CN115004514A - Rotating electrical machine - Google Patents

Abstract

A rotating electrical machine (10) is provided with: an excitation element (20) including a magnet portion (22); and an armature (60) having a multiphase armature winding (61). The armature winding of each phase is formed by winding a Conductor (CR), and has conductor portions (81) arranged at predetermined intervals in the circumferential direction at positions facing the magnet portions. Each of the lead portions is formed by the leads being arranged in one or more rows in a circumferential direction and in one or more rows in a radial direction. Each of the wires is covered with an insulating film (602) in a state where a plurality of wires (601) are stacked in the circumferential direction. Each of the lead wires is formed by connecting the wire members constituting the lead wires in parallel, and the cross section of each of the wire members is formed into a flat shape elongated in the radial direction.

Description

Rotating electrical machine

Citation of related applications

The present application is based on japanese patent application No. 2019-209971, filed on 20/11/2019, the contents of which are incorporated herein by reference.

Technical Field

The present disclosure relates to a rotating electric machine.

Background

Conventionally, for example, as described in patent document 1, there is known a rotating electrical machine including: a field element including a magnet portion having a plurality of magnetic poles whose polarities alternate in a circumferential direction; and an armature having a multiphase armature winding. In this rotating electric machine, in order to eliminate the restriction of magnetic saturation occurring in the pole teeth of the stator core, a slot-less structure is adopted, and in order to increase the magnetic flux density, a magnet having polar anisotropy is adopted. This makes it possible to desirably increase the output torque while eliminating the restriction caused by magnetic saturation.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2019-106864

Disclosure of Invention

In addition, the rotating electric machine has the following problems: when the cross-sectional area of the conductor is increased to increase the space factor indicating the ratio of the conductor in which the current flows in the space in which the armature winding is housed, the eddy current loss increases when the magnetic flux from the magnet is linked with the lead wire. In particular, when a non-slotted structure is employed and a polar anisotropic magnet is employed, there is a problem that eddy current loss is likely to increase.

The present disclosure has been made in view of the above circumstances, and a main object thereof is to provide a rotating electrical machine capable of reducing an eddy current loss.

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

A 1 st aspect for solving the above-described problems is 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 including a plurality of phases of armature windings, wherein either one of the field element and the armature is a rotor, wherein the armature windings of the respective phases are formed by winding lead wires, the armature windings include lead portions arranged in a circumferential direction at predetermined intervals at positions facing the magnet portions, the lead portions are formed by arranging the lead wires in one or more rows in the circumferential direction and in one or more rows in a radial direction, the lead wires are formed by covering a plurality of wire rods in a stacked state in the circumferential direction with an insulating film, the lead wires are formed by connecting the wire rods constituting the lead wires in parallel, and each of the wire rods has a flat shape with a cross section elongated in the radial direction.

In the above configuration, since each wire has a flat shape with a long cross section in the radial direction, an eddy current can be suppressed. Further, by forming the flat shape long in the radial direction, the gap in the radial direction in the lead wire, that is, the gap between the conductor or between the insulating film and the conductor can be reduced, and the space factor of the conductor can be increased.

In the above configuration, since the cross section of each wire rod has a flat shape that is long in the radial direction, the effect of reducing the circulating current is improved. That is, the magnet magnetic flux varies depending on the circumferential position of the magnet portion. Therefore, the magnetic flux of the magnet linked with each wire of each wire varies with the rotation of the rotor, and a difference is generated between electromotive forces generated in each wire at a certain time. Here, in the mode 1, the cross section of each lead has a flat shape that is long in the radial direction. Therefore, in each of the conductive wires, the width dimension in the circumferential direction of the plurality of wires arranged in line can be reduced. As a result, the difference in electromotive force generated in each wire at a certain time can be reduced in each lead. This reduces the difference in electromotive force generated in the wire material constituting the lead wire, thereby reducing the circulating current.

A 2 nd aspect is the wire rod according to the 1 st aspect, wherein the wire rod has a radially long flat cross section, and includes a conductor through which a current flows and a fusion layer covering a surface of the conductor, and the fusion layer is thinner than the insulating film, and the fusion layer is configured to be fused by contacting each other in a state where a plurality of wire rods are stacked in a circumferential direction.

The wires are insulated from each other by an insulating film. On the other hand, although the conductors of the wire are covered with the fusion layer, the conductors may be in contact with each other and electrically conducted because no insulating layer is provided. However, the potential difference between the conductors is small, and when bundling a plurality of wires or covering an insulating film, even if the fusion layer is broken, the area of contact between the conductors is very small, and the contact resistance is very large. Therefore, even if the insulation is not complete, the eddy current can be suppressed from flowing between the conductors.

Therefore, the insulating layer is not provided on the surface of the conductor, but the fusion layer is provided directly on the conductor and fused to each other. This eliminates the need for providing an insulating layer. Further, by providing the fusion layer, the plurality of wires can be easily kept bundled and easily covered with the insulating film. With the above, the lead wire and the rotating electrical machine are easily manufactured, and since the insulating layer of the wire is omitted, the space factor of the conductor can be improved.

In the 3 rd aspect, in addition to the 1 st or 2 nd aspect, the wires are arranged in only one layer in a radial direction in each of the lead wires.

In each of the wires, the wires are arranged in a single layer in a radial direction. Therefore, unlike the structure in which a plurality of wires of each lead are stacked in the radial direction, a difference in electromotive force due to a difference in arrangement position in the radial direction of the wires does not occur. This reduces the difference in electromotive force generated in the wire members constituting the lead wire, thereby reducing the circulating current flowing through the armature winding.

In addition, by providing only one layer, the gap between the conductors in the radial direction in the insulating film can be eliminated as compared with the case of providing a plurality of layers. That is, the space factor of the conductor can be increased.

A 4 th aspect is any one of the 1 st to 3 rd aspects in which the magnet portions are respectively oriented such that a direction of an easy magnetization axis is more parallel to a d-axis on a d-axis side as a magnetic pole center than on a q-axis side as a magnetic pole boundary, and a magnet magnetic path is formed along the easy magnetization axis.

With the above configuration, the magnetic flux density is more likely to be parallel to the radial direction as the d-axis is closer. That is, the radial component of the magnetic flux density tends to be larger as the d-axis is closer, and the circumferential component tends to be smaller. Thus, the eddy current loss can be more effectively suppressed by reducing the thickness dimension in the circumferential direction.

A 5 th aspect is any one of the 1 st to 3 rd aspects, wherein the magnet portion includes a first magnet portion and a second magnet portion, a magnetic pole of the first magnet portion on a d-axis as a magnetic pole center is different from a magnetic pole of the second magnet portion facing the magnetic pole of the first magnet portion in a radial direction, the first magnet portion is disposed to face the wire portion on a radially inner side of the wire portion, and the second magnet portion is disposed to face the wire portion on a radially outer side of the wire portion.

With the above configuration, the magnetic flux density at the d-axis is easily parallel to the radial direction. That is, the radial component of the magnetic flux density tends to be large, while the circumferential component tends to be small. Thus, the eddy current loss can be more effectively suppressed by reducing the thickness dimension in the circumferential direction.

Drawings

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Fig. 25 is a view showing the overlapping positions of the film materials in a state where the coil blocks 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 a structure of a stator unit of an 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 diagram showing a configuration of a first coil module according to modification 2.

Fig. 42 is a cross-sectional view of a lead member according to modification 2.

Fig. 43 is a side view of a wire material according to modification 2.

Fig. 44 is a diagram showing a connection mode of the wire rods of modification 2.

Fig. 45 is a flowchart showing a method of manufacturing a stator winding.

Fig. 46 is a schematic view showing a manufacturing process of the stator winding.

Fig. 47 is a sectional view of another example of the magnet unit.

Fig. 48 is a sectional view of another example of the stator and magnet unit.

Fig. 49 is a flowchart showing another example of a method for manufacturing a stator winding.

Detailed Description

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

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

(first embodiment)

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

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

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

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

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

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

In the magnet unit 22, the magnets 32 are arranged in such a manner as to alternately change polarity in the circumferential direction of the rotor 20. Thus, the magnet unit 22 has a plurality of magnetic poles in the circumferential direction. Magnet 32 is a permanent magnet having polar anisotropy, and is formed using a sintered neodymium magnet having an intrinsic coercive force of 400[ kA/m ] or more and a residual magnetic flux density Br of 1.0[ T ] or more.

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

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

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

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 can be confirmed that there is a difference in magnetic flux density distribution as compared with the conventional halbach array magnet. In fig. 8 and 9, the horizontal axis represents the electrical angle, and the vertical axis represents the magnetic flux density. In fig. 8 and 9, 90 ° on the horizontal axis represents the d axis (i.e., the magnetic pole center), and 0 ° and 180 ° on the horizontal axis represent the q axis.

That is, according to each magnet 32 of the above-described structure, the magnet magnetic flux at the d-axis in the magnet unit 22 is enhanced, and the magnetic flux variation in the vicinity of the q-axis is suppressed. This makes it possible to desirably realize the magnet unit 22 in which the 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 is preferably 40% or more, for example. Thus, the magnetic flux at the deformed center portion can be reliably increased as compared with the case of using a radially oriented magnet having a sine wave matching rate of about 30% or using a parallel oriented magnet. Further, when the sine wave matching rate is 60% or more, the magnetic flux at the center portion of the deformation 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 has a magnetic flux distribution close to a sine wave. Therefore, the variation in magnetic flux density is smaller in the vicinity of the q-axis than in the radial anisotropic magnet. This can suppress the generation of eddy current.

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

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

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

Next, the structure of the stator unit 50 will be 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 constituting the stator winding 61 are assembled to the core assembly CA. The stator winding 61 corresponds to an "armature winding", the stator core 62 corresponds to an "armature core", and the stator holder 70 corresponds to an "armature holding member". In addition, the core assembly CA corresponds to a "support member".

Here, first, the core assembly CA will be explained. Fig. 12 is a perspective view of core assembly CA as viewed from one axial side, fig. 13 is a perspective view of core assembly CA as viewed from the other axial side, fig. 14 is a transverse sectional view of core assembly CA, and fig. 15 is an exploded sectional view of 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 formed into a curved surface shape without unevenness. The stator core 62 functions as a back yoke. The stator core 62 is formed by laminating a plurality of core 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 annularly wound and stacked in the axial direction, whereby the cylindrical stator core 62 is formed as a whole.

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

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

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

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

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

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

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

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 88, an inlet passage 86 and an outlet passage 87 are formed inside the passage forming portion, and the passages 86 and 87 are open to the outer circumferential surface of the inner cylindrical member 81. Further, a partition portion 89 for partitioning the refrigerant passage 85 into an inlet side and an outlet side is provided on the outer peripheral surface of the inner tubular member 81. Thus, the refrigerant flowing in from the inlet-side passage 86 flows in the circumferential direction through the refrigerant passage 85, and then flows out from the outlet-side passage 87.

One end side of the inlet-side passage 86 and the outlet-side passage 87 extends in the radial direction and opens on the outer peripheral surface of the inner cylindrical member 81, and the other end side extends in the axial direction and opens on the axial end surface of the inner cylindrical member 81. Fig. 12 shows an inlet opening 86a leading to the inlet-side passage 86 and an outlet opening 87a leading to the outlet-side passage 87. The inlet-side passage 86 and the outlet-side passage 87 lead to an inlet port 244 and an outlet port 245 (see fig. 1) attached to the housing cover 242, and the refrigerant flows in and out through the respective ports 244 and 245.

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

As shown in fig. 12, the inner tube member 81 has an end plate portion 91 at one end in the axial direction, and a hollow tubular boss portion 92 extending in the axial direction is provided in the end plate portion 91. The boss portion 92 is provided so as to surround an insertion hole 93 for inserting the rotary shaft 11 therethrough. The boss portion 92 is provided with a plurality of fastening portions 94 for fixing the housing cover 242. Further, the end plate portion 91 is provided with a plurality of column portions 95 extending in the axial direction on the radially outer side of the boss portion 92. The column part 95 is a part serving as a fixing part for fixing the bus bar module 200, and details thereof will be described later. The boss portion 92 is a bearing holding member that holds the bearing 12, and the bearing 12 is fixed to a bearing fixing portion 96 provided on an inner peripheral portion thereof (see fig. 3).

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

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

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

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

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

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

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

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

As shown in fig. 11, the stator 60 includes a portion corresponding to the coil side CS radially opposed to the magnet unit 22 of the rotor 20 in the axial direction, and a portion corresponding to the coil side end CE, which is the axially outer side of the coil side CS. In this case, the stator core 62 is provided in a range corresponding to the coil side CS in the axial direction.

In the stator winding 61, the phase winding of each phase has a plurality of partial windings 151 (refer to fig. 16), respectively, and the partial windings 151 are individually provided as the coil modules 150. That is, the coil module 150 is configured by integrally providing the partial windings 151 of the phase windings of the respective phases, and the stator winding 61 is configured by a predetermined number of coil modules 150 corresponding to the number of poles. The coil modules 150 (partial windings 151) of the respective phases are arranged in a predetermined order in the circumferential direction, and thus the lead portions of the respective phases are arranged in a predetermined order on the coil side CS of the stator winding 61. Fig. 10 shows the arrangement order of the U-phase, V-phase, and W-phase lead portions of the coil side CS. In the present embodiment, the number of magnetic poles is set to 24, but the number may be arbitrary.

In the stator winding 61, the partial windings 151 of the coil modules 150 for each phase are connected in parallel or in series to constitute a phase winding for each phase. Fig. 16 is a circuit diagram showing the 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 the respective phases 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 outward in the axial direction of the stator core 62 (i.e., on the coil side end CE side). That is, the stator winding 61 includes a portion corresponding to the coil side end CE protruding outward in the axial direction of the stator core 62, and a portion corresponding to the coil side CS located inward in the axial direction from the coil side end CE.

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

Fig. 17 is a side view showing the first coil 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 have different axial lengths and different end shapes on both sides in the axial direction. The first partial winding 151A has a substantially C-shape in side view, and the second partial winding 151B has a substantially I-shape in side view. Insulation covers 161 and 162 as "first insulation covers" are attached to both axial sides of the first partial winding 151A, and insulation covers 163 and 164 as "second insulation covers" are attached to both axial sides of the second partial winding 151B.

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

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

As shown in fig. 19 (a) and (b), the first coil module 150A includes a first partial winding 151A formed by winding a conductive wire material CR in multiple layers, and insulating covers 161 and 162 attached to one end side and the other end side of the first partial winding 151A in the axial direction. 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 lead portions 152 at both ends in the axial direction, respectively, and the pair of intermediate lead portions 152 and the pair of bridging portions 153A are formed in a ring shape. The pair of intermediate lead portions 152 are provided at a predetermined coil pitch, and the intermediate lead portions 152 of the partial windings 151 of the other phase can be arranged between the pair of intermediate lead portions 152 in the circumferential direction. In the present embodiment, the pair of intermediate lead portions 152 are provided at two coil pitches apart, and one intermediate lead portion 152 of the partial windings 151 of the other two phases is disposed between the pair of intermediate lead portions 152, respectively.

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

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

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

As shown in fig. 20, the first partial winding 151A is formed by winding the wire material CR in multiple layers so that the cross section of the wire assembly portion becomes a quadrangle. Fig. 20 shows a cross section of the intermediate conductor portion 152, in which the conductor material CR is wound in multiple layers in a circumferential and radial arrangement in the intermediate conductor 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 middle wire portion 152, so that the cross section is formed in a substantially rectangular shape. 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 wire material CR is drawn from one first bridging portion 153A (the upper first bridging portion 153A in fig. 19 b) of the first bridging portions 153A on both sides in the axial direction, and the ends thereof are winding ends 154, 155. The winding end portions 154 and 155 are portions 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) which will be described later).

The insulating cover 157 is provided by using a film material FM having at least the axial dimension of the length of the insulating cover range in the axial direction of the intermediate lead portion 152 and winding the film material FM around the intermediate lead portion 152. The film material FM is made of a PEN (polyethylene naphthalate) film, for example. More specifically, the film material FM includes a film base material, and an adhesive layer having foamability provided on one of both surfaces of the film base material. The film material FM is wound around the intermediate 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 generally rectangular cross section with the conductor members CR arranged in the circumferential and radial directions, and the film member FM covers the periphery of the intermediate conductor portion 152 with its 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 overlapping portions OL are provided on the same side in the circumferential direction, respectively.

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

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

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

As shown in fig. 21 (a) and (b), the insulating cover 161 includes a pair of side surface portions 171 serving as circumferential side surfaces, an axially outer surface portion 172, an axially inner surface portion 173, and a radially inner front surface portion 174. The respective portions 171 to 174 are formed in a plate shape and are connected to each other in a three-dimensional manner so as to be opened only radially outward. The pair of side surface portions 171 are provided in a direction extending toward the axial center of the core assembly CA in a state 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, the pair of side surface portions 171 are provided with semicircular recesses 177 extending in the axial direction at positions at both ends of the front surface portion 174 in the circumferential direction, that is, at positions where the side surface portions 171 and the front surface portion 174 intersect. Further, in the outer surface portion 172, a pair of protrusions 178 extending in the axial direction are provided at positions symmetrical in both sides in the circumferential direction with respect to the center line of the insulating cover 161 in the circumferential direction.

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

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

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

The insulating covers 161 and 162 have different height dimensions in the axial direction (i.e., axial width dimensions of the pair of side surface portions 171 and the front surface portion 174). Specifically, as shown in fig. 17, the height dimension W11 in the axial direction of the insulating cover 161 and the height dimension W12 in the axial direction of the insulating cover 162 are W11 > W12. That is, when the conductor material CR is wound in a plurality of layers, the winding layer of the conductor material CR needs to be switched in a direction orthogonal to the winding direction (circumferential direction) (track change), and the winding width may increase due to the switching. In addition, the insulating cover 161 of the insulating covers 161 and 162 covers the first overlapping portion 153A 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 amount of lamination) of the conductor material CR is increased compared to other portions, and as a result, the winding width is increased. In view of this, the axial height dimension W11 of the insulating cover 161 is larger than the axial height dimension W12 of the insulating cover 162. Thus, unlike the case where the height dimensions W11, W12 of the insulating covers 161, 162 are the same, the disadvantage that the number of turns of the wire material CR is limited by the insulating covers 161, 162 is suppressed.

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

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

As shown in fig. 22 (a) and (B), the second coil module 150B includes a second partial winding 151B formed by winding a conductive material CR in a plurality of layers, as in the first partial winding 151A, and insulating covers 163 and 164 attached to one end side and the other end side in the axial direction of the second partial winding 151B. The insulating covers 163 and 164 are made of an insulating material such as synthetic resin.

The second partial winding 151B has a pair of intermediate lead portions 152 provided in parallel with each other and linearly; and a pair of second bridging portions 153B connecting the pair of intermediate conductor portions 152 at both ends in the axial direction, respectively, and formed in a ring shape by the pair of intermediate conductor 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 to extend linearly in the axial direction from the middle wire portion 152, rather than being bent in the radial direction. In fig. 18, the difference between the partial windings 151A and 151B is clearly shown by comparison.

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

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

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

In the second partial winding 151B, an insulating 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 lands 153A and 153B that linearly extends next to the intermediate lead portion 152. However, the axial length of each of the partial windings 151A and 151B is different, and the axial extent of the insulating cover 157 is also different.

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

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

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

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

A front surface 183 of the insulating cover 163 is provided with a projection 186 projecting radially inward. The protruding portion 186 is provided at a central position between one end and the other end in the circumferential direction of the insulating cover 163 so as to protrude radially inward of the second bridging portion 153B. The protruding portion 186 has a tapered shape whose tip becomes thinner toward the radially inner side in plan view, and a through hole 187 extending in the axial direction is provided at the tip thereof. The protruding portion 186 may have any configuration as long as it protrudes radially inward from the second land portion 153B and has a through hole 187 at a central position between one end and the other end in the circumferential direction of the insulating cover 163, and the protruding portion 186 may be provided. However, in consideration of the overlapping state with the axially inner insulating cover 161, it is desirable to form the 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 radially inner front end of the projection 186 is reduced in a stepwise manner, and a through hole 187 is provided in the reduced low-step portion 186 a. The lower step 186a corresponds to a portion having a height from the axial end surface of the inner tube member 81 lower than the height of the second lap joint 153B in a state where the second coil module 150B is assembled to the core assembly CA.

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

Although 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 parts 181, an axially outer surface part 182, a radially inner front surface part 183, and a radially outer rear surface part 184, and has a through hole 187 provided at the front end of a protruding part 186. In addition, the insulating cover 164 is configured not to have an opening for drawing the winding end portions 154 and 155 of the second partial winding 151B, as a difference from the insulating cover 163.

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

Fig. 25 is a diagram showing the overlapping positions of the film materials FM in a state where the coil modules 150A and 150B are arranged in the circumferential direction. As described above, in each of the coil modules 150A and 150B, the periphery of the intermediate wire portion 152 is covered with the film material FM so as to overlap the circumferential side surfaces of the intermediate wire portion 152, which is the opposing portion opposing the intermediate wire portion 152 in the partial winding 151 of the other phase (see fig. 20 and 23). Further, in a state where the coil modules 150A, 150B are arranged in the circumferential direction, the overlapped portions OL of the film materials FM are arranged on the same side (the circumferential right side in the figure) on both sides in the circumferential direction. With this configuration, in each of the intermediate lead portions 152 in the partial windings 151A, 151B of different phases adjacent in the circumferential direction, the overlapping portions OL of the film materials FM do not overlap each other in the circumferential direction. In this case, a maximum of three film materials FM are stacked between the intermediate lead portions 152 arranged in the circumferential direction.

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

The coil modules 150A and 150B are different 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 overlapped in the axial direction at one end side in the axial direction of the coil modules 150A and 150B and the insulating covers 162 and 164 are overlapped in the axial direction at the other end side in the axial direction.

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

As shown in fig. 26, in a state where the plurality of first coil modules 150A are assembled to the core assembly CA, the plurality of insulating covers 161 are respectively disposed so that the side surface portions 171 are in a state of abutting or approaching each other. Each insulating cover 161 is disposed so that a boundary 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, a second coil module 150B is further incorporated into the integrated body of the core assembly CA and the first coil module 150A. With this assembly, the plurality of insulating covers 163 are disposed so that the side surface portions 181 are in a state of abutting against or approaching each other. In this state, the bridging portions 153A and 153B are arranged so as to intersect with each other on a circle on which the intermediate wire portions 153 are arranged in the circumferential direction. Each insulating cover 163 is disposed so that the protruding portion 186 and the insulating cover 161 overlap each other in the axial direction and the through hole 187 of the protruding portion 186 and the through hole portion formed by each recess 177 of the insulating cover 161 communicate with each other in the axial direction.

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

As shown in fig. 28 (a) and (b), the insulating cover 161 and the protruding portion 186 of the insulating cover 163 are fixed by a fixing pin 191 as a fixing member in an overlapped portion where they are overlapped with each other in an engaged state. More specifically, the fixing pin 191 is inserted into the recesses 105, 177 and the through hole 187 of the insulating cover 163 while the recesses 105, 177 of the inner cylindrical member 81, the recesses 177 and the through hole 187 are aligned. Thus, the insulating covers 161 and 163 are integrally fixed to the inner tube member 81. According to this structure, the coil modules 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, an adhesive is filled through the through holes 188 provided in the insulating cover 163. Thereby, the insulating covers 161 and 163 overlapped in the axial direction are firmly coupled to each other. Note that although the through-hole 188 is shown in the range from the upper surface to the lower surface of the insulating cover 163 for convenience in fig. 28 (a) and (b), the through-hole 188 is actually provided in a thin plate portion formed by wall reduction or the like.

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

In the present embodiment, 18 insulating covers 161 and 163 are arranged to overlap each other in the axial direction at the coil side end CE, and recesses 105 are provided at 18 positions equal in number to the number of the insulating covers 161 and 163 on 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 are in a state of abutting or approaching each other, and therefore, the following state is achieved: through holes extending in the axial direction are formed through the recesses 177 of the insulating cover 162, and the through holes are aligned with the recesses 106 on the axial end surface of the outer cylindrical member 71. Then, by assembling the second coil module 150B, the through hole 187 on the insulating cover 164 side is positioned to match the through hole on the insulating cover 163 side and the recess 106 of the outer cylindrical member 71, and the insulating covers 162 and 164 are integrally fixed to the outer cylindrical member 71 by inserting the fixing pin 191 into the recesses 106 and 177 and the through hole 187.

When assembling coil modules 150A and 150B to core assembly CA, it is preferable to attach all first coil modules 150A to the outer peripheral side of core assembly CA in advance, and then assemble all second coil modules 150B and fix them by 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, 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 U-phase bus 211, a connection terminal connected to the V-phase bus 212, a connection terminal connected to the W-phase bus 213, and a connection terminal connected to the neutral-point bus 214. The connection terminals 202 are provided in the same number as the winding end portions 154, 155 of the respective partial windings 151 in the coil module 150, and the winding end portions 154, 155 of the respective partial windings 151 are connected to the connection terminals 202, respectively. Thereby, the bus bar module 200 is connected to the U-phase partial winding 151, the V-phase partial winding 151, and the W-phase partial winding 151, respectively.

The input-output terminal 203 is constituted by, for example, a bus bar member, and is provided in a direction extending in the axial direction. The input/output terminal 203 includes an input/output terminal 203V for the U-phase input/output terminal 203U, V and an input/output terminal 203W for the W-phase. The input/output terminal 203 is connected to each of the bus bars 211 to 213 for each phase in the annular portion 201. The input/output terminals 203 are used to input/output electric power to/from an inverter, not shown, for the phase windings of the respective phases of the stator winding 61.

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

The annular portion 201 has a plurality of projecting portions 205 projecting toward the inner peripheral side as portions to be fixed to the stator holder 70, and through holes 206 extending in the axial direction are formed in the projecting portions 205.

Fig. 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 fixed portion where the bus bar module 200 is fixed. Note that, the structure of the stator holder 70 before the bus bar module 200 is assembled is referred to fig. 12.

In fig. 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 portion 223, the pressing portion 223 pressing an upper surface of the annular portion 201 of the bus bar module 200; and a bent portion 224, the bent portion 224 being provided between the fastened portion 222 and the pressing portion 223.

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

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

As shown in fig. 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 of the rotating electric machine 10 will be described.

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

Fig. 33 is a longitudinal sectional view showing a state where the relay member 230 is attached to the housing cover 242, and fig. 34 is a perspective view of the 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 has a main body portion 231 fixed to the housing cover 242 and a terminal insertion portion 232 inserted into a through hole 242a of the housing cover 242. The terminal insertion portion 232 has three insertion holes 233 through which the input/output terminals 203 of each phase are inserted one by one. The three insertion holes 233 have long-shaped cross-sectional openings and are formed so that the longitudinal directions thereof are all aligned in substantially the same direction.

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

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

Next, the configuration of a control system for controlling the rotating electric machine 10 will be described. Fig. 35 is a circuit diagram of a control system of the rotary 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, for example. In the upper and lower arms of each phase, a capacitor 264 for supplying electric charge to each of the switches 261 and 262, which supplies electric charge necessary for switching, is connected in parallel to the series-connected body of the switches 261 and 262.

One ends of the U-phase winding, the V-phase winding, and the W-phase winding are connected to intermediate connection points between the switches 261, 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 built 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 grooveless structure (non-pole tooth structure), the inductance of the stator 60 is reduced to reduce the electrical time constant, and when the electrical time constant is reduced, it is desirable to increase the switching frequency (carrier frequency) and increase the switching speed. In this regard, since the capacitor 264 for charge supply is connected in parallel to the series connection body of the switches 261 and 262 of each phase, the wiring inductance is reduced, and even with a configuration in which the switching speed is increased, a suitable surge countermeasure can be taken.

The high-potential side terminal of the inverter 260 is connected to the positive terminal of the dc power supply 265, and the low-potential side terminal is connected to the negative terminal (ground) of the dc power supply 265. The dc power supply 265 is formed of, for example, a battery pack in which a plurality of single cells are connected in series. Further, 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 motoring torque command value or the generating torque command value of the rotating electrical machine 10 using the torque-dq map. In addition, for example, when the rotating electrical machine 10 is used as a power source for a vehicle, the generated torque command value is a regenerative torque command value.

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

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

The three-phase converter 275 converts the command voltages for the d-axis and q-axis into command voltages for the U-phase, V-phase, and W-phase. The above-described units 271 to 275 are feedback control units that perform feedback control of the fundamental wave current based on the dq conversion theory, and the command voltages for 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, a 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 a current detection value detected by a current sensor provided for each phase into a d-axis current and a q-axis current. Torque estimation unit 283 calculates torque estimation values corresponding to the U-phase, V-phase, and W-phase based on the d-axis current and the q-axis current. The torque estimation unit 283 may calculate the voltage amplitude command based on map information that sets the relationship between the d-axis current, the q-axis current, and the voltage amplitude command.

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

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

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

(modification example)

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

The structure of the magnets in the magnet unit 22 may also be changed as described below. In the magnet unit 22 shown in fig. 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. In this configuration, the magnet magnetic path length of the magnet 32 can be made longer than the radial thickness dimension, and the magnetic conductance can be improved.

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

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

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

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

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

Instead of the outer rotor type surface magnet type rotating electrical machine, the rotating electrical machine 10 may be embodied as an inner rotor type surface magnet type rotating electrical machine. Fig. 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, thereby constituting a core assembly CA. The plurality of coil modules 310A and 310B are assembled to the inside of the stator core 62 in the radial direction.

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

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

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 projecting 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 is fixed by a fixing pin 321 at each of the above-described 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, in addition to a rotating-field rotating electric machine in which a field element is a rotor and an armature is a stator, a rotating-armature rotating electric machine in which an armature is a rotor and a field element is a stator may be used.

(modification 2)

In the above embodiment or the above modification, the configuration of the conductor material CR as the conductor may be changed as follows. The following description focuses on the structure of the conductor material CR in this modification. In this modification, the description will be given mainly of the portions of the embodiments and modifications that differ in the structure described above. In this modification, the configuration of the first embodiment will be described as an example of the basic configuration of the rotating electric machine 10.

In the above embodiment, the stator 60 has the non-slotted structure (see fig. 4 and the like), and the magnet unit 22 has the magnet 32 (see fig. 7) having the polarity anisotropy that improves the magnetic flux density at the d-axis. Therefore, the magnetic flux of the magnet interlinked with each of the conductor materials CR increases, and as a result, the eddy current loss is expected to increase. Therefore, modification 2 is configured as follows.

Fig. 41 (a) is a cross-sectional view of the intermediate lead portion 152 of the first coil module 150A in modification 2, and fig. 41 (b) is an enlarged cross-sectional view of a part of the intermediate lead portion 152 in fig. 41 (a). Also, fig. 42 shows an enlarged cross-sectional view of the wire material CR. In modification 2, the first coil module 150A is exemplified to explain the wire material CR, but the same applies to the wire material CR of the second coil module 150B.

As shown in fig. 41 and 42, in modification 2, the cross section of the wire member CR is substantially quadrangular. The lead member CR is wound around the intermediate lead portion 152 constituting the first coil module 150A so as to be stacked in the circumferential direction and the radial direction.

Each of the lead members CR is covered with an insulating film 602 in a state where a plurality of wire rods 601 are bundled. Thereby, insulation is secured between the conductor materials CR overlapping each other in the circumferential direction or the radial direction and between the conductor materials CR and the stator core 62, respectively.

In addition, the stator winding 61 made of the wire material CR maintains insulation through the insulating film 602 except for the exposed portion for connection. The exposed portions are, for example, the winding end portions 154 and 155.

The wire 601 includes a conductor 603 through which current flows and a fusion layer 604 covering the surface of the conductor 603. The conductor 603 is, for example, a conductive metal such as copper. The conductor 603 has a rectangular cross section. In modification 2, the cross section of the conductor 603 is a flat rectangular shape having a radial thickness dimension longer than a circumferential thickness dimension. The fusion layer 604 is, for example, an epoxy adhesive resin. The heat resistance is about 150 ℃.

The fusion layer 604 is thinner than the insulating film 602, and has a thickness of, for example, 10 μm or less. In the wire 601, only the fusion layer 604 is formed on the surface of the conductor 603, and no separate insulating layer is provided. The fusion layer 604 may be formed of an insulating member. That is, this is an idea of achieving both the resin and the insulation of the self-fuse. Although the insulating layer and the fusion layer are usually separated, the epoxy adhesive resin corresponding to the fusion layer 604 also doubles as an insulating layer, omitting a structure generally referred to as an insulating layer.

In addition, the fusion layer 604 melts at a lower temperature than the insulating film 602. Or may be characterized by a relatively high dielectric constant. Due to the feature of melting at a low temperature, there is an effect that conduction is easily performed at the end portion between the wire rods 601. In addition, welding and the like are easily performed. The reason why the dielectric constant may be high is that the potential difference between the wires 601 is smaller than the potential difference between the conductor materials CR. By setting in this way, even if the fusion layer 604 melts, the eddy current loss can be effectively reduced only by the contact resistance.

Further, since the fusion layer 604 covers the surface of the conductor 603 so as to have a substantially uniform thickness, the cross section of the wire 601 has a flat rectangular shape in which the thickness in the radial direction is longer than the thickness in the circumferential direction in accordance with the cross-sectional shape of the conductor 603.

When a plurality of wire rods 601 are bundled, as shown in fig. 41 (b) and 42, a plurality of wire rods 601 are stacked in the circumferential direction. On the other hand, the wire 601 is arranged only one layer in the radial direction. That is, the wire member CR is constituted by a plurality of (four in this modification 2) wire members 601a to 601d arranged in one layer in the radial direction. In this modification, for convenience of explanation, the wire member CR and the like are shown linearly in fig. 42. Thus, the wires 601a to 601d are arranged in the circumferential direction.

Then, in a state where the plurality of wires 601 are bundled, the fusion layers 604 are in contact with each other and fused. Thereby, the adjacent wire rods 601 are fixed to each other, and vibration and sound generated by friction between the wire rods 601 are suppressed. In addition, the shape is maintained by bundling and collecting a plurality of wires 601 including the fusion layer 604 and fusing the fusion layer 604 to each other. In addition, the laminated state of the wire rods 601 is maintained.

The insulating film 602 is made of resin, and is, for example, modified PI enamel resin resistant to heat at 220 to 240 ℃. The oil resistance was obtained by modifying PI. ATF and the like are not corroded by hydrolysis and sulfur. In addition, in this case, the epoxy adhesive resin has a linear expansion coefficient larger than that of the modified PI enamel resin.

The insulating film 602 is formed in a wide band shape, and is spirally wound around the outer peripheries of the bundled plurality of wire rods 601. As shown in fig. 43, the insulating films 602 are spirally wound with a slight shift in the extending direction (the left-right direction in fig. 43) of the wire 601 so that the insulating films 602 overlap each other. Specifically, the insulating film 602 is wound so that about half of its width is overlapped. Thus, the insulating film 602 is formed as a double layer at any portion except for the end portion. The number of layers is not necessarily two, and three or more layers may be used. Further, the layer may be one layer as long as no gap is formed.

The insulating film 602 is configured to have higher insulating performance than the fusion layer 604 of the wire 601 and to be capable of insulating phases from each other. For example, when the thickness of the fusion layer 604 of the wire 601 is, for example, about 1 μm, it is desirable that the total thickness of the insulating film 602 is about 9 μm to 50 μm, so that the insulation between the phases can be preferably performed. Specifically, when the insulating film 602 is formed of two layers, one thickness may be about 5 μm.

Here, fig. 44 shows an electrical connection form of a plurality of wire materials 601a to 601d constituting the conductor member CR. The stator winding 61 is formed by winding the conductor material CR, and is connected to other stator windings 61 or a neutral point at the winding ends 154 and 155 of the conductor material CR. Therefore, the plurality of wires 601a to 601d constituting the wire material CR are connected to each other.

Next, a method of manufacturing the stator winding 61 of the rotating electric machine 10 will be described in more detail with reference to fig. 45. Fig. 45 is a flowchart showing a flow of the manufacturing method, and fig. 46 is a schematic view of a manufacturing line.

The conductors 603 are drawn from a plurality of cylindrical bobbins 701 (reels) around which the linear conductors 603 are wound, respectively, and fusion layers 604 are applied to the surfaces (step S101). Further, the wire material 601 with the fusion layer 604 applied to the conductor 603 may be wound around the bobbin 701 and stored, and the wire material 601 may be drawn from the bobbin 701.

Then, the wires 601 are bundled and gathered (step S102). At this time, the fused layers are brought into contact with each other and fused. In step S102, each wire 601 is linearly formed by applying a tension. Further, before the collection (before step S102), the linear shape may be set. The step S102 is a gathering process.

On the other hand, the wide band-shaped insulating film 602 is processed to be further thinned by rolling (step S103). Further, work hardening by rolling improves the tensile strength of the insulating film 602 compared to that before the work. Step S103 is a rolling step.

Then (after step S102 and step S103), the rolled strip-shaped insulating film 602 is spirally wound around the outer peripheries of the bundled plurality of wire rods 601, and the outer peripheries are covered (step S104). Step S104 is a covering step. Then, in a state where the plurality of wire rods 601 are covered with the insulating film 602, a crushing step is performed so that the cross section has a predetermined shape (for example, rectangular shape) (step S105). Thereby, the wire material CR is formed. The crushing step may be performed after the collecting step of the binding wire rods 601.

Then, as described in the first embodiment, the stator winding 61 is formed by winding the wire material CR (step S106). For example, the stator winding 61 is formed by winding the wire material CR along the stator winding bobbin 702. Step S106 is a winding process. The straightness of wire 601 is maintained until wire 601 is wound to form stator winding 61 (step S102 to step S106). That is, the manufacturing line is formed so that the wire material CR is not wound around the cylindrical bobbin again after the wire material CR is formed.

With the configuration of modification 2, the following effects can be obtained.

The magnet unit 22 is configured to be oriented such that the direction of the easy axis is more parallel to the d axis on the d axis side, which is the magnetic pole center, than on the q axis side, which is the magnetic pole boundary. Thus, the closer to the d-axis, the more easily the magnetic flux density becomes parallel to the radial direction. That is, the radial component of the magnetic flux density tends to be larger as the d-axis is closer, and the circumferential component tends to be smaller. Thus, the eddy current loss can be more effectively suppressed by reducing the thickness of the wire 601 in the circumferential direction.

Further, since the cross section of each of the wires 601a to 601d is a flat shape that is long in the radial direction, the effect of reducing the circulating current is improved. That is, the magnet magnetic flux varies according to the circumferential position of the magnet unit 22. Therefore, the magnetic flux of the magnet interlinked with the respective wire materials 601a to 601d of the respective conductive wire materials CR changes with the rotation of the rotor 20, and a difference is generated between electromotive forces generated in the respective wire materials 601a to 601d at a certain time. Here, in modification 2 described above, the cross section of each of the wires 601a to 601d is a flat shape that is long in the radial direction. Therefore, in each of the conductor members CR, the width dimension in the circumferential direction of the plurality of line materials 601a to 601d arranged in line can be reduced. As a result, in each of the lead members CR, the difference in electromotive force generated in each of the wire members 601a to 601d at a certain time can be reduced. This reduces the difference in electromotive force generated in the wire rods 601a to 601d constituting the wire material CR, thereby reducing the circulating current.

Further, by forming the flat shape long in the radial direction, the gap in the radial direction in the lead member CR, that is, the gap between the conductor 603 or between the insulating film 602 and the conductor 603 can be reduced, and the space factor of the conductor 603 can be increased.

The conductor materials CR are insulated from each other by an insulating film 602. On the other hand, although the conductors 603 of the wires 601a to 601d are covered with the fusion layer 604, the conductors 603 may be in contact with each other and electrically connected because no insulating layer is provided. However, the potential difference between the conductors 603 is small, and even if the fusion layer 604 is broken when the plurality of wires 601a to 601d are bundled or the insulating film 602 is covered, the area of contact between the conductors 603 is very small, and the contact resistance is very large. Therefore, even if the insulation is not complete, the eddy current can be suppressed from flowing between the conductors 603.

Therefore, an insulating layer is not provided on the surface of the conductor 603, but the fusion layer 604 is provided directly on the conductor 603 and the fusion layers 604 are fused to each other. This eliminates the need for providing an insulating layer. Further, by providing the fusion layer 604, the plurality of wires 601a to 601d can be easily held in a bundled state, and can be easily covered with the insulating film 602. As described above, the lead member CR and the rotating electrical machine 10 are easily manufactured, and the space factor of the conductor 603 can be increased because the insulating layer of the wire members 601a to 601d is omitted.

In each of the conductor members CR, the wires 601a to 601d are arranged in one layer in the radial direction. Therefore, unlike the structure in which a plurality of wires 601a to 601d of each conductor member CR are stacked in the radial direction, a difference in electromotive force due to a difference in the arrangement position of the wires 601a to 601d in the radial direction does not occur. This can reduce the difference in electromotive force generated in the wire rods 601a to 601d constituting the wire material CR, and can reduce the circulating current flowing through the wire material CR.

In addition, by providing only one layer, the gap between the conductors 603 in the radial direction in the insulating film 602 can be eliminated as compared with the case of providing a plurality of layers. That is, the space factor of the conductor 603 can be increased. Further, the wires 601 of the conductor member CR are arranged in one layer in the radial direction. Therefore, unlike the structure in which a plurality of wire rods 601 of the conductor member CR are stacked in the radial direction, a difference in electromotive force due to a difference in the arrangement position of the wire rods 601 in the radial direction does not occur. That is, although the magnetic flux generally differs depending on the position in the radial direction, in the above configuration, the difference in electromotive force due to the difference in the arrangement position in the radial direction of the wire 601 does not occur. This can reduce the difference in electromotive force generated in the wire rods 601a to 601d, and can reduce the circulating current.

The insulating film 602 is formed in a band shape and is spirally wound around the outer circumference of the bundled plurality of wires 601. Since the strip-shaped insulating film 602 is wound around the plurality of wire rods 601 to form the conductor material CR, the insulating film 602 can be made thinner than in the case of resin molding or the like of the plurality of wire rods 601. Further, since the fusion bonding layer 604 performs fusion bonding, the wire 601 can maintain a shape in a bundled state, and the band-shaped insulating film 602 can be easily wound.

Unlike the conventional step of forming a film by extrusion, the insulating film 602 can be work-hardened while being thin because it is roll-processed. Therefore, in the case of winding the wire material CR to form the stator winding 61, the insulating film 602 is not broken. That is, the insulating film 602 serving as a reinforcing tape can receive a force specific to the dividing line, in which the divided wires 601 move irregularly when they are bent and the insulating film 602 is broken. In addition, when the film is formed by extrusion, there is a possibility that the film may be cracked. Further, since the insulating film 602 can be made thin, the space factor of the conductor 603 with respect to the housing space of the stator winding 61 can be increased.

In the covering step of step S104, when the insulating film 602 is wound around the outer peripheries of the bundled plurality of wire rods 601, the insulating film 602 is spirally wound so as to overlap. This can prevent foreign substances such as dust and water from reaching the wire 601 through the gap between the insulating films 602 from the outside. Further, since the insulating films 602 are overlapped with each other, a gap is not easily generated even if the conductor material CR is wound to form the stator winding 61. In addition, although the gaps between the wires 601 are not satisfactorily subjected to electrodeposition, enamel coating, or the like, and bubbles are generated, the problem can be solved by using the band-shaped insulating film 602.

When the wire material CR wound around the bobbin is used after the wire material CR is formed (after the covering step), the wire material CR drawn from the bobbin is bent, and a slight deviation in straightness occurs, thereby preventing an improvement in space factor. That is, when the conductive wire material CR is wound around the bobbin, there is a problem unique to the divided line in that the inner line and the outer line of the bobbin are stretched differently. Specifically, only the wire outside the spool is in tension. When the conductor material CR stretched only outside to form the stator winding 61 is drawn from the bobbin, a part of the conductor material CR is contracted, and therefore, the conductor material CR is waved. When winding is performed to form the stator winding 61, the lead wire materials CR generate a gap therebetween, which prevents the space factor from being increased and increases the copper loss.

Therefore, in the collecting step of step S101, pressure is applied to the plurality of wire rods 601 in a bundled state to form a straight line, and after the collecting step, each wire rod 601 is maintained in a straight line until the lead wire material CR is wound to form the stator winding 61 in the winding step of step S106. Therefore, the straightness of the wire member CR can be improved as compared with the case where the wire member CR is wound around the cylindrical bobbin again. That is, when the wire material CR is wound around the bobbin, the straightness of the wire material CR is not likely to be deviated due to the difference in curvature between the outer periphery side and the inner periphery side, and the wavy deformation is not likely to occur. Therefore, when winding the conductor materials CR to form the stator winding 61, the conductor materials CR are less likely to form a gap therebetween, and the space factor can be increased.

The first coil module 150A has a shape in which the partial winding 151 at the coil side end CE is bent radially inward, i.e., toward the stator core 62. However, as described above, since the insulating film 602 is roll-processed to improve the tensile strength, it is not easily broken and can be appropriately insulated. Further, the coil edge portion CE is formed by bending in the radial direction, whereby the axial length of the stator winding 61 can be suppressed.

The thickness of the insulating film 602 is made thicker than the fusion layer 604. Thus, the required intra-phase and inter-phase withstand voltages can be ensured, and the eddy current loss can be prevented without increasing the copper loss. Copper loss is caused by the reduction in area of copper due to the increase in film.

In the case where the magnet unit 22 is configured as described above, the magnetic flux easily passes straight in the radial direction due to the orientation of the magnet 32, and therefore the magnetic flux in the lateral direction becomes small. That is, since the magnetic flux passing through the circumferential direction is easily reduced, it is not necessary to make the wire 601 excessively thin in the circumferential direction. Covering wire 601 with a thinner fusion layer 604 can increase the space factor of conductor 603.

(Another example of modification 2)

The structure in modification 2 may be changed as described below. In this other example, a description will be given mainly of a portion different from the structure described in the above embodiments, modifications, and the like. In this modification, the configuration of modification 2 will be described as an example of the basic configuration.

In the magnet 32 of modification 2, as shown in fig. 47, a plurality of arc-shaped easy magnetization axes centered on an orientation center point C10 set on the q-axis may be oriented, and a magnet magnetic path may be formed along the easy magnetization axes. The plurality of arc-shaped easy magnetization axes include an easy magnetization axis on an arc OA which is centered on an orientation center point C10 set on the q-axis and passes through a first intersection point P1 between the d-axis side end and the stator side circumferential surface (magnetic flux acting surface 34). The shape of the magnetic path of the magnet may be an arc shape of a part of a perfect circle or an arc shape of a part of an ellipse. Further, although the orientation center point C10 is on the q-axis, it may not be on the q-axis. However, it is desirable that the orientation center point C10 be on the q-axis side as compared with the d-axis. In fig. 47, the orientation center point C10 is set between the magnet 32 and the stator winding 61, but may be set at a position closer to the opposite side circumferential surface of the stator (the magnet holder 31 side) than the stator side circumferential surface (the magnetic flux acting surface 34).

Although the tangent Tn1 at the first intersection P1 may be set to be parallel to the d-axis, as shown in fig. 47, the tangent at the first intersection P1 on the arc OA may be set to have a predetermined orientation inclination angle θ 10 with respect to the d-axis. To explain in detail, in the magnet 32, the magnetization easy axis may be arranged so as to have an inclination angle within a predetermined angle range (for example, 15 ° to 45 ° [ deg ]) with respect to the d-axis at least at the first intersection point P1 of the d-axis side end portion and the stator side circumferential surface.

In addition, it is considered that, compared to the case where the easy magnetization axis is parallel to the d-axis, the vector of the magnetic flux flowing out from the stator side peripheral surface (magnetic flux acting surface 34) can be concentrated on the d-axis by inclining the plurality of easy magnetization axes to some extent, and the magnetic flux density of the d-axis can be increased.

However, if the magnetization easy axis is inclined more than a certain degree and is excessively inclined, the vector component in the radial direction of the magnetic flux flowing out from the stator side circumferential surface (magnetic flux acting surface 34) is excessively small, and the magnetic flux density of the d-axis decreases. Therefore, the predetermined angle range of the orientation inclination angle is set so that the magnetic flux density at the d-axis becomes larger at least as compared with the case of being parallel to the d-axis, in consideration of the shape of the magnet 32, the size of the air gap, and the like.

In modification 2 described above, a double-rotor type rotating electric machine configured to sandwich the stator winding 61 between the magnets 32 may be used in order to increase the linear force of the magnetic flux density of the magnets 32. Specifically, as shown in fig. 48, in the double rotor type rotating electrical machine 10, the magnet unit 22 includes a first magnet portion 501 disposed to face the intermediate lead portion 152 on the radially inner side of the intermediate lead portion 152, and a second magnet portion 502 disposed to face the intermediate lead portion 152 on the radially outer side of the intermediate lead portion 152. The first magnet portion 501 and the second magnet portion 502 are both annular, and the first magnet portion 501 has a smaller diameter than the second magnet portion 502. In addition, each of the first magnet portion 501 and the second magnet portion 502 has a plurality of magnetic poles whose polarities alternate in the circumferential direction. The first magnet portion 501 and the second magnet portion 502 are arranged so as to sandwich the intermediate lead portion 152 in the radial direction. At this time, predetermined air gaps are formed between the first magnet portion 501 and the intermediate lead portion 152, and between the second magnet portion 502 and the intermediate lead portion 152.

The magnetic pole of the first magnet portion 501 on the d-axis and the magnetic pole of the second magnet portion 502 that is radially opposed to the magnetic pole of the first magnet portion 501 are set to be different. That is, the N pole of the first magnet portion 501 and the S pole of the second magnet portion 502 are arranged to be diametrically opposed, and the S pole of the first magnet portion 501 and the N pole of the second magnet portion 502 are arranged to be diametrically opposed.

With the above configuration, the magnetic flux density at the d-axis is easily parallel to the radial direction. That is, the radial component of the magnetic flux density tends to be large, while the circumferential component tends to be small. As a result, as shown in fig. 48 (b), the eddy current loss can be more effectively suppressed by reducing the thickness of the conductor 603 in the circumferential direction.

In modification 2 described above, the linear expansion coefficient (linear expansion coefficient) of the fusion layer 604 may be different from the linear expansion coefficient of the insulating film 602. That is, as described above, the potential difference between the conductors 603 is small, and even if the fusion layer 604 is broken when bundling a plurality of wires 601 or when covering the insulating film 602, the area of contact between the conductors 603 is very small, and the contact resistance is very large. Therefore, even if the insulation is not complete, the eddy current can be suppressed from flowing between the conductors 603. In addition, even if the fusion layer 604 is broken after the manufacture and the conductors 603 are brought into contact with each other, it can be said that there is no problem. Therefore, an arbitrary material having a linear expansion coefficient different from that of the insulating film 602 can be selected as the fusion layer 604, and design becomes easy. For example, the coefficient of linear expansion of the fusion layer 604 may be made larger than the coefficient of linear expansion of the insulating film 602.

Of course, the coefficient of linear expansion of the fusion layer 604 may be smaller than that of the insulating film 602. When the linear expansion coefficient of the fusion layer 604 is smaller than that of the insulating film 602, the fusion layer 604 is less likely to be broken, and the contact portion between the conductors 603 is not increased, whereby an increase in eddy current loss can be suppressed.

In modification 2 described above, the linear expansion coefficient (linear expansion coefficient) of the fusion layer 604 may be made equal to the linear expansion coefficient of the insulating film 602. This can suppress the fusion layer 604 and the insulating film 602 from cracking simultaneously.

In modification 2, the coefficient of linear expansion (linear expansion coefficient) of the fusion layer 604 may be different from the coefficient of linear expansion of the conductor 603. In addition, when the coefficient of linear expansion (linear expansion coefficient) of the fusion layer 604 is between the coefficient of linear expansion of the conductor 603 and the coefficient of linear expansion of the insulating film 602, the fusion layer 604 serves as a buffer material, and cracking of the insulating film 602 can be suppressed.

As the insulating film 602 in modification 2, PA, PI, PAI, PEEK, or the like may be used. The fusion layer 604 may be formed of fluorine, polycarbonate, silicon, epoxy resin, polyethylene naphthalate, or LCP.

In modification 2 described above, the cross-sectional shape of the conductor 603 need not be rectangular as long as it is a flat shape that is long in the radial direction, and may be, for example, an elliptical shape or a polygonal shape. The cross-sectional shape of the wire material CR may be any of a hexagon, a pentagon, a quadrangle, a triangle, and a circle.

Although the crushing step is provided in modification 2, the crushing step may be omitted as long as the conductors 603 are flat and rectangular and can be bundled without a gap. In the case where the conductor 603 is a circular wire, it is desirable to provide a crushing step. The crushing step may be performed after the wires 601 are bundled, but the crushing step may be provided before the wires 601 are bundled so that the cross-sectional shape of each wire 601 becomes a predetermined shape.

In modification 2 described above, a gap may be provided between the insulating film 602 and the wire 601 or between the wires. The shape of the conductor 603 and the shape of the fusion layer 604 are not necessarily all the same, and the shape of part or all of the conductor 603 and the fusion layer 604 may be different by a crushing step or the like. It is needless to say that the conductor 603 or the fusion layer 604 may be slightly deformed in shape in part or in whole by the crushing step.

In modification 2 described above, the conductor 603 of the wire 601 may be formed as a composite body in which thin fibrous conductive members are bundled. For example, the conductor may be a composite of CNT (carbon nanotube) fibers. As the CNT fiber, a fiber including a boron-containing microfiber in which at least a part of carbon is substituted with boron may be used. As the carbon micro fiber, in addition to the CNT fiber, a Vapor Growth Carbon Fiber (VGCF) or the like can be used, but the CNT fiber is preferably used.

In the above embodiment and modification 2, the stator winding 61 is covered and sealed by the sealing members such as the insulating covers 161 to 164 and the insulating cover 157, but may be sealed by resin molding so as to cover the periphery of each wound conductor material CR. In this case, it is desirable to provide a sealing member formed by resin molding in a range including the coil side end CE of the stator winding 61. That is, it is desirable that substantially the entire stator winding 61 except for the winding end portions 154, 155, i.e., the connection portions, be resin-sealed.

When the rotating electric machine 10 is used as a power source for a vehicle, the sealing member is preferably made of a highly heat-resistant fluororesin, an epoxy resin, a PPS resin, a PEEK resin, an LCP resin, a silicone resin, a PAI resin, a PI resin, or the like. In addition, when considering the linear expansion coefficient from the viewpoint of suppressing cracking due to a difference in expansion, it is desirable that the sealing member and the insulating film 602 have the same material. That is, it is desirable to exclude silicone resins whose linear expansion coefficients are generally multiples or more of those of other resins. Among electric products that do not have a device that uses combustion, such as electric vehicles, PP0 resin, phenol resin, and FRP resin, which have heat resistance of about 180 ℃, are also candidates. In the field where the ambient temperature of the rotating electric machine is regarded as lower than 100 ℃, there is no limitation described above.

In addition, in the case where the sealing member is provided, the linear expansion coefficient of the sealing member may be different from the linear expansion coefficient of the insulating film 602. For example, the insulating film 602 may have a linear expansion coefficient smaller than that of the sealing member and smaller than that of the fusion layer 604. This prevents simultaneous cracking. That is, the insulating film 602 having a small linear expansion coefficient can temporarily prevent expansion due to external temperature change. And vice versa.

In addition, the linear expansion coefficient of the insulating film 602 may be a value between the linear expansion coefficient of the sealing member and the linear expansion coefficient of the fusion layer 604. For example, the sealing member may have a linear expansion coefficient larger than that of the insulating film 602, and the insulating film 602 may have a linear expansion coefficient larger than that of the fusion layer 604. That is, the closer to the outside, the higher the linear expansion coefficient. In addition, the linear expansion coefficient of the sealing member may be smaller than that of the insulating film 602, and the linear expansion coefficient of the insulating film 602 may be smaller than that of the fusion layer 604. That is, the closer to the inside, the higher the linear expansion coefficient. Thus, even if there is a difference between the linear expansion coefficient of the sealing member and the linear expansion coefficient of the fusion layer 604, the insulating film 602 can be made to be a buffer material by interposing the insulating film 602 having a linear expansion coefficient therebetween. Therefore, it is possible to suppress the sealing member and the fusion layer 604 from being simultaneously cracked due to a temperature change outside the stator winding 61 or heat generation of the conductor 603.

In modification 2 described above, the adhesion strength between the conductor 603 and the fusion layer 604, the adhesion strength between the fusion layer 604 and the insulating film 602, and the adhesion strength between the sealing member and the insulating film 602 may be different. For example, the adhesive strength may be configured to be weaker as the outer side is closer to the outer side. The magnitude of the adhesive strength can be determined by, for example, the tensile strength required when peeling the two films. By setting the adhesive strength as described above, even if a difference in internal and external temperatures occurs due to heat generation or cooling, cracking (simultaneous cracking) can be suppressed on both the inner layer side and the outer layer side.

In modification 2, after the wire member CR is formed, the wire member CR may be wound around a cylindrical bobbin and stored. That is, as shown in fig. 49, after the wire member CR is formed in step S105, the wire member CR may be wound around a cylindrical bobbin and stored (step S105 a). Then, the wire material CR may be drawn from the bobbin (step S105b), and the stator winding 61 may be formed by winding the wire material CR as described in the first embodiment (step S106).

In such a case, when the wire member CR is wound around the bobbin, the straightness of the wire member CR varies depending on the difference in curvature between the outer periphery side and the inner periphery side, and wavy deformation occurs. Therefore, when winding conductor material CR to form stator winding 61, a gap is easily formed between conductor material CR. Therefore, the minute gaps between the wires are filled with a filler such as varnish (step S107). This can reduce vibration. Further, since the wire material CR is wound around the cylindrical bobbin once after the formation thereof, it is not necessary to maintain the straightness of the wire material 601 until the winding thereof for forming the stator winding 61 (step S102 to step S106) from the time when the wire material 601 is made straight. That is, it is not necessary to implement the above-described steps in one manufacturing line, and the degree of freedom of the manufacturing line can be improved.

Even in the case where the rotating electrical machine includes the pole teeth or the structure equivalent to the pole teeth, the circulating current can be reduced by applying the structure of modification 2.

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

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

Claims (5)

1. A rotating electrical machine (10) includes a field element (20) including a magnet portion (22) having a plurality of magnetic poles whose polarities alternate in a circumferential direction, and an armature (60) having an armature winding (61) of a plurality of phases, either of which is a rotor,

the armature winding of each phase is formed by winding a Conductor (CR), and has conductor portions (152) arranged at positions facing the magnet portions at predetermined intervals in the circumferential direction,

each of the lead portions is formed by the leads being arranged in one or more rows in the circumferential direction and in one or more rows in the radial direction,

each of the wires is formed by covering a plurality of wires 601 with an insulating film 602 in a state where the wires are laminated in the circumferential direction,

each of the wires is formed by connecting the wires constituting the wire in parallel,

the cross section of each wire rod is a flat shape that is long in the radial direction.

2. The rotating electric machine according to claim 1,

the wire has a cross section of a flat shape long in the radial direction and includes a conductor (603) through which a current flows and a fusion layer (604) covering the surface of the conductor,

the fusion layer is thinner than the insulating film, and the fusion layers are brought into contact with each other and fused in a state where a plurality of wires (601) are stacked in the circumferential direction.

3. The rotating electric machine according to claim 1 or 2,

in each of the conductive wires, the wires are arranged only one layer in a radial direction.

4. The rotating electric machine according to any one of claims 1 to 3,

the magnet portions are respectively oriented such that the direction of the easy magnetization axis is more parallel to the d-axis on the d-axis side as the magnetic pole center than on the q-axis side as the magnetic pole boundary, and a magnet magnetic path is formed along the easy magnetization axis.

5. The rotating electric machine according to any one of claims 1 to 3,

the magnet portion includes a first magnet portion (501) and a second magnet portion (502), the first magnet portion is disposed so as to face the lead portion on the radially inner side of the lead portion, the second magnet portion is disposed so as to face the lead portion on the radially outer side of the lead portion,

a magnetic pole of a first magnet portion at a d-axis as a magnetic pole center is different from a magnetic pole of a second magnet portion opposed to the magnetic pole of the first magnet portion in a radial direction.

Images