JP7268589B2 - Rotating electric machine - Google Patents

Description

The disclosure in this specification relates to a rotating electric machine.

2. Description of the Related Art Conventionally, a rotating electrical machine is known that includes a field element including a magnet portion having a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature having multiphase armature windings. For example, in the rotating electric machine disclosed in Patent Document 1, a stator as an armature includes a ring-shaped yoke portion and teeth portions projecting radially from the yoke portions, and the tooth portions are formed in the yoke portions. flat surface. In the stator, the coil (partial winding) is formed by winding an electric wire, and the tooth portion is inserted into the hollow portion, and fixed to the yoke portion in a state where the coil contact surface is in contact with the plane of the yoke portion. It is In this case, the coil can be reliably fixed to the yoke portion.

JP 2015-122834 A

In a radial gap type rotary electric machine having a stator and a rotor, the coils of the stator and the magnet portion of the rotor are arranged to face each other across a predetermined air gap in the radial direction. In this case, in the rotary electric machine of Patent Document 1, since the coil is fixed to the plane of the yoke portion, the peripheral surface of the coil on the side of the air gap is also planar, and there is a gap between the coil and the magnet portion in the circumferential direction. It is conceivable that the air gap dimension becomes non-uniform. As a result, the magnitude of the magnetic flux linkage in the coil becomes non-uniform in the circumferential direction, and there is concern about the occurrence of problems associated therewith. For example, it becomes difficult to grasp the magnitude of the interlinkage magnetic flux, and there is concern that it will be difficult to achieve desired motor performance. In addition, if a bundled wire in which a plurality of wires are bundled in parallel is used, there is concern that a circulating current is likely to occur because the amount of magnetic flux interlinking with the coil differs in the circumferential direction of the coil.

In addition, the presence or absence of the yoke portion is optional in the stator of the rotary electric machine, but if the yoke portion is formed with a flat surface as described above, a difference in cross-sectional area occurs in the yoke portion in the circumferential direction, causing local magnetic saturation. It is feared that On the other hand, if the cross-sectional area of the yoke is made larger than the predetermined value at all parts in order to suppress magnetic saturation, it is conceivable that the cross-sectional area will become excessively large at some parts, resulting in an increase in weight.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object of the present invention is to properly provide an armature winding in a rotating electric machine, thereby achieving desired performance.

The multiple aspects disclosed in this specification employ different technical means to achieve their respective objectives. Objects, features, and advantages disclosed in this specification will become clearer with reference to the following detailed description and accompanying drawings.

Means 1 is
a field element having a magnet portion including a plurality of magnetic poles with alternating polarities in the circumferential direction;
an armature having a multiphase armature winding including a phase winding composed of a plurality of partial windings per phase, and a cylindrical member to which the armature winding is assembled radially inwardly or radially outwardly;
A rotating electrical machine in which the field element and the armature are provided so as to face each other in the radial direction,
The partial winding is formed in an annular shape by winding a conductive wire material having a rectangular cross section in multiple layers, and the conductive wire material is arranged in a plurality of radial and circumferential directions on the coil side,
In the cross section of the partial winding at the coil side, the circumferential side surfaces of the conductor line are arranged linearly in the radial direction, and the radial side surfaces of the conductor line are stepped in the circumferential direction due to radial displacement. They are lined up.

In the rotating electric machine having the above configuration, in the multi-phase armature winding, the partial winding is formed in an annular shape by multiple windings of a conductor having a rectangular cross section. and are wound in a state in which they are arranged in plural numbers in the circumferential direction. An armature is configured by integrally providing armature windings on the radially inner side or radially outer side of the cylindrical member. In this case, if the outer surface of the field element side in the cross section of the partial winding on the coil side is formed flat, the air gap between the armature winding and the field element is uniform in the circumferential direction. There is concern about the occurrence of inconvenience caused by it.

On the other hand, in the above configuration, in the cross section of the partial winding on the coil side, the circumferential side surfaces of the conducting wire are arranged in a straight line in the radial direction, and the radial side surfaces of the conducting wire are radially displaced in the circumferential direction. It is in a state of being lined up in a stepped manner. As a result, in the cross section of the partial winding on the coil side, it is possible to make the outer surface of the field element side match the field element side, and the air gap between the armature winding and the field element becomes possible. can be made uniform. In addition, since the partial winding is formed by winding the conductor material having a rectangular cross section in multiple layers, the conductor space factor can be improved. As a result, in the rotating electric machine, the armature windings can be appropriately provided, and desired performance can be achieved.

In the cross section of the partial winding on the coil side, the radial side surfaces of the conductor are aligned in a stepped manner due to the radial displacement in the circumferential direction. A configuration in which the conductors are lined up with a shift in the direction, and a configuration in which the radial side surfaces of the conductors are lined up with different amounts of shift in the circumferential direction are conceivable.

In Means 2, in Means 1, the partial winding includes a pair of intermediate conductor portions provided at a predetermined interval in the circumferential direction, and a pair of intermediate conductor portions provided at one end side and the other end side in the axial direction, and the pair of intermediate conductor portions are annularly formed. In each intermediate conductor portion, the conductor includes a region on one circumferential end side and a region on the other circumferential end side of each intermediate conductor portion, and in each of these regions The coils are wound in different directions of radial displacement.

In a partial winding having a pair of intermediate conductor portions spaced apart from each other in the circumferential direction and a transition portion connecting the pair of intermediate conductor portions in a ring, depending on the extending direction of the circumferential side surface of the conductor at each intermediate conductor portion, However, the direction of the radial side surface of the conductor facing the peripheral surface of the cylindrical member may not be the same in each intermediate conductor portion. In this regard, in the above configuration, in each intermediate conductive wire portion, the conductive wire material is arranged in a state in which the direction of radial deviation is different between the region on the one end side in the circumferential direction and the region on the other end side in the circumferential direction of each intermediate conductive wire portion. is wound. As a result, in the partial winding, the outer surface on the coil side on the side of the field element can be suitably aligned with the side of the field element.

In means 3, in means 2, a straight line extending along the circumferential side surface of the conductor in one of the pair of intermediate conductor portions and a straight line extending along the circumferential side surface of the conductor in the other intermediate conductor portion are non-parallel to each other and intersect with each other on the armature center side.

In the partial winding, a straight line extending along the circumferential side surface of the conductor in one intermediate conductor portion and a straight line extending along the circumferential side surface of the conductor in the other intermediate conductor portion are non-parallel to each other, In addition, in the configuration in which they intersect with each other on the armature center side, the direction in which the circumferential side surfaces of the conductors extend toward the center of the armature in each intermediate conductor portion. In such a case, the configuration is such that the directions of the radial side surfaces of the conductive wire facing the peripheral surface of the cylindrical member are not the same. Therefore, as described above, in each intermediate wire portion, the wire material may be wound in a state in which the directions of radial displacement are different between the center side in the circumferential direction and both sides in the circumferential direction of each intermediate wire portion.

In Means 4, in Means 1, the partial winding includes a pair of intermediate conductor portions provided at a predetermined interval in the circumferential direction, and a pair of intermediate conductor portions provided at one end side and the other end side in the axial direction. and a bridge portion connected to the intermediate conductor portion, and in each of the intermediate conductor portions, the conductor has the same direction of radial deviation from one circumferential end to the other circumferential end of each of the intermediate conductor portions. , the pair of intermediate conductor portions are wound in such a manner that the deviation directions are opposite to each other.

In a partial winding having a pair of intermediate conductor portions spaced apart from each other in the circumferential direction and a transition portion connecting the pair of intermediate conductor portions in a ring, depending on the extending direction of the circumferential side surface of the conductor at each intermediate conductor portion, In some cases, the direction of the radial side surface of the conductor facing the peripheral surface of the cylindrical member is the same in each of the intermediate conductor portions. In this regard, in the above configuration, in each intermediate conductor portion, the conductor wire material has the same radial direction of deviation from one circumferential end to the other circumferential end of each intermediate conductor portion, and the pair of intermediate conductor portions are wound in a state in which the directions of deviation are opposite to each other. As a result, in the partial winding, the outer surface on the coil side on the side of the field element can be suitably aligned with the side of the field element.

In the partial winding having a pair of intermediate conductor portions and transition portions on both sides in the axial direction, one intermediate conductor portion of the pair of intermediate conductor portions in the partial winding of the other phase is placed between the pair of intermediate conductor portions. are arranged in a predetermined order in the circumferential direction. As a result, a high space factor can be achieved in the armature winding.

In means 5, in any one of means 1 to 4, the cross section of the partial winding on the coil side has a substantially arcuate shape on the side of the field element in the radial direction.

In this case, the cross section of the partial winding has a substantially arcuate shape on the field element side, so that the outer surface of the coil side on the field element side more closely follows the shape of the field element side. can be

In order to make the outer surface of the partial winding on the side of the field element circular, it is preferable to gradually change the amount of displacement in the radial direction of each conductor arranged in the circumferential direction.

In Means 6, in any one of Means 1 to 5, the conducting wire is a rectangular wire having a long side and a short side, and the partial winding is arranged such that the long side of the conducting wire extends in the circumferential direction at the coil side. and the short sides of the conductors overlap in the radial direction.

The partial winding uses a flat wire having a long side and a short side as a conducting wire, and on the coil side, the long side of the conducting wire overlaps in the circumferential direction and the short side of the conducting wire overlaps in the radial direction. It is configured. That is, the conductors are arranged such that the long sides extend in the radial direction and the short sides face the field element. In this case, since the short side of the conducting wire is arranged on the field element side, the outer surface of the partial winding on the field element side is less likely to be affected than the case where the long side of the conducting wire is arranged on the field element side. It is easy to match with the child side.

Furthermore, since the width dimension of the conductive wire in the circumferential direction is smaller than the width dimension in the radial direction at the coil side, the number of stages of each conductive wire increases in the circumferential direction, and the field element side of the partial winding is increased. It is easy to align the outer surface of the magnet with the field element side.

In addition, since the conductor has a width smaller in the circumferential direction than the width in the radial direction at the coil side, the number of turns can be reduced while matching the outer surface shape of the partial winding on the field element side to that on the field element side. By making it as small as possible, it is possible to reduce the number of man-hours when manufacturing the winding.

In means 7, in any one of means 1 to 6, the cylindrical member is an armature core.

In the configuration in which the partial windings are assembled to the armature core as a cylindrical member, by winding the conductor wire material in a shifted state to make the outer surface of the partial windings on the field element side match the field element side, The gap between the partial winding and the armature core can be made small and the gap can be made uniform for each stage of the conductor. This makes it possible to improve the efficiency of the rotary electric machine.

In Means 8, in any one of Means 1 to 7, the partial winding is integrally provided with a winding holding member having a wall portion interposed between itself and the cylindrical member in the radial direction, and the wall In the part, a step surface is formed on the side of the partial winding according to the state of radial displacement of the conductor, and an arc surface without a step is formed on the side of the cylindrical member.

In the above configuration, the winding holding member is provided integrally with the partial winding, and the wall portion of the winding holding member is interposed between the partial winding and the cylindrical member. In this case, it is possible to attach the partial winding to the cylindrical member by means of the winding holding member. In addition, in the wall portion, a stepped surface is formed on the side of the partial winding according to the state of displacement of the conductor in the radial direction, and an arc surface without a step is formed on the side of the cylindrical member. It is possible to reliably and easily assemble the partial winding to the cylindrical member while suppressing the displacement of the wound conductor.

As for Means 9, in any one of Means 1 to 8, the conducting wire is a rectangular wire having a square cross section.

The magnet flux of the field element has a property of spreading in the circumferential direction from the flux outflow surface, and the direction of the magnet flux with respect to the partial windings changes according to the relative position between the field element and the armature. In this case, by using a rectangular wire having a square cross section as the conductor material of the partial winding, eddy currents can be properly suppressed regardless of the relative positions of the field element and the armature.

In means 10, in any one of means 1 to 9, the magnet part in the field element has a permanent magnet that generates magnetic flux at each magnetic pole, and the magnetic flux acting surface of the permanent magnet on the side of the armature , a magnetic flux is generated intensively in a region near the d-axis, which is the center of the magnetic pole.

In the magnet portion of the field element, in a configuration in which magnetic flux is concentrated in a region near the d-axis on the magnetic flux acting surface of the magnet, there is a strong concern about eddy currents caused by magnet magnetic flux in partial windings. In this respect, as described above, the partial winding is formed by multiple windings of a conductor material having a rectangular cross section, and a plurality of conductor materials are arranged in the radial direction and the circumferential direction on the coil side. suppression can be suitably realized.

As a more specific configuration of the permanent magnet, the permanent magnet is configured so that the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary. It is preferable that it is oriented in the direction of Alternatively, in the permanent magnet, the direction of the axis of easy magnetization is oblique to the d-axis between the magnetic flux acting surface on the armature side and the magnetic flux acting surface on the opposite side of the armature. It is preferable to be linearly oriented such that the side approaches the d-axis and the anti-armature side moves away from the d-axis. Halbach array magnets can also be used in the magnet section.

In Means 11, in any one of Means 1 to 10, the partial winding has a larger number of windings of the conductive wire on the radially outer side than on the radially inner side on the coil side.

In the above configuration, the width dimension in the circumferential direction can be made different between the radially inner side and the radially outer side in each intermediate conductor portion of the partial winding. As a result, the conductor space factor of the armature winding can be improved.

For example, in the case of an outer rotor type rotary electric machine, the surface on the side of the field element is wider in the circumferential direction than the surface on the side opposite to the field element in the cross section perpendicular to the axis on the coil side (that is, the number of conductors is increased). ) is good. In the case of an inner rotor type rotating electric machine, the surface on the anti-field element side is wider in the circumferential direction than the surface on the field element side in the orthogonal cross section of the coil side (that is, the number of conductors is increased). Good.

According to Means 12, in any one of Means 1 to 10, the conducting wire is a flat wire having a long side and a short side, and the partial winding is arranged on the coil side with the long side extending in a radial direction. It has a portion around which the conducting wire is wound and a portion around which the conducting wire is wound with the direction in which the long side extends as the circumferential direction. Width dimensions are different.

In a configuration using a rectangular wire having a long side and a short side as a conductor, changing the direction of the cross section of the conductor changes the dimension in the overlapping direction (stacking dimension). In this case, on the coil side of the partial winding, a portion around which the conductor wire is wound with the long side extending in the radial direction and a portion around which the conductor wire is wound with the long side extending in the circumferential direction are provided. Thus, the radially inner side and the radially outer side can have different widths in the circumferential direction. As a result, the conductor space factor of the armature winding can be improved.

BRIEF DESCRIPTION OF THE DRAWINGS The perspective view which shows the whole rotary electric machine in 1st Embodiment. The top view of a rotary electric machine. FIG. 2 is a vertical cross-sectional view of a rotating electric machine; FIG. 2 is a cross-sectional view of a rotating electrical machine; FIG. 2 is an exploded cross-sectional view of the rotating electrical machine; Sectional drawing of a rotor. FIG. 4 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit; FIG. 4 is a diagram showing the relationship between the electrical angle and the magnetic flux density of the magnet of the embodiment; FIG. 5 is a diagram showing the relationship between the electrical angle and the magnetic flux density for a magnet of a comparative example; The perspective view of a stator unit. FIG. 4 is a longitudinal sectional view of the stator unit; FIG. 3 is a perspective view of the core assembly viewed from one axial side; The perspective view which looked at the core assembly from the axial direction other side. FIG. 4 is a cross-sectional view of the core assembly; 3 is an exploded cross-sectional view of the core assembly; FIG. FIG. 4 is a circuit diagram showing a connection state of partial windings in each phase winding of three phases; The side view which puts a 1st coil module and a 2nd coil module side by side and shows it in contrast. The side view which puts a 1st partial winding and a 2nd partial winding side by side and shows it in comparison. The figure which shows the structure of a 1st coil module. 20-20 line sectional view in FIG. 19(a). The perspective view which shows the structure of an insulating cover. The figure which shows the structure of a 2nd coil module. 23-23 line sectional view in FIG. 22(a). The perspective view which shows the structure of an insulating cover. FIG. 4 is a diagram showing overlapping positions of film materials when coil modules are arranged in the circumferential direction; FIG. 4 is a plan view showing the assembled state of the first coil module with respect to the core assembly; FIG. 4 is a plan view showing how the first coil module and the second coil module are attached to the core assembly; FIG. 4 is a vertical cross-sectional view showing a state of being fixed by a fixing pin; 3 is a perspective view of a busbar module; FIG. Sectional drawing which shows a part of longitudinal section of a bus-bar module. The perspective view which shows the state which assembled|attached the bus-bar module to the stator holder. FIG. 4 is a vertical cross-sectional view of a fixing portion for fixing the busbar module; FIG. 4 is a longitudinal sectional view showing a state where the relay member is attached to the housing cover; The perspective view of a relay member. An electric circuit diagram showing a control system for a rotating electric machine. FIG. 4 is a functional block diagram showing current feedback control processing by a control device; FIG. 4 is a functional block diagram showing torque feedback control processing by a control device; FIG. 5 is a partial cross-sectional view showing the cross-sectional structure of a magnet unit in a modified example; The figure which shows the structure of the stator unit of an inner rotor structure. FIG. 4 is a plan view showing how the coil module is attached to the core assembly; The perspective view which shows the structure of the coil module in 2nd Embodiment. FIG. 4 is a cross-sectional view showing a cross section at an axial intermediate portion of the partial winding; FIG. 3 is an exploded cross-sectional view showing an enlarged intermediate conductor portion of a partial winding and a coil holder; FIG. 3 is an exploded cross-sectional view showing an enlarged intermediate conductor portion of a partial winding and a coil holder; FIG. 4 is a cross-sectional view showing a cross section at an axial intermediate portion of the partial winding; FIG. 4 is an enlarged cross-sectional view showing an intermediate conductor portion of a partial winding and a coil holder; The figure which shows the cross section of the intermediate conductor part of partial winding.

A number of embodiments will be described with reference to the drawings. In several embodiments, functionally and/or structurally corresponding and/or related parts may be labeled with the same reference numerals or reference numerals differing by one hundred or more places. For corresponding and/or associated parts, reference can be made to the description of other embodiments.

The rotary electric machine in this embodiment is used, for example, as a vehicle power source. However, the rotating electric machine can be widely used for industrial use, vehicle use, home appliance use, OA equipment use, game machine use, and the like. In addition, in each of the following embodiments, parts that are the same or equivalent to each other are denoted by the same reference numerals in the drawings, and the description of the same reference numerals is used.

(First embodiment)
The rotary electric machine 10 according to this embodiment is a synchronous multiphase AC motor and has an outer rotor structure (outward rotation structure). An outline of the rotating electric machine 10 is shown in FIGS. 1 to 5. FIG. 1 is a perspective view showing the entire rotary electric machine 10, FIG. 2 is a plan view of the rotary electric machine 10, and FIG. ), FIG. 4 is a cross-sectional view of the rotating electrical machine 10 (sectional view taken along line 4-4 in FIG. 3), and FIG. In the following description, in the rotating electric machine 10, the direction in which the rotating shaft 11 extends is defined as the axial direction, the direction radially extending from the center of the rotating shaft 11 is defined as the radial direction, and the direction extending circumferentially about the rotating shaft 11 is defined as the circumferential direction. direction.

The rotary electric machine 10 is roughly divided into a rotary electric machine main body having a rotor 20, a stator unit 50 and a busbar module 200, and a housing 241 and a housing cover 242 provided so as to surround the rotary electric machine main body. All of these members are arranged coaxially with respect to a rotating shaft 11 that is integrally provided with the rotor 20, and the rotary electric machine 10 is configured by being axially assembled in a predetermined order. The rotary shaft 11 is supported by a pair of bearings 12 and 13 respectively provided in the stator unit 50 and the housing 241, and is rotatable in that state. Bearings 12 and 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls arranged therebetween. The rotation of the rotating shaft 11 rotates an axle of a vehicle, for example. The rotary electric machine 10 can be mounted on a vehicle by fixing the housing 241 to a vehicle body frame or the like.

In the rotating electric machine 10 , the stator unit 50 is provided so as to surround the rotating shaft 11 , and the rotor 20 is arranged radially outside the stator unit 50 . The stator unit 50 has a stator 60 and a stator holder 70 mounted radially inward thereof. The rotor 20 and the stator 60 are arranged to face each other in the radial direction with an air gap interposed therebetween. Rotate. The rotor 20 corresponds to the "field element" and the stator 60 corresponds to the "armature".

FIG. 6 is a longitudinal sectional view of rotor 20. As shown in FIG. As shown in FIG. 6 , the rotor 20 has a substantially cylindrical rotor carrier 21 and an annular magnet unit 22 fixed to the rotor carrier 21 . The rotor carrier 21 has a cylindrical portion 23 having a cylindrical shape and an end plate portion 24 provided at one end in the axial direction of the cylindrical portion 23, and is configured by integrating them. . The rotor carrier 21 functions as a magnet holding member, and the magnet unit 22 is annularly fixed inside the cylindrical portion 23 in the radial direction. A through hole 24a is formed in the end plate portion 24, and the rotating shaft 11 is fixed to the end plate portion 24 by a fastener 25 such as a bolt while being inserted into the through hole 24a. The rotating shaft 11 has a flange 11a extending in a direction that intersects (perpendicularly) with the axial direction. is fixed.

The magnet unit 22 includes a cylindrical magnet holder 31 , a plurality of magnets 32 fixed to the inner peripheral surface of the magnet holder 31 , and one of the two axial sides opposite to the end plate portion 24 of the rotor carrier 21 . It has a fixed end plate 33 . The magnet holder 31 has the same length dimension as the magnet 32 in the axial direction. The magnet 32 is provided so as to be surrounded by the magnet holder 31 from the outside in the radial direction. The magnet holder 31 and the magnet 32 are fixed in contact with the end plate 33 at one end in the axial direction. The magnet unit 22 corresponds to the "magnet section".

FIG. 7 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit 22. As shown in FIG. In FIG. 7, the direction of the axis of easy magnetization of the magnet 32 is indicated by an arrow.

In the magnet unit 22 , the magnets 32 are arranged along the circumferential direction of the rotor 20 so that their polarities alternate. Thereby, the magnet unit 22 has a plurality of magnetic poles in the circumferential direction. The magnet 32 is a polar anisotropic permanent magnet, and uses a sintered neodymium magnet having an intrinsic coercive force of 400 [kA/m] or more and a residual magnetic flux density Br of 1.0 [T] or more. It is configured.

A peripheral surface on the radially inner side (the stator 60 side) of the magnet 32 is a magnetic flux acting surface 34 on which magnetic flux is exchanged. The magnet unit 22 is configured to generate magnetic flux intensively in a region near the d-axis, which is the magnetic pole center, on the magnetic flux acting surface 34 of the magnet 32 . Specifically, in the magnet 32, the direction of the axis of easy magnetization differs between the d-axis side (portion near the d-axis) and the q-axis side (portion near the q-axis). is parallel to the d-axis, and on the q-axis side, the direction of the axis of easy magnetization is perpendicular to the q-axis. In this case, an arcuate magnet magnetic path is formed along the direction of the axis of easy magnetization. In short, the magnet 32 is oriented such that the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary.

In the magnet 32 , the magnet magnetic path length is longer than the thickness dimension of the magnet 32 in the radial direction because the magnet magnetic path is formed in an arc shape. As a result, the permeance of the magnet 32 is increased, and it is possible to exhibit the same ability as a magnet with a large amount of magnets, even though the amount of magnets is the same.

A set of two magnets 32 adjacent in the circumferential direction constitutes one magnetic pole. That is, the plurality of magnets 32 arranged in the circumferential direction in the magnet unit 22 each have a split surface on the d-axis and the q-axis, and the magnets 32 are arranged in contact with or close to each other. . As described above, the magnets 32 have an arc-shaped magnet magnetic path, and along the q-axis, the N poles and the S poles of the magnets 32 that are adjacent in the circumferential direction face each other. Therefore, it is possible to improve the permeance in the vicinity of the q-axis. In addition, since the magnets 32 on both sides of the q-axis are attracted to each other, the magnets 32 can maintain contact with each other. Therefore, it also contributes to the improvement of permeance.

In the magnet unit 22, the magnets 32 cause magnetic fluxes to flow in an arc between adjacent N and S poles, so the magnet magnetic path is longer than, for example, a radially anisotropic magnet. Therefore, as shown in FIG. 8, the magnetic flux density distribution is close to a sine wave. As a result, unlike the magnetic flux density distribution of the radially anisotropic magnet shown in FIG. 9 as a comparative example, the magnetic flux can be concentrated on the center side of the magnetic pole, and the torque of the rotating electric machine 10 can be increased. . In addition, it can be confirmed that the magnet unit 22 of the present embodiment has a different magnetic flux density distribution than the conventional Halbach array magnet. 8 and 9, the horizontal axis indicates the electrical angle, and the vertical axis indicates the magnetic flux density. 8 and 9, 90° on the horizontal axis indicates the d-axis (that is, the magnetic pole center), and 0° and 180° on the horizontal axis indicate the q-axis.

That is, according to the magnets 32 configured as described above, in the magnet unit 22, the magnet magnetic flux is strengthened along the d-axis, and the magnetic flux variation around the q-axis is suppressed. As a result, it is possible to suitably realize the magnet unit 22 in which the surface magnetic flux changes gradually from the q-axis to the d-axis in each magnetic pole.

The sine wave matching rate of the magnetic flux density distribution may be set to a value of 40% or more, for example. By doing so, the amount of magnetic flux at the central portion of the waveform can be reliably improved compared to the case of using radially oriented magnets and parallel oriented magnets having a sine wave matching rate of about 30%. Further, if the sine wave matching rate is 60% or more, the amount of magnetic flux in the central portion of the waveform can be reliably improved compared to a magnetic flux concentrated array such as the Halbach array.

In the radially anisotropic magnet shown in FIG. 9, the magnetic flux density sharply changes near the q-axis. The steeper the change in magnetic flux density, the greater the eddy current in the stator windings 61 of the stator 60, which will be described later. Moreover, the magnetic flux change on the stator winding 61 side also becomes steep. On the other hand, in this embodiment, the magnetic flux density distribution becomes a magnetic flux waveform close to a sine wave. Therefore, near the q-axis, the change in magnetic flux density is smaller than the change in magnetic flux density of the radially anisotropic magnet. Thereby, generation of eddy current can be suppressed.

The magnet 32 has a recessed portion 35 formed in a predetermined range including the d-axis on the radially outer peripheral surface thereof, and a recessed portion 36 formed in a predetermined range including the q-axis on the radially inner peripheral surface thereof. ing. In this case, according to the direction of the axis of easy magnetization of the magnet 32, the magnet magnetic path is shortened near the d-axis on the outer peripheral surface of the magnet 32, and the magnetic magnetic path is shortened near the q-axis on the inner peripheral surface of the magnet 32. . Considering that it is difficult to generate a sufficient magnet magnetic flux in the magnet 32 where the magnet magnetic path length is short, the magnet is removed at a location where the magnet magnetic flux is weak.

Note that the magnet unit 22 may be configured to use the same number of magnets 32 as the magnetic poles. For example, the magnet 32 may be provided as one magnet between the d-axis which is the center of each magnetic pole in two magnetic poles adjacent to each other in the circumferential direction. In this case, the magnet 32 has a configuration in which the center in the circumferential direction is the q-axis and the split surface is along the d-axis. Further, the magnet 32 may have a configuration in which the center in the circumferential direction is the d-axis instead of the q-axis. As the magnets 32, instead of using magnets having the number twice the number of magnetic poles or magnets having the same number as the number of magnetic poles, ring magnets connected in an annular shape may be used.

As shown in FIG. 3, a resolver 41 as a rotation sensor is provided at the opposite end (upper end in the drawing) of the connecting portion to the rotor carrier 21 among both sides of the rotating shaft 11 in the axial direction. ing. The resolver 41 includes a resolver rotor fixed to the rotating shaft 11 and a resolver stator disposed radially outside the resolver rotor so as to face each other. The resolver rotor has a disk-ring shape, and is provided coaxially with the rotating shaft 11 in a state in which the rotating shaft 11 is inserted therethrough. The resolver stator has a stator core and stator coils and is fixed to housing cover 242 .

Next, the configuration of the stator unit 50 will be described. 10 is a perspective view of the stator unit 50, and FIG. 11 is a longitudinal sectional view of the stator unit 50. FIG. 11 is a longitudinal sectional view at the same position as in FIG.

The stator unit 50 generally includes a stator 60 and a radially inner stator holder 70 . Also, the stator 60 has a stator winding 61 and a stator core 62 . The stator core 62 and the stator holder 70 are integrally provided as a core assembly CA, and a plurality of partial windings 151 constituting the stator winding 61 are assembled to the core assembly CA. The stator winding 61 corresponds to the "armature winding", the stator core 62 corresponds to the "armature core", and the stator holder 70 corresponds to the "armature holding member". Also, the core assembly CA corresponds to the "supporting member".

First, the core assembly CA will be described. 12 is a perspective view of the core assembly CA seen from one side in the axial direction, FIG. 13 is a perspective view of the core assembly CA seen from the other side in the axial direction, and FIG. 14 is a cross-sectional view of the core assembly CA. 15 is an exploded cross-sectional view of the core assembly CA.

The core assembly CA has the stator core 62 and the stator holder 70 assembled radially inwardly thereof, as described above. In other words, the stator core 62 is integrally attached to the outer peripheral surface of the stator holder 70 .

The stator core 62 is configured as a core sheet laminated body in which core sheets 62a made of electromagnetic steel plates, which are magnetic materials, are laminated in the axial direction, and has a cylindrical shape with a predetermined thickness in the radial direction. A stator winding 61 is assembled on the radially outer side of the stator core 62 on the rotor 20 side. The outer peripheral surface of the stator core 62 has a curved surface without irregularities. The stator core 62 functions as a back yoke. The stator core 62 is configured by laminating a plurality of core sheets 62a, which are formed by punching into, for example, an annular plate shape, in the axial direction. However, a stator core 62 having a helical core structure may also be used. In the stator core 62 of the helical core structure, a band-shaped core sheet is used, and the core sheet is wound in an annular shape and laminated in the axial direction to form the overall cylindrical stator core 62 . It is

In this embodiment, the stator 60 has a slotless structure that does not have teeth for forming slots. can be anything.
(A) In the stator 60, an inter-conductor member is provided between each conductor portion (intermediate conductor portion 152 described later) in the circumferential direction, and as the inter-conductor member, the width dimension of the inter-conductor member in one magnetic pole in the circumferential direction is Wt, the saturation magnetic flux density of the inter-conductor member is Bs, the width dimension of the magnet 32 in the circumferential direction in one magnetic pole is Wm, and the residual magnetic flux density of the magnet 32 is Br. A magnetic material is used.
(B) In the stator 60, a member between conductors is provided between each conductor portion (intermediate conductor portion 152) in the circumferential direction, and a non-magnetic material is used as the member between conductors.
(C) The stator 60 has a configuration in which no member between conductors is provided between conductors (intermediate conductors 152) in the circumferential direction.

15, the stator holder 70 has an outer cylinder member 71 and an inner cylinder member 81. The outer cylinder member 71 is radially outside and the inner cylinder member 81 is radially inside. It is configured by being integrally assembled. Each of these members 71 and 81 is made of, for example, metal such as aluminum or cast iron, or carbon fiber reinforced plastic (CFRP).

The outer cylindrical member 71 is a cylindrical member having perfectly circular curved surfaces on both the outer peripheral surface and the inner peripheral surface, and an annular flange 72 extending radially inward is formed on one axial end side. A plurality of protrusions 73 extending radially inward are formed on the flange 72 at predetermined intervals in the circumferential direction (see FIG. 13). Opposing surfaces 74 and 75 are formed on the outer cylindrical member 71 at one axial end side and the other axial end side, respectively, to face the inner cylindrical member 81 in the axial direction. Annular grooves 74a and 75a are formed extending to.

The inner cylinder member 81 is a cylindrical member having an outer diameter dimension smaller than the inner diameter dimension of the outer cylinder member 71 , and its outer peripheral surface is a perfectly circular curved surface concentric with the outer cylinder member 71 . An annular flange 82 extending radially outward is formed on one axial end side of the inner cylindrical member 81 . The inner cylinder member 81 is attached to the outer cylinder member 71 while being in contact with the facing surfaces 74 and 75 of the outer cylinder member 71 in the axial direction. As shown in FIG. 13, the outer cylinder member 71 and the inner cylinder member 81 are assembled together with fasteners 84 such as bolts. Specifically, on the inner peripheral side of the inner cylinder member 81, a plurality of projections 83 extending radially inward are formed at predetermined intervals in the circumferential direction. The protrusions 73 and 83 of the member 71 are fastened together with fasteners 84 while the protrusions 73 of the member 71 are overlapped with each other.

As shown in FIG. 14, an annular gap is formed between the inner peripheral surface of the outer tubular member 71 and the outer peripheral surface of the inner tubular member 81 when the outer tubular member 71 and the inner tubular member 81 are assembled together. The gap space serves as a refrigerant passage 85 through which a refrigerant such as cooling water flows. The coolant passage 85 is provided annularly in the circumferential direction of the stator holder 70 . More specifically, the inner cylindrical member 81 is provided with a passage forming portion 88 that protrudes radially inward on its inner peripheral side and in which an inlet side passage 86 and an outlet side passage 87 are formed, Each of these passages 86 and 87 opens on the outer peripheral surface of the inner cylindrical member 81 . A partition portion 89 is provided on the outer peripheral surface of the inner cylindrical member 81 for partitioning the refrigerant passage 85 into an inlet side and an outlet side. Thereby, the refrigerant flowing in from the inlet side passage 86 flows in the circumferential direction through the refrigerant passage 85 and then flows out from the outlet side passage 87 .

One end of the inlet-side passage 86 and the outlet-side passage 87 extends radially and opens to the outer peripheral surface of the inner cylinder member 81 , and the other end extends axially to open to the axial end surface of the inner cylinder member 81 . It's like 12 shows an inlet opening 86a leading to the inlet side passage 86 and an outlet opening 87a leading to the outlet side passage 87. FIG. The inlet-side passage 86 and the outlet-side passage 87 communicate with an inlet port 244 and an outlet port 245 (see FIG. 1) attached to the housing cover 242, through which the refrigerant flows in and out. It's like

Sealing members 101 and 102 are provided at the junction between the outer cylinder member 71 and the inner cylinder member 81 to suppress leakage of refrigerant from the refrigerant passage 85 (see FIG. 15). Specifically, the sealing members 101 and 102 are, for example, O-rings, which are accommodated in the annular grooves 74a and 75a of the outer cylinder member 71 and provided in a state of being compressed by the outer cylinder member 71 and the inner cylinder member 81. there is

As shown in FIG. 12, the inner cylindrical member 81 has an end plate portion 91 on one end side in the axial direction, and the end plate portion 91 has a hollow cylindrical boss portion 92 extending in the axial direction. is provided. The boss portion 92 is provided so as to surround an insertion hole 93 through which the rotating shaft 11 is inserted. The boss portion 92 is provided with a plurality of fastening portions 94 for fixing the housing cover 242 . Further, the end plate portion 91 is provided with a plurality of strut portions 95 extending in the axial direction outside the boss portion 92 in the radial direction. The strut portion 95 is a fixing portion for fixing the busbar module 200, and the details thereof will be described later. The boss portion 92 serves as a bearing holding member that holds the bearing 12, and the bearing 12 is fixed to a bearing fixing portion 96 provided on the inner peripheral portion thereof (see FIG. 3).

12 and 13, recesses 105 and 106 used for fixing a plurality of coil modules 150, which will be described later, are formed in the outer cylinder member 71 and the inner cylinder member 81, respectively.

Specifically, as shown in FIG. 12 , a plurality of grooves are formed at equal intervals in the circumferential direction on the axial end face of the inner cylindrical member 81 , more specifically, on the axial outer end face of the end plate portion 91 around the boss portion 92 . A recess 105 is formed. Further, as shown in FIG. 13 , a plurality of recesses 106 are formed at equal intervals in the circumferential direction on the axial end face of the outer cylinder member 71 , more specifically, on the axial outer end face of the flange 72 . These concave portions 105 and 106 are arranged on a virtual circle concentric with the core assembly CA. The recesses 105 and 106 are provided at the same positions in the circumferential direction, and have the same interval and number.

By the way, the stator core 62 is assembled to the stator holder 70 in a state in which a radial compressive force is generated in order to secure the strength of assembly to the stator holder 70 . Specifically, the stator core 62 is fitted and fixed to the stator holder 70 with a predetermined interference by shrink fitting or press fitting. In this case, it can be said that the stator core 62 and the stator holder 70 are assembled in a state in which one of them exerts a radial stress on the other. In order to increase the torque of the rotary electric machine 10, it is conceivable to increase the diameter of the stator 60, for example. The clamping force of core 62 is increased. However, if the compressive stress (in other words, residual stress) of the stator core 62 is increased, there is concern that the stator core 62 will be damaged.

Therefore, in the present embodiment, in a structure in which the stator core 62 and the stator holder 70 are fitted and fixed to each other with a predetermined interference, the radially opposing portions of the stator core 62 and the stator holder 70 are provided with: A restriction portion is provided to restrict displacement of the stator core 62 in the circumferential direction by engagement in the circumferential direction. 12 to 14, between the stator core 62 and the outer cylindrical member 71 of the stator holder 70 in the radial direction, a plurality of engagement members serving as restricting portions are provided at predetermined intervals in the circumferential direction. A member 111 is provided, and the engagement member 111 suppresses circumferential positional deviation between the stator core 62 and the stator holder 70 . In this case, at least one of the stator core 62 and the outer cylindrical member 71 may be provided with a concave portion, and the engagement member 111 may be engaged with the concave portion. Instead of the engaging member 111, a configuration may be adopted in which a convex portion is provided on either the stator core 62 or the outer cylindrical member 71. FIG.

In the above configuration, the stator core 62 and the stator holder 70 (outer cylindrical member 71) are fitted and fixed with a predetermined interference, and in addition, the engaging member 111 restricts mutual displacement in the circumferential direction. It is installed in the Therefore, even if the interference between the stator core 62 and the stator holder 70 is relatively small, the displacement of the stator core 62 in the circumferential direction can be suppressed. Moreover, since a desired displacement suppression effect can be obtained even if the interference is relatively small, damage to the stator core 62 due to excessive interference can be suppressed. As a result, displacement of the stator core 62 can be properly suppressed.

An annular inner space is formed on the inner peripheral side of the inner cylindrical member 81 so as to surround the rotating shaft 11, and electric parts constituting an inverter as a power converter, for example, are arranged in the inner space. good too. An electrical component is, for example, an electrical module in which semiconductor switching elements and capacitors are packaged. By arranging the electric module in contact with the inner peripheral surface of the inner cylinder member 81 , the electric module can be cooled by the refrigerant flowing through the refrigerant passage 85 . In addition, on the inner peripheral side of the inner cylindrical member 81, it is also possible to eliminate the plurality of projecting portions 83 or reduce the projecting height of the projecting portions 83, thereby expanding the internal space on the inner peripheral side of the inner cylindrical member 81. It is possible.

Next, the configuration of the stator windings 61 assembled to the core assembly CA will be described in detail. The state in which the stator windings 61 are assembled to the core assembly CA is as shown in FIGS. A plurality of partial windings 151 forming the winding 61 are assembled in a state of being arranged in the circumferential direction.

The stator winding 61 has a plurality of phase windings, and is formed in a cylindrical (annular) shape by arranging the phase windings of each phase in a predetermined order in the circumferential direction. In this embodiment, the stator winding 61 is configured to have three phase windings by using U-phase, V-phase, and W-phase windings.

As shown in FIG. 11, the stator 60 includes, in the axial direction, a portion corresponding to the coil side CS of the rotor 20 that faces the magnet unit 22 in the radial direction, and a coil end that is axially outside the coil side CS. and a portion corresponding to CE. In this case, the stator core 62 is provided in a range corresponding to the coil side CS in the axial direction.

In the stator winding 61 , each phase winding has a plurality of partial windings 151 (see FIG. 16), and the partial windings 151 are individually provided as coil modules 150 . That is, the coil module 150 is configured by integrally providing the partial windings 151 of the phase windings of each phase, and the stator winding 61 is configured by a predetermined number of coil modules 150 corresponding to the number of poles. there is By arranging the coil modules 150 (partial windings 151) of each phase in a predetermined order in the circumferential direction, the conductor portions of each phase are arranged in a predetermined order on the coil side CS of the stator winding 61. It has become. FIG. 10 shows the arrangement order of the U-phase, V-phase, and W-phase conductor portions in the coil side CS. In this embodiment, the number of magnetic poles is 24, but the number is arbitrary.

In the stator winding 61, the phase winding of each phase is configured by connecting the partial windings 151 of each coil module 150 in parallel or in series for each phase. FIG. 16 is a circuit diagram showing the connection state of partial windings 151 in each phase winding of three phases. FIG. 16 shows a state in which the partial windings 151 of the phase windings of each phase are connected in parallel.

As shown in FIG. 11, the coil module 150 is assembled radially outward of the stator core 62 . In this case, the coil module 150 is assembled in a state in which both axial end portions of the coil module 150 protrude axially outward (that is, to the coil end CE side) from the stator core 62 . That is, the stator winding 61 has a portion corresponding to the coil end CE projecting axially outward from the stator core 62 and a portion corresponding to the coil side CS axially inward. .

The coil module 150 has two shapes, one of which has a shape in which the partial windings 151 are bent radially inward at the coil ends CE, that is, toward the stator core 62 side. In the other, the partial winding 151 is not bent inward in the radial direction at the coil end CE and has a shape extending linearly in the axial direction. In the following description, for the sake of convenience, the partial winding 151 having a bent shape at both ends in the axial direction will be referred to as the "first partial winding 151A", and the coil module 150 having the first partial winding 151A will be referred to as the "first coil". module 150A". Further, the partial winding 151 that does not have a bent shape on both ends in the axial direction is also called a "second partial winding 151B", and the coil module 150 having the second partial winding 151B is also called a "second coil module 150B". .

FIG. 17 is a side view showing the first coil module 150A and the second coil module 150B arranged side by side for comparison, and FIG. It is a side view shown side by side for comparison. As shown in these figures, the coil modules 150A and 150B and the partial windings 151A and 151B have different lengths in the axial direction and different end shapes on both sides in the axial direction. The first partial winding 151A has a substantially C shape when viewed from the side, and the second partial winding 151B has a substantially I shape when viewed from the side. Insulating covers 161 and 162 as "first insulating covers" are mounted on both axial sides of the first partial winding 151A, and "second insulating covers" are mounted on both axial sides of the second partial winding 151B. insulating covers 163 and 164 are attached.

Next, the configuration of the coil modules 150A and 150B will be described in detail.

First, the first coil module 150A of the coil modules 150A and 150B will be described. FIG. 19(a) is a perspective view showing the configuration of the first coil module 150A, and FIG. 19(b) is an exploded perspective view showing components of the first coil module 150A. 20 is a cross-sectional view taken along the line 20-20 in FIG. 19(a).

As shown in FIGS. 19(a) and 19(b), the first coil module 150A includes a first partial winding 151A formed by multiple windings of a conductive wire CR, and an axial It has insulating covers 161 and 162 attached to one end and the other end. The insulating covers 161 and 162 are molded from an insulating material such as synthetic resin.

The first partial winding 151A has a pair of intermediate conductor portions 152 that are provided in parallel and linearly, and a pair of transition portions 153A that connect the pair of intermediate conductor portions 152 at both ends in the axial direction. , the pair of intermediate conductor portions 152 and the pair of bridging portions 153A form an annular shape. The pair of intermediate conductor portions 152 are spaced apart by a predetermined coil pitch, and the intermediate conductor portion 152 of the partial winding 151 of the other phase can be arranged between the pair of intermediate conductor portions 152 in the circumferential direction. It's becoming In this embodiment, the pair of intermediate conductor portions 152 are provided two coil pitches apart, and one intermediate conductor portion 152 of the partial winding 151 of the other two phases is arranged between the pair of intermediate conductor portions 152. It is configured to be

The pair of transition portions 153A has the same shape on both sides in the axial direction, and both are provided as portions corresponding to the coil ends CE (see FIG. 11). Each bridging portion 153A is provided so as to be bent in a direction orthogonal to the intermediate conductor portion 152, that is, in a direction orthogonal to the axial direction.

As shown in FIG. 18, the first partial winding 151A has transition portions 153A on both axial sides, and the second partial winding 151B has transition portions 153B on both axial sides. The transition portions 153A and 153B of the partial windings 151A and 151B are different in shape from each other. The transition portion 153B of the second partial winding 151B is also referred to as "second transition portion 153B."

In each of the partial windings 151A and 151B, the intermediate conductor portion 152 is provided as a coil side conductor portion arranged circumferentially one by one on the coil side CS. Moreover, each of the bridge portions 153A and 153B is provided as a coil end wire portion that connects the in-phase intermediate wire portions 152 at two different positions in the circumferential direction in the coil end CE.

As shown in FIG. 20, the first partial winding 151A is formed by winding a conductor CR in multiple layers so that the cross section of the conductor assembly portion is square. FIG. 20 shows a cross section of the intermediate conductor portion 152, in which the conductor material CR is wound multiple times so as to be aligned in the circumferential direction and the radial direction. That is, the first partial winding 151A has a substantially rectangular cross section by arranging the conductors CR in the intermediate conductor portion 152 in a plurality of rows in the circumferential direction and in a plurality of rows in the radial direction. formed. At the tip portion of the first bridge portion 153A, the conductor CR is wound in multiple layers so as to line up in the axial direction and the radial direction by bending in the radial direction. In the present embodiment, the first partial winding 151A is formed by concentrically winding the conductor CR. However, the method of winding the conductor CR is arbitrary, and instead of the concentric winding, the conductor CR may be wound multiple times by alpha winding.

In the first partial winding 151A, the end portion of the conductor CR extends from one of the first transition portions 153A on both sides in the axial direction (the upper first transition portion 153A in FIG. 19B). It is pulled out, and its ends are winding ends 154 and 155 . The winding end portions 154 and 155 are the portions that become the winding start and the winding end of the conductor CR, respectively. One of the winding ends 154 and 155 is connected to the current input/output terminal, and the other is connected to the neutral point.

Each intermediate conductor portion 152 of the first partial winding 151A is covered with a sheet-like insulating cover 157 . Note that FIG. 19A shows the first coil module 150A in a state in which the intermediate conductor portion 152 is covered with the insulating covering 157, and the intermediate conducting wire portion 152 exists inside the insulating covering 157. However, for the sake of convenience, that portion is referred to as an intermediate conductor portion 152 (the same applies to FIG. 22(a), which will be described later).

The insulating covering 157 uses a film material FM having at least the length of the insulating covering range in the axial direction of the intermediate conductor portion 152 as an axial dimension, and the film material FM is wound around the intermediate conductor portion 152. is provided. The film material FM is made of, for example, a PEN (polyethylene naphthalate) film. More specifically, the film material FM includes a film substrate and a foamable adhesive layer provided on one of both surfaces of the film substrate. The film material FM is wound around the intermediate conductor portion 152 in a state of being adhered by an adhesive layer. It is also possible to use a non-foaming adhesive as the adhesive layer.

As shown in FIG. 20 , the intermediate conductor portion 152 has a substantially rectangular cross section by arranging the conductor materials CR in the circumferential direction and the radial direction. An insulating cover 157 is provided by covering the ends in an overlapping state. The film material FM is a rectangular sheet whose longitudinal dimension is longer than the axial length of the intermediate conductor portion 152 and whose lateral dimension is longer than the length of one circumference of the intermediate conductor portion 152. It is wound around the intermediate conductor portion 152 in a creased state. In the state in which the film material FM is wound around the intermediate wire portion 152, the gap between the wire material CR of the intermediate wire portion 152 and the film substrate is filled by the foaming of the adhesive layer. Also, in the overlapping portion OL of the film material FM, the ends of the film material FM in the circumferential direction are joined together by an adhesive layer.

In the intermediate conductor portion 152, an insulating covering 157 is provided so as to cover all of two circumferential side surfaces and two radial side surfaces. In this case, the insulating covering 157 surrounding the intermediate conductor portion 152 has a film on one of the two circumferential side surfaces of the intermediate conductor portion 152 , the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase. An overlapping portion OL is provided where the material FM overlaps. In this embodiment, the pair of intermediate conductor portions 152 are provided with overlapping portions OL on the same side in the circumferential direction.

In the first partial winding 151A, the range from the intermediate conductor portion 152 to the portions covered by the insulating covers 161 and 162 (that is, the portions inside the insulating covers 161 and 162) in the first transition portions 153A on both sides in the axial direction. , an insulating covering 157 is provided. Referring to FIG. 17, the range AX1 in the first coil module 150A is a portion not covered by the insulating covers 161 and 162, and the insulating cover 157 is provided in a range extending vertically beyond the range AX1. .

Next, the configuration of the insulating covers 161 and 162 will be described.

The insulating cover 161 is attached to the first transition portion 153A on one axial side of the first partial winding 151A, and the insulating cover 162 is attached to the first transition portion 153A on the other axial side of the first partial winding 151A. be done. 21(a) and 21(b) show the structure of the insulating cover 161 among them. 21A and 21B are perspective views of the insulating cover 161 viewed from two different directions.

As shown in FIGS. 21A and 21B, the insulating cover 161 includes a pair of side surface portions 171 serving as side surfaces in the circumferential direction, an outer surface portion 172 on the outer side in the axial direction, an inner surface portion 173 on the inner side in the axial direction, and a radially inner front portion 174 . Each of these portions 171 to 174 is formed in a plate shape, and is connected to each other in a three-dimensional shape so that only the outer side in the radial direction is open. Each of the pair of side surface portions 171 is provided in a direction extending toward the axial center of the core assembly CA when assembled to the core assembly CA. Therefore, when a plurality of first coil modules 150A are arranged side by side in the circumferential direction, the side portions 171 of the insulating covers 161 of the adjacent first coil modules 150A face each other in an abutting or approaching state. As a result, the first coil modules 150A that are adjacent in the circumferential direction can be insulated from each other and can be preferably arranged in a ring shape.

In the insulating cover 161, the outer surface portion 172 is provided with an opening 175a for pulling out the winding end portion 154 of the first partial winding 151A, and the front portion 174 is provided with the winding end portion of the first partial winding 151A. An opening 175b is provided through which the portion 155 is drawn out. In this case, one winding end portion 154 is pulled out from the outer surface portion 172 in the axial direction, while the other winding end portion 155 is pulled out from the front surface portion 174 in the radial direction.

In the insulating cover 161, the pair of side surface portions 171 are provided with axially extending semicircular grooves at positions corresponding to both ends of the front surface portion 174 in the circumferential direction, i.e., positions at which the side surface portions 171 and the front surface portion 174 intersect. A recess 177 is provided. Further, the outer surface portion 172 is provided with a pair of projections 178 extending in the axial direction at symmetrical positions on both sides in the circumferential direction with respect to the center line of the insulating cover 161 in the circumferential direction.

The description of the recessed portion 177 of the insulating cover 161 will be supplemented. As shown in FIG. 20, the first transition portion 153A of the first partial winding 151A has a curved shape that protrudes toward the radially inner side of the radially inner and outer sides, that is, the core assembly CA side. In such a configuration, a gap is formed between the first transition portions 153A adjacent in the circumferential direction, the gap becoming wider toward the distal end side of the first transition portion 153A. Therefore, in the present embodiment, a recess 177 is provided at a position outside the curved portion of the first transition portion 153A in the side portion 171 of the insulating cover 161 by utilizing the gap between the first transition portions 153A arranged in the circumferential direction. It is configured.

A configuration in which a temperature detector (thermistor) is provided in the first partial winding 151A may be employed. In such a configuration, the insulating cover 161 may be provided with an opening through which a signal line extending from the temperature detector is led out. In this case, the temperature detection section can be suitably accommodated inside the insulating cover 161 .

Although a detailed description by illustration is omitted, the insulating cover 162 on the other side in the axial direction has substantially the same configuration as the insulating cover 161 . Like the insulating cover 161, the insulating cover 162 has a pair of side surface portions 171, an axially outer outer surface portion 172, an axially inner inner surface portion 173, and a radially inner front surface portion 174. . In the insulating cover 162, the pair of side surface portions 171 are provided with semicircular recesses 177 at positions corresponding to both ends of the front surface portion 174 in the circumferential direction, and the outer surface portion 172 is provided with a pair of protrusions 178. . A difference from the insulating cover 161 is that the insulating cover 162 does not have openings for drawing out the winding ends 154 and 155 of the first partial winding 151A.

The insulating covers 161 and 162 have different axial height dimensions (that is, axial width dimensions of the pair of side face portions 171 and front face portion 174). Specifically, as shown in FIG. 17, the axial height dimension W11 of the insulating cover 161 and the axial height dimension W12 of the insulating cover 162 satisfy W11>W12. That is, when the conductor CR is wound in multiple layers, it is necessary to switch (lane change) the winding stage of the conductor CR in a direction perpendicular to the winding direction (wound direction). It is conceivable that the winding width increases as a result. Supplementally, among the insulating covers 161 and 162, the insulating cover 161 is a portion that covers the first transition portion 153A on the side including the winding start and winding end of the conductor CR, and includes the winding start and winding end of the conductor CR. As a result, the winding allowance (overlapping allowance) of the conductor material CR becomes larger than that of the other portions, and as a result, the winding width can be increased. In consideration of this point, the axial height dimension W11 of the insulating cover 161 is larger than the axial height dimension W12 of the insulating cover 162 . As a result, unlike the case where the height dimensions W11 and W12 of the insulating covers 161 and 162 are the same, the problem that the number of turns of the conductor CR is limited by the insulating covers 161 and 162 can be suppressed. It's becoming

Next, the second coil module 150B will be explained.

FIG. 22(a) is a perspective view showing the configuration of the second coil module 150B, and FIG. 22(b) is an exploded perspective view showing components of the second coil module 150B. FIG. 23 is a cross-sectional view taken along the line 23-23 in FIG. 22(a).

As shown in FIGS. 22(a) and 22(b), the second coil module 150B includes a second partial winding 151B formed by multiple windings of the conductor material CR in the same manner as the first partial winding 151A, and It has insulating covers 163 and 164 attached to one axial end side and the other axial end side of the second partial winding 151B. The insulating covers 163 and 164 are made of an insulating material such as synthetic resin.

The second partial winding 151B has a pair of intermediate conductor portions 152 that are provided in parallel and linearly, and a pair of second transition portions 153B that connect the pair of intermediate conductor portions 152 at both ends in the axial direction. The pair of intermediate conductor portions 152 and the pair of second bridging portions 153B form an annular shape. A pair of intermediate conductor portions 152 in the second partial winding 151B has the same configuration as the intermediate conductor portions 152 in the first partial winding 151A. On the other hand, the pair of second bridging portions 153B is different in configuration from the first bridging portion 153A of the first partial winding 151A. The second transition portion 153B of the second partial winding 151B is provided so as to extend linearly in the axial direction from the intermediate conductor portion 152 without being bent in the radial direction. In FIG. 18, the differences between the partial windings 151A and 151B are clearly shown in comparison.

In the second partial winding 151B, the end portion of the conductor CR extends from one second transition portion 153B (second transition portion 153B on the upper side in FIG. 22B) of the second transition portions 153B on both sides in the axial direction. It is pulled out, and its ends are winding ends 154 and 155 . Similarly to the first partial winding 151A, in the second partial winding 151B, one of the winding ends 154 and 155 is connected to the current input/output terminal and the other is connected to the neutral point. It's becoming

In the second partial winding 151B, each intermediate conductor portion 152 is covered with a sheet-like insulating cover 157, similarly to the first partial winding 151A. The insulating covering 157 uses a film material FM having at least the length of the insulating covering range in the axial direction of the intermediate conductor portion 152 as an axial dimension, and the film material FM is wound around the intermediate conductor portion 152. is provided.

The configuration of the insulating cover 157 is also substantially the same for the partial windings 151A and 151B. That is, as shown in FIG. 23, the film material FM covers the periphery of the intermediate conductor portion 152 in a state in which the ends in the circumferential direction are overlapped. In the intermediate conductor portion 152, an insulating covering 157 is provided so as to cover all of two circumferential side surfaces and two radial side surfaces. In this case, the insulating covering 157 surrounding the intermediate conductor portion 152 has a film on one of the two circumferential side surfaces of the intermediate conductor portion 152 , the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase. An overlapping portion OL is provided where the material FM overlaps. In this embodiment, the pair of intermediate conductor portions 152 are provided with overlapping portions OL on the same side in the circumferential direction.

In the second partial winding 151B, the range from the intermediate conductor portion 152 to the portions covered by the insulating covers 163 and 164 (that is, the portions inside the insulating covers 163 and 164) in the second transition portions 153B on both sides in the axial direction. , an insulating covering 157 is provided. Referring to FIG. 17, the range AX2 in the second coil module 150B is a portion not covered by the insulating covers 163 and 164, and the insulating cover 157 is provided in a range extending vertically beyond the range AX2. .

In each of the partial windings 151A and 151B, the insulating covering 157 is provided in a range including part of the transition portions 153A and 153B. That is, each of the partial windings 151A and 151B is provided with an insulating coating 157 on the intermediate conductor portion 152 and on the portions of the connecting portions 153A and 153B that extend straight from the intermediate conductor portion 152. As shown in FIG. However, since the partial windings 151A and 151B have different axial lengths, the axial ranges of the insulating coatings 157 are also different.

Next, the configuration of the insulating covers 163 and 164 will be described.

The insulating cover 163 is attached to the second transition portion 153B on one axial side of the second partial winding 151B, and the insulating cover 164 is attached to the second transition portion 153B on the other axial side of the second partial winding 151B. be done. 24(a) and 24(b) show the structure of the insulating cover 163 among them. 24A and 24B are perspective views of the insulating cover 163 viewed from two different directions.

As shown in FIGS. 24A and 24B, the insulating cover 163 includes a pair of side surface portions 181 serving as side surfaces in the circumferential direction, an axially outer outer surface portion 182, a radially inner front surface portion 183, and a radially outer rear surface portion 184 . Each of these parts 181 to 184 is formed in a plate shape, and is connected to each other in a three-dimensional shape so that only the inner side in the axial direction is open. Each of the pair of side surface portions 181 is provided in a direction extending toward the axial center of the core assembly CA when assembled to the core assembly CA. Therefore, when the plurality of second coil modules 150B are arranged side by side in the circumferential direction, the side portions 181 of the insulating covers 163 of the adjacent second coil modules 150B face each other in an abutting or approaching state. As a result, the second coil modules 150B that are adjacent in the circumferential direction can be insulated from each other and can be preferably arranged in a ring shape.

In the insulating cover 163, the front surface portion 183 is provided with an opening 185a for pulling out the winding end portion 154 of the second partial winding 151B, and the outer surface portion 182 is provided with the winding end portion of the second partial winding 151B. An opening 185b is provided through which the portion 155 is drawn out.

A front surface portion 183 of the insulating cover 163 is provided with a protruding portion 186 that protrudes radially inward. The protruding portion 186 is provided at a central position between one end and the other end of the insulating cover 163 in the circumferential direction so as to protrude radially inward from the second transition portion 153B. The protruding portion 186 has a tapered shape that tapers toward the inner side in the radial direction in plan view, and a through hole 187 extending in the axial direction is provided at the distal end portion of the protruding portion 186 . If the protruding portion 186 protrudes radially inward from the second bridging portion 153B and has a through hole 187 at a central position between one end and the other end of the insulating cover 163 in the circumferential direction, Its configuration is arbitrary. However, assuming an overlapping state with the insulating cover 161 on the inner side in the axial direction, it is desirable that the width is narrow in the circumferential direction so as to avoid interference with the winding end portions 154 and 155 .

The protruding portion 186 has a stepped thickness in the axial direction at the radially inner tip portion, and a through hole 187 is provided in the thinned low step portion 186a. The low step portion 186a corresponds to a portion where the height from the axial end surface of the inner tubular member 81 is lower than the height of the second transition portion 153B in the assembled state of the second coil module 150B to the core assembly CA. .

Further, as shown in FIG. 23, a through hole 188 is provided in the projecting portion 186 so as to extend therethrough in the axial direction. As a result, the gap between the insulating covers 161 and 163 can be filled with the adhesive through the through hole 188 when the insulating covers 161 and 163 overlap in the axial direction.

Although a detailed description by illustration is omitted, the insulating cover 164 on the other side in the axial direction has substantially the same configuration as the insulating cover 163 . Similar to the insulating cover 163, the insulating cover 164 has a pair of side surface portions 181, an axially outer outer surface portion 182, a radially inner front surface portion 183, and a radially outer rear surface portion 184. A through hole 187 is provided at the tip of the portion 186 . Also, as a difference from the insulating cover 163, the insulating cover 164 is configured so as not to have openings for pulling out the winding ends 154 and 155 of the second partial winding 151B.

In the insulating covers 163 and 164, the width dimension in the radial direction of the pair of side surface portions 181 is different. Specifically, as shown in FIG. 17, the radial width dimension W21 of the side surface portion 181 of the insulating cover 163 and the radial width dimension W22 of the side surface portion 181 of the insulating cover 164 satisfy W21>W22. . That is, of the insulating covers 163 and 164, the insulating cover 163 is a portion that covers the second transition portion 153B on the side including the winding start and the winding end of the conductor CR, and includes the winding start and the winding end of the conductor CR. As a result, the winding allowance (overlapping allowance) of the conductor CR becomes larger than that of the other portions, and as a result, the winding width may increase. In consideration of this point, the radial width dimension W21 of the insulating cover 163 is larger than the radial width dimension W22 of the insulating cover 164 . As a result, unlike the case where the width dimensions W21 and W22 of the insulating covers 163 and 164 are the same, the problem that the number of turns of the conductor CR is limited by the insulating covers 163 and 164 is suppressed. ing.

FIG. 25 is a diagram showing overlapping positions of the film material FM when the coil modules 150A and 150B are arranged in the circumferential direction. As described above, in each of the coil modules 150A and 150B, a portion of the partial winding 151 of the other phase that faces the intermediate conductor portion 152, that is, the circumferential side surface of the intermediate conductor portion 152 is overlapped around the intermediate conductor portion 152. Then, the film material FM is covered (see FIGS. 20 and 23). When the coil modules 150A and 150B are arranged in the circumferential direction, the overlapping portions OL of the film material FM are arranged on the same side (the right side in the circumferential direction in the drawing) among both sides in the circumferential direction. ing. As a result, the overlapping portions OL of the film material FM do not overlap in the circumferential direction in each of the intermediate conductor portions 152 of the out-of-phase partial windings 151A and 151B that are circumferentially adjacent to each other. In this case, a maximum of three film materials FM are overlapped between the intermediate conductor portions 152 arranged in the circumferential direction.

Next, a configuration regarding assembly of each coil module 150A, 150B to the core assembly CA will be described.

Coil modules 150A and 150B have different axial lengths, and crossover portions 153A and 153B of partial windings 151A and 151B have different shapes. The second coil module 150B is attached to the core assembly CA with the second transition portion 153B of the second coil module 150B facing axially outward. Regarding the insulating covers 161 to 164, the insulating covers 161 and 163 are axially overlapped on one axial end side of each of the coil modules 150A and 150B, and the insulating covers 162 and 164 are axially overlapped on the other axial end side. Each of the insulating covers 161 to 164 is fixed to the core assembly CA.

FIG. 26 is a plan view showing a state in which a plurality of insulating covers 161 are arranged in the circumferential direction when the first coil module 150A is attached to the core assembly CA. FIG. 11 is a plan view showing a state in which a plurality of insulating covers 161 and 163 are arranged in a circumferential direction in an assembled state of the two-coil module 150B; Also, FIG. 28(a) is a vertical cross-sectional view showing the coil modules 150A and 150B assembled to the core assembly CA before being fixed by the fixing pins 191, and FIG. FIG. 10 is a vertical cross-sectional view showing a state after fixing by a fixing pin 191 in an assembled state of each coil module 150A, 150B;

As shown in FIG. 26, when the plurality of first coil modules 150A are assembled to the core assembly CA, the plurality of insulating covers 161 are arranged with the side portions 171 in contact with each other or close to each other. Each insulating cover 161 is arranged such that the boundary line LB where the side surface portions 171 face each other and the concave portion 105 of the axial end surface of the inner cylindrical member 81 are aligned. In this case, the side portions 171 of the insulating covers 161 that are adjacent in the circumferential direction come into contact with each other or come close to each other, so that the concave portions 177 of the insulating covers 161 form through holes extending in the axial direction. The positions of the hole and the recess 105 are aligned.

In addition, as shown in FIG. 27, the second coil module 150B is further assembled to the integral body of the core assembly CA and the first coil module 150A. Along with this assembly, the plurality of insulating covers 163 are arranged with the side portions 181 in contact with each other or close to each other. In this state, the transition portions 153A and 153B are arranged so as to intersect each other on a circle on which the intermediate conductor portions 152 are arranged in the circumferential direction. Each insulating cover 163 is configured such that the projecting portion 186 overlaps the insulating cover 161 in the axial direction, and the through hole 187 of the projecting portion 186 is axially connected to the through hole formed by the recessed portions 177 of the insulating cover 161. are placed.

At this time, the protruding portion 186 of the insulating cover 163 is guided to a predetermined position by a pair of protruding portions 178 provided on the insulating cover 161 , so that the through hole portion on the insulating cover 161 side and the concave portion 105 of the inner cylinder member 81 are aligned. The position of the through hole 187 on the side of the insulating cover 163 is matched with . That is, when the coil modules 150A and 150B are assembled to the core assembly CA, the recessed portion 177 of the insulating cover 161 is located on the inner side of the insulating cover 163, so that the protruding portion is located with respect to the recessed portion 177 of the insulating cover 161. It may be difficult to align the through holes 187 of 186 . In this respect, the projection 186 of the insulating cover 163 is guided by the pair of projections 178 of the insulating cover 161, so that the insulating cover 163 can be easily aligned with the insulating cover 161. As shown in FIG.

Then, as shown in FIGS. 28(a) and 28(b), in a state in which the insulating cover 161 and the projecting portion 186 of the insulating cover 163 are engaged with each other at the overlapping portion thereof, fixing by a fixing pin 191 as a fixing member is performed. done. More specifically, with the concave portion 105 of the inner cylinder member 81, the concave portion 177 of the insulating cover 161, and the through hole 187 of the insulating cover 163 aligned, the fixing pin is inserted into the concave portions 105, 177 and the through hole 187. 191 is inserted. Thereby, the insulating covers 161 and 163 are integrally fixed to the inner cylindrical member 81 . According to this configuration, the circumferentially adjacent coil modules 150A and 150B are fixed to the core assembly CA by the common fixing pin 191 at the coil end CE. The fixing pin 191 is desirably made of a material with good thermal conductivity, such as a metal pin.

As shown in FIG. 28(b), the fixing pin 191 is attached to the low step portion 186a of the projecting portion 186 of the insulating cover 163. As shown in FIG. In this state, the upper end of the fixing pin 191 protrudes above the lower stepped portion 186a, but does not protrude above the upper surface of the insulating cover 163 (outer surface portion 182). In this case, the fixing pin 191 is longer than the axial height dimension of the overlapping portion between the insulating cover 161 and the projecting portion 186 (lower step portion 186a) of the insulating cover 163, and has a margin that protrudes upward. , the fixing pin 191 can be easily inserted into the recesses 105 and 177 and the through hole 187 (that is, when fixing the fixing pin 191). In addition, since the upper end portion of the fixing pin 191 does not protrude above the upper surface (outer surface portion 182) of the insulating cover 163, it is possible to suppress the inconvenience that the axial length of the stator 60 is increased due to the protrusion of the fixing pin 191. It is a thing.

After the insulating covers 161 and 163 are fixed by the fixing pins 191 , the adhesive is filled through the through holes 188 provided in the insulating cover 163 . As a result, the insulating covers 161 and 163 overlapping in the axial direction are firmly coupled to each other. 28(a) and 28(b), the through hole 188 is shown in the range from the upper surface to the lower surface of the insulating cover 163 for the sake of convenience. It has a set configuration.

As shown in FIG. 28(b), the positions where the insulating covers 161 and 163 are fixed by the fixing pins 191 are on the axial end surface of the stator holder 70 radially inside (on the left side in the drawing) of the stator core 62. , and is fixed to the stator holder 70 by fixing pins 191 . That is, the first transition portion 153A is configured to be fixed to the axial end surface of the stator holder 70 . In this case, since the stator holder 70 is provided with the coolant passage 85, the heat generated in the first partial winding 151A directly flows from the first transition portion 153A to the vicinity of the coolant passage 85 of the stator holder 70. transmitted to Further, the fixing pin 191 is inserted into the concave portion 105 of the stator holder 70 so that heat transfer to the stator holder 70 side is promoted through the fixing pin 191 . With such a configuration, the cooling performance of the stator winding 61 is improved.

In this embodiment, 18 insulating covers 161 and 163 are stacked inside and outside in the axial direction at the coil end CE, while the same number of insulating covers 161 and 163 as the insulating covers 161 and 163 are provided on the axial end surface of the stator holder 70 . Concave portions 105 are provided at 18 locations. Fixing is performed by fixing pins 191 at the 18 concave portions 105 .

Although not shown, the same applies to the insulating covers 162 and 164 on the opposite side in the axial direction. That is, when the first coil module 150A is first assembled, the side surfaces 171 of the insulating covers 162 adjacent in the circumferential direction come into contact with each other or approach each other, so that the concave portions 177 of the insulating covers 162 extend in the axial direction. A through hole is formed, and the position of the through hole and the recess 106 in the axial end face of the outer cylindrical member 71 are aligned. By assembling the second coil module 150B, the through hole 187 on the insulating cover 164 side is aligned with the through hole portion on the insulating cover 163 side and the concave portion 106 of the outer cylindrical member 71, and the concave portions 106 and 177 are aligned. , the insulating covers 162 and 164 are integrally fixed to the outer cylindrical member 71 by inserting the fixing pin 191 into the through hole 187 .

When assembling the coil modules 150A and 150B to the core assembly CA, first attach all the first coil modules 150A to the outer peripheral side of the core assembly CA, and then attach all the second coil modules 150B; It is preferable to perform fixing by a fixing pin 191 . Alternatively, the two first coil modules 150A and one second coil module 150B are first fixed to the core assembly CA with one fixing pin 191, and then the assembly of the first coil module 150A is performed. , the assembly of the second coil module 150B and the fixing by the fixing pin 191 may be repeated in this order.

Next, the busbar module 200 will be described.

The busbar module 200 is electrically connected to the partial windings 151 of each coil module 150 in the stator winding 61, connects one end of the partial windings 151 of each phase in parallel, and 151 at the neutral point. 29 is a perspective view of the busbar module 200, and FIG. 30 is a cross-sectional view showing a part of the longitudinal section of the busbar module 200. As shown in FIG.

The busbar module 200 has an annular portion 201 having an annular shape, a plurality of connection terminals 202 extending from the annular portion 201, and three input/output terminals 203 provided for each phase winding. The annular portion 201 is formed in an annular shape by an insulating member such as resin.

As shown in FIG. 30, the annular portion 201 has a laminated plate 204 that has a substantially annular plate shape and is laminated in multiple layers (five layers in this embodiment) in the axial direction. Four bus bars 211 to 214 are provided sandwiched therebetween. Each of the busbars 211 to 214 has an annular shape, and includes a U-phase busbar 211, a V-phase busbar 212, a W-phase busbar 213, and a neutral point busbar 214. . These bus bars 211 to 214 are arranged side by side in the axial direction in the annular portion 201 so that their plate surfaces face each other. Each laminated plate 204 and each bus bar 211 to 214 are bonded to each other with an adhesive. It is desirable to use an adhesive sheet as the adhesive. However, the configuration may be such that a liquid or semi-liquid adhesive is applied. A connection terminal 202 is connected to each of the bus bars 211 to 214 so as to protrude radially outward from the annular portion 201 .

A protrusion 201a extending in an annular shape is provided on the upper surface of the annular portion 201, that is, on the upper surface of the laminate plate 204 on the outermost layer side of the laminate plates 204 provided in five layers.

The busbar module 200 may be provided with the busbars 211 to 214 embedded in the annular portion 201, and the busbars 211 to 214 arranged at predetermined intervals are integrally insert-molded. can be anything. Further, the arrangement of the bus bars 211 to 214 is not limited to the configuration in which all the plate surfaces are aligned in the axial direction and all the plate surfaces face the same direction. A configuration in which the substrates are arranged in a row, a configuration in which the plate surfaces extend in different directions, or the like may be employed.

In FIG. 29, the connection terminals 202 are arranged in the circumferential direction of the annular portion 201 and are provided so as to extend in the axial direction on the radially outer side. The connection terminals 202 include a connection terminal connected to the U-phase bus bar 211, a connection terminal connected to the V-phase bus bar 212, a connection terminal connected to the W-phase bus bar 213, and a neutral point. and a connection terminal connected to the bus bar 214 for. The connection terminals 202 are provided in the same number as the winding ends 154 and 155 of the partial windings 151 in the coil module 150. The connection terminals 202 have the winding ends 154 and 155 of the partial windings 151. 155 are connected one by one. Thus, the busbar module 200 is connected to the U-phase partial winding 151, the V-phase partial winding 151, and the W-phase partial winding 151, respectively.

The input/output terminal 203 is made of, for example, a busbar material, and is provided so as to extend in the axial direction. Input/output terminals 203 include a U-phase input/output terminal 203U, a V-phase input/output terminal 203V, and a W-phase input/output terminal 203W. These input/output terminals 203 are connected to respective bus bars 211 to 213 for each phase within the annular portion 201 . Through these input/output terminals 203 , power is input/output from an inverter (not shown) to each phase winding of the stator winding 61 .

It should be noted that the busbar module 200 may be configured to be integrally provided with a current sensor for detecting the phase current of each phase. In this case, it is preferable that the busbar module 200 is provided with a current detection terminal, and the detection result of the current sensor is output to a control device (not shown) through the current detection terminal.

Further, the annular portion 201 has a plurality of projecting portions 205 projecting inwardly as portions to be fixed to the stator holder 70, and through holes 206 extending in the axial direction are formed in the projecting portions 205. ing.

FIG. 31 is a perspective view showing a state in which the busbar module 200 is attached to the stator holder 70, and FIG. 32 is a vertical cross-sectional view of a fixing portion where the busbar module 200 is fixed. For the configuration of the stator holder 70 before the busbar module 200 is assembled, see FIG.

In FIG. 31 , the busbar module 200 is provided on the end plate portion 91 so as to surround the boss portion 92 of the inner cylindrical member 81 . The busbar module 200 is fixed to the stator holder 70 (inner cylinder member 81) by tightening fasteners 217 such as bolts in a state in which the busbar module 200 is positioned by being assembled to the strut portion 95 (see FIG. 12) of the inner cylinder member 81. ing.

More specifically, as shown in FIG. 32, the end plate portion 91 of the inner cylinder member 81 is provided with a support portion 95 extending in the axial direction. The busbar module 200 is fixed to the strut portion 95 with fasteners 217 in a state in which the strut portion 95 is inserted through the through holes 206 provided in the plurality of projecting portions 205 . In this embodiment, the busbar module 200 is fixed using a retainer plate 220 made of a metal material such as iron. The retainer plate 220 includes a fastened portion 222 having an insertion hole 221 through which the fastener 217 is inserted; and a bend portion 224 provided at the .

When the retainer plate 220 is mounted, the fastener 217 is inserted into the insertion hole 221 of the retainer plate 220 and screwed onto the support column 95 of the inner cylindrical member 81 . Also, the pressing portion 223 of the retainer plate 220 is in contact with the upper surface of the annular portion 201 of the busbar module 200 . In this case, the retainer plate 220 is pushed downward in the drawing as the fastener 217 is screwed into the strut portion 95 , and the pressing portion 223 presses the annular portion 201 downward accordingly. Since the downward pressing force in the drawing generated by screwing the fastener 217 is transmitted to the pressing portion 223 through the bending portion 224, the pressing portion 223 presses in a state accompanied by the elastic force of the bending portion 224. ing.

As described above, the annular projection 201a is provided on the upper surface of the annular portion 201, and the tip of the retainer plate 220 on the pressing portion 223 side can come into contact with the projection 201a. As a result, the pressing force of the retainer plate 220 downward in the figure is suppressed from escaping radially outward. In other words, the pressing force generated by screwing the fastener 217 is properly transmitted to the pressing portion 223 side.

As shown in FIG. 31, when the busbar module 200 is assembled to the stator holder 70, the input/output terminal 203 is positioned 180 degrees in the circumferential direction opposite to the inlet opening 86a and the outlet opening 87a leading to the coolant passage 85. It is set at a position where However, the input/output terminals 203 and the openings 86a and 87a may be collectively provided at the same position (ie close position).

Next, the relay member 230 that electrically connects the input/output terminals 203 of the busbar module 200 to an external device outside the rotating electric machine 10 will be described.

As shown in FIG. 1 , in rotary electric machine 10 , input/output terminals 203 of busbar module 200 are provided to project outward from housing cover 242 , and are connected to relay member 230 outside housing cover 242 . there is Relay member 230 is a member that relays connection between input/output terminal 203 for each phase extending from busbar module 200 and a power line for each phase extending from an external device such as an inverter.

33 is a longitudinal sectional view showing a state in which the relay member 230 is attached to the housing cover 242, and FIG. 34 is a perspective view of the relay member 230. FIG. As shown in FIG. 33, a through hole 242a is formed in the housing cover 242, and the input/output terminal 203 can be pulled out through the through hole 242a.

The relay member 230 has a body portion 231 fixed to the housing cover 242 and a terminal insertion portion 232 inserted into the through hole 242 a of the housing cover 242 . The terminal insertion portion 232 has three insertion holes 233 into which the input/output terminals 203 of each phase are inserted. These three insertion holes 233 have elongated cross-sectional openings, and are formed side by side with their longitudinal directions substantially the same.

Three relay bus bars 234 provided for each phase are attached to the body portion 231 . The relay bus bar 234 is bent into a substantially L-shape, and is fixed to the main body 231 with fasteners 235 such as bolts. is fixed to the distal end portion thereof by fasteners 236 such as bolts and nuts.

Although not shown, a power line for each phase extending from an external device can be connected to the relay member 230, so that power can be input/output to/from the input/output terminal 203 for each phase.

Next, the configuration of a control system that controls the rotating electric machine 10 will be described. FIG. 35 is an electric circuit diagram of the control system of rotating electric machine 10, and FIG. 36 is a functional block diagram showing control processing by control device 270. As shown in FIG.

As shown in FIG. 35, the stator winding 61 consists of U-phase winding, V-phase winding and W-phase winding, and an inverter 260 corresponding to a power converter is connected to the stator winding 61. there is The inverter 260 is composed of a full bridge circuit having the same number of upper and lower arms as the number of phases. Each of these switches 261 and 262 is turned on and off by a driver 263, and the phase winding of each phase is energized by the on and off. Each of the switches 261 and 262 is composed of a semiconductor switching element such as MOSFET or IGBT. In addition, a charge supply capacitor 264 is connected in parallel to the series connection body of the switches 261 and 262 to the upper and lower arms of each phase to supply the switches 261 and 262 with the charge required for switching.

One end of a U-phase winding, a V-phase winding, and a W-phase winding are connected to intermediate connection points between the switches 261 and 262 of the upper and lower arms, respectively. These phase windings are star-connected (Y-connected), and the other ends of the phase windings are connected to each other at a neutral point.

The control device 270 includes a microcomputer including a CPU and various memories, and controls energization by turning on and off the switches 261 and 262 based on various detection information in the rotating electrical machine 10 and requests for power running and power generation. . The detection information of the rotating electric machine 10 includes, for example, the rotation angle (electrical angle information) of the rotor 20 detected by an angle detector such as a resolver, the power supply voltage (inverter input voltage) detected by a voltage sensor, the current sensor contains the conducting current of each phase detected by The controller 270 performs ON/OFF control of the switches 261 and 262 by, for example, PWM control at a predetermined switching frequency (carrier frequency) or rectangular wave control. Control device 270 may be a built-in control device built into rotating electrical machine 10 or an external control device provided outside rotating electrical machine 10 .

Incidentally, since the rotary electric machine 10 of the present embodiment has a slotless structure (teethless structure), the inductance of the stator 60 is reduced and the electrical time constant is reduced. Under low constant conditions, it is desirable to increase the switching frequency (carrier frequency) and increase the switching speed. In this regard, the wiring inductance is reduced by connecting the charge supply capacitor 264 in parallel to the series connection of the switches 261 and 262 of each phase, and even with a configuration with a high switching speed, an appropriate surge can be prevented. Countermeasures are possible.

A high potential side terminal of the inverter 260 is connected to the positive terminal of the DC power supply 265 , and a low potential side terminal is connected to the negative terminal (ground) of the DC power supply 265 . The DC power supply 265 is composed of, for example, an assembled battery in which a plurality of cells are connected in series. A smoothing capacitor 266 is connected in parallel with the DC power supply 265 to the high potential side terminal and the low potential side terminal of the inverter 260 .

FIG. 36 is a block diagram showing current feedback control processing for controlling each phase current of the U, V, and W phases.

In FIG. 36, a current command value setting unit 271 uses a torque-dq map, and based on a powering torque command value or a power generation torque command value for the rotary electric machine 10 and an electrical angular velocity ω obtained by differentiating the electrical angle θ with time. , set the d-axis current command value and the q-axis current command value. Note that the power generation torque command value is a regenerative torque command value, for example, when the rotary electric machine 10 is used as a vehicle power source.

The dq transform unit 272 converts current detection values (three phase currents) by current sensors provided for each phase into orthogonal 2 It is converted into a d-axis current and a q-axis current, which are components of a dimensional rotating coordinate system.

The d-axis current feedback control unit 273 calculates a d-axis command voltage as a manipulated variable for feedback-controlling the d-axis current to the d-axis current command value. The q-axis current feedback control unit 274 also calculates a q-axis command voltage as an operation amount for feedback-controlling the q-axis current to the q-axis current command value. In each of these feedback control units 273 and 274, a command voltage is calculated using the PI feedback method based on the deviation of the d-axis current and the q-axis current from the current command value.

The three-phase converter 275 converts the d-axis and q-axis command voltages into U-phase, V-phase and W-phase command voltages. The units 271 to 275 described above are feedback control units that perform feedback control of the fundamental wave current based on the dq conversion theory, and the command voltages of the U-phase, V-phase, and W-phase are feedback control values.

The operation signal generator 276 uses a known triangular wave carrier comparison method to generate an operation signal for the inverter 260 based on the three-phase command voltages. Specifically, the operation signal generator 276 performs PWM control based on a magnitude comparison between a signal obtained by standardizing the three-phase command voltage by the power supply voltage and a carrier signal such as a triangular wave signal, thereby controlling the switch of the upper and lower arms in each phase. Generates an operation signal (duty signal). The switch operation signal generated by the operation signal generator 276 is output to the driver 263 of the inverter 260, and the driver 263 turns on/off the switches 261 and 262 of each phase.

Next, torque feedback control processing will be described. This processing is used mainly for the purpose of increasing the output of the rotary electric machine 10 and reducing loss under operating conditions such as a high rotation region and a high output region where the output voltage of the inverter 260 is large. Control device 270 selects and executes either torque feedback control processing or current feedback control processing based on the operating conditions of rotary electric machine 10 .

FIG. 37 is a block diagram showing torque feedback control processing corresponding to the U, V and W phases.

The voltage amplitude calculator 281 is a command value for the magnitude of the voltage vector based on the powering torque command value or the power generation torque command value for the rotary electric machine 10 and the electrical angular velocity ω obtained by time differentiating the electrical angle θ. Calculate the voltage amplitude command.

The dq conversion unit 282, like the dq conversion unit 272, converts current detection values obtained by current sensors provided for each phase into d-axis current and q-axis current. Torque estimator 283 calculates torque estimated values corresponding to the U, V, and W phases based on the d-axis current and the q-axis current. Note that the torque estimator 283 may calculate the voltage amplitude command based on map information in which the d-axis current, the q-axis current, and the voltage amplitude command are associated.

The torque feedback control unit 284 calculates a voltage phase command, which is a command value of the phase of the voltage vector, as a manipulated variable for feedback-controlling the estimated torque value to the powering torque command value or the power generation torque command value. The torque feedback control unit 284 calculates a voltage phase command using the PI feedback technique based on the deviation of the estimated torque value from the powering torque command value or the power generation torque command value.

The operation signal generator 285 generates an operation signal for the inverter 260 based on the voltage amplitude command, the voltage phase command and the electrical angle θ. Specifically, the operation signal generator 285 calculates three-phase command voltages based on the voltage amplitude command, the voltage phase command, and the electrical angle θ, and normalizes the calculated three-phase command voltages by the power supply voltage. , a switch operation signal for the upper and lower arms in each phase is generated by PWM control based on a magnitude comparison with a carrier signal such as a triangular wave signal. The switch operation signal generated by the operation signal generator 285 is output to the driver 263 of the inverter 260, and the driver 263 turns on/off the switches 261 and 262 of each phase.

Incidentally, the operation signal generation unit 285 generates the voltage amplitude command, the voltage phase command, the electrical angle θ, and the pulse pattern information, which is map information in which the switch operation signal is associated, the voltage amplitude command, the voltage phase command, and the electrical angle θ. may be used to generate the switch operation signal.

(Modification)
Modifications of the first embodiment will be described below.

- You may change the structure of the magnet 32 in the magnet unit 22 as follows. In the magnet unit 22 shown in FIG. 38, the direction of the axis of easy magnetization in the magnet 32 is oblique to the radial direction, and a linear magnet magnetic path is formed along the direction of the axis of easy magnetization. That is, in the magnet 32, between the magnetic flux action surface 34a on the stator 60 side (radially inner side) and the magnetic flux action surface 34b on the anti-stator side (radial direction outer side), the direction of the axis of easy magnetization is oriented with respect to the d-axis. It is oblique and linearly oriented in the circumferential direction so that it approaches the d-axis on the stator 60 side and separates from the d-axis on the anti-stator side. Also in this configuration, the magnet magnetic path length of the magnet 32 can be made longer than the thickness dimension in the radial direction, and the permeance can be improved.

- It is also possible to use a Halbach array magnet in the magnet unit 22 .

In each partial winding 151, the direction of bending of the transition portion 153 may be any of the radial direction inside and outside, and the first transition portion 153A is bent toward the core assembly CA in relation to the core assembly CA. Alternatively, the first transition portion 153A may be bent to the opposite side of the core assembly CA. Further, if the second transition portion 153B is in a state of straddling a part of the first transition portion 153A in the axial direction outside the first transition portion 153A in the circumferential direction, the second transition portion 153B may be radially inward or outward. It may be folded.

The partial winding 151 may have one type of partial winding 151 instead of having two types of partial winding 151 (first partial winding 151A and second partial winding 151B). Specifically, the partial winding 151 may be formed to have a substantially L shape or a substantially Z shape when viewed from the side. When the partial winding 151 is formed in a substantially L shape when viewed from the side, the transition portion 153 is bent radially inward or outward at one end in the axial direction, and the transition portion 153 is bent radially at the other end in the axial direction. It is configured to be provided without being bent. Further, when the partial winding 151 is formed in a substantially Z-shape when viewed from the side, the connecting portion 153 is bent in opposite directions in the radial direction at one axial end and the other axial end. In either case, it is preferable that the coil module 150 is fixed to the core assembly CA by the insulating cover that covers the transition portion 153 as described above.

- In the above-described configuration, in the stator winding 61, all the partial windings 151 are connected in parallel for each phase winding, but this may be changed. For example, all partial windings 151 for each phase winding may be divided into a plurality of parallel connection groups, and the plurality of parallel connection groups may be connected in series. That is, the n partial windings 151 in each phase winding are divided into two groups of n/2 parallel connections, three groups of n/3 parallel connections, and the like. It is good also as a structure which connects. Alternatively, the stator winding 61 may have a configuration in which the plurality of partial windings 151 are all connected in series for each phase winding.

- The stator winding 61 in the rotary electric machine 10 may be configured to have two phase windings (a U-phase winding and a V-phase winding). In this case, for example, in the partial winding 151, a pair of intermediate conductor portions 152 are provided separated by one coil pitch. may be arranged as long as one is arranged.

The rotary electric machine 10 can be embodied as an inner rotor type surface magnet type rotary electric machine instead of the outer rotor type surface magnet type rotary electric machine. 39(a) and 39(b) are diagrams showing the configuration of the stator unit 300 in the case of the inner rotor structure. FIG. 39(a) is a perspective view showing the coil modules 310A and 310B assembled to the core assembly CA, and FIG. 39(b) shows partial windings 311A and 311B included in each of the coil modules 310A and 310B. It is a perspective view showing the. In this example, a core assembly CA is configured by assembling a stator holder 70 to the radially outer side of the stator core 62 . Also, a plurality of coil modules 310A and 310B are assembled inside the stator core 62 in the radial direction.

The partial winding 311A has generally the same configuration as the above-described first partial winding 151A, and includes a pair of intermediate conductor portions 312 and axially opposite sides thereof bent toward the core assembly CA side (radially outward). It has a transition portion 313A formed thereon. Further, the partial winding 311B has substantially the same configuration as the second partial winding 151B described above, and includes a pair of intermediate conductor portions 312 and connecting portions 313A on both sides in the axial direction. and a bridging portion 313B provided so as to straddle the . An insulating cover 315 is attached to the transition portion 313A of the partial winding 311A, and an insulating cover 316 is attached to the transition portion 313B of the partial winding 311B.

The insulating cover 315 is provided with semicircular recesses 317 extending in the axial direction on both sides in the circumferential direction. The insulating cover 316 is provided with a protruding portion 318 that protrudes radially outward from the transition portion 313B, and a through hole 319 that extends in the axial direction is provided at the tip of the protruding portion 318 .

FIG. 40 is a plan view showing a state where coil modules 310A and 310B are attached to core assembly CA. In FIG. 40, a plurality of recesses 105 are formed in the axial end face of the stator holder 70 at regular intervals in the circumferential direction. Moreover, the stator holder 70 has a cooling structure using a liquid refrigerant or air, and for example, it is preferable that a plurality of heat radiation fins be formed on the outer peripheral surface as an air cooling structure.

In FIG. 40, the insulating covers 315 and 316 are arranged so as to overlap in the axial direction. In addition, a concave portion 317 provided in the side surface of the insulating cover 315, and a through hole 319 provided in a protruding portion 318 of the insulating cover 316 at a central position between one end and the other end of the insulating cover 316 in the circumferential direction. are connected in the axial direction, and are fixed by fixing pins 321 at each of them.

40, the fixing positions of the insulating covers 315 and 316 by the fixing pins 321 are the axial end surfaces of the stator holder 70 radially outside the stator core 62. In contrast, it is configured to be fixed by a fixing pin 321 . In this case, since the stator holder 70 is provided with a cooling structure, the heat generated in the partial windings 311A and 311B is easily conducted to the stator holder 70 . Thereby, the cooling performance of the stator winding 61 can be improved.

- The stator 60 used in the rotary electric machine 10 may have protrusions (for example, teeth) extending from the back yoke. Also in this case, it is sufficient that the coil module 150 and the like are attached to the stator core with respect to the back yoke.

- The rotary electric machine is not limited to a star-connected one, and may be a delta-connected one.

As the rotating electric machine 10, a rotating armature type rotating electric machine having a field element as a rotor and an armature as a stator is replaced with a rotating field type rotating electric machine having an armature as a rotor and a field element as a stator. It is also possible to employ a rotating electrical machine.

(Second embodiment)
The configuration of the rotary electric machine 10 according to the second embodiment will be described below, focusing on differences from the first embodiment. In this embodiment, in the rotary electric machine 10, the configuration of the stator winding 61 of the stator 60 is changed, and in particular, the arrangement of the conductors CR in the partial winding 151 included in the stator winding 61 is devised. It has become a thing.

18, the partial winding 151 is composed of a first partial winding 151A and a second partial winding 151B having different coil end shapes (crossing portion shapes). The schematic configuration including the shape of is as described above. However, in the present embodiment, a flat wire having a rectangular cross section is used as the conductor CR, and in the partial winding 151, the outer surface on the side of the stator core 62 is arranged along the outer peripheral surface of the stator core 62, so that The difference is that the conductors CR are wound while being shifted in the radial direction, and that the partial winding 151 is integrally provided with a winding holding member, the details of which will be described below. Although the two types of first partial winding 151A and second partial winding 151B have different coil end shapes, they have the same configuration of the intermediate conductor portion 152, and the second partial winding 151B will be shown below. This will be described as a "partial winding 151" while shown.

FIGS. 41(a) and 41(b) are perspective views showing the configuration of a coil module 400 including a partial winding 151, and FIG. 42 is a cross-sectional view showing a cross section of the partial winding 151 at an intermediate portion in the axial direction. is. In FIG. 42, the outer peripheral surface of the stator core 62 is indicated by a dashed line.

As shown in FIGS. 41(a), (b) and 42, the coil module 400 has a partial winding 151 and a pair of coil holders 401 as winding holding members, and is an air-core coil. It is configured by integrating a pair of coil holders 401 with the winding 151 . The partial winding 151 is held by the coil holder 401 while being attached to the stator core 62 . The coil holder 401 is made of an insulating material such as synthetic resin. and a second wall portion 412 positioned at the . The first wall portion 411 corresponds to a “wall portion” interposed between the stator core 62 in the radial direction.

The coil module 400 is attached to the stator core 62 with the first wall portion 411 of the coil holder 401 in contact with the outer peripheral surface of the stator core 62 . However, the method of attaching the coil module 400 to the stator core 62 may be arbitrary, and as shown in FIGS. It may be a configuration.

In addition to the first wall portion 411 and the second wall portion 412 , the pair of coil holders 401 are arranged on the wall portion opposite to the core side when assembled to the stator core 62 and on the outer peripheral side of the partial winding 151 . It may have a wall on which it is placed. For example, the pair of coil holders 401 is configured to have three wall portions surrounding the intermediate conductor portion 152 . However, if the coil holder 401 is provided with a wall on the side opposite to the core (that is, on the side of the rotor), there is concern that the magnetic gap may increase and winding of the conductor CR may become difficult. It is desirable not to provide a wall. Also, the pair of coil holders 401 may be formed as an integral body. In this case, in the coil holder 401, the first wall portion 411 and the second wall portion 412 are preferably formed in an annular shape.

As shown in FIG. 42, the partial winding 151 is formed by multiple windings of a conductor CR having a rectangular cross section. and are wound in a state in which they are arranged in plural numbers in the circumferential direction. The conductor CR is a rectangular wire having long sides and short sides. Moreover, it is preferable that the conducting wire material CR is configured by assembling a plurality of strands.

The winding structure of the intermediate conductor portion 152 in the partial winding 151 will be described in more detail below. FIG. 43 is an exploded sectional view showing an enlarged middle conductor portion 152 of the partial winding 151 and the coil holder 401. FIG. In FIG. 43, the horizontal direction is the circumferential direction, and the vertical direction is the radial direction.

In FIG. 43 , the intermediate conductor portion 152 is configured such that the long sides of the conductor CR are circumferentially overlapped as the circumferential side surfaces 421 and the short sides of the conductor CR are radially overlapped as the radial side surfaces 422 . It is That is, the conductor CR is wound in such a manner that the long sides extend in the radial direction and the short sides face the rotor 20 . In particular, in the radial direction, the circumferential side surfaces 421 of the conductor CR are aligned linearly, and in the circumferential direction, the radial side surfaces 422 of the conductor CR are aligned in a stepped manner due to radial deviation. Ds is the amount of radial deviation between conductors CR that are adjacent in the circumferential direction.

In this case, in order to displace the radial side surface 422 of the conductor CR along the outer peripheral surface of the stator core 62 , the conductor CR is arranged in a region on one circumferential end side of each intermediate conductor portion 152 and on the other circumferential end side. It is wound in a state in which the direction of radial deviation is different between the regions. That is, in the left half region of each intermediate conductor portion 152 in the drawing, the radial side surface 422 of the conductor CR is shifted upward toward the right side, and in the region of the right half region in the drawing, the radial side surface 422 is shifted downward toward the right side. It is wound in a In the intermediate conductor portion 152, the radial side surfaces 422 are shifted in the radial direction in the same manner on both the radially outer and radially inner outer surfaces, that is, the rotor 20 side and the counter-rotor side outer surfaces. state.

In the cross section of the intermediate conductor portion 152, it is preferable that the rotor 20 side has a substantially circular arc shape in the radial direction. In order to form the outer surface of the partial winding 151 on the rotor 20 side in an arcuate shape, it is preferable that the radial displacement amount Ds of each of the conductive wires CR arranged in the circumferential direction is changed little by little in the circumferential direction. In this case, it is preferable that the amount of deviation Ds is smaller on both ends in the circumferential direction of the intermediate conductor portion 152 than on the central side in the circumferential direction.

In the intermediate conductor portion 152, the radial side surfaces of the conductor CR may be radially displaced by a predetermined amount in the circumferential direction. In addition to the configuration in which the conductors CR are aligned in a direction shifted, the radial side surfaces of the conductors CR may be configured to be aligned in a radial direction shifted by a certain amount of deviation.

The configuration in which the conductors CR are arranged radially with a predetermined amount of radial deviation in the circumferential direction may include a configuration in which there is no radial deviation between adjacent conductors in the circumferential direction.

Here, as shown in FIG. 42, in one intermediate conductor portion 152 of the pair of intermediate conductor portions 152, a straight line extending along the circumferential side surface 421 of the conductor CR is L1, and in the other intermediate conductor portion 152, the conductor CR Assuming that a straight line extending along the circumferential side surface 421 of the stator is L2, the straight lines L1 and L2 are non-parallel and intersect with each other on the stator center side. In this configuration, the circumferential side surface 421 of the conductor CR extends toward the center of the stator in each intermediate conductor portion 152 . In such a case, the direction of the radial side surface 422 of the conductor CR facing the outer peripheral surface of the stator core 62 is not the same between the left side and the right side in the drawing. Therefore, as described above, in each intermediate conductor portion 152, the direction of radial deviation of the conductor CR is different between the region on the one end side in the circumferential direction and the region on the other end side in the circumferential direction of each intermediate conductor portion 152. It is configured to be wound with

In the first wall portion 411 of the coil holder 401, a stepped surface 413 is formed on the partial winding 151 side according to the radial displacement of the conductor CR, and a stepped surface 413 is formed on the stator core 62 side. A circular arc surface 414 is formed. In this case, the step surface 413 of the first wall portion 411 preferably has a step having the same height dimension as the displacement amount Ds in accordance with the displacement amount Ds of the conductor CR in the intermediate conductor portion 152 .

Note that the intermediate conductor portion 152 may be covered with an insulating material such as a synthetic resin, and the coil holder 401 may be attached to the intermediate conductor portion 152 in that state. Alternatively, the partial winding 151 covered with the insulating coating may be directly fixed to the stator core 62 without using the coil holder 401 .

According to this embodiment detailed above, the following effects are obtained.

In the intermediate conductor portion 152 of the partial winding 151, the circumferential side surfaces 421 of the conductor CR are arranged linearly in the radial direction, and the radial side surfaces 422 of the conductor CR are arranged stepwise in the circumferential direction due to the radial displacement. state. As a result, the outer surface of the intermediate conductor portion 152 on the radially outer side (on the side of the rotor 20) can be shaped to match the side of the rotor 20, and the air gap between the stator winding 61 and the rotor 20 can be adjusted. can be made uniform. Further, since the partial winding 151 is formed by winding the conductor CR having a rectangular cross section in multiple layers, the conductor space factor can be improved. As a result, in the rotary electric machine 10, the stator windings 61 can be provided appropriately, and thus desired performance can be achieved.

In the partial winding 151 having a pair of intermediate conductor portions 152 and a bridge portion 153, depending on the extending direction of the circumferential side surface 421 of the conductor CR in each of the intermediate conductor portions 152, it may face the outer peripheral surface of the stator core 62. The direction of the radial side surface 422 of the conductor CR may not be the same for each of the intermediate conductor portions 152 . In this regard, in each intermediate conductor portion 152, the conductor CR is wound in a state in which the direction of radial displacement is different between the region on the one end side in the circumferential direction of each intermediate conductor portion 152 and the region on the other end side in the circumferential direction. It is configured to rotate. As a result, the outer surface on the rotor 20 side of the intermediate conductor portion 152 of the partial winding 151 can be suitably aligned with the rotor 20 side.

In the partial winding 151, a straight line L1 extending along the circumferential side surface 421 of the conductor CR in one intermediate conductor portion 152 and a straight line L2 extending along the circumferential side surface 421 of the conductor CR in the other intermediate conductor portion 152 are non-parallel to each other and intersect with each other on the stator center side, the direction in which the circumferential side surface 421 of the conductor CR in each intermediate conductor portion 152 extends is toward the stator center. In such a case, the radial side surface 422 of the conductor CR facing the outer peripheral surface of the stator core 62 does not have the same orientation. Therefore, as described above, in each intermediate conductor portion 152 , the conductor CR may be wound in a state in which the directions of radial displacement are different between the center side and both sides of each intermediate conductor portion 152 in the circumferential direction.

Since the rotor 20 side of the partial winding 151 has a substantially arcuate cross section, the outer surface of the rotor 20 side can more closely follow the shape of the rotor 20 side.

The intermediate conductor portion 152 of the partial winding 151 is configured such that the long sides of the conductor CR overlap in the circumferential direction and the short sides of the conductor CR overlap in the radial direction. In this case, since the short side of the conductor CR is arranged on the rotor 20 side, the outer surface of the intermediate conductor portion 152 on the rotor 20 side is larger than that in the case where the long side of the conductor CR is arranged on the rotor 20 side. is easily aligned with the rotor 20 side.

Furthermore, since the width dimension of the conductive wire CR in the circumferential direction is smaller than the width dimension in the radial direction in the intermediate conductive wire portion 152, the number of stages of the conductive wire rods CR in the circumferential direction increases, and the intermediate conductive wire portion 152 The outer surface on the rotor 20 side of the rotor 20 can be easily matched with the rotor 20 side.

In addition, since the width dimension in the circumferential direction of the conductor CR is smaller than the width dimension in the radial direction, the number of turns can be minimized while matching the outer surface shape of the intermediate conductor portion 152 on the side of the rotor 20 to the side of the rotor 20. As a result, it is possible to reduce the number of man-hours in manufacturing the windings.

In the configuration in which the partial winding 151 is assembled to the stator core 62, the conductor CR is wound in a shifted state so that the outer surface of the partial winding 151 on the rotor 20 side is shaped to match the rotor 20 side. The gap between the partial winding 151 and the stator core 62 can be made small and the gap can be made uniform for each stage of the conductor CR. As a result, the efficiency of the rotary electric machine 10 can be improved.

A coil holder 401 is provided integrally with the partial winding 151 , and a first wall portion 411 of the coil holder 401 is interposed between the partial winding 151 and the stator core 62 . In this case, the partial winding 151 can be attached to the stator core 62 by the coil holder 401 . In addition, in the first wall portion 411, a stepped surface 413 is formed on the side of the intermediate conductor portion 152 in accordance with the radial displacement of the conductor CR, and an arc surface 414 without a step is formed on the side of the stator core 62. Therefore, it is possible to reliably and easily assemble the partial windings 151 to the stator core 62 while suppressing the displacement of the conductor CR wound in a displaced state.

In the magnet unit 22 of the rotor 20, in the configuration in which the magnetic flux acting surface 34 of the magnet 32 concentrates the magnetic flux in the region near the d-axis (configuration of FIG. Concerns about electric currents intensify. In this respect, as described above, the partial winding 151 is formed by multiple windings of the conductor CR having a rectangular cross section, and the middle conductor portion 152 has a configuration in which the conductor CR is arranged in a plurality in the radial direction and the circumferential direction. Thus, suppression of eddy current can be suitably realized.

Eddy current loss can be reduced by using a bundled wire (bundled wire) in which a plurality of strands are bundled as the conductor CR of the partial winding 151 .

(Modification)
A modification of the second embodiment will be described below.

- As shown in FIG. 44, the conductor CR may be a rectangular wire having a square cross section. The magnetic flux of the rotor 20 has the property of spreading in the circumferential direction from the magnetic flux outflow surface, and the direction of the magnetic flux with respect to the partial windings 151 changes according to the relative position between the rotor 20 and the stator 60 . In this case, by using a rectangular wire having a square cross section as the conductor CR of the partial winding 151, eddy currents can be appropriately suppressed regardless of the relative positions of the rotor 20 and the stator 60. FIG.

- You may change the form of each intermediate|middle conductor part 152 in the partial winding 151. FIG. 45 is a cross-sectional view showing a cross section at an axially intermediate portion of the partial winding 151, and FIG. 46 is an enlarged sectional view showing the intermediate conductor portion 152 and the coil holder 401 of the partial winding 151. As shown in FIG. be. In these figures, the horizontal direction is the circumferential direction, and the vertical direction is the radial direction.

As shown in FIGS. 45 and 46, the partial winding 151 is formed by multiple windings of a conductor CR (rectangular wire) having a rectangular cross section. It is wound in a state in which it is arranged in multiple numbers in both the direction and the circumferential direction. A coil holder 401 is integrated in the partial winding 151 . These basic configurations themselves are the same as the configurations of FIG. 42 and the like already described.

The intermediate conductor portion 152 is configured such that the circumferential side surfaces 421, which are the long sides of the conductor CR, overlap in the circumferential direction, and the radial side surfaces 422, which are the short sides of the conductor CR, overlap in the radial direction. The same applies to the fact that the circumferential side surfaces 421 of the conductor CR are arranged in a straight line in the radial direction, and the radial side surfaces 422 of the conductor CR are arranged in a stepped manner in the circumferential direction due to radial displacement. be.

However, in the partial winding 151 of this example, as a difference from the configuration of FIG. L1 and a straight line L2 extending along the circumferential side surface 421 of the conductor CR in the other intermediate conductor portion 152 are parallel to each other. In the intermediate conductor portion 152, the conductor CR has the same radial deviation direction from one end in the circumferential direction of the intermediate conductor portion 152 to the other end in the circumferential direction. The wires are wound in the opposite directions of displacement. That is, the directions of the radial side surfaces 422 of the conductor CR are the same in the pair of intermediate conductor portions 152 .

As a result, the rotor 20 side outer surface of the intermediate conductor portion 152 of the partial winding 151 in the stator winding 61 can be suitably aligned with the rotor 20 side.

In addition, in the cross section of the intermediate conductor portion 152, it is preferable that the rotor 20 side has a substantially arcuate shape in the radial direction. In this case, the amount of radial displacement of each of the conductive wires CR arranged in the circumferential direction may be changed little by little in the circumferential direction. .

- The intermediate conductor portion 152 of the partial winding 151 may be configured as shown in FIGS. 47(a) and 47(b). In FIGS. 47A and 47B, the horizontal direction is the circumferential direction, the vertical direction is the radial direction, and the lower side of the drawing is the radially inner side (the stator core 62 side).

In FIG. 47A, the partial winding 151 has a configuration in which the number of windings of the conductor CR is larger on the radially outer side than on the radially inner side in the intermediate conductor portion 152 (coil side conductor portion). In this case, in each intermediate conductor portion 152 of the partial winding 151, the width dimension in the circumferential direction can be made different between the radially inner side and the radially outer side. Thereby, the conductor space factor of the stator winding 61 can be improved.

In the outer rotor type rotary electric machine 10 , the rotor 20 is arranged radially outward of the stator 60 , and the rotor-side surface of the intermediate conductor portion 152 is arranged circumferentially more circumferentially than the anti-rotor-side surface in the cross section perpendicular to the axis. It should be wide (that is, have a large number of conductors). In an inner rotor type electric rotating machine in which the rotor 20 is arranged radially inside the stator 60 , the stator winding 61 (partial winding 151 ) is assembled radially inside the stator core 62 . In the orthogonal cross section of the conductor portion 152, the surface on the side opposite to the rotor is preferably wider in the circumferential direction than the surface on the rotor side (that is, the number of conductors is increased).

In FIG. 47B, the partial winding 151 includes, in the intermediate conductor portion 152 (coil side conductor portion), a portion where the conductor CR is wound with the direction in which the long side extends in the radial direction, and It has a portion around which the conductive wire CR is wound, with the extending direction being the circumferential direction, and the width dimension in the circumferential direction differs between the radially inner side and the radially outer side due to these portions. It should be noted that by twisting the conductor CR by 90 degrees at the coil end (crossing portion), the direction in which the long side extends may be switched between the radial direction and the circumferential direction.

In a configuration using a rectangular wire having a long side and a short side as the conductor CR, the dimension in the overlapping direction (stacking dimension) is changed by changing the orientation of the cross section of the conductor CR. In this case, the conductor lamination factor of the stator winding 61 can be improved by making the radially inner side and the radially outer side different in width in the circumferential direction. Also, dead space can be minimized.

In the intermediate conductor portion 152, the short sides of the conductor CR are overlapped in the circumferential direction as the circumferential side surfaces 421, and the long sides of the conductor CR are radially overlapped as the radial side surfaces 422 (constitution opposite to that shown in FIG. 43). ).

- In the stator 60 , each partial winding 151 may be directly assembled to the stator holder 70 . In this case, the stator core 62 is not used, and the stator holder 70 corresponds to the "cylindrical member".

The rotating electric machine 10 of the second embodiment uses the armature as the rotor and the field element as the stator instead of the rotating field type rotating electric machine in which the field element is the rotor and the armature is the stator. It is also possible to employ a rotating armature type rotating electric machine.

The disclosure herein is not limited to the illustrated embodiments. The disclosure encompasses the illustrated embodiments and variations thereon by those skilled in the art. For example, the disclosure is not limited to the combinations of parts and/or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure can have additional parts that can be added to the embodiments. The disclosure encompasses omitting parts and/or elements of the embodiments. The disclosure encompasses permutations or combinations of parts and/or elements between one embodiment and another. The disclosed technical scope is not limited to the description of the embodiments. The disclosed technical scope is indicated by the description of the claims, and should be understood to include all changes within the meaning and range of equivalents to the description of the claims.

DESCRIPTION OF SYMBOLS 10... Rotary electric machine, 20... Rotor (field element), 22... Magnet unit (magnet part), 60... Stator (armature), 61... Stator winding (armature winding), 62... Stator Core (cylindrical member) 151 Partial winding 421 Circumferential side surface 422 Radial side surface CR Conducting wire.

Claims (12)

a field element (20) having a magnet portion (22) including a plurality of magnetic poles with alternating polarities in the circumferential direction;
A multiphase armature winding (61) including a phase winding composed of a plurality of partial windings (151) per phase, and a cylindrical member (62, 70), an armature (60) having
A rotating electric machine (10) in which the field element and the armature are provided so as to face each other in the radial direction,
The partial winding is formed in an annular shape by winding a conductive wire (CR) having a rectangular cross section in multiple layers, and the conductive wires are arranged in a plurality of radial and circumferential directions on the coil side. cage,
In the cross section of the partial winding at the coil side, the circumferential side surfaces (421) of the conductor wire are arranged in a straight line in the radial direction, and the radial side surfaces (422) of the conductor wire are arranged in the radial direction. The rotating electric machine is in a state of being arranged in a stepped manner due to the displacement of the rotating electric machine. The partial winding includes a pair of intermediate conductor portions (152) provided at a predetermined interval in the circumferential direction, and transition portions provided at one end side and the other end side in the axial direction and annularly connecting the pair of intermediate conductor portions. (153) and
In each of the intermediate conductor portions, the conductor includes a region on one end side in the circumferential direction and a region on the other end side in the circumferential direction of each of the intermediate conductor portions, and the directions of radial displacement are different between the regions. 2. The rotating electric machine according to claim 1, wherein the rotating electrical machine is wound in a state. A straight line (L1) extending along the circumferential side surface of the conductor in one of the pair of intermediate conductor portions and a straight line (L1) extending along the circumferential side surface of the conductor in the other intermediate conductor portion ( L2) are non-parallel to each other and intersect with each other on the armature center side. The partial winding includes a pair of intermediate conductor portions (152) provided at a predetermined interval in the circumferential direction, and transition portions provided at one end side and the other end side in the axial direction and annularly connecting the pair of intermediate conductor portions. (153) and
In each of the intermediate conductor portions, the conductor material has the same radial deviation direction from one end in the circumferential direction of each intermediate conductor portion to the other end in the circumferential direction of each of the intermediate conductor portions. 2. The electric rotating machine according to claim 1, wherein the wires are wound in a state in which the directions of deviation are opposite to each other. The electric rotating machine according to any one of claims 1 to 4, wherein the cross section of the partial winding on the coil side has a substantially arcuate shape on the side of the field element in the radial direction. The conducting wire is a rectangular wire having a long side and a short side,
6. The partial winding according to any one of claims 1 to 5, wherein, on the coil side, the long sides of the conductor wire overlap in the circumferential direction and the short sides of the conductor wire overlap in the radial direction. The rotary electric machine according to the item. The rotating electric machine according to any one of claims 1 to 6, wherein the cylindrical member is an armature core (62). A winding holding member (401) having a wall portion (411) interposed between the partial winding and the cylindrical member in the radial direction is integrally provided,
In the wall portion, a stepped surface (413) is formed on the side of the partial winding according to the radial displacement of the conductor, and an arc surface (414) with no step is formed on the side of the cylindrical member. ) is formed. The electric rotating machine according to any one of claims 1 to 8, wherein the conductor wire is a rectangular wire having a square cross section. The magnet part in the field element has a permanent magnet (32) that generates a magnetic flux at each magnetic pole, and the magnetic flux acting surface (34) of the permanent magnet on the side of the armature has a magnetic pole center d The rotating electric machine according to any one of claims 1 to 9, wherein the magnetic flux is concentrated in a region near the shaft. The electric rotating machine according to any one of claims 1 to 10, wherein the partial winding has a larger number of windings of the conductive wire on the radially outer side than on the radially inner side on the coil side. The conducting wire is a rectangular wire having a long side and a short side,
The partial winding includes, on the coil side, a portion around which the conductor wire is wound with the direction in which the long sides extend in the radial direction, and a portion around which the conductor wire is wound in the direction in which the long sides extend in the circumferential direction. The rotary electric machine according to any one of claims 1 to 10, wherein the radially inner side and the radially outer side have different width dimensions in the circumferential direction due to these portions.

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