JP2021168531A - Iron core and coil assembly and manufacturing method thereof, rotary electric machine using iron core and coil assembly and manufacturing method thereof - Google Patents

Abstract

[Problem] To provide a rotating electric machine that can reduce the number of connection points of coil terminals and prevent loosening of jumper wires due to insulator installation. [Solution] The present invention includes a stator core including an inner core 33 with multiple teeth 34 and an outer core arranged on the outer periphery thereof, an insulator 51 inserted into the teeth 34, and a jumper wire holding part that holds the jumper wire between coils 42 wound continuously around the insulator, and includes a stator equipped with a mechanism in which the insulator around which the coil is wound rotates in the central axis direction and is inserted into the teeth, and a rotor installed on the inner periphery of the stator. [Selected Figure] Figure 7

Description

The present application relates to an iron core and a coil assembly and a method for manufacturing the same, and a rotary electric machine using the iron core and the coil assembly and a method for manufacturing the same.

As a rotary electric machine, there is a stator core divided into a tooth whose inner peripheral end is connected to each other and a cylindrical back yoke on the outer diameter side of the tooth. The wound insulator is inserted into the tooth from the outer diameter side, and then the back yoke is press-fitted into the outer peripheral portion of the tooth to assemble the stator. In this structure, a winding work space is not required between windings adjacent in the circumferential direction, and the space factor of the coil is improved. As a result, the output of the rotary electric machine can be improved and the size can be reduced.

On the other hand, since an insulator wound individually wound is assembled to each tooth, the number of coil terminals increases, and the connection work of the coil terminals after assembly becomes complicated.

To solve this problem, a stator having a structure that reduces the number of connection points of terminals by continuously winding windings between insulators is disclosed (for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 2000-14095

However, in the stator of Patent Document 1, since each insulator is inserted from the outer diameter side of the teeth, the coil groups wound continuously have different insertion directions into the teeth, and after insertion, the coils are crossed between the coils. The wire becomes loose. If the crossover is loose, the crossover may be broken due to vibration during driving of the rotary electric machine. Therefore, it is necessary to fix the loose crossover after assembling the insulator.

The present application discloses a technique for solving the above-mentioned problems, in which the number of connection points of coil terminals is reduced by continuously winding a plurality of coils, and the crossover is loosened due to the incorporation of an insulator. It is an object of the present invention to provide an iron core and coil assembly and a method for manufacturing the same, and a rotary electric machine using the iron core and the coil assembly and a method for manufacturing the same.

The core and coil assemblies disclosed in the present application include a cylindrical stator core having an inner core having a plurality of teeth arranged radially and a cylindrical outer core arranged on the outer peripheral side of the inner core. The insulator and the crossover holding component for holding the crossover between the coils wound continuously on the plurality of insulators are provided, and the insulator and the crossover holding component are of the crossover holding component. It is equipped with a mechanism in which an insulator around which a coil is wound around an end rotates in the direction of the central axis of the inner iron core and is inserted into a tooth.
The rotary electric machine disclosed in the present application includes a stator which is the iron core and a coil assembly, and a rotor having a permanent magnet installed with a gap in the inner peripheral portion of the stator.

The method of manufacturing an iron core and a coil assembly disclosed in the present application is a cylindrical fixing including an inner core having a plurality of radially arranged teeth and a cylindrical outer core arranged on the outer peripheral side of the inner core. Alignment of a plurality of insulators radially arranged around the crossover holding component using a child core, an insulator inserted into the tooth, and a crossing wire holding component that holds the crossover wire of the coil wound around the insulator. A process, a winding process in which windings are continuously wound around multiple insulators to form a coil, a crossing wire fixing process in which a crossing wire between coils is fixed to a crossing wire holding component, and a crossing wire holding component across an inner iron core. An insertion process in which the insulator placed on the upper part of the wire and wound around the end of the crossover holding part is rotated in the direction of the central axis of the inner iron core and inserted into the tooth, and the wound insulator is inserted into the tooth. It is provided with an iron core assembly process of inserting the outer core into the inner core.
The method for manufacturing a rotary electric machine disclosed in the present application uses a stator which is an iron core and a coil assembly manufactured by the above method for manufacturing an iron core and a coil assembly, and further sandwiches a gap in an inner peripheral portion of the stator. It is equipped with a rotor incorporating process for incorporating a rotor equipped with a permanent magnet.

The iron core and coil assembly disclosed in the present application include a plurality of teeth arranged radially, and includes an inner core fixed to a rotating shaft and a cylindrical outer core arranged on the outer peripheral side of the inner core. A rotor core, an insulator inserted into a tooth, and a crossover holding component for holding a crossover between coils wound continuously on a plurality of insulators are provided, and the insulator and the crossover holding component include a crossover. It is equipped with a mechanism in which an insulator around which a coil is wound around the end of a wire holding component rotates in the direction of the central axis of the inner iron core and is inserted into a tooth.
The rotary electric machine disclosed in the present application includes a rotor which is an iron core and a coil assembly, and a stator having a stator winding which is installed on the outer peripheral portion of the rotor with a gap in between.

The method of manufacturing an iron core and a coil assembly disclosed in the present application includes a plurality of teeth arranged radially, an inner core fixed to a rotating shaft, and a cylindrical outer core arranged on the outer peripheral side of the inner core. A plurality of insulators centered on the crossover holding component are provided by using a rotor core including The alignment process of arranging in a radial pattern, the winding process of winding windings continuously around multiple insulators to make a coil, the crossing wire fixing process of fixing the crossover wire between the coils to the crossover wire holding component, and the inner iron core. An insertion process in which an insulator placed above the crossover holding component and wound around the end of the crossover holding component is rotated in the direction of the central axis of the inner iron core and inserted into the teeth, and a wound insulator. The inner core inserted into the tooth is provided with an iron core and a coil assembly process for inserting the outer core.
The method for manufacturing a rotary electric machine disclosed in the present application uses a rotor which is an iron core and a coil assembly manufactured by the above method for manufacturing an iron core and a coil assembly, and further sandwiches a gap in an outer peripheral portion of the rotor. , It is provided with a stator assembling process for incorporating a stator with a stator winding.

According to the iron core and coil assembly and the rotary electric machine disclosed in the present application, the iron core and coil assembly and the rotary electric machine capable of reducing the number of connection points of the coil terminal and preventing the crossover from loosening due to the incorporation of the insulator can be obtained. ..

According to the method for manufacturing the iron core and the coil assembly and the method for manufacturing the rotary electric machine disclosed in the present application, the number of connection points of the coil terminal can be reduced and the loosening of the cross wire due to the incorporation of the insulator can be prevented. A manufacturing method and a manufacturing method of a rotary electric machine can be obtained.

It is sectional drawing of the rotary electric machine according to Embodiment 1. FIG. It is sectional drawing of the stator of the rotary electric machine according to Embodiment 1. FIG. It is a perspective view of the insulator of the rotary electric machine according to Embodiment 1. FIG. It is a perspective view of the crossover holding part of a rotary electric machine according to Embodiment 1. FIG. 5 is a layout diagram of an insulator of a rotary electric machine and a crossover holding component according to the first embodiment. It is explanatory drawing of the assembly procedure of the iron core and the coil assembly of the rotary electric machine according to Embodiment 1. FIG. It is explanatory drawing of the assembly procedure of the iron core and the coil assembly of the rotary electric machine according to Embodiment 1. FIG. It is explanatory drawing of the assembly procedure of the iron core and the coil assembly of the rotary electric machine according to Embodiment 1. FIG. It is explanatory drawing of the assembly procedure of the iron core and the coil assembly of the rotary electric machine according to Embodiment 1. FIG. It is explanatory drawing of the assembly procedure of the iron core and the coil assembly of the rotary electric machine according to Embodiment 1. FIG. It is explanatory drawing of the assembly procedure of the iron core and the coil assembly of the rotary electric machine according to Embodiment 1. FIG. It is explanatory drawing of the coil assembly of the rotary electric machine according to Embodiment 1. FIG. It is sectional drawing of the insulator explaining the assembly procedure of the iron core and the coil assembly of the rotary electric machine according to Embodiment 1. FIG. It is a processing explanatory drawing of the crossover wire between the coils of a rotary electric machine according to Embodiment 1. FIG. FIG. 5 is a connection diagram of a coil of a rotary electric machine according to a first embodiment. It is explanatory drawing of the assembly procedure of the iron core and the coil assembly of the rotary electric machine according to Embodiment 1. FIG. It is explanatory drawing of the assembly procedure of the iron core and the coil assembly of the rotary electric machine according to Embodiment 1. FIG. FIG. 5 is a perspective view of an insulator for explaining a rotation mechanism when an insulator of a rotary electric machine is inserted according to the first embodiment. FIG. 5 is a perspective view of a main part of a crossover holding component for explaining a rotation mechanism when an insulator of a rotary electric machine is inserted according to the first embodiment. It is a flowchart of the manufacturing method of the iron core and the coil assembly of the rotary electric machine according to Embodiment 1. It is a flowchart of the manufacturing method of the rotary electric machine according to Embodiment 1. It is explanatory drawing of the coil assembly of the rotary electric machine according to Embodiment 2. It is explanatory drawing of the coil assembly of the rotary electric machine according to Embodiment 2. It is a comparison explanatory drawing of the coil assembly of the rotary electric machine according to Embodiment 2. It is a comparison explanatory drawing of the coil assembly of the rotary electric machine according to Embodiment 2. FIG. 5 is a cross-sectional view of a wound insulator and a crossover holding component of a rotary electric machine according to a third embodiment. It is sectional drawing of the insulator of the rotary electric machine according to Embodiment 3. FIG. It is sectional drawing of the insulator of the rotary electric machine according to Embodiment 3. FIG. It is explanatory drawing of the iron core and the coil assembly of the rotary electric machine according to Embodiment 3. FIG. It is sectional drawing of the rotary electric machine according to Embodiment 4. FIG. FIG. 5 is an axial sectional view of a rotor of a rotary electric machine according to a fourth embodiment.

Embodiment 1.
The first embodiment has a cylindrical stator core having an inner core having a plurality of radially arranged teeth and a cylindrical outer core arranged on the outer peripheral side of the inner core, and being inserted into the teeth. The insulator and the crossover holding component for holding the crossover between the coils wound continuously around the plurality of insulators are provided, and the insulator and the crossover holding component are coiled around the end of the crossing wire holding component. A stator with a mechanism in which an insulator wound around the coil rotates in the direction of the central axis of the inner iron core and is inserted into the teeth, and a rotor installed with a gap in the inner circumference of the stator. It relates to a rotary electric machine and its manufacturing method.

Hereinafter, regarding the iron core and coil assembly and its manufacturing method, and the rotary electric machine and its manufacturing method according to the first embodiment, FIG. 1 is a cross-sectional view of the rotary electric machine, FIG. 2 is a cross-sectional view of the stator, and a perspective view of the insulator. FIG. 3, FIG. 3, a perspective view of the crossover holding component, FIG. 5, a layout diagram of the insulator and the crossing wire holding component, and FIGS. 6A and 6B which are explanatory views of the assembly procedure of the iron core and the coil assembly. 7A, 7B, 8A, 8B, 13A, 13B, FIG. 9, which is an explanatory view of the coil assembly, FIG. 10, which is a cross-sectional view of an insulator for explaining an assembly procedure of the iron core and the coil assembly. FIG. 11 which is an explanatory view of processing of the crossover wire between the coils, FIG. 12 which is a connection diagram of the coils, FIG. It will be described with reference to FIG. 15, FIG. 15, which is a flowchart of a method for manufacturing an iron core and a coil assembly, and FIG. 17, which is a flowchart of a method for manufacturing a rotary electric machine.
In each figure, the same portion or the corresponding portion is indicated by the same reference numerals, and redundant description will be omitted.
In the description, the terms "axial direction", "circumferential direction", "diameter direction", "inner peripheral side", "outer peripheral side", "inner peripheral surface", and "outer peripheral surface" are used without particular notice. It refers to the "axial direction", "circumferential direction", "diameter direction", "inner peripheral side", "outer peripheral side", "inner peripheral surface", and "outer peripheral surface" of the rotor of the rotary electric machine.

First, the overall structure of the rotary electric machine 100 according to the first embodiment will be described with reference to FIG. 1, which is a cut surface perpendicular to the axial direction of the rotary electric machine 100.
The rotary electric machine 100 includes a stator 3, a rotor 6, and a motor frame 2 that holds them inside.

The stator 3 has a substantially cylindrical shape, and includes a stator core 31, an insulator 51 assembled to the stator core 31, and a stator winding 41 wound around the insulator 51. The stator core 31 is generally formed by laminating a plurality of thin magnetic plates made of an iron-based material.
The stator 3 constitutes a rotary electric machine 100 in combination with a rotor 6 that is fitted and fixed to the inside of a substantially cylindrical motor frame 2 and rotatably supported by a bearing (not shown) with respect to the motor frame 2. ..

The motor frame 2 mechanically holds the stator 3 and the rotor 6 and serves as a heat dissipation path for the stator 3. Therefore, a metal material such as iron and aluminum is generally used for the motor frame 2.

The rotor 6 includes a substantially cylindrical rotor core 60 fixed to a rotating shaft 65, and a permanent magnet 8 attached to the outer peripheral surface of the rotor core 60.

In general, a rotary electric machine may use an iron core having a winding as a stator or a rotor, but in the first embodiment, an example in which an iron core having a winding is applied to a stator will be described. do.

Further, the structure of the stator 3 will be described with reference to FIG. 2, which is a cross-sectional view perpendicular to the axial direction of the stator 3.
The stator core 31 is composed of a substantially cylindrical outer core 32 serving as a back yoke and an inner core 33 in which a plurality of radially arranged teeth 34 are connected and integrated on the inner peripheral side.
By press-fitting the outer core 32 into the inner core 33 from the axial direction, the outer peripheral end of the teeth 34 and the back yoke are magnetically connected to form the stator core 31 integrally.

The assembly of the outer core 32 and the inner core 33 is not limited to press-fitting, and may be shrink-fitting, bonding, or welding.
The outer core 32 and the inner core 33 are generally formed by laminating a plurality of thin magnetic plates made of an iron-based material. The laminated thin plates are fixed by means such as caulking or bonding.

Next, the coil 42 and the insulator 51 will be described with reference to FIG. 2 which is a cross-sectional view of the stator 3 and FIG. 3 which is a perspective view of the insulator 51.

A coil 42 is arranged in a slot 35 formed between teeth 34 adjacent to each other in the circumferential direction. The stator winding 41 is wound around the insulator 51 a predetermined number of times to form a coil 42 arranged in each slot 35.
The coil 42 needs to be electrically insulated from the stator core 31 and must be held so as to have a predetermined cross-sectional shape. Therefore, the coil 42 is wound around the insulator 51.
The insulator 51 around which the coil 42 is wound is inserted into each tooth 34 of the inner iron core 33 by the method described later.

The insulator 51 is a resin molded product provided with a hollow portion 52 for insertion into the teeth 34. The insulator 51 includes a body portion 53 that covers the circumferential side surface and the axial vertical surface of the tooth 34, an inner flange portion 54 on the inner peripheral side of the stator that serves as a radial wall of the wound coil 42, and an outer flange portion on the outer peripheral side. 55 is provided, and the coil 42 is wound in the space between them.

Next, the manufacturing procedure of the stator 3 will be described in order, but first, the outline will be listed.
(1) The insulator 51 and the crossover holding component 71 are mounted on the winding jig and arranged.
(2) Winding is applied to the insulator 51.
(3) Assemble the crossover holding component 76 to fix the crossover.
(4) The insulator 51 is incorporated into the inner core 33 of the stator core 31.
(5) The outer iron core 32 is press-fitted.
In the following description, the structure manufactured by incorporating the insulator 51 into the inner iron core 33 of (4) is referred to as the coil assembly 90. Further, the structure manufactured by press-fitting the outer iron core 32 into the coil assembly 90 of (5) is referred to as an iron core and a coil assembly 91.

The stator 3 of the first embodiment is manufactured by a method of fitting an insulator 51 around which a coil 42 is wound into a teeth 34 in advance, and here, a stator having 12 teeth 34 will be described as an example. ..

First, regarding the first stage (mounting the insulator 51 and the crossover holding component 71 on the winding jig), FIG. 4, which is a perspective view of the crossover holding component 71, and a layout diagram of the insulator 51 and the crossover holding component 71. 5 and FIG. 6A, which is an explanatory diagram of the assembly procedure of the iron core and the coil assembly, will be described.
In FIG. 4, the crossover holding component 71 includes a storage groove 72 and a stator winding terminal 73. The functions of the storage groove 72 and the stator winding terminal 73 will be described later.
FIG. 5 is a schematic view of the arrangement of the insulator 51 and the crossover holding component 71 at the time of winding, as viewed from the axial direction of the stator 3. Jigs are omitted in FIG.

The twelve insulators 51 are arranged so that the inner flange portion 54 faces upward and the axial directions of the insulators 51 are radially equal pitch in a plane. Since there are 12 insulators 51, they are arranged radially at a pitch of 30 degrees.
The crossover holding component 71 is arranged at the center of the insulators 51 arranged radially.

FIG. 6A is a cross-sectional view parallel to the axis in a state where the insulator 51 and the crossover holding component 71 are arranged on the holding jig 81.
The crossover holding component 71 is fixed to the holding jig 81, insulator holding jigs 82 are arranged on both sides in the radial direction thereof, and insulators 51 are mounted on the insulator holding jigs 82, respectively.

The insulator holding jig 82 includes a frame body 83 that supports the outer flange portion 55 of the insulator 51 and a core portion 84 that is mounted on the hollow portion 52 of the insulator 51.
The core portion 84 is pushed up by a spring 85 in the upper part of the drawing, and can be pushed toward the frame body 83 from the upper part of the drawing.
The frame body 83 has a structure that rotates around an axial center 75 in the direction perpendicular to the paper surface in the vicinity of the radially arranged inner end portion of the axial end portion of the insulator 51.
The details of this rotation operation will be described later. Further, a crossover holding component 71 for holding the crossover 43 between the insulators 51 is arranged at the center of the insulators 51 arranged radially.

Here, the crossover holding component 71 will be described.
The crossover holding component 71 is formed by, for example, resin molding, and includes a storage groove 72 that matches the arrangement of the crossover wire 43 that connects the coils 42 of each insulator 51. A crossover 43 is arranged in the storage groove 72 at the time of winding, and by holding the crossover 43 in the radial and circumferential directions, it is possible to prevent the crossover 43 from being damaged by centrifugal force and vibration when the rotary electric machine 100 is operated. do.
Further, the crossover holding component 71 includes a stator winding terminal 73 for fixing and joining the coil terminal. The portion of the stator winding terminal 73 to be joined to the coil terminal protrudes toward the storage groove side of the crossover holding component 71, and at the time of winding, the nozzle 74 is rotated around each stator winding terminal 73 to wind the stator winding terminal 73. Wrap the wire.
The stator winding terminal 73 is made of a conductive copper, a copper alloy, iron or the like, and has a rod-like shape.
After winding, the stator winding terminal 73 and the wound coil wire are electrically joined by means such as soldering, brazing, or welding.

Although the example in which the coil wire is wound around the rod-shaped terminal is shown here, the terminal may be hooked and the winding may be hooked.
As shown in FIG. 6A, the other end of the stator winding terminal 73 penetrates the crossover holding component 71 and projects to the opposite surface, and is used for connecting the stator winding to the outside.

Here, a method of holding the insulator 51 in the frame body 83 when winding the coil 42 around the insulator 51 will be described with reference to FIG. 10 which is a cross-sectional view of the insulator 51 and the frame body 83 and the like.
FIG. 10 is a cross-sectional view taken along the line XX, which is an intermediate portion of the insulator 51 in FIG. The circumferential end of the outer flange 55 of the insulator 51 is formed obliquely with respect to the radial direction. Here, the pressing members 86 are arranged from both sides in the circumferential direction of the frame body 83, and the pressing members 86 are fixed to the frame body 83 so as to hold the diagonal portion of the outer flange portion 55. As a result, the insulator 51 is fixed to the insulator holding jig 82 in the radial direction. The insulator 51 is held by the core portion 84 in the circumferential direction and the axial direction.

Next, regarding the second stage (winding the insulator 51), FIG. 6B which is an explanatory view of the assembly procedure of the iron core and the coil assembly, FIG. 12 which is a connection diagram of the coil 42, and a crossover line between the coils 42. This will be described with reference to FIG. 11, which is a process explanatory diagram of the above.

FIG. 6B is a schematic view of the winding operation. The nozzle 74 is rotated around the insulator 51 attached to the insulator holding jig 82 to wind the coil 42.
When the winding to the insulator 51 is completed, the crossover 43 connecting the coils 42 is continuously routed by the nozzle 74, and the coil 42 is wound around the next insulator 51. The crossover 43 is routed along a storage groove 72 provided in the crossover holding component 71, and the crossover 43 is housed in the storage groove 72.
FIG. 11 is a view of the insulator 51 and the crossover holding component 71 after the winding is completed as viewed from the nozzle 74 side.

FIG. 12 is a coil connection diagram of a stator 3 provided with 12 teeth 34 and a coil 42 used in the description in the first embodiment.
It is composed of four coils 42 for each of the U, V, and W phases, and the coils 42 for each phase are connected in series, and the three phases are connected by Δ. The crossover holding component 71 shown in FIG. 11 reflects the connection of FIG. 12, and the labels U, V, and W written on the outside of the insulator 51 indicate the phase of the coil 42 wound around each insulator 51. Is shown. The underlined coil 42 (U, V, W) has a magnetic field opposite to that of the unlined coil 42 when a current in the same direction flows through the coil 42. For example, the winding direction is opposite.
The line connecting each phase of the coil 42 is referred to as an interphase connection line.

The situation of the crossover 43 between each coil 42 shown in FIG. 11 shows a form in which all 12 coils 42 are continuously wound, starting from the U terminal in the connection diagram of FIG. 12 and counterclockwise. The U-phase, V-phase, and W-phase are continuously wound to complete the winding at the U terminal. Here, the case where the coils 42 of all 12 insulators 51 are continuously wound will be described. The crossover holding component 71 is provided with a stator winding terminal 73 which is a U, V, W terminal of FIG. 12, of which the coil 42 is fixed to the U terminal 73u which is the winding start and winding end of the coil 42. The V terminal 73v and the W terminal 73w have two portions, and the other V terminal 73v and W terminal 73w are provided with one fixed portion of the coil 42.
FIG. 6B shows a cross section including the stator winding terminal 73.

Next, the third step (assembling the crossover holding component 76 and fixing the crossover 43) will be described with reference to FIG. 7A, which is an explanatory diagram of the assembly procedure of the iron core and the coil assembly.
When the winding of the coil 42 on each insulator 51 and the arrangement of the crossover wire 43 on the crossover wire holding component 71 are completed, the crossover wire holding component 76 is placed over the crossover wire 43 routed to the crossover wire holding component 71 and fixed. do. FIG. 7A shows a state after the crossover 43 is fixed to the crossover holding component 71.
The crossover holding component 76 prevents the crossover 43 arranged in the storage groove 72 of the crossover holding component 71 from falling out of the storage groove 72. The crossover holding component 76 is formed by, for example, resin molding, like the crossover holding component 71.
The crossover holding component 76 is adhered and fitted to the crossover holding component 71, and is fixed by means such as snap fit. Further, it is also possible to fix the crossover wire 43 by applying an adhesive to the groove portion of the crossover wire holding component 71 without using the crossover wire holding component 76.

Next, with respect to the fourth stage (incorporating the insulator 51 into the inner core 33 of the stator core 31), FIGS. 7B, 8A, 8B and the coil assembly 90 are explanatory views of the assembly procedure of the iron core and the coil assembly 91. This will be described with reference to FIG. 9, which is an explanatory diagram of the above.

After completing the winding of the coil 42 on the insulator 51 and the holding of the crossover 43 on the crossover holding component 71, the insulator 51 is inserted into each tooth 34 of the inner iron core 33. At this time, an inner core holding jig (not shown) for holding the iron core is inserted into the space inside the inner core 33 having a substantially cylindrical shape, and the inner core 33 is fixed to the inner core holding jig via the inner core holding jig (not shown). By holding the inner core 33 using the inner peripheral portion of the inner core 33, the inner core holding jig does not hinder the insertion of the insulator 51 from the outside of the inner core 33.

7B and 8A are schematic views in which the insulator 51 around which the coil 42 is wound is inserted into each tooth 34 of the inner iron core 33. The insulator holding jig 82 is rotated in the direction of the arrow in the drawing, with the position of the crossover 43 between each insulator 51 and the crossover holding component 71 as the axis of rotation 75.
The rotation drive mechanism and the like are omitted. As a result, each insulator 51 can be incorporated into the teeth 34 in the manner of closing the umbrella without loosening the crossover 43 connected to the crossover holding component 71 from the coil 42 wound around the insulator 51.

As the insulator holding jig 82 is rotated, the core portion 84 comes into contact with the outer peripheral portion of the teeth 34. However, as shown in FIGS. 7B and 8A, the insulator 51 is pushed into the teeth 34 by the frame body 83 while the spring 85 supporting the core portion 84 is bent and the core portion 84 is retracted.
FIG. 8B shows a state in which the inner iron core 33 of the insulator 51 around which the coil 42 is wound has been inserted into the teeth 34.

After the insertion of the insulator 51 is completed, the crossover holding component 71 is in a state of being supported only by the crossover 43. Therefore, depending on the usage conditions of the rotary electric machine 100, it may be necessary to mechanically fix the crossover 51 separately. In this case, for example, as shown in FIG. 9, the crossover holding component 71 or the crossover holding component 76 can be provided with an engaging portion 77 and held by the insulator 51. Further, it may be fixed by means such as adhesion or welding instead of mechanical engagement.

Next, the fifth step (press-fitting the outer iron core 32) will be described with reference to FIGS. 13A and 13B, which are explanatory views of the assembly procedure of the iron core and the coil assembly 91.

After inserting the insulator 51 around which the coil 42 is wound into the teeth 34 to form the coil assembly 90, the outer iron core 32 is press-fitted into the outer periphery of the coil assembly 90. As shown in FIG. 13A, a substantially cylindrical outer core 32 is press-fitted from the axial direction to fix the coil assembly 90 and the outer core 32. The outer iron core 32 may be heated and fitted, or may be shrink-fitted.
FIG. 13B shows a state after the outer iron core 32 is press-fitted into the coil assembly 90 to form the iron core and the coil assembly 91. Here, the iron core and the coil assembly 91 are the stators 3 described with reference to FIGS. 1 and 2.

In the above description, an example is shown in which the insulator 51 is arranged on a movable winding jig for incorporating the insulator 51 into the inner core 33, and the coil 42 is incorporated into the inner core 33 as it is after being wound. However, the insulator 51 in which the coil 42 is wound in advance may be arranged on the insulator holding jig 82, and the insulator 51 may be incorporated in the inner iron core 33.

Next, an example of a mechanism in which the insulator 51 around which the coil 42 is wound is rotated by 90 degrees and inserted into the teeth 34 around the end of the crossover holding component 71 will be described with reference to FIGS. 14 and 15. FIG. 14 is a perspective view of the insulator 51 for explaining the rotation mechanism when the insulator 51 is inserted. FIG. 15 is a perspective view of a main part of the crossover holding component 71 for explaining the rotation mechanism.

Specifically, an example will be described in which the center of rotation when the insulator 51 is incorporated into the inner iron core 33 is configured by the insulator 51 and the crossover holding component 71.
As shown in FIG. 14, when the insulator 51 is molded with resin, a rotation shaft portion 56 serving as an axis of the rotation center is provided at the end of the outer flange portion 55. The central axis of the rotating shaft portion 56 is oriented perpendicular to the radial direction of the outer flange portion 55, and is positioned so as not to block the trajectory of the nozzle 74 when the coil 42 is wound.

On the other hand, as shown in FIG. 15, a bearing portion 78, which is a hole into which the rotation shaft portion 56 of the insulator 51 is inserted, is provided at the end portion of the crossover holding component 71. Similar to the insulator 51, the crossover holding component 71 is molded according to the resin molding. By fitting the rotating shaft portion 56 of the insulator 51 into the bearing portion 78, it becomes relatively rotatable about the rotating shaft portion 56.
By providing this rotation mechanism, the insulator 51 around which the coil 42 is wound can be incorporated into the inner iron core 33 while rotating around the rotation shaft portion 56.

Although an example in which the rotating shaft portion 56 is integrally formed during resin molding is shown, holes are provided in both the insulator 51 and the crossover holding component 71, and a separately prepared rotating shaft made of resin and metal is used as the hole. It may be fitted so that the insulator 51 and the crossover holding component 71 rotate relative to each other.

Next, the method of manufacturing the iron core and coil assembly 91 of the first embodiment described above will be described with reference to the flowchart of FIG.
The method for manufacturing the iron core and coil assembly 91 of the first embodiment comprises the following steps 1 (S01) to 5 (S05).

In the alignment step of step 1 (S01), the insulator 51 is arranged at equal pitches radially in a plane with the inner flange portion 54 facing upward, centering on the crossover holding component 71. 5 and 6A correspond.

In the winding step of step 2 (S02), the coil 42 is wound around the insulator 51. At this time, the crossover 43 between the insulators 51 is arranged on the storage groove 72 of the crossover holding component 71. 6B and 11 correspond.

In the crossover fixing step of step 3 (S03), the crossover 43 on the storage groove 72 of the crossover holding component 71 is fixed by the crossover holding component 76. FIG. 7A corresponds.

In the insulator insertion step of step 4 (S04), the insulator 51 around which the coil 42 is wound is rotated 90 degrees around the position between the insulator 51 and the crossover holding component 71 to form the teeth 34 of the inner iron core 33. Insert to form the coil assembly 90. 7B, 8A, and 8B correspond.

In the iron core assembly step of step 5 (S05), the outer iron core 32 is inserted into the outer peripheral portion of the coil assembly 90 to form the iron core and the coil assembly 91. 13A and 13B correspond.

Next, the manufacture of the rotary electric machine 100 will be described.
The rotary electric machine 100 is manufactured by installing a rotor 6 provided with a permanent magnet 8 with a gap sandwiched between the inner peripheral portions of the stator 3 which is the iron core and the coil assembly 91 described above.

The manufacturing method of the rotary electric machine 100 will be described with reference to the flowchart of FIG.
The method for manufacturing the rotary electric machine 100 according to the first embodiment includes the following steps 11 (S11) and 12 (S12).

The iron core and coil assembly manufacturing process of step 11 (S11) corresponds to steps 1 (S01) to 5 (S05) of the flowchart of FIG.

In the rotor incorporating step of step 12 (S12), the rotor 6 provided with the permanent magnet 8 is installed with a gap sandwiched between the inner peripheral portions of the stator 3.

Here, the features of the rotary electric machine of the first embodiment and the manufacturing method thereof will be described.
In the rotary electric machine of the first embodiment and the manufacturing method thereof, the crossover wire 43 does not loosen when the coil 42 is wound around the teeth 34 of the inner iron core 33.
By fixing the crossover 43 to the crossover holding component 71 in advance, the insulator 51 around which the coil 42 is wound can be attached to the crossover 43 even after being incorporated into the inner iron core 33 while rotating around the rotation shaft portion 56. It is possible to maintain a state without looseness. As a result, the crossover line 43 is not damaged even when vibration is applied to the rotary electric machine 100.

Even if the crossovers are loosened by incorporating the coil by the conventional method, it is possible to eliminate the looseness of each crossover. However, it takes a lot of man-hours to wind up and fix the looseness of each of a large number of crossovers. On the other hand, it is easy to arrange the crossover 43 at a predetermined position of the crossover holding component 71 during the winding process as in the first embodiment.

Further, in the case of the conventional method, if a coil wound continuously between insulators is incorporated into the iron core, the crossover wire becomes loose. That is, it means that the length of the crossover is always longer than the minimum required value.
In the first embodiment, the crossover wire 43 can be suppressed to the minimum necessary length, whereby the resistance value of the stator winding 41 can be reduced without reducing the number of turns of the coil 42. A loss of 100 can be reduced.

As described above, the first embodiment has a cylindrical iron core having a plurality of radially arranged teeth, a cylindrical outer core having a cylindrical outer core arranged on the outer peripheral side of the inner core, and the teeth. The insulator and the crossover holding component for holding the crossover between the coils wound continuously on the plurality of insulators are provided, and the insulator and the crossing wire holding component are the ends of the crossover holding component. A stator with a mechanism in which an insulator around which a coil is wound rotates in the direction of the central axis of the inner iron core and is inserted into the teeth, and a rotor installed with a gap in the inner circumference of this stator. The present invention relates to a rotary electric machine provided with a child and a method for manufacturing the same. Can prevent loosening.

Embodiment 2.
In the rotary electric machine of the second embodiment, the height on the inner peripheral side of the insulator is made larger than the height on the outer peripheral side.

The difference between the rotary electric machine of the second embodiment and the first embodiment is based on FIGS. 18A and 18B which are explanatory views of the coil assembly and FIGS. 19A and 19B which are comparative explanatory views of the coil assembly. I will explain mainly.
In the configuration diagram of the second embodiment, the same or corresponding parts as those of the first embodiment are designated by the same reference numerals.
In order to distinguish it from the first embodiment, the insulator 251 and the coil assembly 290 are used in the second embodiment.

The difference between the insulator 251 of the second embodiment and the insulator 51 of the first embodiment is a part of the shape of the insulator. The method of winding the coil 42 around the insulator 251 and the method of inserting the coil 42 into the tooth 34 later are the same as those in the first embodiment.

FIG. 18A is a cross-sectional view of the coil assembly 290 in a state in which the insulator 251 is incorporated in the inner iron core 33 according to the second embodiment in a plane parallel to the axial direction. The crossover 43 is arranged at the lower part of the drawing, and the crossover 43 side becomes the center of the rotation trajectory of the insulator 251 when it is incorporated into the teeth 34.
Here, in the second embodiment, among the inner walls of the insulator 251 in contact with the inner core 33, the inner walls on the side opposite to the center of rotation and on the side opposite to the crossover 43 are not parallel to the laminated surface of the inner core 33, but on the inner diameter side. The slope is wider.
That is, the inner wall spacing B of the insulator 251 is wider than the laminated height A of the inner iron core 33. Due to this structure, there is no interference during incorporation into the teeth 34.
The state during assembly is shown in FIG. 1118B, and if the axial dimension on the inner wall side of the inner wall of the insulator 251 is secured at least B or more, it will not interfere with the teeth 34 at the time of assembly.

In order to clarify the structural features of the second embodiment, the case of the first embodiment will be described with reference to FIGS. 19A and 19B as a comparison.
Since the insulator 51 is inserted into the teeth 34 in a circular orbit, the state shown in FIG. 19A is reached during the insertion, and the inner wall spacing B of the insulator 51 must be wider than the laminated height A of the inner iron core 33. Therefore, the height of the insulator 51 increases in the axial direction as compared with the case where the insulator 51 is inserted from the conventional radial direction. As shown in FIG. 19B, after the assembly is completed, a gap of C = AB, which is the difference between A and B in the axial direction, is formed between the inner iron core 33 and the inner wall of the insulator 51.

Next, in the second embodiment, the effect of widening the inner wall spacing of the insulator 251 will be described.
Since the inner diameter side of the insulator 251 has fewer layers than the outer diameter side of the coil 42, even if the inner diameter side of the inner wall of the insulator 251 is widened, the height D of the inner diameter side flange of the insulator 251 is the outer diameter side flange. It should not be higher than the height E of the part. Therefore, the height of the top of the insulator 251 can be made equal to that of the conventional method of inserting the insulator 251 into the teeth 34 in the direction perpendicular to the axial direction.

Further, in the first embodiment, since it is necessary to widen the interval between the inner walls of the insulator 51, the insulator 51 may not move in the axial direction after the insulator 51 is incorporated into the teeth 34 depending on the usage conditions of the rotary electric machine 100. It may have to be fixed separately.

On the other hand, the outer diameter side of the insulator 251 in the second embodiment is narrower than the inner diameter side, and as shown in FIG. 18A, the outer diameter side of the inner wall of the insulator 251 is brought into contact with the inner iron core 33. It is possible. As a result, it is possible to prevent the insulator 251 from moving in the axial direction after assembly.

As described above, in the rotary electric machine of the second embodiment, the height on the inner peripheral side of the insulator is made larger than the height on the outer peripheral side.
Therefore, the rotary electric machine of the second embodiment can reduce the number of connection points of the coil terminal and prevent loosening of the crossover wire due to the incorporation of the insulator. Furthermore, the insulator can be easily inserted into the inner iron core.

Embodiment 3.
In the rotary electric machine of the third embodiment, a stator winding terminal for pulling out the interphase connection wire of the coil to the outside is provided on the side opposite to the crossover wire holding component in the axial direction of the stator core.

Regarding the rotary electric machine of the third embodiment, FIG. 20 is a cross-sectional view of an insulator in which a coil is wound and a crossover holding component, FIGS. 21 and 22 are cross-sectional views of the insulator, and is an explanatory view of a stator. Based on 23, the difference from the first embodiment will be mainly described.
In the configuration diagram of the third embodiment, the same or corresponding parts as those of the first embodiment are designated by the same reference numerals.
In order to distinguish it from the first embodiment, the stator 303, the insulator 351 and the iron core and the coil assembly 391 are used.

In the third embodiment, the crossover wire 43 connecting the coils 42 arranged in each tooth 34 and the stator winding terminal 73 drawn out from the coil 42 to the outside of the stator 303 are held on both sides in the axial direction, that is, the crossover wire is held. It is separately arranged on the opposite side of the component 71.

FIG. 20 is a cross-sectional view showing a state in which the coil 42 is wound around the insulator 351. In FIG. 7A of the first embodiment, the holding jig 81 and the like are omitted.
The crossover 43 and the crossover holding component 71 are arranged inside the radially arranged insulator 351 and the stator winding terminal 73 is arranged outside the insulator 351.
Although the stator winding terminal 73 is fixed to the flange portion of the insulator 351, it is not necessary to provide the stator winding terminal 73 on all insulators 351. The stator winding terminal 73 may be provided only on the insulator 351 around which the coil 42, which needs to be connected to the outside from the stator 303, is wound.

FIG. 21 shows a state in which the stator winding terminal 73 is arranged on the flange portion of the insulator 351. FIG. 21 is a cross-sectional view parallel to the axial direction at the position of the stator winding terminal 73.
The stator winding terminal 73 is fixed by press-fitting it into the hole portion 57 formed in advance in the outer flange portion 55 of the insulator 351 from the axial direction.
Alternatively, the stator winding terminal 73 may be fixed by insert molding during processing of the insulator 351. Here, the terminal shape is rod-shaped and the coil terminal is wound around the stator winding terminal 73. However, as shown in FIG. 22, the tip of the stator winding terminal 73 is hook-shaped to form the coil terminal. The shape may be hooked and fixed.

The method of incorporating the insulator 351 around which the coil 42 is wound around the inner iron core 33 and the method of inserting the outer iron core 32 are the same as those in the first embodiment.
FIG. 23 shows the state of the iron core and coil assembly 391, that is, the stator 303 after the production is completed. The crossover 43 and the crossover holding component 71 are arranged at the lower part of the drawing, and the stator winding terminal 73, which is pulled out from the stator 303, is arranged at the upper part of the drawing on the opposite side.

Here, the features of the third embodiment will be described.
When the crossover 43 between the coils 42 is arranged on one end face side of the stator 303 and the stator winding terminal 73 for connecting the stator 303 to the outside is arranged on the opposite end face, it is as follows. Effect can be obtained.

The stator winding terminal 73 is a terminal for connecting to the outside, and a lead wire is connected thereto or a board on which a drive circuit is mounted is directly connected.
At this time, soldering and welding are used to connect the stator winding terminal 73 to the lead wire and the substrate. At that time, there is a possibility that thermal damage may occur around the joint, and it may be necessary to take measures such as shielding the surroundings. Therefore, by arranging the crossover wire 43 and the stator winding terminal 73 on different surfaces, it is possible to avoid damage to the crossover wire 43 and to easily shield the surroundings.

As described above, in the rotary electric machine of the third embodiment, the stator winding terminal for pulling out the interphase connection wire of the coil to the outside is provided on the opposite side of the stator core in the axial direction with respect to the crossover wire holding component. be.
Therefore, the rotary electric machine of the third embodiment can reduce the number of connection points of the coil terminal and prevent loosening of the crossover wire due to the incorporation of the insulator. Furthermore, damage to the crossover can be avoided.

Embodiment 4.
The rotary electric machine of the fourth embodiment and the manufacturing method thereof are applied to the rotor by the method of incorporating the insulator of the first embodiment into the inner iron core.

The rotary electric machine of the fourth embodiment and a method for manufacturing the same will be described focusing on the difference from the first embodiment based on FIG. 24 which is a cross-sectional view of the rotary electric machine and FIG. 25 which is a sectional view of the rotor in the axial direction. ..
In the configuration diagram of the fourth embodiment, the same or corresponding parts as those of the first embodiment are designated by the same reference numerals.
In order to distinguish it from the first embodiment, the rotary electric machine 400, the rotor 406, the teeth 434, the stator winding 441, the coil 442, the insulator 451 and the rotor winding terminal 473, the coil assembly 490, the iron core and the coil assembly It is a solid 491.

FIG. 24 is a cross-sectional view of the rotary electric machine 400 perpendicular to the axial direction.
A substantially cylindrical stator 3 is fixed to the inside of the motor frame 2, and a rotor 406 is arranged on the inner peripheral side of the stator 3 with a predetermined gap in between. The rotor 406 is rotatably supported by a bearing (not shown) with respect to the motor frame 2.

The stator 3 has a stator winding 441 wound around a substantially cylindrical stator core 31, and the stator winding 441 is placed in a slot formed between the teeth 34 arranged side by side in the circumferential direction. Deploy. Here, an example of the stator core 31 whose entire circumference is integrated is shown, but a split type stator core which is divided into a plurality of parts in the circumferential direction or the radial direction may be assembled.

The rotor core 60 is composed of an inner core 63 including a teeth 434 and an outer core 62. The rotor 406 incorporates an insulator 451 in which a coil 442 is wound around an inner core 63 of a rotor core 60 fixed to a rotating shaft 65.
An insulator 451 wound with a coil 442 is incorporated in the inner core 63 by the method described in the first embodiment, and the outer core 62 is press-fitted into the outer peripheral side thereof to manufacture the iron core and the coil assembly 491, that is, the rotor 406.

FIG. 25 is a cross-sectional view of the rotor 406 perpendicular to the axial direction.
A bearing 66 is arranged at the end of the rotating shaft 65 and is rotatably supported by a motor frame (not shown). A slip ring 64 for energizing the coil 442 in the rotor 406 is incorporated in one end of the rotating shaft 65. A brush 67 that slides on the slip ring 64 to form an energization path is pressed against the slip ring 64 from the outside of the rotor 406. One end of the conductor of the slip ring 64 is connected to the rotor winding terminal 473, and the end of the rotor winding is joined to the rotor winding terminal 473 to form an energization path to the coil 442 of the rotor 406. ..
In the case of a three-phase circuit, three slip rings 64 and three brushes 67 are required, but only two phases are shown in FIG.

Here, an example in which the slip ring 64 is arranged on the side opposite to the crossover holding component 71 is shown. Therefore, the rotor winding terminal 473 is arranged on the surface opposite to the crossover wire 43. This is the configuration described in the third embodiment, but a configuration in which the crossover 43 and the slip ring 64 are arranged on the same side is also possible.

Next, the features of the rotary electric machine 400 of the fourth embodiment will be described.
In the rotor 406 of the fourth embodiment, the field can be made variable by controlling the energizing current to the coil 442 via the slip ring 64.
As an effect, the rotary electric machine 400 can be rotated at high speed. When the rotor 406 of the fourth embodiment is applied, the number of joint points between the coils 442 is reduced, and loosening of the crossover wire 43 can be avoided. As a result, there is an effect that the joint portion of the coil 442 and the crossover 43 are less likely to be damaged by the vibration and centrifugal force of the rotor 406 during high-speed rotation.

Next, the manufacturing method of the rotor 406 and the rotary electric machine 400 of the fourth embodiment will be described only with reference to the flowchart of the first embodiment and only the differences from the first embodiment.

First, the flowchart of FIG. 16 will be described.
In the alignment step of step 1 (S01), the insulator 51 is replaced with the insulator 451.
In the winding step of step 2 (S02), the insulator 51 is replaced with the insulator 451 and the coil 42 is replaced with the coil 442.
In the insulator insertion step of step 4 (S04), the insulator 51 is replaced with the insulator 451, the coil 42 is replaced with the coil 442, the teeth 34 is replaced with the teeth 434, and the inner core 33 is replaced with the inner core 63.
In the iron core assembly step of step 5 (S05), the coil assembly 90 is read as the coil assembly 490, the iron core and the coil assembly 91 are read as the iron core and the coil assembly 491, and the outer core 32 is read as the outer core 62.
Further, regarding the flowchart of FIG. 17, step 12 (S12) is a "stator assembling step", and the content thereof is "fixing with a stator winding 441 with a gap sandwiched in the outer peripheral portion of the rotor 406". Incorporate child 3 ".

As described above, the rotary electric machine of the fourth embodiment and the manufacturing method thereof are applied to the rotor by the method of incorporating the insulator of the first embodiment into the inner iron core.
Therefore, the rotary electric machine of the fourth embodiment and the manufacturing method thereof can reduce the number of connection points of the coil terminal for the rotor and prevent the crossover from loosening due to the incorporation of the insulator.

Although the present application describes various exemplary embodiments and examples, the various features, embodiments, and functions described in one or more embodiments are applications of a particular embodiment. It is not limited to the above, and can be applied to the embodiment alone or in various combinations.
Therefore, innumerable variations not illustrated are envisioned within the scope of the techniques disclosed in the present application. For example, it is assumed that at least one component is modified, added or omitted, and further, at least one component is extracted and combined with the components of other embodiments. ..

2 motor frame, 3,303 stator, 6 rotor, 8 permanent magnet,
31 Stator core, 32 Outer core, 33 Inner core, 34 Teeth,
35 slots, 41 stator windings, 42 coils, 43 crossovers,
51,251,351 Insulator, 52 Hollow part, 53 Body part, 54 Inner collar part, 55 Outer collar part, 56 Rotating shaft part, 57 hole part, 60 Rotor iron core, 62 Outer iron core,
63 Inner core, 64 Slip ring, 65 Rotating shaft, 66 Bearing, 67 Brush,
71 Crossover holding parts, 72 storage grooves, 73 stator winding terminals, 74 nozzles,
75 Axis center, 76 Crossover wire holding parts, 77 Engagement part, 78 Bearing part,
81 holding jig, 82 insulator holding jig, 83 frame, 84 core,
85 springs, 86 retainers, 90,290 coil assemblies,
91,391 Iron core and coil assembly, 100,400 rotary electric machine, 406 rotor, 434 teeth, 441 stator winding, 442 coil, 451 insulator,
473 rotor winding terminals, 491 core and coil assemblies.

Claims (14)

A cylindrical stator core having an inner core having a plurality of radially arranged teeth and a cylindrical outer core arranged on the outer peripheral side of the inner core.
The insulator inserted into the tooth and
A crossover holding component for holding a crossover between coils wound continuously on the plurality of insulators is provided.
The insulator and the crossover holding component have a mechanism in which the insulator around which the coil is wound rotates around the end of the crossover holding component in the direction of the central axis of the inner iron core and is inserted into the tooth. Equipped with iron core and coil assembly. The iron core and coil assembly according to claim 1, wherein the insulator has an axial height on the inner peripheral side of the inner iron core higher than a height on the outer peripheral side of the inner iron core. The iron core and coil assembly according to claim 1 or 2, wherein the stator winding terminal for pulling out the winding of the coil to the outside is provided in the crossover holding component. Claim 1 or claim 2 that the stator winding terminal for pulling out the winding of the coil to the outside is provided on the side opposite to the axial direction of the stator core with respect to the crossover holding component of the insulator. The iron core and coil assembly described in. A rotor having a stator which is the iron core and coil assembly according to any one of claims 1 to 4 and a permanent magnet installed at an inner peripheral portion of the stator with a gap is provided. Rotating electric machine. A cylindrical stator core having an inner core having a plurality of radially arranged teeth and a cylindrical outer core arranged on the outer peripheral side of the inner core.
The insulator inserted into the tooth and
Using a crossover holding component that holds the crossover of the coil wound around the insulator,
An alignment step of arranging a plurality of the insulators radially around the crossover holding component, and
A winding process in which a winding is continuously wound around a plurality of the insulators to form the coil, and
A crossover fixing step of fixing the crossover between the coils to the crossover holding component,
The inner core is placed above the crossover holding component, and the insulator wound around the end of the crossover holding component is rotated in the direction of the central axis of the inner core and inserted into the tooth. Insertion process and
An iron core assembly step of inserting the outer core into the inner core into which the wound insulator is inserted into the tooth.
A method of manufacturing an iron core and coil assembly comprising. The method for manufacturing an iron core and a coil assembly according to claim 6, wherein the height of the insulator in the axial direction on the inner peripheral side of the inner iron core is higher than the height on the outer peripheral side of the inner iron core. The method for manufacturing an iron core and a coil assembly according to claim 6 or 7, wherein the crossover holding component provided with a stator winding terminal for drawing out the winding of the coil is used. 6. The method for manufacturing an iron core and coil assembly according to the description. Using a stator that is an iron core and coil assembly manufactured by the method for manufacturing an iron core and coil assembly according to any one of claims 6 to 9.
Further, a method for manufacturing a rotary electric machine including a rotor incorporating step of incorporating a rotor equipped with a permanent magnet with a gap sandwiched between the inner peripheral portions of the stator. A rotor core having a plurality of radially arranged teeth, an inner core fixed to a rotating shaft, and a cylindrical outer core arranged on the outer peripheral side of the inner core.
The insulator inserted into the tooth and
A crossover holding component for holding a crossover between coils wound continuously on the plurality of insulators is provided.
The insulator and the crossover holding component have a mechanism in which the insulator around which the coil is wound rotates around the end of the crossover holding component in the direction of the central axis of the inner iron core and is inserted into the tooth. Equipped with iron core and coil assembly. A rotary electric machine including a rotor which is an iron core and coil assembly according to claim 11, and a stator having a stator winding installed on an outer peripheral portion of the rotor with a gap in between. A rotor core having a plurality of radially arranged teeth, an inner core fixed to a rotating shaft, and a cylindrical outer core arranged on the outer peripheral side of the inner core.
The insulator inserted into the tooth and
Using a crossover holding component that holds the crossover of the coil wound around the insulator,
An alignment step of arranging a plurality of the insulators radially around the crossover holding component, and
A winding process in which a winding is continuously wound around a plurality of the insulators to form the coil, and
A crossover fixing step of fixing the crossover between the coils to the crossover holding component,
The inner core is placed above the crossover holding component, and the insulator wound around the end of the crossover holding component is rotated in the direction of the central axis of the inner core and inserted into the tooth. Insertion process and
An iron core and coil assembly step of inserting the outer core into the inner core into which the wound insulator is inserted into the tooth.
A method of manufacturing an iron core and coil assembly comprising. Using a rotor that is an iron core and coil assembly manufactured by the method for manufacturing an iron core and coil assembly according to claim 13.
Further, a method for manufacturing a rotary electric machine including a stator incorporating step of incorporating a stator having a stator winding with a gap sandwiched between the outer peripheral portions of the rotor.

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