JP7347186B2 - rotating electric machine - Google Patents

Description

The present invention relates to a rotating electric machine.

Conventionally, as described in Patent Document 1, for example, a field element including a magnet portion having a plurality of magnetic poles with alternating polarity in the circumferential direction, and an armature having multiphase armature windings are used. A rotating electrical machine equipped with the above-mentioned rotating electric machine is known. This rotating electrical machine employs a slotless structure to eliminate limitations due to magnetic saturation caused by the teeth of the stator core, and employs polar anisotropic magnets to improve magnetic flux density. This makes it possible to suitably improve the output torque while eliminating limitations due to magnetic saturation.

JP2019-106864A

By the way, the armature winding is constructed by winding a conductive wire made of a conductor such as copper and covered with an insulating film. However, in large, high-output rotating electric machines such as those used in vehicles, the stator windings are large, so there is a problem that stray capacitance tends to increase due to parallel wiring of conductive wires. In particular, in the slotless structure, since the windings are adjacent to each other in the circumferential direction, the portion where the conductors are wired in parallel through the insulating film becomes long, and stray capacitance tends to increase. Further, even when square wires are used to improve the space factor of the conductor, the area that the conductors oppose tends to increase, which tends to increase stray capacitance. When the stray capacitance increases, resonance tends to occur, causing problems such as noise.

The present invention has been made in view of the above circumstances, and its main purpose is to provide a rotating electrical machine that can reduce resonance.

A first means for solving the above problem includes a field element including a magnet portion having a plurality of magnetic poles with alternating polarities in the circumferential direction, and an armature having a multiphase armature winding. , in a rotating electrical machine in which either the field element or the armature is a rotor, the armature winding is configured by winding a conductive wire, and is opposed to the magnet part. The conductive wire has a conductive wire portion arranged at predetermined intervals in the circumferential direction at the position, and the conductive wire is configured by covering a plurality of wires bundled with an insulating coating, and the insulating coating is a tape. It is formed into a shape and is wound around the outer periphery of a plurality of bundled strands, and between the outer periphery of the plurality of bundled strands and the insulating coating, there is a layer in the extending direction of the conductor wire. A gap is formed that extends along the line.

According to the first means, a gap is formed between the outer periphery of the plurality of bundled strands and the tape-shaped insulating coating, which extends along the extending direction of the conducting wire. Due to this gap, by parallel wiring, it is possible to reduce the area of strands of wires facing each other with an insulating coating interposed between adjacent conductive wires. In other words, capacitance can be reduced. Alternatively, between adjacent conducting wires, the distance between the strands can be discussed. This makes it possible to suppress resonance and reduce noise and the like between adjacent conductive wires.

In the second means, in the first means, the plurality of bundled strands are twisted together, and the gap extending along the extending direction of the conductor wire is formed between the plurality of bundled strands. It is formed in a spiral shape on the outer periphery.

This makes it possible to further reduce the area of the wires facing each other with the insulating coating interposed between adjacent conductive wires, thereby reducing capacitance.

In the third means, in the first or second means, an inter-strand gap extending along the extending direction of the conducting wire is also formed between the plurality of bundled strands.

Thereby, the capacitance generated between adjacent strands can be reduced.

A fourth means is that in any one of the first to third means, the strand includes a conductor through which a current flows and a fusion layer covering a surface of the conductor, and the fusion layer includes the It is made thinner than the insulating coating, and when a plurality of wires are bundled together, the fusion layers come into contact with each other and are fused together.

The conductive wires are insulated by an insulating coating. On the other hand, although the conductors of the strands are covered with a fusion layer, since no insulating layer is provided, the conductors may come into contact with each other and become electrically conductive. However, the potential difference between the conductors is small, and even if the fusion layer is torn when bundling a plurality of wires or covering an insulating coating, the contact area between the conductors is very small and the contact resistance is very high. Therefore, even if the conductors are not completely insulated, it is possible to suppress the flow of eddy current between the conductors.

Therefore, a fusion layer was provided directly on the conductor without providing an insulating layer on the surface of the conductor, and the fusion layers were fused together. This eliminates the need to provide an insulating layer. Further, by providing the fusion layer, it is possible to easily maintain the bundled state of the plurality of wires and to cover them with an insulating coating. The above makes it easier to manufacture the conducting wire and the rotating electric machine, and since the insulating layer of the wire is omitted, the space factor of the conductor can be improved.

A fifth means is that in any one of the first to fourth means, in the armature, an inter-conductor member is provided between each of the conductor portions in the circumferential direction, and as the inter-conductor member, at one magnetic pole. Wt is the circumferential width of the inter-conductor member, Bs is the saturation magnetic flux density of the inter-conductor member, Wm is the circumferential width of the magnet portion at one magnetic pole, and Br is the residual magnetic flux density of the magnet portion. In this case, a configuration is used in which a conductive member is made of a magnetic material and satisfies the relationship Wt×Bs≦Wm×Br.

The inter-conductor member serves as an electromagnetic shield, making it possible to prevent resonance between the conductors. Further, since the inter-conductor member having the relationship of Wt×Bs≦Wm×Br is magnetically saturated by the magnet portion, it can be said that it has a substantially slotless structure. Thereby, restrictions based on magnetic saturation caused by teeth etc. can be eliminated.

FIG. 1 is a perspective view showing the entire rotating electrical machine in the first embodiment. A plan view of a rotating electric machine. A vertical cross-sectional view of a rotating electric machine. A cross-sectional view of a rotating electric machine. An exploded cross-sectional view of a rotating electric machine. A cross-sectional view of the rotor. FIG. 3 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit. FIG. 3 is a diagram showing the relationship between electrical angle and magnetic flux density for the magnet of the embodiment. FIG. 7 is a diagram showing the relationship between electrical angle and magnetic flux density for a comparative example magnet. FIG. 3 is a perspective view of a stator unit. FIG. 3 is a vertical cross-sectional view of the stator unit. FIG. 3 is a perspective view of the core assembly seen from one axial side. FIG. 3 is a perspective view of the core assembly seen from the other axial side. Cross-sectional view of the core assembly. Exploded cross-sectional view of the core assembly. The circuit diagram which shows the connection state of the partial winding in each phase winding of 3 phases. FIG. 3 is a side view showing a first coil module and a second coil module side by side in contrast. FIG. 3 is a side view showing a first partial winding and a second partial winding side by side in contrast. The figure which shows the structure of a 1st coil module. A sectional view taken along the line 20-20 in FIG. 19(a). FIG. 3 is a perspective view showing the configuration of an insulating cover. The figure which shows the structure of a 2nd coil module. A sectional view taken along the line 23-23 in FIG. 22(a). FIG. 3 is a perspective view showing the configuration of an insulating cover. The figure which shows the overlap position of the film material in the state where each coil module was arranged in the circumferential direction. FIG. 3 is a plan view showing a state in which the first coil module is assembled to the core assembly. FIG. 3 is a plan view showing a state in which the first coil module and the second coil module are assembled to the core assembly. FIG. 3 is a vertical cross-sectional view showing a state of fixing with a fixing pin. FIG. 3 is a perspective view of a busbar module. FIG. 3 is a cross-sectional view showing a part of the longitudinal section of the busbar module. FIG. 3 is a perspective view showing a state in which a busbar module is assembled to a stator holder. FIG. 3 is a vertical cross-sectional view of a fixing part that fixes a busbar module. FIG. 3 is a vertical cross-sectional view showing a state in which the relay member is attached to the housing cover. FIG. 3 is a perspective view of a relay member. An electric circuit diagram showing a control system of a rotating electric machine. FIG. 3 is a functional block diagram showing current feedback control processing by the control device. FIG. 3 is a functional block diagram showing torque feedback control processing by the control device. FIG. 7 is a partial cross-sectional view showing a cross-sectional structure of a magnet unit in a modified example. The figure which shows the structure of the stator unit of inner rotor structure. FIG. 3 is a plan view showing how the coil module is assembled to the core assembly. FIG. 7 is a diagram showing the configuration of a first coil module of Modification 2. FIG. FIG. 4 is a cross-sectional view of a conductive wire according to modification 2. FIG. 7 is a side view of a conductive wire material according to modification example 2; 1 is a flowchart showing a method for manufacturing a stator winding. The figure which shows the image of the manufacturing process of a stator winding. A cross-sectional view showing a comparative example of a conducting wire material. (a) and (b) are sectional views of a conducting wire material of another example. 7 is a flowchart showing another example of a method for manufacturing a stator winding.

A plurality of embodiments will be described with reference to the drawings. In embodiments, functionally and/or structurally corresponding and/or related parts may be provided with the same reference numerals or with reference numerals that differ by hundreds or more. Descriptions of other embodiments can be referred to for corresponding and/or related parts.

The rotating electrical machine in this embodiment is used, for example, as a vehicle power source. However, rotating electric machines can be widely used for industrial purposes, vehicles, home appliances, OA equipment, game machines, and the like. Note that in each of the following embodiments, parts that are the same or equivalent to each other are denoted by the same reference numerals in the drawings, and the explanations thereof will be referred to for the parts with the same reference numerals.

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

The rotating electrical machine 10 is roughly divided into a rotating electrical machine main body having a rotor 20, a stator unit 50, and a busbar module 200, and a housing 241 and a housing cover 242 provided so as to surround the rotating electrical machine main body. All of these members are arranged coaxially with respect to the rotating shaft 11 that is integrally provided to the rotor 20, and are assembled in the axial direction in a predetermined order to configure the rotating electrical machine 10. The rotating 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. Note that the bearings 12 and 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls arranged between them. The rotation of the rotating shaft 11 causes, for example, the axle of the vehicle to rotate. The rotating electrical machine 10 can be mounted on a vehicle by fixing the housing 241 to a vehicle body frame or the like.

In the rotating electric machine 10, the stator unit 50 is provided so as to surround the rotating shaft 11, and the rotor 20 is arranged on the radially outer side of the stator unit 50. The stator unit 50 includes a stator 60 and a stator holder 70 assembled inside the stator 60 in the radial direction. The rotor 20 and the stator 60 are arranged to face each other in the radial direction with an air gap in between, and as the rotor 20 rotates together with the rotating shaft 11, the rotor 20 rotates on the outside of the stator 60 in the radial direction. Rotate. 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 carrier 21 and an annular magnet unit 22 fixed to the rotor carrier 21. As shown in FIG. The rotor carrier 21 has a cylindrical portion 23 having a cylindrical shape and an end plate portion 24 provided at one end in the axial direction of the cylindrical portion 23, and is configured by integrating these parts. . The rotor carrier 21 functions as a magnet holding member, and a magnet unit 22 is fixed annularly inside the cylindrical portion 23 in the radial direction. A through hole 24a is formed in the end plate portion 24, and the rotating shaft 11 is fixed to the end plate portion 24 by a fastener 25 such as a bolt while being inserted into the through hole 24a. The rotating shaft 11 has a flange 11a extending in a direction intersecting (orthogonal to) the axial direction, and the rotor carrier 21 is attached to the rotating shaft 11 in a state where the flange 11a and the end plate portion 24 are surface-joined. is fixed.

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

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

In the magnet unit 22, the magnets 32 are arranged in parallel along the circumferential direction of the rotor 20 so that their polarities alternate. Thereby, the magnet unit 22 has a plurality of magnetic poles in the circumferential direction. The magnet 32 is a polar anisotropic permanent magnet, 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. It is configured.

The radially inner circumferential surface of the magnet 32 is a magnetic flux acting surface 34 where magnetic flux is transferred. In the magnet 32, the direction of the axis of easy magnetization is different between the d-axis side (the part closer to the d-axis) and the q-axis side (the part closer to the q-axis), and the direction of the easy axis of magnetization on the d-axis side is the same as the d-axis. On the q-axis side, the axis of easy magnetization is perpendicular to the q-axis. In this case, an arcuate magnet magnetic path is formed along the direction of the axis of easy magnetization. In short, the magnet 32 is configured such that the axis of easy magnetization 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.

In the magnet 32, the magnet magnetic path is formed in an arc shape, so that the length of the magnet magnetic path is longer than the thickness dimension of the magnet 32 in the radial direction. This increases the permeance of the magnet 32, making it possible to exhibit the same ability as a magnet with a larger amount of magnets, even though the amount of magnets is the same.

The magnets 32 are configured such that two circumferentially adjacent magnets constitute one magnetic pole. In other words, the plurality of magnets 32 arranged in the circumferential direction in the magnet unit 22 each have a split surface on the d-axis and the q-axis, and the magnets 32 are arranged in contact with or close to each other. . The magnets 32 have an arc-shaped magnet magnetic path as described above, and the N and S poles of magnets 32 adjacent to each other in the circumferential direction face each other on the q-axis. Therefore, permeance near the q-axis can be improved. Furthermore, since the magnets 32 on both sides of the q-axis attract each other, these magnets 32 can maintain contact with each other. Therefore, it also contributes to improving permeance.

In the magnet unit 22, magnetic flux flows in an arc shape between adjacent N and S poles of each magnet 32, so the magnet magnetic path is longer than, for example, a radial anisotropic magnet. Therefore, as shown in FIG. 8, the magnetic flux density distribution becomes close to 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, making it possible to increase the torque of the rotating electric machine 10. . Furthermore, it can be confirmed that the magnet unit 22 of this embodiment has a different magnetic flux density distribution compared to the conventional Halbach array magnet. In addition, in FIGS. 8 and 9, the horizontal axis shows the electrical angle, and the vertical axis shows the magnetic flux density. Furthermore, in FIGS. 8 and 9, 90° on the horizontal axis indicates the d-axis (that is, the center of the magnetic pole), and 0° and 180° on the horizontal axis indicate the q-axis.

That is, according to each of the magnets 32 having the above configuration, the magnet magnetic flux on the d-axis in the magnet unit 22 is strengthened, and changes in the magnetic flux near the q-axis are suppressed. Thereby, it is possible to suitably realize the magnet unit 22 in which the surface magnetic flux changes gradually from the q-axis to the d-axis in each magnetic pole.

The sinusoidal matching rate of the magnetic flux density distribution may be set to a value of 40% or more, for example. In this way, the amount of magnetic flux in the central portion of the waveform can be reliably improved compared to the case of using radially oriented magnets or parallel oriented magnets with a sinusoidal matching rate of about 30%. Moreover, if the sine wave matching rate is set to 60% or more, the amount of magnetic flux in the central portion of the waveform can be reliably improved compared to a magnetic flux concentration array such as a Halbach array.

In the radially anisotropic magnet shown in FIG. 9, the magnetic flux density changes sharply near the q-axis. The steeper the change in magnetic flux density, the more eddy currents will increase in stator windings 61 of stator 60, which will be described later. Moreover, the magnetic flux change on the stator winding 61 side also becomes steep. In contrast, in this embodiment, the magnetic flux density distribution has a magnetic flux waveform close to a sine wave. Therefore, near the q-axis, the change in magnetic flux density is smaller than the change in magnetic flux density of the radial anisotropic magnet. This makes it possible to suppress the generation of eddy currents.

The magnet 32 has a recess 35 formed in a predetermined range including the d-axis on its radially outer outer circumferential surface, and a recess 36 formed in a predetermined range including the q-axis on its radially inner inner circumferential surface. ing. In this case, according to the orientation of the axis of easy magnetization of the magnet 32, the magnet magnetic path becomes shorter near the d-axis on the outer circumferential surface of the magnet 32, and the magnet magnetic path becomes shorter near the q-axis on the inner circumferential surface of the magnet 32. . Therefore, in consideration of the fact that it is difficult to generate sufficient magnetic flux in the magnet 32 at a location where the magnet magnetic path length is short, the magnet is removed at a location where the magnet magnetic flux is weak.

In addition, in the magnet unit 22, it is good also as a structure using the same number of magnets 32 as magnetic poles. For example, it is preferable that one magnet 32 is provided between two circumferentially adjacent magnetic poles, and between the d axes that are the centers of the respective magnetic poles. In this case, the magnet 32 has a configuration in which the center in the circumferential direction is the q-axis and has a cut surface on the d-axis. Furthermore, the magnet 32 may have a configuration in which the circumferential center is not the q-axis, but the circumferential center is the d-axis. Instead of using twice the number of magnetic poles or the same number of magnets as the number of magnetic poles as the magnets 32, a configuration may be used in which ring magnets connected in an annular shape are used.

As shown in FIG. 3, a resolver 41 as a rotation sensor is provided at the end (upper end in the figure) of the rotating shaft 11 on the opposite side of the joint with the rotor carrier 21 in the axial direction. ing. The resolver 41 includes a resolver rotor fixed to the rotating shaft 11 and a resolver stator disposed opposite to the resolver rotor on the outside in the radial direction. The resolver rotor has a disc ring shape, and is provided coaxially with the rotating shaft 11 with the rotating shaft 11 inserted therethrough. The resolver stator has a stator core and a stator coil, and is fixed to the housing cover 242.

Next, the configuration of the stator unit 50 will be explained. 10 is a perspective view of the stator unit 50, and FIG. 11 is a longitudinal sectional view of the stator unit 50. Note that FIG. 11 is a longitudinal cross-sectional view taken at the same position as FIG. 3.

The stator unit 50 generally includes a stator 60 and a stator holder 70 on the radially inner side thereof. Further, the stator 60 has a stator winding 61 and a stator core 62. The stator core 62 and the stator holder 70 are integrated into a core assembly CA, and a plurality of partial windings 151 constituting the stator winding 61 are assembled to the core assembly CA. Note that 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." Further, the core assembly CA corresponds to a "support member".

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

As described above, the core assembly CA includes the stator core 62 and the stator holder 70 assembled inside the stator core 62 in the radial direction. In other words, the stator core 62 is integrally assembled on the outer peripheral surface of the stator holder 70.

The stator core 62 is configured as a core sheet laminate in which core sheets 62a made of magnetic steel sheets are laminated in the axial direction, and has a cylindrical shape with a predetermined thickness in the radial direction. A stator winding 61 is assembled on the radially outer side of the stator core 62 on the rotor 20 side. The outer peripheral surface of the stator core 62 has a curved shape with no irregularities. Stator core 62 functions as a back yoke. The stator core 62 is configured by stacking a plurality of core sheets 62a punched into, for example, annular plate shapes in the axial direction. However, the stator core 62 may have a helical core structure. In the stator core 62 having a helical core structure, a belt-shaped core sheet is used, and this core sheet is wound in an annular shape and laminated in the axial direction, thereby forming an overall cylindrical stator core 62. has been done.

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

Further, as shown in FIG. 15, the stator holder 70 has an outer cylinder member 71 and an inner cylinder member 81, and these are arranged with the outer cylinder member 71 on the outside in the radial direction and the inner cylinder member 81 on the inside in the radial direction. It is constructed by being assembled in one piece. Each of these 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 whose outer circumferential surface and inner circumferential surface are both perfectly circular curved surfaces, and an annular flange 72 extending radially inward is formed at one end in the axial direction. A plurality of protrusions 73 are formed on the flange 72 at predetermined intervals in the circumferential direction and extend inward in the radial direction (see FIG. 13). Furthermore, opposing surfaces 74 and 75 are formed at one end and the other end in the axial direction of the outer cylinder member 71, respectively, and are opposed to the inner cylinder member 81 in the axial direction. Annular grooves 74a and 75a are formed that extend to.

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

As shown in FIG. 14, when the outer cylinder member 71 and the inner cylinder member 81 are assembled to each other, there is an annular gap between the inner peripheral surface of the outer cylinder member 71 and the outer peripheral surface of the inner cylinder member 81. The gap space serves as a refrigerant passage 85 through which a refrigerant such as cooling water flows. The coolant passage 85 is provided in an annular shape in the circumferential direction of the stator holder 70. More specifically, the inner cylindrical member 81 is provided with a passage forming part 88 that protrudes radially inward on the inner peripheral side thereof and has an inlet side passage 86 and an outlet side passage 87 formed therein, Each of the passages 86 and 87 opens to the outer peripheral surface of the inner cylinder member 81. Furthermore, a partition portion 89 is provided on the outer peripheral surface of the inner cylinder member 81 to partition the refrigerant passage 85 into an inlet side and an outlet side. Thereby, the refrigerant flowing in from the inlet side passage 86 flows circumferentially 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 to the outer peripheral surface of the inner cylinder member 81, and the other end side extends in the axial direction and opens to the axial end surface of the inner cylinder member 81. It looks like this. FIG. 12 shows an inlet opening 86a leading to the inlet passage 86 and an outlet opening 87a leading to the outlet passage 87. Note that the inlet side passage 86 and the outlet side passage 87 communicate with an inlet port 244 and an outlet port 245 (see FIG. 1) attached to the housing cover 242, and refrigerant enters and exits through these ports 244 and 245. It looks like this.

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

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

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

Specifically, as shown in FIG. 12, on the axial end surface of the inner cylinder member 81, specifically on the axial outer end surface surrounding the boss portion 92 of the end plate portion 91, a plurality of holes are formed at equal intervals in the circumferential direction. A recess 105 is formed. Further, as shown in FIG. 13, a plurality of recesses 106 are formed at equal intervals in the circumferential direction on the axial end surface of the outer cylinder member 71, specifically, on the axially outer end surface of the flange 72. These recesses 105 and 106 are arranged on an imaginary circle concentric with the core assembly CA. The recesses 105 and 106 are provided at the same position in the circumferential direction, and the interval and number thereof are also the same.

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

Therefore, in the present embodiment, in a configuration in which the stator core 62 and the stator holder 70 are fitted and fixed to each other with a predetermined interference, the stator core 62 and the stator holder 70 have a diametrically opposed portion. The configuration is such that a regulating portion is provided that regulates displacement of the stator core 62 in the circumferential direction by engagement in the circumferential direction. That is, as shown in FIGS. 12 to 14, between the stator core 62 and the outer cylindrical member 71 of the stator holder 70 in the radial direction, there are a plurality of engagement portions as restricting portions at predetermined intervals in the circumferential direction. A member 111 is provided, and the engagement member 111 suppresses displacement of the stator core 62 and the stator holder 70 in the circumferential direction. In this case, it is preferable to provide a recess in at least one of the stator core 62 and the outer cylinder member 71, and to engage the engaging member 111 in the recess. Instead of the engaging member 111, a convex portion may be provided on either the stator core 62 or the outer cylinder member 71.

In the above configuration, the stator core 62 and the stator holder 70 (outer cylinder member 71) are fitted and fixed with a predetermined interference, and in addition, their mutual circumferential displacement is restricted by the restriction of the engagement member 111. It is set up in the same condition. Therefore, even if the interference between stator core 62 and stator holder 70 is relatively small, displacement of stator core 62 in the circumferential direction can be suppressed. Further, since a desired displacement suppression effect can be obtained even if the interference is relatively small, damage to the stator core 62 caused by an excessively large interference can be suppressed. As a result, displacement of stator core 62 can be appropriately suppressed.

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

Next, the configuration of the stator winding 61 assembled to the core assembly CA will be described in detail. The state in which the stator winding 61 is assembled to the core assembly CA is as shown in FIGS. 10 and 11. A plurality of partial windings 151 constituting the winding 61 are assembled so as to be lined up in the circumferential direction.

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

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

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

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

As shown in FIG. 11, the coil module 150 is assembled on the radially outer side of the stator core 62. In this case, the coil module 150 is assembled with its axially opposite end portions protruding further axially outward than the stator core 62 (that is, toward the coil end CE side). That is, the stator winding 61 has a portion that corresponds to the coil end CE that protrudes further axially outward than the stator core 62, and a portion that corresponds to the coil side CS that is axially inner than the stator core 62. .

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

FIG. 17 is a side view showing the first coil module 150A and the second coil module 150B side by side in comparison, and FIG. 18 is a side view showing the first partial winding 151A and the second partial winding 151B side by side. FIG. As shown in these figures, the coil modules 150A, 150B and the partial windings 151A, 151B have different axial lengths and different axial end shapes. 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. The first partial winding 151A is equipped with insulation covers 161 and 162 as "first insulation covers" on both sides in the axial direction, and the second partial winding 151B is equipped with insulation covers 161 and 162 as "second insulation covers" on both sides in the axial direction. Insulating covers 163 and 164 are attached.

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

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

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

The first partial winding 151A includes a pair of intermediate conductive wire portions 152 that are provided in a straight line and parallel to each other, and a pair of transition portions 153A that connect the pair of intermediate conductive wire portions 152 at both ends in the axial direction. , the pair of intermediate conducting wire portions 152 and the pair of transition portions 153A form an annular shape. The pair of intermediate conductor parts 152 are provided separated by a predetermined coil pitch, and the intermediate conductor part 152 of the partial winding 151 of the other phase can be placed between the pair of intermediate conductor parts 152 in the circumferential direction. It has become. In this embodiment, the pair of intermediate conductor portions 152 are provided at a distance of two coil pitches, and one intermediate conductor portion 152 of the partial windings 151 of the other two phases is arranged between the pair of intermediate conductor portions 152. The configuration is as follows.

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

As shown in FIG. 18, the first partial winding 151A has transition portions 153A on both sides in the axial direction, and the second partial winding 151B has transition portions 153B on both sides in the axial direction. The transition portions 153A and 153B of these partial windings 151A and 151B have different shapes, and in order to make the distinction clear, the transition portion 153A of the first partial winding 151A is referred to as the "first transition portion 153A". The transition portion 153B of the second partial winding 151B is also referred to as a “second transition portion 153B”.

In each of the partial windings 151A and 151B, the intermediate conducting wire portions 152 are provided as coil side conducting wire portions that are lined up one by one in the circumferential direction on the coil side CS. Moreover, each transition part 153A, 153B is provided as a coil end conducting wire part which connects the intermediate conducting wire parts 152 of the same phase at two different positions in the circumferential direction in the coil end CE.

As shown in FIG. 20, the first partial winding 151A is formed by winding the conducting wire CR in multiple layers so that the cross section of the conducting wire gathering portion is square. FIG. 20 shows a cross section of the intermediate conducting wire portion 152, in which the conducting wire material CR is wound in multiple layers so as to be lined up in the circumferential direction and the radial direction. In other words, the first partial winding 151A has a substantially rectangular cross section by arranging the conductive wire CR in a plurality of rows in the circumferential direction and in a plurality of rows in the radial direction in the intermediate conductor portion 152. It is formed. In addition, at the tip of the first transition portion 153A, the conductive wire CR is wound multiple times so as to be aligned in the axial direction and the radial direction by bending in the radial direction. In this embodiment, the first partial winding 151A is configured by concentrically winding the conducting wire CR. However, the winding method of the conductive wire CR is arbitrary, and instead of concentric winding, the conductive wire CR may be wound multiple times using alpha winding.

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

In the first partial winding 151A, each intermediate conductor portion 152 is provided with a sheet-like insulating cover 157 covering it. Note that FIG. 19A shows the first coil module 150A in a state in which the intermediate conductor portion 152 is covered with an insulating sheath 157 and the intermediate conductor portion 152 is present inside the insulating sheath 157. However, for convenience, the corresponding portion is referred to as an intermediate conductor portion 152 (the same applies to FIG. 22(a) to be described later).

The insulation covering 157 is formed by using a film material FM having an axial dimension having at least the length of the insulation covering range in the axial direction in the intermediate conductor part 152, and by wrapping the film material FM around the intermediate conductor part 152. It is provided. The film material FM is made of, for example, a PEN (polyethylene naphthalate) film. More specifically, the film material FM includes a film base material and an adhesive layer provided on one of both surfaces of the film base material and having foaming properties. Then, the film material FM is wound around the intermediate conductor portion 152 while being adhered by an adhesive layer. Note that it is also possible to use a non-foaming adhesive as the adhesive layer.

As shown in FIG. 20, the intermediate conducting wire portion 152 has a substantially rectangular cross section by arranging the conducting wire materials CR in the circumferential direction and the radial direction, and the film material FM is arranged around the intermediate conducting wire portion 152. The insulating coating 157 is provided by covering the circumferential ends thereof in an overlapping manner. The film material FM is a rectangular sheet whose vertical dimension is longer than the axial length of the intermediate conductor part 152 and whose horizontal dimension is longer than one circumferential length of the intermediate conductor part 152. It is wound around the intermediate conductor portion 152 in a folded state. In the state where the film material FM is wrapped around the intermediate conductor part 152, the gap between the conductor material CR of the intermediate conductor part 152 and the film base material is filled by foaming in the adhesive layer. Moreover, in the overlap portion OL of the film material FM, the ends of the film material FM in the circumferential direction are joined together by an adhesive layer.

In the intermediate conductor portion 152, an insulating cover 157 is provided on two circumferential side surfaces and two radial side surfaces so as to cover all of them. In this case, the insulating sheath 157 surrounding the intermediate conductor portion 152 includes a film on the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase, that is, on one of the two circumferential side surfaces of the intermediate conductor portion 152. An overlap portion OL is provided where the materials FM overlap. In this embodiment, in the pair of intermediate conductive wire portions 152, overlapping portions OL are provided on the same side in the circumferential direction.

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

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

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

As shown in FIGS. 21(a) and 21(b), the insulating cover 161 includes a pair of side surfaces 171 serving as side surfaces in the circumferential direction, an outer surface portion 172 on the outer side in the axial direction, and an inner surface portion 173 on the inner side in the axial direction. It has a radially inner front part 174. Each of these parts 171 to 174 is formed into a plate shape, and is connected to each other in a three-dimensional manner so that only the outer side in the radial direction is open. The pair of side portions 171 are each provided in a direction extending toward the axis of the core assembly CA when assembled to the core assembly CA. Therefore, when the plurality of first coil modules 150A are arranged side by side in the circumferential direction, the side surfaces 171 of the insulating covers 161 in the adjacent first coil modules 150A are in contact with or close to each other and face each other. Thereby, mutual insulation is achieved in each of the first coil modules 150A adjacent to each other in the circumferential direction, and a suitable annular arrangement is possible.

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

In addition, in the insulating cover 161, the pair of side surfaces 171 have semicircular shapes extending in the axial direction at positions that are both circumferential ends of the front surface section 174, that is, at positions where each side surface section 171 and the front surface section 174 intersect. A recess 177 is provided. Furthermore, a pair of protrusions 178 extending in the axial direction are provided on the outer surface portion 172 at symmetrical positions on both sides in the circumferential direction with respect to the center line of the insulating cover 161 in the circumferential direction.

A supplementary explanation will be given regarding the recess 177 of the insulating cover 161. As shown in FIG. 20, the first transition portion 153A of the first partial winding 151A has a curved shape that is convex toward the radially inner side, that is, the core assembly CA side. In this configuration, a gap is formed between the circumferentially adjacent first transition portions 153A, which becomes wider toward the distal end side of the first transition portions 153A. Therefore, in this embodiment, a recess 177 is provided at a position on the side surface 171 of the insulating cover 161 on the outside of the curved part of the first transition part 153A by utilizing the gap between the first transition parts 153A arranged in the circumferential direction. It is structured as follows.

Note that the first partial winding 151A may be provided with a temperature detection section (thermistor), and in such a structure, the insulating cover 161 may be provided with an opening for drawing out the signal line extending from the temperature detection section. In this case, the temperature detection section can be suitably accommodated within the insulating cover 161.

Although detailed description with illustrations will be omitted, the other axially insulating cover 162 has roughly the same configuration as the insulating cover 161. Like the insulating cover 161, the insulating cover 162 has a pair of side surfaces 171, an axially outer outer surface 172, an axially inner inner surface 173, and a radially inner front surface 174. . Further, in the insulating cover 162, semicircular recesses 177 are provided in the pair of side surfaces 171 at positions that are both circumferential ends of the front surface 174, and a pair of protrusions 178 are provided in the outer surface 172. . The difference from the insulating cover 161 is that the insulating cover 162 does not have an opening for pulling out the winding ends 154, 155 of the first partial winding 151A.

The insulating covers 161 and 162 have different axial height dimensions (that is, axial width dimensions of the pair of side parts 171 and front part 174). Specifically, as shown in FIG. 17, the axial height W11 of the insulating cover 161 and the axial height W12 of the insulating cover 162 satisfy W11>W12. In other words, when winding the conductor CR in multiple layers, it is necessary to switch the winding stage of the conductor CR in a direction perpendicular to the winding direction (circling direction) (lane change), and due to this switching, It is conceivable that the winding width becomes larger. To supplement, the insulating cover 161 of the insulating covers 161 and 162 is a part that covers the first transition portion 153A on the side that includes the winding start and winding end of the conductive wire CR, and includes the winding start and winding end of the conductive wire CR. As a result, the winding allowance (overlapping allowance) of the conductive wire CR becomes larger than other parts, and as a result, the winding width may become larger. Taking this point into account, the axial height W11 of the insulating cover 161 is larger than the axial height W12 of the insulating cover 162. As a result, unlike the case where the height dimensions W11 and W12 of the insulating covers 161 and 162 are the same, the inconvenience that the number of turns of the conductive wire CR is limited by the insulating covers 161 and 162 is suppressed. It has become.

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

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

As shown in FIGS. 22(a) and 22(b), the second coil module 150B includes a second partial winding 151B configured by multiple windings of the conductive wire material CR similarly to the first partial winding 151A, and The second partial winding 151B has insulating covers 163 and 164 attached to one end and the other end in the axial direction. The insulating covers 163 and 164 are molded from an insulating material such as synthetic resin.

The second partial winding 151B includes a pair of intermediate conductive wire portions 152 that are provided parallel to each other and in a straight line, and a pair of second transition portions 153B that connect the pair of intermediate conductive wire portions 152 at both ends in the axial direction. The pair of intermediate conducting wire portions 152 and the pair of second transition portions 153B form an annular shape. The pair of intermediate conductive wire portions 152 in the second partial winding 151B have the same configuration as the intermediate conductive wire portion 152 of the first partial winding 151A. On the other hand, the pair of second transition portions 153B have a different configuration from the first transition portion 153A of the first partial winding 151A. The second transition portion 153B of the second partial winding 151B is provided so as to extend linearly in the axial direction from the intermediate conductor portion 152 without being bent in the radial direction. FIG. 18 clearly shows the difference between the partial windings 151A and 151B by contrast.

In the second partial winding 151B, the end of the conducting wire CR is connected from one of the second transition parts 153B on both sides in the axial direction (the upper second transition part 153B in FIG. 22(b)). It is pulled out, and its ends become winding ends 154 and 155. Similarly to the first partial winding 151A, in the second partial winding 151B, one of the winding ends 154 and 155 is connected to the current input/output terminal, and the other is connected to the neutral point. It has become.

In the second partial winding 151B, like the first partial winding 151A, each intermediate conductive wire portion 152 is provided with a sheet-shaped insulating cover 157 covered therewith. The insulation covering 157 is formed by using a film material FM having an axial dimension having at least the length of the insulation covering range in the axial direction in the intermediate conductor part 152, and by wrapping the film material FM around the intermediate conductor part 152. It is provided.

The configuration regarding the insulating cover 157 is also generally the same for each partial winding 151A, 151B. That is, as shown in FIG. 23, the film material FM is placed around the intermediate conducting wire portion 152 with its circumferential ends overlapping. In the intermediate conductor portion 152, an insulating cover 157 is provided on two circumferential side surfaces and two radial side surfaces so as to cover all of them. In this case, the insulating sheath 157 surrounding the intermediate conductor portion 152 includes a film on the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase, that is, on one of the two circumferential side surfaces of the intermediate conductor portion 152. An overlap portion OL is provided where the materials FM overlap. In this embodiment, in the pair of intermediate conductive wire portions 152, overlapping portions OL are provided on the same side in the circumferential direction.

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

In each of the partial windings 151A and 151B, an insulating coating 157 is provided in a range that includes part of the transition portions 153A and 153B. That is, in each of the partial windings 151A, 151B, an insulating coating 157 is provided on the intermediate conductor portion 152 and on the portions of the transition portions 153A, 153B that extend linearly following the intermediate conductor portion 152. However, since the axial lengths of the partial windings 151A and 151B are different, the axial ranges of the insulation coverings 157 are also different.

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

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

As shown in FIGS. 24(a) and 24(b), the insulating cover 163 includes a pair of side surfaces 181 serving as side surfaces in the circumferential direction, an outer surface portion 182 on the outer side in the axial direction, and a front surface portion 183 on the inner side in the radial direction. It has a radially outer rear surface portion 184. Each of these parts 181 to 184 is formed into a plate shape, and is connected to each other in a three-dimensional manner so that only the inner side in the axial direction is open. The pair of side portions 181 are each provided in a direction extending toward the axis of the core assembly CA when assembled to the core assembly CA. Therefore, when the plurality of second coil modules 150B are arranged side by side in the circumferential direction, the side surfaces 181 of the insulating covers 163 in the adjacent second coil modules 150B are in contact with or close to each other and face each other. Thereby, mutual insulation is achieved between the second coil modules 150B adjacent to each other in the circumferential direction, and a suitable annular arrangement is possible.

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

A protrusion 186 that protrudes inward in the radial direction is provided on the front surface 183 of the insulating cover 163. The protruding portion 186 is provided at a central position between one circumferential end and the other end of the insulating cover 163 so as to protrude inward in the radial direction from the second transition portion 153B. The protruding portion 186 has a tapered shape that tapers toward the inner side in the radial direction when viewed from above, and a through hole 187 extending in the axial direction is provided at the tip thereof. In addition, if the protrusion part 186 protrudes inward in the radial direction from the second transition part 153B and has a through hole 187 at the center position between one circumferential end and the other end of the insulating cover 163, Its configuration is arbitrary. However, assuming an overlapping state with the insulating cover 161 on the axially inner side, it is desirable that the width is narrow in the circumferential direction to avoid interference with the winding ends 154 and 155.

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

Further, as shown in FIG. 23, the protrusion 186 is provided with a through hole 188 that penetrates in the axial direction. This allows the adhesive to be filled between the insulating covers 161 and 163 through the through hole 188 in a state where the insulating covers 161 and 163 overlap in the axial direction.

Although detailed explanation with illustrations will be omitted, the other insulating cover 164 in the axial direction has approximately the same configuration as the insulating cover 163. Like the insulating cover 163, the insulating cover 164 has a pair of side surfaces 181, an axially outer outer surface section 182, a radially inner front surface section 183, and a radially outer rear surface section 184, and has a protruding surface. A through hole 187 is provided at the tip of the portion 186. Further, as a difference from the insulating cover 163, the insulating cover 164 does not have an opening for drawing out the winding ends 154, 155 of the second partial winding 151B.

In the insulating covers 163 and 164, a pair of side surfaces 181 have different radial width dimensions. Specifically, as shown in FIG. 17, the radial width W21 of the side surface 181 of the insulating cover 163 and the radial width W22 of the side surface 181 of the insulating cover 164 satisfy W21>W22. . That is, among the insulating covers 163 and 164, the insulating cover 163 is a part that covers the second transition portion 153B on the side including the winding start and winding end of the conductive wire CR, and includes the winding start and winding end of the conductive wire CR. As a result, the winding allowance (overlap allowance) of the conductive wire CR becomes larger than other parts, and as a result, the winding width may become larger. Taking this point into account, the radial width W21 of the insulating cover 163 is larger than the radial width W22 of the insulating cover 164. As a result, unlike the case where the width dimensions W21 and W22 of the insulating covers 163 and 164 are the same, the inconvenience that the number of turns of the conductive wire CR is limited by the insulating covers 163 and 164 can be suppressed. ing.

FIG. 25 is a diagram showing the overlapping position of the film material FM when the coil modules 150A and 150B are arranged in the circumferential direction. As described above, in each coil module 150A, 150B, a coil is provided around the intermediate conductor portion 152 so as to overlap the portion of the partial winding 151 of the other phase that faces the intermediate conductor portion 152, that is, the circumferential side surface of the intermediate conductor portion 152. The film material FM is then covered (see FIGS. 20 and 23). When the coil modules 150A and 150B are arranged in the circumferential direction, the overlapping portions OL of the film material FM are arranged on the same side (the right side in the circumferential direction in the figure) of both sides in the circumferential direction. ing. Thereby, in each intermediate conductor portion 152 of the partial windings 151A and 151B of different phases adjacent to each other in the circumferential direction, the overlapping portions OL of the film material FM do not overlap in the circumferential direction. In this case, a maximum of three sheets of film material FM are overlapped between each of the intermediate conducting wire portions 152 arranged in the circumferential direction.

Next, a configuration for assembling each coil module 150A, 150B to core assembly CA will be described.

The coil modules 150A, 150B have different axial lengths, and the shapes of the transition portions 153A, 153B of the partial windings 151A, 151B are different from each other, and the first transition portion 153A of the first coil module 150A is The second coil module 150B is configured to be attached to the core assembly CA with the second transition portion 153B of the second coil module 150B facing the inner side and the outer side in the axial direction. Regarding the insulating covers 161 to 164, the insulating covers 161 and 163 are axially overlapped on one axial end side of each coil module 150A and 150B, and the insulating covers 162 and 164 are axially overlapped on the other axial end side of each coil module 150A and 150B. In this state, each of the insulating covers 161 to 164 is fixed to the core assembly CA.

FIG. 26 is a plan view showing a state in which a plurality of insulating covers 161 are lined up in the circumferential direction when the first coil module 150A is assembled to the core assembly CA, and FIG. FIG. 7 is a plan view showing a state in which a plurality of insulating covers 161 and 163 are lined up in the circumferential direction when the two-coil module 150B is assembled. Further, FIG. 28(a) is a longitudinal cross-sectional view showing the assembled state of each coil module 150A, 150B to core assembly CA before fixing with fixing pin 191, and FIG. FIG. 7 is a longitudinal cross-sectional view showing a state after fixing with fixing pins 191 in an assembled state of each coil module 150A, 150B.

As shown in FIG. 26, when the plurality of first coil modules 150A are assembled to the core assembly CA, the plurality of insulating covers 161 are arranged with the side portions 171 in contact with or close to each other. Each insulating cover 161 is arranged so that the boundary line LB where the side parts 171 face each other matches the recessed part 105 on the axial end surface of the inner cylinder member 81. In this case, when the side surfaces 171 of the insulating covers 161 adjacent to each other in the circumferential direction come into contact with each other or come close to each other, a through hole portion extending in the axial direction is formed by each recess 177 of the insulating covers 161, and the through hole portion extends in the axial direction. The position of the hole and the recess 105 are brought into alignment.

Further, as shown in FIG. 27, a second coil module 150B is further assembled to the integral body of the core assembly CA and the first coil module 150A. With this assembly, the plurality of insulating covers 163 are arranged with the side parts 181 in contact with or close to each other. In this state, the transition portions 153A and 153B are arranged so as to intersect with each other on a circle in which the intermediate conducting wire portions 152 are lined up in the circumferential direction. Each insulating cover 163 is configured such that the protrusion 186 overlaps the insulating cover 161 in the axial direction, and the through hole 187 of the protruding part 186 is axially connected to the through hole formed by each recess 177 of the insulating cover 161. will be placed.

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, so that the through hole on the insulating cover 161 side and the recess 100 of the inner cylinder member 81 The position of the through hole 187 on the insulating cover 163 side is aligned with the position of the insulating cover 163 side. That is, when 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, so that the protruding portion It may become difficult to align the through holes 187 of 186. In this regard, since the protruding part 186 of the insulating cover 163 is guided by the pair of protruding parts 178 of the insulating cover 161, the positioning of the insulating cover 163 with respect to the insulating cover 161 becomes easy.

Then, as shown in FIGS. 28(a) and 28(b), the insulating cover 161 and the protrusion 186 of the insulating cover 163 are fixed by the fixing pin 191 as a fixing member in a state where they are engaged at the overlapping part thereof. It will be done. More specifically, with the recess 105 of the inner cylinder member 81, the recess 177 of the insulating cover 161, and the through hole 187 of the insulating cover 163 aligned, fixing pins are inserted into the recesses 105, 177 and the through hole 187. 191 is inserted. Thereby, the insulating covers 161 and 163 are integrally fixed to the inner cylinder member 81. According to this configuration, the circumferentially adjacent coil modules 150A and 150B are fixed to the core assembly CA at the coil end CE by a common fixing pin 191. The fixing pin 191 is desirably made of a material with good thermal conductivity, and is, for example, a metal pin.

As shown in FIG. 28(b), the fixing pin 191 is assembled to the low step portion 186a of the protruding portion 186 of the insulating cover 163. In this state, the upper end portion of the fixing pin 191 protrudes above the low step portion 186a, but does not protrude above the upper surface (outer surface portion 182) of the insulating cover 163. In this case, the fixing pin 191 is longer than the axial height of the overlapping portion of the insulating cover 161 and the protrusion 186 (lower part 186a) of the insulating cover 163, and has a margin for upward protrusion. It is conceivable that it becomes easier to insert the fixing pin 191 into the recesses 105, 177 and the through hole 187 (that is, when fixing the fixing pin 191). Furthermore, since the upper end portion of the fixing pin 191 does not protrude above the upper surface (outer surface portion 182) of the insulating cover 163, it is possible to suppress the inconvenience that the axial length of the stator 60 becomes longer due to the protrusion of the fixing pin 191. It has become a thing.

After the insulating covers 161 and 163 are fixed by the fixing pins 191, adhesive is filled through the through holes 188 provided in the insulating covers 163. Thereby, the insulating covers 161 and 163 that overlap in the axial direction are firmly connected to each other. Note that in FIGS. 28(a) and 28(b), for convenience, the through hole 188 is shown in the range from the top surface to the bottom surface of the insulating cover 163, but in reality, the through hole 188 is formed in a thin plate portion formed by cutting out the material. It has a set configuration.

As shown in FIG. 28(b), the fixing position of each insulating cover 161, 163 by the fixing pin 191 is on the axial end face of the stator holder 70, which is radially inner than the stator core 62 (left side in the figure). The stator holder 70 is fixed to the stator holder 70 by a fixing pin 191. In other words, the first transition portion 153A is configured to be fixed to the axial end surface of the stator holder 70. In this case, since the stator holder 70 is provided with the refrigerant passage 85, the heat generated in the first partial winding 151A is directly transferred from the first transition portion 153A to the vicinity of the refrigerant passage 85 of the stator holder 70. It is transmitted to Further, the fixing pin 191 is inserted into the recess 105 of the stator holder 70, so that heat is promoted to the stator holder 70 side through the fixing pin 191. With this configuration, the cooling performance of the stator winding 61 is improved.

In the present embodiment, 18 insulating covers 161 and 163 are stacked on the inside and outside in the axial direction at the coil end CE, while the same number of insulating covers 161 and 163 are arranged on the axial end surface of the stator holder 70. Recesses 105 are provided at 18 locations. The structure is such that fixing is performed by fixing pins 191 in the 18 recesses 105.

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

When assembling each coil module 150A, 150B to core assembly CA, all first coil modules 150A are first attached to the outer circumferential side of core assembly CA, and then all second coil modules 150B are attached, It is preferable to fix with a fixing pin 191. Alternatively, two first coil modules 150A and one second coil module 150B are first fixed to the core assembly CA with one fixing pin 191, and then the first coil module 150A is assembled. The assembly of the second coil module 150B and the fixing using the fixing pins 191 may be repeated in this order.

Next, the busbar module 200 will be explained.

The busbar module 200 is electrically connected to the partial windings 151 of each coil module 150 at the stator winding 61, and connects one end of the partial windings 151 of each phase in parallel for each phase, and also connects each partial winding 151 in parallel for each phase. This is a winding connection member that connects the other end of 151 at a neutral point. FIG. 29 is a perspective view of the busbar module 200, and FIG. 30 is a sectional view showing a part of the longitudinal section of the busbar module 200.

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

As shown in FIG. 30, the annular portion 201 has a substantially annular plate shape and has laminated plates 204 laminated in multiple layers (five layers in this embodiment) in the axial direction. Four bus bars 211 to 214 are provided sandwiched therebetween. Each of the bus bars 211 to 214 has an annular shape 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. . These bus bars 211 to 214 are arranged in the axial direction in the annular portion 201 with their plate surfaces facing each other. Each laminate 204 and each bus bar 211 to 214 are bonded to each other with an adhesive. It is desirable to use an adhesive sheet as the adhesive. However, a structure in which a liquid or semi-liquid adhesive is applied may also be used. Connection terminals 202 are connected to each of the bus bars 211 to 214 so as to protrude radially outward from the annular portion 201, respectively.

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

Note that the busbar module 200 may be provided with the busbars 211 to 214 embedded in the annular portion 201, and the busbars 211 to 214 arranged at predetermined intervals are integrally insert-molded. It may be something. Furthermore, the arrangement of each of the bus bars 211 to 214 is not limited to a configuration in which all the bus bars are arranged in the axial direction and all plate surfaces face in the same direction. A configuration in which the plates are arranged in rows, a configuration in which the plate surfaces extend in different directions, etc. may be used.

In FIG. 29, each connection terminal 202 is arranged in the circumferential direction of the annular portion 201 and is provided so as to extend in the axial direction on the outside in the radial direction. The connection terminals 202 include a connection terminal connected to the U-phase bus bar 211, a connection terminal connected to the V-phase bus bar 212, a connection terminal connected to the W-phase bus bar 213, and a neutral point. and a connection terminal connected to a bus bar 214 for use. The connection terminals 202 are provided in the same number as the winding ends 154, 155 of each partial winding 151 in the coil module 150, 155 are connected one by one. 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 made of, for example, a bus bar material, and is provided to extend in the axial direction. The input/output terminal 203 includes a U-phase input/output terminal 203U, a V-phase input/output terminal 203V, and a W-phase input/output terminal 203W. These input/output terminals 203 are connected to bus bars 211 to 213 for each phase within the annular portion 201, respectively. Through these input/output terminals 203, power is input/output from an inverter (not shown) to each phase winding of the stator winding 61.

Note that the bus bar module 200 may be configured to be integrally provided with a current sensor that detects the phase current of each phase. In this case, it is preferable that the bus bar module 200 is provided with a current detection terminal, and the detection result of the current sensor is outputted to a control device (not shown) through the current detection terminal.

Further, the annular portion 201 has a plurality of protrusions 205 that protrude toward the inner circumference as a fixed portion for the stator holder 70, and a through hole 206 extending in the axial direction is formed in the protrusions 205. ing.

FIG. 31 is a perspective view showing a state in which the busbar module 200 is assembled to the stator holder 70, and FIG. 32 is a longitudinal cross-sectional view of a fixed portion where the busbar module 200 is fixed. In addition, please refer to FIG. 12 for the configuration of the stator holder 70 before the busbar module 200 is assembled.

In FIG. 31, the busbar module 200 is provided on the end plate part 91 so as to surround the boss part 92 of the inner cylinder member 81. The busbar module 200 is fixed to the stator holder 70 (inner cylinder member 81) by fastening fasteners 217 such as bolts in a state where the position is determined by assembling the inner cylinder member 81 to the support column 95 (see FIG. 12). ing.

More specifically, as shown in FIG. 32, the end plate portion 91 of the inner cylinder member 81 is provided with a support portion 95 extending in the axial direction. The busbar module 200 is fixed to the support 95 by fasteners 217 with the support 95 inserted through the through holes 206 provided in the plurality of protrusions 205 . In this embodiment, the busbar module 200 is fixed using a retainer plate 220 made of a metal material such as iron. The retainer plate 220 includes a fastened part 222 having an insertion hole 221 through which a fastener 217 is inserted, a pressing part 223 that presses the top surface of the annular part 201 of the busbar module 200, and a space between the fastened part 222 and the pressing part 223. It has a bend portion 224 provided at the bend portion 224 .

When the retainer plate 220 is installed, the fastener 217 is inserted into the insertion hole 221 of the retainer plate 220, and the fastener 217 is screwed onto the support column 95 of the inner cylinder member 81. Further, the pressing portion 223 of the retainer 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 support column 95, the retainer plate 220 is pushed downward in the figure, and the annular section 201 is pressed downward by the pressing section 223 accordingly. The downward pressing force in the drawing that occurs when the fastener 217 is screwed is transmitted to the pressing part 223 through the bend part 224, so the pressing part 223 is pressed with the elastic force in the bend part 224. ing.

As described above, the annular projection 201a is provided on the upper surface of the annular portion 201, and the tip of the retainer plate 220 on the pressing portion 223 side can come into contact with the projection 201a. This suppresses the downward pressing force of the retainer plate 220 in the drawing from escaping to the outside in the radial direction. In other words, the configuration is such that the pressing force generated when the fastener 217 is screwed is properly transmitted to the pressing portion 223 side.

Note that, as shown in FIG. 31, when the busbar module 200 is assembled to the stator holder 70, the input/output terminal 203 is located 180 degrees on the opposite side in the circumferential direction from the inlet opening 86a and the outlet opening 87a communicating with the refrigerant passage 85. It is located at a location where However, these input/output terminals 203 and each of the openings 86a, 87a may be provided at the same position (that is, adjacent position).

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

As shown in FIG. 1, in the rotating electric machine 10, the input/output terminals 203 of the busbar module 200 are provided so as to protrude outward from the housing cover 242, and are connected to the relay member 230 on the outside of the housing cover 242. There is. The relay member 230 is a member that relays connections between the input/output terminals 203 for each phase extending from the bus bar module 200 and the power lines for each phase extending from an external device such as an inverter.

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

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

Three relay bus bars 234 provided for each phase are attached to the main body portion 231. The relay bus bar 234 is bent into a substantially L-shape, and is fixed to the main body 231 with a fastener 235 such as a bolt. It is fixed to the tip of the holder with a fastener 236 such as a bolt and a nut.

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

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

As shown in FIG. 35, the stator winding 61 includes 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. There is. The inverter 260 is constituted by a full bridge circuit having upper and lower arms of the same number as the number of phases, and a series connection body consisting of an upper arm switch 261 and a lower arm switch 262 is provided for each phase. Each of these switches 261 and 262 is turned on and off by a driver 263, and the phase windings of each phase are energized by turning them on and off. Each switch 261, 262 is constituted by a semiconductor switching element such as a MOSFET or an IGBT. Further, a charge supply capacitor 264 is connected to the upper and lower arms of each phase in parallel to the series connection body of the switches 261 and 262 for supplying the charges required during switching to each switch 261 and 262.

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

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

Incidentally, since the rotating electric machine 10 of this embodiment has a slotless structure (teethless structure), the inductance of the stator 60 is reduced and the electrical time constant is small. Under conditions where the constant is small, it is desirable to increase the switching frequency (carrier frequency) and increase the switching speed. In this respect, since the capacitor 264 for charge supply is connected in parallel to the series connection of the switches 261 and 262 of each phase, the wiring inductance is lowered, and even in a configuration with a high switching speed, appropriate surge Countermeasures 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 configured by, for example, a battery pack in which a plurality of single cells are connected in series. Further, a smoothing capacitor 266 is connected to the high potential side terminal and the low potential side terminal of the inverter 260 in parallel to the DC power supply 265.

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

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

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

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

The three-phase converter 275 converts the d-axis and q-axis command voltages into U-phase, V-phase, and W-phase command voltages. The above-mentioned 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 of the U-phase, V-phase, and W-phase are feedback control values.

The operation signal generation unit 276 generates an operation signal for the inverter 260 based on the three-phase command voltage using a well-known triangular wave carrier comparison method. Specifically, the operation signal generation unit 276 controls the upper and lower arm switches in each phase by PWM control based on a magnitude comparison between 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. Generates an operation signal (duty signal). The switch operation signal generated by the operation signal generation section 276 is output to the driver 263 of the inverter 260, and the driver 263 turns on and off the switches 261 and 262 of each phase.

Next, the torque feedback control process will be explained. This process is mainly used for the purpose of increasing the output of the rotating electric machine 10 and reducing losses under operating conditions where the output voltage of the inverter 260 becomes large, such as in a high rotation region and a high output region. The control device 270 selects and executes either the torque feedback control process or the current feedback control process based on the operating conditions of the rotating electrical machine 10.

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

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

Similar to the dq converter 272, the dq converter 282 converts the current detected value by the current sensor provided for each phase into a d-axis current and a q-axis current. The torque estimator 283 calculates estimated torque values corresponding to the U, V, and W phases based on the d-axis current and the q-axis current. Note that the torque estimation unit 283 may calculate the voltage amplitude command based on map information in which the d-axis current, the q-axis current, and the voltage amplitude command are associated.

The torque feedback control unit 284 calculates a voltage phase command, which is a command value of the phase of the voltage vector, as a manipulated variable for feedback controlling the estimated torque value to the power running torque command value or the power generation torque command value. The torque feedback control unit 284 calculates a voltage phase command using a PI feedback method based on the deviation of the estimated torque 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 for 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 three-phase command voltages based on a voltage amplitude command, a voltage phase command, and an electrical angle θ, and generates a signal in which the calculated three-phase command voltages are normalized by the power supply voltage. A switch operation signal for the upper and lower arms in each phase is generated by PWM control based on magnitude comparison between the signal and a carrier signal such as a triangular wave signal. The switch operation signal generated by the operation signal generation section 285 is output to the driver 263 of the inverter 260, and the driver 263 turns on and off the switches 261 and 262 of each phase.

Incidentally, the operation signal generation unit 285 generates a signal based on the voltage amplitude command, the voltage phase command, the electrical angle θ, and the pulse pattern information, which is map information in which the switch operation signal is associated, the voltage amplitude command, the voltage phase command, and the electrical angle θ. The switch operation signal may also be generated.

(Modified example)
Modifications of the above embodiment will be described below.

- You may change the structure of the magnet in the magnet unit 22 as follows. In the magnet unit 22 shown in FIG. 38, the direction of the axis of easy magnetization in the magnet 32 is oblique to the radial direction, and a linear magnet magnetic path is formed along the direction of the axis of easy magnetization. Also in this configuration, the length of the magnetic path of the magnet 32 can be made longer than the thickness dimension in the radial direction, making it possible to improve permeance.

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

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

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

- In the above-described configuration, in the stator winding 61, all the partial windings 151 are connected in parallel for each phase winding, but this may be changed. For example, all partial windings 151 for each phase winding may be divided into a plurality of parallel connection groups, and the plurality of parallel connection groups may be connected in series. In other words, a total of n partial windings 151 in each phase winding are divided into two parallel connection groups of n/2 windings, three parallel connection groups of n/3 windings, etc., and these are connected in series. It may also be configured to connect. Alternatively, the stator winding 61 may have a configuration in which all of the plurality of partial windings 151 are connected in series for each phase winding.

- The stator winding 61 in the rotating electrical machine 10 may have a configuration having two phase windings (U-phase winding and V-phase winding). In this case, for example, in the partial winding 151, a pair of intermediate conductor portions 152 are provided one coil pitch apart, and between the pair of intermediate conductor portions 152, the intermediate conductor portion 152 of the partial winding 151 of the other one phase is provided. It is sufficient if the configuration is such that one is arranged.

- The rotating electric machine 10 can be embodied as an inner rotor type surface magnet type rotating electric machine instead of an outer rotor type surface magnet type rotating electric machine. FIGS. 39(a) and 39(b) are diagrams showing the configuration of the stator unit 300 in the case of an inner rotor structure. Of these, FIG. 39(a) is a perspective view showing the coil modules 310A, 310B assembled to the core assembly CA, and FIG. 39(b) is a partial winding 311A, 311B included in each coil module 310A, 310B. FIG. In this example, a stator holder 70 is assembled to the radially outer side of the stator core 62, thereby forming a core assembly CA. Further, a plurality of coil modules 310A and 310B are assembled inside the stator core 62 in the radial direction.

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

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

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

In FIG. 40, insulating covers 315 and 316 are arranged to overlap in the axial direction. Furthermore, a recess 317 provided on the side surface of the insulating cover 315 and a through hole 319 provided in the protrusion 318 of the insulating cover 316 at a center position between one end of the insulating cover 316 in the circumferential direction and the other end thereof. are continuous in the axial direction, and each part is fixed by a fixing pin 321.

In addition, in FIG. 40, the fixing position of each insulating cover 315, 316 by the fixing pin 321 is on the axial end surface of the stator holder 70 which is radially outer than the stator core 62, and On the other hand, it is configured to be fixed by a fixing pin 321. In this case, since the stator holder 70 is provided with a cooling structure, the heat generated in the partial windings 311A and 311B is easily transmitted to the stator holder 70. Thereby, the cooling performance of the stator winding 61 can be improved.

- The stator 60 used in the rotating electrical machine 10 may have protrusions (for example, teeth) extending from the back yoke. In this case as well, it is only necessary that the coil module 150 and the like be assembled to the stator core to the back yoke.

・The rotating electric machine is not limited to one with a star connection, but may be one with a delta connection.

- As the rotating electrical machine 10, instead of a rotating field-type rotating electrical machine in which the field element is a rotor and the armature is a stator, a rotating armature-type rotating electrical machine in which the armature is a rotor and the field element is a stator is used. It is also possible to employ a rotating electric machine.

(Modification 2)
In the above embodiment or the above modification, the structure of the conducting wire CR as a conducting wire may be as follows. Hereinafter, the structure of the conductive wire CR in this modified example will be explained in detail. Note that, in this modification, differences from the configurations described in each of the embodiments and modifications described above will be mainly explained. Further, in this modification, the basic configuration of the rotating electrical machine 10 will be explained using the first embodiment as an example.

First, the stator winding 61 will be explained. As explained in FIG. 16 etc., the stator winding 61 includes a plurality of partial windings 151 formed into an annular shape by winding the conducting wire CR, and the partial windings 151 are connected in parallel or in series. As a result, the stator winding 61 is configured. Each of the partial windings 151 has a pair of intermediate conductor portions 152 and a pair of transition portions 153A and 153B, as described in FIGS. 18 to 25 and the like. The intermediate conducting wire portions 152 are arranged at predetermined intervals in the circumferential direction. The transition portions 153A and 153B are provided to connect the pair of intermediate conductor portions 152.

Further, as described above, the partial winding 151 is formed by winding the conducting wire material CR in multiple layers so that the cross section of the conducting wire gathering portion is approximately square. At this time, as shown in FIG. 41, the conducting wire material CR is wound multiple times so as to be lined up in the circumferential direction and the radial direction in the intermediate conducting wire portion 152. That is, the partial winding 151 is formed so that the conductive wire CR is laminated in a plurality of layers in the circumferential direction in the intermediate conductor portion 152 and arranged in a plurality of rows in the radial direction, so that the cross section has a substantially rectangular shape. There is. At this time, in order to increase the space factor, it is desirable to arrange the conductor wires CR so that no gaps are formed between them. In this modification example 2, the cross-sectional shape of the conducting wire CR is approximately square, and the conductive wires CR are aligned in the circumferential direction and the radial direction with almost no gaps. Although the first coil module 150A is illustrated and explained in FIG. 41, the same applies to the second coil module 150B.

FIG. 42 shows an enlarged sectional view of the conducting wire CR. In Modification 2, the cross section of the conducting wire CR has a rectangular shape. Note that the cross section of the conductive wire CR is not limited to a square shape, and may be any shape, for example, a polygon other than a square or a circle. The conductive wire material CR is constructed by covering a plurality of wires 501 in a bundled state with an insulating coating 502. Thereby, insulation is ensured between the conducting wire materials CR that overlap each other in the circumferential direction or the radial direction, and between the conducting wire material CR and the stator core 62.

It should be noted that the stator winding 61 made of the conductive wire material CR maintains its insulation properties due to the insulating coating 502, except for exposed portions for connection. The exposed portions are, for example, the winding end portions 154 and 155.

This strand 501 includes a conductor 503 through which current flows, and a fusion layer 504 covering the surface of the conductor 503. The conductor 503 is, for example, a conductive metal such as copper. Although the conductor 503 is a square wire with a substantially octagonal cross section, it may have other shapes such as a round wire (for example, a polygonal shape, an ellipse, etc.). Further, the fusion layer 504 is, for example, an epoxy adhesive resin. Heat resistance is about 150°C.

The fusion layer 504 is thinner than the insulating coating 502, and has a thickness of, for example, 10 μm or less. In the wire 501, only the fusion layer 504 is formed on the surface of the conductor 503, and no separate insulating layer is provided. Note that the fusion layer 504 may be made of an insulating member. In other words, the idea is to serve both as the resin of the self-bonding wire and as insulation. Although the insulating layer and the fusion layer are usually separated, the epoxy adhesive resin serving as the fusion layer 504 also serves as an insulating layer, and what is normally called an insulating layer is missing.

Further, the fusion layer 504 melts at a lower temperature than the insulating coating 502. It is characterized by a high dielectric constant. The characteristic of melting at low temperatures has the effect of making it easier to establish electrical continuity at the ends between the strands 501. Also, fusing etc. are easy to do. Further, the reason why the dielectric constant may be high is the precondition that the potential difference between the strands 501 is smaller than that between the conductive wires CR. With this setting, even if the adhesive layer 504 melts, the eddy current loss can be effectively reduced by contact resistance alone.

When the plurality of wires 501 are bundled together, the fusion layers 504 are in contact with each other and are fused together. As a result, the adjacent strands 501 are fixed to each other, and vibrations and sounds caused by the strands 501 rubbing against each other are suppressed. Further, the shape is maintained by bundling and gathering a plurality of wires 501 provided with the fusion layer 504 and fusing the fusion layers 504 together.

The insulating coating 502 is a modified PI enamel resin having a heat resistance of 220°C to 240°C. Oil resistance is achieved by using modified PI. This prevents ATF from being attacked by hydrolysis and sulfur. In this case, the linear expansion coefficient of the epoxy adhesive resin is larger than that of the modified PI enamel resin.

This insulating coating 502 is formed into a wide tape shape, and is spirally wound around the outer periphery of the bundled plurality of wires 501. As shown in FIG. 43, the insulating coatings 502 are wound in a helical shape while being shifted little by little in the stretching direction of the strands 501 (left-right direction in FIG. 43) so that the insulating coatings 502 overlap each other. Specifically, they are wound so as to overlap by about half the width of the insulating coating 502. Thereby, the insulating coating 502 is configured to have a double layer everywhere except for the ends. Note that it is not always necessary to double the number of layers, and it may be three or more layers. Moreover, a single layer may be used as long as the wire 501 is not exposed.

The insulating coating 502 has a higher insulating performance than the fused layer 504 of the wire 501, and is configured to insulate between phases. For example, when the thickness of the fused layer 504 of the wire 501 is about 1 μm, it is desirable that the total thickness of the insulating coating 502 be about 9 μm to 50 μm so that insulation between phases can be suitably performed. . Specifically, when the insulating coating 502 is made double, the thickness of each layer may be approximately 5 μm.

Next, a method for manufacturing the rotating electrical machine 10, more specifically, the stator winding 61, will be described based on FIGS. 44 and 45. FIG. 44 is a flowchart showing the flow of the manufacturing method, and FIG. 45 is an image diagram of the manufacturing line.

The conductor 503 is drawn out from a plurality of cylindrical bobbins 601 (reels) around which the linear conductor 503 is wound, and a fusion layer 504 is applied to the surface thereof (step S101). Note that the wire 501 on which the conductor 503 is coated with the fusion layer 504 may be wound and stored in the bobbin 601 in advance, and the wire 501 may be pulled out from the bobbin 601.

Then, the wires 501 are bundled and assembled (step S102). At that time, the fusion layers are brought into contact with each other and fused. Further, in step S102, tension is applied to each strand 501 to make it straight. In addition, before gathering (before step S102), it may be made into a straight line. This step S102 becomes an assembly step.

On the other hand, the wide tape-shaped insulating coating 502 is rolled to make it even thinner (step S103). Note that by being rolled, the insulating coating 502 is work-hardened, and the tensile strength of the insulating coating 502 is improved compared to before processing. This step S103 becomes a rolling process.

After that (after step S102 and step S103), a rolled tape-shaped insulating coating 502 is spirally wound around the outer periphery of the bundled plurality of wires 501 to cover the outer periphery. (Step S104). Step S104 is a covering step. Then, with the plurality of wires 501 covered with the insulating coating 502, a crushing process is performed so that the cross section has a predetermined shape (step S105). Thereby, the conductive wire CR is formed. Note that the crushing step may be performed after the gathering step of bundling the strands 501.

Then, the stator winding 61 is formed by winding the conducting wire CR as described in the first embodiment (step S106). For example, the stator winding 61 is formed by winding the conducting wire CR along the stator winding bobbin 602. Step S106 is a winding process. Note that the straightness of the wire 501 is maintained from the time the wire 501 is straightened until it is wound to form the stator winding 61 (from step S102 to step S106). ing. That is, the production line is configured so that after the conductive wire CR is formed, it is not wound up again onto the cylindrical bobbin.

By the way, when forming a conductive wire CR by bundling wires and covering them with an insulating coating, in order to improve the space factor of the conductor, as shown in FIG. It can be said that it is desirable to wrap the insulating coating 702 so that there is no gap between the insulation coating 702 and the coating 702 . Further, for the same reason, it is desirable to arrange the bundled strands 701 without any gaps between them. In addition, in FIG. 46, the cross-sectional shape of the conducting wire CR is square, and the cross-sectional shape of the strands 701 is square, and they are arranged without gaps in the circumferential direction and the radial direction. As shown in FIG. 41, the space factor is improved by arranging the rectangular conductive wire materials CR in the circumferential direction and the radial direction without gaps.

However, when configured in this way, a problem arises in that stray capacitance increases. That is, the intermediate conducting wire portion 152 is arranged straight along the axial direction. Therefore, when the conductive wire CR is arranged without any gaps in the circumferential direction and the radial direction, the conductive wire 701 (more specifically, the conductor 703 of the wire 701) passes through the insulating coating 702, as shown in FIG. , will be wired in parallel. In this case, the area facing each other via the insulating coating 702 becomes large, and the stray capacitance formed between the conductive wire materials CR adjacent in the circumferential direction or the radial direction becomes large. In particular, when the insulation coating 702 is made thinner, the stray capacitance becomes larger. In addition, when there are no teeth or the like as in a slotless structure, stray capacitance also increases between intermediate conductor portions 152 that are adjacent to each other in the circumferential direction.

Similarly, between the wires 701 adjacent to each other in the circumferential direction or the radial direction, the area where the conductors 703 face each other with the insulating layer 704 interposed therebetween becomes large, and the stray capacitance becomes large. When the stray capacitance increases, the influence of resonance increases, which can cause noise and the like.

Therefore, in this modification example 2, as shown in FIG. 42, a gap 810 is formed between the outer periphery of the bundled plurality of wires 501 and the insulating coating 502, extending along the extending direction of the conductive wire material CR. There is. Air may exist in the gap 810. Specifically, when bundling a plurality of wires 501, unevenness is created on the outer periphery, and by wrapping the tape-shaped insulating coating 502 as it is, the outer periphery of the plurality of bundled wires 501 and the insulating coating 502 are separated. A gap 810 is formed between them, extending along the extending direction of the conductive wire CR. In addition, in the crushing process, unevenness may be formed on the outer periphery of the bundled plurality of wires. Further, when performing a crushing step after wrapping the insulating coating 502, it is desirable that the gap 810 is not completely crushed.

Further, an inter-strand gap 820 extending along the extending direction of the conductive wire CR is also formed between the bundled plurality of strands 501. Air may exist in the inter-strand gap 820. Note that when performing the crushing process after bundling the plurality of wires 501, it is desirable that the gaps 820 between the wires are not completely crushed.

In the above modification 2, the following effects can be obtained.

The insulating coating 502 is formed into a tape shape and is wound around the outer periphery of the plurality of bundled strands 501, and there is a gap between the outer periphery of the plurality of bundled strands 501 and the insulating coating 502. A gap 810 is formed that extends along the extending direction of the conductive wire CR. This gap 810 reduces the area of the strands 501 that face each other with the insulating coating 502 in between when the conductive wire CRs are wired in parallel as shown in FIG. 42 between adjacent conductive wire CRs. can be done. In other words, capacitance can be reduced. Alternatively, the distance between the strands 501 can be determined between adjacent conducting wire materials CR. This makes it possible to suppress resonance and reduce noise and the like between adjacent conducting wire materials CR. Furthermore, since the tape-shaped insulating coating 502 is wound, the gap 810 formed to extend in the extending direction of the conductive wire CR can be left in a better manner than when the coating is applied by extrusion.

Further, inter-strand gaps 820 are also formed between the bundled plurality of strands 501, which extend along the extending direction of the conductive wire CR. Thereby, the capacitance generated between adjacent strands 501 can be reduced.

The conductive wires CR are insulated by an insulating coating 502. On the other hand, although the conductors 503 of the wire 501 are covered with the fusion layer 504, since no insulating layer is provided, the conductors 503 may come into contact with each other and become electrically conductive. However, the potential difference between the conductors 503 is small, and even if the fusion layer 504 is torn when bundling the plurality of wires 501 or covering the insulating coating 502, the contact area between the conductors 503 is very small. Contact resistance is very high. Therefore, even if the conductors 503 are not completely insulated, it is possible to suppress the eddy current from flowing between the conductors 503.

Therefore, the fusion layer 504 was directly provided on the conductor 503 without providing an insulating layer on the surface of the conductor 503, and the fusion layers 504 were fused together. This eliminates the need to provide an insulating layer. Further, by providing the fusion layer 504, the plurality of wires 501 can be easily kept in a bundled state and covered with the insulating coating 502. The above makes it easier to manufacture the conductive wire CR and the rotating electric machine 10.

The insulating coating 502 is formed into a tape shape, and is spirally wound around the outer periphery of the bundled plurality of wires 501. Since the conductive wire material CR is formed by winding the tape-shaped insulation coating 502 around the plurality of wires 501, the insulation coating 502 can be made thinner than when the plurality of wires 501 are molded with resin. becomes possible. Furthermore, since the wires 501 are fused by the fusion layer 504, they can maintain their bundled shape, and the tape-shaped insulating coating 502 can be easily wound.

The insulating coating 502 is rolled, unlike the conventional process of applying the coating by extrusion, so it can be thinned and work-hardened. Therefore, when the stator winding 61 is formed by winding the conducting wire CR, the insulating coating 502 will not be torn. In other words, when the split wires 501 are bent, they move irregularly and try to break the insulation coating 502. The force peculiar to the splitting wires is absorbed by the insulating coating 502, which is a strengthened tape. I can do it. Note that if the film is applied by extrusion, there is a risk that it will break. Furthermore, since the insulation coating 502 can be made thinner, the space factor of the conductor 503 with respect to the accommodation space of the stator winding 61 can be improved.

In the coating process of step S104, the insulating coating 502 is spirally wound so that the insulating coatings 502 overlap when the bundled plurality of wires 501 are wound around the outer periphery. This can prevent foreign substances such as dust and water from reaching the strands 501 from the outside through the gaps between the insulation coatings 502. Moreover, since the insulating coatings 502 are overlapped, even if the stator winding 61 is formed by winding the conducting wire material CR, it is difficult to form a gap.

After the conductor CR is formed (after the coating process), when the conductor CR wound around the bobbin is used, the conductor CR pulled out from the bobbin may bend, have slight deviations in straightness, and This inhibits the improvement of product factor. In other words, when winding the conducting wire CR into a bobbin, there is a problem unique to parting lines in that the wires inside and outside the bobbin have different elongations. Specifically, only the outer line of the bobbin is stretched. When the conductive wire CR, which is extended only on the outside, is pulled out from the bobbin to form the stator winding 61, the conductive wire CR becomes wavy because a portion thereof is shrunk. When it is wound to form the stator winding 61, gaps are created between the conducting wire materials CR, which impedes an increase in the space factor and increases copper loss.

Therefore, in the assembling process of step S101, pressure is applied to the bundled plurality of wires 501 to form a straight line, and after the assembling process, the conductive wire CR is wound in the winding process of step S106 to form the stator winding. Each strand 501 was maintained in a straight line until 61 was formed. Therefore, the straightness of the conductive wire CR can be improved compared to the case where the conductive wire CR is wound around a cylindrical bobbin again. In other words, when the conductive wire CR is wound around the bobbin, due to the difference in curvature between the outer circumferential side and the inner circumferential side, deviation in straightness of the conductive wire CR is less likely to occur, and wavy characteristics are less likely to occur. Therefore, when winding the conducting wire material CR to form the stator winding 61, gaps are less likely to be formed between the conducting wire materials CR, making it possible to improve the space factor.

The first coil module 150A has a shape in which the partial winding 151 is bent radially inward, that is, toward the stator core 62 side at the coil end CE. However, as described above, the insulating coating 502 is rolled to improve its tensile strength, so it is difficult to tear and can provide appropriate insulation. Further, by forming the coil end CE to be bent in the radial direction, the axial length of the stator winding 61 can be suppressed.

The thickness of the insulating coating 502 is configured to be thicker than the fusion layer 504. By doing so, the necessary intra-phase withstand voltage and inter-phase withstand voltage can be ensured, and eddy current loss can be prevented without increasing copper loss. Copper loss occurs because the area of copper decreases due to the increase in coating.

(Another example of modification 2)
The configurations of the conducting wire CR and the stator winding 61 in Modification 2 may be changed as described below. In addition, in this other example, differences from the configurations described in each of the above-described embodiments and modifications will be mainly explained. Further, in this modification, the basic configuration will be explained using Modification 2 as an example.

- In the above modification 2, the conductive wire CR may be configured by twisting a plurality of wires 501 together. In this case, the generation of eddy currents in each strand 501 can be further suppressed. Furthermore, since each strand 501 is twisted, there are portions in one strand 501 where the directions of magnetic field application are opposite to each other, so that the back electromotive force is canceled out. Therefore, it is possible to reduce eddy currents. In particular, by forming the wire 501 from a fibrous conductive member, it becomes possible to make the wire thinner and to significantly increase the number of twists, thereby making it possible to more appropriately reduce eddy currents.

Furthermore, by twisting the plurality of wires 501 together, a gap 810 extending along the extending direction of the conductive wire CR can be formed in a spiral shape around the outer periphery of the bundled plurality of wires 501. Thereby, the area of the strands 501 facing each other with the insulating coating 502 interposed between the adjacent conductive wire materials CR can be further reduced, and the capacitance can be reduced.

- PA, PI, PAI, PEEK, etc. may be used as the insulating coating 502 of the second modification. Further, as the fusing layer 504, fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, or LCP may be used.

- Although the crushing step was provided in the second modification, the crushing step may be omitted as long as the wires 501 can be bundled suitably. The crushing step may be performed after the wires 501 are bundled, but a crushing step may be performed before the wires 501 are bundled so that the cross-sectional shape of each wire 501 becomes square.

- In the above modification 2, the cross-sectional shape of the conductor 503 may be hexagonal, pentagonal, square, triangular, or round, and the cross-sectional shape of the conducting wire CR may also be hexagonal, pentagonal, square, or round. It can be triangular or round. For example, as shown in FIG. 47(a), the cross-sectional shape of the conductor 503 may be hexagonal, and the cross-sectional shape of the conducting wire CR may be polygonal. Moreover, as shown in FIG. 47(b), the cross-sectional shape of the conductor 503 and the conducting wire CR may be round. Note that the shapes of the conductors 503 and the welding layer 504 do not all have to be the same, and the shapes of some or all of the conductors 503 and the welding layer 504 may be different due to a crushing process or the like. Moreover, it does not matter if the shape of some or all of the conductor 503 or the fusion layer 504 becomes distorted due to the crushing process. Note that it is desirable that a gap 810 be formed at least between the insulating coating 502 and the outer periphery of the bundled plurality of wires 501.

- In the above-mentioned modification 2, the conductor 503 of the wire 501 may be configured as a composite body made by bundling thin fibrous conductive members. For example, the conductor may be a composite of CNT (carbon nanotube) fibers. As the CNT fibers, fibers containing boron-containing fine fibers in which at least a portion of carbon is replaced with boron may be used. As the carbon-based fine fibers, vapor grown carbon fibers (VGCF) and the like can be used in addition to CNT fibers, but it is preferable to use CNT fibers.

- In the above embodiment and modification 2, the stator winding 61 was covered and sealed with sealing members such as the insulating covers 161 to 164 and the insulating cover 157, but the stator winding 61 was not wound with a resin mold. The periphery of each conductive wire CR may be sealed so as to cover it. In this case, the sealing member formed by resin molding is preferably provided in a range including the coil end CE of the stator winding 61. That is, it is desirable that the stator winding 61 is substantially entirely resin-sealed except for the winding ends 154 and 155, that is, the connecting portions.

Note that when the rotating electric machine 10 is used as a vehicle power source, the above-mentioned sealing member may be made of highly heat-resistant fluororesin, epoxy resin, PPS resin, PEEK resin, LCP resin, silicone resin, PAI resin, PI resin, etc. Preferably, it is made of resin or the like. Furthermore, considering the linear expansion coefficient from the viewpoint of suppressing cracking due to expansion differences, it is desirable that the sealing member and the insulating coating 502 are made of the same material. That is, silicone resins whose coefficient of linear expansion is generally twice or more that of other resins are preferably excluded. In addition, for electric products such as electric vehicles that do not have an engine that uses combustion, PPO resin, phenol resin, and FRP resin, which have heat resistance of about 180° C., are also candidates. This does not apply in fields where the ambient temperature of the rotating electric machine can be considered to be less than 100°C.

- In the above-mentioned modification 2, after forming the conducting wire CR, it may be wound up and housed in a cylindrical bobbin. That is, as shown in FIG. 48, after step S105, after forming the conductive wire CR, it may be wound up and housed in a cylindrical bobbin (step S105a). Then, the stator winding 61 may be formed by pulling out the conducting wire CR from the bobbin (step S105b) and winding the conducting wire CR as described in the first embodiment. Step S106).

In this case, when the conductive wire CR is wound onto the bobbin, the straightness of the conductive wire CR may shift due to the difference in curvature between the outer circumferential side and the inner circumferential side, resulting in a wave-like habit. becomes. For this reason, when the stator winding 61 is formed by winding the conducting wire material CR, gaps are likely to be formed between the conducting wire materials CR. Therefore, a filler such as varnish is filled into the minute gaps between the lines (step S107). This makes it possible to reduce vibration. Further, after forming the conductive wire material CR, since it is once wound around a cylindrical bobbin, the wire 501 is made into a straight shape until it is wound to form the stator winding 61 (step S102 to step (up to S106), there is no need to maintain the straightness of the wire 501. That is, it is no longer necessary to implement these steps in one manufacturing line, and the degree of freedom of the manufacturing line can be improved. Further, by forming a gap between the conductive wires CR wired in parallel, stray capacitance can be suppressed.

- In the above-mentioned modification 2, an inter-conductor member was not provided between the intermediate conductor portions 152 in the circumferential direction, but an inter-conductor member made of a non-magnetic material and conductive may be provided. For example, as the inter-conductor member, the circumferential width of the inter-conductor member at one magnetic pole is Wt, the saturation magnetic flux density of the inter-conductor member is Bs, the circumferential width of the magnet portion at one magnetic pole is Wm, and the width of the inter-conductor member at one magnetic pole is Wt. When the residual magnetic flux density of the magnet portion is Br, a magnetic material satisfying the relationship Wt×Bs≦Wm×Br may be used. Specifically, extremely thin tooth-shaped portions extending in the radial direction that cannot function as teeth may be provided. According to this, since the conductive inter-conductor member is arranged between the intermediate conductor portions 152 that are adjacent to each other in the circumferential direction, the inter-conductor member functions as an electrostatic shield and can reduce the influence of noise. . Note that it is desirable that the inter-conducting wire member be formed along the radial direction so as to block the intermediate conductive wire portions 152 that are adjacent to each other in the circumferential direction.

The disclosure in this specification is not limited to the illustrated embodiments. The disclosure includes the illustrated embodiments and variations thereon by those skilled in the art. For example, the disclosure is not limited to the combinations of parts and/or elements illustrated in the embodiments. The disclosure can be implemented in various combinations. The disclosure may have additional parts that can be added to the embodiments. The disclosure includes those in which parts and/or elements of the embodiments are omitted. The disclosure encompasses any substitutions or combinations of parts and/or elements between one embodiment and other embodiments. The disclosed technical scope is not limited to the description of the embodiments. The technical scope of some of the disclosed technical scopes is indicated by the description of the claims, and should be understood to include equivalent meanings and all changes within the scope of the claims.

DESCRIPTION OF SYMBOLS 10... Rotating electric machine, 20... Rotor, 22... Magnet unit, 60... Stator, 61... Stator winding, 152... Intermediate conductor part, 501... Element wire, 502... Insulating coating, CR... Conductive wire material.

Claims (4)

A field element (20) including a magnet portion (22) having a plurality of magnetic poles with alternating polarity in the circumferential direction, and an armature (60) having a multiphase armature winding (61), In a rotating electric machine (10) in which either the field element or the armature is a rotor,
The armature winding is configured by winding a conducting wire (CR), and has conducting wire portions (152) arranged at predetermined intervals in the circumferential direction at positions facing the magnet portion,
The conductive wire is configured by a plurality of wires (501) bundled and covered with an insulating coating (502),
The insulating coating is formed into a tape shape and is wound around the outer periphery of a plurality of bundled strands, and between the outer periphery of the plurality of bundled strands and the insulating coating, A gap is formed extending along the extending direction of the conductive wire ,
The strand includes a conductor (503) through which current flows, and an insulating layer (504) covering the surface of the conductor,
The rotating electrical machine , wherein inter-strand gaps (820) extending along the extending direction of the conducting wires are also formed between the plurality of bundled strands. The plurality of bundled strands are twisted together, and the gap extending along the extending direction of the conductive wire is formed in a spiral shape around the outer periphery of the plurality of bundled strands. The rotating electric machine described in . The strand includes a conductor (503) through which current flows, and a fusion layer (504) covering the surface of the conductor,
The rotating electric machine according to claim 1 or 2 , wherein the fusing layer is thinner than the insulating coating, and when the plurality of wires are bundled, the fusing layers contact each other and are fused. In the armature,
An inter-conductor member is provided between each conductor portion in the circumferential direction, and as the inter-conductor member, the width dimension in the circumferential direction of the inter-conductor member at one magnetic pole is Wt, the saturation magnetic flux density of the inter-conductor member is Bs, When the circumferential width dimension of the magnet part in one magnetic pole is Wm, and the residual magnetic flux density of the magnet part is Br, a magnetic material and conductive member satisfying the relationship Wt×Bs≦Wm×Br. The rotating electrical machine according to any one of claims 1 to 3 , which uses the above-mentioned configuration.

Images