Abstract: A stator unit for including a plurality of coils includes a stator core configured to have the coils wound around the stator core; and a routing member including a plurality of groove configured to have wires routed in the groove, the wires extending from the coils.

Abstract: A rotor manufacturing method for manufacturing a rotor including a rotor core, the rotor core having a permanent magnet mounted thereon throughout a circumferential direction, includes covering an outer circumference of the rotor core with a tubular rotor cover; and forming an angular portion conforming to an outer shape of the permanent magnet by pressing an open end of the rotor cover radially inward with use of a pressing member, the open end of the rotor cover axially projecting from an end of the rotor core before being pressed.

Abstract: A bus bar unit manufacturing method by insert-molding a plurality of bus bars using insulating resin includes a primary setting step of disposing the plurality of bus bars on a support portion provided in a first die such that the plurality of bus bars are separated from each other in a bus bar axial direction, an insertion step of inserting a gap maintaining member between the bus bars, the gap maintaining member being a member that maintains gaps between the adjacent bus bars disposed on the support portion and is provided to be capable of moving relative to the support portion, and a primary molding step of executing insert molding by injecting the insulating resin into the first die in a condition where the gap maintaining member is inserted between the bus bars.

Abstract: A rotor 2 includes a rotor core 21 fixed to a rotation axis in such a manner that the rotor core 21 is rotatable integrally with the rotation axis, the rotor core 21 being configured to have a plurality of magnets 22 mounted thereon throughout a circumferential direction; a first rotor cover 24 that includes a first tubular portion 26, the first tubular portion 26 having a tubular shape configured to cover an outer circumference of one axial side of the rotor core 21; and a second rotor cover 25 that includes a second tubular portion 28, the second tubular portion 28 having a tubular shape configured to cover an outer circumference of the other axial side of the rotor core 21.

Abstract: A bus bar of a bus bar unit includes a main body part extended along a circumferential direction of the stator such that a plate thickness direction of the bus bar agrees with an axial direction of the stator; an extension part extended from the main body part in a radial direction of the stator; and a coil connection part provided at a tip of the extension part, the coil connection part being connectable to a winding terminal of the coil. The extension part includes a retained part having surfaces perpendicular to the axial direction of the stator on both sides of the plate thickness direction. The retained part are held by molds for the insert molding of the bus bar when the insulating resin is formed by the insert molding of the bus bar.

Abstract: The rotor includes the rotor core unit and a single cylindrical rotor cover. The rotor core unit has the rotor core fixed to a rotation axis so as to be able to rotate integrally therewith and a plurality of permanent magnets mounted on the rotor core along a circumferential direction thereof. The single cylindrical rotor cover has the upper surface portion and the bottom portion so as to cover an outer circumference of the rotor core. The upper surface portion is in contact with an outer circumferential edge portion of on one end surface in an axial direction of the permanent magnets. The bottom portion is in contact with at least one of the permanent magnets and the rotor core so that the rotor core unit is held in the axial direction by the upper surface portion and the bottom portion.

Abstract: Each of busbars of a busbar unit includes a main body part that extends along a circumferential direction of the stator so that a plate thickness direction coincides with an axial direction of a stator; a projecting part that projects radially outwardly of the stator from outer periphery of the main body part; an extending part bent from the projecting parts, the extending part extending in the axial and radial direction of the stator; and a connecting part provided on a tip of the extending part, the connecting part being connectable to the winding wire ends of the coils. A position of the connecting part is specified in accordance with length of the extending part in the axial and radial directions of the stator.

Abstract: In a bus bar unit in which a plurality of bus bars are formed by insert molding and arranged in an axial direction of a stator, each bus bar includes: a main body portion extending in a circumferential direction of the stator; a through hole formed in the main body portion, into which a support pin for supporting the main body portion of another bus bar is inserted in the axial direction of the stator during insert molding; and a projecting portion provided on a side portion of the main body portion in alignment with the through hole so as to increase a sectional area of the main body portion.

Abstract: A rotor includes a rotor core fixed to a shaft in such a manner that the rotor core is rotatable integrally with the shaft, the rotor core having a plurality of permanent magnets mounted thereon throughout a circumferential direction; and a tubular rotor cover covering an outer circumference of the rotor core. The rotor cover includes an angular portion and a groove portion, the angular portion has a shape of a circular ring and is formed at an axial end of the rotor core, the groove portion is formed in the rotor cover, in a course of formation of the angular portion, as a dent between a circumferentially neighboring pair of the plurality of permanent magnets.

Abstract: A rotor manufacturing method for manufacturing a rotor including a rotor core, the rotor core having a permanent magnet mounted thereon throughout a circumferential direction, includes covering an outer circumference of the rotor core with a tubular rotor cover; and forming an angular portion conforming to an outer shape of the permanent magnet by pressing an open end of the rotor cover radially inward with use of a pressing member, the open end of the rotor cover axially projecting from an end of the rotor core before being pressed.

Abstract: In a bus bar unit formed by performing secondary insert molding on a primary molded member, which is formed by performing primary insert molding on a plurality of primary molding bus bars, and a plurality of secondary molding bus bars such that the primary molding bus bars and the secondary molding bus bars are arranged in a bus bar axial direction, each primary molding bus bar includes an insertion hole into which a support pin for supporting another primary molding bus bar during the primary insert molding is inserted in the bus bar axial direction, and a through hole through which an insulating resin can pass during the secondary insert molding is formed in each secondary molding bus bar in a position opposing the insertion hole.

Abstract: At least one bus bar, out of a plurality of bus bars of a bus bar unit, includes: a bent main body part that bends and extends across a first stacked position and a second stacked position, the positions being separated in the axial direction of the stator; a first arc-shaped main body part that extends from one end of the bent main body part to be arranged next to another bus bar at the first stacked position along a circumferential direction of the stator; and a second arc-shaped main body part that extends from other end of the bent main body part to be arranged next to another bus bar at the second stacked position along the circumferential direction of the stator.

Abstract: A stator unit for including a plurality of coils includes a stator core configured to have the coils wound around the stator core; and a routing member including a plurality of groove configured to have wires routed in the groove, the wires extending from the coils.

Abstract: A rotating electric machine with a stator unit having a coil wound therearound includes a busbar unit assembled with the stator unit and having a winding end part of the coil connected thereto, and a thermistor for detecting a temperature of the coil. The busbar unit includes a fixing portion for pressing and fixing the thermistor to the coil.

Abstract: A rotor 2 includes a rotor core 21 fixed to a rotation axis in such a manner that the rotor core 21 is rotatable integrally with the rotation axis, the rotor core 21 being configured to have a plurality of magnets 22 mounted thereon throughout a circumferential direction; a first rotor cover 24 that includes a first tubular portion 26, the first tubular portion 26 having a tubular shape configured to cover an outer circumference of one axial side of the rotor core 21; and a second rotor cover 25 that includes a second tubular portion 28, the second tubular portion 28 having a tubular shape configured to cover an outer circumference of the other axial side of the rotor core 21.

Abstract: A manufacturing method of a bus bar unit includes: a primary setting step of disposing a part of a plurality of bus bars into a first mold; a primary molding step of performing an insert molding by injecting the insulating resin material into the first mold, so as to form a primary molded member having a step part; a secondary setting step of disposing the primary molded member and a remaining bus bar of the plurality of bus bars into a second mold; and a secondary molding step of performing the insert molding by injecting the insulating resin material into the second mold, so as to form the bus bar unit. In the secondary setting step, the primary molded member and the remaining bus bar of the plurality of bus bars are arranged in the second mold in such a manner that at least one of an outer periphery and an inner periphery of the remaining bus bar abuts against the step part of the primary molded member.

Abstract: At least one bus bar, out of a plurality of bus bars of a bus bar unit, includes: a bent main body part that bends and extends across a first stacked position and a second stacked position, the positions being separated in the axial direction of the stator; a first arc-shaped main body part that extends from one end of the bent main body part to be arranged next to another bus bar at the first stacked position along a circumferential direction of the stator; and a second arc-shaped main body part that extends from other end of the bent main body part to be arranged next to another bus bar at the second stacked position along the circumferential direction of the stator.

Abstract: A bus bar of a bus bar unit includes a main body part extended along a circumferential direction of the stator such that a plate thickness direction of the bus bar agrees with an axial direction of the stator; an extension part extended from the main body part in a radial direction of the stator; and a coil connection part provided at a tip of the extension part, the coil connection part being connectable to a winding terminal of the coil. The extension part includes a retained part having surfaces perpendicular to the axial direction of the stator on both sides of the plate thickness direction. The retained part are held by molds for the insert molding of the bus bar when the insulating resin is formed by the insert molding of the bus bar.

Abstract: Each of busbars of a busbar unit includes a main body part that extends along a circumferential direction of the stator so that a plate thickness direction coincides with an axial direction of a stator; a projecting part that projects radially outwardly of the stator from outer periphery of the main body part; an extending part bent from the projecting parts, the extending part extending in the axial and radial direction of the stator; and a connecting part provided on a tip of the extending part, the connecting part being connectable to the winding wire ends of the coils. A position of the connecting part is specified in accordance with length of the extending part in the axial and radial directions of the stator.

Abstract: A bus bar unit manufacturing method by insert-molding a plurality of bus bars using insulating resin includes a primary setting step of disposing the plurality of bus bars on a support portion provided in a first die such that the plurality of bus bars are separated from each other in a bus bar axial direction, an insertion step of inserting a gap maintaining member between the bus bars, the gap maintaining member being a member that maintains gaps between the adjacent bus bars disposed on the support portion and is provided to be capable of moving relative to the support portion, and a primary molding step of executing insert molding by injecting the insulating resin into the first die in a condition where the gap maintaining member is inserted between the bus bars.