WO2019131913A1 - Rotating electrical machine - Google Patents

Abstract

A rotating electrical machine (10) comprising: a field element (40) having a magnet section (42) including a plurality of magnets having the polarity thereof alternating in the circumferential direction; and an armature (50) having a multi-phase armature winding (51) and a base member (52). The armature winding (51) has conducting wire sections (82) arranged at positions facing the field element (40), at prescribed intervals in the circumferential direction. The conducting wire sections (82) form a flat shape that has a width dimension in the circumferential direction that is larger than the thickness dimension in the radial direction. A facing surface (1001a) of the conducting wire sections (82) facing the base member (50) is a curved surface forming an arc shape along a curved surface (52a) of the base member (52) having the facing surface fixed thereto in the circumferential direction.

Description

Electric rotating machine Cross-reference to related applications

This application is based on Japanese Application No. 2017-255072 filed on Dec. 28, 2017, and Japanese Application No. 2018-164841 filed on September 3, 2018, the contents of which are incorporated herein by reference. Incorporate

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

BACKGROUND ART As described in, for example, Patent Document 1, a rotary electric machine applied to home appliances, industrial machines, game machines, agricultural construction machines, and automobiles is conventionally known. Generally, a so-called slot, which is a winding accommodating portion partitioned by teeth, is formed in the stator core (that is, an iron core), and a conductor such as a copper wire or an aluminum wire is accommodated in the slot. The line is configured. On the other hand, a slotless motor in which the teeth of the stator are eliminated has also been proposed (for example, Patent Document 1).

Japanese Patent Application Laid-Open No. 6-70522

In such a motor, it is desirable to improve the ratio occupied by the wire in the housing space of the wire and to increase the output or reduce the size of the motor.

An object of the present disclosure is to provide a rotary electric machine having a slotless structure that improves the ratio of the wire occupied in the wire accommodation space.

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

The means 1 comprises a field element having a magnet portion including a plurality of magnetic poles of alternating polarity in the circumferential direction, an armature winding having a multiphase armature winding and a base member to which the armature winding is fixed. A rotating electrical machine comprising one of the field element and the armature as a rotor,
The armature winding has conducting wire portions arranged at predetermined intervals in a circumferential direction at a position facing the field element,
In the armature,
An inter-conductor member is provided between the conductor portions in the circumferential direction, and as the inter-conductor member, the circumferential width dimension of the inter-conductor member in one magnetic pole is Wt, and the saturation flux density of the inter-conductor member is Bs. A configuration using a magnetic material or nonmagnetic material having a relationship of Wt × Bs ≦ Wm × Br, where Wm is the width dimension of the magnet portion in one magnetic pole and Br is the residual magnetic flux density of the magnet portion. Or
Alternatively, the inter-conductor member is not provided between the conductor portions in the circumferential direction,
The wire portion has a flat shape in which the width dimension in the circumferential direction is larger than the thickness dimension in the radial direction,
The facing surface facing the base member in the conducting wire portion is a curved surface that is arc-shaped along the curved surface of the base member to which the facing surface is fixed in the circumferential direction.

By making the wire portion into a flat rectangular shape in which the width dimension in the circumferential direction is larger than the thickness dimension in the radial direction, it can be expected to reduce the length (thickness) in the radial direction of the armature. However, in the case where the conducting wire portion has a flat rectangular shape, when fixed to the curved surface of the base member, there is a problem that an extra gap is formed between the opposing surface of the conducting wire portion and the curved surface of the base member.

Therefore, the above configuration is adopted. Thereby, the gap between the curved surface of the base member and the facing surface of the conducting wire can be eliminated. Therefore, the length (thickness) in the radial direction of the armature can be reduced while eliminating the extra gap where the conductor portion is not disposed. The rotating electrical machine can be miniaturized by reducing the length (thickness) in the radial direction of the armature, or the space inside the armature or field element (housing space etc.) should be enlarged. Can.

In the means 2, in the means 1, the conductor portion is constituted by a plurality of conductors aligned in the radial direction of the armature,
Of the two conducting wires arranged radially next to each other, the outer side facing the outer conducting wire in the inner conducting wire is a curved surface having a circular arc shape in the circumferential direction and faces the inner conducting wire in the outer conducting wire The inner side surface is a curved surface that is arc-shaped along the outer side surface of the inner lead in the circumferential direction.

With the above configuration, when the plurality of wires are aligned in the radial direction of the armature, it is possible to eliminate an extra gap where the wires are not disposed between the outer side surface of the inner wire and the inner side surface of the outer wire. . For this reason, it is possible to reduce the radial length (thickness) of the armature while increasing the space occupied by the conducting wire.

In the means 2, in the means 2, the thickness dimension in the radial direction of the outer lead is smaller than that of the inner lead among the two leads arranged adjacent to each other in the radial direction in the radial direction, and The circumferential width dimension is longer compared to the inner conductor.

According to the above configuration, it is possible to make the thickness of the outer lead in the radial direction thinner than the thickness of the inner lead while reducing the gap between the leads adjacent in the circumferential direction. Thus, the thickness dimension in the radial direction of the armature can be made thinner while reducing the extra space in which the conducting wire is not disposed between the conducting wires adjacent in the circumferential direction.

In the means 4, in any one of the means 1 to 3, an interphase insulating film for performing insulation is provided between the conductor portions which are at least in different phases;
The conductor portions of different phases adjacent in the circumferential direction are in contact with each other with the interphase insulating film interposed therebetween.

The interphase insulating film can provide insulation between different phases, and can reduce the gap between the conductors of different phases adjacent in the circumferential direction.

Further, by interposing the interphase insulating film between the conducting wires and compressing the conducting wires toward the base member, the stator winding as described above can be easily manufactured. That is, it is possible to easily reduce the gap between the conducting wires while keeping the spacing between the conducting wires constant in the circumferential direction. In particular, even if there is no protrusion or the like for positioning the conductive wire disposed between the conductive wires, such as teethless, slotless, etc., the conductive wire can be formed with the interphase insulating film interposed between the wires. By compressing to the base member side, it is possible to easily reduce the gap between the conducting wires while keeping the spacing between the conducting wires in the circumferential direction constant.

In means 5 according to any one of means 1 to 4, in each of the conductive wires constituting the conductive wire portion, a plurality of strands are bundled, and the resistance value between the bundled strands is the resistance of the strands themselves. It is an assembly of strands larger than the value.

Thereby, the eddy current loss can be further reduced. In addition, since the wire assembly is a wire assembly, the wire can be easily deformed to the above shape by compressing the wire toward the base member.

In the means 6, in the means 5, each of the strands is covered with an insulating layer,
The thickness of the insulating layer is thinner than the thickness of the insulating member covering the bundled strands.

Since the strands in the conducting wire are in the same phase, there is no potential difference. That is, unlike between wires, even if the insulation coating of the strands is thinner than the insulation coating, sufficient insulation can be achieved between the strands. In addition, even if it can not be insulated, no major problems occur. Therefore, the insulation layer of the strands is made thinner than the thickness of the insulation member covering the bundled strands. Thereby, the ratio of the insulating layer in the conducting wire can be reduced and the ratio occupied by the conductor can be increased.

The above object and other objects, features and advantages of the present disclosure will become more apparent from the following detailed description with reference to the attached drawings. The drawing is
Fig. 1 is a longitudinal sectional perspective view of a rotating electric machine, Fig. 2 is a longitudinal sectional view of the rotating electric machine, 3 is a cross-sectional view taken along line III-III in FIG. 4 is a cross-sectional view showing a part of FIG. 3 in an enlarged manner, Fig. 5 is an exploded view of the rotating electrical machine, FIG. 6 is an exploded view of the inverter unit, FIG. 7 is a torque diagram showing the relationship between the ampere turns of the stator winding and the torque density, FIG. 8 is a cross-sectional view of a rotor and a stator, FIG. 9 is an enlarged view of a part of FIG. 8; FIG. 10 is a cross-sectional view of the stator; FIG. 11 is a longitudinal sectional view of a stator, FIG. 12 is a perspective view of a stator winding; FIG. 13 is a perspective view showing the configuration of a lead; FIG. 14 is a schematic view showing the structure of a wire; FIG. 15 is a diagram showing the form of each wire in the n-th layer, FIG. 16 is a side view showing the conductors in the n-th layer and the n + 1-th layer; FIG. 17 is a diagram showing the relationship between the electrical angle and the magnetic flux density for the magnet of the embodiment, FIG. 18 is a diagram showing the relationship between the electrical angle and the magnetic flux density for the magnet of the comparative example, FIG. 19 is an electric circuit diagram of a control system of a rotating electric machine, FIG. 20 is a functional block diagram showing current feedback control processing by the controller; FIG. 21 is a functional block diagram showing a torque feedback control process by the controller; FIG. 22 is a cross-sectional view of a conventional stator winding, FIG. 23 is a cross-sectional view of the stator winding in the first embodiment, FIG. 24 is a transverse sectional view of a rotor and a stator in the second embodiment, 25 is a diagram showing a part of FIG. 22 in an enlarged manner, FIG. 26 is a diagram specifically showing the flow of magnetic flux in the magnet unit, FIG. 27 is a cross-sectional view of a stator in the first modification; FIG. 28 is a cross-sectional view of a stator in the first modification; FIG. 29 is a cross-sectional view of a stator in the second modification; FIG. 30 is a cross-sectional view of a stator in the third modification; FIG. 31 is a cross-sectional view of a stator in the fourth modification; FIG. 32 is a transverse sectional view of a rotor and a stator in the seventh modification; FIG. 33 is a functional block diagram showing a part of processing of the operation signal generation unit in the eighth modification; FIG. 34 is a flowchart showing a procedure of carrier frequency change processing, FIG. 35 is a diagram showing a connection form of each lead forming the lead group in the ninth modification; FIG. 36 is a diagram showing a configuration in which four pairs of conducting wires are stacked and arranged in the ninth modification; FIG. 37 is a cross-sectional view of an inner rotor type rotor and a stator in the tenth modification; FIG. 38 is an enlarged view of a part of FIG. Fig. 39 is a longitudinal sectional view of an inner rotor type rotating electric machine, FIG. 40 is a longitudinal sectional view showing a schematic configuration of an inner rotor type rotating electric machine, FIG. 41 is a diagram showing a configuration of a rotary electric machine having an inner rotor structure in Modification 11; FIG. 42 is a diagram showing the configuration of a rotary electric machine having an inner rotor structure in Modification 11; FIG. 43 is a diagram showing the configuration of a rotary armature type rotary electric machine according to a modification 12; FIG. 44 is a cross-sectional view showing the configuration of the lead in modification 14; FIG. 45 is a diagram showing the relationship between reluctance torque, magnet torque and DM, FIG. 46 is a diagram showing teeth FIG. 47 is a cross-sectional view of a stator winding in an inner rotor structure, FIG. 48 is a cross-sectional view of a stator winding in another example, FIG. 49 is a cross-sectional view of a stator winding in another example.

Several embodiments will be described with reference to the drawings. In embodiments, functionally and / or structurally corresponding portions and / or associated portions may be provided with the same reference symbols, or reference symbols with different places of one hundred or more places. The description of the other embodiments can be referred to for the corresponding parts and / or parts to be associated.

The rotating electrical machine in the present embodiment is, for example, used as a vehicle power source. However, the rotary electric machine can be widely used for industrial use, for vehicles, for home appliances, for OA equipment, for game machines, and the like. In addition, in the following each embodiment, the same code | symbol is attached | subjected to the mutually same or equal part in the figure, and the description is used about the part of the same code | symbol.

First Embodiment
The rotary electric machine 10 according to the present embodiment is a synchronous multiphase AC motor, and has an outer rotor structure (eversion structure). The outline | summary of the rotary electric machine 10 is shown in FIG. 1 thru | or FIG. 1 is a longitudinal sectional perspective view of the rotating electrical machine 10, FIG. 2 is a longitudinal sectional view in the direction along the rotating shaft 11 of the rotating electrical machine 10, and FIG. 3 is a direction perpendicular to the rotating shaft 11. FIG. 4 is a cross-sectional view of the rotary electric machine 10 (a cross-sectional view taken along the line III-III in FIG. 2), FIG. 4 is a cross-sectional view showing a part of FIG. It is. In FIG. 3, hatching indicating a cut surface is omitted except for the rotating shaft 11 for convenience of illustration. In the following description, the direction in which the rotation shaft 11 extends is taken as the axial direction, the direction radially extending from the center of the rotation shaft 11 is taken as the radial direction, and the direction extending circumferentially around the rotation shaft 11 is taken as the circumferential direction.

The rotary electric machine 10 roughly includes a bearing unit 20, a housing 30, a rotor 40, a stator 50, and an inverter unit 60. Each of these members is disposed coaxially with the rotation shaft 11, and is assembled in an axial direction in a predetermined order, whereby the rotary electric machine 10 is configured. The rotary electric machine 10 of the present embodiment is configured to have a rotor 40 as a "field element" and a stator 50 as an "armature", and is embodied as a rotary electric field type rotary electric machine. It has become.

The bearing unit 20 has two bearings 21 and 22 which are disposed to be separated from each other in the axial direction, and a holding member 23 for holding the bearings 21 and 22. The bearings 21 and 22 are, for example, radial ball bearings, and each include an outer ring 25, an inner ring 26, and a plurality of balls 27 disposed between the outer ring 25 and the inner ring 26. The holding member 23 has a cylindrical shape, and the bearings 21 and 22 are assembled on the inner side in the radial direction. The rotary shaft 11 and the rotor 40 are rotatably supported on the inner side in the radial direction of the bearings 21 and 22. The bearings 21 and 22 constitute a set of bearings that rotatably support the rotating shaft 11.

In each of the bearings 21 and 22, the balls 27 are held by a retainer (not shown), and the pitch between the balls is maintained in this state. The bearings 21 and 22 have sealing members at the upper and lower portions in the axial direction of the retainer, and the inside thereof is filled with non-conductive grease (for example, non-conductive urea-based grease). Further, the position of the inner ring 26 is mechanically held by the spacer, and a constant pressure preload that is convex in the vertical direction from the inside is applied.

The housing 30 has a cylindrical peripheral wall 31. The peripheral wall 31 has a first end and a second end opposite in the axial direction. The peripheral wall 31 has an end face 32 at a first end and an opening 33 at a second end. The opening 33 is open at the entire second end. A circular hole 34 is formed in the center of the end face 32, and the bearing unit 20 is fixed by a fixing tool such as a screw or a rivet in a state of being inserted into the hole 34. Further, a hollow cylindrical rotor 40 and a hollow cylindrical stator 50 are accommodated in the housing 30, that is, in an internal space defined by the peripheral wall 31 and the end surface 32. In the present embodiment, the rotary electric machine 10 is of the outer rotor type, and the stator 50 is disposed inside the housing 30 in the radial direction of the cylindrical rotor 40. The rotor 40 is cantilevered on the rotary shaft 11 on the side of the end face 32 in the axial direction.

The rotor 40 has a magnet holder 41 formed in a hollow cylindrical shape, and an annular magnet unit 42 provided radially inward of the magnet holder 41. The magnet holder 41 has a substantially cup shape and has a function as a magnet holding member. The magnet holder 41 is a cylindrical portion 43 having a cylindrical shape, and an intermediate portion serving as a portion connecting the cylindrical portion 43 and the fixing portion 44, which has the same cylindrical shape and has an attachment 44 smaller in diameter than the cylindrical portion 43. And 45. The magnet unit 42 is attached to the inner peripheral surface of the cylindrical portion 43.

The magnet holder 41 is made of cold rolled steel plate (SPCC) having sufficient mechanical strength, steel for forging, carbon fiber reinforced plastic (CFRP) or the like.

The rotating shaft 11 is inserted into the through hole 44 a of the fixed portion 44. The fixing portion 44 is fixed to the rotating shaft 11 disposed in the through hole 44 a. That is, the magnet holder 41 is fixed to the rotating shaft 11 by the fixing portion 44. The fixing portion 44 may be fixed to the rotating shaft 11 by spline connection using an unevenness, key connection, welding, caulking, or the like. Thus, the rotor 40 rotates integrally with the rotating shaft 11.

Further, the bearings 21 and 22 of the bearing unit 20 are assembled on the radial outside of the fixing portion 44. As described above, since the bearing unit 20 is fixed to the end surface 32 of the housing 30, the rotary shaft 11 and the rotor 40 are rotatably supported by the housing 30. Thereby, the rotor 40 is rotatable in the housing 30.

The rotor 40 is provided with a fixing portion 44 only at one of two axially opposite ends thereof, whereby the rotor 40 is supported in a cantilever manner on the rotation shaft 11. Here, the fixed portion 44 of the rotor 40 is rotatably supported by the bearings 21 and 22 of the bearing unit 20 at two different positions in the axial direction. That is, the rotor 40 is rotatably supported by two axially spaced bearings 21 and 22 at one of two axially opposite ends of the magnet holder 41. Therefore, stable rotation of the rotor 40 is realized even if the rotor 40 is supported by the rotary shaft 11 in a cantilever manner. In this case, the rotor 40 is supported by the bearings 21 and 22 at a position shifted to one side with respect to the axial center position of the rotor 40.

Further, in the bearing unit 20, the bearing 22 near the center of the rotor 40 (lower side in the figure) and the bearing 21 on the opposite side (upper side in the figure) The dimensions are different. For example, the bearing 22 near the center of the rotor 40 has a larger gap size than the bearing 21 on the opposite side. In this case, even if vibration due to swing of the rotor 40 or imbalance due to component tolerance acts on the bearing unit 20 on the side closer to the center of the rotor 40, the influence of the swing or vibration is well absorbed. Ru. Specifically, by increasing the play size (gap size) by preloading in the bearing 22 near the center of the rotor 40 (the lower side in the figure), the vibration generated in the cantilever structure is absorbed by the play portion. Ru. The preload may be either fixed position preload or constant pressure preload. In the case of fixed position preloading, the bearing 21 and the outer ring 25 of the bearing 22 are both joined to the holding member 23 using a method such as press fitting or adhesion. Further, the bearing 21 and the inner ring 26 of the bearing 22 are both joined to the rotary shaft 11 using a method such as press fitting or bonding. Here, by disposing the outer ring 25 of the bearing 21 at a position different from the inner ring 26 of the bearing 21 in the axial direction, it is possible to generate a preload. The preload can also be generated by arranging the outer ring 25 of the bearing 22 at a position different from the inner ring 26 of the bearing 22 in the axial direction.

When a constant pressure preload is employed, a preload spring, for example, a wave washer 24 or the like, is bearing so that a preload is generated from the region between the bearing 22 and the bearing 21 toward the outer ring 25 of the bearing 22 in the axial direction. It arrange | positions in the same area | region pinched | interposed into 22 and the bearing 21. FIG. Also in this case, the bearing 21 and the inner ring 26 of the bearing 22 are both joined to the rotating shaft 11 using a method such as press fitting or bonding. The bearing 21 or the outer ring 25 of the bearing 22 is disposed with respect to the holding member 23 via a predetermined clearance. With such a configuration, the spring force of the preload spring acts on the outer ring 25 of the bearing 22 in the direction away from the bearing 21. Then, when this force is transmitted through the rotary shaft 11, a force that presses the inner ring 26 of the bearing 21 in the direction of the bearing 22 acts. As a result, the axial positions of the outer ring 25 and the inner ring 26 deviate in both the bearings 21 and 22, and two bearings can be preloaded in the same manner as the fixed position preload described above.

When generating a constant pressure preload, it is not always necessary to apply a spring force to the outer ring 25 of the bearing 22 as shown in FIG. For example, a spring force may be applied to the outer ring 25 of the bearing 21. Further, the inner ring 26 of any one of the bearings 21 and 22 is disposed with a predetermined clearance with respect to the rotary shaft 11, and the outer rings 25 of the bearings 21 and 22 are press-fit or adhered to the holding member 23 The two bearings may be preloaded by joining them together.

Furthermore, in the case where the inner ring 26 of the bearing 21 exerts a force on the bearing 22 to be separated, it is better to exert the force on the bearing 21 so as to separate the bearing 21 as well. Conversely, in the case where the inner ring 26 of the bearing 21 exerts a force to approach the bearing 22, it is better to apply the force so that the inner ring 26 of the bearing 22 also approaches the bearing 21.

When the rotating electrical machine 10 is applied to a vehicle for the purpose of a vehicle power source or the like, the mechanism for generating the preload may be subjected to vibration having a component in the direction of generation of the preload, or an object for applying the preload. There is a possibility that the direction of gravity on an object may change. Therefore, when applying this rotary electric machine 10 to a vehicle, it is desirable to adopt a fixed position preload.

The middle portion 45 also has an annular inner shoulder 49a and an annular outer shoulder 49b. The outer shoulder 49 b is located outside the inner shoulder 49 a in the radial direction of the middle portion 45. The inner shoulder 49 a and the outer shoulder 49 b are spaced apart from each other in the axial direction of the middle portion 45. Thus, the cylindrical portion 43 and the fixing portion 44 partially overlap in the radial direction of the intermediate portion 45. That is, the cylindrical portion 43 protrudes axially outward with respect to the proximal end (the lower end in the drawing) of the fixed portion 44. In this configuration, it is possible to support the rotor 40 with respect to the rotating shaft 11 at a position near the center of gravity of the rotor 40, compared to the case where the intermediate portion 45 is provided in a flat plate shape without steps. Forty stable operations can be realized.

According to the configuration of the intermediate portion 45 described above, in the rotor 40, the bearing accommodation concave portion 46 which accommodates a part of the bearing unit 20 at a position surrounding the fixing portion 44 in the radial direction and inward of the intermediate portion 45. A coil accommodating recess for accommodating a coil end 54 of a stator winding 51 of the stator 50 described later at a position surrounding the bearing accommodating recess 46 in the radial direction and being on the outer side of the intermediate portion 45 47 are formed. And these each accommodation recessed part 46, 47 is arrange | positioned so that it may adjoin in the radial inside and outside. That is, a part of the bearing unit 20 and the coil end 54 of the stator winding 51 are disposed so as to overlap radially inward and outward. Thereby, in the rotary electric machine 10, shortening of the axial dimension is possible.

The intermediate portion 45 is provided so as to project radially outward from the rotary shaft 11 side. The intermediate portion 45 is provided with a contact avoiding portion which extends in the axial direction and prevents the contact of the stator winding 51 of the stator 50 with the coil end 54. The middle portion 45 corresponds to the overhang portion.

The coil end 54 can be bent radially inward or outward so that the axial dimension of the coil end 54 can be reduced, and the axial length of the stator 50 can be shortened. The bending direction of the coil end 54 may be in consideration of the assembly with the rotor 40. Assuming that the stator 50 is assembled radially inward of the rotor 40, the coil end 54 may be bent radially inward on the insertion tip side with respect to the rotor 40. Although the bending direction of the coil end on the opposite side of the coil end 54 may be arbitrary, an outwardly bent shape having a space is preferable in terms of manufacture.

Moreover, the magnet unit 42 as a magnet part is comprised by the some permanent magnet arrange | positioned so that polarity may change alternately along the circumferential direction in the radial direction inner side of the cylindrical part 43. As shown in FIG. Thus, the magnet unit 42 has a plurality of magnetic poles in the circumferential direction. However, the details of the magnet unit 42 will be described later.

The stator 50 is provided radially inward of the rotor 40. The stator 50 has a stator winding 51 wound in a substantially cylindrical shape (annular shape) and a stator core 52 as a base member disposed radially inward, and the stator winding A line 51 is disposed to face the annular magnet unit 42 across a predetermined air gap. The stator winding 51 is composed of a plurality of phase windings. Each of the phase windings is configured by connecting a plurality of conductive wires arranged in the circumferential direction to each other at a predetermined pitch. In the present embodiment, by using U-phase, V-phase and W-phase three-phase windings and X-phase, Y-phase and Z-phase three-phase windings and using two of these three-phase windings, The stator winding 51 is configured as a six-phase phase winding.

The stator core 52 is formed in an annular shape by a laminated steel plate in which electromagnetic steel sheets, which are soft magnetic materials, are laminated, and is assembled inside the stator winding 51 in the radial direction. The electromagnetic steel sheet is, for example, a silicon steel sheet obtained by adding about several percent (for example, 3%) of silicon to iron. The stator winding 51 corresponds to an armature winding, and the stator core 52 corresponds to an armature core.

The stator winding 51 is a portion overlapping the stator core 52 in the radial direction, and a coil side portion 53 that is radially outward of the stator core 52, and one end side of the stator core 52 in the axial direction and the other. The coil ends 54 and 55 respectively project on the end side. The coil side portion 53 respectively faces the stator core 52 and the magnet unit 42 of the rotor 40 in the radial direction. In a state where the stator 50 is disposed inside the rotor 40, the coil end 54, which becomes the side of the bearing unit 20 (the upper side in the figure), of the coil ends 54 and 55 on both axial sides is the magnet holder of the rotor 40 It is accommodated in the coil accommodation recessed part 47 formed of 41. However, the details of the stator 50 will be described later.

The inverter unit 60 has a unit base 61 fixed to the housing 30 by a fastener such as a bolt, and a plurality of electrical components 62 assembled to the unit base 61. The unit base 61 is made of, for example, a carbon fiber reinforced plastic (CFRP). The unit base 61 has an end plate 63 fixed to the edge of the opening 33 of the housing 30, and an axially extending casing 64 integrally provided on the end plate 63. The end plate 63 has a circular opening 65 at its central portion, and a casing 64 is formed so as to stand up from the peripheral edge of the opening 65.

The stator 50 is assembled to the outer peripheral surface of the casing 64. That is, the outer diameter dimension of the casing 64 is the same as the inner diameter dimension of the stator core 52 or slightly smaller than the inner diameter dimension of the stator core 52. The stator core 52 is assembled to the outside of the casing 64, whereby the stator 50 and the unit base 61 are integrated. Further, when the unit base 61 is fixed to the housing 30, the stator 50 is integrated with the housing 30 in a state where the stator core 52 is assembled to the casing 64.

The stator core 52 may be assembled to the unit base 61 by bonding, shrink fitting, press fitting, or the like. Thus, positional deviation of the stator core 52 in the circumferential direction or axial direction with respect to the unit base 61 side is suppressed.

A radial inner side of the casing 64 is a housing space for housing the electric component 62, and the electric component 62 is disposed in the housing space so as to surround the rotary shaft 11. The casing 64 has a role as a housing space forming part. The electric component 62 is configured to include a semiconductor module 66 constituting an inverter circuit, a control board 67, and a capacitor module 68.

The unit base 61 is provided on the inner side in the radial direction of the stator 50 and corresponds to a stator holder (armature holder) for holding the stator 50. The housing 30 and the unit base 61 constitute a motor housing of the rotary electric machine 10. In this motor housing, the holding member 23 is fixed to the housing 30 on one side of the rotor 40 in the axial direction, and the housing 30 and the unit base 61 are connected to each other on the other side. For example, in an electric vehicle or the like, which is an electric vehicle, the rotating electrical machine 10 is mounted on a vehicle or the like by attaching a motor housing to the side of the vehicle or the like.

Here, the configuration of the inverter unit 60 will be further described using FIG. 6 which is an exploded view of the inverter unit 60 in addition to FIGS. 1 to 5 described above.

In the unit base 61, the casing 64 has a cylindrical portion 71 and an end face 72 provided on one of the opposite ends (the end on the bearing unit 20 side) opposed in the axial direction. Of the axially opposite end portions of the cylindrical portion 71, the side opposite to the end face 72 is entirely open through the opening 65 of the end plate 63. A circular hole 73 is formed at the center of the end face 72, and the rotary shaft 11 can be inserted through the hole 73. The hole 73 is provided with a sealing material 171 for closing a gap between the hole 73 and the outer peripheral surface of the rotating shaft 11. The sealing material 171 may be, for example, a sliding seal made of a resin material.

The cylindrical portion 71 of the casing 64 serves as a partition that divides between the rotor 40 and the stator 50 disposed radially outward and the electric component 62 disposed radially inward. The rotor 40, the stator 50, and the electric component 62 are respectively arranged side by side radially inward and outward with the portion 71 interposed therebetween.

Further, the electric component 62 is an electric component constituting an inverter circuit, and has a power running function of rotating the rotor 40 by supplying current to each phase winding of the stator winding 51 in a predetermined order; The generator has a power generation function of inputting a three-phase alternating current flowing in the stator winding 51 with the rotation of the motor, and outputting the same as generated power to the outside. The electrical component 62 may have only one of the power running function and the power generation function. The power generation function is, for example, a regeneration function that outputs the regenerative electric power to the outside when the rotating electrical machine 10 is used as a vehicle power source.

As a specific configuration of the electrical component 62, as shown in FIG. 4, a hollow cylindrical capacitor module 68 is provided around the rotation shaft 11, and a plurality of capacitor modules 68 are provided on the outer peripheral surface of the capacitor module 68. The semiconductor modules 66 are arranged in the circumferential direction. The capacitor module 68 includes a plurality of smoothing capacitors 68 a connected in parallel with one another. Specifically, the capacitor 68a is a laminated film capacitor in which a plurality of film capacitors are stacked, and the cross section has a trapezoidal shape. The capacitor module 68 is configured by arranging twelve capacitors 68 a in a ring shape.

In the manufacturing process of the capacitor 68a, for example, a long film of a predetermined width formed by laminating a plurality of films is used, the film width direction is a trapezoidal height direction, and the upper and lower bases of the trapezoid alternate. The capacitor film is produced by cutting the long film into an isosceles trapezoidal shape. Then, by attaching an electrode or the like to the capacitor element, the capacitor 68a is manufactured.

The semiconductor module 66 includes semiconductor switching elements such as MOSFETs and IGBTs, for example, and is formed in a substantially plate shape. In the present embodiment, since the rotary electric machine 10 is provided with two sets of three-phase windings, and an inverter circuit is provided for each of the three-phase windings, a total of 12 semiconductor modules 66 are formed in a ring. The semiconductor module group 66 </ b> A is provided to the electrical component 62.

The semiconductor module 66 is disposed between the cylindrical portion 71 of the casing 64 and the capacitor module 68. The outer peripheral surface of the semiconductor module group 66A is in contact with the inner peripheral surface of the cylindrical portion 71, and the inner peripheral surface of the semiconductor module group 66A is in contact with the outer peripheral surface of the capacitor module 68. In this case, the heat generated in the semiconductor module 66 is transferred to the end plate 63 through the casing 64 and is released from the end plate 63.

The semiconductor module group 66A preferably has a spacer 69 between the semiconductor module 66 and the cylindrical portion 71 on the outer peripheral surface side, that is, in the radial direction. In this case, in the capacitor module 68, the cross-sectional shape of the cross section orthogonal to the axial direction is a regular dodecagon, while the cross-sectional shape of the inner peripheral surface of the cylindrical portion 71 is circular. Is a flat surface, and the outer peripheral surface is a curved surface. The spacers 69 may be integrally provided so as to be continuous in an annular shape on the radially outer side of the semiconductor module group 66A. The spacer 69 is a good heat conductor, and may be, for example, a metal such as aluminum or a heat dissipating gel sheet. In addition, it is also possible to make the cross-sectional shape of the inner peripheral surface of the cylindrical part 71 into the same dodecagon as the capacitor module 68. In this case, it is preferable that the inner and outer peripheral surfaces of the spacer 69 be flat.

Further, in the present embodiment, the cooling water passage 74 for circulating the cooling water is formed in the cylindrical portion 71 of the casing 64, and the heat generated by the semiconductor module 66 is to the cooling water flowing through the cooling water passage 74. It is also released. That is, the casing 64 is provided with a water cooling mechanism. As shown in FIGS. 3 and 4, the cooling water passage 74 is annularly formed so as to surround the electric component 62 (the semiconductor module 66 and the capacitor module 68). The semiconductor module 66 is disposed along the inner peripheral surface of the cylindrical portion 71, and the cooling water passage 74 is provided at a position overlapping the semiconductor module 66 in the radial direction and the inside.

Since the stator 50 is disposed outside the cylindrical portion 71 and the electric component 62 is disposed inside, the heat of the stator 50 is transmitted to the cylindrical portion 71 from the outside thereof, The heat of the electrical component 62 (for example, the heat of the semiconductor module 66) is transmitted from the inside. In this case, the stator 50 and the semiconductor module 66 can be cooled simultaneously, and the heat of the heat generating member of the rotary electric machine 10 can be efficiently released.

Furthermore, at least a portion of the semiconductor module 66 that constitutes a part or all of the inverter circuit that operates the rotating electrical machine by energizing the stator winding 51 is the radial outside of the cylindrical portion 71 of the casing 64 The stator core 52 is disposed in the area surrounded by the stator core 52. Desirably, the whole of one semiconductor module 66 is disposed in the area surrounded by the stator core 52. Furthermore, desirably, all of the semiconductor modules 66 are disposed in the area surrounded by the stator core 52.

Further, at least a part of the semiconductor module 66 is disposed in the area surrounded by the cooling water passage 74. Desirably, the whole of all the semiconductor modules 66 is disposed in the area surrounded by the yoke 141.

The electrical component 62 also includes an insulating sheet 75 provided on one end surface of the capacitor module 68 in the axial direction and a wiring module 76 provided on the other end surface. In this case, the capacitor module 68 has two end faces opposed in the axial direction, that is, a first end face and a second end face. A first end face close to the bearing unit 20 of the capacitor module 68 is opposed to the end face 72 of the casing 64, and is superimposed on the end face 72 with the insulating sheet 75 interposed therebetween. Further, the wiring module 76 is assembled to the second end face close to the opening 65 of the capacitor module 68.

The wiring module 76 has a circular plate-like main body 76a made of a synthetic resin material and a plurality of bus bars 76b and 76c embedded therein. The bus bars 76b and 76c allow the semiconductor module 66 and the capacitor to be formed. An electrical connection is made with the module 68. Specifically, the semiconductor module 66 has a connection pin 66a extending from the end face in the axial direction, and the connection pin 66a is connected to the bus bar 76b at the radial outside of the main body 76a. Further, the bus bar 76c extends to the side opposite to the capacitor module 68 at the radially outer side of the main body 76a, and is connected to the wiring member 79 at its tip (see FIG. 2).

According to the configuration in which the insulating sheet 75 is provided on the first end face of the capacitor module 68 facing in the axial direction as described above and the wiring module 76 is provided on the second end face of the capacitor module 68, the heat radiation path of the capacitor module 68 A path from the first end face and the second end face of the capacitor module 68 to the end face 72 and the cylindrical portion 71 is formed. That is, a path from the first end face to the end face 72 and a path from the second end face to the cylindrical portion 71 are formed. Thus, heat can be dissipated from the end surface portion of the capacitor module 68 other than the outer peripheral surface on which the semiconductor module 66 is provided. That is, not only the radiation in the radial direction but also the radiation in the axial direction is possible.

Further, since the capacitor module 68 has a hollow cylindrical shape and the rotary shaft 11 is disposed with a predetermined gap interposed in the inner peripheral portion, the heat of the capacitor module 68 can be released also from the hollow portion ing. In this case, the flow of air is generated by the rotation of the rotating shaft 11, so that the cooling effect is enhanced.

A disk-shaped control board 67 is attached to the wiring module 76. The control board 67 has a printed circuit board (PCB) on which a predetermined wiring pattern is formed, and on the board is mounted a control device 77 corresponding to a control unit including various ICs and a microcomputer. There is. The control board 67 is fixed to the wiring module 76 by a fixing tool such as a screw. The control board 67 has an insertion hole 67a at its central portion for inserting the rotating shaft 11.

The wiring module 76 has a first surface and a second surface facing each other in the axial direction, that is, facing each other in the thickness direction. The first side faces the capacitor module 68. The wiring module 76 is provided with a control board 67 on its second surface. The bus bars 76c of the wiring module 76 extend from one side of the both sides of the control board 67 to the other side. In such a configuration, it is preferable that the control board 67 be provided with a notch for avoiding interference with the bus bar 76c. For example, it is preferable that a part of the outer edge portion of the circular control board 67 be cut away.

As described above, according to the configuration in which the electric component 62 is accommodated in the space surrounded by the casing 64 and the housing 30, the rotor 40 and the stator 50 are provided in layers on the outside thereof, the inverter circuit is generated. The electromagnetic noise is preferably shielded. That is, in the inverter circuit, switching control in each semiconductor module 66 is performed using PWM control with a predetermined carrier frequency, and it is conceivable that electromagnetic noise may be generated due to the switching control. It can shield suitably by the housing 30, the rotor 40, the stator 50 grade | etc., Of 62 radial direction outer side.

Furthermore, at least a portion of the semiconductor module 66 is disposed in a region surrounded by the stator core 52 disposed radially outward of the cylindrical portion 71 of the casing 64, thereby the semiconductor module 66 and the stator winding Compared with the configuration in which the stator core 51 is disposed without the stator core 52, even if magnetic flux is generated from the semiconductor module 66, the stator winding 51 is less likely to be affected. Further, even if magnetic flux is generated from the stator winding 51, the semiconductor module 66 is unlikely to be affected. It is more effective to dispose the whole of the semiconductor module 66 in a region surrounded by the stator core 52 disposed radially outside of the cylindrical portion 71 of the casing 64. In addition, when at least a part of the semiconductor module 66 is surrounded by the cooling water passage 74, an effect can be obtained that heat generated from the stator winding 51 and the magnet unit 42 does not easily reach the semiconductor module 66.

In the cylindrical portion 71, in the vicinity of the end plate 63, a through hole 78 for inserting a wiring member 79 (see FIG. 2) for electrically connecting the stator 50 on the outside and the electric component 62 on the inside is formed. There is. As shown in FIG. 2, the wiring member 79 is connected to the end of the stator winding 51 and the bus bar 76 c of the wiring module 76 by pressure bonding, welding or the like. The wiring member 79 is, for example, a bus bar, and it is desirable that the joint surface is crushed flat. The through holes 78 may be provided at one or a plurality of places, and in the present embodiment, the through holes 78 are provided at two places. In the configuration in which through holes 78 are provided at two locations, it is possible to easily connect the winding terminals extending from two sets of three-phase windings with wiring member 79, which is preferable for performing multiphase connection. It has become.

As described above, in the housing 30, as shown in FIG. 4, the rotor 40 and the stator 50 are provided in order from the radial outer side, and the inverter unit 60 is provided in the radial direction inner side of the stator 50. Here, when the radius of the inner peripheral surface of the housing 30 is d, the rotor 40 and the stator 50 are disposed radially outside the distance of d × 0.705 from the rotation center of the rotor 40 There is. In this case, of the rotor 40 and the stator 50, the region radially inward from the inner circumferential surface of the radially inner stator 50 (that is, the inner circumferential surface of the stator core 52) is the first region X1 in the radial direction Assuming that the area from the inner circumferential surface of the stator 50 to the housing 30 is a second area X2, the area of the cross section of the first area X1 is larger than the area of the cross section of the second area X2. There is. Further, when the magnet unit 42 of the rotor 40 and the stator winding 51 of the rotor 40 overlap in the radial direction, the volume of the first region X1 is larger than the volume of the second region X2.

When the rotor 40 and the stator 50 are a magnetic circuit component assembly, in the housing 30, the first region X1 radially inward from the inner circumferential surface of the magnetic circuit component assembly in the radial direction is the magnetic circuit component assembly The volume is larger than the second region X2 from the inner circumferential surface of the housing 30 to the housing 30.

Next, the configurations of the rotor 40 and the stator 50 will be described in more detail.

Generally, as a configuration of a stator in a rotating electrical machine, it is known to provide a plurality of slots in a circumferential direction on a stator core made of laminated steel plates and having an annular shape, and winding a stator winding in the slots. There is. Specifically, the stator core has a plurality of teeth radially extending at predetermined intervals from the yoke, and a slot is formed between the teeth adjacent in the circumferential direction. In the slot, for example, a plurality of layers of conducting wires are accommodated in the radial direction, and the stator winding is configured by the conducting wires.

However, in the above-described stator structure, when the stator winding is energized, magnetic saturation occurs in the teeth of the stator core as the magnetomotive force of the stator winding increases, which causes rotation of the rotating electric machine. It is conceivable that the torque density is limited. That is, in the stator core, it is considered that magnetic saturation occurs when the rotating magnetic flux generated by energization of the stator winding is concentrated on the teeth.

Generally, as a configuration of an IPM (Interior Permanent Magnet) rotor in a rotating electrical machine, one in which permanent magnets are disposed on the d axis in a dq coordinate system and a rotor core is disposed on the q axis is known. In such a case, by exciting the stator winding in the vicinity of the d-axis, an excitation magnetic flux flows from the stator to the q-axis of the rotor according to Fleming's law. And, it is considered that a wide range of magnetic saturation occurs in the q-axis core portion of the rotor.

FIG. 7 is a torque diagram showing a relationship between an ampere turn [AT] indicating a magnetomotive force of a stator winding and a torque density [Nm / L]. The broken line shows the characteristics of a general IPM rotor type rotating electric machine. As shown in FIG. 7, in a general rotating electric machine, magnetic saturation occurs in two places of the teeth portion between the slots and the q-axis core portion by increasing the magnetomotive force in the stator, which causes The increase in torque is limited. Thus, in the general rotating electric machine, the ampere-turn design value is limited to A1.

So, in this embodiment, in order to eliminate the restriction | limiting resulting from magnetic saturation, in the rotary electric machine 10, the structure shown below shall be provided. That is, as a first device, in order to eliminate magnetic saturation occurring in the stator core teeth in the stator, a slotless structure is adopted in the stator 50 and magnetic saturation occurring in the q-axis core portion of the IPM rotor is eliminated. , SPM (Surface Permanent Magnet) rotor is adopted. According to the first device, it is possible to eliminate the two parts where the magnetic saturation occurs, but it is conceivable that the torque in the low current region is reduced (see the dashed line in FIG. 7). Therefore, as a second device, a pole anisotropic structure is adopted in which the magnet magnetic path is lengthened in the magnet unit 42 of the rotor 40 to increase the magnetic force in order to overcome the torque reduction by increasing the magnetic flux of the SPM rotor. ing.

Further, as a third device, a flat wire structure in which the radial thickness of the wire in the stator 50 is reduced at the coil side portion 53 of the stator winding 51 is employed to achieve the reduction of torque. Here, it is conceivable that a larger eddy current is generated in the stator winding 51 facing the magnet unit 42 due to the above-described pole anisotropic structure in which the magnetic force is enhanced. However, according to the third device, it is possible to suppress the generation of the eddy current in the radial direction in the stator winding 51 because of the flat thin lead wire structure in the radial direction. As described above, according to the first to third configurations, as shown by a solid line in FIG. 7, a magnet having a high magnetic force is employed to expect a significant improvement in torque characteristics, while a magnet having a high magnetic force is expected. The potential for large eddy current generation can also be ameliorated.

Further, as a fourth device, a magnet unit having a magnetic flux density distribution close to a sine wave is adopted by utilizing a pole anisotropic structure. According to this, it is possible to enhance the torque by increasing the sine wave matching rate by pulse control and the like described later, and also to reduce eddy current loss (copper loss due to eddy current: eddy current loss) Can also be further suppressed.

The sine wave matching factor will be described below. The sine wave matching rate can be obtained by comparing the measured waveform of the surface magnetic flux density distribution measured by tracing the surface of the magnet with a magnetic flux probe and the like and the sine wave having the same period and peak value. The ratio of the amplitude of the primary waveform, which is the fundamental wave of the rotary electric machine, to the amplitude of the measured waveform, that is, the amplitude obtained by adding another harmonic component to the fundamental wave corresponds to the sine wave matching ratio. As the sine wave matching rate increases, the waveform of the surface magnetic flux density distribution approaches a sine wave shape. Then, when a primary sine wave current is supplied from the inverter to a rotating electrical machine equipped with a magnet whose sine wave matching rate is improved, the waveform of the surface magnetic flux density distribution of the magnet is close to a sine wave shape. , Can generate a large torque. The surface magnetic flux density distribution may be estimated by a method other than measurement, for example, electromagnetic field analysis using Maxwell's equation.

Further, as a fifth device, the stator winding 51 has a strand conductor structure in which a plurality of strands are gathered and bundled. According to this, since the strands are connected in parallel, a large current can flow, and generation of eddy current generated in the lead which spreads in the circumferential direction of the stator 50 in the flat lead structure is the cross-sectional area of each strand Can be effectively suppressed beyond thinning in the radial direction by the third device. And by making it the structure which twisted the several strand, with respect to the magnetomotive force from a conductor, the eddy current with respect to the magnetic flux which generate | occur | produces with the law of a right-handed screw can be offset with respect to the current conduction direction.

As described above, when the fourth device and the fifth device are further added, the torque enhancement can be performed while suppressing the eddy current loss due to the high magnetic force while adopting the magnet with the high magnetic force, which is the second device. Can be

Below, the slotless structure of the stator 50 mentioned above, the flat conducting wire structure of the stator winding 51, and the pole anisotropic structure of the magnet unit 42 will be individually described. Here, first, the slotless structure of the stator 50 and the flat conductor structure of the stator winding 51 will be described. 8 is a cross-sectional view of the rotor 40 and the stator 50, and FIG. 9 is an enlarged view of a part of the rotor 40 and the stator 50 shown in FIG. FIG. 10 is a cross-sectional view showing a cross-section of the stator 50 along the line XX in FIG. 11, and FIG. 11 is a cross-sectional view showing a vertical cross-section of the stator 50. As shown in FIG. 12 is a perspective view of the stator winding 51. As shown in FIG. In FIGS. 8 and 9, the magnetization directions of the magnets in the magnet unit 42 are indicated by arrows.

As shown in FIGS. 8 to 11, the stator core 52 has a cylindrical shape in which a plurality of electromagnetic steel sheets are stacked in the axial direction and has a predetermined thickness in the radial direction, and is on the rotor 40 side. The stator winding 51 is to be assembled radially outward. In the stator core 52, the outer peripheral surface on the side of the rotor 40 is a conductor installation portion (conductor area). The outer peripheral surface of the stator core 52 is in the form of a curved surface without unevenness, and on the outer peripheral surface, a plurality of wire groups 81 are arranged at predetermined intervals in the circumferential direction. The stator core 52 functions as a back yoke that is part of a magnetic circuit for rotating the rotor 40. In this case, teeth (i.e., iron cores) made of a soft magnetic material are not provided between the two lead wire groups 81 adjacent in the circumferential direction (i.e., slotless structure). In the present embodiment, the resin material of the sealing member 57 enters the gaps 56 of the respective lead groups 81. That is, in the stator 50, an inter-lead member provided between the wire groups 81 in the circumferential direction is configured as a sealing member 57 which is a nonmagnetic material. In the state before sealing of the sealing member 57, the wire groups 81 are disposed at predetermined intervals in the circumferential direction on the radially outer side of the stator core 52 with a gap 56 which is an area between the wires. Thus, the stator 50 of the slotless structure is constructed. In other words, each lead wire group 81 is composed of two conductors 82 as will be described later, and only the nonmagnetic material is occupied between each two lead wire groups 81 adjacent in the circumferential direction of the stator 50. There is. The nonmagnetic material includes, in addition to the sealing member 57, a nonmagnetic gas such as air and a nonmagnetic liquid. In the following, the sealing member 57 is also referred to as a conductor-to-conductor member.

The configuration in which the teeth are provided between the wire groups 81 aligned in the circumferential direction means that the teeth have a predetermined thickness in the radial direction and a predetermined width in the circumferential direction. It can be said that a part of the magnetic circuit, that is, a magnet magnetic path is formed between 81 and 81. In this respect, the configuration in which the teeth are not provided between the conductive wire groups 81 can be said to be a configuration in which the above magnetic circuit is not formed.

As shown in FIG. 10, the stator winding (that is, armature winding) 51 has a predetermined thickness T2 (hereinafter, also referred to as a first dimension) and a width W2 (hereinafter, also referred to as a second dimension). It is formed. The thickness T2 is the shortest distance between the outer surface and the inner surface facing each other in the radial direction of the stator winding 51. The width W2 functions as one of the polyphases of the stator winding 51 (in the embodiment, three phases: U phase, V phase and W phase, or three phases of X phase, Y phase and Z phase). It is a circumferential length of a part of the stator winding 51 of the secondary winding 51. Specifically, in FIG. 10, in the case where two wire groups 81 adjacent in the circumferential direction function as one of the three phases, for example, as a U phase, the two wire groups 81 in the circumferential direction end to end The width is up to W2. The thickness T2 is smaller than the width W2.

In addition, it is preferable that thickness T2 is smaller than the sum total width dimension of two conducting wire groups 81 which exist in width W2. Further, if the cross-sectional shape of the stator winding 51 (more specifically, the conducting wire 82) is a true circular shape, an elliptical shape, or a polygonal shape, of the cross sections of the conducting wire 82 along the radial direction of the stator 50, The maximum radial length of the stator 50 in the cross section may be W12, and the maximum circumferential length of the stator 50 in the cross section may be W11.

As shown in FIGS. 10 and 11, the stator winding 51 is sealed by a sealing member 57 made of a synthetic resin material as a sealing material (mold material). That is, the stator winding 51 is molded by the molding material together with the stator core 52. In addition, resin can be regarded as Bs = 0 as a nonmagnetic material or equivalent of a nonmagnetic material.

As seen in the cross section of FIG. 10, the sealing member 57 is provided with a synthetic resin material filled between the wire groups 81, that is, in the gap 56, and between the wire groups 81 by the sealing member 57. In the configuration, an insulating member is interposed. That is, the sealing member 57 functions as an insulating member in the gap 56. Sealing member 57 includes all the wire groups 81 outside the stator core 52 in the radial direction, that is, in a range in which the radial thickness dimension is larger than the radial thickness dimension of each wire group 81. It is provided.

Further, when viewed in the vertical cross section of FIG. 11, the sealing member 57 is provided in a range including the turn portion 84 of the stator winding 51. A sealing member 57 is provided on the inner side in the radial direction of the stator winding 51 in a range including at least a part of the end face of the stator core 52 facing in the axial direction. In this case, the stator winding 51 is resin-sealed substantially in its entirety except the end of the phase winding of each phase, that is, the connection terminal with the inverter circuit.

In the configuration in which the sealing member 57 is provided in a range including the end face of the stator core 52, the laminated steel plate of the stator core 52 can be pressed axially inward by the sealing member 57. Thereby, the lamination state of each steel plate can be held using sealing member 57. In the present embodiment, although the inner peripheral surface of the stator core 52 is not resin-sealed, instead of this, the entire stator core 52 including the inner peripheral surface of the stator core 52 is resin-sealed It may be a configuration.

In the case where the rotating electrical machine 10 is used as a vehicle power source, the sealing member 57 is made of a high heat resistant fluororesin, epoxy resin, PPS resin, PEEK resin, LCP resin, silicon resin, PAI resin, PI resin, etc. It is preferable that it is comprised. Further, in view of the linear expansion coefficient from the viewpoint of suppressing cracking due to the expansion difference, it is preferable that the material is the same as the outer coating of the conductive wire of the stator winding 51. That is, a silicone resin whose linear expansion coefficient is generally twice or more that of other resins is desirably excluded. In electric products such as electric vehicles which do not have an engine utilizing combustion, PPO resin, phenol resin, and FRP resin having heat resistance of about 180 ° C. are also candidates. This is not the case in the field where the ambient temperature of the rotating electrical machine can be considered to be less than 100 ° C.

The torque of the rotating electrical machine 10 is proportional to the magnitude of the magnetic flux. Here, when the stator core has teeth, the maximum amount of magnetic flux at the stator is limited depending on the saturation magnetic flux density at the teeth, but the stator core does not have teeth. In that case, the maximum amount of flux at the stator is not limited. Therefore, the configuration is advantageous in increasing the current supplied to the stator winding 51 to increase the torque of the rotating electrical machine 10.

In the present embodiment, by using a structure (slotless structure) in which the teeth are eliminated in the stator 50, the inductance of the stator 50 is reduced. Specifically, in the stator of a general rotating electrical machine in which a lead is accommodated in each slot partitioned by a plurality of teeth, the inductance is, for example, around 1 mH, whereas in the stator 50 of the present embodiment, the inductance is It is reduced to about 5 to 60 μH. In the present embodiment, the mechanical time constant Tm can be reduced by reducing the inductance of the stator 50 while using the rotary electric machine 10 having the outer rotor structure. That is, the mechanical time constant Tm can be reduced while achieving high torque. Assuming that the inertia is J, the inductance is L, the torque constant is Kt, and the back electromotive force constant is Ke, the mechanical time constant Tm is calculated by the following equation.
Tm = (J × L) / (Kt × Ke)
In this case, it can be confirmed that the mechanical time constant Tm is reduced by the reduction of the inductance L.

Each group of conducting wires 81 on the radially outer side of the stator core 52 is configured by arranging a plurality of conducting wires 82 having a flat rectangular shape in cross section in the radial direction of the stator core 52. Each conducting wire 82 is arranged in a direction such that "radial dimension <circumferential dimension" in the cross section. Thereby, thickness reduction in the radial direction is achieved in each wire group 81. Moreover, while achieving thickness reduction of radial direction, a conductor area | region extends flatly to the area | region where teeth conventionally existed, and it has a flat conducting wire area | region structure. Thereby, the increase in the calorific value of the conducting wire which is concerned due to the reduction of the cross-sectional area due to the reduction in thickness is suppressed by flattening in the circumferential direction to increase the cross-sectional area of the conductor. Even if a plurality of conducting wires are arranged in the circumferential direction and connected in parallel, the same effect can be obtained although the cross-sectional area reduction of the conductive film occurs although the conductive coating is reduced. In the following, each of the conductor groups 81 and each of the conductors 82 are also referred to as conductive members (conductive members).

Since there is no slot, in the stator winding 51 in the present embodiment, the conductor area occupied by the stator winding 51 in one circumferential direction is designed to be larger than the conductor non-occupied area where the stator winding 51 does not exist. be able to. In the conventional automotive electric rotating machine, it is natural that the conductor area / conductor non-occupied area in one circumferential direction of the stator winding is 1 or less. On the other hand, in the present embodiment, the conductor groups 81 are provided such that the conductor area is equal to the non-conducted area or the conductor area is larger than the non-occupied area. Here, as shown in FIG. 10, when the conducting wire area in which the conducting wire 82 (that is, the linear portion 83 described later) is disposed in the circumferential direction is WA, and the conducting wire area between adjacent conducting wires 82 is WB, The area WA is larger in the circumferential direction than the inter-conductor area WB.

As a configuration of the wire group 81 in the stator winding 51, the thickness dimension in the radial direction of the wire group 81 is smaller than the width dimension in the circumferential direction of one phase in one magnetic pole. That is, in the configuration in which the wire group 81 is composed of two layers of wire 82 in the radial direction and two wire groups 81 are provided in the circumferential direction per one phase in one magnetic pole, the thickness dimension of each wire 82 Tc, when the width dimension of each conducting wire 82 in the circumferential direction is Wc, it is configured to be “Tc × 2 <Wc × 2”. As another configuration, in a configuration in which conductor group 81 is composed of two layers of conductors 82, and one conductor group 81 is provided in the circumferential direction per one phase in one magnetic pole, the relationship of “Tc × 2 <Wc” It should be configured to be In short, in the stator winding 51, the conductor wire portions (conductor wire groups 81) arranged at predetermined intervals in the circumferential direction have a thickness dimension in the radial direction that is greater than a width dimension in the circumferential direction of one phase in one magnetic pole. It is small.

In other words, each of the lead wires 82 preferably has a thickness dimension Tc in the radial direction smaller than a width dimension Wc in the circumferential direction. Furthermore, the radial thickness dimension (2Tc) of the conducting wire group 81 consisting of the two layers of conducting wires 82 in the radial direction, that is, the radial thickness dimension (2Tc) of the conducting wire group 81 is greater than the width dimension Wc in the circumferential direction. It is good to be small.

The torque of the rotary electric machine 10 is approximately in inverse proportion to the radial thickness of the stator core 52 of the wire group 81. In this respect, by reducing the thickness of the wire group 81 outside the stator core 52 in the radial direction, the configuration is advantageous in achieving an increase in torque of the rotary electric machine 10. The reason is that the magnetic resistance can be reduced by reducing the distance from the magnet unit 42 of the rotor 40 to the stator core 52 (that is, the distance of the portion without iron). According to this, it is possible to increase the flux linkage of the stator core 52 by the permanent magnet, and to enhance the torque.

Further, by reducing the thickness of the wire group 81, even if the magnetic flux leaks from the wire group 81, it is easily collected by the stator core 52, and the magnetic flux leaks to the outside without being effectively used for improving the torque. Can be suppressed. That is, it is possible to suppress the decrease in the magnetic force due to the magnetic flux leakage, and it is possible to increase the torque by increasing the flux linkage of the stator core 52 by the permanent magnet.

Conductor 82 is a coated conductor in which the surface of conductor body 82a is covered with insulating coating 82b, and between conductor 82 which mutually overlaps in the radial direction, and between conductor 82 and stator core 52 In each case, insulation is secured. The insulating coating 82b is formed of an insulating member that is stacked separately from the coating of the strand 86 if the strand 86 described later is a self-bonding coated line. In addition, each phase winding configured by the conducting wire 82 is such that the insulating property by the insulating coating 82 b is maintained except for the exposed portion for connection. The exposed portion is, for example, an input / output terminal portion or a neutral point portion in the case of star connection. In the conducting wire group 81, the conducting wires 82 adjacent to each other in the radial direction are fixed to each other using a resin fixing or a self-fusion coated wire. Thereby, dielectric breakdown, vibration, and sound due to rubbing between the conducting wires 82 are suppressed.

In the present embodiment, the conductor 82 a is configured as an assembly of a plurality of wires 86. Specifically, as shown in FIG. 13, the conductor 82 a is formed in a twisted thread shape by twisting a plurality of strands 86. In addition, as shown in FIG. 14, the strands 86 are configured as a composite obtained by bundling thin fibrous conductive materials 87. For example, the strand 86 is a composite of CNT (carbon nanotube) fibers, and as the CNT fibers, fibers including boron-containing fine fibers in which at least a part of carbon is substituted by boron are used. As carbon-based fine fibers, vapor grown carbon fibers (VGCF) or the like can be used in addition to CNT fibers, but it is preferable to use CNT fibers. The surface of the wire 86 is covered with a polymer insulating layer such as enamel. Further, the surface of the strand 86 is preferably covered with a so-called enamel film made of a polyimide film or an amidimide film. The polymer insulating layer is thinner than the insulating coating 82b.

The conducting wire 82 constitutes an n-phase winding in the stator winding 51. The strands 86 of each of the leads 82 (i.e., the conductors 82a) are adjacent to each other in contact with each other. The conductor 82 has a portion where the winding conductor is formed by twisting a plurality of strands 86 at one or more places in the phase, and the resistance value between the strands 86 which are twisted is the strand 86 itself The wire assembly is larger than the resistance value of. In other words, if each two adjacent strands 86 have a first electrical resistivity in their adjacent direction, and each of the strands 86 has a second electrical resistivity in its length direction, the first electrical resistance The rate is a value larger than the second electrical resistivity. In addition, while the conducting wire 82 is formed of the several strand 86, it may become a strand aggregate | assembly which covers the several strand 86 by the insulation member with very high 1st electrical resistivity. Also, the conductor 82 a of the conducting wire 82 is constituted by a plurality of strands 86 twisted together.

In the conductor 82a described above, since the plurality of strands 86 are twisted together, generation of eddy current in each strand 86 can be suppressed, and eddy current in the conductor 82a can be reduced. In addition, since the strands 86 are twisted, in one strand 86, portions where the application directions of the magnetic field are reverse to each other are generated, and the back electromotive force is offset. Therefore, the eddy current can be reduced as well. In particular, by forming the strands 86 with the fibrous conductive material 87, it is possible to reduce the number of wires and to significantly increase the number of times of twisting, and it is possible to more preferably reduce the eddy current.

In addition, the insulation method of strands 86 here is not limited to the above-mentioned polymer insulating film, You may be the method of making an electric current hard to flow between strands 86 twisted using contact resistance. That is, if the resistance value between the twisted strands 86 is in a relation larger than the resistance value of the strands 86 themselves, the above effect can be obtained by the potential difference generated due to the difference in the resistance values. . For example, by using the manufacturing equipment for producing the wire 86 and the manufacturing equipment for producing the stator 50 (armature) of the rotary electric machine 10 as separate non-continuous equipment, the wire from the moving time and the work interval etc. 86 is preferable because it can oxidize and increase the contact resistance.

As described above, the conducting wire 82 has a flat rectangular shape in cross section, and is arranged in plural in the radial direction, for example, a plurality of wires covered with a self-fusion coated wire including a fusion layer and an insulating layer The strands of wire 86 are gathered in a twisted state, and their fusion layers are fused to maintain their shape. In addition, in a state in which the strands of the wire without the fusion layer and the strands of the self-fusion-coated wire are twisted, they may be compacted into a desired shape by a synthetic resin or the like. In the case where the thickness of the insulating film 82b in the conducting wire 82 is, for example, 80 μm to 100 μm and thicker than the film thickness (5 to 40 μm) of a commonly used conducting wire, insulation between the conducting wire 82 and the stator core 52 Even without interposing paper or the like, the insulation between the two can be secured.

In addition, it is desirable that the insulating coating 82 b be configured to have insulation performance higher than that of the strands 86 and to insulate between the phases. For example, when the thickness of the polymer insulating layer of the strand 86 is, for example, about 5 μm, the thickness of the insulating coating 82 b of the conducting wire 82 is about 80 μm to 100 μm so that the insulation between the phases can be suitably implemented. Is desirable.

Moreover, the structure which the wire 82 is bundled without the several strand 86 being twisted may be sufficient. That is, the conductor 82 has a configuration in which a plurality of strands 86 are twisted in the entire length, a configuration in which a plurality of strands 86 are twisted in part of the entire length, and a plurality of strands 86 are twisted in the entire length It may be any of the configurations bundled. In summary, in each of the conducting wires 82 constituting the conducting wire portion, a plurality of strands 86 are bundled, and a strand assembly in which the resistance value between the bundled strands is larger than the resistance of the strand 86 itself It has become.

Each conducting wire 82 is bent and formed so as to be arranged in a predetermined arrangement pattern in the circumferential direction of the stator winding 51, whereby a phase winding for each phase is formed as the stator winding 51. . As shown in FIG. 12, in the stator winding 51, the coil side portions 53 are formed by the linear portions 83 linearly extending in the axial direction of each of the conducting wires 82, and both side outside the coil side portions 53 in the axial direction A coil end 54, 55 is formed by the protruding turn portion 84. Each conducting wire 82 is configured as a series of wave-like conducting wires by alternately repeating the straight portions 83 and the turn portions 84. The straight portions 83 are disposed at positions facing the magnet unit 42 in the radial direction, and in-phase straight portions 83 arranged at predetermined intervals on the axially outer side of the magnet unit 42 are They are connected to each other by the turn portions 84. The straight portion 83 corresponds to the "magnet facing portion".

In the present embodiment, the stator winding 51 is wound in an annular shape by distributed winding. In this case, in the coil side portion 53, linear portions 83 are arranged circumferentially at intervals corresponding to one pole pair of the magnet unit 42 for each phase, and in the coil ends 54 and 55, each linear portion 83 for each phase is They are connected to each other by turn portions 84 formed in a substantially V-shape. The directions of the currents of the straight portions 83 corresponding to one pole pair are opposite to each other. Further, the combination of the pair of straight portions 83 connected by the turn portion 84 is different between one coil end 54 and the other coil end 55, and the connection at the coil ends 54 and 55 is in the circumferential direction. By being repeated, the stator winding 51 is formed in a substantially cylindrical shape.

More specifically, the stator winding 51 constitutes a winding for each phase using two pairs of conductors 82 for each phase, and one of the three-phase windings (U A phase, a V phase, a W phase) and the other three phase winding (X phase, Y phase, Z phase) are provided in two layers radially inside and outside. In this case, assuming that the number of phases of the stator winding 51 is S (6 in the case of the embodiment) and the number per phase of the conducting wire 82 is m, 2 × S × m = 2Sm conducting wires per pole pair 82 will be formed. In this embodiment, since the number of phases S is 6, the number m is 4, and the rotating electrical machine is an 8-pole pair (16 poles), the conductor 82 of 6 × 4 × 8 = 192 is the periphery of the stator core 52 It is arranged in the direction.

In the stator winding 51 shown in FIG. 12, in the coil side portion 53, the linear portions 83 are disposed so as to overlap in two layers adjacent in the radial direction, and in the coil ends 54 and 55, the linear portions overlapping in the radial direction From 83, the turn portions 84 extend in the circumferential direction in directions opposite to each other in the circumferential direction. That is, in each of the conductive wires 82 adjacent in the radial direction, the direction of the turn portion 84 is opposite to each other except for the end of the stator winding 51.

Here, the winding structure of the conducting wire 82 in the stator winding 51 will be specifically described. In the present embodiment, a plurality of conducting wires 82 formed by wave winding are provided so as to be superimposed on a plurality of layers (for example, two layers) adjacent in the radial direction. 15 (a) and 15 (b) are diagrams showing the form of each conducting wire 82 in the n-th layer, and FIG. 15 (a) is a view of the conducting wire 82 seen from the side of the stator winding 51. The shape is shown, and the shape of the conducting wire 82 seen from one axial direction side of the stator winding 51 is shown in FIG. In FIGS. 15 (a) and 15 (b), the positions at which the wire groups 81 are disposed are indicated as D1, D2, D3,. Moreover, for convenience of explanation, only three conducting wires 82 are shown, which are referred to as a first conducting wire 82_A, a second conducting wire 82_B, and a third conducting wire 82_C.

In each of the conducting wires 82 _A to 82 _C, the linear portions 83 are all arranged at the n-th layer position, ie, the same position in the radial direction, and the linear portions 83 separated by 6 positions (3 × m pair) in the circumferential direction It is mutually connected by the turn part 84. As shown in FIG. In other words, in each of the conducting wires 82 _A to 82 _C, the ends of the seven straight portions 83 adjacently arranged in the circumferential direction of the stator winding 51 on the same circle centering on the axial center of the rotor 40. Two are connected to each other by one turn 84. For example, in the first conducting wire 82_A, a pair of straight portions 83 are disposed at D1 and D7, respectively, and the pair of straight portions 83 are connected by an inverted V-shaped turn portion 84. Further, the other conducting wires 82 _B and 82 _C are arranged in the same n-th layer while shifting their circumferential positions one by one. In this case, since all the conductors 82 _A to 82 _C are disposed in the same layer, it is conceivable that the turn portions 84 interfere with each other. Therefore, in the present embodiment, in the turn portion 84 of each of the conducting wires 82_A to 82_C, an interference avoidance portion in which a part thereof is offset in the radial direction is formed.

Specifically, the turn portion 84 of each of the conducting wires 82_A to 82_C is one inclined portion 84a which is a portion extending in the circumferential direction on the same circle (first circle), and from the same circle from the inclined portion 84a The peak 84b is also shifted radially inward (upper side in FIG. 15B) and reaches another circle (second circle), the inclined portion 84c circumferentially extending on the second circle and the first circle And a return portion 84d returning to the second circle. The top portion 84 b, the sloped portion 84 c, and the return portion 84 d correspond to the interference avoiding portion. The inclined portion 84c may be configured to shift radially outward with respect to the inclined portion 84a.

That is, the turn portion 84 of each of the conducting wires 82_A to 82_C has one side inclined portion 84a and the other side inclined portion 84c on both sides of the top portion 84b which is the center position in the circumferential direction. Positions in the radial direction of the inclined portions 84a and 84c (positions in the front and rear direction in FIG. 15A and positions in the vertical direction in FIG. 15B) are different from each other. For example, after the turn portion 84 of the first conductive wire 82_A extends along the circumferential direction starting from the position D1 of the n layer and bent in the radial direction (for example, radially inward) at the top portion 84b which is the center position in the circumferential direction, By bending in the circumferential direction again, it extends along the circumferential direction again, and is bent in the radial direction (for example, the radially outer side) again at the return portion 84d to reach the D7 position of the n layer which is the end point position. There is.

According to the above configuration, in the conducting wires 82_A to 82_C, one inclined portion 84a is vertically arranged from the top in the order of the first conducting wire 82_A → the second conducting wire 82_B → the third conducting wire 82_C, and the conducting wire 82_A ~ at the top 84b The upper and lower portions of 82_C are interchanged, and the other inclined portions 84c are arranged vertically in the order of the third conductive wire 82_C, the second conductive wire 82_B, and the first conductive wire 82_A from the top. Therefore, the conductors 82_A to 82_C can be arranged in the circumferential direction without interfering with each other.

Here, in the configuration in which the plurality of conducting wires 82 are overlapped in the radial direction to form the conducting wire group 81, the turn portion 84 connected to the straight portion 83 inside the radial direction among the linear portions 83 of the plurality of layers; It is preferable that the turn portions 84 connected to the linear portions 83 be disposed more radially apart than the respective linear portions 83. In addition, in the case where the lead wires 82 of multiple layers are bent in the same radial direction at the end of the turn portion 84, that is, near the boundary with the straight portion 83, the insulation properties are due to interference between the lead wires 82 of adjacent layers. It is good to prevent the loss of

For example, in D7 to D9 of FIGS. 15A and 15B, the lead wires 82 overlapping in the radial direction are bent in the radial direction at the return portion 84d of the turn portion 84, respectively. In this case, as shown in FIG. 16, the radius of curvature of the bent portion may be made different between the n-th conductive wire 82 and the n + 1-th conductive wire 82. Specifically, the radius of curvature R1 of the radially inner (n-th layer) conducting wire 82 is made smaller than the radius of curvature R2 of the radially outer (n + 1-th) layer conducting wire 82.

Further, it is preferable to make the shift amount in the radial direction different between the n-th conductive wire 82 and the n + 1-th conductive wire 82. Specifically, the shift amount S1 of the radially inner (n-th layer) conducting wire 82 is made larger than the shift amount S2 of the radially outer (n + 1-th) conducting wire 82.

According to the above configuration, even when the radially overlapping wires 82 are bent in the same direction, mutual interference of the wires 82 can be suitably avoided. Thereby, good insulation can be obtained.

Next, the structure of the magnet unit 42 in the rotor 40 will be described. In the present embodiment, it is assumed that the magnet unit 42 is a permanent magnet, and the residual magnetic flux density Br = 1.0 [T] and the intrinsic coercive force Hcj = 400 [kA / m] or more. The important point is that the permanent magnet used in the present embodiment is a sintered magnet obtained by sintering granular magnetic material and forming and solidifying it, and the intrinsic coercivity Hcj on the JH curve is 400 [kA / m] or more. And residual magnetic flux density Br is 1.0 [T] or more. When 5000 to 10000 [AT] is applied by interphase excitation, the magnetic length of one pole pair, that is, the N pole and the S pole, in other words, the path of the magnetic flux flowing between the N pole and the S pole passes through the magnet If a permanent magnet with a length of 25 [mm] is used, then Hcj = 10000 [A], indicating that demagnetization is not performed.

In other words, when the magnetic unit 42 has a saturation magnetic flux density Js of 1.2 T or more and a crystal grain size of 10 μm or less, and the orientation ratio is α, Js × α is 1 .0 [T] or more.

The magnet unit 42 will be supplemented below. The magnet unit 42 (magnet) is characterized in that 2.15 [T] J Js T 1.2 [T]. In other words, examples of the magnet used for the magnet unit 42 include NdFe11 TiN, Nd2 Fe14 B, Sm2 Fe17 N3, and an FeNi magnet having an L10 type crystal. It is to be noted that a configuration such as SmCo5, which is generally called Samachoba, FePt, Dy2Fe14B, or CoPt can not be used. Note that the same type of compounds, such as Dy2Fe14B and Nd2Fe14B, generally utilize the heavy rare earth dysprosium to lose some of the high Js properties of neodymium while the high coercivity of Dy has In some cases, even a magnet having the above may satisfy 2.15 [T] s Js 1.2 1.2 [T], and this case can also be adopted. In such a case, for example, it will be called ([Nd1-xDyx] 2Fe14B). Furthermore, two or more types of magnets of different compositions, for example, magnets composed of two or more types of materials such as FeNi plus Sm2Fe17N3, can be achieved, for example, Js = 1.6 [T] and Js This can also be achieved by a mixed magnet or the like in which the coercive force is increased by mixing a small amount of, for example, Dy2Fe14B of Js <1 [T] with a Nd2Fe14B magnet having a surplus, for example.

In addition, a rotating electrical machine that is operated at a temperature outside the human activity range, for example, 60 ° C or higher exceeding the desert temperature, for example, in a motor for motor vehicle application where the temperature in the vehicle approaches 80 ° C if summer In particular, it is desirable to include the components of FeNi and Sm2Fe17N3 having a small temperature dependence coefficient. This is a temperature-dependent coefficient in motor operation from a temperature condition near -40 ° C in Nordic which is within human activity range to 60 ° C or more exceeding the desert temperature mentioned above, or heat resistant temperature 180 ° C to 240 ° C of coil enamel film. This is because it is difficult to optimize the control with the same motor driver because the motor characteristics are largely different depending on If FeNi or Sm2Fe17N3 or the like having the L10 type crystal is used, the load on the motor driver can be suitably reduced because of the characteristics having a temperature dependence coefficient which is less than half that of Nd2Fe14B.

In addition, the magnet unit 42 is characterized in that the particle size in the fine powder state before orientation is 10 μm or less and the single magnetic domain particle size or more using the magnet composition. In the magnet, since the coercive force is increased by reducing the size of powder particles to the order of several hundred nm, in recent years, the powder as fine as possible has been used. However, if it is too fine, the BH product of the magnet may be reduced due to oxidation or the like, so a single magnetic domain particle diameter or more is preferable. It is known that if the particle size is up to the single magnetic domain particle size, the coercivity is increased by miniaturization. Incidentally, the size of the particle size described here is the size of the particle size in the fine powder state in the orientation step in the manufacturing process of the magnet.

Furthermore, each of the first magnet 91 and the second magnet 92 of the magnet unit 42 is a so-called sintered magnet formed by sintering magnetic powder at a high temperature. In this sintering, when the saturation magnetization Js of the magnet unit 42 is 1.2 T or more, the crystal grain size of the first magnet 91 and the second magnet 92 is 10 μm or less, and the orientation ratio is α, Js × α is It is performed to satisfy the condition of 1.0 T (Tesla) or more. Moreover, each of the 1st magnet 91 and the 2nd magnet 92 is sintered so that the following conditions may be satisfied. Then, orientation is performed in the orientation process in the manufacturing process, so that the orientation ratio is obtained unlike the definition of the magnetic force direction in the magnetization process of the isotropic magnet. The saturation magnetization Js of the magnet unit 42 of the present embodiment is as high as 1.2 T or more, and the orientation ratio α of the first magnet 91 and the second magnet 92 is high so that Jr ≧ Js × α ≧ 1.0 [T]. The orientation rate is set. Here, the orientation ratio α referred to here is, for example, six easy magnetization axes in each of the first magnet 91 or the second magnet 92, and the direction A10 in which five of them are the same direction is the other one. When one is in the direction B10 inclined 90 degrees with respect to the direction A10, α = 5/6, and the remaining one is in the direction B10 inclined with 45 degrees with respect to the direction A10, the remaining The component facing in one direction A10 of is cos 45 ° = 0.707, so that α = (5 + 0.707) / 6. Although the first magnet 91 and the second magnet 92 are formed by sintering in the present embodiment, the first magnet 91 and the second magnet 92 may be formed by another method if the above conditions are satisfied. . For example, a method of forming an MQ3 magnet or the like can be employed.

In this embodiment, since a permanent magnet in which the axis of easy magnetization is controlled by orientation is used, the magnetic circuit length inside the magnet is the magnetic circuit length of a linear orientation magnet which emits 1.0 T or more according to the prior art Compared with, it can be longer. That is, the magnetic circuit length per one pole pair can be achieved with a small amount of magnet, and the reversible demagnetization range is maintained even when exposed to severe high-temperature conditions as compared with the design using a conventional linearly oriented magnet. Can. In addition, the person who has disclosed the present application has found a configuration that can obtain characteristics close to that of a polar anisotropic magnet even when using a prior art magnet.

The magnetization easy axis refers to a crystal orientation that is easily magnetized in a magnet. The direction of the magnetization easy axis in the magnet is a direction in which the orientation ratio, which indicates the degree to which the direction of the magnetization easy axis is aligned, is 50% or more, or a direction in which the orientation of the magnet is averaged.

As shown in FIGS. 8 and 9, the magnet unit 42 has an annular shape, and is provided on the inner side of the magnet holder 41 (specifically, on the inner side in the radial direction of the cylindrical portion 43). The magnet unit 42 includes a first magnet 91 and a second magnet 92 which are polar anisotropic magnets and have different polarities. The first magnets 91 and the second magnets 92 are alternately arranged in the circumferential direction. The first magnet 91 is a magnet that forms an N pole in a portion close to the stator winding 51, and the second magnet 92 is a magnet that forms an S pole in a portion close to the stator winding 51. The 1st magnet 91 and the 2nd magnet 92 are permanent magnets which consist of rare earth magnets, such as a neodymium magnet, for example.

In each of the magnets 91 and 92, as shown in FIG. 9, it is the magnetic pole boundary between the d-axis (direct-axis) which is the magnetic pole center and the N and S poles in the known dq coordinate system (in other words, the magnetic flux density The magnetization direction extends in a circular arc between the q-axis (quadrature of which is 0 Tesla) and the quadrature-axis. In each of the magnets 91 and 92, the magnetization direction is the radial direction of the annular magnet unit 42 on the d-axis side, and the magnetization direction of the annular magnet unit 42 is the circumferential direction on the q-axis side. This will be described in more detail below. Each of the magnets 91 and 92 has a first portion 250 and two second portions 260 located on both sides of the first portion 250 in the circumferential direction of the magnet unit 42, as shown in FIG. In other words, the first portion 250 is closer to the d-axis than the second portion 260, and the second portion 260 is closer to the q-axis than the first portion 250. The magnet unit 42 is configured such that the direction of the magnetization easy axis 300 of the first portion 250 is more parallel to the d axis than the direction of the magnetization easy axis 310 of the second portion 260. In other words, the magnet unit 42 is configured such that the angle θ11 that the magnetization easy axis 300 of the first portion 250 makes with the d axis is smaller than the angle θ12 that the magnetization easy axis 310 of the second part 260 makes with the q axis. There is.

More specifically, the angle θ11 is an angle formed by the d axis and the easy magnetization axis 300 when the direction from the stator 50 (armature) to the magnet unit 42 in the d axis is positive. The angle θ12 is an angle between the q axis and the easy magnetization axis 310 when the direction from the stator 50 (armature) to the magnet unit 42 in the q axis is positive. In the present embodiment, both the angle θ11 and the angle θ12 are 90 ° or less. Here, each of the magnetization easy axes 300 and 310 has the following definition. Assuming that one easy magnetization axis is in the direction A11 and the other easy magnetization axis is in the direction B11 in each portion of the magnets 91 and 92, the cosine of the angle θ formed by the directions A11 and B11 The absolute value (| cos θ |) is taken as the magnetization easy axis 300 or the magnetization easy axis 310.

That is, in each of the magnets 91 and 92, the direction of the magnetization easy axis is different between the d-axis side (portion near the d-axis) and the q-axis side (portion near the q-axis). The direction of the easy axis is close to the direction parallel to the d axis, and on the q axis side, the direction of the easy magnetization axis is close to the direction orthogonal to the q axis. An arc-shaped magnet magnetic path is formed in accordance with the direction of the magnetization easy axis. In each of the magnets 91 and 92, the magnetization easy axis may be parallel to the d axis on the d axis side, and the magnetization easy axis may be orthogonal to the q axis on the q axis side.

Further, in the magnets 91 and 92, of the circumferential surfaces of the magnets 91 and 92, the stator side outer surface that is on the stator 50 side (the lower side in FIG. 9) and the end surface on the q axis side in the circumferential direction A magnetic flux path is formed so as to connect the magnetic flux acting surfaces (the outer surface on the stator side and the end surface on the q axis side) of the magnetic flux acting surfaces which are the inflow and outflow surfaces.

In the magnet unit 42, the magnetic flux flows in an arc shape between adjacent N and S poles by the magnets 91 and 92, so the magnet magnetic path is longer than, for example, a radial anisotropic magnet. For this reason, as shown in FIG. 17, the magnetic flux density distribution is close to a sine wave. As a result, unlike the magnetic flux density distribution of the radial anisotropic magnet shown as a comparative example in FIG. 18, the magnetic flux can be concentrated on the center side of the magnetic pole, and the torque of the rotating electrical machine 10 can be increased. Moreover, in the magnet unit 42 of this embodiment, it can be confirmed that there is a difference in the magnetic flux density distribution as compared with the conventional Halbach-arrayed magnet. In FIG. 17 and FIG. 18, the horizontal axis shows the electrical angle, and the vertical axis shows the magnetic flux density. Further, in FIG. 17 and FIG. 18, 90 ° on the horizontal axis indicates the d axis (that is, the center of the magnetic pole), and 0 ° and 180 ° on the horizontal axis indicate the q axis.

That is, according to each magnet 91, 92 of the said structure, the magnet magnetic flux in d axis | shaft is reinforced, and the magnetic flux change around q axis | shaft is suppressed. Thereby, magnets 91 and 92 in which the surface magnetic flux change from the q-axis to the d-axis in each magnetic pole is smooth can be suitably realized.

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 portion of the waveform can be reliably improved as compared to the case of using a radially oriented magnet or a parallel oriented magnet having a sine wave matching ratio of about 30%. Further, if the sine wave matching ratio is set to 60% or more, the amount of magnetic flux in the central portion of the waveform can be surely improved as compared with the magnetic flux concentration array such as the Halbach array.

In the radial anisotropic magnet shown in FIG. 18, the magnetic flux density changes sharply near the q-axis. As the change in magnetic flux density is steeper, the eddy current generated in the stator winding 51 is increased. In addition, the magnetic flux change on the stator winding 51 side is also sharp. On the other hand, in the present embodiment, the magnetic flux density distribution has a magnetic flux waveform close to a sine wave. Therefore, in the vicinity of the q-axis, the change in magnetic flux density is smaller than the change in magnetic flux density of the radial anisotropic magnet. Thereby, the generation of the eddy current can be suppressed.

In the magnet unit 42, a magnetic flux is generated in the direction orthogonal to the magnetic flux acting surface 280 on the stator 50 side in the vicinity of the d axis of the magnets 91 and 92 (that is, the center of the magnetic pole). The farther away from the surface 280, the more it is arced away from the d-axis. Further, as the magnetic flux is perpendicular to the magnetic flux acting surface, the magnetic flux becomes stronger. In this point, in the rotating electrical machine 10 of the present embodiment, since the wire groups 81 are thinned in the radial direction as described above, the radial center position of the wire groups 81 approaches the magnetic flux acting surface of the magnet unit 42, A strong magnetic flux can be received from the rotor 40 at the stator 50.

In the stator 50, a cylindrical stator core 52 is provided radially inside the stator winding 51, that is, on the opposite side of the rotor 40 with the stator winding 51 interposed therebetween. Therefore, the magnetic flux extending from the magnetic flux acting surface of each of the magnets 91 and 92 is attracted to the stator core 52 and circulates while using the stator core 52 as a part of the magnetic path. In this case, the direction and path of the magnet flux can be optimized.

Hereinafter, an assembling procedure of the bearing unit 20, the housing 30, the rotor 40, the stator 50, and the inverter unit 60 shown in FIG. 5 will be described as a method of manufacturing the rotating electrical machine 10. The inverter unit 60 has a unit base 61 and an electric component 62 as shown in FIG. 6, and each operation process including the assembly process of the unit base 61 and the electric component 62 will be described. In the following description, the assembly consisting of the stator 50 and the inverter unit 60 is taken as a first unit, the assembly consisting of the bearing unit 20, the housing 30 and the rotor 40 as a second unit.

This manufacturing process
A first step of mounting the electrical component 62 radially inward of the unit base 61;
A second step of manufacturing the first unit by mounting the unit base 61 radially inward of the stator 50;
A third step of manufacturing the second unit by inserting the fixing portion 44 of the rotor 40 into the bearing unit 20 assembled to the housing 30;
A fourth step of mounting the first unit radially inward of the second unit;
A fifth step of fastening and fixing the housing 30 and the unit base 61;
have. The order of implementation of each of these steps is: first step → second step → third step → fourth step → fifth step.

According to the above manufacturing method, after assembling the bearing unit 20, the housing 30, the rotor 40, the stator 50 and the inverter unit 60 as a plurality of assemblies (sub-assemblies), the assemblies are assembled together, Ease of handling and complete inspection of each unit can be realized, making it possible to construct a rational assembly line. Therefore, it is possible to easily cope with multi-variety production.

In the first step, a good thermal conductor having good thermal conductivity is attached to at least one of the radially inner side of the unit base 61 and the radial direction outer side of the electric component 62 by coating, adhesion or the like. The electrical component 62 may be attached to the unit base 61. As a result, the heat generation of the semiconductor module 66 can be effectively transmitted to the unit base 61.

In the third step, the insertion operation of the rotor 40 may be performed while maintaining the coaxial between the housing 30 and the rotor 40. Specifically, for example, the position of the outer peripheral surface of the rotor 40 (the outer peripheral surface of the magnet holder 41) or the inner peripheral surface of the rotor 40 (the inner peripheral surface of the magnet unit 42) is determined based on the inner peripheral surface of the housing 30 Assembly of the housing 30 and the rotor 40 is performed using a jig and sliding either the housing 30 or the rotor 40 along the jig. As a result, it becomes possible to assemble heavy parts without applying a partial load to the bearing unit 20, and the reliability of the bearing unit 20 is improved.

In the fourth step, the two units may be assembled while maintaining the coaxiality between the first unit and the second unit. Specifically, using, for example, a jig for determining the position of the inner peripheral surface of unit base 61 with reference to the inner peripheral surface of fixing portion 44 of rotor 40, the first unit and the second unit These units are assembled while sliding one of them. As a result, the assembly can be performed while preventing mutual interference between the rotor 40 and the stator 50 in an extremely small gap, so that the assembly winding is caused by damage to the stator winding 51, chipping of the permanent magnet, or the like. It will be possible to eradicate defective products.

It is also possible to make the order of the above-mentioned each process 2nd process-3rd process-4th process-5th process-1st process. In this case, the delicate electrical component 62 is finally assembled, and the stress on the electrical component 62 in the assembling process can be minimized.

Next, the configuration of a control system that controls the rotating electrical machine 10 will be described. FIG. 19 is an electric circuit diagram of a control system of rotary electric machine 10, and FIG. 20 is a functional block diagram showing control processing by control device 110.

In FIG. 19, two sets of three- phase windings 51a and 51b are shown as the stator winding 51, and the three-phase winding 51a is composed of a U-phase winding, a V-phase winding and a W-phase winding, The phase winding 51b is composed of an X-phase winding, a Y-phase winding and a Z-phase winding. A first inverter 101 and a second inverter 102 corresponding to the power converter are provided for each of the three- phase windings 51a and 51b. The inverters 101 and 102 are configured by full bridge circuits having upper and lower arms equal in number to the number of phases of the phase windings, and the switches (semiconductor switching elements) provided on each arm turn on and off the stator winding 51. The conduction current is adjusted in each phase winding.

A DC power supply 103 and a smoothing capacitor 104 are connected in parallel to each of the inverters 101 and 102. The DC power supply 103 is configured of, for example, a battery pack in which a plurality of single cells are connected in series. The switches of the inverters 101 and 102 correspond to the semiconductor module 66 shown in FIG. 1 and the like, and the capacitor 104 corresponds to the capacitor module 68 shown in FIG. 1 and the like.

The control device 110 includes a microcomputer including a CPU and various memories, and performs energization control by turning on and off each switch in the inverters 101 and 102 based on various detection information in the rotating electric machine 10 and a request for powering drive and power generation. carry out. The control device 110 corresponds to the control device 77 shown in FIG. The detection information of the rotating electrical machine 10 includes, for example, a rotation angle (electrical angle information) of the rotor 40 detected by an angle detector such as a resolver, a power supply voltage (inverter input voltage) detected by a voltage sensor, and a current sensor The conduction current of each phase detected by is included. Control device 110 generates and outputs operation signals for operating the switches of inverters 101 and 102. The request for power generation is, for example, a request for regenerative drive when the rotating electrical machine 10 is used as a vehicle power source.

The first inverter 101 is provided with a series connection of an upper arm switch Sp and a lower arm switch Sn in three phases consisting of a U phase, a V phase and a W phase. The high potential side terminal of the upper arm switch Sp of each phase is connected to the positive terminal of the DC power supply 103, and the low potential side terminal of the lower arm switch Sn of each phase is connected to the negative terminal (ground) of the DC power supply 103 . One end of each of a U-phase winding, a V-phase winding, and a W-phase winding is connected to an intermediate connection point between the upper arm switch Sp and the lower arm switch Sn of each phase. These respective phase windings are star-connected (Y-connected), and the other ends of the respective phase windings are connected to each other at a neutral point.

The second inverter 102 has a configuration similar to that of the first inverter 101, and includes a series connection of an upper arm switch Sp and a lower arm switch Sn in three phases consisting of X phase, Y phase and Z phase. ing. The high potential side terminal of the upper arm switch Sp of each phase is connected to the positive terminal of the DC power supply 103, and the low potential side terminal of the lower arm switch Sn of each phase is connected to the negative terminal (ground) of the DC power supply 103 . One end of each of an X-phase winding, a Y-phase winding, and a Z-phase winding is connected to an intermediate connection point between the upper arm switch Sp and the lower arm switch Sn of each phase. These respective phase windings are star-connected (Y-connected), and the other ends of the respective phase windings are connected to each other at a neutral point.

FIG. 20 shows current feedback control processing for controlling each phase current of U, V and W phases, and current feedback control processing for controlling each phase current of X, Y and Z phases. Here, first, control processing on the U, V, and W phases will be described.

In FIG. 20, current command value setting unit 111 uses a torque-dq map, based on a powering torque command value or a power generation torque command value for rotating electric machine 10, or based on an electrical angular velocity ω obtained by time differentiation of electrical angle θ. , D-axis current command value and q-axis current command value are set. The current command value setting unit 111 is commonly provided on the U, V, W phase side and the X, Y, Z phase side. The power generation torque command value is, for example, a regenerative torque command value when the rotary electric machine 10 is used as a vehicle power source.

The dq conversion unit 112 is a two-dimensional orthogonal two-dimensional system in which a current detection value (three phase currents) by a current sensor provided for each phase is taken as a d-axis of a direction of an axis of a magnetic field or field direction. It is converted into d-axis current and q-axis current which are components of the rotational coordinate system.

The d-axis current feedback control unit 113 calculates a d-axis command voltage as an operation amount for feedback controlling the d-axis current to the d-axis current command value. Further, the q-axis current feedback control unit 114 calculates a q-axis command voltage as an operation amount for feedback controlling the q-axis current to the q-axis current command value. Each of these feedback control units 113 and 114 calculates a command voltage 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 115 converts the d-axis and q-axis command voltages into U-phase, V-phase, and W-phase command voltages. Each of the units 111 to 115 described above is a feedback control unit that performs feedback control of the fundamental wave current according to the dq conversion theory, and the command voltages of the U phase, the V phase and the W phase are feedback control values.

Then, the operation signal generation unit 116 generates an operation signal of the first inverter 101 based on the three-phase command voltage using a known triangular wave carrier comparison method. Specifically, the operation signal generation unit 116 switches the upper and lower arms in each phase by PWM control based on a magnitude comparison between a signal obtained by standardizing the three-phase command voltages with the power supply voltage and a carrier signal such as a triangular wave signal. An operation signal (duty signal) is generated.

In addition, the same configuration is also applied to the X, Y, and Z phases, and the dq conversion unit 122 determines the field direction of the current detection value (three phase currents) by the current sensor provided for each phase. It is converted into a d-axis current and a q-axis current which are components of an orthogonal two-dimensional rotational coordinate system as the d-axis.

The d-axis current feedback control unit 123 calculates the d-axis command voltage, and the q-axis current feedback control unit 124 calculates the q-axis command voltage. The three-phase conversion unit 125 converts the d-axis and q-axis command voltages into X-phase, Y-phase, and Z-phase command voltages. Then, the operation signal generation unit 126 generates an operation signal of the second inverter 102 based on the three-phase command voltages. Specifically, the operation signal generation unit 126 switches the upper and lower arms in each phase by PWM control based on magnitude comparison between a signal obtained by standardizing the three-phase command voltage with the power supply voltage and a carrier signal such as a triangular wave signal. An operation signal (duty signal) is generated.

The driver 117 turns on / off the three-phase switches Sp and Sn in the inverters 101 and 102 based on the switch operation signals generated by the operation signal generation units 116 and 126.

Subsequently, torque feedback control processing will be described. This process is mainly used for the purpose of increasing the output of the rotary electric machine 10 and reducing the loss under operating conditions in which the output voltage of each of the inverters 101 and 102 is increased, such as a high rotation area and a high output area. Control device 110 selects and executes one of torque feedback control processing and current feedback control processing based on the operating conditions of rotating electrical machine 10.

FIG. 21 shows torque feedback control processing corresponding to the U, V, and W phases, and torque feedback control processing corresponding to the X, Y, and Z phases. In FIG. 21, the same components as in FIG. 20 are assigned the same reference numerals and descriptions thereof will be omitted. Here, first, control processing on the U, V, and W phases will be described.

The voltage amplitude calculation unit 127 is a command value of the magnitude of the voltage vector based on the powering torque command value or the power generation torque command value for the rotary electric machine 10 and the electric angular velocity ω obtained by time-differentiating the electric angle θ. Calculate voltage amplitude command.

The torque estimation unit 128 a calculates a torque estimated value corresponding to the U, V, and W phases based on the d-axis current and the q-axis current converted by the dq conversion unit 112. The torque estimation unit 128a may calculate the voltage amplitude command based on the map information in which the d-axis current, the q-axis current, and the voltage amplitude command are related.

Torque feedback control unit 129a calculates a voltage phase command that is a command value of the phase of the voltage vector, as an operation amount for feedback controlling the torque estimated value to the powering torque command value or the power generation torque command value. The torque feedback control unit 129a calculates a voltage phase command using a PI feedback method based on the power running torque command value or the deviation of the torque estimated value from the power generation torque command value.

The operation signal generation unit 130 a generates an operation signal of the first inverter 101 based on the voltage amplitude command, the voltage phase command, and the electrical angle θ. Specifically, the operation signal generation unit 130a calculates a three-phase command voltage based on the voltage amplitude command, the voltage phase command, and the electrical angle θ, and normalizes the calculated three-phase command voltage with the power supply voltage. The switch operation signal of the upper and lower arms in each phase is generated by PWM control based on the magnitude comparison between the signal and the carrier signal such as the triangular wave signal.

Incidentally, the operation signal generation unit 130a is 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 related, a voltage amplitude command, a voltage phase command and an electrical angle θ. The switch operation signal may be generated.

In addition, the X-, Y-, and Z-phase sides have the same configuration, and the torque estimation unit 128 b determines the X, Y, and Z based on the d-axis current and the q-axis current converted by the dq conversion unit 122. An estimated torque value corresponding to the Z phase is calculated.

The torque feedback control unit 129 b calculates a voltage phase command as an operation amount for performing feedback control of the torque estimated value to the powering torque command value or the power generation torque command value. The torque feedback control unit 129 b calculates a voltage phase command using a PI feedback method based on the power running torque command value or the deviation of the torque estimated value from the power generation torque command value.

The operation signal generation unit 130 b generates an operation signal of the second inverter 102 based on the voltage amplitude command, the voltage phase command, and the electrical angle θ. Specifically, the operation signal generation unit 130b calculates a three-phase command voltage based on the voltage amplitude command, the voltage phase command, and the electrical angle θ, and normalizes the calculated three-phase command voltage with the power supply voltage. The switch operation signal of the upper and lower arms in each phase is generated by PWM control based on the magnitude comparison between the signal and the carrier signal such as the triangular wave signal. The driver 117 turns on / off the three-phase switches Sp and Sn in the inverters 101 and 102 based on the switch operation signals generated by the operation signal generation units 130a and 130b.

Incidentally, the operation signal generation unit 130b is 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 related, a voltage amplitude command, a voltage phase command and an electrical angle θ. The switch operation signal may be generated.

By the way, in the rotary electric machine 10, there is concern that electrolytic corrosion of the bearings 21 and 22 may occur with the generation of the axial current. For example, when the energization of the stator winding 51 is switched by switching, a slight deviation of switching timing (switching imbalance) causes distortion of the magnetic flux, which causes the bearings 21, 22 to support the rotating shaft 11 There is concern that electrolytic corrosion will occur in The distortion of the magnetic flux occurs according to the inductance of the stator 50, and an axial electromotive voltage generated by the distortion of the magnetic flux causes a dielectric breakdown in the bearings 21 and 22 to cause electrolytic corrosion.

In this respect, in the present embodiment, the following three measures are taken as a measure against galvanic corrosion. The first galvanic corrosion countermeasure is a galvanic corrosion suppression countermeasure by reducing the inductance along with making the stator 50 coreless and making the magnet magnetic flux of the magnet unit 42 smooth. The second countermeasure against electrolytic corrosion is a countermeasure against the electrolytic corrosion due to the rotary shaft having a cantilever structure by the bearings 21 and 22. The third galvanic corrosion countermeasure is a galvanic corrosion suppression countermeasure by molding the annular stator winding 51 together with the stator core 52 with a molding material. The details of each of these measures are individually described below.

First, in the first countermeasure against electrolytic corrosion, in the stator 50, the gaps between the wire groups 81 in the circumferential direction are made teethless, and between the wire groups 81, a seal made of nonmagnetic material instead of teeth (iron core) A member 57 is provided (see FIG. 10). Thus, the inductance of the stator 50 can be reduced. By reducing the inductance in the stator 50, even if a shift in switching timing occurs when the stator winding 51 is energized, generation of magnetic flux distortion due to the shift in switching timing is suppressed. It is possible to suppress the electrolytic corrosion of The inductance of the d axis may be equal to or less than the inductance of the q axis.

Further, in the magnets 91 and 92, orientation is made such that the direction of the magnetization easy axis is parallel to the d axis on the d axis side as compared to the q axis side (see FIG. 9). As a result, the magnet magnetic flux in the d-axis is strengthened, and the surface magnetic flux change (increase or decrease of the magnetic flux) from the q-axis to the d-axis in each magnetic pole becomes smooth. Therefore, the rapid voltage change resulting from the switching imbalance is suppressed, and as a result, the configuration can contribute to the electrolytic corrosion suppression.

In the second countermeasure against electrolytic corrosion, in the rotary electric machine 10, the bearings 21 and 22 are arranged to be biased to one side in the axial direction with respect to the axial center of the rotor 40 (see FIG. 2). Thereby, the influence of the electrolytic corrosion can be reduced as compared with the configuration in which the plurality of bearings are provided on both sides of the rotor in the axial direction. That is, in the configuration in which the rotor is supported on both sides by a plurality of bearings, a closed circuit passing through the rotor, the stator, and each bearing (that is, each bearing on both sides in the axial direction across the rotor) There is concern about the electrolytic corrosion of the bearing due to the axial current. On the other hand, in the configuration in which the rotor 40 is supported in a cantilever manner by the plurality of bearings 21 and 22, the above-mentioned closed circuit is not formed, and the electrolytic corrosion of the bearings is suppressed.

In addition, the rotary electric machine 10 has the following configuration in connection with a configuration for one-side arrangement of the bearings 21 and 22. In the magnet holder 41, a contact avoiding portion that extends in the axial direction to avoid contact with the stator 50 is provided in the radially extending intermediate portion 45 of the rotor 40 (see FIG. 2). In this case, when the closed circuit of the axial current is formed via the magnet holder 41, it is possible to increase the closed circuit length and increase the circuit resistance. Thereby, suppression of the electrolytic corrosion of the bearings 21 and 22 can be aimed at.

The holding member 23 of the bearing unit 20 is fixed to the housing 30 on one side of the rotor 40 in the axial direction, and the housing 30 and the unit base 61 (stator holder) are connected to each other on the other side. (See Figure 2). According to this configuration, it is possible to preferably realize a configuration in which the bearings 21 and 22 are disposed on one side in the axial direction in the axial direction of the rotating shaft 11 in a biased manner. Further, in the present configuration, the unit base 61 is connected to the rotating shaft 11 through the housing 30, so that the unit base 61 can be disposed at a position electrically separated from the rotating shaft 11. When an insulating member such as a resin is interposed between the unit base 61 and the housing 30, the unit base 61 and the rotating shaft 11 are electrically separated further. Thereby, the electrolytic corrosion of the bearings 21 and 22 can be suppressed appropriately.

In the rotating electrical machine 10 of the present embodiment, the axial voltage acting on the bearings 21 and 22 is reduced by the arrangement of the bearings 21 and 22 on one side or the like. Also, the potential difference between the rotor 40 and the stator 50 is reduced. Therefore, even if the conductive grease is not used in the bearings 21 and 22, the potential difference acting on the bearings 21 and 22 can be reduced. The conductive grease generally contains fine particles such as carbon, and therefore it is considered that noise is generated. In this respect, in the present embodiment, non-conductive grease is used in the bearings 21 and 22. Therefore, it is possible to suppress the occurrence of noise in the bearings 21 and 22. For example, when applied to an electric vehicle such as an electric car, it is considered that measures against the sounding of the rotary electric machine 10 are required, but it is possible to preferably implement the measures against the sounding.

In the third countermeasure against electrolytic corrosion, the stator winding 51 and the stator core 52 are molded with a molding material to suppress positional deviation of the stator winding 51 in the stator 50 (see FIG. 11). ). In particular, in the rotating electrical machine 10 of the present embodiment, since there is no inter-lead member (teeth) between the conductor wire groups 81 in the circumferential direction of the stator winding 51, there is a concern that positional deviation in the stator winding 51 may occur. Although conceivable, by molding the stator winding 51 together with the stator core 52, the displacement of the conductor position of the stator winding 51 is suppressed. Therefore, distortion of magnetic flux due to positional deviation of the stator winding 51 and generation of electrolytic corrosion of the bearings 21 and 22 resulting therefrom can be suppressed.

In addition, since the unit base 61 as a housing member for fixing the stator core 52 is made of carbon fiber reinforced plastic (CFRP), discharge to the unit base 61 is suppressed as compared with, for example, aluminum. As a result, suitable electrolytic corrosion measures are possible.

In addition, as measures against electrolytic corrosion of the bearings 21 and 22, it is also possible to use a configuration in which at least one of the outer ring 25 and the inner ring 26 is made of a ceramic material or an insulating sleeve is provided outside the outer ring 25.

By the way, generally, at the time of driving of a motor, in the conducting wire which constitutes a stator winding, loss due to the skin effect and eddy current loss may occur. This tendency is particularly noticeable in motors with high output. For this reason, it is desirable to adopt a stranded wire (Litz wire) obtained by twisting a large number of thin insulated copper wires in place of a single insulated copper wire (enamel wire). However, when a stranded wire is employed, the ratio of the insulating film per unit area is increased as compared with the case where a single-layered insulated copper wire is employed, and there is a problem that the resistance of the conducting wire is increased. Therefore, it is desirable to counteract the increase in resistance and to minimize the space in which the wire is not accommodated as much as possible to improve the ratio of the wire occupied in the wire accommodation space.

Then, when the conducting wire 82 is formed into a flat rectangular shape as in the present embodiment, when fixed to the outer peripheral surface of the stator core 52, longitudinal end portions of the conducting wire 82 as shown in a region 1000 indicated by a broken line in FIG. Are separated from the outer peripheral surface of the stator core 52. That is, an extra space in which the conducting wire 82 is not disposed is formed between the inner side surface of the conducting wire 82 and the outer circumferential surface of the stator core 52. That is, there is a concern that the space in which the conducting wire 82 is not accommodated will be large. So, in this embodiment, in order to eliminate such an extra space, lead 82 was constituted as follows.

FIG. 23 is a cross-sectional view of the conducting wire 82 (linear portion 83) in the present embodiment. As shown in FIG. 23, in the conducting wire 82, the facing surface 1001a facing the stator core 52 as the base member is along the curved surface 52a (peripheral surface) of the stator core 52 to which the facing surface 1001a is fixed in the circumferential direction. It is a curved surface which becomes circular arc shape. That is, the cross section (the cross section in the direction orthogonal to the axial direction) of the facing surface 1001 a is arc-shaped along the circumferential direction, and the curvature of the facing surface 1001 a is the curvature of the curved surface 52 a of the stator core 52 And almost the same. The facing surface 1001 a is an inner side surface of the conducting wire 82 (inner conducting wire 1001) closest to the stator core 52 in the radial direction, and is a surface in contact with the stator core 52.

Further, as described above, the wire group 81 is composed of the two layers of the wire 82 in the radial direction. Specifically, as shown in FIG. 23, the two layers of conducting wires 82 are arranged in radial alignment. That is, the plurality of conducting wires 82 are stacked in the radial direction so that the circumferential center of the conducting wire 82 is substantially disposed on a straight line along the radial direction passing through the rotation center.

Here, among the two lead wires disposed adjacent to each other in the radial direction, the lead wire 82 disposed inside is referred to as an inner lead 1001, and the lead 82 disposed outside is referred to as an outer lead 1002. The outer side surface 1001 b of the inner lead 1001 that faces the outer lead 1002 is a curved surface that is arc-shaped in the circumferential direction. That is, the cross section (the cross section in the direction orthogonal to the axial direction) of the outer side surface 1001 b is arc-shaped along the circumferential direction.

Further, in the outer lead wire 1002, the inner side surface 1002a that faces the inner lead wire 1001 is a curved surface that is arc-shaped along the outer side surface 1001b of the inner lead wire 1001 in the circumferential direction. That is, the cross section (the cross section in the direction orthogonal to the axial direction) of the inner side surface 1002a is arc-shaped along the circumferential direction, and the curvature of the inner side surface 1002a is the curvature of the outer side surface 1001b of the inner lead 1001. And almost the same.

Further, the thickness dimension (R 1002) in the radial direction of the outer lead 1002 is thinner than the thickness dimension (R 1001) of the inner lead 1001. The thickness dimension is, as shown in FIG. 23, the thickness dimension at the center in the circumferential direction of each lead 82.

The circumferential width dimension (L 1002) of the outer lead 1002 is longer than the width dimension (L 1001) of the inner lead 1001. That is, an end-to-end angular range (θ 1000) in the circumferential direction of the outer lead 1002 around the rotation center is relative to an end-to-end angular range in the circumferential direction of the inner lead 1001 about the rotation center , Has become the same.

In addition, as shown in FIG. 23, the width dimension is the width dimension at the radial direction central portion of each conducting wire 82. As shown in FIG. In addition, the width dimension at the radially inner side of the inner lead 1001 (ie, the width dimension at the opposing surface 1001a) is shorter than the width dimension at the radially inner side of the outer lead 1002 (ie, the width dimension at the inner side surface 1002a). It has become. In addition, the width dimension at the radially outer side of the inner lead 1001 (ie, the width dimension at the outer side surface 1001b) is shorter than the width dimension at the radially outer side of the outer lead 1002 (ie, the width dimension at the outer side surface 1002b). It has become. On the other hand, the width dimension at the radially outer side of the inner lead 1001 (that is, the width dimension at the outer side surface 1001b) is the same as the width dimension at the radially inner end of the outer lead 1002 (i.e., the width dimension at the inner side surface 1002a) .

The cross-sectional area of the cross section of the outer lead 1002 is the same as the cross-sectional area of the cross section of the inner lead 1001. Further, the outer side surface 1002 b located on the radially outer side of the outer lead 1002 is a curved surface that is arc-shaped in the circumferential direction.

Here, a method of manufacturing the stator 50 will be briefly described. As described above, by bending the respective conducting wires 82 so as to be arranged in a predetermined arrangement pattern in the circumferential direction, the stator winding 51 has a substantially annular shape in which the linear portions 83 are arranged in the circumferential direction. In this bending formation, the inner diameter is formed to be slightly larger than the outer diameter of the stator core 52. Then, after the stator core 52 is inserted into the annular stator winding 51, pressure is applied to the stator winding 51 from the radially outer side to deform the respective conducting wires 82. In the process of this deformation, the opposing surface 1001 a of the inner lead 1001 becomes an arc-shaped curved surface along the curved surface 52 a (the outer peripheral surface) of the stator core 52 in the circumferential direction. Further, the inner side surface 1002 a of the outer lead 1002 is a curved surface in an arc shape along the outer side surface 1001 b of the inner lead 1001 in the circumferential direction.

Note that when bending and forming, the inner diameter of the stator winding 51 is formed to be slightly smaller than the outer diameter of the stator core 52, and the stator core 52 is press-fit into the stator winding 51, so that the respective conducting wires 82 are formed. It may be deformed. At this time, by preventing the stator winding 51 from spreading radially outward, the respective conducting wires 82 are appropriately deformed.

According to the first embodiment, the following excellent effects are obtained.

By making the conductive wire portion 81 and the conductive wire 82 into a flat rectangular shape in which the width dimension in the circumferential direction is larger than the thickness dimension in the radial direction, it is expected that the length (thickness) in the radial direction of the stator can be reduced. . However, when the conducting wire portion 81 and the conducting wire 82 have a flat rectangular shape, fixing to the curved surface 52 a (outer peripheral surface) of the stator core 52 results in an extra gap between the facing surface 1001 a of the conducting wire 82 and the curved surface 52 a. There is a problem that it can be formed.

So, in 1st Embodiment, the opposing surface 1001a of the conducting wire 82 was formed in the curved surface which becomes circular arc shape along the curved surface 52a of the stator core 52 in the circumferential direction. Thereby, the gap between the curved surface 52 a of the stator core 52 and the facing surface 1001 a of the conducting wire 82 can be eliminated. Therefore, the length (thickness) in the radial direction of the stator 50 can be reduced while eliminating the extra gap where the conducting wire 82 is not disposed.

The outer side surface 1001 b of the inner lead 1001 opposite to the outer lead 1002 is curved in a circumferential arc. In the outer lead 1002, the inner side surface 1002a facing the inner lead 1001 is curved in an arc along the outer side surface 1001b of the inner lead 1001 in the circumferential direction. Thereby, when the plurality of conducting wires 82 are aligned in the radial direction of the stator 50, an extra gap in which the conducting wire 82 is not disposed is eliminated between the outer side surface 1001b of the inner conducting wire 1001 and the inner side surface 1002a of the outer conducting wire 1002. be able to. For this reason, the length (thickness) in the radial direction of the stator 50 can be reduced while increasing the space occupied by the conducting wire 82.

When the conducting wires 82 are stacked in the radial direction, the housing space of the conducting wires 82 is wider because the outer circumference is longer than the inside in the radial direction. That is, the gap tends to be large between the adjacent conducting wires 82 in the circumferential direction. Therefore, the thickness dimension (R1002) in the radial direction of the outer conductor 1002 is made thinner than the thickness dimension (R1001) of the inner conductor 1001, and the width dimension (L1002) in the circumferential direction of the outer conductor 1002 is It was longer than the width dimension (L1001) of the inner lead 1001. At this time, the cross-sectional areas of the inner conductor 1001 and the outer conductor 1002 are the same. Thereby, the thickness of the outer lead 1002 in the radial direction can be made smaller than the thickness of the inner lead 1001 while reducing the gap between the adjacent leads 82 in the circumferential direction. Therefore, the thickness dimension in the radial direction of the stator 50 can be made thinner while reducing the extra space where the conducting wire 82 is not disposed between the conducting wires 82 adjacent in the circumferential direction.

By reducing the thickness dimension in the radial direction of the stator winding 51, the distance from the stator core 52 to the magnet unit 42 can be shortened, and the torque can be improved.

The conducting wire 82 is a wire assembly which is formed of a plurality of strands 86 and is covered with the insulating coating 82 b. Thereby, the eddy current loss can be reduced. Further, since the wire assembly is a wire assembly, the wire 82 can be easily deformed to the above shape by compressing the wire 82 toward the stator core 52 side.

Since the strands 86 in the conducting wire 82 are in the same phase, there is no potential difference. That is, unlike between the conducting wires 82, even if the polymer insulating layer of the strands 86 is thinner than the insulating coating 82b, sufficient insulation can be achieved between the strands 86. In addition, even if it can not be insulated, no major problems occur. Therefore, the polymer insulating layer as the insulating layer of each wire 86 is thinner than the thickness of the insulating film 82b as the insulating member. Thereby, the ratio of the insulating part in the conducting wire 82 can be reduced and the ratio occupied by the conductor can be increased.

Further, the outer side surface 1002 b located on the radially outer side of the outer lead 1002 is a curved surface that is arc-shaped in the circumferential direction. For this reason, it is possible to prevent the end in the circumferential direction of the conducting wire 82 from jumping radially outward more than the central portion, and to make the stator winding 51 thin.

Hereinafter, other embodiments will be described focusing on differences from the first embodiment.

Second Embodiment
In this embodiment, the pole anisotropic structure of the magnet unit 42 in the rotor 40 is changed, and will be described in detail below.

As shown in FIGS. 24 and 25, the magnet unit 42 is configured using a magnet arrangement called a Halbach arrangement. That is, the magnet unit 42 has a first magnet 131 whose radial direction is the magnetization direction (direction of magnetization vector) and a second magnet 132 whose circumferential direction is the magnetization direction (direction of the magnetization vector), The first magnets 131 are disposed at predetermined intervals in the circumferential direction, and the second magnets 132 are disposed at positions between the adjacent first magnets 131 in the circumferential direction. The first magnet 131 and the second magnet 132 are permanent magnets made of, for example, a rare earth magnet such as a neodymium magnet.

The first magnets 131 are spaced apart from each other in the circumferential direction such that poles on the side (radially inner side) facing the stator 50 are alternately N poles and S poles. Further, the second magnets 132 are arranged adjacent to the first magnets 131 so that the polarities alternate in the circumferential direction. The cylindrical portion 43 provided to surround the magnets 131 and 132 may be a soft magnetic core made of a soft magnetic material and functions as a back core. The relationship of the magnetization easy axis with respect to the d axis and the q axis in the dq coordinate system of the magnet unit 42 of the second embodiment is also the same as that of the first embodiment.

Further, a magnetic body 133 made of a soft magnetic material is disposed radially outside the first magnet 131, that is, on the side of the cylindrical portion 43 of the magnet holder 41. For example, the magnetic body 133 may be made of a magnetic steel sheet, a soft iron, or a dust core material. In this case, the circumferential length of the magnetic body 133 is the same as the circumferential length of the first magnet 131 (in particular, the circumferential length of the outer peripheral portion of the first magnet 131). Moreover, the thickness in the radial direction of the one-piece in the state in which the first magnet 131 and the magnetic body 133 are integrated is the same as the thickness in the radial direction of the second magnet 132. In other words, the thickness of the first magnet 131 in the radial direction is thinner than that of the second magnet 132 by the amount of the magnetic substance 133. The magnets 131 and 132 and the magnetic body 133 are fixed to each other by, for example, an adhesive. In the magnet unit 42, the radially outer side of the first magnet 131 is the opposite side to the stator 50, and the magnetic body 133 is the opposite side to the stator 50 of both sides of the first magnet 131 in the radial direction Provided on the stator side).

On the outer peripheral portion of the magnetic body 133, a key 134 is formed as a convex portion protruding radially outward, that is, the cylindrical portion 43 side of the magnet holder 41. Further, on the inner peripheral surface of the cylindrical portion 43, a key groove 135 is formed as a recess for accommodating the key 134 of the magnetic body 133. The protruding shape of the keys 134 and the groove shape of the key grooves 135 are the same, and the key grooves 135 equal in number to the keys 134 are formed corresponding to the keys 134 formed on each magnetic body 133. By the engagement of the key 134 and the key groove 135, positional deviation between the first magnet 131 and the second magnet 132 and the magnet holder 41 in the circumferential direction (rotational direction) is suppressed. The key 134 and the key groove 135 (protrusions and depressions) may be provided on either of the cylindrical portion 43 and the magnetic body 133 of the magnet holder 41, and contrary to the above, on the outer peripheral portion of the magnetic body 133 It is also possible to provide the key groove 135 and to provide the key 134 on the inner peripheral portion of the cylindrical portion 43 of the magnet holder 41.

Here, in the magnet unit 42, it is possible to increase the magnetic flux density in the first magnet 131 by arranging the first magnet 131 and the second magnet 132 alternately. Therefore, in the magnet unit 42, magnetic flux can be concentrated on one side, and the magnetic flux can be strengthened on the side closer to the stator 50.

In addition, by disposing the magnetic body 133 on the radially outer side of the first magnet 131, that is, on the side opposite to the stator, it is possible to suppress partial magnetic saturation on the radially outer side of the first magnet 131 and, consequently, due to the magnetic saturation. It is possible to suppress the demagnetization of the first magnet 131 that is generated. As a result, the magnetic force of the magnet unit 42 can be increased. The magnet unit 42 of the present embodiment has a configuration in which a portion where demagnetization easily occurs in the first magnet 131 is replaced with the magnetic body 133.

26 (a) and 26 (b) are diagrams specifically showing the flow of magnetic flux in the magnet unit 42, and FIG. 26 (a) is a conventional configuration in which the magnetic unit 133 is not included in the magnet unit 42. 26B shows the case where the configuration of the present embodiment in which the magnetic unit 133 is provided in the magnet unit 42 is used. In FIGS. 26 (a) and 26 (b), the cylindrical portion 43 of the magnet holder 41 and the magnet unit 42 are expanded in a straight line, and the lower side of the drawing is the stator side and the upper side is the opposite stator. It is on the side.

In the configuration of FIG. 26A, the magnetic flux acting surface of the first magnet 131 and the side surface of the second magnet 132 are in contact with the inner peripheral surface of the cylindrical portion 43, respectively. Further, the magnetic flux acting surface of the second magnet 132 is in contact with the side surface of the first magnet 131. In this case, a magnetic flux F1 entering the contact surface with the first magnet 131 through the outer path of the second magnet 132 and a magnetic flux F2 of the second magnet 132 substantially parallel to the cylindrical portion 43 A combined magnetic flux with the attracting magnetic flux is generated. Therefore, there is a concern that magnetic saturation partially occurs in the vicinity of the contact surface between the first magnet 131 and the second magnet 132 in the cylindrical portion 43.

On the other hand, in the configuration of FIG. 26 (b), the magnetic substance 133 is between the magnetic flux acting surface of the first magnet 131 and the inner circumferential surface of the cylindrical portion 43 on the opposite side of the first magnet 131 with the stator 50. Since it is provided, the magnetic body 133 allows the passage of magnetic flux. Therefore, magnetic saturation in the cylindrical portion 43 can be suppressed, and resistance to demagnetization is improved.

Also, in the configuration of FIG. 26B, unlike in FIG. 26A, F2 that promotes magnetic saturation can be eliminated. Thus, the permeance of the entire magnetic circuit can be effectively improved. By this configuration, the magnetic circuit characteristics can be maintained even under severe high heat conditions.

Further, compared to the radial magnet in the conventional SPM rotor, the magnet magnetic path passing through the inside of the magnet is longer. Therefore, the magnet permeance is increased, the magnetic force can be increased, and the torque can be increased. Furthermore, the magnetic flux can be concentrated at the center of the d-axis to increase the sine wave matching rate. In particular, the torque can be more effectively enhanced by using a switching IC with a current waveform as a sine wave or a trapezoidal wave or by using a 120-degree conduction switching IC by PWM control.

In the case where the stator core 52 is formed of an electromagnetic steel sheet, the radial thickness of the stator core 52 is preferably larger than 1/2 or 1/2 of the radial thickness of the magnet unit 42. For example, the radial thickness of the stator core 52 may be 1/2 or more of the radial thickness of the first magnet 131 provided at the magnetic pole center of the magnet unit 42. Further, the radial thickness of the stator core 52 may be smaller than the radial thickness of the magnet unit 42. In this case, since the magnet magnetic flux is approximately 1 [T] and the saturation magnetic flux density of the stator core 52 is 2 [T], the radial thickness of the stator core 52 is equal to the radial thickness of the magnet unit 42. The magnetic flux leakage to the inner peripheral side of the stator core 52 can be prevented by setting it to 1/2 or more.

In the Halbach structure or pole-anisotropic magnet, the magnetic path has a pseudo arc shape, so that the magnetic flux can be increased in proportion to the thickness of the magnet that handles the magnetic flux in the circumferential direction. In such a configuration, it is considered that the magnetic flux flowing to the stator core 52 does not exceed the circumferential magnetic flux. That is, when an iron-based metal having a saturation magnetic flux density of 2 [T] with respect to the magnetic flux of 1 [T] of the magnet is used, magnetic saturation does not occur preferably if the thickness of the stator core 52 is half or more A small and lightweight rotary electric machine can be provided. Here, since the demagnetizing field from the stator 50 acts on the magnet flux, the magnet flux is generally 0.9 T or less. Therefore, if the stator core has half the thickness of the magnet, its magnetic permeability can be suitably kept high.

Below, the modification which changed a part of structure mentioned above is demonstrated.

(Modification 1)
In the above embodiment, the outer peripheral surface of the stator core 52 has a curved surface without unevenness, and the plurality of wire groups 81 are arranged side by side at predetermined intervals on the outer peripheral surface. For example, as shown in FIG. 27, the stator core 52 is an annular yoke 141 provided on the opposite side (lower side in the figure) of the stator winding 51 in the radial direction to the rotor 40; A protrusion 142 extends from the yoke 141 so as to project between the linear portions 83 adjacent in the circumferential direction. The protrusions 142 are provided on the radially outer side of the yoke 141, that is, on the side of the rotor 40 at predetermined intervals. The conductor groups 81 of the stator winding 51 are engaged with the projections 142 in the circumferential direction, and are arranged in the circumferential direction while using the projections 142 as positioning portions for the conductor groups 81. In addition, the projection part 142 corresponds to "a member between conducting wires".

The protrusion 142 has a thickness dimension in the radial direction from the yoke 141, in other words, as shown in FIG. 27, in the radial direction of the yoke 141, from the inner side surface 320 adjacent to the yoke 141 of the straight portion 83 The distance W to the apex is smaller than half (H1 in the figure) of the thickness dimension in the radial direction of the linear portion 83 adjacent to the yoke 141 in the radial direction among the plurality of linear portions 83 inside and outside the radial direction It is a structure. In other words, the dimension (thickness) T1 (the thickness) of the conductive wire group 81 (conductive member) in the radial direction of the stator winding 51 (the stator core 52), in other words, the stator core of the conductive wire group 81 The nonmagnetic member (sealing member 57) may occupy a range of three quarters of the surface 320 in contact with the surface 52 and the shortest distance between the surface 330 of the conductor group 81 facing the rotor 40). Due to such thickness limitation of the protrusion 142, the protrusion 142 does not function as teeth between the wire groups 81 (that is, the straight portions 83) adjacent in the circumferential direction, and magnetic paths are not formed by the teeth. . The protrusions 142 may not be all provided between the wire groups 81 aligned in the circumferential direction, and may be provided between at least one pair of wire groups 81 adjacent in the circumferential direction. For example, the protrusions 142 may be provided at equal intervals for each predetermined number between the wire groups 81 in the circumferential direction. The shape of the protrusion 142 may be any shape such as a rectangular shape or an arc shape.

Further, on the outer peripheral surface of the stator core 52, the linear portion 83 may be provided in a single layer. Therefore, in a broad sense, the thickness dimension in the radial direction from the yoke 141 in the protrusion 142 may be smaller than 1⁄2 of the thickness dimension in the radial direction of the straight portion 83.

Assuming that a virtual circle is centered on the axis of the rotary shaft 11 and passes through the radial center position of the straight portion 83 adjacent to the yoke 141 in the radial direction, the projection 142 is within the range of the virtual circle. It is preferable that the shape which protrudes from the yoke 141, in other words, the shape which does not protrude in the radial direction outer side (that is, the rotor 40 side) than the virtual circle.

According to the above configuration, the thickness of the protrusion 142 in the radial direction is limited, and the protrusion 142 does not function as teeth between the adjacent linear portions 83 in the circumferential direction. As compared with the case where is provided, adjacent linear parts 83 can be brought closer. Thereby, the cross-sectional area of the conductor 82a can be enlarged, and the heat generation which accompanies the energization of the stator winding 51 can be reduced. In such a configuration, the absence of the teeth makes it possible to eliminate the magnetic saturation, and it is possible to increase the current flow to the stator winding 51. In this case, an increase in the amount of heat generation can be suitably coped with as the current flows. Further, in the stator winding 51, since the turn portion 84 is shifted in the radial direction and has an interference avoiding portion for avoiding interference with other turn portions 84, the different turn portions 84 are separated in the radial direction. It can be arranged. Thereby, the heat dissipation can be improved also in the turn portion 84. As described above, the heat dissipation performance of the stator 50 can be optimized.

If the yoke 141 of the stator core 52 and the magnet units 42 of the rotor 40 (ie, the magnets 91 and 92) are separated by a predetermined distance or more, the thickness dimension of the projection 142 in the radial direction is as shown in FIG. Not tied to H1. Specifically, as long as the yoke 141 and the magnet unit 42 are separated by 2 mm or more, the thickness dimension of the protrusion 142 in the radial direction may be H1 or more in FIG. For example, when the radial thickness dimension of the linear portion 83 exceeds 2 mm, and the lead wire group 81 is constituted by the two layers of the lead 82 inside and outside the radial direction, the straight portion 83 not adjacent to the yoke 141, That is, the projecting portion 142 may be provided in a range from the yoke 141 to a half position of the second-layer conductive wire 82. In this case, if the radial thickness dimension of the projection 142 is “H1 × 3/2”, the effect can be obtained to some extent by enlarging the cross-sectional area of the conductor in the wire group 81.

The stator core 52 may be configured as shown in FIG. In addition, although the sealing member 57 is abbreviate | omitted in FIG. 28, the sealing member 57 may be provided. In FIG. 28, for convenience, the magnet unit 42 and the stator core 52 are shown linearly developed.

In the configuration of FIG. 28, the stator 50 has a projection 142 as an inter-conductor member between the circumferentially adjacent conductors 82 (i.e., the linear portions 83). The stator 50 magnetically functions with one of the magnetic poles (N or S pole) of the magnet unit 42 when the stator winding 51 is energized, and a circumferentially extending portion 350 of the stator 50 is formed. Have. Assuming that the length in the circumferential direction of the stator 50 of this portion 350 is Wn, the total width of the protrusions 142 present in the length range Wn (ie, the total dimension in the circumferential direction of the stator 50) Assuming that Wt is the saturation magnetic flux density of the projection 142, Bs is the width dimension of the magnet unit 42 in the circumferential direction, and Br is the residual magnetic flux density of the magnet unit 42, the projection 142 is
Wt × Bs ≦ Wm × Br (1)
It is comprised by the magnetic material which becomes.

The range Wn is set so as to include a plurality of conductor groups 81 adjacent in the circumferential direction, the plurality of conductor groups 81 having overlapping excitation timings. At that time, it is preferable to set the center of the gap 56 of the wire group 81 as a reference (boundary) when setting the range Wn. For example, in the case of the configuration illustrated in FIG. 28, up to the fourth conductor group 81 corresponds to the plurality of conductor groups 81 in order from the shortest distance from the magnetic pole center of the N pole in the circumferential direction. Then, the range Wn is set to include the four lead wire groups 81. At this time, the end (start and end points) of the range Wn is the center of the gap 56.

In FIG. 28, since the protrusions 142 are respectively included in half at both ends of the range Wn, a total of four protrusions 142 are included in the range Wn. Therefore, assuming that the width of the protrusion 142 (that is, the dimension of the protrusion 142 in the circumferential direction of the stator 50, in other words, the distance between adjacent wire groups 81) is A, the total of the protrusions 142 included in the range Wn The width is Wt = 1 / 2A + A + A + A + 1 / 2A = 4A.

Specifically, in the present embodiment, the three-phase winding of the stator winding 51 is a distributed winding, and in the stator winding 51, the number of the projecting portions 142 with respect to one pole of the magnet unit 42, ie, each The number of gaps 56 between the wire groups 81 is “number of phases × Q”. Here, Q is the number of the one-phase conducting wire 82 in contact with the stator core 52. In addition, when the conducting wire 82 is the conducting wire group 81 laminated | stacked on the radial direction of the rotor 40, it can be said that it is the number of the conducting wire 82 of the inner peripheral side of the conducting wire group 81 of 1 phase. In this case, when the three-phase winding of the stator winding 51 is energized in each phase in a predetermined order, the projections 142 for two phases are excited in one pole. Therefore, the total width dimension Wt in the circumferential direction of the protrusions 142 excited by the energization of the stator winding 51 in the range of one pole of the magnet unit 42 is the width in the circumferential direction of the protrusions 142 (that is, the gap 56). Assuming that the dimension is A, “the number of phases to be excited × Q × A = 2 × 2 × A”.

Then, after the total width dimension Wt is thus defined, in the stator core 52, the protrusion 142 is configured as a magnetic material that satisfies the relationship of the above (1). The total width dimension Wt is also a circumferential dimension of a portion where the relative permeability can be larger than 1 in one pole. Also, in consideration of the margin, the total width dimension Wt may be the width dimension in the circumferential direction of the protrusion 142 in one magnetic pole. Specifically, since the number of protrusions 142 with respect to one pole of the magnet unit 42 is “number of phases × Q”, the circumferential width dimension (total width dimension Wt) of the protrusions 142 in one magnetic pole is The number of phases x Q x A = 3 x 2 x A = 6 A "may be used.

The term "distributed winding" as used herein means one pole pair period (N pole and S pole) of the magnetic pole, and one pole pair of the stator winding 51. A single pole pair of the stator winding 51 mentioned here is composed of two straight portions 83 and a turn portion 84 electrically connected by the current flow in opposite directions. As long as the above conditions are satisfied, even Short Pitch Winding is regarded as equivalent to the distributed pitch of Full Pitch Winding.

Next, an example in the case of concentrated winding is shown. The concentrated winding referred to here is one in which the width of one pole pair of the magnetic pole is different from the width of one pole pair of the stator winding 51. As an example of concentrated winding, three lead groups 81 for one pole pair, three lead groups 81 for two pole pairs, nine lead groups 81 for four pole pairs There is a case where the wire group 81 has a relationship such as nine for one magnetic pole pair.

Here, when the stator winding 51 is concentrated, when the three-phase windings of the stator winding 51 are energized in a predetermined order, the stator winding 51 for two phases is excited. As a result, the projections 142 for two phases are excited. Therefore, the circumferential width dimension Wt of the protrusion 142 excited by the energization of the stator winding 51 in the range of one pole of the magnet unit 42 is “A × 2”. Then, after the width dimension Wt is defined in this way, the protrusion 142 is configured as a magnetic material that satisfies the relationship of the above (1). In the case of the concentrated winding described above, the sum of the widths of the protrusions 142 in the circumferential direction of the stator 50 is A in a region surrounded by the wire groups 81 of the same phase. Further, Wm in the concentrated winding corresponds to “the entire circumference of the surface of the magnet unit 42 facing the air gap” × “the number of phases” / “the number of dispersions of the wire groups 81”.

Incidentally, Bd = 1.0 strong [T] for magnets with a BH product of 20 [MGOe (kJ / m ^ 3)] such as neodymium magnets, samarium cobalt magnets, and ferrite magnets, Br = 2.0 strong for iron ]. Therefore, as the high output motor, in the stator core 52, the protrusion 142 may be a magnetic material that satisfies the relationship of Wt <1/2 × Wm.

Further, as described later, when the lead 82 includes the outer coating 182, the lead 82 may be disposed in the circumferential direction of the stator core 52 such that the outer coating 182 of the leads 82 is in contact with each other. In this case, Wt can be regarded as zero or the thickness of the outer layer coating 182 of both the leads 82 in contact.

In the configurations of FIGS. 27 and 28, the inter-conductor member (protrusion 142) which is undesirably small with respect to the magnet flux on the rotor 40 side is provided. The rotor 40 is a surface magnet type rotor having a low inductance and a flat surface, and has no saliency in terms of magnetic resistance. In such a configuration, the inductance of the stator 50 can be reduced, and the generation of magnetic flux distortion due to the shift in the switching timing of the stator winding 51 is suppressed, which in turn suppresses the electrolytic corrosion of the bearings 21 and 22. .

(Modification 2)
It is also possible to adopt the following configuration as the stator 50 using the inter-conductor member satisfying the relationship of the above-mentioned formula (1). In FIG. 29, on the outer peripheral surface side (upper surface side in the drawing) of the stator core 52, a toothed portion 143 is provided as an inter-conductor member. The toothed portions 143 are provided at predetermined intervals in the circumferential direction so as to protrude from the yoke 141, and have the same thickness dimension as the wire group 81 in the radial direction. The side surfaces of the teeth 143 are in contact with the leads 82 of the lead group 81. However, there may be a gap between the teeth 143 and the wires 82.

The toothed portion 143 is limited in width in the circumferential direction, and is provided with pole teeth (stator teeth) which are undesirably thin with respect to the amount of magnet. With such a configuration, the toothed portion 143 is surely saturated by the magnetic flux of the magnet at 1.8 T or more, and the inductance can be reduced by the reduction of the permeance.

Here, in the magnet unit 42, assuming that the surface area per pole of the magnetic flux acting surface on the stator side is Sm and the residual flux density of the magnet unit 42 is Br, the magnetic flux on the magnet unit side is, for example, “Sm × Br”. Become. Further, the surface area on the rotor side in each toothed portion 143 is St, the number per phase of the conducting wire 82 is m, and by energizing the stator winding 51, the toothed portions 143 for two phases in one pole are excited If so, the magnetic flux on the stator side is, for example, “St × m × 2 × Bs”. in this case,
St × m × 2 × Bs <Sm × Br (2)
The inductance is reduced by limiting the dimension of the toothed portion 143 so that the following relationship is established.

When the dimensions in the axial direction of the magnet unit 42 and that of the toothed portion 143 are the same, the circumferential width of one pole of the magnet unit 42 is Wm, and the width of the toothed portion 143 in the circumferential direction is Wst. Then, the equation (2) is replaced by the equation (3).
Wst × m × 2 × Bs <Wm × Br (3)
More specifically, assuming that, for example, Bs = 2T and Br = 1T, and m = 2, the above equation (3) has a relationship of “Wst <Wm / 8”. In this case, by setting the width dimension Wst of the toothed portion 143 smaller than 1/8 of the width dimension Wm of one pole of the magnet unit 42, the inductance is reduced. If the number m is 1, then the width dimension Wst of the toothed portion 143 may be smaller than 1⁄4 of the width dimension Wm of one pole of the magnet unit 42.

In the above equation (3), “Wst × m × 2” is the width dimension in the circumferential direction of the toothed portion 143 excited by energization of the stator winding 51 in the range of one pole of the magnet unit 42. Equivalent to.

In the configuration of FIG. 29, as in the configurations of FIG. 27 and FIG. 28 described above, the inter-conductor member (tooth portion 143) which is undesirably small with respect to the magnet magnetic flux on the rotor 40 side. In such a configuration, the inductance of the stator 50 can be reduced, and the generation of magnetic flux distortion due to the shift in the switching timing of the stator winding 51 is suppressed, which in turn suppresses the electrolytic corrosion of the bearings 21 and 22. .

(Modification 3)
In the above embodiment, the sealing member 57 covering the stator winding 51 is in a range including all the wire groups 81 at the radial outer side of the stator core 52, that is, the thickness dimension in the radial direction is the diameter of each wire group 81 Although provided in the range which becomes larger than the thickness dimension of the direction, this may be changed. For example, as shown in FIG. 30, the sealing member 57 is provided so that a part of the conducting wire 82 protrudes. More specifically, the sealing member 57 is provided in a state in which a part of the conducting wire 82 which is the most radially outward in the conducting wire group 81 is exposed radially outward, that is, the stator 50 side. In this case, the radial thickness dimension of the sealing member 57 may be the same as or smaller than the radial thickness dimension of each wire group 81.

(Modification 4)
As shown in FIG. 31, in the stator 50, each wire group 81 may not be sealed by the sealing member 57. That is, the sealing member 57 covering the stator winding 51 is not used. In this case, no inter-conductor member is provided between the wire groups 81 aligned in the circumferential direction, and there is a gap. In short, the inter-conductor member is not provided between the conductor groups 81 aligned in the circumferential direction. Note that air may be regarded as a nonmagnetic substance or a nonmagnetic substance equivalent as Bs = 0, and the air may be disposed in this air gap.

(Modification 5)
When the inter-lead member in the stator 50 is made of a nonmagnetic material, it is possible to use a material other than resin as the nonmagnetic material. For example, a metallic nonmagnetic material may be used such as using SUS304 which is an austenitic stainless steel.

(Modification 6)
The stator 50 may not have the stator core 52. In this case, the stator 50 is configured by the stator winding 51 shown in FIG. In the stator 50 not having the stator core 52, the stator winding 51 may be sealed with a sealing material. Alternatively, instead of the stator core 52 made of a soft magnetic material, the stator 50 may be configured to include an annular winding holding portion (base member) made of a nonmagnetic material such as a synthetic resin.

(Modification 7)
In the first embodiment, although the plurality of magnets 91 and 92 arranged in the circumferential direction are used as the magnet unit 42 of the rotor 40, this is changed to an annular permanent magnet as the magnet unit 42. It is good also as composition using a magnet. Specifically, as shown in FIG. 32, an annular magnet 95 is fixed to the inside in the radial direction of the cylindrical portion 43 of the magnet holder 41. The annular magnet 95 is provided with a plurality of magnetic poles of alternating polarity in the circumferential direction, and a magnet is integrally formed on both the d axis and the q axis. In the annular magnet 95, an arc-shaped magnet magnetic path is formed such that the direction of orientation in the d axis of each magnetic pole is radial and the direction of orientation in the q axis between the magnetic poles is circumferential.

In the ring magnet 95, the easy magnetization axis is parallel to the d axis or near parallel to the d axis in the part near the d axis, and in the part near the q axis, the easy magnetization axis is orthogonal to the q axis or q It suffices that the orientation is performed so as to form an arc-shaped magnet magnetic path having a direction close to orthogonal.

(Modification 8)
In this modification, a part of the control method of the control device 110 is changed. In this modification, differences from the configuration described in the first embodiment will be mainly described.

First, with reference to FIG. 33, processing in the operation signal generation units 116 and 126 shown in FIG. 20 and the operation signal generation units 130a and 130b shown in FIG. 21 will be described. The processes in the operation signal generation units 116, 126, 130a, and 130b are basically the same. Therefore, in the following, the process of the operation signal generation unit 116 will be described as an example.

The operation signal generation unit 116 includes a carrier generation unit 116 a and U, V, W phase comparators 116 b U, 116 b V, and 116 b W. In the present embodiment, the carrier generation unit 116 a generates and outputs a triangular wave signal as the carrier signal SigC.

Carrier signal SigC generated by carrier generation unit 116a and U, V, W-phase command voltage calculated by three-phase conversion unit 115 are input to U, V, W-phase comparators 116bU, 116bV, 116bW. Ru. The U, V, and W phase command voltages are, for example, sinusoidal waveforms, and their phases are shifted by 120 ° in electrical angle.

U, V, W phase comparators 116bU, 116bV, 116bW are controlled by the PWM (pulse width modulation) control based on the magnitude comparison between the U, V, W phase command voltages and the carrier signal SigC. An operation signal of each switch Sp, Sn of the upper arm and the lower arm of the H, V, W phases is generated. Specifically, the operation signal generation unit 116 performs U, V, and W phases by PWM control based on magnitude comparison between a signal obtained by standardizing the U, V, and W phase command voltages with the power supply voltage, and a carrier signal. An operation signal of the switches Sp and Sn is generated. The driver 117 turns on / off the switches Sp and Sn of the U, V, and W phases in the first inverter 101 based on the operation signal generated by the operation signal generation unit 116.

The control device 110 performs processing of changing the carrier frequency fc of the carrier signal SigC, that is, the switching frequency of each switch Sp and Sn. The carrier frequency fc is set high in the low torque region or high rotation region of the rotary electric machine 10 and is set low in the high torque region of the rotary electric machine 10. This setting is made to suppress a decrease in controllability of the current flowing in each phase winding.

That is, as the stator 50 is made coreless, the inductance in the stator 50 can be reduced. Here, when the inductance decreases, the electrical time constant of the rotary electric machine 10 decreases. As a result, the ripples of the current flowing in each phase winding increase, the controllability of the current flowing in the winding decreases, and there is a concern that current control may diverge. The influence of the decrease in controllability may be significant when the current (e.g., the effective value of the current) flowing through the winding is included in the low current region as compared to when included in the high current region. In order to cope with this problem, in the present modification, control device 110 changes carrier frequency fc.

The process of changing the carrier frequency fc will be described with reference to FIG. This process is repeatedly performed by the control device 110, for example, in a predetermined control cycle, as the process of the operation signal generation unit 116.

In step S10, it is determined whether the current flowing through the winding 51a of each phase is included in the low current region. This process is a process for determining that the current torque of the rotary electric machine 10 is in the low torque region. As a method of determining whether or not included in the low current region, for example, the following first and second methods may be mentioned.

<First method>
Based on the d-axis current and the q-axis current converted by the dq conversion unit 112, a torque estimated value of the rotary electric machine 10 is calculated. Then, if it is determined that the calculated torque estimated value is less than the torque threshold, it is determined that the current flowing through the winding 51a is included in the low current region, and it is determined that the torque estimated value is equal to or greater than the torque threshold. , And determined to be included in the high current region. Here, the torque threshold may be set to, for example, one half of the starting torque (also referred to as restraining torque) of the rotary electric machine 10.

<Second method>
If it is determined that the rotation angle of the rotor 40 detected by the angle detector is equal to or greater than the speed threshold, it is determined that the current flowing through the winding 51a is included in the low current region, that is, the high rotation region. Here, the speed threshold may be set to, for example, a rotational speed when the maximum torque of the rotary electric machine 10 is the torque threshold.

When negative determination is carried out in step S10, it determines with it being a high electric current area | region, and progresses to step S11. In step S11, the carrier frequency fc is set to the first frequency fL.

When an affirmative determination is made in step S10, the process proceeds to step S12, and the carrier frequency fc is set to a second frequency fH higher than the first frequency fL.

According to this modification described above, the carrier frequency fc is set higher in the case where the current flowing in each phase winding is included in the low current region than in the case where the current is included in the high current region. Therefore, in the low current region, the switching frequency of the switches Sp and Sn can be increased, and an increase in current ripple can be suppressed. Thereby, the decrease in current controllability can be suppressed.

On the other hand, when the current flowing in each phase winding is included in the high current region, the carrier frequency fc is set lower than that in the low current region. In the high current region, since the amplitude of the current flowing through the winding is larger than that in the low current region, the increase in current ripple due to the decrease in inductance has little influence on the current controllability. Therefore, in the high current region, the carrier frequency fc can be set lower than in the low current region, and the switching loss of each of the inverters 101 and 102 can be reduced.

In this modification, implementation of the form shown below is possible.

· When the carrier frequency fc is set to the first frequency fL, the carrier frequency fc is gradually changed from the first frequency fL to the second frequency fH when an affirmative determination is made in step S10 of FIG. It is also good.

When the carrier frequency fc is set to the second frequency fH, the carrier frequency fc may be gradually changed from the second frequency fH to the first frequency fL when the negative determination is made in step S10. .

-Instead of PWM control, operation signal of the switch may be generated by space vector modulation (SVM) control. Even in this case, the change of the switching frequency described above can be applied.

(Modification 9)
In each of the above-described embodiments, two pairs of conductors in each phase of the conductor group 81 are connected in parallel as shown in FIG. FIG. 35 (a) is a diagram showing an electrical connection of first and second conductors 88a and 88b which are two pairs of conductors. Here, instead of the configuration shown in FIG. 35 (a), as shown in FIG. 35 (b), the first and second conducting wires 88a and 88b may be connected in series.

Also, three or more pairs of multi-layered conducting wires may be stacked in the radial direction. FIG. 36 shows a configuration in which four pairs of first to fourth conducting wires 88a to 88d are stacked. The first to fourth conducting wires 88a to 88d are arranged in the radial direction of the first, second, third, and fourth conducting wires 88a, 88b, 88c, 88d in this order from the side closer to the stator core 52. .

Here, as shown in FIG. 35 (c), the third and fourth conducting wires 88c and 88d are connected in parallel, and the first conducting wire 88a is connected to one end of the parallel connection body, and the second conducting wire is connected to the other end. 88b may be connected. The parallel connection can reduce the current density of the parallel connected leads, and can suppress the heat generation at the time of energization. Therefore, in the configuration in which the cylindrical stator winding is assembled to the housing (unit base 61) in which the cooling water passage 74 is formed, the first and second conducting wires 88a and 88b not connected in parallel abut on the unit base 61 The third and fourth conducting wires 88c and 88d disposed on the stator core 52 side and connected in parallel are disposed on the side opposite to the stator core. This makes it possible to equalize the cooling performance of each of the conductors 88a to 88d in the multilayer conductor structure.

The thickness dimension in the radial direction of the conductor group 81 including the first to fourth conductors 88a to 88d may be smaller than the width dimension in the circumferential direction of one phase in one magnetic pole.

(Modification 10)
The rotary electric machine 10 may have an inner rotor structure (inner structure). In this case, for example, in the housing 30, the stator 50 may be provided radially outside, and the rotor 40 may be provided radially inside. In addition, it is preferable that the inverter unit 60 be provided on one side or both sides of both axial ends of the stator 50 and the rotor 40. FIG. 37 is a cross-sectional view of the rotor 40 and the stator 50, and FIG. 38 is an enlarged view of a part of the rotor 40 and the stator 50 shown in FIG.

37 and 38 premised on the inner rotor structure is that the rotor 40 and the stator 50 are reversed in the radial direction inside and outside with respect to the configurations shown in FIGS. 8 and 9 premised on the outer rotor structure. Except for the same configuration. Briefly described, the stator 50 has a stator winding 51 of flat wire structure and a stator core 52 without teeth. The stator winding 51 is assembled on the radially inner side of the stator core 52. The stator core 52 has one of the following configurations, as in the case of the outer rotor structure.
(A) In the stator 50, an inter-conductor member is provided between the conductor portions in the circumferential direction, and as the inter-conductor member, the circumferential width dimension of the conductor member in one magnetic pole is Wt, saturation of the conductor members Assuming that the magnetic flux density is Bs, the circumferential width dimension of the magnet unit in one magnetic pole is Wm, and the residual magnetic flux density of the magnet unit is Br, a magnetic material having a relationship of Wt × Bs ≦ Wm × Br is used.
(B) In the stator 50, an inter-conductor member is provided between the conductor portions in the circumferential direction, and a nonmagnetic material is used as the inter-conductor member.
(C) In the stator 50, no inter-conductor member is provided between the conductor portions in the circumferential direction.

The same applies to the magnets 91 and 92 of the magnet unit 42. That is, in the magnet unit 42, the magnets 91 and 92 are oriented such that the direction of the magnetization easy axis is parallel to the d axis on the d axis side, which is the magnetic pole center, as compared to the q axis side that is the magnetic pole boundary. It is configured using The details of the magnetization direction and the like in each of the magnets 91 and 92 are as described above. It is also possible to use an annular magnet 95 (see FIG. 32) in the magnet unit 42.

FIG. 39 is a longitudinal sectional view of the rotary electric machine 10 in the case of the inner rotor type, which corresponds to FIG. 2 described above. The differences from the configuration of FIG. 2 will be briefly described. In FIG. 39, an annular stator 50 is fixed inside the housing 30, and a rotor 40 is rotatably provided inside the stator 50 with a predetermined air gap interposed therebetween. Similarly to FIG. 2, each of the bearings 21 and 22 is disposed on one side in the axial direction with respect to the axial center of the rotor 40, whereby the rotor 40 is supported in a cantilever manner. There is. Further, an inverter unit 60 is provided inside the magnet holder 41 of the rotor 40.

FIG. 40 shows another configuration as the rotary electric machine 10 having an inner rotor structure. In FIG. 40, the rotating shaft 11 is rotatably supported by the bearings 21 and 22 in the housing 30, and the rotor 40 is fixed to the rotating shaft 11. As in the configuration shown in FIG. 2 and the like, the bearings 21 and 22 are disposed offset to one side in the axial direction with respect to the axial center of the rotor 40. The rotor 40 has a magnet holder 41 and a magnet unit 42.

The rotary electric machine 10 of FIG. 40 is different from the rotary electric machine 10 of FIG. 39 in that the inverter unit 60 is not provided inside the rotor 40 in the radial direction. The magnet holder 41 is connected to the rotating shaft 11 at a position that is radially inward of the magnet unit 42. The stator 50 also has a stator winding 51 and a stator core 52 and is attached to the housing 30.

(Modification 11)
Another configuration will be described below as a rotating electric machine having an inner rotor structure. FIG. 41 is an exploded perspective view of the rotary electric machine 200, and FIG. 42 is a side cross-sectional view of the rotary electric machine 200. Here, the vertical direction is shown based on the states of FIGS. 41 and 42.

As shown in FIGS. 41 and 42, the rotary electric machine 200 is rotatably disposed inside the stator core 201 and a stator 203 having an annular stator core 201 and multiphase stator windings 202. And a rotor 204. The stator 203 corresponds to an armature, and the rotor 204 corresponds to a field element. The stator core 201 is configured by laminating a large number of silicon steel plates, and the stator winding 202 is attached to the stator core 201. Although illustration is omitted, the rotor 204 has a rotor core and a plurality of permanent magnets as a magnet unit. The rotor core is provided with a plurality of magnet insertion holes at equal intervals in the circumferential direction. In each of the magnet insertion holes, permanent magnets magnetized so as to alternately change the magnetization direction for each adjacent magnetic pole are attached. The permanent magnets of the magnet unit may have a Halbach arrangement as described with reference to FIG. 25 or a similar configuration. Alternatively, the permanent magnet of the magnet unit is a pole whose orientation direction (magnetization direction) extends in an arc between the d axis which is the pole center and the q axis which is the pole boundary as described in FIG. 9 and FIG. It is preferable to have anisotropic characteristics.

Here, the stator 203 may have any one of the following configurations.
(A) In the stator 203, an inter-conductor member is provided between the conductor portions in the circumferential direction, and as the inter-conductor member, the circumferential width dimension of the conductor member in one magnetic pole is Wt, saturation of the conductor members Assuming that the magnetic flux density is Bs, the circumferential width dimension of the magnet unit in one magnetic pole is Wm, and the residual magnetic flux density of the magnet unit is Br, a magnetic material having a relationship of Wt × Bs ≦ Wm × Br is used.
(B) In the stator 203, an inter-conductor member is provided between the conductor portions in the circumferential direction, and a nonmagnetic material is used as the inter-conductor member.
(C) In the stator 203, an inter-conductor member is not provided between the conductor portions in the circumferential direction.

Further, in the rotor 204, the magnet unit is oriented such that the direction of the magnetization easy axis is parallel to the d axis on the d axis side, which is the pole center, as compared to the q axis side, which is the pole boundary. It is configured using a plurality of magnets.

An annular inverter case 211 is provided on one end side in the axial direction of the rotary electric machine 200. The inverter case 211 is arranged such that the lower surface of the case is in contact with the upper surface of the stator core 201. In the inverter case 211, a plurality of power modules 212 constituting an inverter circuit, a smoothing capacitor 213 for suppressing ripples of voltage and current generated by switching operation of the semiconductor switching element, and a control board 214 having a control unit , A current sensor 215 for detecting a phase current, and a resolver stator 216 which is a rotational speed sensor of the rotor 204. The power module 212 has an IGBT or a diode which is a semiconductor switching element.

At the periphery of the inverter case 211, a power connector 217 connected to a DC circuit of a battery mounted on a vehicle, and a signal connector 218 used for delivery of various signals between the rotating electric machine 200 side and the vehicle side control device Is provided. The inverter case 211 is covered by a top cover 219. The direct current power from the on-vehicle battery is inputted through the power connector 217, converted into alternating current by switching of the power module 212, and sent to the stator winding 202 of each phase.

A bearing unit 221 rotatably holding the rotation shaft of the rotor 204 and an annular rear case 222 accommodating the bearing unit 221 are provided on the opposite side of the axial direction of the stator core 201 on the opposite side of the inverter case 211. It is provided. The bearing unit 221 has, for example, a pair of bearings, and is disposed so as to be biased to one side in the axial direction with respect to the axial center of the rotor 204. However, a plurality of bearings in the bearing unit 221 may be dispersedly provided on both sides in the axial direction of the stator core 201, and the rotary shaft may be supported on both sides by the respective bearings. The rotating electrical machine 200 is mounted on the vehicle side by fixing the rear case 222 to a mounting portion such as a gear case or a transmission of the vehicle.

In the inverter case 211, a cooling channel 211a for flowing the refrigerant is formed. The cooling flow passage 211 a is formed by closing the space recessed in an annular shape from the lower surface of the inverter case 211 with the upper surface of the stator core 201. The cooling channel 211 a is formed to surround the coil end of the stator winding 202. A module case 212a of the power module 212 is inserted into the cooling flow passage 211a. A cooling channel 222 a is formed in the rear case 222 so as to surround the coil end of the stator winding 202. The cooling flow path 222 a is formed by closing a space, which is recessed annularly from the upper surface of the rear case 222, with the lower surface of the stator core 201.

(Modification 12)
So far, the configuration embodied in the rotating field type rotating electrical machine has been described, but it is also possible to change this and to embody the rotating armature type rotating electrical machine. FIG. 43 shows the configuration of a rotary armature type rotary electric machine 230. As shown in FIG.

In the rotary electric machine 230 of FIG. 43, bearings 232 are fixed to the housings 231a and 231b, respectively, and the rotary shaft 233 is rotatably supported by the bearings 232. The bearing 232 is, for example, an oil-impregnated bearing formed by including oil in a porous metal. A rotor 234 as an armature is fixed to the rotating shaft 233. The rotor 234 has a rotor core 235 and a polyphase rotor winding 236 fixed to the outer periphery thereof. In the rotor 234, the rotor core 235 has a slotless structure, and the rotor winding 236 has a flat wire structure. That is, the rotor winding 236 has a flat structure in which the region for each phase is longer in the circumferential direction than in the radial direction.

In addition, a stator 237 as a field element is provided radially outside the rotor 234. The stator 237 has a stator core 238 fixed to the housing 231 a and a magnet unit 239 fixed to the inner peripheral side of the stator core 238. The magnet unit 239 is configured to include a plurality of magnetic poles of alternating polarity in the circumferential direction, and the pole boundary q on the d axis side, which is the center of the magnetic pole, as in the magnet unit 42 described above. It is configured to be oriented such that the direction of the magnetization easy axis is parallel to the d axis as compared to the side of the axis. The magnet unit 239 has a sintered neodymium magnet oriented, and has an intrinsic coercive force of 400 kA / m or more and a residual magnetic flux density of 1.0 T or more.

The rotating electrical machine 230 of this example is a coreless motor with a brush of 2 poles and 3 coils, the rotor winding 236 is divided into three, and the magnet unit 239 is 2 poles. The number of poles and the number of coils of the brushed motor vary depending on the application, such as 2: 3, 4:10, 4:21.

A commutator 241 is fixed to the rotation shaft 233, and a plurality of brushes 242 are disposed radially outside thereof. The commutator 241 is electrically connected to the rotor winding 236 via the lead wire 243 embedded in the rotating shaft 233. The inflow and outflow of DC current to and from the rotor winding 236 are performed through the commutator 241, the brush 242, and the lead wire 243. The commutator 241 is appropriately divided in the circumferential direction according to the number of phases of the rotor winding 236. The brush 242 may be connected as it is to a DC power supply such as a storage battery via an electrical wiring, or may be connected to a DC power supply via a terminal block or the like.

The rotating shaft 233 is provided with a resin washer 244 as a sealing material between the bearing 232 and the commutator 241. The resin washer 244 prevents the oil that has leaked out from the bearing 232, which is an oil-impregnated bearing, from flowing out to the commutator 241 side.

(Modification 13)
In the stator winding 51 of the rotary electric machine 10, each lead 82 may be configured to have a plurality of insulating coatings on the inside and the outside. For example, a plurality of conductive wires (wires) with an insulating coating may be bundled into one and covered with an outer layer coating to constitute the conductive wire 82. In this case, the insulation coating of the strands constitutes the inner insulation coating, and the outer coating constitutes the outer insulation coating. Furthermore, in particular, it is preferable that the insulation ability of the outer insulation film among the plurality of insulation films in the conducting wire 82 be higher than that of the inner insulation film. Specifically, the thickness of the outer insulating film is made thicker than the thickness of the inner insulating film. For example, the thickness of the outer insulating film is 100 μm, and the thickness of the inner insulating film is 40 μm. Alternatively, a material having a dielectric constant lower than that of the inner insulating film may be used as the outer insulating film. At least one of these may be applied. In addition, it is good for a wire to be comprised as an aggregate | assembly of several electroconductive materials.

As described above, by strengthening the insulation of the outermost layer of the conducting wire 82, it is suitable for use in a high voltage vehicle system. Further, even in a high altitude where the air pressure is low, etc., it is possible to properly drive the rotary electric machine 10.

(Modification 14)
In the conducting wire 82 having a plurality of insulating coatings on the inside and outside, at least one of the coefficient of linear expansion (coefficient of linear expansion) and the bonding strength may be different between the outer insulating coating and the inner insulating coating. The structure of the conducting wire 82 in this modification is shown in FIG.

In FIG. 44, the conducting wire 82 includes a plurality of (four in the drawing) strands 181, an outer layer coating 182 (outer insulating coating) made of resin, for example, surrounding the plurality of strands 181, and each element in the outer layer coating 182. And an intermediate layer 183 (intermediate insulating film) filled around the line 181. The strands of wire 181 have a conductive portion 181a made of a copper material and a conductive film 181b (inner insulating film) made of an insulating material. When viewed as a stator winding, the outer layer coating 182 insulates the phases. In addition, it is good for the strand 181 to be comprised as an aggregate | assembly of several electroconductive materials.

The intermediate layer 183 has a coefficient of linear expansion higher than that of the conductor film 181 b of the wire 181 and has a coefficient of linear expansion lower than that of the outer film 182. That is, in the conducting wire 82, the linear expansion coefficient is higher toward the outside. Generally, the outer layer film 182 has a linear expansion coefficient higher than that of the conductor film 181b, but the intermediate layer 183 functions as a cushioning material by providing an intermediate layer 183 having an intermediate linear expansion coefficient therebetween. It is possible to prevent simultaneous cracking on the outer layer side and the inner layer side.

In the conducting wire 82, the conductive portion 181a and the conductor coating 181b are adhered to each other in the strand 181, and the conductor coating 181b and the intermediate layer 183, and the intermediate layer 183 and the outer layer coating 182 are adhered to each other. Then, the bonding strength is weaker toward the outside of the conducting wire 82. That is, the adhesive strength of the conductive portion 181 a and the conductive film 181 b is weaker than the adhesive strength of the conductive film 181 b and the intermediate layer 183 and the adhesive strength of the intermediate layer 183 and the outer film 182. Further, comparing the adhesive strength of the conductor film 181 b and the intermediate layer 183 with the adhesive strength of the intermediate layer 183 and the outer layer film 182, it is preferable that the latter (outer side) is weaker or equal. In addition, the magnitude | size of the adhesive strength of each film can be grasped | ascertained by the tensile strength etc. which are required, for example, when peeling off the film of 2 layers. By setting the adhesive strength of the conducting wire 82 as described above, it is possible to suppress the occurrence of cracking (co-cracking) on both the inner layer side and the outer layer side even if a temperature difference between the inside and the outside occurs due to heat generation or cooling. .

Here, the heat generation and temperature change of the rotary electric machine occur mainly as a copper loss generated from the conductive portion 181a of the wire 181 and an iron loss generated from the inside of the iron core. In the intermediate layer 183, there is no heat generation source. In this case, the simultaneous cracking can be prevented by the adhesive force that the intermediate layer 183 can serve as a cushion for both. Therefore, suitable use is possible also when used in fields with high withstand voltage or large temperature change, such as vehicle applications.

The following supplements. The wire 181 may be, for example, an enameled wire, and in such a case, has a resin film layer (conductor film 181b) such as PA, PI, PAI or the like. Further, it is desirable that the outer layer film 182 outside the strands of wire 181 be made of the same PA, PI, PAI or the like and be thick. Thereby, the destruction of the film due to the difference in linear expansion coefficient can be suppressed. The outer layer film 182 has a dielectric constant such as PPS, PEEK, fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, LCP, etc., apart from those corresponding to the above-mentioned materials such as PA, PI, PAI, etc. by thickening. Using smaller ones than PI and PAI is also desirable to increase the conductor density of the rotating machine. With these resins, even if they are thinner than the PI, PAI coatings equivalent to the conductor coating 181b, or have a thickness equivalent to that of the conductor coating 181b, their insulating ability can be increased, and thereby the occupancy of the conductive portion It is possible to raise In general, the above-mentioned resin has a better insulation than the insulation coating of enameled wire. Naturally, there are also cases where the dielectric constant is deteriorated by the molding condition or the mixture. Among them, PPS and PEEK are suitable as the outer layer coating of the second layer because their linear expansion coefficient is generally larger than that of the enamel coating but smaller than that of other resins.

In addition, the adhesion strength between the two types of coatings (intermediate insulating coating and outer insulating coating) on the outside of the wire 181 and the enamel coating of the wire 181 is the adhesion strength between the copper wire and the enamel coating on the wire 181 It is desirable to be weaker than This suppresses the phenomenon that the enamel coating and the two types of coatings are destroyed at one time.

In the case where a water-cooled structure, a liquid-cooled structure, and an air-cooled structure are added to the stator, basically, it is considered that thermal stress or impact stress is applied first from the outer layer film 182. However, even in the case where the insulating layer of the strand 181 and the two types of films are different from each other, the thermal stress and the impact stress can be reduced by providing a portion where the films are not adhered. That is, the insulation structure is achieved by providing a wire (enamel wire) and an air gap and arranging fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, and LCP. In this case, it is desirable to bond the outer layer coating and the inner layer coating using an adhesive having a low dielectric constant and a low linear expansion coefficient, such as epoxy. In this way, it is possible to suppress not only the mechanical strength but also the breakage of the coating due to friction due to the vibration of the conductive part or the like, or the breakage of the outer layer coating due to the difference in linear expansion coefficient.

The outermost layer fixing, which is generally the final step around the stator winding, responsible for mechanical strength, fixing, etc., to the lead wire 82 of the above configuration, and the formability of epoxy, PPS, PEEK, LCP, etc. It is preferable to use a resin having properties close to that of the enamel coating, such as dielectric constant and linear expansion coefficient.

In general, resin potting by urethane or silicon is usually performed, but in the resin, the linear expansion coefficient is nearly doubled compared with other resins, and a thermal stress which can shear the resin is generated. Therefore, it is unsuitable for the use of 60V or more where strict insulation regulations are used internationally. In this respect, according to the final insulation process which is easily produced by injection molding or the like by epoxy, PPS, PEEK, LCP or the like, it is possible to achieve the above-mentioned respective requirements.

Modifications other than the above are listed below.

The distance DM in the radial direction between the surface on the armature side in the radial direction of the magnet unit 42 and the axial center of the rotor may be 50 mm or more. Specifically, for example, in the radial direction between the radially inner surface of the magnet unit 42 (specifically, the first and second magnets 91 and 92) shown in FIG. 4 and the axial center of the rotor 40, for example The distance DM may be 50 mm or more.

As a rotary electric machine of a slotless structure, the small-scale thing whose output is used for models for dozens of watts to hundreds of watts is known. And, the person who discloses the present invention does not grasp the case where the slotless structure is generally adopted for an industrial large-sized electric rotating machine which exceeds 10 kW. The applicant of the present application examined the reason.

In recent years, the mainstream electric rotating machines are roughly classified into the following four types. The rotary electric machines are a brushed motor, a cage type induction motor, a permanent magnet synchronous motor and a reluctance motor.

An excitation current is supplied to the brushed motor via the brush. Therefore, in the case of a large-sized brushed motor, the size of the brush may be increased, and maintenance may be complicated. As a result, with the remarkable development of semiconductor technology, there is a history of being replaced by a brushless motor such as an induction motor. On the other hand, in the small motor world, coreless motors are also supplied to many people because of the advantages of low inertia and economy.

In the cage type induction motor, the magnetic field generated by the stator winding on the primary side is received by the iron core of the rotor on the secondary side, and the induction current is flowed intensively to the cage conductor to form a reaction magnetic field. The principle is to generate torque. For this reason, it is not always a good idea to eliminate the iron core on both the stator side and the rotor side from the viewpoint of the small size and high efficiency of the device.

The reluctance motor is a motor that takes advantage of the reluctance change of the iron core, and in principle it is not desirable to eliminate the iron core.

In permanent magnet type synchronous motors, IPMs (that is, embedded magnet type rotors) have been mainstream in recent years, and particularly in large machines, they are often IPMs unless there is special circumstances.

The IPM has a characteristic having both a magnet torque and a reluctance torque, and is operated while the ratio of the torque is adjusted appropriately by the inverter control. For this reason, the IPM is a small motor with excellent controllability.

According to the analysis of the present applicant, the torque of the rotor surface which generates the magnet torque and the reluctance torque is the radial distance DM between the surface on the armature side in the radial direction of the magnet unit and the shaft center of the rotor, When the radius of the stator core of a general inner rotor is drawn on the horizontal axis, it becomes as shown in FIG.

The magnet torque is determined by the magnetic field strength generated by the permanent magnet as shown in the following equation (eq1), while the reluctance torque is an inductance, in particular q, as shown in the following equation (eq2). The magnitude of the axial inductance determines its potential.

Magnet torque = k · Ψ · Iq ·············· (eq 1)
Reluctance torque = k · (Lq−Ld) · Iq · Id ······ (eq 2)
Here, DM was used to compare the magnetic field strength of the permanent magnet and the magnitude of the inductance of the winding. The magnetic field strength emitted by the permanent magnet, that is, the amount of magnetic flux Ψ, is proportional to the total area of the permanent magnet on the surface facing the stator. If it is a cylindrical rotor, it will become the surface area of a cylinder. Strictly speaking, since the north pole and the south pole are present, they are proportional to the occupied area of half of the cylindrical surface. The surface area of the cylinder is proportional to the radius of the cylinder and the length of the cylinder. That is, if the cylinder length is constant, it is proportional to the radius of the cylinder.

On the other hand, although the inductance Lq of the winding is dependent on the core shape, the sensitivity is low, and rather, it is proportional to the square of the number of turns of the stator winding, so the number of turns is highly dependent. When μ is the magnetic permeability of the magnetic circuit, N is the number of turns, S is the cross-sectional area of the magnetic circuit, and δ is the effective length of the magnetic circuit, the inductance L = μ · N ^ 2 × S / δ. Since the number of turns of the winding depends on the size of the winding space, in the case of a cylindrical motor, it depends on the winding space of the stator, that is, the slot area. As shown in FIG. 46, the slot area is proportional to the product a × b of the circumferential length dimension a and the radial length dimension b, since the shape of the slot is substantially square.

The circumferential length dimension of the slot is proportional to the diameter of the cylinder, as it increases as the diameter of the cylinder increases. The radial dimension of the slot is proportional to the diameter of the cylinder. That is, the slot area is proportional to the square of the diameter of the cylinder. Also, as can be seen from the above equation (eq2), since the reluctance torque is proportional to the square of the stator current, the performance of the rotating electrical machine is determined by how large a current can flow, the performance being the slot area of the stator Dependent. From the above, if the length of the cylinder is constant, the reluctance torque is proportional to the square of the diameter of the cylinder. Based on this, FIG. 45 is a diagram in which the relationship between the magnet torque and the reluctance torque and DM is plotted.

As shown in FIG. 45, the magnet torque increases linearly with DM, and the reluctance torque increases quadratically with DM. It can be seen that the magnet torque is dominant when DM is relatively small, and the reluctance torque is dominant as the stator core radius increases. The applicant of the present application has concluded that the intersection point of the magnet torque and the reluctance torque in FIG. 45 is approximately in the vicinity of the stator core radius = 50 mm under predetermined conditions. In other words, with motors of 10 kW class where the stator core radius sufficiently exceeds 50 mm, it is difficult to eliminate the iron core because it is the current mainstream to utilize reluctance torque, which is a problem in the field of large machines It is presumed to be one of the reasons why the slotless structure is not adopted.

In the case of a rotating electrical machine in which an iron core is used for the stator, magnetic saturation of the iron core is always a problem. In particular, in the radial gap type rotating electrical machine, the longitudinal cross-sectional shape of the rotating shaft is fan-shaped per magnetic pole, and the width of the magnetic path narrows toward the device inner circumferential side, and the inner circumferential dimension of the teeth forming the slot is the performance of the rotating electrical machine Determine the limit. No matter how high performance permanent magnets are used, if magnetic saturation occurs in this part, the performance of the permanent magnets can not be fully utilized. In order not to generate magnetic saturation in this portion, the inner diameter is designed to be large, and as a result, the size of the device is increased.

For example, in a distributed winding rotating electric machine, in the case of a three-phase winding, three to six teeth per magnetic pole share magnetic flux, but magnetic flux tends to concentrate on teeth in the circumferential direction. The magnetic flux does not flow evenly to three to six teeth. In this case, while the magnetic flux flows intensively to some (for example, one or two) teeth, the teeth that are magnetically saturated along with the rotation of the rotor also move in the circumferential direction. This also causes slot ripple.

From the above, it is desirable to eliminate teeth in order to eliminate magnetic saturation in a slotless rotary electric machine in which DM is 50 mm or more. However, if the teeth are abolished, the reluctance of the magnetic circuit in the rotor and the stator increases, and the torque of the rotating electrical machine decreases. The reason for the increase in reluctance is, for example, an increase in the air gap between the rotor and the stator. For this reason, there is room for improvement in increasing torque in a slotless structure rotary electric machine in which the above-mentioned DM is 50 mm or more. Therefore, the advantage of applying the configuration that can increase the torque described above is great for a slotless structure rotating electrical machine in which the above-described DM is 50 mm or more.

In addition, not only the rotating electric machine having the outer rotor structure but also the rotating electric machine having the inner rotor structure, the distance DM in the radial direction between the surface on the armature side in the radial direction of the magnet unit and the shaft center of the rotor is 50 mm or more It may be

In the stator winding 51 of the rotary electric machine 10, the linear portion 83 of the conducting wire 82 may be provided in a single layer in the radial direction. Moreover, when arranging the linear part 83 in multiple layers inside and outside in the radial direction, the number of layers may be arbitrary, and three layers, four layers, five layers, six layers or the like may be provided.

For example, in the configuration of FIG. 2, the rotary shaft 11 is provided so as to protrude in both the one end side and the other end side of the rotary electric machine 10 in the axial direction. It is also good. In this case, the rotary shaft 11 may be provided so as to extend axially outward with a portion cantilevered by the bearing unit 20 as an end. In this configuration, since the rotary shaft 11 does not protrude inside the inverter unit 60, the internal space of the inverter unit 60, specifically, the internal space of the cylindrical portion 71 can be used more widely.

In the rotary electric machine 10 configured as described above, non-conductive grease is used in the bearings 21 and 22. However, this may be changed to use conductive grease in the bearings 21 and 22. For example, a conductive grease containing metal particles, carbon particles and the like is used.

-As the structure which supports the rotating shaft 11 rotatably, it is good also as a structure which provides a bearing in two places of the axial direction one end side of the rotor 40, and the other end side. In this case, in the configuration of FIG. 1, bearings may be provided at two positions on one end side and the other end side of the inverter unit 60.

In the rotary electric machine 10 configured as described above, in the rotor 40, the middle portion 45 of the magnet holder 41 has the inner shoulder 49a and the outer shoulder 49b of emotion, but these shoulders 49a and 49b are eliminated and the flat It is good also as composition which has an aspect.

In the rotating electrical machine 10 configured as described above, the conductor 82a is configured as an assembly of a plurality of strands 86 in the conducting wire 82 of the stator winding 51, but this is changed to use a rectangular conducting wire having a rectangular cross section as the conducting wire 82 It is good also as composition. Further, as the conducting wire 82, a round conducting wire having a circular cross section or an elliptical cross section may be used.

In the rotating electrical machine 10 configured as described above, the inverter unit 60 is provided inside the stator 50 in the radial direction, but instead of this, the inverter unit 60 may not be provided inside the stator 50 in the radial direction. . In this case, it is possible to use an inner area which is radially inward of the stator 50 as a space. Moreover, it is possible to arrange components different from the inverter unit 60 in the internal area.

In the rotary electric machine 10 configured as described above, the housing 30 may not be provided. In this case, for example, the rotor 40, the stator 50, and the like may be held at parts of the wheel and other vehicle components.

In the embodiment described above, the conductor 82a of the conductor 82 of the stator winding 51 is configured as an assembly of a plurality of strands 86. However, the conductor 82a may be modified to use a rectangular conductor having a flat cross section as the conductor 82. Good. Alternatively, a round conductive wire having an oval cross section may be used as the conductive wire 82.

In the above embodiment, when the rotary electric machine having the inner rotor structure (inner structure) is applied, as shown in FIG. 47, the outer side surface 1002b as the opposing surface facing the stator core 52 in the outer conducting wire 1002 of the conducting wire 82 May be curved along the curved surface 52a (inner peripheral surface) of the stator core 52 to which the outer side surface 1002b is fixed in the circumferential direction. The rotary electric machine having the inner rotor structure is described in Modifications 10 to 11 (FIGS. 37 to 42), and thus detailed description will be omitted.

In the above embodiment, as shown in FIG. 48, the insulating film 3001 may be provided between the conducting wires 82 of different phases as an interphase insulating film. In this case, the wires 82 of different phases adjacent in the circumferential direction may be in contact with each other with the insulating film 3001 interposed therebetween. Thus, the insulation film 3001 can perform insulation between different phases, and can reduce the gap between the conductors 82 of different phases adjacent in the circumferential direction.

In addition, before deforming each conducting wire 82, the insulating film 3001 is interposed between the conducting wires 82, and in this state, the conducting wire 82 is compressed toward the stator core 52 (or the stator winding 51 is made into the stator core The stator winding 51 as described above can be easily manufactured by press-fitting it into 52). That is, it is possible to easily reduce the gap between the conducting wires 82 while keeping the spacing between the conducting wires 82 in the circumferential direction constant. In particular, the insulating film 3001 is interposed between the conducting wires 82 even if teeth, slotless, etc., are not provided between the conducting wires 82, such as protrusions for positioning the conducting wires 82. By compressing the conducting wires 82 toward the stator core 52 in the state, it is possible to easily reduce the gap between the conducting wires 82 while keeping the interval between the conducting wires 82 in the circumferential direction constant.

In the above embodiment, as shown in FIG. 23, the angular range (θ 1000) from the end to the end in the circumferential direction of the outer lead 1002 around the rotation center is the end to the end in the circumferential direction of the inner lead 1001. The same was true for the angle range. As another example, an end-to-end angle range (θ 1000) in the circumferential direction of the outer lead 1002 around the rotation center is larger than an angle range from the end to the end in the circumferential direction of the inner lead 1001. You may In this case, when the cross-sectional areas of the respective conducting wires 82 are the same, the thickness dimension (R 1002) of the outer conducting wire 1002 may be thinner.

In the above embodiment, as shown in FIG. 49, the thickness R2002 of the outer lead 1002 may be the same as the thickness R2002 of the inner lead 1001. Also, the width L2002 of the outer lead 1002 may be the same as the width L2002 of the inner lead 1001. That is, the width dimensions of the inner side surfaces 1001 a and 1002 a of the inner lead 1001 and the outer lead 1002 may be the same. In addition, the width dimensions of the outer side surfaces 1001b and 1002b of the inner lead 1001 and the outer lead 1002 may be the same. Also, the width dimension of the outer side surface 1001 b of the inner lead 1001 may be longer than the width dimension of the inner side surface 1002 a of the outer lead 1002.

In the embodiment, as shown in FIG. 49, the corners may be rounded in the cross section of each wire 82.

In the embodiment described above, the cross-sectional area of the outer lead wire 1002 in the cross section may be larger than the cross-sectional area of the inner lead wire 1001 in the cross section.

In the above embodiment, each conductor 82 is pressed against the stator core 52 (or a cylindrical member having the same curvature as that of the stator core 52) before bending the conductor 82 to form the stator winding 51. Thus, an arc-shaped curved surface as described above may be provided for each conducting wire 82.

In the above embodiment, the arc-shaped curved surface as described above is provided by deforming the respective conducting wires 82. However, the arc-shaped curved surface as described above is provided to each conducting wire 82 when manufacturing the respective conducting wires 82. It is also good.

In the above embodiment, the conducting wires 82 configured by the strands 86 having the polymer insulating layer may be connected in parallel or in series, but the potential difference between the outsides of the strands 86, particularly between the phases, is It is necessary to increase the insulation capacity at the site of maximum. The strand 86 has a resin coating layer such as PA, PI, PAI or the like generally referred to as an enameled wire. On the other hand, it is desirable that the insulating coating 82b as the outer layer coating that insulates the phases on the outer peripheral side of the strand 86 be thick even if they are similar PA, PI, and PAI. This is to suppress the breakage of the coating due to the difference in linear expansion coefficient. As the insulating film 82b, one having a dielectric constant smaller than that of PI or PAI, such as PPS, PEEK, fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, LCP, separately from the one corresponding to the above-mentioned thick material. Use is also desirable to increase the conductor density of the rotating machine. If it is the above-mentioned resin, even if it is thinner than PI, PAI coating of strand 86, or it is the same thickness as the above-mentioned coating, since the insulation capability can be made high, the occupancy rate of a conductor can be raised. In general, the above-mentioned resin has a better insulation than the insulating layer of enameled wire. Naturally, there are also cases where the dielectric constant is deteriorated by the molding condition or the mixture. Among them, PPS and PEEK are suitable as the insulating coating 82b because their linear expansion coefficients are generally larger than that of the insulating layer of enameled wire but smaller than that of other resins. In this case, it is desirable that the adhesive strength between the two types of resin (insulation film 82b) and the enamel film (the insulation layer of the strands 86) be looser than the adhesion layer between the enamel and the conductor. By doing this, it is possible to suppress the phenomenon that the insulating layer of the strand 86 and the insulating coating 82b are broken at one time. In the water-cooled structure, the liquid-cooled structure, and the air-cooled structure, basically, thermal stress and impact stress are applied sequentially from the insulating coating 82b as the outer layer coating. However, even in the case where the insulating layer of the strand 86 and the insulating coating 82b are different resins, the stress can be reduced by providing a portion to which the coating is not adhered. That is, the insulation structure is made by providing an air gap between the strands 86 and arranging fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, and LCP. In this case, it is desirable to bond the outer coat (insulation coat 82b) and the inner coat (insulation layer of the wire 86) with an adhesive having a low dielectric constant and a low linear expansion coefficient made of epoxy or the like. By doing this, it is possible to suppress not only mechanical strength but also film breakage due to friction due to vibration due to vibration of the conductor or the destruction of the outer film (insulation film 82b) due to difference in linear expansion coefficient. Epoxy, PPS, and the like, which are responsible for mechanical strength, fixation, and the like for the wire 82 having the insulation layer of the strand 86 and the insulation film 82b, generally as the final step around the winding, It is preferable to use a resin such as PEEK or LCP which has good moldability and has properties such as dielectric constant and coefficient of linear expansion close to those of enamel coating. Generally, resin potting with urethane or silicon is commonly used, but in the resin, the coefficient of linear expansion is nearly doubled compared with other resins, and a thermal stress which can shear the resin is generated. Therefore, it is not suitable for applications of 60 V or more where strict insulation regulations are used internationally. In this respect, according to the final insulation process easily made by injection molding or the like by epoxy, PPS, PEEK, LCP or the like, it is possible to achieve the above requirements.

The disclosure in this specification is not limited to the illustrated embodiments. The disclosure includes the illustrated embodiments and variations based on them 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 those in which parts and / or elements of the embodiments have been omitted. The disclosure includes replacements or combinations of parts and / or elements between one embodiment and another embodiment. The disclosed technical scope is not limited to the description of the embodiments. It is to be understood that the technical scopes disclosed herein are indicated by the description of the scope of the claims, and further include all modifications within the meaning and scope equivalent to the descriptions of the scope of the claims.

Although the present disclosure has been described based on the examples, it is understood that the present disclosure is not limited to the examples and structures. The present disclosure also includes various modifications and variations within the equivalent range. In addition, various combinations and forms, and further, other combinations and forms including only one element, or more or less than these elements are also within the scope and the scope of the present disclosure.

Claims (6)

1. A field element (40) having a magnet portion (42) including a plurality of magnetic poles of alternating polarity in the circumferential direction, a multiphase armature winding (51) and a base member to which the armature winding is fixed An electric rotating machine (10) comprising: an armature (50) having (52, 201), wherein any one of the field element and the armature is a rotor,
   The armature winding has conducting wire portions (81, 82) arranged at predetermined intervals in the circumferential direction at a position facing the field element,
   In the armature,
   An inter-conductor member (57, 142, 143) is provided between the conductor portions in the circumferential direction, and as the inter-conductor member, the circumferential width dimension of the inter-conductor member in one magnetic pole is Wt, the inter-conductor member A magnetic material having a relationship of Wt × Bs ≦ Wm × Br, where Bs is a saturation magnetic flux density, Wm is a width of the circumferential direction of the magnet portion in one magnetic pole, and Br is a residual magnetic flux density of the magnet portion. Or a configuration using a nonmagnetic material,
   Alternatively, the inter-conductor member is not provided between the conductor portions in the circumferential direction,
   The wire portion has a flat shape in which the width dimension in the circumferential direction is larger than the thickness dimension in the radial direction,
   An electric rotating machine according to an electric rotating machine, wherein facing surfaces (1001a, 1002b) facing the base member in the conducting wire portion are curved along a curved surface (52a) of the base member to which the facing surface is fixed in a circumferential direction.
2. The conductor portion is composed of a plurality of conductors (82) aligned in the radial direction of the armature,
   Of the two conducting wires arranged in the radial direction, the outer side surface (1001b) facing the outer conducting wire in the inner conducting wire (1001) is a curved surface having a circular arc shape in the circumferential direction, and The rotating electrical machine according to claim 1, wherein the inner side surface (1002a) opposed to the inner lead wire in 1002) is a curved surface that is arc-shaped along the outer side surface of the inner lead wire in the circumferential direction.
3. The thickness dimension in the radial direction of the outer conductor is thinner than that of the inner conductor, and the circumferential width dimension of the outer conductor is the inner conductor, of the two conductors arranged adjacent to each other in the radial direction. The electric rotating machine according to claim 2, wherein the electric motor is long as compared with.
4. An interphase insulating film (3001) for performing insulation is provided at least between the conductor portions which are in different phases,
   The electric rotating machine according to any one of claims 1 to 3, wherein the conductor portions of different phases adjacent in the circumferential direction are in contact with each other with the interphase insulating film interposed therebetween.
5. Each of the conductive wires constituting the conductive wire portion is a bundle of a plurality of strands (86) and is a bundle of strands whose resistance value between the bundled strands is larger than the resistance of the strands themselves. The electric rotating machine according to any one of claims 1 to 4, wherein
6. Each of the strands is covered by an insulating layer,
   The electric rotating machine according to claim 5, wherein a thickness of the insulating layer is thinner than a thickness of an insulating member covering the bundled strands.

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