Rotary electric machine, electric power steering device, and method of manufacturing a rotary electric machine

A method of manufacturing a rotary electric machine,

• the rotary electric machine including:
• a rotor;
• and
• a stator including a stator core, the stator core including a core back portion having an annular shape and a plurality of tooth portions arranged at an interval in a circumferential direction of the stator to extend from the core back portion in a radial direction of the stator, the stator core having a slot portion formed between the plurality of tooth portions being adjacent to each other in the circumferential direction, the stator being arranged with respect to the rotor through a magnetic air gap portion therebetween,
• each of the plurality of tooth portions including a distal end being an end located on a side of the each of the plurality of tooth portions that is closer to the rotor,
• the stator core further including a connecting portion made of a magnetic material, which is formed at the distal end of each of the plurality of tooth portions and projects from the distal end of the each of the plurality of tooth portions in the circumferential direction to connect the plurality of tooth portions being adjacent to each other in the circumferential direction,
• the connecting portion having a cutout portion formed on a side of the connecting portion that is closer to the magnetic air gap portion,
• the connecting portion including a slot portion-side thin connecting portion formed so as to be closer to the slot portion than the cutout portion,
• a portion of the connecting portion that is shifted in the circumferential direction from a portion of the connecting portion in which the slot portion-side thin connecting portion having formed therein a slot projecting portion projecting from the slot portion toward the magnetic air gap portion with respect to the slot portion-side thin connecting portion,
• the connecting portion further including:
• a magnetic air gap portion-side thin connecting portion formed so as to be closer to the magnetic air gap portion than a position at which the slot projecting portion is formed;
• and
• a radial thin connecting portion, which connects the slot portion-side thin connecting portion and the magnetic air gap portion-side thin connecting portion to each other,
• the slot projecting portion being arranged on each of circumferential sides of the cutout portion, or the cutout portion being arranged on each of circumferential sides of the slot projecting portion,
• the stator core further including:
• a stator core inner diameter portion including the plurality of tooth portions and the connecting portion;
• and
• a stator core outer diameter portion having the core back portion, inside of which the stator core inner diameter portion is to be fitted to apply a radially inward force to the stator core inner diameter portion,
• when the radially inward force is applied to the stator core inner diameter portion by the stator core outer diameter portion, a circumferentially compressing force being applied to the connecting portion,
• when the slot projecting portion is arranged on each of the circumferential sides of the cutout portion, a force for deforming the radial thin connecting portion in a direction in which a circumferential width of the cutout portion on the side closer to the magnetic air gap portion is reduced being applied to the radial thin connecting portion,
• when the cutout portion is arranged on each of the circumferential sides of the slot projecting portion, a force for deforming the radial thin connecting portion in a direction in which a circumferential width of the slot projecting portion on the side closer to the slot portion is reduced being applied to the radial thin connecting portion,
• the method comprising a fitting step of fitting the stator core inner diameter portion inside of the stator core outer diameter portion.