JP7787006B2 - Rotating electric machine stator structure - Google Patents

Description

This disclosure relates to a stator structure for a rotating electric machine.

Patent Document 1 discloses an outer rotor type rotating electric machine. The stator of this rotating electric machine has a connection portion for electrically connecting the stator coil to form a predetermined electrical circuit. The connection portion is provided with an electrode having terminals on both ends. The electrode penetrates the stator core and is positioned so as to protrude from both end faces of the stator. One terminal of the electrode is connected to a coil end of the stator coil, and the other terminal is connected to a wire harness. The coil end connected to one terminal is made of an aluminum-based metal, and the wire harness connected to the other terminal is made of a copper-based metal. In other words, the material connected to one terminal is different from the material connected to the other terminal.

The connection portion also has a protective member for protecting the coil end and one terminal. The protective member includes a protective resin and a wall member. The protective resin is an electrically insulating resin, also known as potting resin or sealing resin, and is tightly adhered to the surfaces of the coil end and one terminal. The wall member forms an enclosure wall that surrounds the coil end and one terminal. This enclosure wall defines a reservoir for storing the electrically insulating protective resin that surrounds the connection portion of the coil end and one terminal. The wall member accommodates the coil end in a manner that prevents the protective resin from leaking out.

JP 2017-99223 A

In the rotating electric machine described in Patent Document 1, the connection between one terminal of the electrode (terminal member) protruding from one end face of the stator and the coil end of the stator coil is enclosed in protective resin, so the surrounding wall that defines the protective resin storage tank must protrude further toward one side of the stator (one axial side) than the terminal member. As a result, the surrounding wall may increase the axial length of the stator.

The present disclosure therefore aims to provide a stator structure for a rotating electric machine that can reduce the axial length of the stator.

To solve the above problem, the first aspect of the present invention is a stator structure for a rotating electric machine, comprising a stator core, a coil formed by winding a winding around the stator core, an insulating support member attached to the stator core, and a conductive terminal member disposed on one axial side of the stator core and having a one-side terminal portion to which an end of the winding of the coil is connected, the terminal member being supported by the stator core via the insulating support member, the terminal member being made of the same type of metal as the winding of the coil.

A second aspect of the present invention is a stator structure for a rotating electric machine according to the first aspect, comprising a conductive second terminal member connected to the terminal member and extending continuously from the terminal member to the other side in the axial direction, the second terminal member having an other-side terminal portion disposed on the other side of the stator core and to which a lead wire can be connected, and one end of the one side of the second terminal member is connected to the other end of the other side of the terminal member.

A third aspect of the present invention is a stator structure for a rotating electric machine according to the second aspect, in which the second terminal member is formed from a metal different from that of the terminal member.

A fourth aspect of the present invention is a stator structure for a rotating electric machine according to the second or third aspect, wherein the insulating support member defines a space that opens to the one side, the second terminal member penetrates the bottom of the insulating support member that defines the other side of the space, the connection portion between the other end of the terminal member and the one end of the second terminal member is disposed within the space, the space in the insulating support member is filled with a sealant that seals the connection portion between the other end of the terminal member and the one end of the second terminal member, and the connection portion between the one side terminal portion of the terminal member and the end of the winding of the coil is exposed to the one side beyond the sealant.

A fifth aspect of the present invention is a stator structure for a rotating electric machine according to the second or third aspect, in which the other end of the terminal member and the one end of the second terminal member are formed in a plate shape and are connected in a state where they overlap and are in surface contact with each other.

A sixth aspect of the present invention is a stator structure for a rotating electric machine according to the fourth aspect, in which the other end of the terminal member and the one end of the second terminal member are formed in a plate shape and are connected in a state where they overlap and make surface contact with each other.

A seventh aspect of the present invention is a stator structure for a rotating electric machine according to the first aspect, wherein the terminal member has a second terminal portion that is arranged on the other side of the stator core in the axial direction and to which a lead wire can be connected, and extends continuously from the first terminal portion to the second terminal portion.

An eighth aspect of the present invention is a stator structure for a rotating electric machine according to the seventh aspect, wherein the insulating support member defines a space that opens to one side, the terminal member penetrates the bottom of the insulating support member that defines the other side of the space, the space in the insulating support member is filled with a sealing material that seals at least a portion of the terminal member within the space, and the connection portion between the one-side terminal portion of the terminal member and the end of the winding of the coil is exposed to the one side beyond the sealing material.

This disclosure makes it possible to reduce the axial length of the stator.

1 is a cross-sectional view of a rotating electric machine according to an embodiment of the present invention. 1 is a plan view of a stator of a rotating electric machine according to a first embodiment of the present invention, viewed from one side in the axial direction. FIG. 3 is a plan view of the stator of FIG. 2 as viewed from the other axial side. FIG. FIG. 3 is a perspective view of FIG. 2 as viewed in the direction of arrow IV. FIG. 4 is a perspective view of the first connection portion from one axial side. FIG. 4 is a plan view of the first connection portion from one axial side. FIG. 7 is a perspective view of FIG. 3 as viewed in the direction of arrow VII. FIG. 8 is a cross-sectional view taken along the line VIII-VIII in FIG. 6. FIG. 10 is a perspective view of the second connection portion from one axial side. 10 is a cross-sectional view taken along the line XX in FIG. 9. FIG. 10 is a cross-sectional view of a first connection portion of a stator of a rotating electric machine according to a second embodiment of the present invention.

One embodiment of the present invention will be described below with reference to the drawings. In each drawing, X indicates one side in the axial direction, and Y indicates the inner side in the radial direction.

Figure 1 is a cross-sectional view of a rotating electric machine according to one embodiment of the present invention. Figure 2 is a plan view of the stator 11 of the rotating electric machine 10 according to the first embodiment of the present invention, viewed from one axial side. Figure 3 is a plan view of the stator 11 of Figure 2, viewed from the other axial side. Figure 4 is a perspective view of Figure 2, viewed from the direction of arrow IV. Figure 5 is a perspective view of the first connection portion 18, viewed from one axial side. Figure 6 is a plan view of the first connection portion 18, viewed from one axial side. Figure 7 is a perspective view of Figure 3, viewed from the direction of arrow VII. Figure 8 is a cross-sectional view taken along arrows VIII-VIII in Figure 6. Figure 9 is a perspective view of the second connection portion 19, viewed from one axial side. Figure 10 is a cross-sectional view taken along arrows X-X in Figure 9.

As shown in Figure 1, the stator structure according to one embodiment of the present invention is applied to the structure of a stator 11 of an outer rotor type rotating electric machine 10.

The rotating electric machine 10 is an ACG (alternating current generator) starter used, for example, as a starter and generator for a motorcycle. When starting an engine (not shown), it operates as a starter motor by receiving drive current from an onboard battery (not shown), and after the engine has started, it operates as an AC generator by the engine's driving force. The rotating electric machine 10 is connected to a three-phase power conversion circuit (not shown). The rotating electric machine 10 is formed in an overall disk shape. The rotating electric machine 10 includes a stator 11 fixed to the vehicle body (e.g., the engine crankcase 1), and a rotor 12 fixed to the engine crankshaft 2 and rotating relative to the stator 11.

The rotor 12 has a cylindrical rotor yoke 13 with a bottom and permanent magnets 14 fixed to the inner surface of the rotor yoke 13. Multiple permanent magnets 14 are arranged circumferentially around the rotor yoke 13 so that different magnetic poles are arranged alternately in the circumferential direction. The stator 11 is arranged radially inside the permanent magnets 14 of the rotor 12, with a gap between them. In the following description, the axial direction refers to the direction along the rotation axis (axial center) CL of the rotor 12, the radial direction refers to the direction perpendicular to the rotation axis CL, and the circumferential direction refers to the direction along the rotation direction of the rotor 12 centered on the rotation axis CL.

As shown in Figures 2 and 3, the stator 11 of the rotating electric machine 10 according to the first embodiment of the present invention includes an annular stator core 15, an insulator 16, a coil 17, and two connection portions 18 and 19.

The stator core 15 is formed by stacking multiple steel plates (magnetic materials) in the axial direction. The stator core 15 has a cylindrical central portion 15a extending in the axial direction and multiple teeth 15b protruding radially outward from the central portion 15a. The base ends (radially inner sides) of the multiple teeth 15b are integrated with the central portion 15a. In this embodiment, there are 18 teeth 15b in total, six for each of the U, V, and W phases. Note that Figures 2 and 3 show only one tooth 15b, with the other teeth 15b not shown.

The insulator 16 is an insulating member molded from resin, and is attached to the multiple teeth 15b, continuing from the outer periphery of the central portion 15a of the stator core 15. The insulator 16 covers the surfaces of the multiple teeth 15b and blocks the flow of current between the windings 20 (described below) of the coil 17 and the teeth 15b.

The coil 17 is formed by winding a winding 20 around multiple teeth 15b of the stator core 15. An insulator 16 is interposed between the winding 20 and the multiple teeth 15b. The winding 20 is a solid metal conductor whose surface is coated with an insulating coating 34 (see Figure 4). In this embodiment, the winding 20 is made of aluminum or an aluminum alloy. However, the winding 20 is not limited to being made of aluminum or an aluminum alloy, and can be made of various conductive materials (e.g., copper, etc.).

Two connection portions 18, 19 are provided in the central portion 15a of the stator core 15. One of the two connection portions 18, 19, the first connection portion 18, is provided to axially penetrate the central portion 15a of the stator core 15 and connects the three-phase lead wires 3, which function as power supply paths to (or from) the coils 17, to the ends 20a of the windings 20 of the three-phase coils 17. The other of the two connection portions 18, 19, the second connection portion 19, is provided on one axial side of the central portion 15a (hereinafter referred to as "the one side") of the central portion 15a of the stator core 15 without penetrating it, and connects the ends 20b of the windings 20 of the three-phase coils 17 together.

As shown in Figures 4 to 8, the first connection portion 18 includes a support member (insulating support member) 21, three power terminals 22 corresponding to the U, V, and W phases, and a sealing material 23 (see Figure 8). Because the three power terminals 22 have substantially the same configuration, the following description will focus on one power terminal 22 and omit the description of the others.

The support member 21 is an insulating support member (insulating support member) that supports three power terminals 22. It is molded from resin and attached to the stator core 15. A core through-hole 24 that penetrates in the axial direction is provided in the central portion 15a of the stator core 15. The support member 21 is inserted into the core through-hole 24 of the stator core 15 from the one side and passes through the core through-hole 24. One end 21a of the one side of the support member 21 (in this embodiment, one end of the winding support portion 30 described later) is located on the one side of the surface of the one side of the stator core 15 and on the other axial side of the edge 16a of the one side of the radial inner end of the insulator 16 (hereinafter referred to as the "other side"). The other end 21b of the support member 21 (in this embodiment, the other end of the cylindrical portion 29 described below) is located on the other side of the other axial surface of the stator core 15 and on the one side of the other edge 16b of the radial inner end of the insulator 16.

The support member 21 is formed in a shape that defines three spaces 25 (see Figures 6 and 8) that open to the one side. The three spaces 25 are sized to allow the insertion of power terminals 22 and are arranged side by side in the circumferential direction. As shown in Figure 8, the other side of each space 25 is defined by the bottom 21c of the support member 21. The bottom 21c of the support member 21 is positioned on the other side of the axial center of the stator core 15. Three cylindrical portions 29 are formed on the other side of the bottom 21c of the support member 21, extending from the bottom 21c to the other side. Through holes 26 are formed inside the cylindrical portions 29, connecting the spaces 25 inside the support member 21 to the outside on the other side. The through holes 26 are sized to contact (be in close contact with) the surfaces of the power terminals 22 to prevent the sealant 23 from leaking from the spaces 25 to the other side, and extend linearly in the axial direction.

Three winding support portions 30 are provided in the radially outer region of the outer peripheral edge of the one side of the support member 21. Each winding support portion 30 has a notch 30a recessed from the one side to the other. The notch 30a is formed with a width sufficient to support the winding 20.

The power terminal 22 is a member that electrically connects the end 20a of the winding 20 of the coil 17 to the lead wire 3, and is composed of a first terminal member (terminal member) 27 and a second terminal member (second terminal member) 28.

The first terminal member 27 is a conductive metal member formed of a plate-like member. The first terminal member 27 is formed of the same type of metal (in this embodiment, aluminum or an aluminum alloy) as the winding 20 of the coil 17. In this embodiment, the first terminal member 27 integrally includes a vertical plate portion 27a extending linearly in the axial direction, a horizontal plate portion 27b bending from the end on one side of the vertical plate portion 27a and extending linearly radially inward, and an upright plate portion 27c bending from the radially inner end of the horizontal plate portion 27b and standing toward the one side.

The vertical plate portion 27a of the first terminal member 27 is formed in a plate shape that intersects the radial direction and is inserted into the space 25 of the support member 21 from the one side. The other end portion 31 (see Figure 8) of the vertical plate portion 27a on the other side is positioned near the bottom portion 21c within the space 25 of the support member 21. The one side of the vertical plate portion 27a protrudes from the space 25 of the support member 21 to the one side.

The horizontal plate portion 27b of the first terminal member 27 is formed in a plate shape that intersects the axial direction and is positioned on one side of the space 25 of the support member 21, supporting the end 20a of the connected winding 20 from the other side. The horizontal plate portion 27b is supported from the other side by the end 47a on one side of the inner wall portion 47 that defines the radial inner side of the space 25 of the support member 21.

The upright plate portion 27c of the first terminal member 27 is formed in a plate shape that intersects the radial direction, is positioned on the one side of the space 25 of the support member 21, and faces the winding support portion 30 of the support member 21 from the inside in the radial direction. The upright plate portion 27c has a notch 33 that is recessed from the one side to the other side. The notch 33 is formed with a width that can support the winding 20.

The end 20a of the winding 20 of the coil 17 is electrically and physically connected to the horizontal plate portion 27b and the upright plate portion 27c of the first terminal member 27. In other words, the horizontal plate portion 27b and the upright plate portion 27c of the first terminal member 27 are positioned on the one side of the space 25 of the support member 21, and function as the one-side terminal portion 32 to which the end 20a of the winding 20 of the coil 17 is connected.

The end 20a of the winding 20 of the coil 17 is connected to one side terminal portion 32 of the first terminal member 27 with the coating 34 removed. Specifically, the end 20a of the winding 20 of the coil 17 extends radially inward from the coil 17 side, is supported in the notch 30a of the winding support portion 30 of the support member 21, contacts the horizontal plate portion 27b of the first terminal member 27 from the above-mentioned side, and is supported in the notch 33 of the upright plate portion 27c. Then, the end 20a is fixed to the one side terminal portion 32 of the first terminal member 27 by welding, and is electrically and physically connected (joined). In this embodiment, when the end 20a of the winding 20 of the coil 17 is connected to the one side terminal portion 32 of the first terminal member 27, the support member 21 does not protrude beyond the winding 20 of the coil 17 to the above-mentioned side. In this embodiment, the first terminal member 27 is provided with a horizontal plate portion 27b and an upright plate portion 27c, and the horizontal plate portion 27b and the upright plate portion 27c function as the one-side terminal portion 32. However, the shape of the one-side terminal portion 32 is not limited to this and may be any shape that allows connection of the winding 20 of the coil 17. For example, the first terminal member 27 may be formed only with a vertical plate portion extending in the axial direction, and one end portion on the one side of the vertical plate portion may be formed into a shape that allows connection of the winding 20 of the coil 17 to function as the one-side terminal portion 32.

The second terminal member 28 is a conductive metal member formed from a plate-like member that extends continuously from the first terminal member 27 to the other side. The second terminal member 28 is formed from a different type of metal (e.g., iron) than the first terminal member 27. In this embodiment, the second terminal member 28 is formed in a plate shape that intersects the radial direction, extends linearly in the axial direction, and is inserted through the through hole 26 of the support member 21. The through hole 26 of the support member 21 and the surface (outer surface) of the second terminal member 28 are in contact.

One end 35 (see Figure 8) of the second terminal member 28 on the aforementioned side is disposed in the space 25 of the support member 21, overlaps the other end 31 of the first terminal member 27 from the radially inner side, and is connected in face-to-face contact with the radially inner surface of the other end 31 of the first terminal member 27. The one end 35 of the second terminal member 28 and the other end 31 of the first terminal member 27 are fixed, for example, by welding, and are electrically and physically connected (joined).

The other side of the second terminal member 28 protrudes to the other side through the through hole 26 of the support member 21. The other end 36 of the other side of the second terminal member 28 has a notch 37 recessed from the other side to the one side. The notch 37 is formed with a width sufficient to support the lead wire 3. The lead wire 3 can be connected to the notch 37 in the other end 36 of the second terminal member 28. In other words, the other end 36 of the second terminal member 28 is positioned on the other side of the bottom 21c of the support member 21 and functions as the other side terminal portion 38 to which the lead wire 3 can be connected. Note that each figure shows the state in which the lead wire 3 is connected to the other side terminal portion 38 of the second terminal member 28.

The lead wire 3 is a power line connected to the rotating electric machine 10 from the power conversion circuit (not shown) side. It is a twisted wire coated with an insulating coating. The end 3a of the lead wire 3 extends radially from the outside to the inside and is supported by the notch 37 of the other terminal portion 38, electrically and physically connected to the other terminal portion 38 of the second terminal member 28. The method for connecting the lead wire 3 to the other terminal portion 38 of the second terminal member 28 is not particularly limited, and various connection methods such as welding, crimping, and connectors can be applied. Note that in each figure, the twisted lead wire 3 is illustrated as a single wire. In addition, in this embodiment, the notch 37 is provided in the other terminal portion 38 of the second terminal member 28, but the shape of the other terminal portion 38 is not limited to this and may be any shape that allows the lead wire 3 to be connected.

The sealing material 23 is an electrically insulating protective resin that fills the space 25 of the support member 21. It covers the entire connection between the other end 31 of the first terminal member 27 and one end 35 of the second terminal member 28, sealing the connection within the space 25. As shown in FIG. 8 , the surface 23a on one side of the sealing material 23 is located on the one side of the connection between the other end 31 of the first terminal member 27 and one end 35 of the second terminal member 28, and on the other side of the horizontal plate portion 27b (one-side terminal portion 32) of the first terminal member 27. In other words, the connection between the one-side terminal portion 32 of the first terminal member 27 and the end 20a of the winding 20 of the coil 17 is exposed to the one side of the surface 23a of the sealing material 23.

As shown in Figures 9 and 10, the second connection portion 19 includes a support member (insulating support member) 39 and one neutral point terminal member (terminal member) 40.

The support member 39 is an insulating support member that supports the neutral point terminal member 40. It is molded from resin and attached to the stator core 15. A recess 41 that opens to the one side is formed in the central portion 15a of the stator core 15 at a position circumferentially spaced from the core through-hole 24 (see Figure 8). The support member 39 is inserted into the recess 41 of the stator core 15 from the one side. One end 39a of the one side of the support member 39 (in this embodiment, one end of a winding support portion 42 described later) is located on the one side of the surface of the one side of the stator core 15 and on the other side of the edge 16a of the one side of the radially inner end of the insulator 16.

The support member 39 is formed in a cylindrical shape with a bottom that opens to the above-mentioned one side. Inside the support member 39, a space 43 is defined that opens to the above-mentioned one side and into which the neutral point terminal member 40 can be inserted. The space 43 is formed to be slightly larger than the outer shape of the neutral point terminal member 40.

Three winding support portions 42 are provided in the radially outer region of the outer peripheral edge of the one side of the support member 39. Each winding support portion 42 has a notch 42a recessed from the one side to the other. The notch 42a is formed with a width sufficient to support the end 20b of the winding 20 of the coil 17.

The neutral point terminal member 40 is a conductive metal member formed from a plate-like member that connects the ends 20b of the windings 20 of the three-phase coils 17. The neutral point terminal member 40 is formed from the same type of metal (in this embodiment, aluminum or an aluminum alloy) as the windings 20 of the coils 17. In this embodiment, the neutral point terminal member 40 integrally comprises a vertical plate portion 40a extending linearly in the axial direction, a horizontal plate portion 40b bending from the end on one side of the vertical plate portion 40a and extending linearly radially inward, and an upright plate portion 40c bending from the radially inner end of the horizontal plate portion 40b and standing toward the one side.

The vertical plate portion 40a of the neutral point terminal member 40 is formed in a plate shape that intersects the radial direction and is inserted into the space 43 of the support member 39 from the above-mentioned one side. The vertical plate portion 40a is supported by the support member 39 while inserted into the space 43 of the support member 39. The above-mentioned one side of the vertical plate portion 40a protrudes from the space 43 of the support member 39 to the above-mentioned one side.

The horizontal plate portion 40b of the neutral point terminal member 40 is formed in a plate shape that intersects the axial direction and extends circumferentially. It is positioned on the one side of the space 43 of the support member 39 and supports the ends 20b of the three connected windings 20 from the other side. The horizontal plate portion 40b is supported from the other side by a boss portion 46 that protrudes from the surface of the one side of the support member 21 toward the one side, and is fixed to the boss portion 46.

The upright plate portion 40c of the neutral point terminal member 40 is positioned on the one side of the space 43 in the support member 39 and faces the winding support portion 42 of the support member 39 from the inside in the radial direction. The upright plate portion 40c has a notch 44 recessed from the one side to the other side. The notch 44 is formed with a width sufficient to support the winding 20.

The end 20b of the winding 20 of the coil 17 is connected to the horizontal plate portion 40b and the upright plate portion 40c of the neutral point terminal member 40. In other words, the horizontal plate portion 40b and the upright plate portion 40c of the neutral point terminal member 40 are positioned on the one side of the space 43 of the support member 39, and function as the one-side terminal portion 45 to which the end 20b of the winding 20 of the coil 17 is connected.

The end 20b of the winding 20 of the coil 17, with the coating 34 removed, is connected to one side terminal portion 45 of the neutral point terminal member 40. Specifically, the end 20b of the winding 20 of the coil 17 extends radially inward from the coil 17 side, is supported in the notch 42a of the winding support portion 42 of the support member 39, contacts the horizontal plate portion 40b of the neutral point terminal member 40 from the above-mentioned side, and is supported in the notch 44 of the upright plate portion 40c. Then, the end 20b is fixed to the one side terminal portion 45 of the neutral point terminal member 40 by welding, and is electrically and physically connected (joined). In this embodiment, when the end 20b of the winding 20 of the coil 17 is connected to the one side terminal portion 45 of the neutral point terminal member 40, the support member 39 does not protrude beyond the winding 20 of the coil 17 to the above-mentioned one side. In this embodiment, the neutral point terminal member 40 is provided with a horizontal plate portion 40b and an upright plate portion 40c, and the horizontal plate portion 40b and the upright plate portion 40c function as the one-side terminal portion 45, but the shape of the one-side terminal portion 45 is not limited to this and may be any shape that allows connection of the winding 20 of the coil 17.

In the stator 11 of the rotating electric machine 10 configured as described above, the first terminal member 27 of the power terminal 22 having the one-side terminal portion 32 is formed from the same metal as the winding 20 of the coil 17. Therefore, unlike when the one-side terminal portion 32 of the first terminal member 27 and the end 20a of the winding 20 of the coil 17 are formed from different metals, electrolytic corrosion can be suppressed at the connection between the one-side terminal portion 32 of the first terminal member 27 and the end 20a of the winding 20 of the coil 17 (hereinafter referred to as the "connection between the first terminal member 27 and the coil 17"). This eliminates the need to provide a sealant 23 for preventing electrolytic corrosion at the connection between the first terminal member 27 and the end 20a of the winding 20 of the coil 17, and the connection can be exposed to the one side of the surface 23a of the sealant 23. Therefore, there is no need to provide a wall portion around the connection between the first terminal member 27 and the coil 17 to block the sealing material 23, and the wall portion does not need to protrude beyond the winding 20 of the coil 17 to the one side in the axial direction, thereby reducing the axial length of the stator 11.

The stator 11 also includes a second terminal member 28 that extends continuously from the first terminal member 27 of the power terminal 22 to the other side, and the second terminal member 28 has a second terminal portion 38 to which the lead wire 3 is connected. Therefore, as described above, the axial length of the stator 11 can be reduced at the first connection portion 18 that connects the end portion 20a of the coil 17 to the lead wire 3.

Furthermore, the neutral point terminal member 40 having the one-side terminal portion 45 is formed from the same type of metal as the winding 20 of the coil 17. Therefore, as with the connection portion between the first terminal member 27 of the first connection portion 18 and the coil 17 described above, it is not necessary to provide a sealing material to prevent electrolytic corrosion around the connection portion between the one-side terminal portion 45 of the neutral point terminal member 40 and the end 20b of the winding 20 of the coil 17. Therefore, the axial length of the stator 11 can be reduced at the second connection portion 19 connecting the end portions 20b of the windings 20 of the three-phase coils 17.

In addition, the connection portion between the other end 31 of the first terminal member 27 and one end 35 of the second terminal member 28 (hereinafter referred to as the "connection portion between the first terminal member 27 and the second terminal member 28") is disposed within the space 25 of the support member 21 and sealed with the sealing material 23. Therefore, even if the first terminal member 27 and the second terminal member 28 are made of different metals, as in this embodiment, the connection portion between the first terminal member 27 and the second terminal member 28 is sealed with the sealing material 23, thereby preventing electrolytic corrosion of the connection portion.

The sealant 23 is filled into the space 25 of the support member 21, so the sealant 23 can restrict movement of the power terminal 22 relative to the support member 21. This ensures the strength of the power terminal 22.

Furthermore, the first terminal member 27 and the second terminal member 28 are formed from different metals. Therefore, even if the first terminal member 27 is limited to the same metal as the winding 20 of the coil 17, a desired metal different from that of the first terminal member 27 (for example, a metal to which the lead wire 3 can be easily connected) can be selected for the second terminal member 28.

In addition, since there is no need to provide the sealing material 23 for preventing electrolytic corrosion at the connection between the first terminal member 27 of the power terminal 22 and the end 20a of the winding 20 of the coil 17, and at the connection between one side terminal portion 45 of the neutral terminal member 40 and the end 20b of the winding 20 of the coil 17, the amount of sealing material 23 can be reduced, thereby reducing the material cost of the sealing material 23.

The first terminal member 27 and the second terminal member 28 are formed in a plate shape, and one end 35 of the second terminal member 28 is connected in face-to-face contact with the radially inner surface of the other end 31 of the first terminal member 27. This allows the first terminal member 27 and the second terminal member 28 to be firmly joined, thereby ensuring the strength of the power terminal 22.

Furthermore, the power terminal 22 is formed by connecting dissimilar metals (the first terminal member 27 and the second terminal member 28). In this way, the power terminal 22, which can be manufactured as a single member in advance, is formed by connecting dissimilar metals together. Therefore, unlike when one side terminal portion 32 of the power terminal 22 supported by the stator core 15 and the end portion 20a of the winding 20 of the coil 17 are connected to each other, joining the dissimilar metals can be easily performed.

In this embodiment, the first terminal member 27 and the second terminal member 28 are formed in a plate shape, but the shapes of the first terminal member 27 and the second terminal member 28 are not limited to this. For example, the other end 31 of the first terminal member 27 and one end 35 of the second terminal member 28, which are joined to each other, may be formed in a plate shape, and other regions may be formed in a shape other than a plate shape. Alternatively, the first terminal member 27 and the second terminal member 28 may be formed in a shape other than a plate shape. For example, the first terminal member 27 and the second terminal member 28 may be formed in a cylindrical shape and joined to each other in line contact.

In addition, in this embodiment, the space 43 of the support member 39 into which the neutral point terminal member 40 is inserted is not filled with a sealant. However, to ensure the strength of the neutral point terminal member 40, a sealant may be filled to seal the vertical plate portion 40a of the neutral point terminal member 40 within the space 43 of the support member 39.

Next, a second embodiment of the present invention will be described with reference to the drawings. The stator 50 of this embodiment differs from the first embodiment in that the power terminal is a single power terminal member 51. Note that components similar to those of the first embodiment are designated by the same reference numerals and will not be described again.

Figure 11 is a cross-sectional view of the first connection portion 18 of the stator 50 of the rotating electric machine 10 according to the second embodiment of the present invention.

The stator 50 includes a stator core 15, an insulator 16, a coil 17, and two connection portions 18 and 19. The second connection portion 19 has the same configuration as in the first embodiment.

As shown in FIG. 11, the first connection portion 18 includes a support member 21, three power terminal members (terminal members) 51 corresponding to the U, V, and W phases, and a sealing material 23. Note that FIG. 11 shows a cross section of one power terminal member 51. Furthermore, because the three power terminal members 51 have substantially the same configuration, the following description will focus on one power terminal member 51, and descriptions of the other power terminal members 51 will be omitted.

The power terminal member 51 is a conductive metal member formed of a plate-like member. The power terminal member 51 is formed of the same type of metal (aluminum or aluminum alloy in this embodiment) as the winding 20 of the coil 17. In this embodiment, the power terminal member 51 integrally comprises a vertical plate portion 51a extending linearly in the axial direction, a horizontal plate portion 51b bending from the end on one side of the vertical plate portion 51a and extending linearly radially inward, and an upright plate portion 51c bending from the radially inner end of the horizontal plate portion 51b and standing up toward the one side.

The vertical plate portion 51a of the power terminal member 51 is formed in a plate shape that intersects the radial direction and is inserted into the space 25 of the support member 21 from the one side and passes through the through hole 26 of the support member 21. The through hole 26 of the support member 21 and the outer peripheral surface of the power terminal member 51 are in contact. The one side of the vertical plate portion 51a protrudes from the space 25 of the support member 21 to the one side. The other side of the power terminal member 51 protrudes from the through hole 26 of the support member 21 to the other side.

The horizontal plate portion 51b of the power terminal member 51 is formed in a plate shape that intersects the axial direction and is positioned on one side of the space 25 of the support member 21, supporting the end 20a of the connected winding 20 from the other side. The horizontal plate portion 51b is supported from the other side by the end 47a on one side of the inner wall portion 47 that defines the radial inner side of the space 25 of the support member 21.

The upright plate portion 51c of the power terminal member 51 is positioned on the one side of the space 25 of the support member 21 and faces the winding support portion 30 of the support member 21 from the radially inner side. A notch (not shown) recessed from the one side to the other side is formed in the upright plate portion 51c. The notch is formed with a width sufficient to support the winding 20. The notch in the upright plate portion 51c of the power terminal member 51 has a configuration similar to, for example, the notch 33 in the upright plate portion 27c of the power terminal 22 of the first embodiment (see Figure 4).

The end 20a of the winding 20 of the coil 17 is connected to the horizontal plate portion 51b and the upright plate portion 51c of the power terminal member 51. In other words, the horizontal plate portion 51b and the upright plate portion 51c of the power terminal member 51 function as a side terminal portion 53 to which the end 20a of the winding 20 of the coil 17 is connected.

The end 20a of the winding 20 of the coil 17, with the coating 34 removed, is electrically and physically connected to one side terminal portion 53 of the power terminal member 51. Specifically, the end 20a of the winding 20 of the coil 17 extends radially inward from the coil 17 side, is supported in the notch 30a (see Figure 4) of the winding support portion 30 of the support member 21, contacts the horizontal plate portion 51b of the power terminal member 51 from the above-mentioned side, and is supported in the notch of the upright plate portion 51c. Then, the end 20a is fixed to the one side terminal portion 53 of the power terminal member 51 by welding, and is electrically and physically connected (joined). In this embodiment, when the end 20a of the winding 20 of the coil 17 is connected to the one side terminal portion 53 of the power terminal member 51, the support member 21 does not protrude beyond the winding 20 of the coil 17 to the above-mentioned side. In this embodiment, the power terminal member 51 is provided with a horizontal plate portion 51b and an upright plate portion 51c, and the horizontal plate portion 51b and the upright plate portion 51c function as the one-side terminal portion 53. However, the shape of the one-side terminal portion 53 is not limited to this and may have any shape that allows connection of the winding 20 of the coil 17. For example, the power terminal member 51 may be formed only with a vertical plate portion extending in the axial direction, and one end portion on the one side of the vertical plate portion may be formed in a shape that allows connection of the winding 20 of the coil 17 to function as the one-side terminal portion 53.

A notch (not shown) recessed from the other side to the one side is formed in the other end 54 of the power terminal member 51. The notch is formed with a width sufficient to support the lead wire 3. The lead wire 3 can be connected to the notch in the other end 54 of the power terminal member 51. In other words, the other end 54 of the power terminal member 51 is located on the other side of the bottom 21c of the support member 21 and functions as the other-side terminal portion 56 to which the lead wire 3 can be connected. The notch in the other end 54 of the power terminal member 51 has a configuration similar to, for example, the notch 37 in the other end 36 of the power terminal 22 of the first embodiment (see Figure 7). Note that Figure 11 illustrates the state in which the lead wire 3 is connected to the other-side terminal portion 56 of the power terminal member 51.

The end 3a of the lead wire 3 extends radially from the outside to the inside and is supported in the notch of the other terminal portion 56, and is electrically and physically connected to the other terminal portion 56 of the power terminal member 51. The method for connecting the lead wire 3 to the other terminal portion 56 of the power terminal member 51 is not particularly limited, and various connection methods such as welding, crimping, and connectors can be used. Note that in Figure 11, the lead wire 3, which is a twisted wire, is shown as a single wire. Also, in this embodiment, a notch is provided in the other terminal portion 56 of the power terminal member 51, but the shape of the other terminal portion 56 is not limited to this and may be any shape that allows the lead wire 3 to be connected.

The sealing material 23 is an electrically insulating protective resin that fills the space 25 of the support member 21. The sealing material 23 seals at least a portion of the power terminal member 51 within the space 25 of the support member 21 (in this embodiment, the area on the bottom 21c side of the support member 21). The surface 23a on one side of the sealing material 23 is positioned on the other side of the horizontal plate portion 51b of the power terminal member 51. In other words, the connection portion between the one terminal portion 53 of the power terminal member 51 and the end 20a of the winding 20 of the coil 17 is exposed to the one side beyond the surface 23a of the sealing material 23.

In the stator 50 of the rotating electric machine 10 configured as described above, the power terminal member 51 is formed from the same metal as the winding 20 of the coil 17. Therefore, unlike when the one-side terminal portion 53 of the power terminal member 51 and the end 20a of the winding 20 of the coil 17 are formed from different metals, electrolytic corrosion can be suppressed at the connection between the one-side terminal portion 53 of the power terminal member 51 and the end 20a of the winding 20 of the coil 17 (hereinafter referred to as the "connection between the power terminal member 51 and the coil 17"). This eliminates the need to provide a sealant 23 to prevent electrolytic corrosion at the connection between the power terminal member 51 and the coil 17, and allows the connection to be exposed to the one side beyond the surface 23a of the sealant 23. Therefore, a wall to block the sealant 23 does not need to be provided around the connection between the power terminal member 51 and the coil 17, and the wall does not need to protrude axially beyond the winding 20 of the coil 17, thereby reducing the axial length of the stator 50.

In addition, the axial length of the stator 50 can be reduced by using a simple structure in which a single power terminal member 51 is provided, which is made of the same type of metal as the winding 20 of the coil 17.

In addition, since there is no need to provide a sealing material 23 to prevent electrolytic corrosion at the connection between one side terminal portion 53 of the power terminal member 51 and the end portion 20a of the winding 20 of the coil 17, the amount of sealing material 23 can be reduced, thereby reducing the material cost of the sealing material 23.

In addition, since the space 25 of the support member 21 is filled with the sealant 23, the movement of the power terminal member 51 relative to the support member 21 can be restricted by the sealant 23. This ensures the strength of the power terminal member 51.

In this embodiment, the power terminal member 51 is formed in a plate shape, but the shape of the power terminal member 51 is not limited to this.

In addition, in the first and second embodiments, support members 21, 39 separate from the insulator 16 were provided as insulating support members for supporting the power terminal 22 or neutral terminal member 40, but the insulating support member is not limited to this. For example, the insulator 16 may be formed in a shape that can support the power terminal 22 or neutral terminal member 40, and the insulator 16 may function as an insulating support member.

Furthermore, in the first and second embodiments described above, the stator structure according to the present disclosure is applied to the stators 11, 50 of ACG starters used as starters and generators for motorcycles, but this is not limited to this, and it may also be applied, for example, to the stator of a rotating electrical machine that functions as either a motor or a generator.

The present invention has been described above based on the above embodiment, but the present invention is not limited to the content of the above embodiment, and modifications can naturally be made as appropriate without departing from the scope of the present invention. In other words, all other embodiments, examples, operational techniques, etc. made by those skilled in the art based on this embodiment are naturally included within the scope of the present invention.

3: Lead wire 10: Rotating electric machine 11, 50: Stator 15: Stator core 17: Coil 20: Winding 21, 39: Support member (insulating support member)
21c: bottom 23: sealing material 25: space 27: first terminal member (terminal member)
28: Second terminal member (second terminal member)
31: Other end of first terminal member 32, 45, 53: One side terminal portion 35: One end of second terminal member 38, 56: Other side terminal portion 51: Power terminal member (terminal member)

Claims (6)

A stator core;
a coil formed by winding a winding around the stator core;
an insulating support member attached to the stator core;
a conductive terminal member disposed on one side of the stator core in the axial direction, the terminal member having a one-side terminal portion to which an end of the winding of the coil is connected, the conductive terminal member being supported by the stator core via the insulating support member;
a conductive second terminal member connected to the terminal member and extending continuously from the terminal member toward the other side in the axial direction ,
the terminal member is formed of the same metal as the winding of the coil ,
the second terminal member is formed of a metal different from that of the terminal member,
the second terminal member has an other-side terminal portion that is disposed on the other side of the stator core and to which a lead wire can be connected,
One end of the one side of the second terminal member is connected to the other end of the other side of the terminal member.
A stator structure for a rotating electric machine characterized by: A stator core;
a coil formed by winding a winding around the stator core;
an insulating support member attached to the stator core;
a conductive terminal member disposed on one side of the stator core in the axial direction, the terminal member having a one-side terminal portion to which an end of the winding of the coil is connected, the conductive terminal member being supported by the stator core via the insulating support member;
a conductive second terminal member connected to the terminal member and extending continuously from the terminal member toward the other side in the axial direction ,
the terminal member is formed of the same metal as the winding of the coil ,
the second terminal member has an other-side terminal portion that is disposed on the other side of the stator core and to which a lead wire can be connected,
one end of the one side of the second terminal member is connected to the other end of the other side of the terminal member,
the insulating support member defines a space that is open to the one side,
the second terminal member penetrates a bottom portion of the insulating support member that defines the other side of the space,
a connection portion between the other end of the terminal member and the one end of the second terminal member is disposed within the space,
a sealing material is filled in the space of the insulating support member to seal a connection portion between the other end of the terminal member and the one end of the second terminal member;
A connection portion between the one terminal portion of the terminal member and the end of the winding of the coil is exposed to the one side beyond the sealing material.
A stator structure for a rotating electric machine characterized by: 2. The stator structure of a rotating electric machine according to claim 1 , wherein the other end of the terminal member and the one end of the second terminal member are formed in a plate shape and are connected in a state where they overlap and are in surface contact with each other. 3. The stator structure of a rotating electric machine according to claim 2 , wherein the other end of the terminal member and the one end of the second terminal member are formed in a plate shape and are connected in a state where they overlap and are in surface contact with each other. 2. The stator structure of a rotating electric machine according to claim 1, wherein the terminal member has a second terminal portion arranged on the other side of the stator core in the axial direction and to which a lead wire can be connected, and extends continuously from the first terminal portion to the second terminal portion. the insulating support member defines a space that is open to the one side,
the terminal member penetrates a bottom portion of the insulating support member that defines the other side of the space,
The space of the insulating support member is filled with a sealant that seals at least a portion of the space of the terminal member,
6. The stator structure for a rotating electric machine according to claim 5 , wherein a connection portion between the one terminal portion of the terminal member and an end portion of the winding of the coil is exposed to the one side beyond the sealing material.