core 132.

The coil unit 141 includes a substantially annular air-core coil portion 142 (corresponding to an example of an air-core coil) formed of the conductor 31 and a substantially annular resin portion 143 obtained by solidifying and molding the air-core coil portion 142. Prepare One end (for example, the winding start side) and the other end (for example, the winding end side) of the conductive wire 31 project from the anti-load side coil end portion to the anti-load side.

In the air-core coil portion 142, the conductor wire 31 is wound in a substantially annular shape a plurality of times, and the cross-sectional shapes of the plurality of portions of the conductor wire 31 are each an arbitrary shape by pressurization (for example, a substantially square shape, a substantially pentagonal shape, a substantially hexagonal shape, a substantially circular shape). Etc.) so as to have a predetermined outer shape by being plastically deformed. The air-core coil portion 142 is formed by melting the fusion coating 34 of the conductor 31 and adhering the adjacent conductors 32 to each other from the insulating coating 33 by fusion of the fusion coating 34. Has been done. Specifically, the outer shape of the portion of the air-core coil portion 142 corresponding to the coil side portion 150 is formed in a shape that substantially matches the inner shape of the inner region 131a, and corresponds to the coil side portion 151. The outer shape of the portion is formed in a shape that substantially matches the inner shape of the outer region 131b. In addition, the outer shape of the portion of the air-core coil portion 142 corresponding to the load side coil end portion is formed in a shape that substantially matches the inner shape of the mounting recess (not shown) of the load side bracket 112. ..

Of the surface of the coil unit 141, the two circumferentially inner surfaces 1501 and 1511 that face the teeth portion 134 in the circumferential direction include the resin portion 143 and the conductor wire 31 laminated on the circumferential inner side of the air-core coil portion 142. And the flat portion 310. That is, the conductive wire 31 forming the circumferentially inner surfaces 1501 and 1511 has two adjacent flat portions 310, and the circumferentially inner surfaces 1501 and 1511 have a resin portion between the two flat portions 310. 143 is interposed. Surfaces 1501 and 1511 on the inner side in the circumferential direction are surfaces facing each other on the inner peripheral side of the coil side portions 150 and 151. It should be noted that the flat portion 310 of the conductive wire 31 laminated on the inner side in the circumferential direction of the air-core coil portion 142 as shown in the drawing may not be entirely exposed, but may be partially exposed. Further, either one of the surfaces 1501 and 1511 on the inner side in the circumferential direction may be configured by only the resin portion 143.

Similarly, of the surfaces of the coil unit 141, the two circumferentially outer surfaces 1502 and 1512 that face the teeth portion 134 in the circumferential direction are laminated on the resin portion 143 and the air core coil portion 142 in the circumferential direction. And the flat portion 310 of the conductive wire 31 formed. That is, the conducting wire 31 forming the circumferentially outer surfaces 1502 and 1512 has two adjacent flat portions 310, and the circumferentially outer surfaces 1502 and 1512 are made of resin between the two flat portions 310. The part 143 is configured to intervene. The outer circumferential surfaces 1502 and 1512 are outer circumferential surfaces of the coil side portions 150 and 151. It should be noted that the flat portion 310 of the conductor wire 31 laminated on the outer side in the circumferential direction of the air-core coil portion 142 as shown in the drawing may not be entirely exposed, but may be partially exposed. Further, one of the circumferentially outer surfaces 1502 and 1512 may be composed of only the resin portion 143.

The flat portion 310 of the conductive wire 31 is formed not only on the surface of the coil unit 141 but also inside the coil unit 141 by pressure molding. That is, inside the coil unit 141, the flat portions 310 of the adjacent conductors 31 face (contact) each other.

On the other hand, of the surfaces of the coil unit 141, the two axially inner surfaces (not shown) that face the teeth portions 134 in the axial direction are composed of only the resin portion 143. That is, on the two axially inner surfaces, the flat portion 310 of the conductive wire 31 laminated on the axially inner side of the air-core coil portion 142 is not exposed. The two inner surfaces in the axial direction are surfaces facing each other on the inner peripheral side of the two coil end portions. In addition to or instead of at least one of the circumferentially inner surfaces 1501 and 1511 and the circumferentially outer surfaces 1502 and 1512, at least one of the two axially inner surfaces is provided with the resin portion 143 and the conductor. It may be composed of 31 flat portions 310.

Further, of the surfaces of the coil unit 141, two axially outer surfaces (not shown) are composed of only the resin portion 143. That is, on the two axially outer surfaces, the flat portion 310 of the conductive wire 31 laminated on the axially outer side of the air-core coil portion 142 is not exposed. The two axially outer surfaces are the axially outer surfaces of the two coil end portions. In addition to or in place of at least one of the circumferentially inner surfaces 1501 and 1511 and the circumferentially outer surfaces 1502 and 1512, at least one of the two axially outer surfaces is provided with the resin portion 143 and the conductive wire. It may be composed of 31 flat portions 310.

Similarly, the surface 1411 on the radially inner side of the surface of the coil unit 141 is composed of only the resin portion 143. That is, on the radially inner surface 1411, the flat portion 310 of the conductive wire 31 laminated on the radially inner side of the air-core coil portion 142 is not exposed. The radially inner surface 1411 includes the radially inner surfaces of the coil side portions 150 and 151 and the radially inner surfaces of the two coil end portions. In addition, all or a part of the surface 1411 on the radially inner side may be configured by the resin portion 143 and the flat portion 310 of the conductive wire 31.

Similarly, of the surfaces of the coil unit 30, the radially outer surface 1412 is composed of only the resin portion 143. That is, on the radially outer surface 1412, the flat portion 310 of the conductive wire 31 laminated on the radially outer side of the air-core coil portion 142 is not exposed. The radially outer surface 1412 is composed of the radially outer surfaces of the coil side portions 150 and 151 and the radially outer surfaces of the two coil end portions. In addition, all or a part of the radially outer surface 1412 may be configured by the resin portion 143 and the flat portion 310 of the conductive wire 31.

Of the surfaces of the coil unit 141, the surface formed by the resin portion 143 and the flat portion 310 of the conductive wire 31 is formed such that the flat surface of the resin portion 143 and the flat portion 310 of the conductive wire 31 are substantially flush with each other. Has been done. Further, the surface of the resin portion 143 and the flat portion 310 of the conducting wire 31 are formed so as to be continuous in a substantially flat shape or a substantially curved shape. In other words, in the circumferentially inner surfaces 1501 and 1511 and the circumferentially outer surfaces 1502 and 1512 of the coil unit 141, the surface of the resin portion 143 and the flat portion 310 of the conductive wire 31 extend along the surfaces of the teeth portions 134 facing each other. Are formed so as to extend in a substantially planar shape.

Between the six coil units 141 and 141 separated from each other, the resin portion 143 forming the radially outer surface 1412 of the coil side portion 150 of one coil unit 141 accommodated in the inner region 131 a of the slot 131, and The resin portion 143 forming the radially inner surface 1411 of the coil side portion 151 of the other coil unit 141 accommodated in the outer region 131b of the slot 131 is in direct contact. An appropriate insulating material may be interposed between the six coil units 141 and 141 separated from each other so that the coil units 141 and 141 do not come into direct contact with each other. In this case, the radially inner and outer surfaces 1411 and 1412 of the coil unit 141 may also be configured by the resin portion 143 and the flat portion 310 of the conductive wire 31.

Since the surface of the coil unit 141 is configured as described above, the outer dimensions of the coil unit 141 are substantially equal to the outer dimensions of the air-core coil portion 142 excluding the resin portion 143. It should be noted that which of the surfaces of the coil unit 141 is constituted by the resin portion 143 and the flat portion 310 of the conducting wire 31 can be selectively changed according to the required specifications.

The resin portion 143 is also filled in the gap between the adjacent conductors 31 inside the coil unit 141. As the resin forming the resin portion 143, a resin having a high impregnating property (for example, varnish) is preferable.

The ratio of the resin portion 141 to the conductive wire 31 in the coil unit 141 having the above configuration is the same as that of the coil unit 30 described above. Further, the above is an example, and the configurations of the rotary electric machine 110 and the coil unit 141 are not limited to the example shown in FIG. 19.

According to the present modified example described above, the partial discharge inception voltage can be increased without thickening the film of the conductive wire 31 as in the first embodiment, so that the partial discharge can be performed without reducing the conductor space factor. Can be suppressed. Further, the heat dissipation can be improved and the cost of the conductive wire 31 can be reduced as compared with the case where the coating film of the conductive wire 31 is thickened. Further, in the present modification, the coil unit 141 is mounted across the plurality of teeth portions 134. Accordingly, in the rotating electric machine 110 in which the coil unit 141 is arranged in the distributed winding method, it is possible to realize the rotating electric machine 110 that can suppress the occurrence of partial discharge without reducing the conductor space factor.

<2. Second Embodiment>
Next, a second embodiment will be described with reference to the drawings.

(2-1. Example of overall configuration of rotating electric machine)
First, an example of the overall configuration of the rotating electric machine according to the second embodiment will be described with reference to FIGS. 20 and 21. The same components as those in FIGS. 1 and 13 described above are designated by the same reference numerals, and description thereof will be omitted as appropriate.

When the load side coil end portion 38a of the coil unit 30 is brought into contact with the load side bracket 6 via the insulator 19 or directly as in the first embodiment described above, the load side coil end portion 38a is caused by dimensional tolerance or the like. It is difficult to bring the load side bracket 6 and the load side bracket 6 into close contact with each other. Further, in order to ensure the insulation between the load side coil end portion 38a and the load side bracket 6, it is preferable to prevent damage to the insulating film 33 of the conducting wire 31 of the coil unit 30, which requires labor. Furthermore, since it is necessary to change the shape of the load side bracket 6 when the specifications of the coil unit 30 are changed, the cost is increased.

Therefore, in the rotary electric machine 1A according to the second embodiment, as shown in FIG. 20, the cover member 70 is provided between the load side coil end portion 38a and the load side bracket 6. The cover member 70 covers at least a part of the load-side coil end portion 38 a of the coil unit 30 (in this example, the axial-direction load-side end portion and the radial-direction outer end portion), and is arranged so as to come into contact with the load-side bracket 6. Has been done.

As shown in FIGS. 20 and 21, the cover member 70 has a disc portion 71 and a cylindrical portion 72. The disc portion 71 is an annular plate member formed such that the plate thickness increases toward the center side, and has a tapered surface 73 on the anti-load side. The tapered surface 73 faces the surface 38a2 on the axially outer side of the surface of the coil unit 30 (load-side coil end portion 38a) and is in contact therewith. The surface 74 of the disk portion 71, which is the load-side surface, has a surface direction orthogonal to the axial direction, and contacts the inner wall surface 6b2 of the recess 6b of the load-side bracket 6. Further, the inner peripheral surface 75 of the disk portion 71 is fitted to the annular protruding portion 6c on the inner peripheral side of the recess 6b of the load side bracket 6.

The cylindrical portion 72 is a cylindrical member provided on the outer peripheral side end portion of the disc portion 71, and is provided so as to project from the disc portion 71 to the anti-load side. The inner peripheral surface 72a of the cylindrical portion 72 faces and contacts the radially outer surface of the load-side coil end portion 38a of the radially outer surface 30b2 of the coil unit 30. The outer peripheral surface 72b of the cylindrical portion 72 fits into the recess 6b of the load side bracket 6.

The material of the cover member 70 is not particularly limited, but may be made of metal such as aluminum. In this case, an insulating film (anodized film or the like) is formed on at least the surface facing (contacting) the load side coil end portion 38a, that is, the tapered surface 73 and the inner peripheral surface 72a. The insulating film may be formed so as to cover at least a part of the inner peripheral surface 75 and the outer peripheral surface 72b of the cover member 70. This facilitates ensuring the creepage distance between the conductor 31 and the cover member 70. Further, the cover member 70 may be made of ceramic or resin that is an insulator. In this case, a resin whose thermal conductivity is improved by adding a filler such as carbon nanotube may be used.

In this modification, in addition to the circumferentially inner surfaces 37a1 and 37b1, the radially inner surface 30b1, and the radially outer surface 30b2 of the surface of the coil unit 30, the axially outer surface 38a2 includes the resin portion 36. And a conductor 31. The axially outer surface 38a2 of the coil unit 30 is formed such that the flat surface of the resin portion 36 and the flat portion 310 of the conducting wire 31 are substantially flush with each other. Further, the surface of the resin portion 36 and the flat portion 310 of the conducting wire 31 are formed so as to be continuous in a substantially flat shape or a substantially curved shape along the tapered surface 73 of the facing cover member 70. Similarly, of the radially outer surface 30b2 of the coil unit 30, the radially outer surface of the load-side coil end portion 38a is substantially flush with the flat surface of the resin portion 36 and the flat portion 310 of the conductor 31. Is formed. Further, the surface of the resin portion 36 and the flat portion 310 of the conducting wire 31 are formed so as to be continuous in a substantially planar shape or a curved surface shape along the inner peripheral surface 72a of the cover member 70 facing each other.

The configuration of the rotating electric machine 1A is the same as that of the rotating electric machine 1 described above except for the above.

(2-2. Example of manufacturing method of rotating electric machine)
Regarding the example of the manufacturing method of the rotary electric machine 1A of the present modification, parts different from the rotary electric machine 1 described above will be described. As shown in FIG. 21, in the manufacturing process of the rotary electric machine 1A, before the load side coil end portions 38a of the plurality of coil units 30 arranged in a substantially annular shape are attached to the load side bracket 6, the cover member 70 is placed on the load side. It is attached to the recess 6b of the bracket 6. Then, the load side coil end portion 38 a of the coil unit 30 is fitted to the cover member 70 attached to the load side bracket 6, so that the plurality of coil units 30 are mounted on the load side bracket 6.

The manufacturing method of the rotating electric machine 1A other than the above is the same as that of the rotating electric machine 1 described above.

(2-3. Example of effect of second embodiment)
According to the second embodiment described above, the following effects are achieved. That is, in the rotating electric machine 1A, the cover member 70 that covers at least a part of the load-side coil end portion 38a and that contacts the load-side bracket 6 is disposed between the load-side bracket 6 and the load-side coil end portion 38a. Since the shape of the cover member 70 can be freely designed according to the shapes of the load side coil end portion 38a and the load side bracket 6, it is possible to highly closely adhere to both the load side coil end portion 38a and the load side bracket 6. Is. Therefore, the heat of the coil unit 30 can be efficiently transferred to the load side bracket 6 via the cover member 70, so that the heat dissipation can be improved. Further, by forming the cover member 70 with an insulating material or providing an insulating film on the cover member 70, insulation can be secured regardless of whether the conductor wire 31 of the coil unit 30 is damaged by the film. Further, even if the specification of the coil unit 30 is changed, it can be dealt with only by changing the cover member 70, and the housing can be shared, so that the cost can be reduced. Further, the processing of the conical surface (tapered surface) with which the load side coil end portion 38a is in close contact is easier for the cover member 70 than for the load side bracket 6, and by using the cover member 70, the load side bracket Since the recess 6b of 6 need only be machined flat, the machining can be facilitated and the cost can be reduced.

Further, particularly in the present embodiment, in the load side coil end portion 38a, the surface 38a2 on the outer side in the axial direction and the surface on the outer side in the radial direction are constituted by the resin portion 36 and the conductive wire 31, and the cover member 70 is formed by the load. The surface 38a2 on the outer side in the axial direction and the surface on the outer side in the radial direction of the side coil end portion 38a are arranged so as to be in contact with each other.

Thereby, the contact area between the cover member 70 and the conductive wire 31 forming the coil unit 30 can be increased. Further, since the cover member 70 covers the axial end portion and the radially outer end portion of the load-side coil end portion 38a, the heat of the coil unit 30 is transferred to the axial direction and the radial direction via the cover member 70. Can dissipate heat. Therefore, heat dissipation can be further improved.

(2-4. Modifications, etc.)
The second embodiment is not limited to the above contents, and various modifications can be made without departing from the spirit and technical idea of the second embodiment. Hereinafter, such a modified example will be described.

(2-4-1. When the cover member contacts the load side bracket and the frame)
As shown in FIG. 22, in the rotary electric machine 1B of the present modification, a cover member 70A is provided between the load side coil end portion 38a and the load side bracket 6. A cover member 70B is provided between the anti-load side coil end portion 38b and the frame 5. The cover member 70A is arranged so as to cover at least a part of the load-side coil end portion 38a (in this example, the axial load-side end portion and the radial outer end portion), and to contact the load-side bracket 6 and the frame 5. ing. Further, the cover member 70B is arranged so as to cover at least part of the anti-load side coil end portion 38b (in this example, the axial direction load side end portion and the radial direction outer side end portion), and to be in contact with the frame 5. ..

The coil unit 30 of the present modification is arranged on the stator core 22 in a distributed winding system as shown in FIG. 19, for example, and the cross-sectional shapes of the load-side coil end portion 38a and the anti-load-side coil end portion 38b are Each has a substantially rectangular shape. The cover member 70A includes a disc portion 71A having a substantially constant plate thickness and a cylindrical portion 72A. The anti-load side surface of the disc portion 71A faces and contacts the axially outer surface 38a2 of the load side coil end portion 38a. The load side surface of the disk portion 71A contacts the inner wall surface 6b2 of the recess 6b of the load side bracket 6. The inner peripheral surface of the cylindrical portion 72A faces and contacts the radially outer surface of the load-side coil end portion 38a of the radially outer surface 30b2 of the coil unit 30. The outer peripheral surface of the cylindrical portion 72A contacts the load side bracket 6 and the inner peripheral surface of the frame 5.

The cover member 70B has a disc portion 71B having a substantially constant plate thickness and a cylindrical portion 72B. The load-side surface of the disk portion 71B faces and contacts the axially outer surface 38b2 of the load-side coil end portion 38a. The surface of the disk portion 71B on the counter-load side faces the inner wall surface of the bracket 8 on the counter-load side with a gap, but may be in contact. The inner peripheral surface of the cylindrical portion 72B faces and contacts the radially outer surface of the anti-load side coil end portion 38b of the radially outer surface 30b2 of the coil unit 30. The outer peripheral surface of the cylindrical portion 72B contacts the inner peripheral surface of the frame 5.

Inside the frame 5, a cooling flow path 5b is formed through which cooling water (or oil) may flow. The configuration and manufacturing method of the rotary electric machine 1B other than the above are the same as those of the rotary electric machine 1A described above.

According to this modification, since the cover members 70A and 70B are provided on both the load-side and anti-load-side coil end portions 38a and 38b, not only the load-side coil end portion 38a but also the anti-load-side coil end portion 38b. The heat of can also be dissipated efficiently. Further, since the cover member 70A is arranged so as to contact the frame 5 as well as the load side bracket 6, the heat of the coil unit 30 can be efficiently radiated through the load side bracket 6 and the frame 5. Further, since the cooling channel 5b is formed in the frame 5, the coil unit 30 can be cooled more efficiently by water cooling. Therefore, the cooling performance of the rotary electric machine 1B can be further improved.

In each of the embodiments described above, the case where the disclosed technique is applied to the rotating electric machine has been described, but the present invention is not limited to the rotating type, and may be applied to a linear type motor or generator.

In the above description, when there is a description such as “vertical”, “parallel”, “plane”, etc., the description is not strict. That is, the terms “vertical”, “parallel”, “planar”, etc. mean “substantially vertical”, “substantially parallel”, “substantially flat”, etc., due to design tolerances and manufacturing tolerances. Is.

Further, in the above description, when there is a description such as “same”, “equal”, “different” or the like in external dimension or size, the description is not strict. That is, the terms “identical”, “equal”, “different”, etc. mean “substantially the same”, “substantially equal”, “substantially different”, etc., due to design tolerances and manufacturing tolerances. Is.

Further, in addition to the above description, the methods according to the above-described embodiment and each modification may be appropriately combined and used.

In addition, although not illustrated one by one, the above-described embodiment and each modified example are implemented with various modifications within a range not departing from the gist thereof.

1 rotating electric machine 1A rotating electric machine 1B rotating electric machine 2 rotor 5 frame 6 load side bracket (an example of a bracket)
18 Insulator (an example of insulating material)
18A insulator (an example of insulating material)
22 Stator core 24 Teeth part 30 Coil unit 30' Coil unit part (an example of coil unit)
30″ coil unit 31 conducting wire 310 flat portion 35 air core coil portion (an example of air core coil)
36 Resin Part 36″ Resin Part 36a First Resin Part 36b Second Resin Part 37a1, b1 Circumferentially Inner Surface 38a Load Side Coil End Part (Example of Coil End Part)
38b Anti-load side coil end part (an example of coil end part)
38a1, b1 surface inside in the axial direction 60 annular coil body 70 cover member 70A cover member 70B cover member 110 rotary electric machine 111 frame 112 load side bracket (an example of bracket)
120 rotor 132 stator iron core 134 teeth part 141 coil unit 142 air core coil part (an example of air core coil)
143 Resin part 1501 Circumferential inner surface 1511 Circumferential inner surface 1502 Circumferential outer surface 1512 Circumferential outer surface AX Rotation axis AX1 Rotation axis

Claims (14)

A stator core with teeth
A coil unit that is attached to the teeth portion and includes a conductor wire and a resin portion,
The coil unit is
Of multiple faces, two circumferential inner surface facing in a circumferential direction about the rotation axis in the teeth portion is constituted by the said resin portion and the lead Rutotomoni, the said coil unit adjacent Two outer circumferential surfaces facing each other in the circumferential direction are formed of the resin portion,
The conductor wire forming the two inner circumferential surfaces is
It has two adjacent flat parts,
The two inner circumferential surfaces are
The resin portion is configured to be interposed between the two flat portions, and the flat surface of the intervening resin portion and the flat portion are formed to be substantially flush with each other. Characteristic rotating electric machine. The resin part is
The rotating electrical machine according to claim 1, characterized in that it is filled in the gap between the conductors in the interior of the coil unit. The rotating electrical machine according to claim 1 or 2, characterized by further comprising an insulating material disposed between the multiple surfaces you face the tooth portion and the tooth portions of the coil unit. The plurality of coil units,
It is configured as an annular coil body that is annularly connected by the resin portion,
The annular coil body,
One of the tooth portions multiple surfaces you face the one set, and having a plurality of sets in a circumferential direction of the rotation axis about said plurality of surfaces facing the teeth on each of the teeth The rotary electric machine according to any one of claims 1 to 3 . A frame accommodating the stator core;
And a bracket arranged at an axial end portion of the frame,
The resin part is
A first resin portion arranged in at least a contact portion of the coil unit with the bracket;
The 2nd resin part which comprises a part other than said 1st resin part among said resin parts is included, The rotary electric machine of any one of Claim 1 thru|or 4 characterized by the above-mentioned. The first resin portion,
The rotary electric machine according to claim 5 , wherein the rotary electric machine is made of a resin having a higher thermal conductivity than the second resin portion. The coil unit is
The rotary electric machine according to any one of claims 1 to 6 , wherein each of the teeth portions is individually mounted. The coil unit is
The rotary electric machine according to any one of claims 1 to 6 , wherein the rotary electric machine is mounted over a plurality of the teeth portions. The coil unit is
A coil end portion arranged outside the slot of the stator core;
The rotating electric machine,
A housing,
Wherein the housing is disposed between the coil end portion, of the claims 1 to 8, further comprising a cover member which is in contact with the casing covering at least a portion of the coil end portion The rotary electric machine according to any one of items. The coil end portion is
The surface of the end portion in the axial direction with respect to the rotation axis, and the surface of at least one end portion on the outer side or the inner side in the radial direction with respect to the rotation axis is composed of the resin portion and the conductive wire,
The cover member is
Claim 9, characterized in that the the plane of the axial end of the coil end portion, on the outside or inside of at least one end face of the radial direction and are arranged to contact each The rotating electric machine described in. Forming the outer shape of the air-core coil into a predetermined shape by deforming the cross-sectional shape of the lead wire by applying pressure,
Wherein among the multiple faces of the air-core coil, Rutotomoni two circumferential inner surface facing in a circumferential direction about the rotation axis on the tooth portion of the stator core is composed of a resin portion and the conductor, becomes Two outer circumferential surfaces that face the matching coil unit in the circumferential direction are formed of the resin portion, and the conductive wires that form the two inner circumferential surfaces have two adjacent flat portions. The two circumferentially inner surfaces are configured such that the resin portion is interposed between the two flat portions, and the flat surface of the intervening resin portion and the flat portion are substantially as it is formed to be flush, and forming the coil unit the air-core coil hardened with resin,
The method comprising mounting the coil unit to the teeth,
A method of manufacturing a rotating electric machine, comprising: When attaching the coil unit to the teeth portion,
The method for manufacturing a rotary electric machine according to claim 11 , wherein a plurality of inner circumferential surfaces of the coil unit are bonded to the teeth portion with an adhesive. The method for manufacturing a rotary electric machine according to claim 11 or 12 , further comprising: connecting ends of the lead wires of the plurality of coil units so as to form a predetermined connection pattern. A conducting wire wound in a ring,
An annular resin portion obtained by hardening the conductive wire,
Of multiple faces, two circumferential inner surface of the plan to face each other in the circumferential direction of the rotation axis around the tooth portions when attached to the tooth portion of the stator core of the rotary electric machine, the resin portion and the is composed of a conductor Rutotomoni, two circumferential outer surface of scheduled facing in the circumferential direction in the coil unit adjacent, are composed of the resin portion, the two circumferential inner surface The conductive wire has two adjacent flat portions, and the two inner circumferential surfaces are configured such that the resin portion is interposed between the two flat portions. A coil unit, wherein a flat surface of the intervening resin portion and the flat portion are formed to be substantially flush with each other.

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