Patent ID: 8161625

Claim:
A method of manufacturing a rotating electric machine in which a rotor is formed by fixing a rotor core having p number of magnetic poles around a shaft which is a rotational axis, m number of split cores are formed by stacking a plurality of split core members which each include a yoke portion and a magnetic pole tooth portion protruding from the yoke portion inward in a radial direction, a stator core is formed by rotatably connecting ends of the split cores adjacent to each other upon arranging the m number of split cores in an annular shape, and a stator is formed by winding a coil around the respective split cores included in the stator core, and the stator is disposed in an annular shape around an outer circumference of the rotor, the method comprising: punching from a steel sheet in an annularly arranged shape the m number of split core members A each of which include the yoke portion including a first end on one end side in a circumferential direction, a second end having a shape different from the shape of the first end to complement the first end on the other end side in the circumferential direction and a caulking concavo-convex portion on a surface of the first end, and the magnetic pole tooth portion protruding from the yoke portion inward in a radial direction; forming the split core members B in which locations of a first end and a second end in a circumferential direction are reverse to those in the split core members A by the same punching as that in the split core members A, and forming the m number of split cores by alternatively stacking the split core members A and the split core members B by a predetermined thickness while maintaining the annularly arranged shape in the punching to form n number of (where n≧2) annularly arranged laminates, by matching an i-th annularly arranged laminate among the n number of annularly arranged laminates with a first annularly arranged laminate at a location of the magnetic pole tooth portions in the circumferential direction, and by stacking the i-th annularly arranged laminate in a state where the i-th annularly arranged laminate is rotated in a certain direction by a predetermined angle αi (where 0<αi<2π and i=2 to n) with respect to the first annularly arranged laminate; and forming the stator core so as to arrange the rotatably connected split cores in the annular shape by rotatably connecting the adjacent split cores one another by the caulking concavo-convex portions formed on the surface of the first ends of the yokes of the split cores in an overlapped portion in which the first ends of the yokes of the split cores overlap in a stack direction with the first ends of the yokes of the adjacent split cores in the circumferential direction.