JP7487511B2 - Rotating Electric Machine - Google Patents

Description

The disclosure in this specification relates to rotating electrical machines.

Conventionally, a rotating electric machine is known that includes a field element having a magnet section including multiple magnetic poles with alternating polarity in the circumferential direction, and an armature having a multi-phase armature winding. Also known is an armature configured such that a fibrous woven fabric coated or impregnated with adhesive is wound around the outer peripheral surface on the radially outer side of the armature winding (see, for example, Patent Document 1).

Japanese Patent Application Laid-Open No. 56-83234

In the above-mentioned Patent Document 1, a fibrous glass woven fabric is wound around the magnetic flux linkage portion (i.e., the coil side portion) of the armature winding. In such a configuration, there is a concern that the presence of the glass woven fabric in the air gap between the armature and the field coil will force an increase in the air gap.

The present invention was made in consideration of the above circumstances, and aims to provide a rotating electric machine that can hold the armature winding in an optimal state in the armature.

The various aspects disclosed in this specification employ different technical means to achieve their respective objectives. The objectives, features, and advantages disclosed in this specification will become more apparent by reference to the following detailed description and the accompanying drawings.

Means 1 is
a field element having a magnet portion including a plurality of magnetic poles whose polarities alternate in a circumferential direction;
an armature having a teethless structure and a multi-phase armature winding including a phase winding for each phase;
a rotor being one of the field element and the armature,
the armature winding has a coil side facing the magnet portion in a radial direction and a coil end disposed outside the magnet portion in an axial direction,
A string-like or cloth-like winding member is wound around the coil ends of the armature winding, and the phase windings of each phase arranged in the circumferential direction are fixed by the winding member.

In a rotating electric machine having an armature with a teeth-less structure, unlike a configuration in which the armature winding is fixed while housed in the slots of the armature core, there are concerns about fixing the armature winding in a stable state. In this regard, in the above-mentioned configuration, a string-like or cloth-like winding member is wound around the coil ends of the armature winding, and the winding members fix the phase windings of each phase arranged in the circumferential direction to each other. In this case, by fixing the phase windings with the winding member, it is possible to fix the armature winding in a stable state even in an armature with a teeth-less structure. In particular, since the winding member is wound only around the coil ends of the armature winding, it is possible to prevent the string-like or cloth-like winding member from being interposed in the air gap between the armature and the field element, and it is possible to prevent the air gap from becoming excessively large. As a result, the armature winding can be maintained in a suitable state.

In the second embodiment, in the first embodiment, the phase winding has a plurality of partial windings per phase, and the partial windings have a pair of intermediate conductor sections extending in the axial direction and spaced apart from each other in the circumferential direction, and a transition section that is provided on one axial end side and the other axial end side and connects the pair of intermediate conductor sections in a ring shape, and the pair of intermediate conductor sections and the transition sections are wound with multiple windings of wire material, and the partial windings are arranged in a circumferential direction, and the winding members are wound around the partial windings arranged in a circumferential direction at the coil ends of the armature winding.

As a teethless structure for the armature, a configuration is conceivable in which multiple partial windings, each having a pair of intermediate conductor portions and a transition portion, are arranged in a circumferential direction. In this case, since each partial winding is provided separately, there is a concern that radial positional deviation of any of the partial windings may occur when the partial windings are assembled. In this regard, by wrapping a winding member around the coil ends of the armature winding around the partial windings arranged in a circumferential direction, the multiple partial windings that are arranged separately can be held in place.

In the third embodiment, in the second embodiment, the transition portion has a winding end portion extending in the circumferential direction at the axial end portion of the partial winding, and when the partial windings are lined up in the circumferential direction, the winding ends of each partial winding are lined up in a ring shape, and the winding member is wound around the radial outside of the winding end portion.

In the armature winding of the above configuration, the winding ends provided at the axial ends of the partial windings in the transition section can be arranged in a ring shape. The winding member is then wound around the radially outer side of the winding ends. In this case, the winding member can be wound around the outer periphery of each of the winding ends arranged in a ring shape, making it easy to wind the winding member around the armature winding.

In means 4, in means 3, a covering member is attached to at least the winding end of the partial winding, a groove portion extending in the circumferential direction is formed on the outer peripheral surface of the covering member on the radially outer side, and the winding member is wound along the groove portion.

In the above configuration, a covering member is attached to at least the winding end of the partial winding, and the covering member ensures insulation between adjacent partial windings in the circumferential direction and enables the positioning of each partial winding. In addition, a groove extending in the circumferential direction is formed on the outer peripheral surface of the covering member on the radially outer side, and the winding member is wound along the groove, which facilitates the winding operation of the winding member and prevents the winding member from shifting position after winding.

In the fifth embodiment, the winding member is wound around the coil ends of the armature windings in the circumferential direction of the adjacent partial windings so as to fix them to each other.

In the above configuration, adjacent partial windings in the circumferential direction are fixed to each other by winding the winding member, making it possible to fix adjacent partial windings to each other, thereby enabling each partial winding to be fixed more firmly.
It is also possible to adopt a configuration in which only some of the partial windings arranged in the circumferential direction are wound with the winding member. For example, in a configuration in which the partial windings of each phase are arranged in a predetermined order in the circumferential direction, only the partial windings of a specific phase among the partial windings of multiple phases are wound with the winding member. Specifically, for example, in a configuration having U-phase, V-phase, and W-phase windings, only the partial windings of two of the phases are wound with the winding member. In this configuration, partial windings wound with the winding member and partial windings not wound with the winding member are mixed, but the relative movement of each partial winding in the circumferential direction is restricted.

In a sixth aspect of any of the second to fifth aspects, a winding support member is provided on the radially inner or radially outer side of the armature winding, opposite the field element, to support the multiple partial windings, and the partial windings are provided with integral mounting members for mounting the partial windings to the winding support member, and the mounting members integrated with the circumferentially adjacent partial windings are fixed to the winding support member at the coil ends by a common fixing member, and the winding member is wound around the coil ends of the armature winding with one end and the other end fixed to the fixing members.

In the above configuration, the mounting members integrated with circumferentially adjacent partial windings are fixed to the winding support member at the coil ends by a common fixing member, so that multiple partial windings can be easily attached to the winding support member. In addition, one end and the other end of the winding member are fixed using a fixing member for fixing the mounting members of each partial winding. This makes it possible to realize an optimal winding configuration when winding an end-shaped winding member around the coil ends of the armature winding.

In addition, the configuration for fixing each partial winding has a dual structure of fixing the winding with a fixing member and winding with a winding member, which makes it possible to fix each partial winding more effectively. In this case, fixing the winding with a fixing member makes it possible to suppress relative movement of the armature winding in the circumferential direction with respect to the winding support member.

In the seventh aspect of any one of the first to fifth aspects, a winding support member is provided to which the armature winding is attached, and the winding member is wound around the coil end of the armature winding with one end and the other end of the winding member fixed to the winding support member.

In the above configuration, one end and the other end of the winding member are fixed to the winding support member. This allows for an optimal winding configuration when winding the end-shaped winding member around the coil end of the armature winding. In addition, it is possible to prevent the armature winding from moving circumferentially relative to the winding support member.

In the eighth embodiment, the armature winding is adhesively fixed to the winding support member in the sixth or seventh embodiment.

In the above configuration, the armature winding is adhesively fixed to the winding support member, which allows the armature winding to be fixed on the coil side in addition to the coil end, making it possible to fix the armature winding more reliably.

In a ninth aspect of any one of the first to eighth aspects, a housing is provided that surrounds the field element and the armature, and the housing is provided with an inlet for introducing a cooling liquid from the outside, and the cooling liquid that has flowed in from the inlet is dripped onto the coil end of the armature winding.

In the above configuration, the coolant flowing in from the inlet of the housing drips onto the coil ends of the armature winding, thereby cooling the coil ends. In this case, the coolant spreads around the entire circumferential area of the coil ends along the string-like or cloth-like winding material wrapped around the coil ends, improving cooling performance. In other words, the winding material can be used as a guide for the coolant.

In this case, particularly in a configuration in which the winding member is wound around the radial outside of the armature winding (see FIG. 43), the winding member is provided so as to be continuous in the circumferential direction at the coil end. This allows the coolant to be distributed throughout almost the entire coil end via the winding member, realizing a configuration that is suitable for cooling the coil end.

1 is a perspective view showing an entire rotating electric machine according to a first embodiment; FIG. FIG. FIG. FIG. Cross-sectional view of the rotor. FIG. 4 is a partial cross-sectional view showing the cross-sectional structure of a magnet unit. FIG. 4 is a diagram showing the relationship between the electrical angle and the magnetic flux density of the magnet according to the embodiment. FIG. 13 is a graph showing the relationship between electrical angle and magnetic flux density for a magnet of a comparative example. FIG. FIG. FIG. 4 is a perspective view of the core assembly as viewed from one axial side. FIG. 4 is a perspective view of the core assembly as viewed from the other axial side. FIG. FIG. FIG. 4 is a circuit diagram showing a connection state of partial windings in each of three phase windings. FIG. 4 is a side view showing the first coil module and the second coil module arranged side by side for comparison; FIG. 4 is a side view showing a first partial winding and a second partial winding arranged side by side for comparison; FIG. 4 is a diagram showing a configuration of a first coil module. Cross-sectional view taken along line 20-20 in FIG. FIG. FIG. 4 is a diagram showing the configuration of a second coil module. Cross-sectional view taken along line 23-23 in Figure 22(a). FIG. FIG. 13 is a diagram showing overlap positions of film materials when each coil module is aligned in the circumferential direction. FIG. 4 is a plan view showing a state in which the first coil module is assembled to the core assembly. FIG. 4 is a plan view showing the assembled state of the first coil module and the second coil module to the core assembly. FIG. 4 is a vertical cross-sectional view showing a fixed state by a fixing pin. FIG. FIG. 2 is a cross-sectional view showing a portion of a vertical cross section of the bus bar module. FIG. 4 is a perspective view showing a state in which the bus bar module is assembled to the stator holder. FIG. 4 is a longitudinal cross-sectional view of a fixing portion for fixing the bus bar module. FIG. 4 is a vertical cross-sectional view showing a state in which the relay member is attached to the housing cover. FIG. FIG. 2 is an electric circuit diagram showing a control system for a rotating electric machine. FIG. 4 is a functional block diagram showing a current feedback control process performed by a control device. FIG. 4 is a functional block diagram showing a torque feedback control process performed by the control device. FIG. 11 is a partial cross-sectional view showing a cross-sectional structure of a magnet unit in a modified example. FIG. 4 is a diagram showing the configuration of a stator unit having an inner rotor structure. FIG. 4 is a plan view showing the state in which the coil module is assembled to the core assembly. FIG. 11 is a front view showing a winding area of the stator winding by the winding member in the second embodiment. FIG. 4 is a front view showing a state in which a plurality of partial windings are arranged in the circumferential direction. FIG. 4 is a perspective view showing the configuration of a stator unit. FIG. FIG. 4 is a vertical cross-sectional view showing a state in which each insulating cover is fixed by a fixing pin. FIG. FIG. 13 is a perspective view showing a coil module according to a modified example of the second embodiment. FIG. FIG.

Several embodiments will be described with reference to the drawings. In several embodiments, functionally and/or structurally corresponding and/or associated parts may be given the same reference numerals or reference numerals that differ in the hundredth or higher digit. For corresponding and/or associated parts, the descriptions of other embodiments may be referred to.

The rotating electric machine in this embodiment is used, for example, as a vehicle power source. However, rotating electric machines can be widely used in industrial applications, vehicles, home appliances, office automation equipment, gaming machines, etc. In the following embodiments, parts that are identical or equivalent to each other are given the same reference numerals in the drawings, and the explanations of the parts with the same reference numerals are used.

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

The rotating electric machine 10 is roughly divided into a rotating electric machine main body having a rotor 20, a stator unit 50, and a busbar module 200, and a housing 241 and a housing cover 242 that are arranged to surround the rotating electric machine main body. All of these components are arranged coaxially with a rotating shaft 11 that is integral with the rotor 20, and the rotating electric machine 10 is configured by assembling them in the axial direction in a predetermined order. The rotating shaft 11 is supported by a pair of bearings 12, 13 that are respectively provided on the stator unit 50 and the housing 241, and is rotatable in this state. The bearings 12, 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a number of balls arranged between them. The rotation of the rotating shaft 11 rotates, for example, the axle of a vehicle. The rotating electric machine 10 can be mounted on a vehicle by fixing the housing 241 to a vehicle frame or the like.

In the rotating electric machine 10, the stator unit 50 is provided to surround the rotating shaft 11, and the rotor 20 is disposed radially outside the stator unit 50. The stator unit 50 has a stator 60 and a stator holder 70 attached radially inside the stator 60. The rotor 20 and the stator 60 are disposed radially opposite each other with an air gap between them, and the rotor 20 rotates integrally with the rotating shaft 11, causing the rotor 20 to rotate radially outside the stator 60. The rotor 20 corresponds to the "field element" and the stator 60 corresponds to the "armature".

Figure 6 is a longitudinal cross-sectional view of the rotor 20. As shown in Figure 6, the rotor 20 has a rotor carrier 21 that is substantially cylindrical, and a ring-shaped magnet unit 22 fixed to the rotor carrier 21. The rotor carrier 21 has a cylindrical portion 23 and an end plate portion 24 provided at one axial end of the cylindrical portion 23, which are integrated together. The rotor carrier 21 functions as a magnet holding member, and the magnet unit 22 is fixed in a ring shape to the radial inside of the cylindrical portion 23. 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 that extends in a direction that intersects (orthogonally) the axial direction, and the rotor carrier 21 is fixed to the rotating shaft 11 while the flange 11a and the end plate portion 24 are surface-jointed.

The magnet unit 22 has a cylindrical magnet holder 31, a plurality of magnets 32 fixed to the inner peripheral surface of the magnet holder 31, and an end plate 33 fixed to the axially opposite end plate portion 24 of the rotor carrier 21. The magnet holder 31 has the same length dimension as the magnet 32 in the axial direction. The magnet 32 is provided in a state in which it is surrounded by the magnet holder 31 from the radially outside. The magnet holder 31 and the magnet 32 are fixed in a state in which they abut against the end plate 33 at one end on the axial direction. The magnet unit 22 corresponds to the "magnet portion".

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

In the magnet unit 22, the magnets 32 are arranged in a line so that their polarity alternates along the circumferential direction of the rotor 20. This gives the magnet unit 22 multiple magnetic poles in the circumferential direction. The magnets 32 are polar anisotropic permanent magnets, and are constructed using sintered neodymium magnets with an intrinsic coercive force of 400 kA/m or more and a residual magnetic flux density Br of 1.0 T or more.

The radially inner peripheral surface (stator 60 side) of magnet 32 is magnetic flux action surface 34 where magnetic flux is exchanged. In magnet unit 22, magnetic flux is generated intensively in the area near the d-axis, which is the magnetic pole center, on magnetic flux action surface 34 of magnet 32. Specifically, in magnet 32, the orientation of the magnetization easy axis is different on the d-axis side (part closer to the d-axis) and the q-axis side (part closer to the q-axis), and on the d-axis side, the orientation of the magnetization easy axis is parallel to the d-axis, and on the q-axis side, the orientation of the magnetization easy axis is perpendicular to the q-axis. In this case, an arc-shaped magnetic flux path is formed along the orientation of the magnetization easy axis. In short, magnet 32 is configured so that the orientation of the magnetization easy axis is parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary.

In magnet 32, the magnetic flux path is formed in an arc shape, so the magnetic flux path length is longer than the radial thickness dimension of magnet 32. This increases the permeance of magnet 32, making it possible to exert the same performance as a magnet with a larger amount of magnet, despite the same amount of magnet.

The magnets 32 are arranged in pairs, two adjacent to each other in the circumferential direction, to form one magnetic pole. In other words, the magnets 32 arranged in the circumferential direction in the magnet unit 22 have cut surfaces on the d-axis and q-axis, and the magnets 32 are arranged in contact with or in close proximity to each other. As described above, the magnets 32 have an arc-shaped magnetic flux path, and the N pole and S pole of the magnets 32 adjacent to each other in the circumferential direction face each other on the q-axis. This makes it possible to improve the permeance near the q-axis. In addition, the magnets 32 on both sides of the q-axis attract each other, so that the magnets 32 can maintain contact with each other. This also contributes to improving the permeance.

In the magnet unit 22, the magnetic flux flows in an arc between the adjacent N and S poles due to each magnet 32, so the magnetic path is longer than that of a radially anisotropic magnet, for example. Therefore, as shown in FIG. 8, the magnetic flux density distribution is close to a sine wave. As a result, unlike the magnetic flux density distribution of a radially anisotropic magnet shown as a comparative example in FIG. 9, the magnetic flux can be concentrated toward the center of the magnetic pole, making it possible to increase the torque of the rotating electric machine 10. In addition, in the magnet unit 22 of this embodiment, it can be confirmed that there is a difference in the magnetic flux density distribution compared to the conventional Halbach array magnet. In addition, in FIG. 8 and FIG. 9, the horizontal axis indicates the electrical angle, and the vertical axis indicates the magnetic flux density. In addition, in FIG. 8 and FIG. 9, 90° on the horizontal axis indicates the d-axis (i.e., the magnetic pole center), and 0° and 180° on the horizontal axis indicate the q-axis.

In other words, with each magnet 32 configured as described above, the magnetic flux on the d-axis in the magnet unit 22 is strengthened, and the magnetic flux change near the q-axis is suppressed. This makes it possible to preferably realize a magnet unit 22 in which the surface magnetic flux change from the q-axis to the d-axis is smooth at each magnetic pole.

The sine wave matching rate of the magnetic flux density distribution may be, for example, 40% or more. In this way, the amount of magnetic flux in the central part of the waveform can be reliably improved compared to the use of radially oriented magnets or parallel oriented magnets, which have a sine wave matching rate of about 30%. Furthermore, if the sine wave matching rate is set to 60% or more, the amount of magnetic flux in the central part of the waveform can be reliably improved compared to a magnetic flux concentration arrangement such as a Halbach arrangement.

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

The magnet 32 has a recess 35 formed on the outer peripheral surface on the radially outer side in a predetermined range including the d-axis, and a recess 36 formed on the inner peripheral surface on the radially inner side in a predetermined range including the q-axis. In this case, depending on the direction of the easy axis of magnetization of the magnet 32, the magnetic flux path becomes short near the d-axis on the outer peripheral surface of the magnet 32, and the magnetic flux path becomes short near the q-axis on the inner peripheral surface of the magnet 32. Therefore, taking into consideration that it is difficult to generate sufficient magnetic flux in places where the magnetic flux path length is short in the magnet 32, magnets are removed in places where the magnetic flux is weak.

The magnet unit 22 may be configured to use the same number of magnets 32 as the number of magnetic poles. For example, the magnets 32 may be provided between two circumferentially adjacent magnetic poles, with one magnet being provided between the d-axis, which is the center of each magnetic pole. In this case, the magnet 32 is configured so that the circumferential center is the q-axis and has a cut surface on the d-axis. The magnet 32 may also be configured so that the circumferential center is the d-axis, rather than the q-axis. Instead of using magnets with twice the number of magnetic poles or the same number of magnets as the number of magnetic poles, the magnets 32 may be configured to use ring magnets connected in a ring shape.

As shown in FIG. 3, a resolver 41 is provided as a rotation sensor on both axial ends of the rotating shaft 11 opposite the connection with the rotor carrier 21 (the upper end in the figure). The resolver 41 includes a resolver rotor fixed to the rotating shaft 11 and a resolver stator arranged radially outside the resolver rotor to face it. The resolver rotor is in the shape of a circular ring, and is provided coaxially with the rotating shaft 11 with the rotating shaft 11 inserted through it. 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 described. Figure 10 is a perspective view of the stator unit 50, and Figure 11 is a vertical cross-sectional view of the stator unit 50. Note that Figure 11 is a vertical cross-sectional view taken at the same position as Figure 3.

The stator unit 50 generally comprises a stator 60 and a stator holder 70 located radially inside the stator 60. The stator 60 comprises a stator winding 61 and a stator core 62. The stator core 62 and the stator holder 70 are integrated together to form a core assembly CA, to which multiple partial windings 151 constituting the stator winding 61 are attached. The stator winding 61 corresponds to the "armature winding", the stator core 62 corresponds to the "armature core", and the stator holder 70 corresponds to the "armature holding member". The core assembly CA corresponds to the "support member".

Here, we will first explain the core assembly CA. Figure 12 is a perspective view of the core assembly CA seen from one axial side, Figure 13 is a perspective view of the core assembly CA seen from the other axial side, Figure 14 is a cross-sectional view of the core assembly CA, and Figure 15 is an exploded cross-sectional view of the core assembly CA.

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

The stator core 62 is configured as a core sheet 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. The stator winding 61 is assembled to the radially outer side of the stator core 62, which is the rotor 20 side. The outer peripheral surface of the stator core 62 is curved without any irregularities. The stator core 62 functions as a back yoke. The stator core 62 is configured by laminating multiple core sheets 62a, for example, punched into an annular plate shape, in the axial direction. However, a stator core 62 having a helical core structure may also be used. In the helical core structure stator core 62, a strip-shaped core sheet is used, and this core sheet is wound in an annular shape and laminated in the axial direction to form a cylindrical stator core 62 as a whole.

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

As shown in FIG. 15, the stator holder 70 has an outer cylinder member 71 and an inner cylinder member 81, which are assembled together with the outer cylinder member 71 on the radial outside and the inner cylinder member 81 on the radial inside. Each of these members 71, 81 is made of metal, such as aluminum or cast iron, or carbon fiber reinforced plastic (CFRP).

The outer tube member 71 is a cylindrical member whose outer and inner circumferential surfaces are both perfectly circular curved surfaces, and an annular flange 72 extending radially inward is formed on one axial end side. This flange 72 has a plurality of protrusions 73 extending radially inward at a predetermined interval in the circumferential direction (see FIG. 13). In addition, the outer tube member 71 has opposing surfaces 74, 75 formed on one and the other axial ends, respectively, that axially face the inner tube member 81, and the opposing surfaces 74, 75 have annular grooves 74a, 75a extending annularly.

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

As shown in FIG. 14, when the outer tube member 71 and the inner tube member 81 are assembled to each other, an annular gap is formed between the inner peripheral surface of the outer tube member 71 and the outer peripheral surface of the inner tube member 81, and the gap space serves as a refrigerant passage 85 through which a refrigerant such as cooling water flows. The refrigerant passage 85 is provided in an annular shape in the circumferential direction of the stator holder 70. More specifically, the inner tube member 81 is provided with a passage forming portion 88 that protrudes radially inward on its inner peripheral side and has an inlet side passage 86 and an outlet side passage 87 formed therein, and each of these passages 86, 87 opens to the outer peripheral surface of the inner tube member 81. In addition, a partition portion 89 is provided on the outer peripheral surface of the inner tube member 81 to divide the refrigerant passage 85 into an inlet side and an outlet side. As a result, 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.

The inlet side passage 86 and the outlet side passage 87 have one end extending radially and opening on the outer circumferential surface of the inner cylinder member 81, and the other end extending axially and opening on the axial end surface of the inner cylinder member 81. FIG. 12 shows an inlet opening 86a leading to the inlet side passage 86 and an outlet opening 87a leading to the outlet side passage 87. The inlet side passage 86 and the outlet side passage 87 lead to an inlet port 244 and an outlet port 245 (see FIG. 1) attached to the housing cover 242, and the refrigerant flows in and out through these ports 244, 245.

At the joint between the outer tube member 71 and the inner tube member 81, sealing materials 101, 102 are provided to prevent leakage of the refrigerant from the refrigerant passage 85 (see FIG. 15). Specifically, the sealing materials 101, 102 are, for example, O-rings, which are housed in the annular grooves 74a, 75a of the outer tube member 71 and are provided in a compressed state by the outer tube member 71 and the inner tube member 81.

12, the inner tube member 81 has an end plate portion 91 at one axial end, and the end plate portion 91 is provided with a hollow cylindrical boss portion 92 extending in the axial direction. The boss portion 92 is provided so as to surround an insertion hole 93 for inserting the rotating shaft 11. The boss portion 92 is provided with a plurality of fastening portions 94 for fixing the housing cover 242. The end plate portion 91 is provided with a plurality of support portions 95 extending in the axial direction on the radial outside of the boss portion 92. The support portions 95 are portions that serve as fixing portions for fixing the busbar module 200, and will be described in detail later. The boss portion 92 is a bearing holding member that holds the bearing 12, and the bearing 12 is fixed to a bearing fixing portion 96 provided on the inner periphery of the boss portion 92 (see FIG. 3).

As shown in Figures 12 and 13, the outer tube member 71 and the inner tube member 81 are formed with recesses 105, 106 that are used to secure multiple coil modules 150, which will be described later.

Specifically, as shown in FIG. 12, a plurality of recesses 105 are formed at equal intervals in the circumferential direction on the axial end face of the inner tube member 81, more specifically, on the axial outer end face of the end plate portion 91 that surrounds the boss portion 92. Also, as shown in FIG. 13, a plurality of recesses 106 are formed at equal intervals in the circumferential direction on the axial end face of the outer tube member 71, more specifically, on the axial outer end face of the flange 72. These recesses 105, 106 are arranged so as to be aligned on an imaginary circle that is concentric with the core assembly CA. The recesses 105, 106 are each provided at the same position in the circumferential direction, and the intervals and numbers are also the same.

The stator core 62 is assembled in a state where it generates a radial compressive force on 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 tightening margin 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 generates a radial stress on the other. In addition, when increasing the torque of the rotating electric machine 10, for example, it is considered that the diameter of the stator 60 is increased, and in such a case, the tightening force of the stator core 62 is increased to strengthen the connection of the stator core 62 to the stator holder 70. However, if the compressive stress (in other words, the residual stress) of the stator core 62 is increased, there is a concern that the stator core 62 may be damaged.

In this embodiment, the stator core 62 and the stator holder 70 are fitted and fixed to each other with a predetermined tightening margin, and a restricting portion is provided at the radially opposing portions of the stator core 62 and the stator holder 70 to restrict the circumferential displacement of the stator core 62 by engaging in the circumferential direction. In other words, as shown in Figures 12 to 14, a plurality of engaging members 111 are provided as restricting portions at a predetermined interval in the circumferential direction between the stator core 62 and the outer tube member 71 of the stator holder 70 in the radial direction, and the engaging members 111 suppress the circumferential positional deviation between the stator core 62 and the stator holder 70. In this case, it is preferable to provide a recess in at least one of the stator core 62 and the outer tube member 71, and to engage the engaging member 111 in the recess. Instead of the engaging member 111, a convex portion may be provided in either the stator core 62 or the outer tube member 71.

In the above configuration, the stator core 62 and the stator holder 70 (outer tube member 71) are fitted and fixed with a predetermined tightening margin, and are provided in a state in which their mutual circumferential displacement is restricted by the restriction of the engaging member 111. Therefore, even if the tightening margin in the stator core 62 and the stator holder 70 is relatively small, the circumferential displacement of the stator core 62 can be suppressed. In addition, since the desired displacement suppression effect can be obtained even if the tightening margin is relatively small, damage to the stator core 62 caused by an excessively large tightening margin can be suppressed. As a result, the displacement of the stator core 62 can be appropriately suppressed.

A ring-shaped internal space is formed on the inner periphery of the inner cylinder member 81 so as to surround the rotating shaft 11, and electrical components constituting, for example, an inverter as a power converter may be arranged in the internal space. The electrical components are, for example, electrical modules in which semiconductor switching elements and capacitors are packaged. By arranging the electrical module in contact with the inner periphery of the inner cylinder member 81, it is possible to cool the electrical module by the refrigerant flowing through the refrigerant passage 85. It is also possible to eliminate the multiple protrusions 83 on the inner periphery of the inner cylinder member 81 or to reduce the protruding height of the protrusions 83, thereby expanding the internal space on the inner periphery of the inner cylinder member 81.

Next, the configuration of the stator winding 61 that is 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 Figures 10 and 11, where the multiple partial windings 151 that make up the stator winding 61 are assembled in a circumferentially aligned state on the radial outside of the core assembly CA, i.e., on the radial outside of the stator core 62.

The stator winding 61 has multiple 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 windings.

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

In the stator winding 61, 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 the partial windings 151 in the phase winding of each phase, and the stator winding 61 is configured by a predetermined number of coil modules 150 according to the number of poles. The coil modules 150 (partial windings 151) of each phase are arranged in a predetermined order in the circumferential direction, so that the conductor parts of each phase are arranged in a predetermined order on the coil side CS of the stator winding 61. FIG. 10 shows the order of the conductor parts of the U-phase, V-phase, and W-phase 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 series for each phase to form a phase winding. Figure 16 is a circuit diagram showing the connection state of the partial windings 151 in each of the three phase windings. Figure 16 shows the partial windings 151 in the phase windings of each phase connected in parallel.

As shown in FIG. 11, the coil module 150 is assembled to the radial outside of the stator core 62. In this case, the coil module 150 is assembled with both axial ends protruding axially outward from the stator core 62 (i.e., toward the coil end CE). In other words, the stator winding 61 has a portion corresponding to the coil end CE that protrudes axially outward from the stator core 62, and a portion corresponding to the coil side CS that is axially inward from that.

The coil module 150 has two types of shapes. One has a shape in which the partial winding 151 is bent radially inward at the coil end CE, i.e., toward the stator core 62, and the other has a shape in which the partial winding 151 is not bent radially inward at the coil end CE and extends linearly in the axial direction. In the following description, for convenience, the partial winding 151 having a bent shape at both axial ends is also referred to as the "first partial winding 151A," and the coil module 150 having the first partial winding 151A is also referred to as the "first coil module 150A." In addition, the partial winding 151 not having a bent shape at both axial ends is also referred to as the "second partial winding 151B," and the coil module 150 having the second partial winding 151B is also referred to as the "second coil module 150B."

Figure 17 is a side view showing the first coil module 150A and the second coil module 150B side by side for comparison, and Figure 18 is a side view showing the first partial winding 151A and the second partial winding 151B side by side for comparison. As shown in these figures, the coil modules 150A, 150B and the partial windings 151A, 151B have different axial lengths and different end shapes on both axial sides. The first partial winding 151A is approximately C-shaped in side view, and the second partial winding 151B is approximately I-shaped in side view. The first partial winding 151A is fitted with insulating covers 161, 162 as "first insulating covers" on both axial sides, and the second partial winding 151B is fitted with insulating covers 163, 164 as "second insulating covers" on both axial sides.

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

First, we will explain the first coil module 150A of the coil modules 150A and 150B. Figure 19(a) is a perspective view showing the configuration of the first coil module 150A, and Figure 19(b) is a perspective view showing the components of the first coil module 150A disassembled. Also, Figure 20 is a cross-sectional view taken along line 20-20 in Figure 19(a).

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

The first partial winding 151A has a pair of intermediate conductor parts 152 arranged parallel to each other and linearly, and a pair of transition parts 153A that connect the pair of intermediate conductor parts 152 at both axial ends, and is formed into a ring shape by the pair of intermediate conductor parts 152 and the pair of transition parts 153A. The pair of intermediate conductor parts 152 are arranged at a predetermined coil pitch apart, and the intermediate conductor parts 152 of the partial winding 151 of the other phase can be arranged between the pair of intermediate conductor parts 152 in the circumferential direction. In this embodiment, the pair of intermediate conductor parts 152 are arranged at a two coil pitch apart, and one intermediate conductor part 152 of the partial winding 151 of the other two phases is arranged between the pair of intermediate conductor parts 152.

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

As shown in FIG. 18, the first partial winding 151A has a crossover portion 153A on both axial sides, and the second partial winding 151B has a crossover portion 153B on both axial sides. The crossover portions 153A, 153B of the partial windings 151A, 151B have different shapes, and to clearly distinguish between them, the crossover portion 153A of the first partial winding 151A is also referred to as the "first crossover portion 153A," and the crossover portion 153B of the second partial winding 151B is also referred to as the "second crossover portion 153B."

In each partial winding 151A, 151B, the intermediate conductor portions 152 are provided as coil side conductor portions arranged one by one in the circumferential direction on the coil side CS. In addition, each transition portion 153A, 153B is provided as a coil end conductor portion that connects intermediate conductor portions 152 of the same phase at two different positions in the circumferential direction on the coil end CE.

As shown in FIG. 20, the first partial winding 151A is formed by winding the conductor wire CR in multiple layers so that the cross section of the conductor assembly portion is rectangular. FIG. 20 shows a cross section of the intermediate conductor portion 152, in which the conductor wire CR is wound in multiple layers so as to be aligned in the circumferential and radial directions. In other words, the first partial winding 151A is formed so that the conductor wire CR is arranged in multiple rows in the circumferential direction and multiple rows in the radial direction in the intermediate conductor portion 152, so that the cross section is approximately rectangular. In addition, at the tip of the first crossover portion 153A, the conductor wire CR is wound in multiple layers so as to be aligned in the axial and radial directions by bending in the radial direction. In this embodiment, the first partial winding 151A is formed by winding the conductor wire CR in a concentric manner. However, the winding method of the conductor wire CR is arbitrary, and instead of concentric winding, the conductor wire CR may be wound multiple times using alpha winding.

In the first partial winding 151A, an end of the conductor wire CR is pulled out from one of the first crossover parts 153A on both axial sides (the upper first crossover part 153A in FIG. 19(b)), and these ends serve as winding ends 154, 155. The winding ends 154, 155 are the start and end of the winding of the conductor wire CR, respectively. One of the winding ends 154, 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 covered with a sheet-like insulating cover 157. Note that in FIG. 19(a), the first coil module 150A is shown in a state in which the intermediate conductor portion 152 is covered with the insulating cover 157 and the intermediate conductor portion 152 is present inside the insulating cover 157, but for convenience, the corresponding portion is referred to as the intermediate conductor portion 152 (the same applies to FIG. 22(a) described below).

The insulating cover 157 is provided by using a film material FM having an axial dimension of at least the length of the axial insulating cover range of the intermediate conductor portion 152, and wrapping the film material FM around the intermediate conductor portion 152. 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 a foaming adhesive layer provided on one of the two surfaces of the film base material. The film material FM is then wrapped around the intermediate conductor portion 152 while being adhered to the intermediate conductor portion 152 by the adhesive layer. It is also possible to use a non-foaming adhesive as the adhesive layer.

20, the intermediate conductor portion 152 has a substantially rectangular cross section due to the conductor material CR arranged in the circumferential and radial directions, and the intermediate conductor portion 152 is covered with a film material FM with its circumferential ends overlapped to provide an insulating cover 157. The film material FM is a rectangular sheet whose vertical dimension is longer than the axial length of the intermediate conductor portion 152 and whose horizontal dimension is longer than the circumference of the intermediate conductor portion 152, and is wound around the intermediate conductor portion 152 with creases made to match the cross-sectional shape of the intermediate conductor portion 152. When the film material FM is wound around the intermediate conductor portion 152, the gap between the conductor material CR of the intermediate conductor portion 152 and the film base material is filled by foaming in the adhesive layer. In addition, in the overlap portion OL of the film material FM, the circumferential ends of the film material FM are joined together by an adhesive layer.

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

In the first partial winding 151A, an insulating cover 157 is provided in the range from the intermediate conductor portion 152 to the portion of the first crossover portion 153A on both axial sides that is covered by the insulating covers 161, 162 (i.e., the portion inside the insulating covers 161, 162). In FIG. 17, the range AX1 in the first coil module 150A is the portion not covered by the insulating covers 161, 162, and the insulating cover 157 is provided in a range extending above and below the range AX1.

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

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

21(a) and (b), the insulating cover 161 has a pair of side portions 171 that are circumferential side surfaces, an outer surface portion 172 on the axially outer side, an inner surface portion 173 on the axially inner side, and a front surface portion 174 on the radially inner side. Each of these portions 171 to 174 is formed in a plate shape and is connected to each other in a three-dimensional shape so that only the radially outer side is open. Each of the pair of side portions 171 is provided in a direction that extends toward the axis of the core assembly CA when assembled to the core assembly CA. Therefore, when multiple first coil modules 150A are arranged in a circumferential line, the side portions 171 of the insulating cover 161 of each adjacent first coil module 150A face each other in abutment or close proximity. This allows each of the first coil modules 150A adjacent in the circumferential direction to be insulated from each other while being preferably arranged in an annular arrangement.

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 175b for pulling out the winding end 155 of the first partial winding 151A. In this case, one winding end 154 is pulled out axially from the outer surface portion 172, while the other winding end 155 is pulled out radially from the front surface portion 174.

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

Additional explanation on the recess 177 of the insulating cover 161. As shown in FIG. 20, the first crossover portion 153A of the first partial winding 151A is curved so that it is convex on the radially inner side, i.e., on the side of the core assembly CA. In this configuration, a gap is formed between adjacent first crossover portions 153A in the circumferential direction, and the gap becomes wider toward the tip side of the first crossover portion 153A. Therefore, in this embodiment, the gap between the first crossover portions 153A arranged in the circumferential direction is utilized to provide a recess 177 at a position on the side portion 171 of the insulating cover 161 that is outside the curved portion of the first crossover portion 153A.

The first partial winding 151A may be provided with a temperature detection unit (thermistor). In such a configuration, an opening may be provided in the insulating cover 161 for pulling out a signal line extending from the temperature detection unit. In this case, the temperature detection unit can be conveniently housed within the insulating cover 161.

Although detailed explanation with illustrations is omitted, the other insulating cover 162 in the axial direction has a configuration generally similar to that of the insulating cover 161. Like the insulating cover 161, the insulating cover 162 has a pair of side portions 171, an outer surface portion 172 on the axial outside, an inner surface portion 173 on the axial inside, and a front surface portion 174 on the radial inside. In addition, in the insulating cover 162, the pair of side portions 171 are provided with semicircular recesses 177 at positions that are both circumferential ends of the front surface portion 174, and a pair of protrusions 178 are provided on the outer surface portion 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 (i.e., axial width dimensions at the pair of side portions 171 and the front portion 174). Specifically, as shown in FIG. 17, the axial height dimension W11 of the insulating cover 161 and the axial height dimension W12 of the insulating cover 162 are W11>W12. In other words, when winding the conductor CR in multiple layers, it is necessary to switch (change lanes) the winding stages of the conductor CR in a direction perpendicular to the winding direction (circumferential direction), and it is considered that the winding width becomes larger due to the switching. To supplement, the insulating cover 161 of the insulating covers 161 and 162 is a portion that covers the first crossover portion 153A on the side including the winding start and winding end of the conductor CR, and by including the winding start and winding end of the conductor CR, the winding allowance (overlap allowance) of the conductor CR becomes larger than other portions, which may result in a larger winding width. Taking this into consideration, the axial height dimension W11 of the insulating cover 161 is greater than the axial height dimension W12 of the insulating cover 162. This prevents the insulating covers 161 and 162 from limiting the number of turns of the conductor wire CR, which would occur if the height dimensions W11 and W12 of the insulating covers 161 and 162 were the same.

Next, we will explain the second coil module 150B.

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

As shown in Figures 22(a) and (b), the second coil module 150B has a second partial winding 151B that is formed by multiple turns of conductive wire CR, similar to the first partial winding 151A, and insulating covers 163, 164 attached to one and the other axial ends of the second partial winding 151B. The insulating covers 163, 164 are molded from an insulating material such as synthetic resin.

The second partial winding 151B has a pair of intermediate conductor parts 152 arranged parallel to each other and linearly, and a pair of second bridge parts 153B that connect the pair of intermediate conductor parts 152 at both axial ends, and is formed into a ring shape by the pair of intermediate conductor parts 152 and the pair of second bridge parts 153B. In the second partial winding 151B, the pair of intermediate conductor parts 152 has the same configuration as the intermediate conductor part 152 of the first partial winding 151A. In contrast, the pair of second bridge parts 153B has a different configuration from the first bridge part 153A of the first partial winding 151A. The second bridge part 153B of the second partial winding 151B is arranged to extend linearly in the axial direction from the intermediate conductor part 152 without being bent in the radial direction. Figure 18 clearly shows the difference between the partial windings 151A and 151B.

In the second partial winding 151B, an end of the conductor wire CR is pulled out from one of the second crossover parts 153B on both axial sides (the upper second crossover part 153B in FIG. 22(b)), and this end serves as the winding ends 154, 155. As in the first partial winding 151A, in the second partial winding 151B, one of the winding ends 154, 155 is connected to a current input/output terminal, and the other is connected to a neutral point.

In the second partial winding 151B, similar to the first partial winding 151A, each intermediate conductor portion 152 is covered with a sheet-like insulating covering 157. The insulating covering 157 is provided by using a film material FM whose axial dimension is at least the length of the axial insulating covering range of the intermediate conductor portion 152, and wrapping the film material FM around the intermediate conductor portion 152.

The configuration of the insulating cover 157 is also generally the same for each partial winding 151A, 151B. That is, as shown in FIG. 23, the intermediate conductor portion 152 is covered with a film material FM with its circumferential end overlapped. The intermediate conductor portion 152 is provided with an insulating cover 157 so as to cover all of its two circumferential side surfaces and two radial side surfaces. In this case, the insulating cover 157 surrounding the intermediate conductor portion 152 is provided with an overlap portion OL where the film material FM overlaps on a portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase, i.e., on one of the two circumferential side surfaces of the intermediate conductor portion 152. In this embodiment, the overlap portion OL is provided on the same circumferential side of each of the pair of intermediate conductor portions 152.

In the second partial winding 151B, an insulating cover 157 is provided in the range from the intermediate conductor portion 152 to the portion of the second crossover portion 153B on both axial sides that is covered by the insulating covers 163, 164 (i.e., the portion inside the insulating covers 163, 164). In FIG. 17, the range AX2 in the second coil module 150B is the portion not covered by the insulating covers 163, 164, and the insulating cover 157 is provided in a range extending above and below the range AX2.

In each of the partial windings 151A, 151B, the insulating cover 157 is provided in an area that includes a portion of the transition portion 153A, 153B. That is, in each of the partial windings 151A, 151B, the insulating cover 157 is provided on the intermediate conductor portion 152 and on the portion of the transition portion 153A, 153B that extends linearly beyond the intermediate conductor portion 152. However, because the axial lengths of the partial windings 151A, 151B are different, the axial ranges of the insulating cover 157 are also different.

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

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

24(a) and (b), the insulating cover 163 has a pair of side portions 181 that are circumferential side surfaces, an outer surface portion 182 on the axially outer side, a front surface portion 183 on the radially inner side, and a rear surface portion 184 on the radially outer side. Each of these portions 181 to 184 is formed in a plate shape and is connected to each other in a three-dimensional shape so that only the axially inner side is open. Each of the pair of side portions 181 is provided in a direction that extends toward the axis of the core assembly CA when assembled to the core assembly CA. Therefore, when multiple second coil modules 150B are arranged in a circumferential line, the side portions 181 of the insulating cover 163 of adjacent second coil modules 150B face each other in abutment or close proximity. This allows each of the second coil modules 150B adjacent in the circumferential direction to be insulated from each other while being preferably arranged in an annular arrangement.

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

The front surface 183 of the insulating cover 163 is provided with a protruding portion 186 that protrudes radially inward. The protruding portion 186 is provided at a position that is the center between one end and the other end of the circumferential direction of the insulating cover 163, so as to protrude radially inward from the second bridge portion 153B. The protruding portion 186 has a tapered shape that tapers toward the radially inner side in a plan view, and a through hole 187 extending in the axial direction is provided at its tip. Note that the protruding portion 186 may have any configuration as long as it protrudes radially inward from the second bridge portion 153B and has a through hole 187 at a position that is the center between one end and the other end of the circumferential direction of the insulating cover 163. However, assuming an overlapping state with the insulating cover 161 on the axial inner side, it is desirable to form the protruding portion 186 narrow in the circumferential direction to avoid interference with the winding ends 154, 155.

The protrusion 186 has a stepped axial thickness at its radially inner tip, and a through hole 187 is provided in the thin lower step 186a. This lower step 186a corresponds to a portion where the height from the axial end face of the inner tube member 81 is lower than the height of the second bridge portion 153B when the second coil module 150B is assembled to the core assembly CA.

As shown in FIG. 23, the protrusion 186 is provided with a through hole 188 that penetrates in the axial direction. This makes it possible to fill the gap between the insulating covers 161 and 163 through the through hole 188 when the insulating covers 161 and 163 are overlapped in the axial direction.

Although detailed explanation using the drawings will be omitted, the other insulating cover 164 in the axial direction has a configuration generally similar to that of the insulating cover 163. Like the insulating cover 163, the insulating cover 164 has a pair of side portions 181, an outer surface portion 182 on the axial outside, a front surface portion 183 on the radial inside, and a rear surface portion 184 on the radial outside, and also has a through hole 187 provided at the tip of the protruding portion 186. Also, as a difference from the insulating cover 163, the insulating cover 164 is configured not to have an opening for pulling out the winding ends 154, 155 of the second partial winding 151B.

In the insulating covers 163 and 164, the radial width dimensions of the pair of side portions 181 are different. Specifically, as shown in FIG. 17, the radial width dimension W21 of the side portion 181 of the insulating cover 163 and the radial width dimension W22 of the side portion 181 of the insulating cover 164 are W21>W22. In other words, of the insulating covers 163 and 164, the insulating cover 163 is a portion that covers the second crossover portion 153B on the side including the winding start and winding end of the conductor material CR, and by including the winding start and winding end of the conductor material CR, the winding allowance (overlap allowance) of the conductor material CR is larger than other portions, and as a result, the winding width may be larger. Taking this into consideration, the radial width dimension W21 of the insulating cover 163 is larger than the radial width dimension W22 of the insulating cover 164. This prevents the inconvenience of the insulating covers 163 and 164 limiting the number of turns of the conductor wire CR, unlike when the width dimensions W21 and W22 of the insulating covers 163 and 164 are the same.

Figure 25 is a diagram showing the overlap position of the film material FM when the coil modules 150A, 150B are arranged in the circumferential direction. As described above, in each coil module 150A, 150B, the film material FM is covered around the intermediate conductor portion 152 so as to overlap the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase, i.e., the circumferential side surface of the intermediate conductor portion 152 (see Figures 20 and 23). Then, when the coil modules 150A, 150B are arranged in the circumferential direction, the overlap portion OL of the film material FM is arranged on the same side (the right side in the circumferential direction in the figure) of both sides in the circumferential direction. As a result, the overlap portions OL of the film material FM in the intermediate conductor portions 152 of the partial windings 151A, 151B of different phases adjacent to each other in the circumferential direction do not overlap each other in the circumferential direction. In this case, a maximum of three sheets of film material FM overlap between each of the intermediate conductor portions 152 arranged in the circumferential direction.

Next, we will explain the configuration for assembling each coil module 150A, 150B to the core assembly CA.

The coil modules 150A, 150B have different axial lengths and different shapes of the bridge portions 153A, 153B of the partial windings 151A, 151B, and are configured to be attached to the core assembly CA with the first bridge portion 153A of the first coil module 150A facing axially inward and the second bridge portion 153B of the second coil module 150B facing axially outward. With regard to the insulating covers 161-164, the insulating covers 161, 163 are stacked in the axial direction at one axial end of each coil module 150A, 150B, and the insulating covers 162, 164 are stacked in the axial direction at the other axial end, and each of the insulating covers 161-164 is fixed to the core assembly CA.

Figure 26 is a plan view showing a state where multiple insulating covers 161 are lined up in the circumferential direction when the first coil module 150A is assembled to the core assembly CA, and Figure 27 is a plan view showing a state where multiple insulating covers 161, 163 are lined up in the circumferential direction when the first coil module 150A and the second coil module 150B are assembled to the core assembly CA. Also, Figure 28 (a) is a vertical cross-sectional view showing a state before fixing by the fixing pin 191 in the assembled state of each coil module 150A, 150B to the core assembly CA, and Figure 28 (b) is a vertical cross-sectional view showing a state after fixing by the fixing pin 191 in the assembled state of each coil module 150A, 150B to the core assembly CA.

As shown in FIG. 26, when multiple first coil modules 150A are assembled to the core assembly CA, multiple insulating covers 161 are arranged with their side portions 171 abutting or in close proximity to each other. Each insulating cover 161 is arranged so that the boundary line LB between the opposing side portions 171 coincides with the recess 105 on the axial end surface of the inner tube member 81. In this case, the side portions 171 of circumferentially adjacent insulating covers 161 abut or come into close proximity to each other, so that the recesses 177 of the insulating covers 161 form through-holes extending in the axial direction, and the positions of the through-holes and the recesses 105 coincide with each other.

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

At this time, the protrusion 186 of the insulating cover 163 is guided to a predetermined position by a pair of protrusions 178 provided on the insulating cover 161, so that the position of the through hole 187 on the insulating cover 163 side matches the through hole portion on the insulating cover 161 side and the recess 105 of the inner tube member 81. In other words, when each coil module 150A, 150B is assembled to the core assembly CA, the recess 177 of the insulating cover 161 is located at the back side of the insulating cover 163, so it may be difficult to align the through hole 187 of the protrusion 186 with the recess 177 of the insulating cover 161. In this regard, the protrusion 186 of the insulating cover 163 is guided by the pair of protrusions 178 of the insulating cover 161, making it easier to align the insulating cover 163 with the insulating cover 161.

As shown in Figs. 28(a) and (b), the insulating cover 161 and the protruding portion 186 of the insulating cover 163 are engaged at the overlapping portion of the insulating cover 161 and the protruding portion 186 of the insulating cover 163, and the fixing pin 191 is fixed by the fixing member. More specifically, the recess 105 of the inner tube member 81, the recess 177 of the insulating cover 161, and the through hole 187 of the insulating cover 163 are aligned, and the fixing pin 191 is inserted into the recesses 105, 177 and the through hole 187. This fixes the insulating covers 161 and 163 to the inner tube member 81 as a unit. According to this configuration, the coil modules 150A and 150B adjacent in the circumferential direction are fixed to the core assembly CA at the coil end CE by a common fixing pin 191. The fixing pin 191 is preferably made of a material with good thermal conductivity, such as a metal pin.

As shown in FIG. 28B, the fixing pin 191 is attached to the lower step 186a of the protruding portion 186 of the insulating cover 163. In this state, the upper end of the fixing pin 191 protrudes above the lower step 186a, but does not protrude above the upper surface (outer surface 182) of the insulating cover 163. In this case, the fixing pin 191 is longer than the axial height dimension of the overlapping portion between the insulating cover 161 and the protruding portion 186 (lower step 186a) of the insulating cover 163, and has a margin for protruding upward, which is thought to make it easier to insert the fixing pin 191 into the recesses 105, 177 and the through hole 187 (i.e., when fixing the fixing pin 191). In addition, because the upper end of the fixing pin 191 does not protrude above the upper surface (outer surface portion 182) of the insulating cover 163, the inconvenience of the axial length of the stator 60 becoming longer due to the fixing pin 191 protruding can be suppressed.

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 cover 163. This allows the insulating covers 161 and 163, which overlap in the axial direction, to be firmly joined to each other. Note that for convenience, the through holes 188 are shown in the range from the top to the bottom of the insulating cover 163 in Figures 28(a) and (b), but in reality, the through holes 188 are provided in a thin plate portion formed by hollowing out or the like.

28(b), the fixing position of each insulating cover 161, 163 by the fixing pin 191 is the axial end face of the stator holder 70 radially inward (left side of the figure) from the stator core 62, and the fixing pin 191 is fixed to the stator holder 70. In other words, the first bridge portion 153A is fixed to the axial end face of the stator holder 70. In this case, since the stator holder 70 is provided with a refrigerant passage 85, the heat generated in the first partial winding 151A is directly transferred from the first bridge portion 153A to the vicinity of the refrigerant passage 85 of the stator holder 70. In addition, the fixing pin 191 is inserted into the recess 105 of the stator holder 70, and the transfer of heat to the stator holder 70 side is promoted through the fixing pin 191. With this configuration, the cooling performance of the stator winding 61 is improved.

In this embodiment, 18 insulating covers 161, 163 are stacked on the inside and outside of the axial direction in the coil end CE, while 18 recesses 105 are provided on the axial end face of the stator holder 70, the same number as the insulating covers 161, 163. The 18 recesses 105 are then fixed by fixing pins 191.

Although not shown, the same is true for the insulating covers 162 and 164 on the opposite axial side. That is, when the first coil module 150A is assembled, the side portions 171 of the insulating covers 162 adjacent in the circumferential direction come into contact with or approach each other, so that the recesses 177 of the insulating covers 162 form through-holes extending in the axial direction, and the positions of the through-holes and the recesses 106 on the axial end surface of the outer tube member 71 are aligned. Then, when the second coil module 150B is assembled, the positions of the through-holes 187 on the insulating cover 164 side are aligned with the through-holes on the insulating cover 163 side and the recesses 106 of the outer tube member 71, and the fixing pins 191 are inserted into the recesses 106, 177, and the through-holes 187, so that the insulating covers 162 and 164 are fixed together with the outer tube member 71.

When assembling each coil module 150A, 150B to the core assembly CA, it is preferable to first attach all the first coil modules 150A to the outer periphery of the core assembly CA, and then assemble all the second coil modules 150B and fix them with the fixing pins 191. Alternatively, it is also possible to first fix two first coil modules 150A and one second coil module 150B to the core assembly CA with one fixing pin 191, and then assemble the first coil modules 150A, assemble the second coil modules 150B, and fix them with the fixing pins 191 repeatedly in this order.

Next, we will explain the busbar module 200.

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

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

As shown in FIG. 30, the annular portion 201 has laminated plates 204 that are approximately annular and laminated in multiple layers (five layers in this embodiment) in the axial direction, and four bus bars 211 to 214 are provided between the laminated plates 204. Each bus bar 211 to 214 is annular and includes a U-phase bus bar 211, a V-phase bus bar 212, a W-phase bus bar 213, and a neutral bus bar 214. Each bus bar 211 to 214 is arranged in the axial direction with the plate surfaces facing each other in the annular portion 201. Each laminated plate 204 and each bus bar 211 to 214 are bonded to each other with an adhesive. It is preferable to use an adhesive sheet as the adhesive. However, a liquid or semi-liquid adhesive may be applied. A connection terminal 202 is connected to each bus bar 211 to 214 so as to protrude radially outward from the annular portion 201.

A protrusion 201a extending in a circular shape is provided on the top surface of the annular portion 201, i.e., the top surface of the laminate 204 on the outermost side of the five laminated layers 204.

The busbar module 200 may be one in which the busbars 211-214 are embedded in the annular portion 201, and the busbars 211-214 arranged at predetermined intervals may be integrally insert-molded. The arrangement of the busbars 211-214 is not limited to a configuration in which all are lined up in the axial direction and all of the plate surfaces face the same direction, but may be a configuration in which they are lined up in the radial direction, a configuration in which they are lined up in two axial rows and two radial rows, a configuration in which the plate surfaces extend in different directions, etc.

29, the connection terminals 202 are arranged in a line in the circumferential direction of the annular portion 201 and extend in the axial direction on the radially outer side. The connection terminals 202 include a connection terminal connected to the U-phase busbar 211, a connection terminal connected to the V-phase busbar 212, a connection terminal connected to the W-phase busbar 213, and a connection terminal connected to the neutral busbar 214. 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, and each of the connection terminals 202 is connected to one of the winding ends 154, 155 of each partial winding 151. In this way, the busbar module 200 is connected to the U-phase partial winding 151, the V-phase partial winding 151, and the W-phase partial winding 151, respectively.

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

The busbar module 200 may be configured to have an integrated current sensor for detecting the phase current of each phase. In this case, the busbar module 200 may be provided with a current detection terminal, and the detection result of the current sensor may be output to a control device (not shown) through the current detection terminal.

In addition, the annular portion 201 has a number of protrusions 205 that protrude toward the inner circumference as fixed portions to the stator holder 70, and the protrusions 205 have through holes 206 that extend in the axial direction.

Figure 31 is a perspective view showing the state in which the busbar module 200 is assembled to the stator holder 70, and Figure 32 is a vertical cross-sectional view of the fixing portion that fixes the busbar module 200. Please refer to Figure 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 91 so as to surround the boss 92 of the inner tube member 81. The busbar module 200 is positioned by assembly to the support 95 (see FIG. 12) of the inner tube member 81, and is then fixed to the stator holder 70 (inner tube member 81) by fastening fasteners 217 such as bolts.

More specifically, as shown in FIG. 32, the end plate portion 91 of the inner tube member 81 is provided with a support portion 95 extending in the axial direction. The busbar module 200 is fixed to the support portion 95 by a fastener 217 with the support portion 95 inserted into the through holes 206 provided in the multiple 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 has a fastened portion 222 having an insertion hole 221 through which the fastener 217 is inserted, a pressing portion 223 that presses the upper surface of the annular portion 201 of the busbar module 200, and a bend portion 224 provided between the fastened portion 222 and the pressing portion 223.

When the retainer plate 220 is attached, the fastener 217 is inserted into the insertion hole 221 of the retainer plate 220 and screwed to the support 95 of the inner tube member 81. The pressing portion 223 of the retainer plate 220 is in contact with the upper surface of the annular portion 201 of the busbar module 200. In this case, the retainer plate 220 is pushed downward in the figure as the fastener 217 is screwed into the support 95, and the annular portion 201 is pressed downward by the pressing portion 223 accordingly. The downward pressing force in the figure generated by screwing the fastener 217 is transmitted to the pressing portion 223 through the bend portion 224, so pressing by the pressing portion 223 is performed in a state accompanied by the elastic force of the bend portion 224.

As described above, an annular protrusion 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 abut against the protrusion 201a. This prevents the downward pressing force of the retainer plate 220 from escaping radially outward. In other words, the pressing force generated by the screwing of the fastener 217 is properly transmitted to the pressing portion 223 side.

As shown in FIG. 31, when the busbar module 200 is attached to the stator holder 70, the input/output terminals 203 are located 180 degrees circumferentially opposite the inlet opening 86a and the outlet opening 87a that lead to the refrigerant passage 85. However, the input/output terminals 203 and the openings 86a and 87a may be located together in the same position (i.e., in close proximity).

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

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. The relay member 230 is a member that relays the connection between the input/output terminals 203 for each phase extending from the busbar module 200 and the power lines for each phase extending from an external device such as an inverter.

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

The relay member 230 has a main body 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 through 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 aligned so that the longitudinal directions of the three insertion holes 233 are all oriented in approximately the same direction.

Three relay bus bars 234, one for each phase, are attached to the main body 231. The relay bus bars 234 are bent into a roughly L-shape and are fixed to the main body 231 with fasteners 235 such as bolts, and are fixed to the tip of the input/output terminal 203 inserted into the insertion hole 233 of the terminal insertion portion 232 with fasteners 236 such as bolts and nuts.

Although not shown in the figure, the relay member 230 can be connected to a power line for each phase extending from an external device, making it possible to input and output power to and from the input/output terminal 203 for each phase.

Next, we will explain the configuration of the control system that controls the rotating electric machine 10. Figure 35 is an electrical circuit diagram of the control system for the rotating electric machine 10, and Figure 36 is a functional block diagram showing the control process by the control device 270.

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

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

The control device 270 is equipped with a microcomputer consisting of a CPU and various memories, and performs energization control by turning on and off each switch 261, 262 based on various detection information in the rotating electric machine 10 and requests for power running and power generation. The detection information of the rotating electric machine 10 includes, for example, the rotation angle (electrical angle information) of the rotor 20 detected by an angle detector such as a resolver, the power supply voltage (inverter input voltage) detected by a voltage sensor, and the energization current of each phase detected by a current sensor. The control device 270 performs on/off control of each switch 261, 262, for example, by PWM control at a predetermined switching frequency (carrier frequency) or square wave control. The control device 270 may be an internal control device built into the rotating electric machine 10, or an external control device provided outside the rotating electric 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. In a situation where the electrical time constant is small, it is desirable to increase the switching frequency (carrier frequency) and the switching speed. In this regard, the charge supply capacitor 264 is connected in parallel to the series connection of the switches 261, 262 of each phase, thereby reducing the wiring inductance, and appropriate surge countermeasures are possible even in a configuration with a high switching speed.

The high-potential terminal of the inverter 260 is connected to the positive terminal of the DC power supply 265, and the low-potential terminal is connected to the negative terminal (ground) of the DC power supply 265. The DC power supply 265 is, for example, configured as a battery pack in which multiple single cells are connected in series. In addition, a smoothing capacitor 266 is connected in parallel to the DC power supply 265 to the high-potential terminal and low-potential terminal of the inverter 260.

Figure 36 is a block diagram showing the current feedback control process that controls the currents of the U, V, and W phases.

In FIG. 36, the current command value setting unit 271 uses a torque-dq map to set a d-axis current command value and a q-axis current command value based on the powering 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. Note that the power generation torque command value is a regenerative torque command value, for example, when the rotating electric machine 10 is used as a power source for a vehicle.

The dq converter 272 converts the current detection values (three phase currents) from the current sensors provided for each phase into d-axis current and q-axis current, which are components of an orthogonal two-dimensional rotating coordinate system in which the d-axis is the direction of an axis of a magnetic field, or field direction.

The d-axis current feedback control unit 273 calculates a d-axis command voltage as an operation amount for feedback-controlling the d-axis current to the d-axis current command value. The q-axis current feedback control unit 274 calculates a q-axis command voltage as an operation amount for feedback-controlling the q-axis current to the q-axis current command value. In each of these feedback control units 273 and 274, the 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 conversion unit 275 converts the d-axis and q-axis command voltages into U-phase, V-phase, and W-phase command voltages. Each of the above units 271 to 275 is a feedback control unit that performs feedback control of the fundamental wave current according to the dq conversion theory, and the U-phase, V-phase, and W-phase command voltages are the feedback control values.

The operation signal generating unit 276 generates an operation signal for the inverter 260 based on the three-phase command voltages using a well-known triangular wave carrier comparison method. Specifically, the operation signal generating unit 276 generates switch operation signals (duty signals) for the upper and lower arms in each phase by PWM control based on a magnitude comparison between a signal in which the three-phase command voltages are normalized by the power supply voltage and a carrier signal such as a triangular wave signal. The switch operation signals generated by the operation signal generating unit 276 are 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 described. 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 is large, such as in the high rotation range and high output range. 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 electric machine 10.

Figure 37 is a block diagram showing the torque feedback control process for the U, V, and W phases.

The voltage amplitude calculation unit 281 calculates a voltage amplitude command, which is a command value for the magnitude of a voltage vector, based on a powering torque command value or a 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 dq conversion unit 282 converts the current detection values from the current sensors provided for each phase into d-axis current and q-axis current, similar to the dq conversion unit 272. The torque estimation unit 283 calculates the torque estimation values corresponding to the U, V, and W phases based on the d-axis current and the q-axis current. The torque estimation unit 283 calculates the voltage amplitude command based on map information that correlates the d-axis current, the q-axis current, and the voltage amplitude command.

The torque feedback control unit 284 calculates a voltage phase command, which is a command value for the phase of the voltage vector, as an operation amount for feedback control of the torque estimate value to the powering torque command value or the power generation torque command value. The torque feedback control unit 284 calculates the voltage phase command using a PI feedback method based on the deviation of the torque estimate value from the powering torque command value or the power generation torque command value.

The operation signal generating 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 generating unit 285 calculates three-phase command voltages based on the voltage amplitude command, the voltage phase command, and the electrical angle θ, and generates switch operation signals for the upper and lower arms in each phase by PWM control based on a comparison of the magnitude between a signal obtained by normalizing the calculated three-phase command voltages with the power supply voltage and a carrier signal such as a triangular wave signal. The switch operation signals generated by the operation signal generating unit 285 are 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 generating unit 285 may generate a switch operation signal based on pulse pattern information, which is map information in which a voltage amplitude command, a voltage phase command, an electrical angle θ, and a switch operation signal are associated, a voltage amplitude command, a voltage phase command, and an electrical angle θ.

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

- The configuration of the magnet 32 in the magnet unit 22 may be changed as follows. In the magnet unit 22 shown in FIG. 38, the magnetization easy axis of the magnet 32 is inclined to the radial direction, and a linear magnetic flux path is formed along the direction of the magnetization easy axis. In other words, the magnet 32 is configured so that the direction of the magnetization easy axis is inclined to the d-axis between the magnetic flux action surface 34a on the stator 60 side (radially inner side) and the magnetic flux action surface 34b on the opposite stator side (radially outer side), and is linearly oriented so that it approaches the d-axis on the stator 60 side in the circumferential direction and moves away from the d-axis on the opposite stator side. Even in this configuration, the magnetic flux path length of the magnet 32 can be made longer than the radial thickness dimension, 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 bending direction of the crossover portion 153 may be either radially inward or outward, and in terms of its relationship with the core assembly CA, the first crossover portion 153A may be bent toward the core assembly CA, or the first crossover portion 153A may be bent toward the opposite side of the core assembly CA. In addition, the second crossover portion 153B may be bent either radially inward or outward, as long as it is axially outside the first crossover portion 153A and circumferentially spans a portion of the first crossover portion 153A.

・The partial winding 151 may have only one type of partial winding 151, instead of two types of partial winding 151 (first partial winding 151A, second partial winding 151B). Specifically, the partial winding 151 may be formed to have an approximately L-shape or an approximately Z-shape in side view. When the partial winding 151 is formed to have an approximately L-shape in side view, the crossover portion 153 is bent radially inward or outward at one axial end, and is not bent radially at the other axial end. When the partial winding 151 is formed to have an approximately Z-shape in side view, the crossover portion 153 is bent radially in opposite directions at one axial end and the other axial end. In either case, the coil module 150 may be fixed to the core assembly CA by an insulating cover that covers the crossover portion 153 as described above.

- In the above configuration, all partial windings 151 for each phase winding in the stator winding 61 are connected in parallel, but this may be changed. For example, all partial windings 151 for each phase winding may be divided into multiple parallel connection groups, and the multiple parallel connection groups may be connected in series. In other words, all n partial windings 151 in each phase winding may be divided into two parallel connection groups of n/2 pieces each, or three parallel connection groups of n/3 pieces each, and these may be connected in series. Alternatively, all multiple partial windings 151 for each phase winding in the stator winding 61 may be connected in series.

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

-Instead of the outer rotor type surface magnet type rotating electric machine 10, it is also possible to embody it as an inner rotor type surface magnet type rotating electric machine. Figures 39(a) and (b) are diagrams showing the configuration of the stator unit 300 when an inner rotor structure is used. Of these, Figure 39(a) is a perspective view showing the state in which the coil modules 310A, 310B are assembled to the core assembly CA, and Figure 39(b) is a perspective view showing the partial windings 311A, 311B included in each coil module 310A, 310B. In this example, the core assembly CA is formed by assembling the stator holder 70 to the radial outside of the stator core 62. In addition, multiple coil modules 310A, 310B are assembled to the radial inside of the stator core 62.

The partial winding 311A has a configuration similar to that of the first partial winding 151A described above, and includes a pair of intermediate conductor portions 312 and a bridge portion 313A that is bent toward the core assembly CA side (radially outward) on both axial sides. The partial winding 311B has a configuration similar to that of the second partial winding 151B described above, and includes a pair of intermediate conductor portions 312 and a bridge portion 313B that is provided on both axial sides so as to straddle the bridge portion 313A circumferentially on the axially outer side. An insulating cover 315 is attached to the bridge portion 313A of the partial winding 311A, and an insulating cover 316 is attached to the bridge portion 313B of the partial winding 311B.

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

Figure 40 is a plan view showing the state in which coil modules 310A, 310B are assembled to core assembly CA. In addition, in Figure 40, multiple recesses 105 are formed at equal intervals in the circumferential direction on the axial end face of stator holder 70. In addition, stator holder 70 has a cooling structure that uses liquid refrigerant or air, and for example, as an air-cooled structure, multiple heat dissipation fins may be formed on the outer circumferential surface.

In FIG. 40, the insulating covers 315 and 316 are arranged so that they overlap in the axial direction. In addition, a recess 317 provided on the side of the insulating cover 315 and a through hole 319 provided in the protruding portion 318 of the insulating cover 316 at a position that is central between one end and the other end of the circumference of the insulating cover 316 are connected in the axial direction, and each of these portions 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 the axial end face of the stator holder 70 radially outward of the stator core 62, and the fixing pin 321 is fixed to the stator holder 70. In this case, since the stator holder 70 is provided with a cooling structure, heat generated in the partial windings 311A, 311B is easily transferred to the stator holder 70. This improves the cooling performance of the stator winding 61.

The stator 60 used in the rotating electric machine 10 may have protrusions (e.g., teeth) extending from the back yoke. In this case, it is sufficient that the coil module 150 and the like are attached to the stator core by the back yoke.

- Rotating electric machines are not limited to star-connected ones, and can also be delta-connected ones.

Second Embodiment
The configuration of the rotating electric machine 10 in the second embodiment will be described below, focusing on the differences from the first embodiment. In this embodiment, a part of the configuration of the stator 60 in the rotating electric machine 10 is changed. Specifically, in the stator 60 having a teethless structure, a string-like or cloth-like winding member 401 is wound around the coil ends CE of the stator winding 61, and the winding member 401 fixes the phase windings of each phase arranged in the circumferential direction.

As explained in FIG. 10 etc., the stator winding 61 has a first coil module 150A and a second coil module 150B, and these coil modules 150A, 150B are arranged in the circumferential direction. The coil modules 150A, 150B have a first partial winding 151A and a second partial winding 151B that have different coil end shapes (transfer portion shapes) (see FIG. 18), and insulating covers 161 to 164 are attached to both axial ends of each partial winding 151A, 151B, respectively (see FIG. 17).

Figure 41 is a front view showing the area where winding is performed by the winding member 401 in the stator winding 61, in which multiple partial windings 151A, 151B are arranged in the circumferential direction. Note that in Figure 41, the insulating covers 161 to 164 provided at both axial ends of each partial winding 151A, 151B are not shown.

In the stator winding 61 shown in FIG. 41, the coil end CE of the coil side CS is the winding region of the winding member 401, and the string-like or cloth-like winding member 401 is wound around the cylindrical stator winding 61 from the outside in the winding region. The winding member 401 is, for example, a string or cloth material made of carbon fiber material, and is wound around the outer circumference of the stator winding 61, with the ends of the string or cloth material being bonded together by adhesive or the like. Note that it is also possible to use a fiber material other than carbon fiber material as the winding member 401, such as glass fiber or metal fiber.

Figure 42 is a front view showing a state where multiple partial windings 151A, 151B are arranged in the circumferential direction. Here, in the jumper portion 153 of the second partial winding 151B of each partial winding 151A, 151B, the axial end of the second partial winding 151B is a winding end 404 extending in the circumferential direction, and when each partial winding 151A, 151B is arranged in the circumferential direction, the winding end 404 of the second partial winding 151B is arranged in a ring shape. Then, the winding member 401 is wound in a circular state around the radial outside of the winding end 404.

A more specific configuration will be described with reference to Figure 43. Figure 43 is a perspective view showing the configuration of a stator unit 50 in which multiple coil modules 150A, 150B are assembled to a core assembly CA.

In the stator unit 50, the coil modules 150A and 150B are arranged in the circumferential direction with a portion of each adjacent coil module overlapping, and the intermediate conductor portions 152 of the partial windings 151A and 151B are arranged in the circumferential direction at the coil side CS. In addition, at the coil end CE, the insulating covers 163 and 164 of the second coil module 150B of each coil module 150A and 150B are arranged in a ring shape in the circumferential direction, and the winding member 401 is wound around the insulating covers 163 and 164. The insulating covers 163 and 164 are attached to the winding end 404 and correspond to the covering member. Here, a string-like winding member 401 is used, and the winding member 401 is wound around each of the coil ends CE on both axial sides by two turns. The number of turns of the winding member 401 is arbitrary. If a string material is used as the winding member 401, it is preferable to have the winding member 401 arranged in the axial direction and wound multiple times.

Figure 44 is an enlarged perspective view of the insulating cover 163 around which the winding member 401 is wound. As described above, the insulating cover 163 has a pair of side portions 181 that form the circumferential side surfaces, an outer surface portion 182 on the axially outer side, a front surface portion 183 on the radially inner side, and a rear surface portion 184 on the radially outer side, and is configured by these portions 181 to 184 being joined together in a three-dimensional shape. A groove 402 extending in the circumferential direction is formed in the rear surface portion 184 of the insulating cover 163. The grooves 402 may be provided in one or more rows, and three rows of grooves 402 are provided in Figure 44.

When each coil module 150A, 150B is assembled to the core assembly CA, the grooves 402 in the insulating cover 163 are connected in the circumferential direction to form an annular groove, and a string-like winding member 401 is wound around the annular groove.

Although not shown, the other insulating cover 164 of the second coil module 150B has a similar configuration.

The end of the winding member 401 (e.g., the end of the string material) may be fastened to a core assembly CA, which serves as a winding support member to which the stator winding 61 is attached. This configuration is described in FIG. 45. As described above, the stator 60 has the stator winding 61 and the stator core 62, and the core assembly CA is an integral body including the stator core 62 and the stator holder 70. A plurality of partial windings 151 that constitute the stator winding 61 are attached to the core assembly CA.

The core assembly CA is a winding support member provided on the radial inside of the stator winding 61 (opposite side from the rotor 20). When multiple coil modules 150A, 150B are assembled to the core assembly CA, the crossover portions 153 of the partial windings 151A, 151B of different phases cross each other, and in the two partial windings 151A, 151B where the crossover portions 153 cross each other, the insulating covers 161, 163 (mounting members) integrated with the partial windings 151A, 151B are fixed to the core assembly CA by a common fixing pin 191 (fixing member).

Figure 45 is a vertical cross-sectional view showing the state in which each insulating cover 161, 163 is fixed by a fixing pin 191 when each coil module 150A, 150B is assembled to the core assembly CA.

In FIG. 45, the fixed pin 191 protrudes from the upper end surface of the insulating cover 163 on the axially outer side, and the winding member 401 is fastened to the protruding portion. In this case, with one end of the winding member 401 fastened to the protruding portion of the fixed pin 191, the winding member 401 is wound around the outer periphery of the insulating cover 163, and the other end of the winding member 401 is similarly fastened to the protruding portion of the fixed pin 191. The fixed pins 191 fastening one end and the other end of the winding member 401 may be the same or different. Although not shown, the configuration of the insulating covers 162 and 164 on the opposite axial side is the same.

Each coil module 150A, 150B may be adhesively fixed to the core assembly CA. In this case, the coil side portion (corresponding to the intermediate conductor portion 152) of each coil module 150A, 150B is fixed to the core assembly CA.

In the rotating electric machine 10, lubricating oil is supplied from the outside into the housing 241 that surrounds the rotor 20 and the stator 60, and the rotor 20 and the stator 60 are cooled by the lubricating oil. Figure 46 is a vertical cross-sectional view of the rotating electric machine 10. Figure 46 shows the rotating electric machine 10 in a state where the axial direction of the rotating shaft 11 is horizontal (left-right direction).

As shown in FIG. 46, through holes 411 and 412 are provided in the peripheral wall of the housing 241. Of these, through hole 411 is an oil supply port and is provided at an upper position of the housing 241, and through hole 412 is an oil discharge port and is provided at a lower position of the housing 241. In the rotating electric machine 10, lubricating oil is supplied to the inside of the housing through through hole 411, while lubricating oil is discharged from the inside of the housing through through hole 412. Note that the lubricating oil corresponds to the "cooling liquid" and the through hole 411 corresponds to the "inlet portion."

In FIG. 46, X1 indicates the winding portion of the winding member 401 of the stator winding 61, and the housing 241 is provided with a through hole 411 at a position above the winding portion X1. When lubricating oil is supplied, the lubricating oil is dripped from the through hole 411 of the housing 241 onto the coil end CE of the stator winding 61. The lubricating oil then travels circumferentially along the winding member 401 of the stator winding 61. This allows the coil end CE of the stator winding 61 to be cooled by the lubricating oil.

The rotating electric machine 10 of this embodiment has the following configuration:

A string-like or cloth-like winding member 401 is wound around the coil end CE of the stator winding 61, and the winding member 401 fixes each of the partial windings 151 arranged in the circumferential direction to each other. In this case, by fixing each partial winding 151 with the winding member 401, it is possible to fix the stator winding 61 in a stable state even in a stator 60 with a teethless structure. In particular, since the winding member 401 is wound only around the coil end of the stator winding 61, it is possible to prevent the winding member 401 from being interposed in the air gap between the stator 60 and the rotor 20, and to prevent the air gap from becoming excessively large. As a result, the stator winding 61 can be maintained in a suitable state.

When the stator winding 61 is made up of multiple partial windings 151, each partial winding 151 is provided individually, and there is a concern that some of the partial windings 151 may become misaligned in the radial direction when assembled. In this regard, the winding member 401 is wound around the coil end CE of the stator winding 61 around the partial windings 151 that are arranged in the circumferential direction, so that the multiple partial windings 151 that are provided individually can be held in place.

When multiple partial windings 151 are arranged in the circumferential direction, the winding ends 404 of the partial windings 151 are arranged in a ring shape. In this state, the winding member 401 is wound around the radial outside of the winding ends 404. In this case, the winding member 401 can be easily wound around the stator winding 61.

The insulating covers 161-164 are attached to the bridge portion 153 of the partial winding 151, and these insulating covers 161-164 ensure insulation between circumferentially adjacent partial windings 151 and allow the positioning of each partial winding 151. In addition, grooves 402 are formed on the outer peripheral surface on the radially outer side of the insulating covers 163, 164 of the second coil module 150B, and the winding member 401 is wound along the grooves 402. This makes it easier to wind the winding member 401 and prevents the winding member 401 from shifting position after winding.

In the coil modules 150A, 150B adjacent in the circumferential direction, insulating covers 161-164 are attached to the partial windings 151A, 151B, respectively, and the insulating covers 161-164 are fixed to the core assembly CA by a common fixing pin 191. This makes it easy to attach multiple partial windings 151 (coil modules 150) to the core assembly CA.

Furthermore, one end and the other end of the winding member 401 are fixed using the fixing pin 191. This allows for an optimal winding configuration when winding the end-shaped winding member 401 around the coil end CE of the stator winding 61.

In addition, the configuration for fixing each partial winding 151 has a double structure of fixing the winding with the fixing pin 191 and winding the winding member 401, so that the fixing of each partial winding 151 can be more suitably carried out. In this case, by fixing the winding with the fixing pin 191, it is possible to suppress the stator winding 61 from moving relative to the core assembly CA in the circumferential direction.

Each partial winding 151 is adhesively fixed to the core assembly CA. This allows the partial winding 151 to be fixed at the coil side CS in addition to the coil end CE, allowing the stator winding 61 to be fixed more reliably.

The lubricating oil flowing in from the through hole 411 of the housing 241 drips onto the coil end CE of the stator winding 61, thereby cooling the coil end CE. In this case, the lubricating oil spreads along the winding member 401 wrapped around the coil end CE to the entire circumferential area of the coil end CE, improving cooling performance. In other words, the winding member 401 can be used as a guide member for the lubricating oil.

In this case, particularly in a configuration in which the winding member 401 is wound around the radial outside of the stator winding 61 (see FIG. 43), the winding member 401 is arranged so as to be continuous in the circumferential direction at the coil end CE. This allows the lubricating oil to be distributed throughout almost the entire coil end CE via the winding member 401, realizing a configuration that is suitable for cooling the coil end CE.

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

- The stator winding 61 may be configured to use the first coil module 450A and the second coil module 450B shown in FIG. 47. Each of these coil modules 450A and 450B is provided with an insulating cover 451 made of an insulating material such as synthetic resin as a covering member on the entire winding including the pair of intermediate conductor parts 152 and the crossover parts 153 on both axial sides of the partial windings 151A and 151B described above, and is arranged side by side as shown in the figure. In detail, the first coil module 450A includes a first partial winding 151A having a bent shape on both axial ends, and the entire first partial winding 151A is covered with the insulating cover 451. The second coil module 450B includes a second partial winding 151B not having a bent shape on both axial ends, and the entire second partial winding 151B is covered with the insulating cover 451.

Even in a configuration using coil modules 450A, 450B, similar to the above, a string-like or cloth-like winding member 401 is wound around the coil end CE of the stator winding 61, and the coil modules 450A, 450B (partial windings 151A, 151B) arranged in the circumferential direction are fixed by the winding member 401.

As shown in FIG. 48, in the second coil module 450B, in which the bridge portion 153 of the partial winding 151 extends in the axial direction, of the coil modules 450A and 450B, grooves 452 extending in the circumferential direction are formed on the outer circumferential surface of the coil end of the insulating cover 451. The grooves 452 may be provided in one or more rows, and in FIG. 48, four rows of grooves 452 are provided. In this case, when each coil module 450A, 450B is assembled to the core assembly CA, the grooves 452 of the insulating cover 451 are connected in the circumferential direction to form an annular groove, and the winding member 401 is wound around the annular groove.

- The configuration shown in FIG. 49 can also be used to wind the winding member 401 around each coil module 450A, 450B. FIG. 49 is a front view showing two coil modules 450A and one coil module 450B assembled together in the circumferential direction.

In more detail, the first coil module 450A has a first partial winding 151A in which the crossover portion 153 is bent in the radial direction, and the coils arranged in the circumferential direction at the coil end CE are fixed to each other by the winding member 401. In addition, the first coil module 450A and the second coil module 450B are fixed to each other by the winding member 401 at the coil end CE.

Note that each of the coil modules 450A, 450B may be configured such that the partial windings 151A, 151B are wrapped (wound) with a film material FM to provide the insulating coating 451. In this configuration, similarly to the above, each of the coil modules 450A, 450B (partial windings 151A, 151B) arranged in the circumferential direction at the coil ends CE of the stator winding 61 may be fixed by the winding member 401.
In addition, the winding member 401 may be wound only on some of the coil modules 450 (partial windings 151) arranged in the circumferential direction. For example, in a configuration in which the coil modules 450 of each phase are arranged in a predetermined order in the circumferential direction, the winding member 401 may be wound only on the coil modules 450 of a specific phase among the multi-phase coil modules 450. Specifically, the winding member 401 may be wound only on the coil modules 450 of two phases out of the U phase, V phase, and W phase. In this configuration, the coil modules 450 wound by the winding member 401 and the coil modules 450 not wound by the winding member 401 are mixed, but the relative movement of the coil modules 450 in the circumferential direction is restricted.

- In the above embodiment, one end and the other end of the winding member 401 are fixed to the core assembly CA (winding support member) side by fixing the ends of the winding member 401 to the fixing pins 191 that fix the insulating covers 161-164 to the core assembly CA, but this may be changed. For example, the ends of the winding member 401 may be directly fixed to the stator core 62 or the stator holder 70 of the core assembly CA. This makes it possible to preferably realize the winding configuration when winding the end-shaped winding member 401 around the coil end CE of the stator winding 61. It also makes it possible to suppress relative movement of the stator winding 61 in the circumferential direction with respect to the core assembly CA.

- The partial winding 151 may be a full-pitch concentrated winding coil or a short-pitch concentrated winding coil. For example, it may be a 2/3π short-pitch concentrated winding coil. In addition, the stator winding 61 may be formed by continuous wave winding without using the partial winding 151.

-It is also possible to realize an inner rotor type rotating electric machine. As is well known, an inner rotor type rotating electric machine has a configuration in which the rotor is arranged radially inside the stator. However, other configurations are generally similar to the outer rotor type rotating electric machine 10. In this case, as explained in FIG. 49, it is preferable that the coil modules (partial windings) adjacent in the circumferential direction at the coil ends of the stator winding are fixed to each other by a string-like or cloth-like winding member.

-As the rotating electric machine 10 of the second embodiment, instead of a rotating field type rotating electric machine in which the field element is the rotor and the armature is the stator, it is also possible to adopt a rotating armature type rotating electric machine in which the armature is the rotor and the field element is the stator.

The disclosure in this specification is not limited to the exemplified embodiments. The disclosure includes the exemplified embodiments and modifications based thereon by those skilled in the art. For example, the disclosure is not limited to the combination of parts and/or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure can have additional parts that can be added to the embodiments. The disclosure includes the omission of parts and/or elements of the embodiments. The disclosure includes the substitution or combination of parts and/or elements between one embodiment and another embodiment. The technical scope of the disclosure is not limited to the description of the embodiments. Some technical scopes disclosed are indicated by the description of the claims, and should be interpreted as including all modifications within the meaning and scope equivalent to the description of the claims.

10... rotating electric machine, 20... rotor (field element), 22... magnet unit (magnet section), 60... stator (armature), 61... stator winding (armature winding), 401... winding member, CE... coil end, CS... coil side.

Claims (5)

A field element (20) having a magnet portion (22) including a plurality of magnetic poles whose polarities alternate in a circumferential direction;
An armature (60) having a teethless structure having a multi-phase armature winding (61) including a phase winding for each phase;
A rotating electric machine (10) comprising:
The phase winding has a plurality of partial windings (151) per phase,
The partial winding has a pair of intermediate conductor portions (152) extending in the axial direction and spaced a predetermined distance apart in the circumferential direction, and transition portions (153) that are provided at one and the other axial ends and connect the pair of intermediate conductor portions in an annular shape, and is configured by winding a conductor material (CR) in multiple layers around the pair of intermediate conductor portions and each transition portion, and the partial winding is arranged side by side in the circumferential direction,
the armature winding has a coil side (CS) facing the magnet portion in a radial direction and a coil end (CE) arranged on an outer side of the magnet portion in an axial direction,
The transition portion has a winding end portion (404) extending in a circumferential direction at an axial end portion of the partial winding, and when the partial windings are arranged in the circumferential direction, the winding ends of the partial windings are arranged in an annular shape,
In the partial winding, a covering member (163, 164, 451) is attached to at least the winding end portion, and a groove portion (402, 452) extending in a circumferential direction is formed in an outer peripheral surface of the covering member on a radially outer side,
The armature winding has a string-like or cloth-like winding member (401) wound around the coil end of the coil side or the coil end of the armature winding, and the phase windings of each phase arranged in the circumferential direction are fixed by the winding member.
The winding member is wound around the radially outer side of the winding end portion and along the groove portion . A field element (20) having a magnet portion (22) including a plurality of magnetic poles whose polarities alternate in a circumferential direction;
An armature (60) having a teethless structure having a multi-phase armature winding (61) including a phase winding for each phase;
A rotating electric machine (10) comprising:
The phase winding has a plurality of partial windings (151) per phase,
The partial winding has a pair of intermediate conductor portions (152) extending in the axial direction and spaced a predetermined distance apart in the circumferential direction, and transition portions (153) that are provided at one and the other axial ends and connect the pair of intermediate conductor portions in an annular shape, and is configured by winding a conductor material (CR) in multiple layers around the pair of intermediate conductor portions and each transition portion, and the partial winding is arranged side by side in the circumferential direction,
the armature winding has a coil side (CS) facing the magnet portion in a radial direction and a coil end (CE) arranged on an outer side of the magnet portion in an axial direction,
A string-like or cloth-like winding member (401) is wound around the partial windings arranged in the circumferential direction at the coil ends of the armature winding , and the phase windings of each phase arranged in the circumferential direction are fixed by the winding member ;
a winding support member (CA) provided on one of the radially inner side and the radially outer side of the armature winding, opposite to the field element, for supporting the plurality of partial windings;
The partial winding is integrally provided with mounting members (161 to 164) for mounting the partial winding to the winding support member,
The mounting members integrated with the partial windings adjacent in the circumferential direction are fixed to the winding support member at the coil end by a common fixing member (191),
a rotating electric machine, one end and the other end of the winding member being fixed to the fixed member; A field element (20) having a magnet portion (22) including a plurality of magnetic poles whose polarities alternate in a circumferential direction;
An armature (60) having a teethless structure having a multi-phase armature winding (61) including a phase winding for each phase;
A rotating electric machine (10) comprising:
a winding support member (CA) to which the armature winding is attached,
the armature winding has a coil side (CS) facing the magnet portion in a radial direction and a coil end (CE) arranged on an outer side of the magnet portion in an axial direction,
A string-like or cloth-like winding member (401) is wound around the coil ends of the coil sides and coil ends of the armature winding, and the phase windings of each phase arranged in the circumferential direction are fixed by the winding member,
a rotating electric machine, one end and the other end of the winding member being fixed to the winding support member; 4. The rotating electric machine according to claim 2 , wherein the armature winding is fixed to the winding support member with an adhesive. The rotor includes a housing (241) that surrounds the field element and the armature, and the housing is provided with an inlet (411) through which a cooling liquid is introduced from the outside.
5. The rotating electric machine according to claim 1, wherein the cooling liquid flowing in from the inlet portion is dripped onto a coil end of the armature winding.

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