CN114641919A - Rotating electrical machine - Google Patents

Abstract

A rotating electrical machine (10) is provided with: a field element (20) including a magnet portion (22) having a plurality of magnetic poles whose polarities alternate in the circumferential direction; and an armature (60) having a multiphase armature winding (61). The armature windings of each phase have lead portions (152, 63U 1-63U 4) extending in the axial direction and arranged in the circumferential direction. In the armature, the inter-wire members are provided between the respective circumferential wire portions, and the inter-wire members are made of a magnetic material or a non-magnetic material that satisfies a relationship of Wt × Bs ≦ Wm × Br when the circumferential width of the inter-wire members of one magnetic pole is Wt, the saturation magnetic flux density of the inter-wire members is Bs, the circumferential width of the magnet portion of one magnetic pole is Wm, and the residual magnetic flux density of the magnet portion is Br, or the inter-wire members are not provided between the respective circumferential wire portions. The product of the number of phases of the armature winding and the number of magnetic poles is 48, and the cross-sectional shape of each lead portion is square.

Description

Rotating electrical machine

Citation of related applications

The present application is based on japanese patent application No. 2019-202678, applied on 11/7/2019, the contents of which are incorporated herein by reference.

Technical Field

The present disclosure relates to a rotating electric machine.

Background

Conventionally, for example, as described in patent document 1, there is known a rotating electrical machine including: a field element including a magnet portion having a plurality of magnetic poles whose polarities alternate in a circumferential direction; and an armature having a multiphase armature winding. The armature windings of the respective phases have lead portions extending in the axial direction and arranged in a circumferential direction.

Documents of the prior art

Patent literature

Patent document 1: japanese patent application laid-open No. 2010-41907

Disclosure of Invention

There is a rotary electric machine configured such that, in an armature, inter-lead members are provided between respective lead portions in a circumferential direction, and the inter-lead members are made of a magnetic material or a non-magnetic material that satisfies a relationship of Wt × Bs ≦ Wm × Br when a circumferential width of the inter-lead members of one magnetic pole is Wt, a saturation magnetic flux density of the inter-lead members is Bs, a circumferential width of the magnet portions of one magnetic pole is Wm, and a residual magnetic flux density of the magnet portions is Br (hereinafter, a non-slotted structure), or such that the inter-lead members are not provided between the respective lead portions in the circumferential direction. In this rotating electrical machine, the armature does not have a portion that functions as a pole tooth that guides the magnet magnetic flux of the magnet portion. Therefore, the magnetic flux of the magnet linked with the lead portions constituting the armature winding is reduced, and the torque of the rotating electrical machine may be reduced.

A main object of the present disclosure is to provide a rotating electric machine capable of achieving high torque.

The various aspects disclosed in the present specification achieve the respective objects by adopting mutually different technical means. The objects, features and effects disclosed in the present specification can be more clearly understood by referring to the following detailed description and accompanying drawings.

Mode 1 is a rotating electric machine including: a field element including a magnet portion having a plurality of magnetic poles whose polarities alternate in a circumferential direction; and

an armature having a multiphase armature winding, wherein either the field element or the armature is a rotor,

the armature windings of the respective phases have lead portions extending in the axial direction and arranged in a circumferential direction.

In the above-described armature, the magnetic flux density is,

wherein an inter-lead member is provided between the lead portions in the circumferential direction, and the inter-lead member is formed by using a magnetic material or a non-magnetic material that satisfies a relationship of Wt × Bs ≦ Wm × Br when the circumferential width of the inter-lead member of one magnetic pole is Wt, the saturation magnetic flux density of the inter-lead member is Bs, the circumferential width of the magnet portion of one magnetic pole is Wm, and the residual magnetic flux density of the magnet portion is Br, or by not providing the inter-lead member between the lead portions in the circumferential direction,

the product of the number of phases of the armature winding and the number of magnetic poles is 48,

the cross-sectional shape of each of the lead portions is square.

When the number of magnetic poles of the magnet portion is increased, the circumferential width of each magnetic pole of the magnet portion is decreased, and the magnetic path of the magnet for each magnetic pole tends to be shortened. Therefore, if the number of magnetic poles is too large, the magnetic flux of the magnet linked with the lead portion may be reduced.

In contrast, in embodiment 1, the product of the number of phases of the armature winding and the number of magnetic poles of the magnetic pole portion is 48. Thus, when a certain number of phases are used, the number of magnetic poles can be prevented from becoming excessive, and the decrease in the magnetic flux of the magnet linked with the lead portion can be suppressed. As a result, the torque of the rotating electric machine can be increased.

In embodiment 1, each lead portion has a square cross-sectional shape. This is a structure for achieving further higher torque of the rotating electric machine. This structure will be explained below.

In the rotating electrical machine, a magnetic circuit including a magnet portion, an air gap between the magnet portion and an armature, and the armature is formed.

Here, the larger the radial thickness dimension of the lead portion is, the larger the air gap is, and therefore, the magnetic resistance of the magnetic circuit becomes large. Therefore, conventionally, it is considered that the larger the radial thickness dimension of the lead portion is, the smaller the magnetic flux of the magnet linked with the lead portion is, and the lower the torque of the rotating electrical machine is. However, the inventors of the present application found that the following thickness dimensions exist: when the thickness dimension in the radial direction of the lead portion is changed to various values, the product value of the cross-sectional area of the lead portion when the thickness dimension is set and the magnetic flux of the magnet at the operating point of the magnet portion when the thickness dimension is set is the maximum value. Since the product value is a value corresponding to the torque constant of the rotating electrical machine, the rotating electrical machine can be increased in torque by adopting the thickness dimension in the radial direction of the lead portion where the product value is the largest.

The inventors of the present invention confirmed through calculation and experiments that the thickness dimension in the radial direction of the lead portion at or near the maximum value of the above-described product value is a thickness dimension in which the cross-sectional shape of the lead portion is square. Therefore, in the embodiment 1, the cross-sectional shape of each lead portion is square. According to the above-described aspect 1, the rotating electric machine can be increased in torque.

Embodiment 2 is the case where, in addition to embodiment 1, the lead part has a plurality of leads arranged in a radial direction and a circumferential direction, respectively, and is constituted by a parallel connection body of the plurality of leads,

the conductor portions of the same phase adjacent in the circumferential direction maintain the relative positional relationship of the conductors,

the arrangement position of each of the lead wires constituting one of the lead wires of the same phase adjacent in the circumferential direction is an arrangement position in which the arrangement position of each of the lead wires constituting the other lead wire is rotated by 90 degrees when viewed in the axial direction.

There are rotating electric machines as follows: the lead portion of each phase includes a plurality of leads arranged in a radial direction and a circumferential direction, and is formed of a parallel connection body of the plurality of leads. Since the lead portion is formed of a parallel connection body of a plurality of leads, a closed loop circuit is formed in a pair of lead portions of the same phase adjacent in the circumferential direction. In this case, the following problems arise.

When the magnetic flux of the magnet portion is linked with the wire, an electromotive force (induced voltage) corresponding to the time rate of change of the linked magnetic flux is generated on the wire. The magnetic flux of the magnet interlinked with the conductive wire differs depending on the circumferential position of the conductive wire with respect to the magnet portion and the radial position of the conductive wire with respect to the magnet portion. When the position of the conductor portion is different, a difference between electromotive forces generated in the respective conductor lines becomes large in a pair of conductor lines of the same phase adjacent in the circumferential direction. As a result, the circulating current flowing through the closed loop circuit may increase.

Therefore, in the embodiment 2, the relative positional relationship of the respective lead wires is maintained in each of the lead wire portions of the same phase adjacent in the circumferential direction. The arrangement position of each of the conductive wires constituting one of the circumferentially adjacent conductive wire portions of the same phase is rotated by 90 degrees when viewed in the axial direction. This makes it possible to realize a structure that easily reduces the difference between electromotive forces generated by the lead wires at different circumferential and radial positions with respect to the magnet portion. This can reduce the circulating current flowing in the closed loop circuit.

In addition, in the aspect 2, since each of the lead portions has a square cross-sectional shape, the thickness dimension in the radial direction of one of the lead portions of the same phase adjacent in the circumferential direction can be made equal to the thickness dimension in the radial direction of the other lead portion. Thus, in the configuration in which the arrangement position of each of the lead wires constituting one of the lead wire portions of the same phase adjacent in the circumferential direction is rotated by 90 degrees as viewed in the axial direction, the air gap between the armature and the field element can be made uniform in the circumferential direction.

The mode 2 can be embodied as in the mode 3, for example. In the aspect 3, the armature winding of each phase is formed of a plurality of partial windings,

the partial winding includes: a pair of the lead portions extending in an axial direction and provided at a predetermined interval in a circumferential direction; and a bridging portion provided on one end side and the other end side in the axial direction and connecting the pair of lead portions in a ring shape, wherein a lead material is wound in a plurality of layers in the pair of lead portions and each of the bridging portions,

one of the pair of lead portions of the partial winding of the other phase is arranged between the pair of lead portions of the partial winding, whereby the lead portions of the respective phases are arranged in a predetermined order in the circumferential direction,

the lead material is composed of a parallel connection body of a plurality of leads,

in each of the lead portions of the same phase adjacent in the circumferential direction, the relative positional relationship of the lead materials and the relative positional relationship of the leads are maintained.

Drawings

The above objects, other objects, features and advantages of the present disclosure will become more apparent with reference to the accompanying drawings and the following detailed description. The drawings are as follows.

Fig. 1 is a perspective view showing the entire rotary electric machine according to the first embodiment.

Fig. 2 is a plan view of the rotating electric machine.

Fig. 3 is a longitudinal sectional view of the rotating electric machine.

Fig. 4 is a cross-sectional view of the rotary electric machine.

Fig. 5 is an exploded sectional view of the rotating electric machine.

Fig. 6 is a cross-sectional view of the rotor.

Fig. 7 is a partial cross-sectional view showing a sectional structure of the magnet unit.

Fig. 8 is a diagram showing a relationship between an electrical angle and a magnetic flux density of the magnet according to the embodiment.

Fig. 9 is a graph showing a relationship between an electrical angle and a magnetic flux density of the magnet of the comparative example.

Fig. 10 is a perspective view of the stator unit.

Fig. 11 is a longitudinal sectional view of the stator unit.

Fig. 12 is a perspective view of the core assembly as viewed from the axial side.

Fig. 13 is a perspective view of the core assembly as viewed from the other axial side.

Fig. 14 is a cross-sectional view of the core assembly.

Fig. 15 is an exploded sectional view of the core assembly.

Fig. 16 is a circuit diagram showing a connection state of a part of windings among the windings of the three phases.

Fig. 17 is a side view showing the first coil block and the second coil block arranged laterally and contrastingly.

Fig. 18 is a side view showing the first partial winding and the second partial winding arranged laterally and contrastingly.

Fig. 19 is a diagram showing a structure of the first coil module.

Fig. 20 is a sectional view taken along line 20-20 in fig. 19 (a).

Fig. 21 is a perspective view showing the structure of the insulating cover.

Fig. 22 is a diagram showing a structure of the second coil block.

Fig. 23 is a sectional view taken along line 23-23 in fig. 22 (a).

Fig. 24 is a perspective view showing the structure of the insulating cover.

Fig. 25 is a view showing the overlapping positions of the film materials in a state where the coil modules are arranged in the circumferential direction.

Fig. 26 is a plan view showing an assembled state of the first coil module with respect to the core assembly.

Fig. 27 is a plan view showing an assembled state of the first coil module and the second coil module with respect to the core assembly.

Fig. 28 is a longitudinal sectional view showing a fixed state by a fixing pin.

Fig. 29 is a diagram for explaining a structure relating to the winding end portion of the coil block.

Fig. 30 is a perspective view of a bus bar module.

Fig. 31 is a sectional view showing a part of a longitudinal section of the bus bar module.

Fig. 32 is a perspective view showing a state in which the bus bar module is assembled to the stator holder.

Fig. 33 is a longitudinal sectional view of a fixing portion that fixes the bus bar module.

Fig. 34 is a vertical cross-sectional view showing a state in which the relay member is attached to the housing cover.

Fig. 35 is a perspective view of the relay member.

Fig. 36 is a circuit diagram showing a control system of the rotating electric machine.

Fig. 37 is a functional block diagram showing a current feedback control process of the control device.

Fig. 38 is a functional block diagram showing a torque feedback control process of the control device.

Fig. 39 is a partial cross-sectional view showing a cross-sectional structure of a magnet unit in a modification.

Fig. 40 is a diagram showing a structure of a stator unit of an inner rotor structure.

Fig. 41 is a cross-sectional view of a rotor and a stator of the second embodiment.

Fig. 42 is a diagram showing an electrical configuration of one partial winding.

Fig. 43 is a view showing a magnetic circuit of the rotor and the stator.

Fig. 44 is a cross-sectional view showing a part of the rotor and the stator expanded in the circumferential direction.

Fig. 45 is a graph showing a demagnetization curve of a magnet.

Fig. 46 is a diagram showing a relationship between a magnetic flux of a magnet and a magnetomotive force.

Fig. 47 is a view showing air gaps corresponding to the respective thickness dimensions of the intermediate conductor portions.

Fig. 48 is a diagram showing a relationship between a magnetic flux and a magnetomotive force of a magnet and a permeance line.

Fig. 49 is a diagram showing a relationship between magnetic flux flowing through a magnetic circuit and magnetic resistance.

Fig. 50 is a diagram showing a relationship between a torque constant and a magnetic resistance.

Fig. 51 is a view showing a cross-sectional shape of the in-phase intermediate lead portion.

Fig. 52 is a diagram showing an electrical structure of one wire material.

Detailed Description

Hereinafter, a plurality of embodiments will be described with reference to the drawings. In the embodiments, the same reference signs are given to functionally and/or structurally corresponding parts and/or related parts, or reference signs differing by more than one hundred bits are given. For corresponding parts and/or associated parts, reference may be made to the description of the other embodiments.

The rotating electric machine in the present embodiment is used as a vehicle power source, for example. However, the rotating electric machine is widely used for industrial use, vehicles, home appliances, OA equipment, game machines, and the like. In the following embodiments, the same or equivalent portions are denoted by the same reference numerals in the drawings, and the description thereof will be referred to for the portions having the same reference numerals.

(first embodiment)

The rotating electrical machine 10 of the present embodiment is a synchronous multiphase ac motor, and has an outer rotor structure (external rotor structure). Fig. 1 to 5 show an outline of the rotary electric machine 10. 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, fig. 3 is a vertical sectional view of the rotary electric machine 10 (a sectional view taken along line 3-3 in fig. 2), fig. 4 is a horizontal sectional view of the rotary electric machine 10 (a sectional view taken along line 4-4 in fig. 3), and fig. 5 is an exploded sectional view showing components of the rotary electric machine 10 in an exploded manner. In the following description, in the rotating electrical machine 10, a direction in which the rotating shaft 11 extends is an axial direction, a direction in which the rotating shaft 11 radially extends from a center thereof is a radial direction, and a direction in which the rotating shaft 11 circumferentially extends around the center thereof is a circumferential direction.

The rotary electric machine 10 generally includes: a rotating electric machine main body having a rotor 20, a stator unit 50, and a bus bar module 200; and a housing 241 and a housing cover 242 provided so as to surround the rotating electric machine main body. The rotary electric machine 10 is configured by disposing the above-described members coaxially with respect to the rotary shaft 11 integrally provided to the rotor 20 and assembling the members in the axial direction in a predetermined order. The rotary shaft 11 is supported by a pair of bearings 12 and 13 provided in the stator unit 50 and the housing 241, respectively, and is rotatable in this state. The bearings 12 and 13 are radial ball bearings having an inner ring, an outer ring, and a plurality of balls arranged between the inner ring and the outer ring, for example. The rotation of the rotary shaft 11 rotates, for example, an axle of a vehicle. The rotating electrical machine 10 can be mounted on the vehicle by fixing the housing 241 to the vehicle body frame or the like.

In the rotating electrical machine 10, the stator unit 50 is provided so as to surround the rotating shaft 11, and the rotor 20 is disposed radially outward of the stator unit 50. The stator unit 50 has: a stator 60; and a stator holder 70 assembled to a radially inner side thereof. The rotor 20 and the stator 60 are arranged to face each other in the radial direction with an air gap therebetween, and the rotor 20 rotates together with the rotating shaft 11, whereby the rotor 20 rotates on the outer side in the radial direction of the stator 60. The rotor 20 corresponds to a "field element", and the stator 60 corresponds to an "armature".

Fig. 6 is a longitudinal sectional view of the rotor 20. As shown in fig. 6, the rotor 20 includes a substantially cylindrical rotor frame 21 and an annular magnet unit 22 fixed to the rotor frame 21. The rotor frame 21 has: a cylindrical portion 23 having a cylindrical shape; and an end plate portion 24 provided at one axial end of the cylindrical portion 23, and the rotor frame 21 is configured by integrating the cylindrical portion 23 and the end plate 24. The rotor frame 21 functions as a magnet holding member, and the magnet unit 22 is annularly fixed to the radially inner side of the cylindrical portion 23. The end plate 24 has a through hole 24a, and the rotary shaft 11 is fixed to the end plate 24 by a fastener 25 such as a bolt in a state inserted through the through hole 24 a. The rotary shaft 11 has a flange 11a extending in a direction intersecting with (orthogonal to) the axial direction, and the rotor frame 21 is fixed to the rotary shaft 11 in a state where the flange 11a is surface-bonded to the end plate portion 24.

The magnet unit 22 has a cylindrical magnet holder 31, a plurality of magnets 32 fixed to an inner peripheral surface of the magnet holder 31, and an end plate 33 fixed to the side opposite to the end plate portion 24 of the rotor frame 21, of both sides in the axial direction. The magnet holder 31 has the same length dimension in the axial direction as the magnet 32. The magnet 32 is provided in a state of being surrounded by the magnet holder 31 from the radial outside. The magnet holder 31 and the magnet 32 are fixed at the end portion on one side in the axial direction in a state of abutting against the end plate 33. The magnet unit 22 corresponds to a "magnet portion".

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

In the magnet unit 22, the magnets 32 are arranged in such a manner as to alternately change polarity in the circumferential direction of the rotor 20. Thus, the magnet unit 22 has a plurality of magnetic poles in the circumferential direction. Magnet 32 is a permanent magnet having polar anisotropy, and is formed using 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.

The magnet 32 has a radially inner circumferential surface serving as a magnetic flux acting surface 34 for transmitting magnetic flux. In the magnet 32, the directions of the easy magnetization axes are different between the d-axis side (portion close to the d-axis) where the direction of the easy magnetization axis is parallel to the d-axis and the q-axis side (portion close to the q-axis) where the direction of the easy magnetization axis is orthogonal to the q-axis. In this case, a magnet magnetic path of an arc shape is formed in accordance with the direction of the magnetization easy axis. In short, the magnet 32 is configured to be oriented such that the direction of the magnetization easy axis is more parallel to the d axis at the magnetic pole center, i.e., the d axis side than the q axis side, which is the magnetic pole boundary.

In the magnet 32, since the magnet magnetic circuit is formed in an arc shape, the magnet magnetic circuit length is longer than the thickness dimension in the radial direction of the magnet 32. This increases the magnetic conductance of the magnet 32, and can exhibit the same ability as a magnet having a large number of magnets with the same amount of magnets.

The magnets 32 constitute one magnetic pole by grouping two circumferentially adjacent magnets. That is, the plurality of magnets 32 arranged in the circumferential direction in the magnet unit 22 have split surfaces in the d axis and the q axis, respectively, and the magnets 32 are arranged in a state of abutting or approaching each other. As described above, the magnets 32 have the circular-arc-shaped magnet magnetic paths, and the N-pole and S-pole of the circumferentially adjacent magnets 32 are opposed to each other at the q-axis. Therefore, the permeance near the q-axis can be improved. Further, since the magnets 32 on both sides sandwiching the q-axis attract each other, the contact state between the magnets 32 can be maintained. Thus, the flux guide is still improved.

In the magnet unit 22, the magnetic flux flows in an arc shape between the adjacent N pole and S pole by each magnet 32, and therefore the magnet magnetic path is longer than that of, for example, a radial anisotropic magnet. Therefore, as shown in fig. 8, the magnetic flux density distribution approaches a sine wave. As a result, unlike the magnetic flux density distribution of the radial anisotropic magnet shown as a comparative example in fig. 9, the magnetic flux can be concentrated on the center side of the magnetic pole, and the torque of the rotating electrical machine 10 can be increased. In addition, in the magnet unit 22 of the present embodiment, it was confirmed that there was a difference in magnetic flux density distribution as compared with the magnet of the conventional halbach array. In fig. 8 and 9, the horizontal axis represents the electrical angle, and the vertical axis represents the magnetic flux density. In fig. 8 and 9, 90 ° on the horizontal axis represents the d axis (i.e., the magnetic pole center), and 0 ° and 180 ° on the horizontal axis represent the q axis.

That is, according to each magnet 32 of the above-described structure, the magnet magnetic flux at the d-axis in the magnet unit 22 is enhanced, and the magnetic flux variation in the vicinity of the q-axis is suppressed. This makes it possible to desirably realize the magnet unit 22 in which the surface magnetic flux change from the q axis to the d axis in each magnetic pole is relaxed.

The sine wave matching rate of the magnetic flux density distribution is preferably 40% or more, for example. Thus, the magnetic flux at the center of the waveform can be reliably increased as compared with the case of using a radially oriented magnet having a sine wave matching rate of about 30% or using a parallel oriented magnet. Further, when the sine wave matching rate is 60% or more, the magnetic flux at the center of the waveform can be reliably increased as compared with a flux concentration array such as a halbach array.

In the radial anisotropic magnet shown in fig. 9, the magnetic flux density changes sharply near the q-axis. The more rapid the change in the magnetic flux density, the more the eddy current in the stator winding 61 of the stator 60 described later increases. Further, the magnetic flux change on the stator winding 61 side also becomes abrupt. In contrast, in the present embodiment, the magnetic flux density distribution has a waveform close to a sine wave. Therefore, the variation in magnetic flux density is smaller in the vicinity of the q-axis than in the radial anisotropic magnet. This can suppress the generation of eddy current.

In the magnet 32, a recess 35 is formed in a predetermined range including the d-axis on the outer peripheral surface on the outer side in the radial direction, and a recess 36 is formed in a predetermined range including the q-axis on the inner peripheral surface on the inner side in the radial direction. In this case, the magnet magnetic circuit in the vicinity of the d-axis becomes short on the outer peripheral surface of the magnet 32, and the magnet magnetic circuit in the vicinity of the q-axis becomes short on the inner peripheral surface of the magnet 32, depending on the direction of the easy magnetization axis of the magnet 32. Therefore, it is considered that it is difficult to generate a sufficient magnet magnetic flux at a portion of the magnet 32 where the magnetic path length of the magnet is short, and the magnet is removed at a portion where the magnet magnetic flux is weak.

In the magnet unit 22, the same number of magnets 32 as the number of magnetic poles may be used. For example, the magnet 32 is disposed as one magnet between d-axes, which are the centers of each of two magnetic poles adjacent in the circumferential direction. In this case, the magnet 32 is configured such that the circumferential center is the q-axis and has a split surface on the d-axis. In addition, instead of the configuration in which the circumferential center is the q-axis, the magnet 32 may be configured such that the circumferential center is the d-axis. Instead of using two times as many magnets as the number of magnetic poles or using the same number of magnets as the number of magnetic poles, the magnet 32 may be configured to use annular magnets that are connected in an annular shape.

As shown in fig. 3, a resolver 41 as a rotation sensor is provided at an end (an upper end in the figure) opposite to the coupling portion of the rotor frame 21 on both sides in the axial direction of the rotary shaft 11. The resolver 41 includes a resolver rotor fixed to the rotating shaft 11 and a resolver stator disposed to face the resolver rotor radially outward. The resolver rotor is in the shape of a circular plate and is coaxially provided on the rotary shaft 11 in a state where the rotary shaft 11 is inserted. The resolver stator has a stator core and a stator coil, and is fixed to the housing cover 242.

Next, the structure of the stator unit 50 will be described. Fig. 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 of the same position as fig. 3.

As a summary thereof, the stator unit 50 has a stator 60 and a stator holder 70 on the radially inner side thereof. The stator 60 has a stator winding 61 and a stator core 62. Further, the stator core 62 and the stator holder 70 are integrated to provide a core assembly CA, and the plurality of partial windings 151 constituting the stator winding 61 are assembled to the core assembly CA. The stator winding 61 corresponds to an "armature winding", the stator core 62 corresponds to an "armature core", and the stator holder 70 corresponds to an "armature holding member". In addition, the core assembly CA corresponds to a "support member".

Here, first, the core assembly CA will be explained. Fig. 12 is a perspective view of the core assembly CA as viewed from one axial side, fig. 13 is a perspective view of the core assembly CA as viewed from the other axial side, fig. 14 is a transverse sectional view of the core assembly CA, and fig. 15 is an exploded sectional view of the core assembly CA.

As described above, the core assembly CA has the stator core 62 and the stator holder 70 assembled to the radially inner side thereof. In other words, the stator core 62 is integrally assembled to the outer peripheral surface of the stator holder 70.

The stator core 62 is configured as a core segment laminate in which core segments 62a made of electromagnetic steel plates as magnetic bodies are laminated in the axial direction, and has a cylindrical shape having 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 is formed into a curved surface shape without unevenness. The stator core 62 functions as a back yoke. The stator core 62 is formed by laminating a plurality of core segments 62a punched out in an annular plate shape in the axial direction, for example. However, the stator core 62 having a helical core structure may also be used. In the stator core 62 having the helical core structure, a band-shaped core piece is used, and the core pieces are annularly wound and stacked in the axial direction, whereby the cylindrical stator core 62 is formed as a whole.

In the present embodiment, the stator 60 has a non-slotted structure having no pole teeth for forming the slots, but any one of the following structures (a) to (C) may be used.

(A) In the stator 60, the inter-lead members are provided between the respective lead portions in the circumferential direction (intermediate lead portions 152 described later), and as the inter-lead members, a magnetic material is used that satisfies the relationship Wt × Bs ≦ Wm × Br when the circumferential width of the inter-lead members of one magnetic pole is Wt, the saturation magnetic flux density of the inter-lead members is Bs, the circumferential width of the magnet 32 of one magnetic pole is Wm, and the residual magnetic flux density of the magnet 32 is Br.

(B) In the stator 60, an inter-wire member is provided between the respective lead portions (intermediate lead portions 152) in the circumferential direction, and a non-magnetic material is used as the inter-wire member.

(C) In the stator 60, no inter-wire member is provided between the respective lead portions (intermediate lead portions 152) in the circumferential direction.

As shown in fig. 15, the stator holder 70 includes an outer cylindrical member 71 and an inner cylindrical member 81, and is configured by integrally assembling the outer cylindrical member 71 radially outward and the inner cylindrical member 81 radially inward. Each of the members 71 and 81 is made of metal such as aluminum or cast iron, or Carbon Fiber Reinforced Plastic (CFRP).

The outer cylindrical member 71 is a cylindrical member having a circular curved surface on both the outer peripheral surface and the inner peripheral surface, and has an annular flange 72 formed on one end side in the axial direction and extending radially inward. The flange 72 is formed with a plurality of projections 73 extending radially inward at predetermined intervals in the circumferential direction (see fig. 13). Further, opposing surfaces 74, 75 axially opposing the inner tubular member 81 are formed on one end side and the other end side in the axial direction of the outer tubular member 71, and annular grooves 74a, 75a extending annularly are formed on the opposing surfaces 74, 75, respectively.

The inner cylindrical member 81 is a cylindrical member having an outer diameter smaller than the inner diameter of the outer cylindrical member 71, and the outer circumferential surface thereof is a circular curved surface concentric with the outer cylindrical member 71. An annular flange 82 extending radially outward is formed on one axial end side of the inner cylindrical member 81. The inner cylindrical member 81 is assembled to the outer cylindrical member 71 in a state of being in contact with the opposing surfaces 74, 75 of the outer cylindrical member 71 in the axial direction. As shown in fig. 13, the outer cylindrical member 71 and the inner cylindrical member 81 are assembled to each other by a fastener 84 such as a bolt. Specifically, a plurality of projecting portions 83 extending radially inward at predetermined intervals in the circumferential direction are formed on the inner peripheral side of the inner tubular member 81, and the projecting portions 73, 83 are fastened to each other by fasteners 84 in a state where the axial end surfaces of the projecting portions 83 and the projecting portions 73 of the outer tubular member 71 overlap each other.

As shown in fig. 14, in a state where the outer tubular member 71 and the inner tubular member 81 are assembled with each other, 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, and this gap space is a refrigerant passage 85 through which a refrigerant such as cooling water flows. The refrigerant 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, the passage forming portion 88 protrudes radially inward from the inner circumferential side of the inner cylindrical member 88, an inlet passage 86 and an outlet passage 87 are formed inside the passage forming portion, and the passages 86 and 87 are open to the outer circumferential surface of the inner cylindrical member 81. Further, a partition portion 89 for partitioning the refrigerant passage 85 into an inlet side and an outlet side is provided on the outer peripheral surface of the inner tubular member 81. Thus, 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 side of the inlet-side passage 86 and the outlet-side passage 87 extends in the radial direction and opens on the outer peripheral surface of the inner cylindrical member 81, and the other end side extends in the axial direction and opens on the axial end surface of the inner cylindrical member 81. Fig. 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. The inlet-side passage 86 and the outlet-side passage 87 lead to an inlet port 244 and an outlet port 245 (see fig. 1) attached to the housing cover 242, and the refrigerant flows in and out through the respective ports 244 and 245.

Seals 101 and 102 (see fig. 15) for suppressing leakage of the refrigerant in the refrigerant passage 85 are provided at the joint portion between the outer cylindrical member 71 and the inner cylindrical member 81. Specifically, the seals 101, 102 are, for example, O-rings, are housed in the annular grooves 74a, 75a of the outer cylindrical member 71, and are provided in a state of being compressed by the outer cylindrical member 71 and the inner cylindrical member 81.

As shown in fig. 12, the inner tube member 81 has an end plate portion 91 at one end in the axial direction, and a hollow tubular boss portion 92 extending in the axial direction is provided in the end plate portion 91. The boss portion 92 is provided so as to surround an insertion hole 93 for inserting the rotary shaft 11 therethrough. 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 column portions 95 extending in the axial direction on the radially outer side of the boss portion 92. The column part 95 is a part serving as a fixing part for fixing the bus bar module 200, and details thereof will be described later. The boss portion 92 is a bearing holding member that holds the bearing 12, and the bearing 12 is fixed to a bearing fixing portion 96 provided on an inner peripheral portion thereof (see fig. 3).

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

Specifically, as shown in fig. 12, a plurality of recesses 105 are formed at equal intervals in the circumferential direction on the axial end surface of the inner tubular member 81, specifically, on the axially outer end surface of the end plate portion 91 that is around the boss portion 92. As shown in fig. 13, a plurality of recesses 106 are formed at equal intervals in the circumferential direction on the axial end surface of the outer tubular member 71, specifically, on the axially outer end surface of the flange 72. The recesses 105 and 106 are arranged to be aligned on a virtual circle concentric with the core assembly CA. The recesses 105 and 106 are provided at the same position in the circumferential direction, and the intervals and the number thereof are also the same.

In addition, in order to ensure the assembling strength with respect to the stator holder 70, the stator core 62 is assembled in a state in which a compressive force with respect to the radial direction of the stator holder 70 is generated. 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, the stator core 62 and the stator holder 70 are assembled in a state where radial stress from one to the other is generated, as it were. In addition, when the rotating electrical machine 10 is increased in torque, for example, it is conceivable to increase the diameter of the stator 60, and in this case, the fastening force of the stator core 62 is increased in order to firmly couple the stator core 62 to the stator holder 70. However, if the compressive stress (in other words, residual stress) of the stator core 62 increases, the stator core 62 may be damaged.

Therefore, in the present embodiment, in the structure in which the stator core 62 and the stator holder 70 are fitted and fixed to each other with a predetermined interference, the restricting portions that restrict the circumferential displacement of the stator core 62 by the circumferential engagement are provided at the portions of the stator core 62 and the stator holder 70 that face each other in the radial direction. That is, as shown in fig. 12 to 14, a plurality of engaging members 111 as restricting portions are provided at predetermined intervals in the circumferential direction between the stator core 62 and the outer cylinder member 71 of the stator holder 70 in the radial direction, and the engaging members 111 suppress positional displacement in the circumferential direction between the stator core 62 and the stator holder 70. In this case, it is preferable that a recess be provided in at least one of the stator core 62 and the outer tube member 71, and the engaging member 111 be engaged with the recess. Instead of the engaging member 111, a convex portion may be provided on either the stator core 62 or the outer tube member 71.

In the above configuration, the stator core 62 and the stator holder 70 (outer tube member 71) are fitted and fixed with a predetermined interference, and are also provided in a state in which the circumferential displacement between the stator core and the stator holder is restricted by the engagement member 111. Therefore, even if the interference between the stator core 62 and the stator holder 70 is relatively small, the circumferential displacement of the stator core 62 can be suppressed. Further, since a desired displacement suppression effect can be obtained even if the interference is relatively small, it is possible to suppress damage to the stator core 62 due to an excessively large interference. As a result, displacement of the stator core 62 can be appropriately suppressed.

An annular internal space surrounding the rotary shaft 11 may be formed on the inner peripheral side of the inner tubular member 81, and electric components constituting an inverter as a power converter, for example, may be arranged in the internal space. The electrical component is, for example, an electrical module in which a semiconductor switching element or a capacitor is packaged. By disposing the electric module in contact with the inner peripheral surface of the inner tube member 81, the electric module can be cooled by the refrigerant flowing through the refrigerant passage 85. Further, the inner space on the inner peripheral side of the inner tubular member 81 can be expanded by not providing a plurality of protrusions 83 on the inner peripheral side of the inner tubular member 81 or by reducing the protruding height of the protrusions 83.

Next, the structure of the stator winding 61 assembled to the core assembly CA will be described in detail. As shown in fig. 10 and 11, the state in which the stator winding 61 is assembled to the core assembly CA is a state as follows: the plurality of partial windings 151 constituting the stator winding 62 are assembled radially outward of the core assembly CA, that is, radially outward of the stator core 61 in a state of being arranged in the circumferential direction.

The stator winding 61 has a plurality of phase windings, and the phase windings of the respective phases are arranged in a predetermined order in the circumferential direction to form a cylindrical shape (ring shape). In the present embodiment, the stator winding 61 is provided with three phase windings by using U-phase, V-phase, and W-phase windings.

As shown in fig. 11, the stator 60 includes a portion corresponding to the coil side CS radially opposed to the magnet unit 22 of the rotor 20 in the axial direction, and a portion corresponding to the coil side end CE, which is the axially outer side of the coil side CS. 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, the phase winding of each phase has a plurality of partial windings 151 (refer to fig. 16), respectively, and the partial windings 151 are individually provided as the coil modules 150. That is, the coil module 150 is configured by integrally providing the partial windings 151 of the phase windings of the respective phases, and the stator winding 61 is configured by a predetermined number of coil modules 150 corresponding to the number of poles. The coil modules 150 (partial windings 151) of the respective phases are arranged in a predetermined order in the circumferential direction, and thus the lead portions of the respective phases are arranged in a predetermined order on the coil side CS of the stator winding 61. Fig. 10 shows the arrangement order of the U-phase, V-phase, and W-phase lead portions of the coil side CS. In the present embodiment, the number of magnetic poles is set to 24, but the number may be arbitrary.

In the stator winding 61, the partial windings 151 of the coil modules 150 for each phase are connected in parallel or in series to constitute a phase winding for each phase. Fig. 16 is a circuit diagram showing a connection state of a part of windings 151 in each phase winding of three phases. Fig. 16 shows a state in which some of the phase windings 151 of the respective phases are connected in parallel.

As shown in fig. 11, the coil module 150 is assembled to the radially outer side of the stator core 62. In this case, the coil module 150 is assembled in a state in which both axial end portions thereof protrude outward in the axial direction of the stator core 62 (i.e., on the coil side end CE side). That is, the stator winding 61 includes a portion corresponding to the coil side end CE protruding outward in the axial direction of the stator core 62, and a portion corresponding to the coil side CS located inward in the axial direction from the coil side end CE.

The coil module 150 has two shapes, one is a shape in which the partial winding 151 is bent radially inward, i.e., toward the stator core 62 at the coil edge CE, and the other is a shape in which the partial winding 151 is not bent radially inward but linearly extends in the axial direction at the coil edge CE. In the following description, for convenience, the partial windings 151 having a bent shape on both axial end sides are referred to as "first partial windings 151A", and the coil module 150 having the first partial windings 151A is referred to as "first coil module 150A". The partial winding 151 having no bent shape on both axial end sides is referred to as a "second partial winding 151B", and the coil block 150 having the second partial winding 151B is referred to as a "second coil block 150B".

Fig. 17 is a side view showing the first coil block 150A and the second coil block 150B arranged laterally and in contrast, and fig. 18 is a side view showing the first partial winding 151A and the second partial winding 151B arranged laterally and in contrast. As shown in the above figures, the coil modules 150A and 150B and the partial windings 151A and 151B have different axial lengths and different end shapes on both sides in the axial direction. The first partial winding 151A has a substantially C-shape in side view, and the second partial winding 151B has a substantially I-shape in side view. Insulation covers 161 and 162 as "first insulation covers" are attached to both axial sides of the first partial winding 151A, and insulation covers 163 and 164 as "second insulation covers" are attached to both axial sides of the second partial winding 151B.

Next, the structure 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 structure of the first coil module 150A, and fig. 19 (b) is a perspective view showing the first coil module 150A with its constituent components exploded. Fig. 20 is a sectional view taken along line 20-20 in fig. 19 (a).

As shown in fig. 19 (a) and (b), the first coil module 150A includes a first partial winding 151A formed by winding a conductive wire material CR in a plurality of layers, and insulating covers 161 and 162 attached to one end side and the other end side in the axial direction of the first partial winding 151A. The insulating covers 161 and 162 are formed of an insulating material such as synthetic resin.

The first partial winding 151A has: a pair of intermediate conductor portions 152 provided in parallel and linearly; and a pair of bridging portions 153A connecting the pair of intermediate lead portions 152 at both ends in the axial direction, respectively, and the pair of intermediate lead portions 152 and the pair of bridging portions 153A are formed in a ring shape. The pair of intermediate lead portions 152 are provided at a predetermined coil pitch, and the intermediate lead portions 152 of the partial windings 151 of the other phase can be arranged between the pair of intermediate lead portions 152 in the circumferential direction. In the present embodiment, the pair of intermediate lead portions 152 are provided at two coil pitches apart, and one intermediate lead portion 152 of the partial windings 151 of the other two phases is disposed between the pair of intermediate lead portions 152, respectively.

The pair of bridging portions 153A have the same shape on both sides in the axial direction, and are each provided as a portion corresponding to the coil side end CE (see fig. 11). Each of the bridging portions 153A is provided so as to be bent in a direction orthogonal to the intermediate lead portion 152, i.e., in a direction orthogonal to the axial direction.

As shown in fig. 18, the first partial winding 151A has a lap 153A on both sides in the axial direction, and the second partial winding 151B has a lap 153B on both sides in the axial direction. The shapes of the lap portions 153A and 153B of the partial windings 151A and 151B are different from each other, and for the sake of clear distinction, the lap portion 153A of the first partial winding 151A is also referred to as a "first lap portion 153A", and the lap portion 153B of the second partial winding 151B is referred to as a "second lap portion 153B".

In each of the partial windings 151A and 151B, the intermediate lead portions 152 are provided as coil side lead portions arranged one by one in the circumferential direction at the coil side portion CS. Further, each of the bridging portions 153A, 153B is provided as a coil side end portion lead portion that connects the two same-phase intermediate lead portions 152 at two circumferentially different positions to each other at the coil side end CE.

As shown in fig. 20, the first partial winding 151A is formed by winding the wire material CR in multiple layers so that the cross section of the wire assembly portion becomes a quadrangle. Fig. 20 shows a cross section of the intermediate wire portion 152, in which the wire material CR is wound in multiple layers in a manner arranged in the circumferential direction and the radial direction in the intermediate wire portion 152. That is, the first partial winding 151A has the wire materials CR arranged in a plurality of rows in the circumferential direction and in a plurality of rows in the radial direction in the intermediate wire portion 152, thereby forming a substantially rectangular cross section. Further, the lead wire material CR is bent in the radial direction at the tip end portion of the first bridging portion 153A, and is wound in multiple layers so as to be aligned in the axial direction and the radial direction. In the present embodiment, first partial winding 151A is configured by concentrically winding wire material CR. However, the winding method of the wire material CR is arbitrary, and the wire material CR may be wound in a plurality of layers by α winding (japanese: アルファ coil) in addition to the concentric winding.

In the first partial winding 151A, the end of the wire material CR is drawn from one first bridging portion 153A (the upper first bridging portion 153A in fig. 19 b) of the first bridging portions 153A on both sides in the axial direction, and the ends thereof are winding ends 154, 155. The winding end portions 154 and 155 are portions to be a winding start end and a winding end of the wire material CR, respectively. One of the winding end portions 154, 155 is connected to the current input-output terminal, and the other is connected to the neutral point.

In the first partial winding 151A, each intermediate conductor portion 152 is provided in a state of being covered with a sheet-like insulating cover 157. In fig. 19 (a), the first coil module 150A is shown in a state where the intermediate conductor portion 152 is covered with the insulating cover 157 and the intermediate conductor portion 152 is present inside the insulating cover 157, but this portion is referred to as the intermediate conductor portion 152 for convenience (the same applies to fig. 22 (b) described later).

The insulating cover 157 is provided by using a film material FM having at least the axial dimension of the length of the insulating cover range in the axial direction of the intermediate lead portion 152 and winding the film material FM around the intermediate lead portion 152. The film material FM is made of a PEN (polyethylene naphthalate) film, for example. More specifically, the film material FM includes a film base material, and an adhesive layer having foamability provided on one of both surfaces of the film base material. The film material FM is wound around the intermediate conductor portion 152 in a state of being bonded by the adhesive layer. In addition, a non-foaming adhesive can be used as the adhesive layer.

As shown in fig. 20, the intermediate conductor portion 152 has a substantially rectangular cross section with the conductor members CR arranged in the circumferential direction and the radial direction, and the film member FM covers the periphery of the intermediate conductor portion 152 with the circumferential ends overlapping, thereby providing an insulating cover 157. The film material FM is a rectangular sheet having a longitudinal dimension longer than the axial length of the intermediate lead portion 152 and a lateral dimension longer than the circumferential length of the intermediate lead portion 152, and is wound around the intermediate lead portion 152 in a state where a fold is provided in accordance with the cross-sectional shape of the intermediate lead portion 152. In a state where the film material FM is wound around the intermediate lead portion 152, the gap between the lead material CR of the intermediate lead portion 152 and the film base material is filled with the foam of the adhesive layer. In addition, in the overlapping portion OL of the film material FM, the circumferential end portions of the film material FM are bonded to each other by the adhesive layer.

In the intermediate wire portion 152, the insulating cover 157 is provided so as to cover all of the two circumferential side surfaces and the two radial side surfaces. In this case, the insulating cover 157 surrounding the intermediate wire portion 152 is provided with an overlapping portion OL in which the thin-film material FM overlaps at an opposing portion opposing the intermediate wire portion 152 in the partial winding 151 of the other phase, i.e., at one of both circumferential side surfaces of the intermediate wire portion 152. In the present embodiment, in the pair of intermediate lead portions 152, the overlap portions OL are provided on the same side in the circumferential direction, respectively.

In the first partial winding 151A, an insulating cover 157 is provided in a range from the intermediate wire portion 152 to a portion of the first bridging portion 153A on both sides in the axial direction that is covered with the insulating covers 161 and 162 (i.e., a portion inside the insulating covers 161 and 162). In fig. 17, in the first coil module 150A, the range of AX1 is a portion not covered by the insulating covers 161 and 162, and the insulating cover 157 is provided in a range vertically expanded from the range of AX 1.

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

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

As shown in fig. 21 (a) and (b), the insulating cover 161 includes a pair of side surface portions 171 serving as circumferential side surfaces, an axially outer surface portion 172, an axially inner surface portion 173, and a radially inner front surface portion 174. The respective portions 171 to 174 are formed in a plate shape and are connected to each other in a three-dimensional manner so as to be opened only radially outward. The pair of side surface portions 171 are provided in a direction extending toward the axial center of the core assembly CA in a state of being assembled to the core assembly CA. Therefore, in a state where the plurality of first coil modules 150A are arranged in the circumferential direction, the side surface portions 171 of the insulating cover 161 face each other in a state of abutting or approaching each other in the adjacent first coil modules 150A. This allows the first coil modules 150A adjacent to each other in the circumferential direction to be insulated from each other and to be appropriately arranged in an annular shape.

In the insulating cover 161, an opening 175a for drawing out the winding end portion 154 of the first partial winding 151A is provided in the outer surface portion 172, and an opening 175b for drawing out the winding end portion 155 of the first partial winding 151A is provided in the front surface portion 174. In this case, one of the winding overhang portions 154 is axially drawn out from the outer surface portion 172, and the other winding overhang portion 155 is radially drawn out from the front surface portion 174.

In the insulating cover 161, semicircular recesses 177 extending in the axial direction are provided in the pair of side surface portions 171 at both ends of the front surface portion 174 in the circumferential direction, that is, at positions where the side surface portions 171 and the front surface portion 174 intersect. Further, in the outer surface portion 172, a pair of protrusions 178 extending in the axial direction are provided at positions symmetrical in both sides in the circumferential direction with respect to the center line of the insulating cover 161 in the circumferential direction.

The concave portion 177 of the insulating cover 161 is explained. As shown in fig. 20, the first overlapping portion 153A of the first partial winding 151A has a curved shape protruding radially inward of the radially inward and outward portions, i.e., toward the core assembly CA. In this structure, a gap having a width that is wider toward the tip side of the first overlapping portion 153A is formed between the circumferentially adjacent first overlapping portions 153A. Therefore, in the present embodiment, the recess 177 is provided at a position outside the bent portion of the first overlapping portion 153A in the side surface portion 171 of the insulating cover 161 by utilizing the gap between the first overlapping portions 153A arranged in the circumferential direction.

In addition, a temperature detection portion (thermistor) may be provided in first partial winding 151A, and in this configuration, it is preferable that an opening portion for drawing out a signal line extending from the temperature detection portion is provided in insulating cover 161. In this case, the temperature detection unit can be preferably housed in the insulating cover 161.

Although not shown in detail, the insulation cover 162 on the other axial side has substantially the same structure as the insulation cover 161. Like the insulating cover 161, the insulating cover 162 has a pair of side surface portions 171, an axially outer surface portion 172, an axially inner surface portion 173, and a radially inner front surface portion 174. In the insulating cover 162, semicircular recesses 177 are provided at positions that become both ends of the front surface portion 174 in the circumferential direction in the pair of side surface portions 171, and a pair of protrusions 178 are provided on the outer surface portion 172. The insulating cover 162 is configured not to have an opening for drawing the winding end portions 154 and 155 of the first partial winding 151A, as a difference from the insulating cover 161.

The insulating covers 161 and 162 have different height dimensions in the axial direction (i.e., axial width dimensions of the pair of side surface portions 171 and the front surface 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 are W11 > W12. That is, when the conductor member CR is wound in a plurality of layers, the winding layer (track change) of the conductor member CR needs to be switched in a direction orthogonal to the winding direction (circumferential direction), and the switching may increase the winding width. In addition, the insulating cover 161 of the insulating covers 161 and 162 covers the first contact portion 153A including the winding start end and the winding end of the conductor material CR, and includes the winding start end and the winding end of the conductor material CR, so that the winding amount (the stacking amount) of the conductor material CR is increased compared to other portions, and as a result, the winding width is increased. In view of this, the axial height dimension W11 of the insulating cover 161 is larger than the axial height dimension W12 of the insulating cover 162. Thus, unlike the case where the height dimensions W11, W12 of the insulating covers 161, 162 are the same, the disadvantage that the number of turns of the wire material CR is limited by the insulating covers 161, 162 is suppressed.

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

Fig. 22 (a) is a perspective view showing the structure of the second coil block 150B, and fig. 22 (B) is a perspective view showing the second coil block 150B with its constituent parts exploded. Fig. 23 is a sectional view taken along line 23-23 in fig. 22 (a).

As shown in fig. 22 (a) and (B), the second coil module 150B includes a second partial winding 151B formed by winding a conductive material CR in a plurality of layers, as in the first partial winding 151A, and insulating covers 163 and 164 attached to one end side and the other end side in the axial direction 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 lead portions 152 provided in parallel with each other and linearly; and a pair of second bridging portions 153B connecting the pair of intermediate lead portions 152 at both ends in the axial direction, respectively, and formed in a ring shape by the pair of intermediate lead portions 152 and the pair of second bridging portions 153B. In the second partial winding 151B, the pair of intermediate lead portions 152 have the same configuration as the intermediate lead portions 152 of the first partial winding 151A. In contrast, the pair of second bridging portions 153B has a structure different from that of the first bridging portions 153A of the first partial winding 151A. The second lap portions 153B of the second partial winding 151B are provided to extend linearly in the axial direction from the intermediate wire portion 152, rather than being bent in the radial direction. In fig. 18, the difference between the partial windings 151A and 151B is clearly shown by comparison.

In the second partial winding 151B, the end of the conductive wire material CR is drawn out from one second bridging portion 153B (the upper second bridging portion 153B in fig. 22B) of the second bridging portions 153B on both sides in the axial direction, and the ends thereof become the winding ends 154 and 155. In the second partial winding 151B, one of the winding end portions 154 and 155 is connected to the current input/output terminal, and the other is connected to the neutral point, as in the first partial winding 151A.

Similarly to the first partial winding 151A, the second partial winding 151B is provided in a state where each intermediate conductor portion 152 is covered with a sheet-like insulating cover 157. The insulating cover 157 is provided by using a film material FM having at least the axial dimension of the length of the insulating cover range in the axial direction of the intermediate lead portion 152 and winding the film material FM around the intermediate lead portion 152.

The structure of insulating cover 157 is substantially the same for each of partial windings 151A and 151B. That is, as shown in fig. 23, the film member FM is covered around the intermediate conductor portion 152 in a state where the circumferential end portions overlap. In the intermediate wire portion 152, the insulating cover 157 is provided so as to cover all of the two circumferential side surfaces and the two radial side surfaces. In this case, the insulating cover 157 surrounding the intermediate wire portion 152 is provided with an overlapping portion OL in which the thin-film material FM overlaps at an opposing portion opposing the intermediate wire portion 152 in the partial winding 151 of the other phase, i.e., at one of both circumferential side surfaces of the intermediate wire portion 152. In the present embodiment, in the pair of intermediate lead portions 152, the overlap portions OL are provided on the same side in the circumferential direction, respectively.

In the second partial winding 151B, an insulating cover 157 is provided in a range from the intermediate conductor portion 152 to a portion of the second bridging portion 153B on both sides in the axial direction covered with the insulating covers 163 and 164 (i.e., a portion inside the insulating covers 163 and 164). In fig. 17, in the second coil module 150B, the range of AX2 is a portion not covered by the insulating covers 163 and 164, and the insulating cover 157 is provided in a range vertically expanded from the range of AX 2.

In each of the partial windings 151A and 151B, the insulating coating 157 is provided in a range including a part of the lap portions 153A and 153B. That is, in each of the partial windings 151A and 151B, the insulating coating 157 is provided on the intermediate lead portion 152 and the portion of the lands 153A and 153B that linearly extends next to the intermediate lead portion 152. However, the axial length of each of the partial windings 151A and 151B is different, and the axial extent of the insulating cover 157 is also different.

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

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

As shown in fig. 24 (a) and (b), the insulating cover 163 includes a pair of side surface portions 181 serving as circumferential side surfaces, an axially outer surface portion 182, a radially inner front surface portion 183, and a radially outer rear surface portion 184. The parts 181 to 184 are each formed in a plate shape and are connected to each other in a three-dimensional manner so as to be open only in the axial direction. The pair of side surface portions 181 are provided in a direction extending toward the axial center of the core assembly CA in a state of being assembled to the core assembly CA. Therefore, in a state where the plurality of second coil modules 150B are arranged in the circumferential direction, the side surface portions 181 of the insulating cover 163 face each other in a state of abutting or approaching each other in each of the adjacent second coil modules 150B. This allows the second coil modules 150B adjacent to each other in the circumferential direction to be insulated from each other and to be appropriately arranged in a ring shape.

In the insulating cover 163, an opening 185a for drawing out the winding end portion 154 of the second partial winding 151B is provided in the front surface portion 183, and an opening 185B for drawing out the winding end portion 155 of the second partial winding 151B is provided in the outer surface portion 182.

A front surface 183 of the insulating cover 163 is provided with a projection 186 projecting radially inward. The protruding portion 186 is provided at a central position between one end and the other end in the circumferential direction of the insulating cover 163 so as to protrude radially inward of the second bridging portion 153B. The protruding portion 186 has a tapered shape whose tip becomes narrower toward the radially inner side in plan view, and a through hole 187 extending in the axial direction is provided at the tip thereof. The protruding portion 186 may have any configuration as long as it protrudes radially inward from the second land portion 153B and has a through hole 187 at a central position between one end and the other end in the circumferential direction of the insulating cover 163, and the protruding portion 186 may be provided. However, in consideration of the overlapping state with the axially inner insulating cover 161, it is desirable to form the width in the circumferential direction to be narrow in order to avoid interference with the winding overhang 154, 155.

The axial thickness of the radially inner front end of the projection 186 is reduced in a stepwise manner, and a through hole 187 is provided in the reduced low-step portion 186 a. The lower step 186a corresponds to a portion having a height from the axial end surface of the inner tube member 81 lower than the height of the second lap joint 153B in a state where the second coil module 150B is assembled to the core assembly CA.

As shown in fig. 23, the projection 186 is provided with a through hole 188 that penetrates in the axial direction. Therefore, in a state where the insulating covers 161 and 163 are overlapped in the axial direction, the adhesive can be filled between the insulating covers 161 and 163 through the through hole 188.

Although the detailed description is omitted, the insulating cover 164 on the other axial side has substantially the same structure as the insulating cover 163. Similarly to the insulating cover 163, the insulating cover 164 has a pair of side surface portions 181, an axially outer surface portion 182, a radially inner front surface portion 183, and a radially outer rear surface portion 184, and has a through hole 187 provided at a front end portion of the protruding portion 186. In addition, the insulating cover 164 is configured not to have an opening for drawing the winding end portions 154 and 155 of the second partial winding 151B, as a difference from the insulating cover 163.

In the insulating covers 163 and 164, the width dimensions in the radial direction of the pair of side surface portions 181 are different. Specifically, as shown in fig. 17, a radial width dimension W21 of the side surface portion 181 of the insulating cover 163 and a radial width dimension W22 of the side surface portion 181 of the insulating cover 164 are W21 > W22. That is, the insulating cover 163 of the insulating covers 163 and 164 covers the second overlapping portion 153B including the winding start end and the winding end side of the conductor material CR, and includes the winding start end and the winding end of the conductor material CR, and therefore, the winding amount (the lamination amount) of the conductor material CR is increased compared to other portions, and as a result, the winding width may be increased. In this regard, the radial width dimension W21 of the insulation cover 163 is greater than the radial width dimension W22 of the insulation cover 164. Thus, unlike the case where the width dimensions W21, W22 of the insulating covers 163, 164 are the same, the disadvantage that the number of turns of the wire material CR is limited by the insulating covers 163, 164 is suppressed.

Fig. 25 is a diagram showing the overlapping positions of the film materials FM in a state where the coil modules 150A and 150B are arranged in the circumferential direction. As described above, in each of the coil modules 150A and 150B, the periphery of the intermediate wire portion 152 is covered with the film material FM so as to overlap the circumferential side surfaces of the intermediate wire portion 152, which is the opposing portion opposing the intermediate wire portion 152 in the partial winding 151 of the other phase (see fig. 20 and 23). Further, in a state where the coil modules 150A, 150B are arranged in the circumferential direction, the overlapped portions OL of the film materials FM are arranged on the same side (the circumferential right side in the figure) on both sides in the circumferential direction. This structure prevents the overlapping portions OL of the film materials FM from overlapping each other in the circumferential direction in the intermediate lead portions 152 of the partial windings 151A and 151B of different phases adjacent in the circumferential direction. In this case, a maximum of three film materials FM are stacked between the intermediate lead portions 152 arranged in the circumferential direction.

Next, a description will be given of a structure relating to assembly of each coil module 150A, 150B to the core assembly CA.

The coil modules 150A and 150B are different from each other in axial length, and the lap portions 153A and 153B of the partial windings 151A and 151B are different from each other in shape, and are attached to the core assembly CA in a state where the first lap portion 153A of the first coil module 150A is axially inside and the second lap portion 153B of the second coil module 150B is axially outside. Regarding the insulating covers 161 to 164, the insulating covers 161 to 164 are fixed to the core assembly CA in a state where the insulating covers 161 and 163 are overlapped in the axial direction at one end side in the axial direction of the coil modules 150A and 150B and the insulating covers 162 and 164 are overlapped in the axial direction at the other end side in the axial direction.

Fig. 26 is a plan view showing a state in which a plurality of insulation covers 161 are arranged in the circumferential direction in a state in which the first coil module 150A is assembled to the core assembly CA, and fig. 27 is a plan view showing a state in which a plurality of insulation covers 161, 163 are arranged in the circumferential direction in a state in which the first coil module 150A and the second coil module 150B are assembled to the core assembly CA. Fig. 28 (a) is a vertical sectional view showing a state before the coil modules 150A and 150B are assembled to the core assembly CA and fixed by the fixing pins 191, and fig. 28 (B) is a vertical sectional view showing a state after the coil modules 150A and 150B are assembled to the core assembly CA and fixed by the fixing pins 191.

As shown in fig. 26, in a state where the plurality of first coil modules 150A are assembled to the core assembly CA, the plurality of insulating covers 161 are respectively disposed so that the side surface portions 171 are in a state of abutting or approaching each other. Each insulating cover 161 is disposed so that a boundary line LB between the side surface portions 171 and the recess 105 of the axial end surface of the inner cylindrical member 81 coincide with each other. In this case, since the side surface portions 171 of the insulating covers 161 adjacent in the circumferential direction are in a state of abutting or approaching each other, the following state is achieved: through holes extending in the axial direction are formed in the respective recesses 177 of the insulating cover 161, and the through holes are aligned with the recesses 105.

As shown in fig. 27, a second coil module 150B is further incorporated into the integrated body of the core assembly CA and the first coil module 150A. With this assembly, the plurality of insulating covers 163 are disposed so that the side surface portions 181 are in a state of abutting against or approaching each other. In this state, the respective bridging portions 153A and 153B are arranged so as to intersect each other on a circle on which the intermediate wire portions 153 are arranged in the circumferential direction. Each insulating cover 163 is disposed so that the protruding portion 186 and the insulating cover 161 overlap each other in the axial direction and the through hole 187 of the protruding portion 186 and the through hole portion formed by each recess 177 of the insulating cover 161 communicate with each other in the axial direction.

At this time, the protrusion 186 of the insulating cover 163 is guided to a predetermined position by the pair of protrusions 178 provided on the insulating cover 161, and the position of the through hole 187 on the insulating cover 163 side is matched with the through hole portion on the insulating cover 161 side and the recess 105 of the inner cylindrical member 81. That is, in a state where the coil modules 150A and 150B are assembled to the core assembly CA, the recess 177 of the insulating cover 161 is located on the back side of the insulating cover 163, and therefore, it may be difficult to align the through hole 187 of the protruding portion 186 with respect to the recess 177 of the insulating cover 161. In this regard, the protruding portion 186 of the insulating cover 163 is guided by the pair of protruding portions 178 of the insulating cover 161, thereby making it easy to align the position of the insulating cover 163 with respect to the insulating cover 161.

As shown in fig. 28 (a) and (b), the insulating cover 161 and the protruding portion 186 of the insulating cover 163 are fixed by a fixing pin 191 as a fixing member in an overlapped portion where they are overlapped with each other in an engaged state. More specifically, the fixing pin 191 is inserted into the recesses 105, 177 and the through hole 187 of the insulating cover 163 while the recesses 105, 177 of the inner cylindrical member 81, the recesses 177 and the through hole 187 are aligned. Thus, the insulating covers 161 and 163 are integrally fixed to the inner tube member 81. According to this structure, the coil modules 150, 150B adjacent in the circumferential direction are fixed to the core assembly CA at the coil edge end CE by the common fixing pin 191. The fixing pin 191 is preferably made of a material having good thermal conductivity, such as a metal pin.

As shown in fig. 28 (b), the fixing pin 191 is assembled to the lower step 186a of the protrusion 186 of the insulating cover 163. In this state, the upper end of the fixing pin 191 protrudes upward from the lower step 186a, but does not protrude upward from the upper surface (outer surface 182) of the insulating cover 163. In this case, since the fixing pin 191 is longer than the axial height dimension of the overlapping portion of the insulating cover 161 and the protruding portion 186 (the low-step portion 186a) of the insulating cover 163 and has a margin protruding upward, it is considered that this operation can be easily performed when the fixing pin 191 is inserted into the recesses 105 and 177 and the through hole 187 (that is, when the fixing operation of the fixing pin 191 is performed). Further, 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 a problem that the axial length of the stator 60 is increased due to the protrusion of the fixing pin 191.

After the insulating covers 161 and 163 are fixed by the fixing pins 191, an adhesive is filled through the through holes 188 provided in the insulating cover 163. Thereby, the insulating covers 161 and 163 overlapped in the axial direction are firmly coupled to each other. Note that although the through-hole 188 is shown in the range from the upper surface to the lower surface of the insulating cover 163 for convenience in fig. 28 (a) and (b), the through-hole 188 is actually provided in a thin plate portion formed by wall reduction or the like.

As shown in fig. 28 (b), the fixing positions of the insulating covers 161 and 163 by the fixing pins 191 are located at the axial end surfaces of the stator holder 70 on the radially inner side (left side in the figure) of the stator core 62, and the fixing pins 191 fix the stator holder 70. That is, the first bridging portion 153A is fixed to the axial end face of the stator holder 70. In this case, since the refrigerant passage 85 is provided in the stator holder 70, the heat generated in the first partial winding 151A is directly transferred from the first bridging portion 153A to the vicinity of the refrigerant passage 85 of the stator holder 70. Further, the fixing pin 191 is inserted into the recess 105 of the stator holder 70, and the heat transfer to the stator holder 70 side is promoted by the fixing pin 191. With this configuration, the cooling performance of the stator winding 61 can be improved.

In the present embodiment, 18 insulating covers 161 and 163 are arranged to overlap each other in the axial direction at the coil edge CE, and recesses 105 are provided in 18 positions equal in number to the insulating covers 161 and 163 at the axial end face of the stator holder 70. Then, the 18 recesses 105 are fixed by the fixing pins 191.

Here, the configuration of the winding end portions 154 and 155 of the coil modules 150A and 150B in a state where the coil modules 150A and 150B are assembled to the core assembly CA will be described with reference to fig. 29.

In fig. 29, the winding end portions 154 and 155 are drawn out from the openings 175a and 175b and extended radially inward from the insulating cover 161, and the winding end portions 154 and 155 are drawn out from the openings 185a and 185b and extended radially inward from the insulating cover 163. In this case, in particular, the winding end portions 154 and 155 drawn out from the axially outer insulating cover 163 extend so as to pass across the axially outer insulating cover 161 in the radial direction, and the intermediate portions thereof are fixed to the upper surface (outer surface portion 172) of the insulating cover 161.

Although not shown, the same applies to the insulating covers 162 and 164 on the axially opposite sides. That is, first, when the first coil module 150A is assembled, the side surface portions 171 of the insulating covers 162 adjacent in the circumferential direction are in a state of abutting or approaching each other, and therefore, the following state is achieved: through holes extending in the axial direction are formed through the recesses 177 of the insulating cover 162, and the through holes are aligned with the recesses 106 on the axial end surface of the outer cylindrical member 71. Then, by assembling the second coil module 150B, the through hole 187 on the insulating cover 164 side is positioned to match the through hole on the insulating cover 163 side and the recess 106 of the outer cylindrical member 71, and the insulating covers 162 and 164 are integrally fixed to the outer cylindrical member 71 by inserting the fixing pin 191 into the recesses 106 and 177 and the through hole 187.

When the coil modules 150A and 150B are assembled to the core assembly CA, it is preferable that all of the first coil modules 150A are previously attached to the outer peripheral side of the core assembly CA, and then all of the second coil modules 150B are assembled and fixed by the fixing pins 191. Alternatively, first, two first coil modules 150A and one second coil module 150B are fixed to core assembly CA with one fixing pin 191, and thereafter, the assembly of first coil module 150A, the assembly of second coil module 150B, and the fixing by fixing pin 191 are repeated in this order.

Next, the bus bar module 200 will be explained.

The bus bar module 200 is a winding connection member that is electrically connected to the partial windings 151 of each coil module 150 in the stator winding 61, and connects one ends of the partial windings 151 of each phase in parallel for each phase and connects the other ends of the partial windings 151 at a neutral point. Fig. 30 is a perspective view of the bus bar module 200, and fig. 31 is a cross-sectional view showing a part of a longitudinal section of the bus bar module 200.

The bus bar module 200 includes: an annular ring-shaped portion 201; 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. 31, the annular portion 201 has a plurality of stacked plates 204 (five layers in this example) stacked in the axial direction in a substantially annular plate shape, and four bus bars 211 to 214 are provided so as to be sandwiched between the stacked plates 204. Each of the bus bars 211 to 214 is annular and includes a U-phase bus bar 211, a V-phase bus bar 212, a W-phase bus bar 213, and a neutral point bus bar 214. The bus bars 211 to 214 are arranged in the annular portion 201 in an axial direction so that the plate surfaces thereof face each other. The laminated plates 204 and the bus bars 211 to 214 are bonded to each other by an adhesive. As the adhesive, an adhesive sheet is desirably used. However, the adhesive may be applied in a liquid or semi-liquid form. The connection terminals 202 are connected to the bus bars 211 to 214 so as to protrude radially outward from the annular portion 201.

On the upper surface of the annular portion 201, that is, on the upper surface of the outermost laminated plate 204 of the five-layered laminated plate 204, there is provided an annularly extending projection 201 a.

The bus bar module 200 may be provided in a state where the bus bars 211 to 214 are embedded in the annular portion 201, or may be integrally insert-molded with the bus bars 211 to 214 arranged at predetermined intervals. The arrangement of the bus bars 211 to 214 is not limited to the structure in which all the bus bars are arranged in the axial direction and all the plate surfaces face the same direction, and may be a structure in which all the bus bars are arranged in the radial direction, a structure in which all the bus bars are arranged in two rows in the axial direction and arranged in two rows in the radial direction, a structure including bus bars having different plate surface extending directions, or the like.

In fig. 30, the respective connection terminals 202 are provided so as to be aligned in the circumferential direction of the ring-shaped portion 201, and extend in the axial direction at the radially outer side. The connection terminal 202 includes a connection terminal connected to the U-phase bus 211, a connection terminal connected to the V-phase bus 212, a connection terminal connected to the W-phase bus 213, and a connection terminal connected to the neutral-point bus 214. The connection terminals 202 are provided in the same number as the winding end portions 154, 155 of the respective partial windings 151 in the coil module 150, and the winding end portions 154, 155 of the respective partial windings 151 are connected to the connection terminals 202, respectively. Thereby, the bus bar 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 constituted by, for example, a bus bar member, and is provided in a direction extending in the axial direction. The input/output terminal 203 includes an input/output terminal 203V for the U-phase input/output terminal 203U, V and an input/output terminal 203W for the W-phase input/output terminal 203W. The input/output terminal 203 is connected to each of the bus bars 211 to 213 for each phase in the annular portion 201. The input/output terminals 203 are used to input/output electric power to/from an inverter, not shown, for the phase windings of the respective phases of the stator winding 61.

Further, a current sensor for detecting a phase current of each phase may be integrally provided in the bus bar module 200. In this case, it is preferable that a current detection terminal is provided in the bus bar module 200, and a detection result of the current sensor is output to a control device, not shown, through the current detection terminal.

The annular portion 201 has a plurality of projecting portions 205 projecting toward the inner peripheral side 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.

Fig. 32 is a perspective view showing a state where the bus bar module 200 is assembled to the stator holder 70, and fig. 33 is a vertical cross-sectional view of a fixed portion where the bus bar module 200 is fixed. Note that, the structure of the stator holder 70 before the bus bar module 200 is assembled is referred to fig. 12.

In fig. 32, the bus bar module 200 is provided on the end plate portion 91 so as to surround the boss portion 92 of the inner tube member 81. The bus bar module 200 is fixed to the stator holder 70 (inner tube member 81) by fastening a fastening member 217 such as a bolt in a state of being positioned by a support portion 95 (see fig. 12) assembled to the inner tube member 81.

More specifically, as shown in fig. 33, a column portion 95 extending in the axial direction is provided in the end plate portion 91 of the inner tubular member 81. Then, the bus bar module 200 is fixed to the support portion 95 by the fastener 217 in a state where the support portion 95 is inserted into the through hole 206 provided in the plurality of protruding portions 205. In the present embodiment, the bus bar module 200 is fixed using the stopper plate 220 made of a metal material such as iron. The stopper plate 220 includes: a fastened portion 222, the fastened portion 222 having an insertion hole 221 through which the fastening member 217 is inserted; a pressing portion 223, the pressing portion 223 pressing an upper surface of the annular portion 201 of the bus bar module 200; and a bent portion 224, the bent portion 224 being provided between the fastened portion 222 and the pressing portion 223.

In the attached state of the stopper plate 220, the fastener 217 is screwed into the pillar portion 95 of the inner cylindrical member 81 in a state where the fastener 217 is inserted into the insertion hole 221 of the stopper plate 220. Further, the pressing portion 223 of the stopper plate 220 is in a state of abutting on the upper surface of the annular portion 201 of the bus bar module 200. In this case, as the fastener 217 is screwed into the column portion 95, the stopper plate 220 is pressed downward in the drawing, and accordingly, the annular portion 201 is pressed downward by the pressing portion 223. Since the pressing force generated downward in the drawing accompanying the screwing of the fastening tool 217 is transmitted to the pressing portion 223 through the bent portion 224, the pressing portion 223 is pressed in a state of an elastic force accompanying the bent portion 224.

As described above, the annular projection 201a is provided on the upper surface of the annular portion 201, and the pressing portion 223 side tip of the stopper plate 220 can abut against the projection 201 a. This suppresses the radially outward escape of the pressing force of the stopper plate 220 downward in the drawing. That is, the pressing force generated by the screwing of the fastening tool 217 is appropriately transmitted to the pressing portion 223 side.

As shown in fig. 32, in a state where the bus bar module 200 is assembled to the stator holder 70, the input/output terminal 203 is provided at a position opposite to the inlet opening 86a and the outlet opening 87a to the refrigerant passage 85 by 180 degrees in the circumferential direction. However, the input/output terminal 203 and the openings 86a and 87a may be collectively provided at the same position (i.e., close position).

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

As shown in fig. 1, in the rotary electric machine 10, the input/output terminal 203 of the bus bar module 200 is provided to protrude outward from the housing cover 242, and is connected to the relay member 230 on the outside of the housing cover 242. The relay member 230 is a member that relays connection between the input/output terminal 203 for each phase extending from the bus bar module 200 and the power line for each phase extending from an external device such as an inverter.

Fig. 34 is a vertical sectional view showing a state in which relay member 230 is attached to housing cover 242, and fig. 35 is a perspective view of relay member 230. As shown in fig. 34, a through hole 242a is formed in the housing cover 242, and the input/output terminal 203 can be drawn out through the through hole 242 a.

The relay member 230 has a main body portion 231 fixed to the housing cover 242 and a terminal insertion portion 232 inserted into a through hole 242a of the housing cover 242. The terminal insertion portion 232 has three insertion holes 233 through which the input/output terminals 203 of each phase are inserted one by one. The three insertion holes 233 have long-shaped cross-sectional openings and are formed so that the longitudinal directions thereof are all aligned in substantially the same direction.

Three relay bus bars 234 provided for each phase are attached to the main body 231. The relay bus 234 is bent into a substantially L-shape, fixed to the main body 231 by a fastener 235 such as a bolt, and fixed to the distal end of the input/output terminal 203 inserted into the insertion hole 233 of the terminal insertion portion 232 by a fastener 236 such as a bolt and a nut.

Although not shown, power lines for each phase extending from an external device can be connected to relay member 230, and input/output of power to/from input/output terminal 203 can be performed for each phase.

Next, the configuration of a control system for controlling the rotating electric machine 10 will be described. Fig. 36 is a circuit diagram of a control system of the rotary electric machine 10, and fig. 37 is a functional block diagram showing a control process of the control device 270.

As shown in fig. 36, the stator winding 61 is composed of a U-phase winding, a V-phase winding, and a W-phase winding, and an inverter 260 corresponding to a power converter is connected to the stator winding 61. The inverter 260 is configured by a full bridge circuit having the same number of upper and lower arms as the number of phases, and a series connection body including an upper arm switch 261 and a lower arm switch 262 is provided for each phase. The switches 261 and 262 are turned on and off by a driver 263, and the phase windings of the respective phases are energized by the on and off. Each of the switches 261 and 262 is formed of a semiconductor switching element such as a MOSFET or an IGBT, for example. In the upper and lower arms of each phase, a capacitor 264 for supplying electric charge to each of the switches 261 and 262, which supplies electric charge necessary for switching, is connected in parallel to the series-connected body of the switches 261 and 262.

One ends of the U-phase winding, the V-phase winding, and the W-phase winding are connected to intermediate connection points between the switches 261 and 262 of the upper and lower arms, respectively. The above-mentioned 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 having a CPU and various memories, and performs energization control by turning on and off the switches 261 and 262 based on various kinds of detection information in the rotating electrical machine 10 and requests for power running drive and power generation. The detection information of the rotating electrical 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, and the conduction current of each phase detected by a current sensor. The controller 270 performs on/off control of the switches 261 and 262 by PWM control or rectangular wave control at a predetermined switching frequency (carrier frequency), for example. The controller 270 may be a built-in controller incorporated in the rotating electric machine 10, or may be an external controller provided outside the rotating electric machine 10.

Since the rotating electric machine 10 of the present embodiment has a non-slotting structure (non-pole tooth structure), it is desirable to increase the switching speed while increasing the switching frequency (carrier frequency) when the inductance of the stator 60 is reduced to reduce the electrical time constant. In this regard, since the capacitor 264 for charge supply is connected in parallel to the series connection body of the switches 261 and 262 of each phase, the wiring inductance is reduced, and even with a configuration in which the switching speed is increased, a suitable surge countermeasure can be taken.

The high-potential side terminal of the inverter 260 is connected to the positive terminal of the dc power supply 265, and the low-potential side terminal is connected to the negative terminal (ground) of the dc power supply 265. The dc power supply 265 is formed of, for example, a battery pack in which a plurality of single cells are connected in series. A smoothing capacitor 266 is connected in parallel to the dc power supply 265 to the high-potential side terminal and the low-potential side terminal of the inverter 260.

Fig. 37 is a block diagram showing a current feedback control process for controlling the currents of the respective phases of the U-phase, V-phase, and W-phase.

In fig. 37, the current command value setting unit 271 sets the d-axis current command value and the q-axis current command value based on the electrical angular velocity ω obtained by time-differentiating the electrical angle θ with respect to the motoring torque command value or the generating torque command value of the rotating electrical machine 10 using the torque-dq map. In addition, for example, when the rotating electrical machine 10 is used as a power source for a vehicle, the generated torque command value is a regenerative torque command value.

The dq conversion unit 272 converts current detection values (three phase currents) detected by current sensors provided for the respective phases into d-axis current and q-axis current, which are components of an orthogonal two-dimensional rotating coordinate system having an excitation direction (or field direction) as the d-axis.

The d-axis current feedback control part 273 calculates a command voltage of the d-axis as an operation amount for feedback-controlling the d-axis current to a current command value of the d-axis. Further, the q-axis current feedback control portion 274 calculates a command voltage of the q-axis as an operation amount for feedback-controlling the q-axis current to a current command value of the q-axis. In the feedback control units 273 and 274, the command voltage is calculated by the PI feedback method based on the deviation between the d-axis current and the q-axis current and the current command value.

The three-phase converter 275 converts the command voltages for the d-axis and q-axis into command voltages for the U-phase, V-phase, and W-phase. The above-mentioned parts 271 to 275 are feedback control parts for performing 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 generating unit 276 generates an operation signal of the inverter 260 based on the three-phase command voltages by using a well-known triangular wave carrier comparison method. Specifically, the operation signal generating unit 276 generates switching operation signals (duty signals) of the upper and lower arms of each phase by PWM control based on comparison of the magnitude of a signal obtained by normalizing the three-phase command voltage with the power supply voltage and a carrier signal such as a triangular wave signal. The switching operation signal generated by the operation signal generating section 276 is output to a driver 263 of the inverter 260, and the switches 261, 262 of each phase are turned on and off by the driver 263.

Next, the torque feedback control process will be described. Under operating conditions in which the output voltage of each inverter 260 increases, such as a high rotation region and a high output region, the above-described processing is mainly used for the purpose of increasing the output of the rotating electrical machine 10 and reducing the loss. Control device 270 selects and executes one of the torque feedback control process and the current feedback control process based on the operating conditions of rotating electric machine 10.

Fig. 38 is a block diagram showing torque feedback control processing corresponding to U-phase, V-phase, and W-phase.

The voltage amplitude calculation unit 281 calculates a voltage amplitude command, which is a command value of the magnitude of the voltage vector, based on the power running torque command value or the power generation torque command value of the rotating electrical machine 10 and the electrical angular velocity ω obtained by time-differentiating the electrical angle θ.

Similarly to the dq conversion unit 272, the dq conversion unit 282 converts a current detection value detected by a current sensor provided for each phase into a d-axis current and a q-axis current. Torque estimation unit 283 calculates torque estimation values corresponding to the U-phase, V-phase, and W-phase based on the d-axis current and the q-axis current. The torque estimation unit 283 may calculate the voltage amplitude command based on map information that sets the relationship between the d-axis current, the q-axis current, and the voltage amplitude command.

Torque feedback control unit 284 calculates a voltage phase command, which is a command value of the phase of the voltage vector, as an operation amount for feedback-controlling the torque estimation value to the power running torque command value or the power generation torque command value. In torque feedback control unit 284, a voltage phase command is calculated by a PI feedback method based on a deviation of the torque estimated value from the power running torque command value or the power generation torque command value.

The operation signal generation unit 285 generates an operation signal of the inverter 260 based on the voltage amplitude command, the voltage phase command, and the electrical angle θ. Specifically, the operation signal generation unit 285 calculates command voltages for three phases based on the voltage amplitude command, the voltage phase command, and the electrical angle θ, and generates switching operation signals for the upper and lower arms in each phase by PWM control based on comparison of the magnitude of a signal obtained by normalizing the calculated command voltages for three phases with the power supply voltage and a carrier signal such as a triangular wave signal. The switching operation signal generated by the operation signal generation unit 285 is output to the driver 263 of the inverter 260, and the switches 261 and 262 of each phase are turned on and off by the driver 263.

The operation signal generation unit 285 may generate the switching operation signal based on pulse pattern information, which is mapping information for setting the relationship between the voltage amplitude command, the voltage phase command, the electrical angle θ, and the switching operation signal, the voltage amplitude command, the voltage phase command, and the electrical angle θ.

(modification of the first embodiment)

Next, a modified example of the above embodiment will be described.

The structure of the magnets in the magnet unit 22 may also be changed as described below. In the magnet unit 22 shown in fig. 39, the direction of the magnetization easy axis in the magnet 32 is inclined with respect to the radial direction, and a linear magnet magnetic path is formed in the direction of the magnetization easy axis. In this configuration, the magnet magnetic path length of the magnet 32 can be made longer than the radial thickness dimension, and the magnetic conductance can be improved.

A halbach array of magnets may also be used in the magnet unit 22.

In each of the partial windings 151, the bending direction of the lap portions 153 may be either radially inward or outward, and the first lap portion 153A may be bent toward the core assembly CA or the first lap portion 153A may be bent toward the opposite side of the core assembly CA as a relation with the core assembly CA. The second overlapping portion 153B may be bent in either the radially inward or outward direction as long as it is positioned on the axially outer side of the first overlapping portion 153A so as to straddle a portion of the first overlapping portion 153A in the circumferential direction.

The partial winding 151 may be provided with one partial winding 151 without two kinds of partial windings 151 (first partial winding 151A and second partial winding 151B). Specifically, it is preferable that the partial winding 151 is formed in a substantially L shape or a substantially Z shape in a side view. When the partial coil 151 is formed in a substantially L-shape in a side view, the bridging portion 153 is bent in any one of radially inward and outward directions at one end side in the axial direction, and the bridging portion 153 is provided so as not to be bent in the radial direction at the other end side in the axial direction. When the partial winding 151 is formed in a substantially zigzag shape in a side view, the bridging portion 153 is bent in opposite directions in the radial direction at one end side and the other end side in the axial direction. In either case, as described above, it is preferable that the coil module 150 is fixed to the core assembly CA by the insulating cover covering the overlapping portion 153.

In the above configuration, the configuration in which all the partial windings 151 are connected in parallel for each phase winding in the stator winding 61 has been described, but this configuration may be modified. For example, all the 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, all the n partial windings 151 of each phase winding may be divided into two parallel connection groups of n/2, three parallel connection groups of n/3, and the like, and connected in series. Alternatively, the stator winding 61 may be configured such that all of the plurality of partial windings 151 are connected in series for each phase winding.

The stator winding 61 in the rotating electric machine 10 may be configured to have two-phase windings (U-phase winding and V-phase winding). In this case, for example, the pair of intermediate lead portions 152 may be provided at a coil pitch in the partial winding 151, and the intermediate lead portions 152 in the partial winding 151 of the other phase may be disposed between the pair of intermediate lead portions 152.

Instead of the outer rotor type surface magnet type rotating electrical machine, the rotating electrical machine 10 may be embodied as an inner rotor type surface magnet type rotating electrical machine. Fig. 40 (a) and (b) are diagrams showing the structure of the stator unit 300 in the case of the inner rotor structure. Fig. 40 (a) is a perspective view showing a state in which the coil modules 310A and 310B are assembled to the core assembly CA, and fig. 40 (B) is a perspective view showing partial windings 311A and 311B included in the coil modules 310A and 310B. In this example, the stator holder 70 is assembled to the radially outer side of the stator core 62, thereby constituting a core assembly CA. The plurality of coil modules 310A and 310B are assembled to the inside of the stator core 62 in the radial direction.

The partial winding 311A has substantially the same configuration as the first partial winding 151A, and includes a pair of intermediate conductor portions 312 and a lap portion 313A formed by bending both sides in the axial direction toward the core assembly CA (radially outward). The partial winding 311B has substantially the same configuration as the second partial winding 151B, and includes a pair of intermediate conductor portions 312 and bridging portions 313B provided on both axial sides so as to span the bridging portions 313A in the circumferential direction on the axial outer side. An insulating cover 315 is attached to the lap portion 313A of the partial winding 311A, and an insulating cover 316 is attached to the lap portion 313B of the partial winding 311B.

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

The stator 60 used in the rotary electric machine 10 may have a projection (e.g., pole tooth) extending from the back yoke. In this case, the back yoke may be assembled to the stator core by, for example, the coil module 150.

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

As the rotating electric machine 10, in addition to a rotating excitation type rotating electric machine in which a field element is a rotor and an armature is a stator, a rotating armature type rotating electric machine in which an armature is a rotor and a field element is a stator can be used.

(second embodiment)

Hereinafter, the second embodiment will be described mainly focusing on differences from the first embodiment with reference to the drawings. Fig. 41 is a longitudinal sectional view of a rotor and a stator of a rotating electric machine according to the present embodiment. The rotary electric machine of the present embodiment has an outer rotor structure as in the first embodiment.

The magnet unit 22 of the rotator 20 has: a cylindrical magnet holder 31; and a plurality of magnets 37 fixed to the inner peripheral surface of the magnet holder 31. The magnet holder 31 has the same length dimension in the axial direction as the magnet 37. The magnet 37 is provided in a state of being surrounded by the magnet holder 31 from the radial outside. The magnet holder 31 and the magnet 37 are fixed at one axial end in a state of being abutted against an end plate not shown.

In the magnet unit 22, the magnets 37 are arranged in such a manner as to alternately change polarity in the circumferential direction of the rotor 20. Thus, the magnet unit 22 has a plurality of magnetic poles in the circumferential direction. The magnet 37 is a permanent magnet having polar anisotropy, and is formed by using 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.

The magnet 37 has a radially inner circumferential surface serving as a magnetic flux acting surface for transmitting magnetic flux. In the magnet 37, the directions of the easy magnetization axes are different between the d-axis side where the direction of the easy magnetization axis is parallel to the d-axis and the q-axis side where the direction of the easy magnetization axis is orthogonal to the q-axis. In this case, a magnet magnetic path of an arc shape is formed in accordance with the direction of the magnetization easy axis. In short, the magnet 37 is configured to be oriented such that the direction of the magnetization easy axis is more parallel to the d axis at the magnetic pole center, i.e., the d axis side, than the magnetic pole boundary, i.e., the q axis side.

In the magnet 37, since the magnet magnetic circuit is formed in an arc shape, the magnet magnetic circuit length is longer than the thickness dimension in the radial direction of the magnet 37. This increases the magnetic conductance of the magnet 37, and the same amount of magnet can exhibit the same capability as a magnet with a larger amount of magnet.

In the present embodiment, the product of the number of phases of the stator winding 61 and the number of magnetic poles of the magnet unit 22 is 48. In the present embodiment, since the number of phases is 3, the number of magnetic poles of the magnet unit 22 is 16 poles. This structure is intended to increase the magnetic flux of the magnet interlinked with the intermediate conductor portion 152 constituting the stator winding 61, thereby achieving a high torque of the rotating electric machine. That is, when the number of magnetic poles of the magnet unit is increased, the circumferential width of each magnetic pole of the magnet unit is decreased, and the magnetic path of the magnet for each magnetic pole tends to be shortened. Therefore, if the number of magnetic poles is too large, the magnetic flux of the magnet linked with the intermediate conductor portion 152 is reduced. Therefore, in the present embodiment, the product value is 48. This prevents the number of magnetic poles from becoming excessive, and suppresses a decrease in the magnetic flux of the magnet that interlinks with the intermediate conductor portion 152. As a result, the torque of the rotating electric machine can be increased.

The stator 60 has a stator winding 61 and a stator core 62. In the present embodiment, as in the first embodiment, the plurality of partial windings 151 constituting the stator winding 61 are assembled radially outward of the stator core 62 in a state of being arranged in the circumferential direction. The pair of intermediate lead portions 152 are provided at a predetermined coil pitch, and the intermediate lead portions 152 of the partial windings 151 of the other phase can be arranged between the pair of intermediate lead portions 152 in the circumferential direction. In the present embodiment, the pair of intermediate lead portions 152 are provided at two coil pitches apart, and one intermediate lead portion 152 of the partial windings 151 of the other two phases is disposed between the pair of intermediate lead portions 152, respectively.

In the present embodiment, the partial winding 151 is also formed by winding the conductor material CR in multiple layers. As shown in fig. 42, the partial winding 151 of each phase is formed of a parallel connection body of a plurality of conductor materials CR. Each of the conductor members CR is formed of a parallel connection body of a plurality of conductors TT (see fig. 51 and 52). This structure is used to reduce eddy current losses. Fig. 42 is a diagram showing an electrical connection relationship of the partial winding 151 of any one phase.

In the present embodiment, as shown in fig. 41 and 51, the partial coil 151 is formed by winding the conductor material CR in a plurality of layers so that the cross-sectional shape of each intermediate conductor portion 152 becomes a square. Fig. 51 is a cross-sectional view of the intermediate lead portion 152 of a predetermined one phase. Hereinafter, the reason why the cross-sectional shape is a square will be mainly described.

Fig. 43 shows a magnetic circuit including the magnetomotive force Ft of the magnet unit 22, the magnetic resistance Rag of the air gap between the magnet unit 22 and the stator core 62, and the magnetic resistance Rcore of the stator core 62. The magnetic flux Φ t flowing through the magnetic circuit is expressed by the following equation (eq 1).

[ mathematical formula 1]

The total value Ragt of the magnetic resistance of the air gap of the magnetic circuit shown in fig. 43 is expressed by the following equation (eq 2).

[ mathematical formula 2]

In the above equation (eq2), Lag represents the distance between the inner circumferential surface of the magnet 37 in the radial direction and the outer circumferential surface of the stator core 62 in the radial direction, i.e., the length of the air gap (see fig. 44). In the above equation (eq2), μ 0 represents the permeability of vacuum, and Am represents the width of each magnetic pole of the magnet 37 in the circumferential direction. The total value Ragt of the magnetic resistance indicated by the above equation (eq2) is a value per unit length in the axial direction of the rotating electrical machine.

In the present embodiment, the easy axis of magnetization of the magnet 37 is oriented in an arc shape with the orientation center CP set on the q-axis as the center. In the present embodiment, the intersection of the inner peripheral surface of the magnet 37 and the q-axis is the orientation center CP.

Fig. 45 shows a demagnetization curve of the magnet 37. Br represents the residual magnetic flux density of each pole pair of the magnet 37, and bHc represents the intrinsic coercive force of each pole pair of the magnet 37. Hereinafter, a structure per unit length in the axial direction of the rotating electric machine will be described.

The value obtained by multiplying the circumferential width dimension Am of each pole of the magnet 37 by the residual magnetic flux density Br is represented by the magnetic flux Φ t [ wb ] per unit length in the axial direction as shown by the vertical axis of fig. 46. The value obtained by multiplying the magnetic path length Lm of each pole pair of the magnet 37 by the intrinsic coercive force bHc is magnetomotive force F [ a ] as shown on the abscissa of fig. 46. Here, when the radial thickness dimension of the magnet 37 is tm, the magnetic path length Lm of the magnet 37 shown in fig. 44 may be "Lm × tm", for example.

Next, as shown in fig. 47, a case where the thickness dimension in the radial direction of the lead wire assembly portion of the intermediate lead portion 152 is changed will be discussed. The thickness dimension increases in the order of (a), (b), and (c) of fig. 47, "Lg 1 < Lg2 < Lg 3". The cross-sectional areas of the intermediate lead portions 152 in fig. 47 (a), (b), and (c) are S1, S2, and S3. Since Am has the same value in (a), (b), and (c) of fig. 47, "S1 < S2 < S3". Here, for example, a condition may be provided that the radial distance between the outer peripheral surface of the intermediate lead portion 152 and the inner peripheral surface of the magnet 37 is constant in each of the cases (a), (b), and (c) of fig. 47.

Fig. 48 shows a flux guide line of a magnetic circuit including the intermediate conductor portion 152 having each cross-sectional area. The magnetic fluxes at the intersections (specifically, the operating points) of the respective flux guide straight lines and the demagnetization curves are defined as a first magnetic flux Φ 1, a second magnetic flux Φ 2, and a third magnetic flux Φ 3. The magnetic fluxes Φ 1 to Φ 3 are magnetic fluxes generated when the same voltage is applied to the intermediate lead portions 152 having the respective cross-sectional areas S1 to S3.

When the Lag is increased, the air gap Lag becomes large, and the magnetic resistance Ragt of the magnetic circuit becomes large. When the magnetic resistance Ragt becomes large, as shown in fig. 49, the magnetic flux of the magnet linked with the intermediate lead portion 152 becomes small.

On the other hand, as shown in fig. 50, when the thickness dimension in the radial direction of the intermediate lead portion 152 is changed to various values, there are the following thickness dimensions: the thickness dimension in the radial direction of the intermediate lead portion 152 is such that the product value of the cross-sectional area of the intermediate lead portion 152 when the thickness dimension is set and the magnetic flux amount of the magnet at the operating point of the magnet 37 when the thickness dimension is set is the largest. Since the product value is a value corresponding to the torque constant Kt of the rotating electrical machine, the use of the radial thickness dimension of the intermediate conductor portion 152, at which the product value is the largest, enables a higher torque of the rotating electrical machine.

In the present embodiment, the thickness dimension in the radial direction of the intermediate lead portion 152 at or near the maximum value of the product value is a thickness dimension in which the cross-sectional shape of the intermediate lead portion 152 is square. Therefore, in the present embodiment, the cross-sectional shape of the intermediate lead portion 152 is a square.

The thickness dimension in the radial direction of the intermediate conductor portion 152 in which the product value is in the vicinity of the maximum value is, for example, a thickness dimension in which the product value is 95% or more and less than 100% of the maximum value.

In the present embodiment, as shown in fig. 51, the circumferential center positions of each of the circumferentially adjacent in-phase intermediate lead portions 152 are electrically different by 180 degrees. Further, in each of the intermediate lead portions 152 of the same phase adjacent in the circumferential direction, the relative positional relationship of the respective lead materials CR and the relative positional relationship of the respective leads TT are maintained. In fig. 51, a circular shape is illustrated as the sectional shapes of the wire material CR and the wire TT, but is not limited thereto. In addition, fig. 51 shows an example in which each of the wire materials CR is constituted by a parallel connection body of seven wires TT, but is not limited thereto.

The arrangement position of each of the conductive wires TT constituting one of the intermediate conductive portions 152 of the same phase adjacent in the circumferential direction is an arrangement position in which the arrangement position of each of the conductive wires TT constituting the other intermediate conductive portion is rotated by 90 degrees in a specific rotational direction when viewed in the axial direction. Fig. 51 shows four intermediate lead portions 152 of only the U-phase among the U-phase, V-phase, and W-phase, and the intermediate lead portions 152 are referred to as first lead portions 63U1 to fourth lead portions 63U 4. In fig. 51, the stator core 52 and the like are shown in a linearly expanded form for convenience, and a specific one CA of the respective conductor members CR is hatched for convenience of understanding by 90-degree rotation.

The arrangement position of each of the conductor members CR in the second conductor portion 63U2 is an arrangement position in which the arrangement position of each of the conductor members CR in the first conductor portion 63U1 is rotated by 90 degrees in a specific rotational direction when viewed from the axial direction. The second lead portion 63U2 and the first lead portion 63U1 form a partial winding 151. The direction of the current flowing through each of the conductor members CR of the second conductor portion 63U2 is opposite to the direction of the current flowing through each of the conductor members CR of the first conductor portion 63U 1.

The arrangement position of each of the conductor members CR in the third conductor portion 63U3 is an arrangement position in which the arrangement position of each of the conductor members CR in the second conductor portion 63U2 is rotated by 90 degrees in a specific rotational direction when viewed from the axial direction. The direction of the current flowing through each of the conductor materials CR of the third conductor portion 63U3 is opposite to the direction of the current flowing through each of the conductor materials CR of the second conductor portion 63U 2.

The arrangement position of each of the conductor members CR in the fourth conductor portion 63U4 is the arrangement position of each of the conductor members CR in the third conductor portion 63U3 rotated by 90 degrees in the specific rotation direction when viewed from the axial direction. The fourth wire portion 63U4 and the third wire portion 63U3 form one partial winding 151. The direction of the current flowing through each of the conductor members CR of the fourth conductor portion 63U4 is opposite to the direction of the current flowing through each of the conductor members CR of the third conductor portion 63U 3. The reason for adopting the above-described arrangement position will be described below.

The description will be given focusing on one conductor material CR constituting the first conductor portion 63U1 and the second conductor portion 63U2 with reference to fig. 52. The wire material CR is constituted by a parallel connection body of a plurality of wires TT. The parallel connection body has a first end electrically connected to bus bar 211 on the inverter 260 side and a second end electrically connected to bus bar 214 on the neutral point side. Thereby, a closed loop circuit is formed in the first wire part 63U1 and the second wire part 63U 2.

When the magnet flux of the magnet unit 22 is interlinked with the wire TT, an electromotive force (induced voltage) corresponding to a time rate of change of the interlinkage flux is generated in the wire TT. The magnetic flux of the magnet interlinked with the wire TT differs depending on the circumferential position of the wire TT with respect to the magnet unit 22 and the radial position of the wire TT with respect to the magnet unit 22. If the position of the conductor member CR with respect to the magnet unit 22 is different, the difference between the electromotive force generated in the portion constituting the first conductor portion 63U1 and the electromotive force generated in the portion constituting the second conductor portion 63U2 in the conductor member CR becomes large, and there is a possibility that the circulating current flowing through the closed loop circuit described above increases.

Therefore, in the present embodiment, the arrangement method shown in fig. 51 is adopted. This makes it possible to realize a structure that easily reduces the difference between electromotive forces generated by the difference in circumferential and radial positions of the conductive wire TT with respect to the magnet unit 22. In detail, according to the configuration shown in fig. 51, the difference in electromotive force generated in the respective lead members CR can be reduced as compared with a configuration in which the arrangement positions of the respective leads TT constituting the respective intermediate lead portions 152 of the same phase adjacent in the circumferential direction are all the same as each other when viewed from the axial direction. As a result, the circulating current flowing through the closed loop circuit can be reduced.

In the present embodiment, the cross-sectional shape of the intermediate lead portion 152 is a square. Therefore, the thickness dimension in the radial direction of one of the intermediate lead portions 152 of the same phase adjacent in the circumferential direction can be made equal to the thickness dimension in the radial direction of the other intermediate lead portion. Thus, when the arrangement method shown in fig. 51 is adopted, the air gap between the outer peripheral surface of the stator core 62 and the inner peripheral surface of the magnet unit 22 can be made uniform in the circumferential direction.

(modification of the second embodiment)

The magnets are not limited to circular arc orientations, and may be parallel orientations, for example.

The number of phases of the stator winding may be 6, and the number of poles of the magnet unit may be 8.

The disclosure of the present specification is not limited to the illustrated embodiments. The present disclosure includes the illustrated embodiments and variations thereon by those skilled in the art. For example, the present disclosure is not limited to the combinations of components and/or elements shown in the embodiments. The disclosure may be implemented in various combinations. The present disclosure may have an additional part that can be added to the embodiment. The present disclosure includes embodiments in which components and/or elements of the embodiments are omitted. The present disclosure includes substitutions or combinations of parts and/or elements between one embodiment and another. The technical scope of the disclosure is not limited to the description of the embodiments. The technical scope of the disclosure should be understood to be expressed by the description of the claims, and also includes all modifications equivalent in meaning and scope to the description of the claims.

Although the present disclosure has been described based on the embodiments, it should be understood that the present disclosure is not limited to the embodiments and configurations described above. The present disclosure also includes various modifications and variations within an equivalent range. In addition, various combinations and modes, including only one element, one or more other combinations and modes, also belong to the scope and the idea of the present disclosure.

Claims (3)

1. A rotating electrical machine (10) comprising:

an excitation element (20) including a magnet portion (22) having a plurality of magnetic poles whose polarities alternate in the circumferential direction; and

an armature (60) having a multi-phase armature winding (61),

one of the field element and the armature is configured as a rotor,

the armature windings of each phase have lead portions (152, 63U 1-63U 4) extending in the axial direction and arranged in the circumferential direction,

in the above-mentioned armature, the magnetic flux is applied to the armature,

a magnetic material or a non-magnetic material that satisfies a relationship of Wt × Bs ≦ Wm × Br when a circumferential width of the inter-wire member of one magnetic pole is Wt, a saturation magnetic flux density of the inter-wire member is Bs, a circumferential width of the magnet portion of one magnetic pole is Wm, and a residual magnetic flux density of the magnet portion is Br is used as the inter-wire member,

or no inter-wire member is provided between the respective wire portions in the circumferential direction,

the product of the number of phases of the armature winding and the number of poles is 48,

the cross-sectional shape of each of the lead portions is square.

2. The rotating electric machine according to claim 1,

the lead portion has a plurality of leads (TT) arranged in a radial direction and a circumferential direction, respectively, and is constituted by a parallel connection body of a plurality of the leads,

in each of the lead wire portions of the same phase which are adjacent in the circumferential direction, the relative positional relationship of the lead wires is maintained,

the arrangement position of each of the conductive wires constituting one of the conductive wire portions of the same phase adjacent in the circumferential direction is an arrangement position obtained by rotating the arrangement position of each of the conductive wires constituting the other conductive wire portion by 90 degrees when viewed from the axial direction.

3. The rotating electric machine according to claim 2,

the armature winding of each phase is composed of a plurality of partial windings (151),

the partial winding has: a pair of the lead portions extending in an axial direction and provided at a predetermined interval in a circumferential direction; and a lap joint portion provided on one end side and the other end side in the axial direction and connecting the pair of lead portions annularly, a lead material (CR) being wound in a plurality of layers in the pair of lead portions and each of the lap joint portions,

one of the pair of lead portions of the partial winding of the other phase is arranged between the pair of lead portions of the partial winding, whereby the lead portions of the respective phases are arranged in a predetermined order in the circumferential direction,

the lead material is composed of a plurality of parallel-connected bodies of the leads,

in each of the circumferentially adjacent same-phase lead portions, the relative positional relationship of the lead materials and the relative positional relationship of the leads are maintained.

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