CN114788138A - Rotating electrical machine - Google Patents

Abstract

In a rotating electrical machine, a stator includes: a stator winding (61) of a plurality of phases including, for each phase, a phase winding composed of a plurality of partial windings (151); and a cylindrical member (62) to which the stator winding is assembled on the radially outer side. The partial winding is formed in a ring shape by winding a plurality of conductor materials (CR) having a rectangular cross section in a plurality of layers, and the conductor materials are arranged in a plurality of states in the radial direction and the circumferential direction at the coil side portion. In the cross section of the partial winding at the coil side, the circumferential side surfaces (421) of the wire material are linearly arranged in the radial direction, and the radial side surfaces (422) of the wire material are arranged in a step shape in the circumferential direction by the radial offset.

Description

Rotating electrical machine

Cross reference to related applications

The present application is based on japanese patent application No. 2019-223606, filed on 12/11/2019, the contents of which are incorporated herein by reference.

Technical Field

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

Background

Conventionally, 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. For example, in a rotating electrical machine described in patent document 1, a stator as an armature includes: a yoke having an annular shape; and a pole tooth portion protruding from the yoke portion in a radial direction, wherein a surface of the yoke portion on which the pole tooth portion is formed is a plane. In the stator, a coil (partial winding) is formed by winding an electric wire, and is fixed to a yoke in a state in which a pole tooth portion is inserted into a hollow portion and a coil contact surface is in contact with a plane of the yoke. In this case, the coil can be reliably fixed to the yoke.

Documents of the prior art

Patent literature

Patent document 1: japanese patent laid-open publication No. 2015-122834.

Disclosure of Invention

In a radial gap type rotating electrical machine having a stator and a rotor, a coil of the stator and a magnet portion of the rotor are disposed to face each other with a predetermined air gap in a radial direction. In this case, in the rotating electric machine of patent document 1, since the coil is fixed to the plane of the yoke, it is considered that the circumferential surface of the coil on the air gap side is also planar, and the air gap between the coil and the magnet portion is not uniform in the circumferential direction. This may cause a problem that the magnitude of the interlinkage magnetic flux in the coil is not uniform in the circumferential direction. For example, the magnitude of the interlinkage magnetic flux becomes difficult to grasp, and it may be difficult to achieve desired motor performance. In addition, in a configuration in which a wire harness in which a plurality of wires are bundled side by side is used, a circulating current may easily occur because the magnetic flux linked with the coil is different in the circumferential direction of the coil.

In addition, in the stator of the rotating electric machine, although the presence or absence of the yoke portion is arbitrary, when the yoke portion is formed with the above-described plane, a difference in cross-sectional area occurs in the yoke portion in the circumferential direction, and there is a possibility that local magnetic saturation occurs. On the other hand, if the yoke cross-sectional area is set to be equal to or larger than a predetermined value at all locations in order to suppress magnetic saturation, there is a possibility that a location where the cross-sectional area is excessively increased occurs, resulting in an increase in weight.

The present disclosure has been made in view of the above circumstances, and an object thereof is to appropriately provide an armature winding in a rotating electrical machine and achieve desired performance.

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 with reference to the following detailed description and the accompanying drawings.

Mode 1 is a rotating electrical machine including:

an exciting element having a magnet portion including a plurality of magnetic poles whose polarities alternate in a circumferential direction; and

an armature having a multi-phase armature winding including a phase winding composed of a plurality of partial windings for each phase, and a cylindrical member to which the armature winding is assembled on a radially inner side or a radially outer side,

the field element and the armature are disposed to be opposed to each other in a radial direction,

the partial winding is formed in a ring shape by winding a wire material having a rectangular cross section in multiple layers, the wire material being arranged in a plurality of states in the radial direction and the circumferential direction at the coil side portion,

in a cross section at the coil side portion of the partial winding, a state is made in which circumferential side surfaces of the wire material are linearly arranged in a radial direction, and radial side surfaces of the wire material are arranged stepwise in the circumferential direction by a radial misalignment.

In the rotating electrical machine of the above-described structure, in the armature winding of multiple phases, the partial winding is formed in a ring shape by winding a wire material having a rectangular cross section in multiple layers, and at the coil side portion, the wire material is wound in a state where a plurality of the wire materials are arranged in the radial direction and the circumferential direction, respectively. The armature winding is integrally provided on the radial inner side or the radial outer side of the cylindrical member, thereby constituting the armature. In this case, assuming that the outer surface of the field element side is formed in a planar shape in the cross section of the partial winding at the coil side portion, the air gap between the armature winding and the field element is not uniform in the circumferential direction, and a malfunction may occur due to this.

In contrast, in the above-described configuration, in the cross section of the partial winding at the coil side portion, the circumferential side surfaces of the wire material are linearly arranged in the radial direction, and the radial side surfaces of the wire material are arranged stepwise in the circumferential direction by the radial misalignment. Thus, in the cross section of the partial winding at the coil side portion, the outer surface on the field element side can be formed into a shape matching the field element side, and the air gap between the armature winding and the field element can be made uniform. Further, since the partial winding is formed by winding a wire material having a rectangular cross section in multiple layers, the conductor space factor can be improved. As a result, in the rotating electric machine, the armature winding can be designed appropriately, and desired performance can be achieved.

In addition, as a structure in which the radial side surfaces of the wire material are arranged stepwise in the circumferential direction by being offset in the radial direction in the cross section of the partial winding at the coil side portion, a structure in which the radial side surfaces of the wire material are arranged offset in the radial direction by a fixed offset amount and a structure in which the radial side surfaces of the wire material are arranged offset in the radial direction by different offset amounts in the circumferential direction can be considered.

In the aspect 2, in the aspect 1, the partial winding includes a pair of intermediate conductor portions provided at a predetermined interval in the circumferential direction, and a loop portion provided on one end side and the other end side in the axial direction and connecting the pair of intermediate conductor portions in a loop shape, and the wire material includes a region on the one end side in the circumferential direction and a region on the other end side in the circumferential direction of each of the intermediate conductor portions, and is wound in a state where the directions of the radial direction shifts are different in each of the regions.

In a partial winding having a pair of intermediate lead portions separated from each other in the circumferential direction and a crossover portion connecting the pair of intermediate lead portions in a ring shape, the direction of the radial side surface of the lead material opposed to the circumferential surface of the cylindrical member may be different in each intermediate lead portion depending on the extending direction of the circumferential side surface of the lead material in each intermediate lead portion. In this regard, in the above-described configuration, the wire material is wound in the respective intermediate wire portions in a state in which the directions of the radial displacement are different between the region on the one end side in the circumferential direction and the region on the other end side in the circumferential direction of the respective intermediate wire portions. Thus, in the partial winding, the outer surface of the coil side on the excitation element side can be appropriately fitted to the excitation element side.

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

In the partial winding, in a structure in which a straight line extending along a circumferential side surface of the wire material in one of the intermediate wire portions and a straight line extending along a circumferential side surface of the wire material in the other of the intermediate wire portions are not parallel to each other and intersect each other on the armature center side, the extending direction of the circumferential side surface of the wire material is concentrated toward the armature center in each of the intermediate wire portions. In this case, the direction of the radial side surface of the wire material facing the circumferential surface of the cylindrical member is different. Therefore, as described above, in each of the intermediate conductor portions, the conductor material is preferably wound in a state in which the directions of the radial displacement are different between the circumferential center side and the circumferential both sides of each of the intermediate conductor portions.

Mode 4 is the one of mode 1, in which the partial winding includes a pair of intermediate conductor portions provided at a predetermined interval in a circumferential direction, and a pair of jumper portions provided at one end side and the other end side in an axial direction and connecting the pair of intermediate conductor portions in a ring shape, and the wire material is wound around each of the intermediate conductor portions in a state as follows: the direction of the radial offset is the same in a range from one end to the other end in the circumferential direction of each of the intermediate lead portions, and the directions of the offset are made opposite to each other in each of the pair of intermediate lead portions.

In the partial winding having the pair of intermediate lead portions separated from each other in the circumferential direction and the crossover portion connecting the pair of intermediate lead portions in a ring shape, the direction of the radial side surface of the lead material opposed to the circumferential surface of the cylindrical member may be the same in each intermediate lead portion depending on the extending direction of the circumferential side surface of the lead material in each intermediate lead portion. In this regard, in the above structure, in each of the intermediate lead portions, the lead material is wound in a state as follows: the direction of the radial offset is the same in a range from one end to the other end in the circumferential direction of each of the intermediate lead portions, and the directions of the offset are made opposite to each other in each of the pair of intermediate lead portions. Thus, in the partial winding, the outer surface of the coil side portion on the side of the excitation element can be appropriately fitted to the side of the excitation element.

In addition, it is preferable that the partial windings having the pair of intermediate conductor portions and the bridging portions on both sides in the axial direction are arranged in a predetermined order in the circumferential direction in a state where one of the pair of intermediate conductor portions of the partial windings of the other phase is arranged between the pair of intermediate conductor portions. This makes it possible to realize a high space factor in the armature winding.

Mode 5 is the one of modes 1 to 4 in which, in a cross section of the partial winding at the coil side portion, the exciting element side in a radial direction has a substantially circular arc shape.

In this case, by making the excitation element side substantially circular-arc-shaped in the cross section of the partial winding, the outer surface of the coil side portion on the excitation element side can be further matched with the shape of the excitation element side.

In addition, in order to make the outer surface of the partial winding on the excitation element side in an arc shape, the amount of displacement in the radial direction of the respective lead materials arranged in the circumferential direction may be changed little by little.

Mode 6 is the one of modes 1 to 5, wherein the wire material is a flat wire including long sides and short sides, and the partial winding is configured such that the long sides of the wire material overlap in a circumferential direction and the short sides of the wire material overlap in a radial direction at the coil side portion.

The partial winding uses a flat wire including long sides and short sides as a wire material, and is configured such that the long sides of the wire material overlap in the circumferential direction and the short sides of the wire material overlap in the radial direction at the coil side portion. That is, the wire material is arranged such that the long side extends in the radial direction and the short side is in the direction opposite to the exciting element. In this case, since the short side of the wire material is disposed on the excitation element side, the outer surface of the partial winding on the excitation element side can be easily matched with the excitation element side, as compared with the case where the long side of the wire material is disposed on the excitation element side.

Further, the width dimension in the circumferential direction of the wire material at the coil side portion is smaller than the width dimension in the radial direction, and therefore, the number of layers of each wire material in the circumferential direction increases, and it is easy to match the outer surface of the partial winding on the exciting element side with the exciting element side.

Further, by making the circumferential width dimension of the coil side portion of the wire material smaller than the radial width dimension, the number of turns can be made as small as possible while matching the outer surface shape of the partial winding on the field element side with the field element side, thereby achieving reduction in man-hours in manufacturing the winding.

Mode 7 is the one of modes 1 to 6 in which the cylindrical member is an armature core.

In the structure in which the partial winding is assembled to the armature core, which is a cylindrical member, the wire material is wound in a staggered state, and the outer surface of the partial winding on the side of the field element is shaped to match the side of the field element, whereby the gap between the partial winding and the armature core can be reduced, and the gap can be made uniform for each layer of the wire material. This makes it possible to increase the efficiency of the rotating electric machine.

Mode 8 is the one of modes 1 to 7 in which a winding holding member having a wall portion interposed between the partial winding and the cylindrical member in a radial direction is integrally provided on the partial winding, a stepped surface is formed on the wall portion on the partial winding side in accordance with a radially displaced state of the wire material, and an arc surface is formed on the cylindrical member side, the arc surface having no step.

In the above-described structure, the winding holding member is integrally provided to the partial winding with the wall portion of the winding holding member interposed between the partial winding and the cylindrical member. In this case, the cylindrical member can be assembled with the partial winding by the winding holding member. Further, since the wall portion has a stepped surface formed on the partial winding side in accordance with the state of being shifted in the radial direction of the wire material and an arc surface having no step formed on the cylindrical member side, the assembly of the partial winding with respect to the cylindrical member can be reliably and easily performed while suppressing the displacement of the wire material wound in the shifted state.

Mode 9 in any of modes 1 to 8, the wire material is a square-shaped cross-section angular wire.

The magnet magnetic flux of the field element has a property of spreading in the circumferential direction from the magnetic flux outflow surface, and the direction of the magnet magnetic flux with respect to the partial winding changes depending on the relative position of the field element and the armature. In this case, by using the angular line having a square cross section as the wire material of the partial winding, it is possible to appropriately suppress the eddy current regardless of the relative positions of the field element and the armature.

Mode 10 is the one of modes 1 to 9 in which the magnet portion of the field element includes a permanent magnet that generates a magnetic flux in each magnetic pole, and the magnetic flux is generated in a concentrated manner in a region near the d-axis that is the center of the magnetic pole in a magnetic flux acting surface of the permanent magnet on the armature side.

In the magnet portion of the field element, in a structure in which magnetic flux is generated in a concentrated manner in the region near the d-axis in the magnetic flux acting surface of the magnet, the concern of eddy current caused by the magnet magnetic flux at a partial winding becomes strong. In this regard, as described above, the partial winding is configured by winding the wire material having a rectangular cross section in a plurality of layers, and arranging a plurality of wire materials in the radial direction and the circumferential direction at the coil side portion, respectively, thereby suitably suppressing the eddy current.

In addition, as a more specific configuration of the permanent magnet, the permanent magnet may be 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. Alternatively, the permanent magnet may be configured to be linearly oriented such that the direction of the magnetization easy axis is inclined with respect to the d-axis between the magnetic flux acting surface on the armature side and the magnetic flux acting surface on the opposite armature side, and the magnetization easy axis is close to the d-axis on the armature side in the circumferential direction and is away from the d-axis on the opposite armature side. Further, a halbach array of magnets may be used in the magnet section.

Mode 11 is the one of modes 1 to 10 in which the partial winding is configured such that the number of turns of the wire material is larger on a radially outer side than on a radially inner side in a coil side portion.

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

In addition, for example, in the case of an outer rotor type rotating electrical machine, it is preferable that the surface on the field element side is expanded in the circumferential direction (that is, the number of conductors is larger) than the surface on the opposite side of the field element in the axis-orthogonal cross section at the coil side portion. In the case of an inner rotor type rotating electrical machine, it is preferable that, in an orthogonal cross section at the coil side portion, a surface on the side opposite to the field element is expanded in the circumferential direction as compared with a surface on the side of the field element (that is, the number of conductors is large).

Mode 12 is the one set forth in any of modes 1 to 10, wherein the wire material is a flat wire including a long side and a short side, and the partial winding includes, at a coil side portion: setting an extending direction of a long side as a portion where the wire material is radially wound; and a portion in which the wire material is wound in a circumferential direction, the extending direction of the long side being set to be different in width dimension in the circumferential direction between a radially inner side and a radially outer side.

In a structure using a flat wire including a long side and a short side as a wire material, a dimension in an overlapping direction (lamination dimension) is changed by changing a direction of a cross section of the wire material. In this case, by providing a portion in which the extending direction of the long side is set to radially wind the wire material and a portion in which the extending direction of the long side is set to circumferentially wind the wire material at the coil side portion of the partial winding, the width dimension in the circumferential direction can be made different between the radially inner side and the radially outer side by these portions. This can improve the conductor space factor of the armature winding.

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 in 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 graph showing a relationship between an electrical angle and a magnetic flux density of the magnet of 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 respective phases 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 in the lateral direction in comparison.

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

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 perspective view of the bus bar module.

Fig. 30 is a sectional view showing a part of a longitudinal section of the bus bar module.

Fig. 31 is a perspective view showing a state in which the bus bar module is assembled to the stator holder.

Fig. 32 is a longitudinal sectional view of a fixing portion that fixes the bus bar module.

Fig. 33 is a longitudinal sectional view showing a state in which the relay member is assembled to the housing cover.

Fig. 34 is a perspective view of the relay member.

Fig. 35 is a circuit diagram showing a control system of the rotating electric machine.

Fig. 36 is a functional block diagram showing a current feedback control process of the control device.

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

Fig. 38 is a partial cross-sectional view showing a cross-sectional structure of a magnet unit in a modification.

Fig. 39 is a diagram showing the structure of a stator unit of the inner rotor structure.

Fig. 40 is a plan view showing an assembled state of the coil module with respect to the core assembly.

Fig. 41 is a perspective view showing the structure of a coil module in the second embodiment.

Fig. 42 is a sectional view showing a cross section at an axially intermediate portion in a partial winding.

Fig. 43 is an exploded cross-sectional view showing the intermediate conductor portion of the partial winding and the coil holder in an enlarged manner.

Fig. 44 is an exploded cross-sectional view showing an enlarged view of the intermediate lead portion of the partial winding and the coil holder.

Fig. 45 is a sectional view showing a cross section at an axially intermediate portion in a partial winding.

Fig. 46 is a cross-sectional view showing the intermediate conductor portion of the partial winding and the coil holder in an enlarged manner.

Fig. 47 is a diagram showing a cross section of the intermediate wire portion of the partial winding.

Detailed Description

Hereinafter, a plurality of embodiments will be described with reference to the drawings. In the embodiments, the same reference signs may be used for functionally and/or structurally corresponding parts and/or related parts, or reference signs with more than one hundred bits different may be used. For corresponding parts and/or associated parts, reference may be made to the description of 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 given to 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 (a sectional view taken along line 3-3 in fig. 2) of the rotary electric machine 10, fig. 4 is a transverse sectional view (a sectional view taken along line 4-4 in fig. 3) of the rotary electric machine 10, and fig. 5 is an exploded sectional view showing the 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 defined as an axial direction, a direction in which the rotating shaft 11 radially extends from the center thereof is defined as a radial direction, and a direction in which the rotating shaft 11 circumferentially extends around the center thereof is defined as 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 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 electric 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 disposed to face each other in the radial direction with an air gap therebetween, and the rotor 20 rotates together with the rotary 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 as the magnet 32 in the axial direction. 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 easy magnetization axis of the magnet 32 is indicated by an arrow.

In the magnet unit 22, the magnets 32 are arranged in a manner of alternately changing 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 magnetic flux acting surface 34 on the radially inner circumferential surface (on the stator 60 side) for transmitting magnetic flux. The magnet unit 22 is configured to generate magnetic flux intensively in a region near the d-axis as the magnetic pole center at the magnetic flux acting surface 34 of the magnet 32. Specifically, in the magnet 32, the directions of the magnetization easy axes are different between the d-axis side (portion close to the d-axis) in which the direction of the magnetization easy axis is parallel to the d-axis and the q-axis side (portion close to the q-axis) in which the direction of the magnetization easy axis is orthogonal to the q-axis. In this case, a magnet magnetic path having an arc shape is formed along the direction of the magnetization easy axis. In summary, the magnet 32 is configured to be oriented as follows: the direction of the easy axis of magnetization is parallel to the d axis at the magnetic pole center, i.e., the d axis side, than at the magnetic pole boundary, i.e., the q axis side.

In the magnet 32, since the magnet magnetic path is formed in an arc shape, the magnet magnetic path 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 the same amount of magnet can exhibit the same capability as a magnet with a larger amount of magnet.

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 magnet magnetic paths of circular arcs, and the N-pole and S-pole of circumferentially adjacent magnets 32 are opposed to each other at the q-axis. Therefore, the flux guide 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 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 appropriately realize the magnet unit 22 in which the change in the surface magnetic flux from the q-axis to the d-axis is relaxed in each magnetic pole.

The sine wave matching rate of the magnetic flux density distribution may be, for example, 40% or more. 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 in the central portion of the waveform can be reliably increased as compared with a magnetic 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 becomes shorter near the d-axis on the outer peripheral surface of the magnet 32, and the magnet magnetic circuit becomes shorter near the q-axis 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 to have a q-axis as a circumferential center and a division surface on a 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 magnets twice as many as the number of magnetic poles or magnets as many as the number of magnetic poles, the magnets 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 portion (an upper end portion in the drawing) opposite to the coupling portion of the rotor frame 21, of 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 a circular plate shape 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 explained. 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 configuring 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 formed 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 a curved surface having no irregularities. The stator core 62 functions as a back yoke. The stator core 62 is formed by laminating a plurality of core pieces 62a punched out into a circular ring 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 formed by annularly winding and laminating 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, an inter-lead member is provided between each of the lead portions in the circumferential direction (intermediate lead portions 152 described later), and as the inter-lead member, a magnetic material satisfying a relationship Wt × Bs ≦ Wm × Br is used, where Wt is a circumferential width of the inter-lead member of one magnetic pole, Bs is a saturation magnetic flux density of the inter-lead member, Wm is a circumferential width of the magnet 32 of one magnetic pole, and Br is a residual magnetic flux density of the magnet 32.

(B) In the stator 60, an inter-conductor member is provided between the conductor portions (intermediate conductor portions 152) in the circumferential direction, and a non-magnetic material is used as the inter-conductor 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. A plurality of projections 73 extending radially inward are formed at predetermined intervals in the circumferential direction on the flange 72 (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 projections 83 extending radially inward are formed at predetermined intervals in the circumferential direction on the inner circumferential side of the inner tubular member 81, and the projections 73, 83 are fastened to each other by fasteners 84 in a state where the axial end surfaces of the projections 83 and the projections 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 annularly provided 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 81, an inlet-side passage 86 and an outlet-side passage 87 are formed in the passage forming portion 88, and the passages 86 and 87 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 sides of the inlet-side passage 86 and the outlet-side passage 87 extend in the radial direction and open at the outer peripheral surface of the inner cylindrical member 81, and the other end sides extend in the axial direction and open at 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 open into 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, 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 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 stator core 62 and the stator holder 70 are configured to have a restriction portion that restricts circumferential displacement of the stator core 62 by circumferential engagement at portions facing 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, a recess may be provided in at least one of the stator core 62 and the outer cylindrical member 71, and the engaging member 111 may 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 cylindrical 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-suppressing 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, the displacement of the stator core 62 can be appropriately suppressed.

An annular internal space may be formed on the inner peripheral side of the inner tubular member 81 so as to surround the rotary shaft 11, and electric components constituting an inverter as a power converter, for example, may be arranged in the internal space. The electric component is an electric module in which a semiconductor switching element or a capacitor is packaged, for example. 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 may be expanded by not providing a plurality of the protruding portions 83 on the inner peripheral side of the inner tubular member 81 or by reducing the protruding height of the protruding portions 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 stator winding 61 is assembled to the core assembly CA, and the plurality of partial windings 151 constituting the stator winding 61 are assembled to the radially outer side of the core assembly CA, that is, the radially outer side of the stator core 62 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, and are formed in a cylindrical shape (ring shape). In the present embodiment, the stator winding 61 is configured to have three phase windings by using U-phase, V-phase, and W-phase windings.

As shown in fig. 11, the stator 60 includes a portion corresponding to the coil side CS radially facing the magnet unit 22 of the rotor 20 in the axial direction, and a portion corresponding to the coil side end CE that 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 in the coil side portions 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 are connected in parallel or in series for each phase, thereby constituting a phase winding for each phase. Fig. 16 is a circuit diagram showing a connection state of a part of windings 151 in each of three phases. Fig. 16 shows a state in which some of the phase windings 151 of each phase are connected in parallel.

As shown in fig. 11, the coil block 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 further to the axial outer side than the stator core 62 (i.e., the coil side end CE side). That is, the stator winding 61 has a portion corresponding to the coil side end CE protruding axially outward of the stator core 62 and a portion corresponding to the coil side CS axially inward of 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 winding 151 having a bent shape on both axial end sides is referred to as a "first partial winding 151A", and the coil module 150 having the first partial winding 151A is referred to as a "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 module 150A and the second coil module 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 are different from each other in axial length and 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 members 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 lead portions 152 provided in parallel and linearly; and a pair of bridging portions 153A connecting the pair of intermediate conductor portions 152 at both ends in the axial direction, respectively, and the pair of intermediate conductor 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 conductor portions 152 are provided as coil side conductor portions arranged one by one in the circumferential direction at the coil side portions 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 conductor material CR in multiple layers so that the cross section of the conductor 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 conductor material CR is arbitrary, and the conductor material CR may be wound in a plurality of layers by a winding (japanese: アルファ reel) in addition to the concentric winding.

In the first partial winding 151A, the end of the conductive 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 end thereof is the winding end 154, 155. The winding end portions 154 and 155 are portions that become the winding start end and the winding end of the conductor 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 formed by using a film material FM having an axial dimension at least as long as the axial insulating cover range 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 lead 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 conductor portion 152 to a portion of the first bridging portion 153A on both sides in the axial direction 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 will be described. As shown in fig. 20, the first lap 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, an opening portion for drawing out a signal line extending from the temperature detection portion may be provided in insulating cover 161. In this case, the temperature detection unit can be appropriately housed in the insulating cover 161.

Although the detailed description is omitted, 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 module 150B, and fig. 22 (B) is a perspective view showing the second coil module 150B with its constituent components 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 conductor 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 bridging portion 153B of the second partial winding 151B is provided so as not to be bent in the radial direction but to linearly extend in the axial direction from the intermediate wire portion 152. 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 end thereof becomes the winding end portions 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 formed by using a film material FM having an axial dimension of at least the length of the insulating cover range of the intermediate conductor portion 152 in the axial direction, and winding the film material FM around the intermediate conductor portion 152.

The structure of the insulating cover 157 is substantially the same also in the respective partial windings 151A and 151B. That is, as shown in fig. 23, the film material FM covers the periphery of the intermediate lead portion 152 in a state where the circumferential end portions overlap. In the intermediate conductor portion 152, the insulating coating 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 overlapping portions OL are provided on the same side in the circumferential direction, respectively.

In the second partial winding 151B, an insulating coating 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 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 bridging portions 153A and 153B extending linearly 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 covers 163 face each other in a state of abutting or approaching each other in 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 bridging 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. However, in consideration of the overlapping state with the axially inner insulating cover 161, it is desirable to form the insulating cover in a narrow width in the circumferential direction in order to avoid interference with the winding end portions 154 and 155.

The axial thickness of the protruding portion 186 is reduced stepwise at the radially inner front end, 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 not shown in detail, the insulation cover 164 on the other axial side has substantially the same structure as the insulation 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 different from the insulating cover 163 in that it does not have an opening for drawing the winding end portions 154 and 155 of the second partial winding 151B.

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 on the side 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, 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 insulating boot 163 is greater than the radial width dimension W22 of the insulating boot 164. Thus, unlike the case where the width dimensions W21, W22 of the insulating covers 163, 164 are the same, the trouble 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, 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 respective 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 sheets of the film materials FM are stacked between the intermediate conductor 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 in axial length from each other, and the lap portions 153A and 153B of the partial windings 151A and 151B are different in shape from each other, and are attached to the core assembly CA in a state where the first lap portion 153A of the first coil module 150A is located axially inward and the second lap portion 153B of the second coil module 150B is located axially outward. 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 axially overlapped on one end side in the axial direction of the coil modules 150A and 150B and the insulating covers 162 and 164 are axially overlapped on 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 fixing by the fixing pin 191 in a state where the coil modules 150A and 150B are assembled to the core assembly CA, and fig. 28 (B) is a vertical sectional view showing a state after fixing by the fixing pin 191 in a state where the coil modules 150A and 150B are assembled to the core assembly CA.

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 LB between the side surface portions 171 faces the recess 105 of the axial end surface of the inner cylindrical member 81. 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, second coil module 150B is further assembled to the integrated body of core assembly CA and 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 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 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 a state of being engaged with each other at the overlapping portion where they overlap. 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 150A, 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 lower step portion 186a) of the insulating cover 163 and has a margin to protrude upward, it is considered that this operation can be easily performed when the fixing pin 191 is inserted into the recessed portions 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, the adhesive is filled through the through holes 188 provided in the insulating cover 163. Thereby, the insulating covers 161, 163 overlapped in the axial direction are firmly coupled to each other. Note that, although the through-hole 188 is illustrated in a range from the upper surface to the lower surface of the insulating cover 163 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.

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 come into contact with or close to 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, all of the first coil modules 150A may be previously attached to the outer peripheral side of the core assembly CA, and thereafter, all of the second coil modules 150B may be 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. 29 is a perspective view of the bus bar module 200, and fig. 30 is a 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. 30, 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 with 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 configuration 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 configuration in which all the bus bars are arranged in the radial direction, a configuration 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 configuration including bus bars having different plate surface extending directions, or the like.

In fig. 29, 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 bus 211 for the U-phase, a connection terminal connected to the bus 212 for the V-phase, a connection terminal connected to the bus 213 for the W-phase, and a connection terminal connected to the bus 214 for the neutral point. 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 respective connection terminals 202. 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. 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 input/output electric power to/from an inverter, not shown, to/from the phase windings of the respective phases of the stator winding 61.

Further, the bus bar module 200 may be integrally provided with a current sensor for detecting a phase current of each phase. In this case, a current detection terminal may be provided in the bus bar module 200, and the detection result of the current sensor may be 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. 31 is a perspective view showing a state where the bus bar module 200 is assembled to the stator holder 70, and fig. 32 is a vertical cross-sectional view of a fixing portion to which 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. 31, 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. 32, 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 part 223, wherein the pressing part 223 presses the upper surface of the annular part 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 fastening member 217 is screwed into the pillar portion 95 of the inner cylindrical member 81 in a state where the fastening member 217 is inserted into the insertion hole 221 of the stopper plate 220. The pressing portion 223 of the stopper plate 220 is in contact with 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 part 95, the stopper plate 220 is pressed downward in the figure, and accordingly, the annular part 201 is pressed downward by the pressing part 223. Since the downward pressing force in the drawing generated by 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 accompanied by the elastic force of 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 screwing the fastening tool 217 is appropriately transmitted to the pressing portion 223 side.

As shown in fig. 31, 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 rotating electrical 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. 33 is a vertical sectional view showing a state where relay member 230 is attached to housing cover 242, and fig. 34 is a perspective view of relay member 230. As shown in fig. 33, 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 includes a main body 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 a long-shaped cross-sectional opening, and the three insertion holes 233 are formed so as to be aligned in substantially the same direction in the longitudinal 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, a configuration of a control system for controlling the rotating electric machine 10 will be described. Fig. 35 is a circuit diagram of a control system of the rotating electric machine 10, and fig. 36 is a functional block diagram showing a control process of the control device 270.

As shown in fig. 35, 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. In addition, a capacitor 264 for supplying electric charge necessary for switching to the switches 261 and 262 is connected in parallel to the series connection body of the switches 261 and 262 in the upper and lower arms of each phase.

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, 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 (grounded) to the negative terminal of the dc power supply 265. The dc power supply 265 is composed 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. 36 is a block diagram showing a current feedback control process for controlling the respective phase currents of the U-phase, V-phase, and W-phase.

In fig. 36, 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 powering 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) of 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 (direction of a magnetic field or field direction) as a 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. 37 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 the current detection value of the 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. Torque feedback control unit 284 calculates a voltage phase command by using a PI feedback method based on a deviation of the torque estimation 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 the command voltages of the three phases based on the voltage amplitude command, the voltage phase command, and the electrical angle θ, and generates the switching operation signals of the upper and lower arms in each phase by PWM control based on comparison between the magnitude of a signal obtained by normalizing the calculated command voltages of the three phases by 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 generator 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 example)

A modification of the first embodiment will be described below.

The structure of the magnet 32 in the magnet unit 22 may also be changed as described below. In the magnet unit 22 shown in fig. 38, the direction of the axis of easy magnetization 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 axis of easy magnetization. That is, the magnet 32 is configured such that the direction of the magnetization easy axis is inclined with respect to the d-axis between the magnetic flux acting surface 34a on the stator 60 side (radially inner side) and the magnetic flux acting surface 34b on the side opposite to the stator (radially outer side), and is linearly oriented so as to be close to the d-axis on the stator 60 side in the circumferential direction and to be away from the d-axis on the side opposite to the stator. 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 bridge portion 153B may be bent in any direction, i.e., radially inward and outward, as long as it is positioned on the axially outer side of the first bridge portion 153A so as to straddle a portion of the first bridge portion 153A in the circumferential direction.

Instead of two types of partial windings 151 (first partial winding 151A and second partial winding 151B), one type of partial winding 151 may be provided as the partial winding 151. Specifically, the partial winding 151 may be formed in a substantially L shape or a substantially Z shape when viewed from the side. When the partial winding 151 is formed in a substantially L-shape in a side view, the overlapping portion 153 is bent in one axial end side in either radially inward or outward direction, and the overlapping portion 153 is provided at the other axial end side so as not to be bent in the radial 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 may be configured such that the coil module 150 is fixed to the core assembly CA by the insulating cover covering the lap 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 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 in 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. 39 (a) and (b) are diagrams showing the structure of the stator unit 300 in the case of the inner rotor structure. Fig. 39 (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. 39 (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 to form 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 lead portions 312 and a lap portion 313A formed by bending the core assembly CA side (radially outward side) on both axial sides. The partial winding 311B has substantially the same configuration as the second partial winding 151B, and includes a pair of intermediate lead 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.

Fig. 40 is a plan view showing a state where the coil modules 310A and 310B are assembled to the core assembly CA. In fig. 40, a plurality of recesses 105 are formed at equal intervals in the circumferential direction on the axial end face of the stator holder 70. The stator holder 70 has a cooling structure by a liquid refrigerant or air, and as an air cooling structure, for example, a plurality of heat radiating fins are formed on an outer peripheral surface.

In fig. 40, the insulating covers 315 and 316 are arranged so as to overlap in the axial direction. The recess 317 provided in the side surface of the insulating cover 315 communicates with a through hole 319 provided in the protruding portion 318 of the insulating cover 316 at a central position between one end and the other end in the circumferential direction of the insulating cover 316 in the axial direction, and the fixing pins 321 fix the above portions.

In fig. 40, the fixing positions of the insulating covers 315 and 316 by the fixing pins 321 are located on the axial end surface of the stator holder 70 on the radially outer side than the stator core 62, and the fixing pins 321 fix the stator holder 70. In this case, since the cooling structure is provided in the stator holder 70, the heat generated in the partial windings 311A, 311B is easily transmitted to the stator holder 70. This can improve the cooling performance of the stator winding 61.

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, a rotating armature type rotating electric machine in which an armature is a rotor and a field element is a stator may be used instead of a rotating field type rotating electric machine in which a field element is a rotor and an armature is a stator.

(second embodiment)

Hereinafter, the structure of the rotating electric machine 10 according to the second embodiment will be described mainly focusing on differences from the first embodiment. In the present embodiment, the structure of the stator winding 61 of the stator 60 in the rotary electric machine 10 is changed, and particularly, the arrangement of the wire material CR in the partial winding 151 included in the stator winding 61 is carefully studied.

As described with reference to fig. 18, the partial winding 151 includes the first partial winding 151A and the second partial winding 151B having different coil side end shapes (lap joint shapes), and the schematic configuration is as described above including the shapes of the respective partial windings 151A and 151B. However, in the present embodiment, the following is different: using a flat wire having a rectangular cross section as the conductor material CR, the conductor materials CR arranged in the circumferential direction are wound in the partial winding 151 so as to be shifted in the radial direction so that the outer surface of the stator core 62 side is along the outer circumferential surface of the stator core 62; and a winding holding member is integrally provided to a part of the winding 151, the details of which will be described below. The two types of first partial winding 151A and second partial winding 151B have different coil side end shapes, but have the same configuration of intermediate conductor portion 152, and second partial winding 151B will be described as "partial winding 151" in the following drawings.

Fig. 41 (a), (b) are perspective views showing the structure of the coil module 400 including the partial winding 151, and 42 is a sectional view showing a cross section at an axially intermediate portion in the partial winding 151. In fig. 42, the outer peripheral surface of the stator core 62 is indicated by a chain line.

As shown in fig. 41 (a), (b), and 42, the coil module 400 has a partial winding 151 and a pair of coil holders 401 as winding holding members, and is configured by integrating the pair of coil holders 401 with the partial winding 151 as an air-core coil. The partial winding 151 is held in an assembled state to the stator core 62 by the coil holder 401. The coil holder 401 is formed of an insulating material such as a synthetic resin, and includes: a first wall 411 which becomes a core side in the partial winding 151 in a state of being assembled to the stator core 62; and a second wall portion 412 disposed on the inner peripheral side of partial winding 151. The first wall 411 corresponds to a "wall" interposed between the stator core 62 and the radial direction.

The coil module 400 is assembled to the stator core 62 with the first wall 411 of the coil holder 401 in contact with the outer peripheral surface of the stator core 62. However, the method of attaching the coil module 400 to the stator core 62 may be arbitrary, and as shown in fig. 27, fig. 28, and the like, the coil module 400 may be configured to be fixed to the stator core 62 (core assembly CA) by an insulating cover.

The pair of coil holders 401 may have, in addition to the first wall 411 and the second wall 412, a wall that is on the opposite side of the core when assembled to the stator core 62, and a wall that is disposed on the outer peripheral side of the partial winding 151. For example, the pair of coil holders 401 is configured to have three wall portions surrounding the intermediate lead portion 152. However, when the wall portion on the opposite side of the core (i.e., on the rotor side) is provided in the coil holder 401, the magnetic gap may increase, and the wire material CR may be difficult to wind. Further, the pair of coil holders 401 may be formed as an integrated body. In this case, in the coil holder 401, the first wall portion 411 and the second wall portion 412 may be formed in a ring shape, respectively.

As shown in fig. 42, the partial coil 151 is formed by winding a plurality of layers of the conductor material CR having a rectangular cross section, and the conductor material CR is wound in a state where a plurality of conductor materials CR are arranged in the radial direction and the circumferential direction in the middle conductor portion 152 as the coil side conductor portion. The wire material CR is a flat wire including a long side and a short side. The conductor material CR may be formed by collecting a plurality of wires.

The winding structure at the intermediate conductor portion 152 in the partial winding 151 will be described in further detail below. Fig. 43 is an exploded cross-sectional view showing the intermediate conductor portion 152 of the partial coil 151 and the coil holder 401 in an enlarged manner. The horizontal direction in fig. 43 is the circumferential direction, and the vertical direction is the radial direction.

In fig. 43, the intermediate lead portion 152 is configured as follows: the long sides of the wire members CR overlap in the circumferential direction as circumferential side surfaces 421, and the short sides of the wire members CR overlap in the radial direction as radial side surfaces 422. That is, the wire material CR is wound in a state in which the long side extends in the radial direction and the short side faces the rotor 20. In particular, the circumferential side surfaces 421 of the conductor members CR are linearly arranged in the radial direction, and the radial side surfaces 422 of the conductor members CR are arranged in a stepwise manner by being shifted in the radial direction in the circumferential direction. The amount of radial misalignment in circumferentially adjacent conductor materials CR is Ds.

In this case, in order to shift the radial direction side surface 422 of the conductor member CR along the outer peripheral surface of the stator core 62, the conductor member CR is wound in a state in which the direction of the radial shift is different between the region on the one end side in the circumferential direction and the region on the other end side in the circumferential direction of each intermediate conductor portion 152. That is, the wire material CR is wound in the following state: in the left half of each intermediate conductor portion 152, the radial side surface 422 is shifted upward toward the right, and in the right half of the intermediate conductor portion 152, the radial side surface 422 is shifted downward toward the right. In the intermediate conductor portion 152, the radially outer and radially inner outer surfaces, i.e., the rotor 20 side and the rotor opposite side surfaces, are all in a state in which the radial side surfaces 422 are shifted in the radial direction in the same manner.

The intermediate conductor portion 152 may have a substantially arc shape in a cross section toward the rotor 20. In order to make the outer surface of the partial winding 151 on the rotor 20 side have an arc shape, the amount Ds of displacement in the radial direction of the respective conductor members CR arranged in the circumferential direction may be changed little by little in the circumferential direction. In this case, the shift amount Ds may be smaller on both ends in the circumferential direction of the intermediate lead portion 152 than on the center in the circumferential direction.

In the intermediate lead portions 152, as the radial side surfaces of the lead members CR are arranged in the circumferential direction with a predetermined amount of displacement in the radial direction, the radial side surfaces of the lead members CR may be arranged in the circumferential direction with a different amount of displacement in the radial direction, or the radial side surfaces of the lead members CR may be arranged with a constant amount of displacement in the radial direction.

The configuration in which the conductor members CR are arranged in the circumferential direction while being shifted by a predetermined amount in the radial direction may include a case in which adjacent conductor members CR in the circumferential direction are not shifted in the radial direction.

Here, as shown in fig. 42, when a straight line extending along the circumferential side surface 421 of the wire material CR in one of the pair of intermediate wire portions 152 is L1 and a straight line extending along the circumferential side surface 421 of the wire material CR in the other intermediate wire portion 152 is L2, the straight lines L1 and L2 are nonparallel and intersect each other on the stator center side. In this configuration, in each intermediate lead portion 152, the extending direction of the circumferential side surface 421 of the lead material CR is concentrated toward the center of the stator. In this case, the direction of the radial side surface 422 of the conductor material CR facing the outer peripheral surface of the stator core 62 is different between the left side and the right side in the drawing. Therefore, as described above, the intermediate conductor portions 152 are configured such that the conductor material CR is wound in a state in which the direction of the radial direction shift is different between the region on the one end side in the circumferential direction and the region on the other end side in the circumferential direction of each intermediate conductor portion 152.

Further, in the first wall portion 411 of the coil holder 401, a stepped surface 413 is formed on the partial winding 151 side in accordance with the radial displacement of the conductor material CR, and an arc surface 414 having no step is formed on the stator core 62 side. In this case, the step surface 413 of the first wall portion 411 may have a step having the same height dimension as the shift amount Ds of the wire material CR in the intermediate wire portion 152 in matching with the shift amount Ds.

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

According to the present embodiment described in detail above, the following effects can be obtained.

The intermediate conductor portions 152 of the partial windings 151 are arranged in a state in which the circumferential side surfaces 421 of the conductor members CR are linearly arranged in the radial direction and the radial side surfaces 422 of the conductor members CR are arranged in a stepwise manner in the circumferential direction by a radial shift. This allows the outer surface of the radially outer side (rotor 20 side) of the intermediate conductor portion 152 to have a shape matching the rotor 20 side, thereby making it possible to make the air gap between the stator winding 61 and the rotor 20 uniform. Further, the conductor material CR having a rectangular cross section is wound in multiple layers to form the partial winding 151, so that an increase in conductor space factor can be achieved. As a result, in the rotating electric machine 10, the stator winding 61 can be designed appropriately, and desired performance can be achieved.

In the partial winding 151 having the pair of intermediate conductor portions 152 and the bridging portions 153, the direction of the radial side surface 422 of the conductor material CR facing the outer peripheral surface of the stator core 62 may be different in each intermediate conductor portion 152 depending on the extending direction of the circumferential side surface 421 of the conductor material CR in each intermediate conductor portion 152. In this regard, each of the intermediate lead portions 152 is configured such that the lead material CR is wound in a state in which the direction of the radial displacement is different between the region on the one end side in the circumferential direction and the region on the other end side in the circumferential direction of each of the intermediate lead portions 152. Thus, the outer surface of the partial winding 151 on the rotor 20 side can be appropriately fitted to the rotor 20 side at the intermediate conductor portion 152.

In the partial winding 151, in a configuration in which the straight line L1 extending along the circumferential side surface 421 of the conductor material CR in one of the intermediate conductor portions 152 and the straight line L2 extending along the circumferential side surface 421 of the conductor material CR in the other of the intermediate conductor portions 152 are not parallel to each other and intersect each other on the stator center side, the extending direction of the circumferential side surface 421 of the conductor material CR in each of the intermediate conductor portions 152 converges toward the stator center. In this case, the direction of the radial side surface 422 of the conductor material CR facing the outer peripheral surface of the stator core 62 is different. Therefore, as described above, the wire material CR can be wound around each of the intermediate wire portions 152 in a state in which the directions of the radial direction shifts are different between the circumferential center side and the circumferential both sides of each of the intermediate wire portions 152.

In the cross section of the partial winding 151, the rotor 20 side is formed in a substantially circular arc shape, and therefore, the outer surface of the rotor 20 side can be further matched to the shape of the rotor 20 side.

The intermediate conductor portions 152 of the partial windings 151 are configured such that the long sides of the conductor members CR overlap in the circumferential direction and the short sides of the conductor members CR overlap in the radial direction. In this case, since the short sides of the wire members CR are disposed on the rotor 20 side, the outer surface of the center wire portion 152 on the rotor 20 side can be easily matched with the rotor 20 side, as compared with the case where the long sides of the wire members CR are disposed on the rotor 20 side.

Further, since the width of the conductor material CR in the intermediate conductor portion 152 in the circumferential direction is smaller than the width in the radial direction, the number of layers of the conductor materials CR in the circumferential direction is increased, and it is easy to match the outer surface of the intermediate conductor portion 152 on the rotor 20 side with the outer surface on the rotor 20 side.

Further, by making the circumferential width of the wire member CR smaller than the radial width, the number of turns can be made as small as possible while matching the outer surface shape of the intermediate wire portion 152 on the rotor 20 side with the rotor 20 side, thereby reducing the number of steps in manufacturing the coil.

In the structure in which the partial winding 151 is assembled to the stator core 62, the conductor material CR is wound in a staggered state, and the outer surface of the partial winding 151 on the rotor 20 side is shaped to match the rotor 20 side, whereby the gap between the partial winding 151 and the stator core 62 can be reduced, and the gap can be made uniform for each layer of the conductor material CR. This can improve the efficiency of the rotating electric machine 10.

The coil holder 401 is integrally provided to the partial winding 151, and the first wall 411 of the coil holder 401 is interposed between the partial winding 151 and the stator core 62. In this case, the stator core 62 can be assembled with the partial winding 151 by the coil holder 401. Further, since the first wall 411 has the stepped surface 413 formed on the intermediate conductor portion 152 side in accordance with the radial displacement of the conductor material CR and the circular arc surface 414 without a step formed on the stator core 62 side, the assembly of the partial coil 151 to the stator core 62 can be reliably and easily performed while suppressing the displacement of the conductor material CR wound in the displaced state.

In the magnet unit 22 of the rotor 20, in the configuration (configuration of fig. 7) in which the magnetic flux is generated in a concentrated manner in the region near the d-axis in the magnetic flux acting surface 34 of the magnet 32, the concern of eddy current due to the magnet magnetic flux at the partial winding 151 becomes strong. In this regard, as described above, the partial coil 151 is configured by winding the conductor material CR having a rectangular cross section in a plurality of layers, and arranging a plurality of conductor materials CR in the radial direction and the circumferential direction in the intermediate conductor portion 152, respectively, thereby suitably suppressing the eddy current.

As the conductor material CR of the partial winding 151, by using an aggregate wire (wire harness) in which a plurality of wires are aggregated, eddy current loss reduction can be achieved.

(modification example)

A modified example of the second embodiment will be described below.

As shown in fig. 44, the wire material CR may be a square cross-section diagonal wire. The magnet flux of the rotor 20 has a property of spreading in the circumferential direction from the flux outflow surface, and the direction of the magnet flux with respect to the partial winding 151 changes depending on the relative position of the rotor 20 and the stator 60. In this case, by using an angular line having a square cross section as the conductor material CR of the partial winding 151, it is possible to appropriately suppress eddy current regardless of the relative position of the rotor 20 and the stator 60.

The form of each intermediate lead portion 152 may be changed in the partial winding 151. Fig. 45 is a sectional view showing a cross section at an axially intermediate portion in the partial winding 151, and fig. 46 is a sectional view showing the intermediate wire portion 152 and the coil holder 401 of the partial winding 151 in an enlarged manner. In the above figures, the left-right direction is the circumferential direction, and the up-down direction is the radial direction.

As shown in fig. 45 and 46, the partial coil 151 is formed by winding a plurality of layers of a conductive wire material CR (flat wire) having a rectangular cross section, and the conductive wire material CR is wound in a state where a plurality of the conductive wire materials CR are arranged in the radial direction and the circumferential direction in the intermediate conductive wire portion 152. The coil holder 401 is integrated with the partial winding 151. The basic structure itself is the same as that of the above-described structure of fig. 42 and the like.

The same applies to the intermediate wire portions 152, in which the long sides of the wire members CR, that is, the circumferential side surfaces 421 overlap in the circumferential direction, the short sides of the wire members CR, that is, the radial side surfaces 422 overlap in the radial direction, the circumferential side surfaces 421 of the wire members CR are arranged linearly in the radial direction, and the radial side surfaces 422 of the wire members CR are arranged stepwise in the circumferential direction by being shifted in the radial direction.

However, the partial winding 151 of the present example differs from the configuration shown in fig. 42 and the like in that a straight line L1 extending along the circumferential side surface 421 of the conductor material CR of one of the pair of intermediate conductor portions 152 and a straight line L2 extending along the circumferential side surface 421 of the conductor material CR of the other intermediate conductor portion 152 are parallel to each other. In the intermediate wire portion 152, the wire material CR is wound in the following state: the radial direction of the offset is the same in the range from one circumferential end to the other circumferential end of the intermediate lead portions 152, and the offset directions are made opposite to each other in each of the pair of intermediate lead portions 152. That is, the directions of the radial side surfaces 422 of the conductor member CR are the same in the pair of intermediate conductor portions 152.

Thereby, in the stator winding 61, the outer surface of the rotor 20 side in the middle wire portion 152 of the partial winding 151 can be properly aligned with the rotor 20 side.

In the cross section of the intermediate conductor portion 152, the rotor 20 side in the radial direction may be substantially arc-shaped. In this case, the amount of radial shift of the respective conductor members CR arranged in the circumferential direction may be changed little by little in the circumferential direction, or may be decreased as the partial winding 151 is closer to the circumferential center side.

The intermediate lead portions 152 of the partial windings 151 may be configured as shown in fig. 47 (a) and (b). In fig. 47 (a) and (b), the horizontal direction is the circumferential direction, the vertical direction is the radial direction, and the lower side in the figure is the radial inner side (the stator core 62 side).

In fig. 47 (a), the partial coil 151 is configured such that the number of turns of the wire material CR is larger on the radially outer side than on the radially inner side in the intermediate lead portion 152 (coil side lead portion). In this case, the width in the circumferential direction of each intermediate conductor portion 152 of the partial winding 151 can be made different between the radially inner side and the radially outer side. This can improve the conductor space factor of the stator winding 61.

In the outer rotor type rotating electric machine 10, the rotor 20 is disposed radially outward of the stator 60, and it is preferable that the rotor-side surface is expanded in the circumferential direction (that is, the number of conductors is larger) than the rotor-opposite surface in the axially orthogonal cross section of the intermediate conductor portion 152. In the inner rotor type rotating electrical machine in which the rotor 20 is disposed radially inward of the stator 60, the stator winding 61 (partial winding 151) is assembled radially inward of the stator core 62, and therefore, in the orthogonal cross section of the intermediate conductor portion 152, the surface on the opposite side of the rotor preferably extends in the circumferential direction (i.e., the number of conductors is larger) than the surface on the rotor side.

In fig. 47 (b), the partial coil 151 has a portion in which the lead material CR is wound in the radial direction and a portion in which the lead material CR is wound in the circumferential direction in the extension direction of the long side in the intermediate lead portion 152 (coil side lead portion), and the width dimension in the circumferential direction is made different between the radially inner side and the radially outer side by the above portions. In addition, the wire member CR may be twisted by 90 degrees at the edge portion (lap portion) of the coil so that the extending direction of the long side is switched between the radial direction and the circumferential direction.

In the structure using a flat wire including a long side and a short side as the wire material CR, the dimension in the overlapping direction (lamination dimension) is changed by changing the direction of the cross section of the wire material CR. In this case, the conductor space factor of the stator winding 61 can be improved by making the width dimension in the circumferential direction different between the radially inner side and the radially outer side. Furthermore, dead space can be minimized.

In the intermediate wire portion 152, the short sides of the wire member CR may be stacked in the circumferential direction as the circumferential side surfaces 421, and the long sides of the wire member CR may be stacked in the radial direction as the radial side surfaces 422 (in contrast to fig. 43).

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

As the rotating electrical machine 10 according to the second embodiment, a rotating armature type rotating electrical machine in which an armature is a rotor and a field element is a stator may be used instead of a rotating field type rotating electrical machine in which a field element is a rotor and an armature is a stator.

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 addition portion 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 and 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, and other combinations and modes including only one element, one or more elements, and one or less elements also belong to the scope and idea of the present disclosure.

Claims (12)

1. A rotary electric machine (10) comprising:

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

an armature (60) having a multiphase armature winding (61) including a phase winding having a plurality of partial windings (151) for each phase and a cylindrical member (62, 70) assembled with the armature winding on a radially inner side or a radially outer side,

the field element and the armature are disposed to be diametrically opposed to each other,

the partial winding is formed in a ring shape by winding a plurality of conductor materials (CR) having a rectangular cross section in a plurality of layers, the conductor materials being arranged in a plurality of states in a radial direction and a circumferential direction, respectively, at a coil side portion,

in a cross section at the coil side of the partial winding, a state is formed in which circumferential side surfaces (421) of the wire material are linearly arranged in a radial direction, and radial side surfaces (422) of the wire material are arranged stepwise in the circumferential direction by a radial offset.

2. The rotating electric machine according to claim 1,

the partial winding includes a pair of intermediate conductor portions (152) provided at a predetermined interval in the circumferential direction, and a crossover portion (153) provided at one end side and the other end side in the axial direction and connecting the pair of intermediate conductor portions in a ring shape,

in each of the intermediate conductive wire portions, the conductive wire material includes a region on one end side in the circumferential direction and a region on the other end side in the circumferential direction, and is wound in a state in which the directions of the radial direction shifts are different in each of the regions.

3. The rotating electric machine according to claim 2,

a straight line (L1) extending along the circumferential side surface of the wire material in one of the pair of intermediate wire portions and a straight line (L2) extending along the circumferential side surface of the wire material in the other intermediate wire portion are non-parallel to each other and intersect each other on the armature center side.

4. The rotating electric machine according to claim 1,

the partial winding includes a pair of intermediate conductor portions (152) provided at a predetermined interval in the circumferential direction, and bridging portions (153) provided on one end side and the other end side in the axial direction and connecting the pair of intermediate conductor portions in a ring shape,

in each of the intermediate wire portions, the wire material is wound in a state in which: the direction of the radial offset is the same in a range from one end to the other end in the circumferential direction of each of the intermediate lead portions, and the directions of the offset are made opposite to each other in each of the pair of intermediate lead portions.

5. A rotating electric machine according to any one of claims 1 to 4,

in a cross section at the coil side portion of the partial winding, the exciting element side in a radial direction is substantially circular-arc-shaped.

6. The rotating electric machine according to any one of claims 1 to 5,

the wire material is a flat wire comprising long sides and short sides,

the partial windings are configured at coil side portions such that long sides of the wire material overlap in a circumferential direction and short sides of the wire material overlap in a radial direction.

7. The rotating electric machine according to any one of claims 1 to 6,

the cylindrical member is an armature core (62).

8. The rotating electric machine according to any one of claims 1 to 7,

a winding holding member (401) having a wall portion (411) interposed between the partial winding and the cylindrical member in a radial direction is integrally provided at the partial winding,

a stepped surface (413) is formed on the wall portion on the side of the partial winding in accordance with the state of the wire material shifted in the radial direction, and an arc surface (414) having no step is formed on the cylindrical member side.

9. The rotating electric machine according to any one of claims 1 to 8,

the conducting wire material is a corner line with a square cross section.

10. The rotating electric machine according to any one of claims 1 to 9,

the magnet part in the field element has a permanent magnet (32) that generates magnetic flux in each magnetic pole, and the magnetic flux is generated in a region near the d-axis, which is the center of the magnetic pole, in a region of a magnetic flux acting surface (34) of the permanent magnet on the armature side.

11. The rotating electric machine according to any one of claims 1 to 10,

the partial winding is configured such that, at a coil side portion, the number of turns of the wire material is larger on a radially outer side than on a radially inner side.

12. The rotating electric machine according to any one of claims 1 to 10,

the wire material is a flat wire comprising long sides and short sides,

the partial winding has, at a coil side: a portion in which the wire material is radially wound is defined as an extending direction of a long side; and a portion in which the wire material is wound in a circumferential direction, the extending direction of the long side being set to be different in width dimension in the circumferential direction between a radially inner side and a radially outer side.

Images