Rotating electrical machine and method of manufacturing the same

A method of manufacturing a rotary electric machine that comprises:

• an armature that comprises an armature core and first-, second-, and third-phase armature windings wound at least around the armature core;
• a magnetic field generator that generates a magnetic field;
• a busbar unit that comprises:
• at least first-, second-, and third-phase busbars electrically connected to the respective first-, second-, and third-phase armature windings,
• the first-phase busbar serving as a lowermost busbar located to face the armature core in an axial direction,
• the second-phase busbar serving as an intermediate busbar stacked over the lowermost busbar in the axial direction, and
• the third-phase busbar serving as an uppermost busbar stacked over the intermediate busbar in the axial direction so that the lowermost busbar, the intermediate busbar, and the uppermost busbar are stacked in the axial direction;
• and
• a resin member that covers the lowermost busbar, the intermediate busbar, and the uppermost busbar stacked in the axial direction so that the lowermost busbar, the intermediate busbar, and the uppermost busbar are integrated to constitute a busbar stack;
• and
• a protrusion member mounted to the intermediate busbar and protruding radially outward from the intermediate busbar, at least part of the protrusion member being located so as to be nonoverlapped with the uppermost busbar and the lowermost busbar in the axial direction,
• the method comprising:
• covering the intermediate busbar with first resin while a part of the protrusion portion is supported, resulting in the supported part of the protrusion member being an exposed part that is non-covered with the first resin;
• locating, below the intermediate busbar, the first-phase busbar to serve as the lowermost busbar;
• stacking, over the intermediate busbar, the third-phase busbar to serve as the uppermost busbar so that the busbar stack comprised of the lowermost busbar, the intermediate busbar, and the uppermost busbar is constructed;
• and
• covering the busbar stack with second resin to accordingly enclose the busbar stack, including the exposed part, with the second resin, thus integrally packaging the busbar stack with the second resin, wherein
• the exposed part of the protrusion member is radially offset with respect to the uppermost busbar and the lowermost busbar.

An armature comprising:

• an armature core;
• first-, second-, and third-phase armature windings wound at least around the armature core;
• a busbar unit that comprises:
• at least first-, second-, and third-phase busbars electrically connected to the respective first-, second-, and third-phase armature windings,
• the first-phase busbar serving as a lowermost busbar located to face the armature core in an axial direction,
• the second-phase busbar serving as an intermediate busbar stacked over the lowermost busbar in the axial direction, and
• the third-phase busbar serving as an uppermost busbar stacked over the intermediate busbar in the axial direction so that the lowermost busbar, the intermediate busbar, and the uppermost busbar are stacked in the axial direction;
• and
• a resin member that covers the lowermost busbar, the intermediate busbar, and the uppermost busbar stacked in the axial direction so that the lowermost busbar, the intermediate busbar, and the uppermost busbar are integrated to constitute a busbar stack;
• and
• a protrusion member mounted to the intermediate busbar and protruding radially outward from the intermediate busbar, at least part of the protrusion member being located so as to be nonoverlapped with the uppermost busbar and the lowermost busbar in the axial direction, wherein:
• the intermediate busbar is covered with first resin;
• at least part of the protrusion member is an exposed part that is non-covered with the first resin;
• the exposed part of the protrusion member is radially offset with respect to the uppermost busbar and the lowermost busbar;
• and
• the resin member is a second resin that covers the uppermost busbar, the resin-covered intermediate busbar and the exposed part, and the lowermost busbar.