JP6656474B2 - Rotating electric machine - Google Patents

Description

Cross-reference of related applications

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

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

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

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

  In the configuration of the related art, when the coil and the cover interfere with each other, the position of the sensor element may be shifted from a desired position. For example, it is desirable that the outer shape of the coil attached to the teeth portion has a prescribed shape. However, if the shape of the coil deviates from the prescribed shape, the coil may interfere with the cover. In this case, the position of the cover may shift, and the position of the sensor element in the cover may shift. The displacement of the sensor element may decrease the detection accuracy of the rotational position.

  In view of the above, or other aspects not mentioned, there is a need for further improvements in rotating electrical machines and methods of manufacturing rotating electrical machines.

  An object disclosed herein is to provide a rotating electric machine and a method for manufacturing the rotating electric machine, which has high detection accuracy of a rotational position.

  Another object disclosed is to provide a rotating electric machine and a method for manufacturing the rotating electric machine, in which a shift of a sensor element for detecting a rotational position is suppressed.

  Still another object disclosed is a rotary electric machine and a rotary electric machine in which a coil element wire can be accurately arranged on a bobbin, and displacement of a sensor element caused by interference between the coil element wire and a sensor unit is suppressed. Is to provide a method of manufacturing the same.

  Still another object disclosed is that coil wires can be accurately and quickly arranged on a bobbin so that it is suitable for mass production, and the displacement of a sensor element caused by interference between the coil wires and a sensor unit is suppressed. To provide a rotating electric machine and a method for manufacturing the rotating electric machine.

According to this disclosure, a rotating electric machine according to a first invention is provided. The rotating electric machine is provided with a rotor (21) for providing a magnetic field and a plurality of magnetic poles provided at ends of a plurality of radially extending teeth portions so as to receive the field and arranged apart from each other along a circumferential direction. A stator core (32) having a stator core (32a) and a stator (31) having a stator coil (33) mounted on the teeth portion and a sensor gap (38b) between two adjacent magnetic poles, and a magnetic flux of the rotor And a sensor unit (41) accommodating a sensor (43) for detecting an air conditioner. The plurality of magnetic poles define a normal gap (38a) in which the sensor unit is not arranged and a sensor gap (38b) in which the sensor unit is arranged. formed and the sensor unit extends into the sensor gap along the axial direction from one end face of the (SD1) side in the axial direction of the stator, the stator core and stearyl A resin insulator (35) is arranged between the coil and the coil, and the insulator has a coil guide portion (36e, 36f, 37e, 237e) for radially separating the stator coil from the magnetic pole on one end face side. , 337e, 437e, 537e, 637e, 737e, 837e, A36f), the insulator has a flange portion (37) disposed between the magnetic pole and the stator coil, and the insulator usually forms a gap. The coil guide has a normal insulator portion corresponding to the magnetic pole and a sensor insulator portion corresponding to the magnetic pole forming the sensor gap, and the coil guide portion projects from the flange portion along the teeth portion toward the stator coil (37e). , 237e, 337 e, 5 37e , 637e, 737e, 837e) The projecting portion of the flange portion of the sensor insulator portion projects on both sides in the circumferential direction, and the coil wire (33d) of the stator coil facing the sensor unit is formed on both sides in the circumferential direction and on one end surface side , Are arranged radially away from the magnetic poles by the protruding portions.

According to the disclosed rotating electric machine, the coil element wire of the stator coil facing the sensor unit is arranged radially away from the magnetic pole on one end face side. Therefore, interference between the sensor unit and the coil element wire is suppressed. As a result, reduction in the detection accuracy of the rotational position due to interference between the sensor unit and the coil wire is Ru is suppressed.

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

  The embodiments disclosed in this specification employ different technical means to achieve their respective objects. The reference numerals in parentheses described in the claims and this section exemplarily show the correspondence with the parts of the embodiment described later, and are not intended to limit the technical scope. The objects, features, and advantages disclosed in this specification will become more apparent with reference to the following detailed description and the accompanying drawings.

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

  A plurality of embodiments will be described with reference to the drawings. In embodiments, functionally and / or structurally corresponding parts and / or associated parts may be provided with the same reference signs or reference signs that differ by more than a hundred places. For corresponding parts and / or associated parts, the description of the other embodiments can be referred to.

First Embodiment In FIG. 1, a rotating electric machine for an internal combustion engine (hereinafter simply referred to as a rotating electric machine) 10 is also called a generator motor or an AC generator starter. The rotating electric machine 10 is electrically connected to an electric circuit 11 including an inverter circuit (INV) and a control device (ECU). The electric circuit 11 provides a three-phase power conversion circuit. An example of the application of the rotating electric machine 10 is a generator motor of an internal combustion engine 12 for a vehicle. The vehicle is a vehicle, a ship, or an aircraft, and a typical example is a saddle-ride type vehicle.

  The electric circuit 11 provides a rectifier circuit that rectifies the output AC power and supplies power to an electric load including a battery when the rotating electric machine 10 functions as a generator. The electric circuit 11 provides a signal processing circuit that receives a reference position signal for ignition control supplied from the rotating electric machine 10. The electric circuit 11 may provide an ignition controller that performs an ignition control.

  The electric circuit 11 provides a drive circuit that causes the rotating electric machine 10 to function as an electric motor. The electric circuit 11 receives a rotation position signal for causing the rotating electric machine 10 to function as a motor from the rotating electric machine 10. The electric circuit 11 controls the energization of the rotating electric machine 10 according to the detected rotational position, thereby causing the rotating electric machine 10 to function as an electric motor.

  The rotating electric machine 10 is assembled to an internal combustion engine 12. The internal combustion engine 12 has a body 13 and a rotating shaft 14 rotatably supported by the body 13 and rotating in conjunction with the internal combustion engine 12. The rotating electric machine 10 is assembled to a body 13 and a rotating shaft 14. The body 13 is a structure such as a crankcase and a transmission case of the internal combustion engine 12. The rotating shaft 14 is a crankshaft of the internal combustion engine 12 or a rotating shaft interlocked with the crankshaft. The rotating shaft 14 rotates when the internal combustion engine 12 is operated.

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

  The rotating electric machine 10 includes a rotor 21, a stator 31, and a sensor unit 41. In the following description, the term axial direction AD means the direction of the central axis when the stator 31 is regarded as a cylindrical body. The term “radial direction RD” means a radial direction when the stator 31 is regarded as a cylindrical body.

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

  The rotor 21 has a cup-shaped rotor core 22. The rotor core 22 is connected to the rotating shaft 14 of the internal combustion engine 12. The rotor core 22 has an inner cylinder fixed to the rotating shaft 14, an outer cylinder positioned radially outside the inner cylinder, and an annular bottom plate extending between the inner cylinder and the outer cylinder. The rotor core 22 provides a yoke for a permanent magnet described later. The rotor core 22 is made of a magnetic metal.

  The rotor 21 has a permanent magnet 23 arranged on the inner surface of the rotor core 22. The permanent magnet 23 is fixed inside the outer cylinder. The permanent magnet 23 is fixed in the axial direction AD and the radial direction RD by a holding cup 24 arranged radially inside. The holding cup 24 is made of a thin non-magnetic metal. The holding cup 24 is fixed to the rotor core 22.

  The permanent magnet 23 has a plurality of segments. Each segment is partially cylindrical. The permanent magnet 23 provides a plurality of north poles and a plurality of south poles inside. The permanent magnet 23 provides at least a field. Permanent magnet 23 provides six pairs of north and south poles, i.e., a twelve pole field, with twelve segments. The number of magnetic poles may be another number. The permanent magnet 23 provides a partial special magnetic pole for providing a reference position signal for ignition control. Special poles are provided by partial poles different from the pole arrangement for the field.

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

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

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

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

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

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

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

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

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

  The case 51 has at least one cover 53 for housing and supporting at least one sensor 43. The sensor 43 is fixed inside the cover 53. The cover 53 is a bottomed cylindrical member formed to extend from the bottom surface of the container 52. The cover 53 is provided on the outside in the radial direction. The cover 53 is inserted into a gap between the two magnetic poles 32a.

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

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

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

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

  The case 51 has a fastening part 54. The fastening portion 54 is provided radially inside the container 52 with respect to the radial direction RD of the rotary electric machine 10. A connecting portion 55 is provided between the container 52 and the tightening portion 54 for connecting between them. The fixing bolt 44 is arranged so as to penetrate the stator core 32 from a surface of the stator core 32 opposite to the body 13. The distal end of the fixing bolt 44 protruding from the stator core 32 is screwed into a female screw portion of the fastening portion 54. As a result, the sensor unit 41 is fixed to the stator core 32. The inside of the container 52 is filled with a sealing resin 56 for protection. The sealing resin 56 is a potting resin for protecting the electric circuit component 42.

  The sensor unit 41 has an external connection wiring 11a for extracting a signal output from one or a plurality of sensors 43 to the outside. The wiring 11a can transmit an ignition signal indicating a reference position and / or a rotation position signal indicating a rotation angle. The rotating electric machine 10 has a plurality of power lines 11 b connecting the stator coil 33 and the electric circuit 11. The power line 11b supplies electric power induced in the stator coil 33 to the electric circuit 11 when the rotating electric machine 10 functions as a generator. Power line 11 b supplies electric power for exciting stator coil 33 from electric circuit 11 to stator coil 33 when rotating electric machine 10 functions as a motor.

  2 and 3, the stator 31 is an annular member. Stator 31 has a through hole that can receive rotation shaft 14 and the inner cylinder of rotor core 22. The stator core 32 defines a through-hole for receiving the rotating shaft 14 and the inner cylinder of the rotor core 22. Further, stator core 32 has a plurality of through holes for receiving a plurality of fixing bolts 34. These through holes contribute to defining the position of the stator core 32 in the circumferential direction. Stator core 32 has a through hole for receiving fixing bolt 44 for fixing sensor unit 41.

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

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

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

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

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

  The insulator 35 has a guide fin 35d for guiding the jumper wire 33j on the central portion 35c. The guide fin 35d is positioned at the fixed portion. The guide fin 35d is a plate-shaped member. The guide fin 35d extends in the radial direction. The guide fin 35d extends in the axial direction. The guide fin 35d is integrally formed of a material that is continuous with the insulator 35. The guide fin 35d has a radially outer edge extending in the axial direction. The guide fin 35d has a radially inner edge that is inclined away from the stator core 32 toward the radial outside. The guide fin 35d is a part of the end face of the stator 31 and protrudes in the axial direction from the end face of the stator core 32. The insulator 35 includes a plurality of guide fins 35d. The plurality of guide fins 35d are separated from each other along the circumferential direction. The plurality of guide fins 35d are radially arranged.

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

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

  Stator 31 has a plurality of gaps 38. The gap 38 is formed between two adjacent magnetic poles 32a. The plurality of gaps 38 have a normal gap 38a and a sensor gap 38b. The sensor gap 38b is used for disposing the cover 53. Stator core 32 has 18 gaps 38. In this embodiment, the sensor unit 41 has four covers 53. Therefore, the stator 31 has four sensor gaps 38b. Therefore, it has 14 normal gaps 38a and 4 sensor gaps 38b. Instead, when the sensor unit 41 has one sensor 43, one sensor gap 38b is provided. When the sensor unit 41 has three sensors 43, three sensor gaps 38b are provided.

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

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

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

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

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

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

  The normal bobbin portion 36a and the first flange portion 37a provide a normal insulator portion corresponding to the magnetic pole 32a forming the normal gap 38a. The sensor bobbin portion 36b and the second flange portion 37b provide a sensor insulator portion corresponding to the magnetic pole 32a forming the sensor gap 38b. The sensor bobbin portion 36b and the third flange portion 37c provide a sensor insulator portion corresponding to the magnetic pole 32a forming the sensor gap 38b. The coil guide described below is provided only in the sensor insulator. As a result, the coil wire 33d of the stator coil 33 facing the sensor unit 41 is arranged radially away from the magnetic pole 32a on one end surface SD1 side.

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

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

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

  Referring back to FIGS. 6 and 7, the half body 35a has a third flange portion 37c. The third flange portion 37c has a protruding portion 37e. The protruding portion 37e protrudes on one end surface SD1 side. The projecting portion 37e projects radially inward from the flange portion along the teeth portion 32c toward the inner stator coil 33. The radially inner surface of the protruding portion 37e is away from the field of the rotor 21. The surface of the protruding portion 37e protrudes radially inward. The surface of the protruding portion 37e protrudes toward the root of the tooth portion 32c. Of the flange portion 37 extending over the entire periphery of the tooth portion 32c, only a portion near one end face SD1 protrudes as a protruding portion 37e. The protruding portion 37e protrudes from the base flange surface 37d. The base flange surface 37d is a surface of the flange portion 37 facing the stator coil 33 on the other end surface SD2 side of the stator 31. In other words, the base flange surface 37d is the inner surface of the flange portion 37 provided on the half body 35b.

  The protruding portion 37e radially moves the stator coil 33 away from the third magnetic pole 32as. The protruding portion 37e is one of coil guide portions that radially separates the stator coil 33 from the third magnetic pole 32as on one end surface side.

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

  FIG. 9 is a perspective view showing a sensor insulator portion for the third magnetic pole 32as. The sensor insulator portion has a surface 36e for providing irregularities on the sensor bobbin portion 36b and a plurality of fins 36f. The sensor insulator portion has a protruding portion 37e on the third flange portion 37c. The uneven portion and the protruding portion 37e provide a coil guide for radially separating the stator coil 33 from the third magnetic pole 32as.

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

  The sensor insulator part for the second magnetic pole 32am also has a surface 36e providing unevenness and a plurality of fins 36f on the sensor bobbin part 36b, as in FIG. The sensor insulator portion for the second magnetic pole 32am also has a protruding portion 37e on the third flange portion 37c as in FIG. The uneven portion and the protruding portion 37e provide a coil guide for radially separating the stator coil 33 from the second magnetic pole 32am.

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

  Returning to FIG. 9, the protruding portion 37e separates the stator coil 33 radially inward, and defines its position. The stator coil 33 is radially separated so as to avoid the cover 53 only at the position where the cover 53 enters. It is desirable that the distance in which the stator coil 33 is separated in the radial direction be kept to a minimum necessary for stably disposing the cover 53. As described later, the winding step that proceeds from the inner layer to the outer layer contributes to reducing the distance. In addition, the uneven portion on the sensor bobbin portion 36b also contributes to accurately controlling the distance.

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

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

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

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

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

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

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

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

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

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

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

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

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

  In FIG. 18, the stator coil 33 has a multilayer single coil 33s arranged outside the teeth portion 32c. The single coil 33s has an inner layer 33a and an outermost layer 33b. The inner layer 33a is a layer one inside the outermost layer 33b. The inner layer 33a is also the innermost layer. The inner layer 33a is formed by winding a coil wire on the bobbin portion 36. The inner layer 33a is formed by winding the coil wire in the radial direction along the bobbin portion 36. Therefore, the coil wire moves from the inner layer 33a to the outermost layer 33b at a position adjacent to the flange portion 37.

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

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

  The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is located above a concave portion formed between the plurality of coil wires 33c of the inner layer 33a. Thus, the coil wire 33d is arranged radially inward from the magnetic pole 32a on one end surface SD1 side. Such an arrangement of the coil wires makes it possible to arrange the coil wires 33d of the outermost layer 33b at desired positions. In particular, the single coil 33s has a circumferential width smaller than the axial length. Therefore, in the winding step, the coil wire 33d is wound so as to bend the coil wire 33d on one end face SD1 side. For this reason, the coil element wire 33d is easily arranged on the concave portion on one end surface SD1 side.

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

  The insulator 35 has a flange portion 37 disposed between the magnetic pole 32a and the stator coil 33. The flange portion 37 has a protruding portion 37e protruding from the flange portion 37 toward the stator coil 33 along the teeth portion 32c. The protruding portion 37e protrudes from the base flange surface 37d. The protruding portion 37e radially moves the stator coil 33 away from the magnetic pole 32a on one end surface SD1 side. Therefore, the protruding portion 37e is also a coil guide. The coil wire 33d is arranged radially away from the magnetic pole 32a only on one end face SD1 side.

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

  The amount by which the coil wire 33d of the outermost layer 33b moves radially inward on one end surface SD1 side depends on the amount of protrusion of the protruding portion 37e from the base flange surface 37d. The amount of protrusion can be about 1/2 of the diameter of the coil wire 33c. The amount of protrusion is set in consideration of the accuracy of the winding machine and the like so that the coil wire 33d is positioned above the concave portion formed by the coil wire 33c. As a result, the coil wire 33d is positioned radially inward of the base flange surface 37d by the diameter of the coil wire 33d.

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

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

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

  The method for manufacturing the rotating electric machine 10 includes a winding step and an insertion step after the winding step. In the winding step, the stator coil 33 is wound around the outer periphery of the plurality of bobbin portions 36 attached to the plurality of teeth portions 32c each having a magnetic pole 32a at the tip. The winding process is performed by a winding machine. The winding process has a high-speed process that is normally performed on the bobbin portion 36a and a low-speed process that is performed on the sensor bobbin portion 36b. The low-speed portion is also called a high-precision process in which the coil wires are arranged at specified positions with higher precision than in the high-speed process.

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

  In the winding step, the coil wire is wound so that the coil wire 33d of the stator coil 33 is disposed radially away from the magnetic pole 32a on one end surface SD1 side. The coil element wire 33d is wound so as to be radially away from the magnetic pole 32a on one end face SD1 side of the other end face SD1 side. Thereby, a coil shape in which the sensor 43 can be easily inserted is obtained. The insertion step is a step of inserting the sensor 43 only into the sensor gap 38b among the plurality of normal gaps 38a and the sensor gaps 38b formed by the plurality of magnetic poles 32a. That is, the insertion process is performed on a part of the stator 31 in the circumferential direction.

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

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

  As described above, in this embodiment, the coil wires 33d are arranged so as to be separated from the cover 53. Thereby, the insertion of the cover 53 becomes easy. Further, since a gap is formed between the cover 53 and the coil wire 33d, cooling of the coil is facilitated. Further, a gap between the cover 53 and the coil element wire 33d facilitates changing the stator coil 33. For example, the length, diameter, number of turns, material, thickness of the insulating layer, and the like of the coil strand can be changed. For example, two sensor units 41 having the same shape can be used for a coil wire made of a copper-based metal and a coil wire made of an aluminum-based metal.

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

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

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

Third Embodiment This embodiment is a modified example based on the preceding embodiment. In this embodiment, a protruding portion 337e is employed.

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

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

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

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

  As shown in FIG. 23, the third flange portion 37c has two projecting portions 537e. The protruding portions 537e are arranged on both sides in the circumferential direction of the third flange portion 37c. The protruding portion 537e has a columnar shape. The protruding portion 537e protrudes radially inward from a radially inner surface of the third flange portion 37c. The protruding portion 537e is provided only partially in the axial direction. When the protruding portion 537e is provided on the second flange portion 37b, it may be provided only on a portion adjacent to the sensor gap 38b. The protruding portion 537e arranges the coil element wire near the cover 53 away from the base flange surface 37d inward in the axial direction.

Sixth Embodiment This embodiment is a modified example based on the preceding embodiment. In this embodiment, a protruding portion 637e is employed.

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

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

  As shown in FIG. 25, the third flange portion 37c has a plurality of projecting portions 737e. The plurality of protruding portions 737e are arranged apart from each other in the circumferential direction. The base flange surface 37d is exposed in a groove shape between the plurality of projecting portions 737e. The groove forms a gap between the third flange portion 37c and the coil wire. The gap may allow air as a cooling medium to pass through and contribute to improving heat radiation of the coil wires. In this embodiment, the same operation and effect as those of the preceding embodiment can be obtained.

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

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

Ninth Embodiment This embodiment is a modified example based on the preceding embodiment. In the above embodiment, a coil guide is employed. Instead, in this embodiment, the coil wire 33d of the outermost layer 33b is arranged away from the magnetic pole 32a without the coil guide.

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

  The coil wire 33d of the outermost layer 33b rides on the inner layer 33a at a portion adjacent to the magnetic pole 32a and moves to the outermost layer 33b. The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is inclined so as to be radially away from the magnetic pole 32a from the other end face SD2 side of the stator 31 toward the one end face SD1 side. I have. The coil wire 33d of the outermost layer 33b facing the sensor unit 41 is located above the recess formed between the plurality of coil wires 33c of the inner layer 33a. They are arranged radially apart. The coil element wire 33d rides on the inner layer 33a at a portion adjacent to the magnetic pole 32a and moves to the outermost layer 33b. The coil wire 33c and the coil wire 33d pass through the riding position 33r. At the riding position 33r, the coil wire 33c and the coil wire 33d overlap in the circumferential direction. The riding position 33r is located on a side surface of the tooth portion 32c facing the circumferential direction. At the riding position 33r, the coil wire 33d expands outside the teeth portion 32c.

  In FIG. 27, the sensor unit 41 and the cover 53 are indicated by broken lines. The riding position 33r is located closer to the other end face CD2 than the tip of the cover 53. Therefore, interference between the coil wire 33d and the cover 53 is suppressed. Such a shape of the coil wire is realized on at least the plurality of sensor bobbin portions 36b. Such a shape of the coil wire is not normally realized on the bobbin portion 36a. Therefore, the winding step can be performed on the bobbin portion 36a for another purpose. For example, the speed of the winding process can be more important than the arrangement of the coil wires. However, such a shape of the coil wire may be realized on all the bobbin portions 36.

  According to this embodiment, the coil wire 33d of the stator coil 33 facing the sensor unit 41 can be disposed radially away from the magnetic pole 32a on one end surface SD1 side without the coil guide portion. Therefore, interference between the coil wire and the cover 53 can be suppressed.

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

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

  The bobbin portion 36 has a plurality of fins A36f. The plurality of fins A36f are arranged at the corners of the core. The plurality of fins A36f are provided intermittently in the left-right direction of the drawing, that is, in the length direction. Further, the plurality of fins A36f are provided intermittently in the vertical direction in the figure, that is, in the circumferential direction. In other words, the plurality of fins A36f are provided only at four corners. For example, on the front side surface S1, the two fins A36f that are vertically separated from each other in the figure are positioned at the same position in the length direction. The plurality of fins A36f intermittently arranged in the circumferential direction allow the coil wire to be skewed in the length direction. The skewing portion allows the coil element wire to advance and rewind.

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

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

  The plurality of fins A36f are positioned on the outer periphery of the core so as to be aligned with each other in the circumferential direction. A plurality of virtual circumferential trajectories can be assumed on the outer periphery of the core. In the figure, two representative virtual circumferential orbits RI and RO are shown. The plurality of virtual circumferential trajectories are perpendicular to the central axis of the tooth portion 32c. One virtual circumferential trajectory orbits around the core. The plurality of virtual orbits are parallel to each other. Four fins A36f are positioned on one virtual circumferential trajectory. In other words, the four fins A36f arranged in the circumferential direction of the core define one virtual circumferential trajectory. Since the bobbin portion 36 has the plurality of fins A36f, the outer peripheral shape of the bobbin portion 36 has irregularities at a predetermined pitch. Moreover, the bobbin portion 36 is characterized by unevenness at regular intervals in the length direction.

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

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

  As illustrated in the front side surface S1, the coil wire 33c has a start end ST at which winding starts. The starting end ST is provided at the root of the tooth. The start end ST is provided at the opposite end in the direction in which the magnetic pole projects (the length direction). The coil wire 33c is not disconnected at the start end ST. The coil wire 33c is drawn onto the bobbin portion 36 from outside the bobbin portion 36 as shown by a broken line. The coil wire 33c has a return end RN for changing the winding direction. The coil wire 33c is not disconnected at the return end RN. The coil wire 33c is continuous as shown by a broken line. The return end RN is arranged so as to contact the base flange surface 37d.

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

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

  The inner layer 33a terminates at the return end RN located on the back side surface S3. Before the return end RN, the coil wire 33c is arranged so as to be able to contact the base flange surface 37d from the right side surface S4. The return end RN is an end set for the purpose of explanation, and the coil wire is continuous at the return end RN.

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

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

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

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

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

  The outermost layer 33b has a skew portion 33fs. The skew portion 33fs may be a transition portion from the inner layer 33a to the outermost layer 33b. The skew portion 33fs is the first skew portion in the outermost layer 33b. The skewing portion 33fs has a circumferential length ADfs. The skewing portion 33fs provides rewinding at a pitch of 1/2 Pt in the length direction. The pitch of the skewed section 33fs is の of the pitch of the skewed section 33ss. After climbing on the inner layer 33a, the skewed portion 33fs shifts to a concave portion between two adjacent coil wires 33c. The coil wire 33d passes over the coil wire 33c of the inner layer 33a in the sloping portion 33fs. After riding on the coil wire 33c, the coil wire 33d moves along a concave portion between two adjacent coil wires 33c.

  Further, the outermost layer 33b has a skew portion 33ss. The skewing portion 33ss has a circumferential length ADs. The skewing portion 33ss provides a rewind of the pitch Pt in the length direction. The length ADs is longer than the length ADfs (ADfs <ADs).

  The skew portion 33fs and the skewing portion 33ss are shifted in the circumferential direction. The skewing portion 33fs is positioned at a position preceding the skewing portion 33ss in the winding direction. The interior angle formed by the skew portion 33fs and the virtual circumferential trajectory is larger than the interior angle formed by the skew portion 33ss and the virtual circumferential trajectory. The skewing 33fs provides the first turn in the outermost layer 33b. The skewing portion 33ss provides a plurality of remaining turns in the outermost layer 33b. The arrangement of the skewed portion 33fs and the skewed portion 33ss shifts the outermost layer 33b away from the flange portion A37c while suppressing mutual interference. The outermost layer 33b moves away from the flange portion A37c. Therefore, the cover part 53 of the sensor unit 41 is installed avoiding strong interference with the coil wire 33d.

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

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

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

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

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

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

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

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

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

  The thin solid line CMP indicates the movement of the molding machine of the comparative example. The molding device of the comparative example moves at a constant speed. Therefore, the coil wires are arranged obliquely on all side surfaces. In this comparative example, the intersection angle between the coil wire of the inner layer and the coil wire of the outermost layer is small. For this reason, the position of the coil wire of the outermost layer is not stable. As a result, the coil of the outermost layer may collapse.

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

  In this embodiment, the amount of movement of the forming device 64 on the front side S1, the left side S2, and the back side S3 is zero (0). The movement amount of the forming device 64 on the right side surface S4 is the pitch Pt. The molding device 64 is fixed on 、 ３ of the four side surfaces. The former 64 advances only on one quarter side. As a result, the coil wires 63a are arranged straight on three-quarters of the side surfaces. The coil wires 63a are arranged so as to form the skewed portions 33ff only on １ ／ side surfaces.

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

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

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

  At the same time, the forming device 64 moves as the winding process proceeds. The forming device 64 is controlled so as to retreat intermittently even in the returning process. The moving amount of the forming device 64 on the front side surface S1, the left side surface S2, and the back side surface S3 is smaller than the moving amount of the forming device 64 on the right side surface S4. The shaper 64 advances only one side of the plurality of sides more than the remaining sides.

  In this embodiment, the amount of movement of the forming device 64 on the front side S1, the left side S2, and the back side S3 is zero (0). The moving amount of the forming device 64 on the right side surface S4 is １ ／ Pt or Pt. The forming device 64 is circumferentially fixed on three-quarters of the four side surfaces. The former 64 returns only on one quarter side. As a result, the coil wires 63a are arranged straight on three-quarters of the side surfaces. The coil wires 63a are arranged so as to form the skewed portions 33fs only on the quarter side surfaces.

  The molding device 64 is retracted by Ｐ Pt on the first right side surface S4. Thereby, the skewed portion 33fs is formed. The behavior of the forming device 64 is such that the coil wires 63a are arranged so as to get over the coil wires 33c of the inner layer 33a. Thereby, one intersection is formed. The intersection of the skewing portions 33ff and 33fs provides a relatively large intersection angle. Therefore, the displacement of the coil wire 63a is suppressed.

  The molding device 64 retreats by Pt on the next right side surface S4. Thereby, the skewing portion 33ss is formed. The behavior of the forming device 64 is such that the coil wires 63a are arranged so as to get over the coil wires 33c of the inner layer 33a. Thereby, one intersection is formed. The intersection of the skew 33ff and the skew 33ss provides a relatively large intersection angle. Therefore, the displacement of the coil wire 63a is suppressed.

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

  The winding step of this embodiment includes a step of arranging the coil wires 33c of the inner layer 33a and a step of arranging the coil wires 33d of the outermost layer 33b outside the inner layer 33a. The step of disposing the outermost layer 33b is to form outermost layer inclined portions 33fs and 33ss that are inclined away from the magnetic pole only on one specific side surface S4 other than the one side surface S1 that is one end surface SD1. The method includes the step of disposing the coil wire 33d. The step of arranging the outermost layer 33b includes arranging the coil wires 33d straight along the circumferential direction on the remaining side surface other than the specific side surface S4.

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

  The step of arranging the inner layer 33a includes the step of arranging the coil element wires 33c so as to form the inner layer sloping portion 33ff inclined toward the magnetic pole only on the specific side surface S4. The step of arranging the inner layer 33a includes the step of arranging the coil wires 33c straight along the circumferential direction on the remaining side surface other than the specific side surface S4. Further, in the step of arranging the outermost layer 33b, the outermost layer sloping portions 33fs and 33ss are arranged so as to cross over the inner layer skewing portion 33ff.

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

  In this embodiment, the coil wire 63a can be positioned at a predetermined position by the forming device 64. For this reason, a coil having a regular shape can be obtained. Further, the coil wires can be arranged so as to avoid strong interference with the cover portion 53 of the sensor unit 41. In addition, a large intersection angle is provided because the oblique portions 33fs of the outermost layer 33b intersect the oblique portions 33ff of the inner layer 33a. Thereby, the displacement of the coil wire can be suppressed. In addition, the method for manufacturing the stator is suitable for mass production because the coil wires 33c and 33d can be accurately and quickly arranged on the bobbin portion 36.

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

  In the above embodiment, the protruding portion 37e is provided only on one end surface SD1 side, and only next to the sensor gap. Instead, the protruding portion 37e may be provided at any other position. In the above embodiment, both the uneven portion and the protruding portion 37e are provided only in the sensor insulator portion. Instead, only the protruding portion 37e may be provided only in the sensor insulator portion. For example, the uneven portions may be provided on all bobbin portions 36.

  In the above embodiment, the irregularities in the bobbin portion 36 are provided by the surface 36e and the fin 36f. Alternatively, the irregularities can be provided in various shapes. For example, the irregularities may be provided by the surface 36e and the groove.

  In the above embodiment, the single coil 33ss has a series of coil wires. Alternatively, a plurality of coil wires may be arranged on one tooth portion 32c. In this case, multiple coil strands provide a single coil 33ss. For example, two groups of coil wires for providing two coils having different numbers of turns may be arranged on one tooth portion. Further, in the above embodiment, the stator coil 33 is a concentrated winding, but may be formed by a distributed winding, for example, a wave winding or a dispersed winding.

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

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

  In the above embodiment, one sensor 43 is arranged in one cover 53. Instead, a plurality of sensors may be arranged. Further, some sensors may be arranged in the container 52. Thereby, adverse effects, for example, damage due to interference between the coil and the cover 53 are suppressed. Further, the sensor unit 41 having one cover 53 may be employed. For example, a rotating electric machine as a generator including only the sensor 43 for ignition control may be provided.

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

  In the above embodiment, the plurality of fins 36f and A36f are provided at equal intervals. Alternatively, the plurality of fins 36f and A36f may be provided only at both end ranges in the length direction. In this case, the central area of the bobbin portion 36 provides a flat tubular portion without the fins 36f, A36f. The fins 36f and A36f in the both end ranges suppress the displacement of the coil wire 33c at the start of winding. The fins 36f and A36f in the both end ranges suppress the displacement of the coil wire 33c in the winding direction change portion after coming into contact with the base flange surfaces 36f and 37d.

10 rotating electric machine, 12 internal combustion engine, 13 body, 21 rotor,
22 rotor core, 23 permanent magnet, 31 stator,
32 stator core, 32a magnetic pole, 32c teeth part,
33 stator coil, 33a inner layer, 33b outermost layer,
33c coil wire, 33d coil wire, 33j jumper wire,
33s single coil, 33r riding position,
33ff Inner layer skew section, 33fs, 33ss outermost skew section,
35 insulator, 35d guide fin,
36 bobbin part, 36a normal bobbin part,
36b Sensor bobbin part, 36e Surface (uneven part, coil guide part),
36f, A36f fin (uneven part, coil guide part),
37 flange part,
37e, 237e, 337e, 437e projecting part (coil guide part),
537e, 637e, 737e, 837e Projecting part (coil guide part),
38a normal clearance, 38b sensor clearance, 41 sensor unit,
43 sensors, 51 cases, 52 containers,
53 cover, 57 protrusion, 58 cavity,
SD1 One end face, SD2 The other end face.

Claims (13)

A rotor (21) for providing a field;
A stator core (32) having a plurality of magnetic poles (32a) arranged at ends of a plurality of radially extending teeth to receive the field and spaced apart from each other along a circumferential direction; A stator (31) having a stator coil (33) mounted on
A sensor unit (41) disposed in a sensor gap (38b) between two adjacent magnetic poles and containing a sensor (43) for detecting a magnetic flux of the rotor;
The plurality of magnetic poles
A normal gap (38a) where the sensor unit is not arranged;
The sensor gap (38b) in which the sensor unit is arranged;
The sensor unit extends into the sensor gap along the axial direction from one end face (SD1) in the axial direction of the stator,
A resin insulator (35) is disposed between the stator core and the stator coil,
The insulator includes a coil guide portion (36e, 36f, 37e, 237e, 337e, 437e, 537e, 637e, 737e, 837e, A36f) that radially separates the stator coil from the magnetic pole on the one end surface side. Have
The insulator has a flange portion (37) disposed between the magnetic pole and the stator coil,
The insulator,
A normal insulator portion corresponding to the magnetic pole forming the normal gap,
A sensor insulator portion corresponding to the magnetic pole forming the sensor gap,
The coil guide portion, the protruding portion protruding toward the stator coil from said flange portion along said tooth part has (37e, 237e, 337 e, 5 37e, 637e, 737e, 837e) and,
The projecting portion of the flange portion of the sensor insulator portion projects on both sides in the circumferential direction,
The rotating electric machine wherein the coil element wire (33d) of the stator coil facing the sensor unit is radially separated from the magnetic pole by the protruding portion on both sides in the circumferential direction and on the one end surface side. The stator coil includes a coil wire (33c) of an inner layer (33a) and a coil wire (33d) of an outermost layer (33b) disposed outside the inner layer,
All the coil wires (33d) of the outermost layer are:
The outermost layer sloping portions (33fs, 33ss) which are arranged only on one specific side surface (S2, S3, S4) other than the one side surface (S1) which is the one end surface (SD1) and are inclined away from the magnetic pole. )When,
The rotating electric machine according to claim 1, further comprising: a portion disposed on a remaining side surface other than the specific side surface, the portion extending straight along the circumferential direction. The coil wire (33c) of the inner layer is
An inner layer skewing portion (33ff) that is arranged only on the specific side surface (S2, S3, S4) and is inclined to approach the magnetic pole;
A portion that is disposed on the remaining side surface other than the specific side surface and that extends straight along the circumferential direction,
The rotating electric machine according to claim 2, wherein the outermost oblique portion is disposed so as to intersect with the inner oblique portion. The insulator has a bobbin portion (36) disposed between the teeth portion and the stator coil,
The rotating electric machine according to any one of claims 1 to 3, wherein the coil guide includes an uneven portion (36e, 36f, A36f) for defining a position of the coil wire on the bobbin portion. The rotating electric machine according to any one of claims 1 to 4, wherein the coil guide is provided only in the sensor insulator. The stator core has a fixing portion for fixing the stator core,
The insulator is a plate-shaped member that is positioned at the fixing portion and extends in the radial direction. The insulator extends in the axial direction, and the fixing portion of the jumper wire (33j) for connecting a plurality of coils included in the stator coil. The rotating electric machine according to any one of claims 1 to 5 , further comprising a guide fin (35d) that guides the jumper wire so as to suppress intrusion into the motor. The sensor unit includes:
A case (51) disposed on one axial end surface of the stator;
A cover (53) extending from the case into the sensor gap;
The rotating electric machine according to any one of claims 1 to 6 , further comprising a projecting portion (57) provided on both sides in a circumferential direction of the case and projecting from the case. The sensor unit includes:
A case (51) disposed on one axial end surface of the stator;
A cover (53) extending from the case into the sensor gap;
A container (52) containing an electric component and sealed with a resin material;
The rotating electric machine according to any one of claims 1 to 7, further comprising a hollow portion (58) not sealed with the resin material. The sensor unit includes:
A case (51) disposed on one axial end surface of the stator;
A cover (53) extending from the case into the sensor gap;
The rotating electric machine according to any one of claims 1 to 8 , wherein a cross-sectional area of the cover perpendicular to the axial direction gradually decreases from the case toward the distal end. The stator coil has a multilayer coil arranged outside the teeth portion,
The coil wire (33d) rides on the inner layer at a portion adjacent to the magnetic pole and moves to the outermost layer,
The outermost coil wire (33d) facing the sensor unit is inclined from the other end face side in the axial direction of the stator toward the one end face so as to be radially away from the magnetic pole. The rotating electric machine according to claim 1 . The riding position (33r) at which the coil wire of the outermost layer and the coil wire of the inner layer are stacked in the circumferential direction is located closer to the other end surface (SD2) of the stator than the sensor unit. The rotating electric machine according to claim 10 . The coil wire (33d) of the outermost layer facing the sensor unit is located above the concave portion formed between the plurality of coil wires of the inner layer, so that the one end face side has a diameter from the magnetic pole. The rotating electric machine according to any one of claims 1 to 11, wherein the rotating electric machine is arranged apart from the direction. The coil wire, the only at one end face of the, according to any one of claims 1 to 12, which is disposed the other end face of the stator (SD2) apart radially from the magnetic pole than the side Rotary electric machine.

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