WO2020022282A1 - Rotating electrical machine - Google Patents

Rotating electrical machine Download PDF

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Publication number
WO2020022282A1
WO2020022282A1 PCT/JP2019/028697 JP2019028697W WO2020022282A1 WO 2020022282 A1 WO2020022282 A1 WO 2020022282A1 JP 2019028697 W JP2019028697 W JP 2019028697W WO 2020022282 A1 WO2020022282 A1 WO 2020022282A1
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WO
WIPO (PCT)
Prior art keywords
stator
magnet
rotor
conductor
electric machine
Prior art date
Application number
PCT/JP2019/028697
Other languages
French (fr)
Japanese (ja)
Inventor
高橋　裕樹
友久 佐野
龍太 田辺
雄太 橋本
渉 舟津
Original Assignee
株式会社デンソー
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2019111595A external-priority patent/JP7183968B2/en
Application filed by 株式会社デンソー filed Critical 株式会社デンソー
Priority to CN201980049369.2A priority Critical patent/CN112470379A/en
Publication of WO2020022282A1 publication Critical patent/WO2020022282A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K7/00—Disposition of motor in, or adjacent to, traction wheel
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/30—Structural association with control circuits or drive circuits
    • H02K11/33—Drive circuits, e.g. power electronics
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/22—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating around the armatures, e.g. flywheel magnetos
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

Definitions

  • the disclosure in this specification relates to a rotating electric machine.
  • a rotating electric machine mounted on a vehicle or the like a configuration including a rotor having a permanent magnet and a stator having a multi-phase stator winding is generally known. Further, as a control system of a rotating electric machine, a configuration in which energization to a stator winding is controlled by switching control is known.
  • a dielectric layer is provided between an outer core and an inner core in a rotor. It is configured to be provided. The dielectric layer adjusts the capacitance between the outer iron core and the inner iron core to suppress electrolytic corrosion of the bearing.
  • Patent Document 1 is a configuration in which the dielectric layer is provided between the outer core and the inner core in the rotor, so that the configuration is special, and the cost increases. And so on. It is considered that there is room for technical improvement in suppressing electrolytic corrosion of bearings.
  • the present disclosure has been made in view of the above circumstances, and has an object to appropriately suppress electrolytic corrosion of a bearing in a rotating electric machine.
  • Means 1 A rotor having a magnet portion including a plurality of magnetic poles having alternating polarities in the circumferential direction, A cylindrical stator having a multi-phase stator winding; A stator holding member having a first cylindrical portion assembled radially inward or radially outward of the stator; A pair of bearings rotatably supporting a rotating shaft of the rotor, and The stator holding member has a second cylindrical portion concentric with the first cylindrical portion and smaller in diameter than the first cylindrical portion, and a connecting portion connecting the first cylindrical portion and the second cylindrical portion. And The rotating shaft is inserted into the second cylindrical portion, and the pair of bearings are provided between the second cylindrical portion and the rotating shaft in the axial direction.
  • the stator holding member in the stator holding member, is integrated with the first cylindrical portion assembled radially inward or radially outward of the stator and at a position radially inward from the first cylindrical portion. Two cylindrical portions are provided, and a pair of bearings are arranged between the second cylindrical portion and the rotating shaft in the axial direction. According to this configuration, it is possible to eliminate the potential difference between the pair of bearings, and to suppress the occurrence of electrolytic corrosion.
  • the stator winding has a conductor portion arranged at a predetermined interval in a circumferential direction at a position facing the magnet portion, and in the stator, the respective conductor portions in a circumferential direction are provided.
  • the width of the circumferential portion of the inter-wire member at one magnetic pole is Wt
  • the saturation magnetic flux density of the inter-wire member is Bs
  • the magnet portion of the magnetic pole at one magnetic pole is provided as the inter-wire member.
  • the teeth are not provided or are magnetically weakly provided as members between conductors in the stator, and a magnetic path is provided for each tooth as a member between conductors. It is considered that the unintended current generation due to the electromotive force and the problem of the electrolytic corrosion of the bearing caused by the electromotive force are more concerned than the configuration formed.
  • the configuration formed as described above, by providing a pair of bearings arranged in the axial direction between the second cylindrical portion of the stator holding member and the rotating shaft, it is possible to preferably suppress the occurrence of electrolytic corrosion in the bearings. Can be.
  • Means 3 is the outer rotor type rotating electric machine according to means 1 or 2, wherein the rotor is radially outside and the stator is radially inside, and the rotor and the stator are radially opposed to each other.
  • the rotor has a magnet holding member that holds the magnet portion, and the magnet holding member has a tubular portion to which the magnet portion is fixed, and an end plate that extends radially from the rotation axis to the tubular portion.
  • the second cylindrical portion of the stator holding member is provided so as to radially oppose the first cylindrical portion, and the second cylindrical portion of the second cylindrical portion in the axial direction.
  • the connecting portion is connected to the second end portion of the first end portion on the end plate portion side and the second end portion on the opposite side.
  • a first cylindrical portion and a second cylindrical portion of a stator holding member are radially opposed to each other, and a first end portion (an end plate of a magnet holding member) on both axial sides of the second cylindrical portion. (The end on the part side) and the second end (the end on the side opposite to the end plate part), the connecting part is connected to the second end.
  • one side in the axial direction is closed by the end plate portion of the magnet holding member, and the other side is the stator.
  • a closed space can be formed on the inner peripheral side of the stator, surrounding the rotating shaft and closed on both sides in the axial direction.
  • a preferable configuration can be realized when an electric device such as a power converter (inverter) is integrally provided with the rotating electric machine.
  • the switching element connected to the phase winding of each phase in the stator winding is provided in the annular space between the first cylindrical portion and the second cylindrical portion in the stator holding member, and A power converter for energizing the phase windings may be provided.
  • Means 4 is the outer rotor type rotating electric machine according to the means 1 or 2, wherein the rotor is radially outside and the stator is radially inside, and the rotor and the stator are radially opposed to each other.
  • the rotor has a magnet holding member that holds the magnet portion, and the magnet holding member has a tubular portion to which the magnet portion is fixed, and an end plate that extends radially from the rotation axis to the tubular portion.
  • the second cylindrical portion of the stator holding member is provided so as to radially oppose the first cylindrical portion, and the second cylindrical portion of the second cylindrical portion in the axial direction.
  • the connecting portion is connected to the first end side of the first end portion on the end plate portion side and the second end portion on the opposite side.
  • a first cylindrical portion and a second cylindrical portion of a stator holding member are radially opposed to each other, and a first end portion (an end plate of a magnet holding member) on both axial sides of the second cylindrical portion. (The end on the part side) and the second end (the end on the side opposite to the end plate part), the connecting part is connected to the first end side.
  • the end plate portion of the magnet holding member and the stator holding member By providing the connecting portion, the other side in the axial direction of the annular space is opened.
  • the magnetic circuit section including the rotor and the stator and the pair of bearings so as to be radially inward and outward.
  • the transmission or the like is axially disposed from one side in the annular space between the first cylindrical portion and the second cylindrical portion of the stator holding member. It is possible to assemble.
  • Means 5 is the inner rotor type rotating electric machine according to means 1 or 2, wherein the rotor is radially inward, the stator is radially outward, and the rotor and the stator are radially opposed to each other.
  • the rotor has a magnet holding member that holds the magnet portion, and the magnet holding member has a tubular portion to which the magnet portion is fixed, and an end plate that extends radially from the rotation axis to the tubular portion.
  • the second cylindrical portion in the stator holding member is provided radially inward of the cylindrical portion so as to radially face the cylindrical portion, In the axial direction, the connecting portion is connected to the second end portion of the first end portion of the second cylindrical portion on the end plate portion side and the second end portion on the opposite side.
  • the second cylindrical portion of the stator holding member and the cylindrical portion of the magnet holding member are radially opposed to each other, and the first end portion (the magnet holding member) on both axial sides of the second cylindrical portion.
  • the end portion on the side of the end plate portion) and the second end portion (end portion on the side opposite to the end plate portion) are connected to the connecting portion on the side of the second end portion.
  • a closed space can be formed on the inner peripheral side of the rotor, surrounding the rotating shaft and closed on both sides in the axial direction. This makes it possible to reduce the size of the rotating electric machine by arranging the magnetic circuit section including the rotor and the stator and the pair of bearings so as to be radially inward and outward.
  • a preferable configuration can be realized when an electric device such as a power converter (inverter) is integrally provided with the rotating electric machine.
  • FIG. 1 is a vertical sectional perspective view of a rotating electric machine
  • FIG. 2 is a longitudinal sectional view of the rotating electric machine
  • FIG. 3 is a sectional view taken along line III-III of FIG.
  • FIG. 4 is an enlarged sectional view showing a part of FIG.
  • FIG. 5 is an exploded view of the rotating electric machine
  • FIG. 6 is an exploded view of the inverter unit
  • FIG. 7 is a torque diagram showing the relationship between the ampere turn of the stator winding and the torque density.
  • FIG. 8 is a cross-sectional view of the rotor and the stator
  • FIG. 1 is a vertical sectional perspective view of a rotating electric machine
  • FIG. 2 is a longitudinal sectional view of the rotating electric machine
  • FIG. 3 is a sectional view taken along line III-III of FIG.
  • FIG. 4 is an enlarged sectional view showing a part of FIG.
  • FIG. 5 is an exploded view of the rotating electric machine
  • FIG. 6 is an
  • FIG. 9 is an enlarged view of a part of FIG.
  • FIG. 10 is a cross-sectional view of the stator
  • FIG. 11 is a longitudinal sectional view of the stator
  • FIG. 12 is a perspective view of a stator winding
  • FIG. 13 is a perspective view showing a configuration of a conductor
  • FIG. 14 is a schematic diagram showing a configuration of a strand
  • FIG. 15 is a diagram showing the form of each lead in the n-th layer
  • FIG. 16 is a side view showing the respective conductors of the n-th layer and the (n + 1) -th layer.
  • FIG. 17 is a diagram illustrating a relationship between an electric angle and a 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 the control system of the rotating electric machine
  • FIG. 20 is a functional block diagram illustrating a current feedback control process performed by the control device.
  • FIG. 21 is a functional block diagram illustrating a torque feedback control process performed by the control device.
  • FIG. 22 is a cross-sectional view of the rotor and the stator according to the second embodiment
  • FIG. 23 is a diagram showing a part of FIG. 22 in an enlarged manner.
  • FIG. 24 is a diagram specifically showing the flow of magnetic flux in the magnet unit.
  • FIG. 25 is a cross-sectional view of the stator according to the first modification.
  • FIG. 26 is a cross-sectional view of the stator according to the first modification.
  • FIG. 27 is a cross-sectional view of a stator according to a second modification.
  • FIG. 28 is a cross-sectional view of a stator according to a third modification;
  • FIG. 29 is a cross-sectional view of a stator according to a fourth modification;
  • FIG. 30 is a cross-sectional view of the rotor and the stator in Modification Example 7,
  • FIG. 31 is a functional block diagram illustrating a part of the processing of the operation signal generation unit in Modification Example 8.
  • FIG. 32 is a flowchart illustrating a procedure of a carrier frequency change process.
  • FIG. 32 is a flowchart illustrating a procedure of a carrier frequency change process.
  • FIG. 33 is a diagram illustrating a connection form of each of the conductors forming the conductor group in Modification Example 9.
  • FIG. 34 is a diagram illustrating a configuration in which four pairs of conductive wires are stacked and arranged in Modification Example 9.
  • FIG. 35 is a cross-sectional view of an inner rotor type rotor and a stator in Modification Example 10,
  • FIG. 36 is an enlarged view of a part of FIG.
  • FIG. 37 is a longitudinal sectional view of an inner rotor type rotating electric machine
  • FIG. 38 is a longitudinal sectional view showing a schematic configuration of an inner rotor type rotating electric machine
  • FIG. 39 is a diagram illustrating a configuration of a rotating electric machine having an inner rotor structure in Modification Example 11.
  • FIG. 39 is a diagram illustrating a configuration of a rotating electric machine having an inner rotor structure in Modification Example 11.
  • FIG. 40 is a diagram illustrating a configuration of a rotating electric machine having an inner rotor structure in Modification Example 11.
  • FIG. 41 is a diagram illustrating a configuration of a rotary armature type rotary electric machine according to Modification Example 12.
  • FIG. 42 is a cross-sectional view illustrating a configuration of a conductor according to Modification Example 14.
  • FIG. 43 is a diagram showing a relationship between reluctance torque, magnet torque and DM,
  • FIG. 44 shows teeth.
  • FIG. 45 is a perspective view showing a wheel having an in-wheel motor structure and a peripheral structure thereof.
  • FIG. 46 is a longitudinal sectional view of the wheel and its peripheral structure
  • FIG. 47 is an exploded perspective view of wheels.
  • FIG. 41 is a diagram illustrating a configuration of a rotating electric machine having an inner rotor structure in Modification Example 11.
  • FIG. 41 is a diagram illustrating a configuration of a rotary armature type rotary electric machine according to Modification Example 12.
  • FIG. 48 is a side view of the rotating electric machine viewed from a protruding side of the rotating shaft
  • FIG. 49 is a sectional view taken along line 49-49 of FIG.
  • FIG. 50 is a sectional view taken along line 50-50 of FIG.
  • FIG. 51 is an exploded sectional view of the rotating electric machine
  • FIG. 52 is a partial cross-sectional view of the rotor
  • FIG. 53 is a perspective view of a stator winding and a stator core
  • FIG. 54 is a front view showing a stator winding developed in a plane.
  • FIG. 55 is a diagram showing the skew of the conductor
  • FIG. 56 is an exploded sectional view of the inverter unit
  • FIG. 57 is an exploded sectional view of the inverter unit
  • FIG. 58 is a diagram showing a state of arrangement of each electric module in the inverter housing;
  • FIG. 59 is a circuit diagram showing an electrical configuration of the power converter.
  • FIG. 60 is a diagram illustrating an example of a cooling structure of a switch module.
  • FIG. 61 is a diagram illustrating an example of a cooling structure of a switch module;
  • FIG. 62 is a diagram illustrating an example of a cooling structure of a switch module.
  • FIG. 63 is a diagram illustrating an example of a cooling structure of a switch module;
  • FIG. 64 is a diagram illustrating an example of a cooling structure of the switch module.
  • FIG. 65 is a diagram showing an arrangement order of each electric module with respect to the cooling water passage;
  • FIG. 66 is a sectional view taken along line 66-66 of FIG.
  • FIG. 67 is a sectional view taken along line 67-67 of FIG.
  • FIG. 68 is a perspective view showing the bus bar module alone
  • FIG. 69 is a diagram showing an electrical connection state between each electric module and a bus bar module
  • FIG. 70 is a diagram showing an electrical connection state between each electric module and a bus bar module
  • FIG. 71 is a diagram showing an electrical connection state between each electric module and a bus bar module
  • FIG. 72 is a configuration diagram for explaining a first modification of the in-wheel motor.
  • FIG. 73 is a configuration diagram for describing a second modification of the in-wheel motor.
  • FIG. 74 is a configuration diagram for explaining a third modification of the in-wheel motor.
  • FIG. 75 is a configuration diagram for explaining a fourth modification of the in-wheel motor.
  • FIG. 76 is a front view showing the entire main part of the rotary electric machine according to Modification Example 15.
  • FIG. 77 is a longitudinal sectional view of the rotating electric machine
  • FIG. 78 is an exploded sectional view showing components of the rotating electric machine in an exploded manner.
  • FIG. 79 is a perspective view of a stator
  • FIG. 80 is a plan view of the stator
  • FIG. 81 is a longitudinal sectional view of the stator
  • FIG. 82 is a perspective view of a stator core
  • FIG. 83 is a circuit diagram showing a connection state of partial windings of each phase.
  • FIG. 84 (a) is a perspective view showing one partial winding of each phase extracted from the stator winding
  • FIG. 84 (b) is a front view showing one partial winding of each phase.
  • FIG. 85 is a perspective view showing only the U-phase partial winding among the three-phase partial windings.
  • FIG. 86 is a diagram showing the relationship between the phase winding of each phase and the magnetic poles of the rotor
  • FIG. 87 is a perspective view showing a state where all the partial windings of each phase are assembled to the stator core
  • FIG. 88 is a diagram showing a cross-sectional structure of a conductive wire
  • FIG. 89 is an exploded perspective view showing a power bus bar in the stator.
  • FIG. 90 is a diagram showing a connection state of each of the U-phase partial windings
  • FIG. 91 is a cross-sectional view showing a part of a longitudinal section of the rotating electric machine in an enlarged manner.
  • FIG. 92 is a longitudinal sectional view of the stator holder;
  • FIG. 93 is a longitudinal sectional view showing a rotating electric machine according to another example of Modification Example 15.
  • FIG. 94 is a vertical cross-sectional view showing a rotating electric machine according to another example of the fifteenth modification.
  • the rotating electric machine according to the present embodiment is used, for example, as a vehicle power source.
  • rotating electric machines can be widely used for industrial use, vehicles, home appliances, OA equipment, gaming machines, and the like.
  • parts that are the same or equivalent to each other are given the same reference numerals in the drawings, and the description of the parts with the same reference numerals is used.
  • the rotating electric machine 10 is a synchronous polyphase AC motor and has an outer rotor structure (eternal rotation structure).
  • the outline of the rotating electric machine 10 is shown in FIGS. 1 is a vertical cross-sectional perspective view of the rotary electric machine 10,
  • FIG. 2 is a vertical cross-sectional view of the rotary electric machine 10 in a direction along a rotation axis 11, and
  • FIG. 3 is a cross-sectional view of the rotary electric machine 10 (a cross-sectional view taken along line III-III in FIG. 2).
  • FIG. 4 is a cross-sectional view illustrating a part of FIG. 3 in an enlarged manner. It is.
  • FIG. 1 is a vertical cross-sectional perspective view of the rotary electric machine 10
  • FIG. 2 is a vertical cross-sectional view of the rotary electric machine 10 in a direction along a rotation axis 11
  • FIG. 3 is a cross-sectional view of the rotary electric machine 10 (a cross-sectional view taken along line III-III
  • hatching indicating a cut surface is omitted except for the rotation shaft 11 for convenience of illustration.
  • the direction in which the rotating shaft 11 extends is defined as the axial direction
  • the direction radially extending from the center of the rotating shaft 11 is defined as the radial direction
  • the direction extending circumferentially around the rotating shaft 11 is defined as the circumferential direction.
  • the rotating 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 arranged coaxially with the rotating shaft 11 and assembled in a predetermined order in the axial direction to form the rotating electric machine 10.
  • the rotating electric machine 10 of the present embodiment has a configuration having a rotor 40 as a “field element” and a stator 50 as an “armature”, and is embodied as a rotating field type rotating electric machine. It has become something.
  • the bearing unit 20 has two bearings 21 and 22 that are arranged apart from each other in the axial direction, and a holding member 23 that holds the bearings 21 and 22.
  • the bearings 21 and 22 are, for example, radial ball bearings, each of which has an outer ring 25, an inner ring 26, and a plurality of balls 27 arranged between the outer ring 25 and the inner ring 26.
  • the holding member 23 has a cylindrical shape, and bearings 21 and 22 are attached to the inside in the radial direction.
  • the rotating shaft 11 and the rotor 40 are rotatably supported inside the bearings 21 and 22 in the radial direction.
  • the bearings 21 and 22 constitute a set of bearings that rotatably support the rotating shaft 11.
  • the ball 27 is 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 upper and lower portions in the axial direction of the retainer, and are filled with non-conductive grease (for example, non-conductive urea grease). Further, the position of the inner ring 26 is mechanically held by a spacer, and a constant-pressure preload that is vertically convex 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 that face each other 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 to the end face 32 by a fixing tool such as a screw or a rivet while being inserted through the hole 34.
  • 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.
  • the rotating electric machine 10 is of an outer rotor type, and a stator 50 is disposed inside a housing 30 in a radial direction of a cylindrical rotor 40.
  • the rotor 40 is cantilevered by the rotating shaft 11 on the end face 32 side 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 inside 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 includes a cylindrical portion 43 having a cylindrical shape, a fixed portion (attachment) 44 also having a cylindrical shape and a smaller diameter than the cylindrical portion 43, and an intermediate portion serving as a portion connecting the cylindrical portion 43 and the fixed portion 44. 45.
  • the magnet unit 42 is mounted on the inner peripheral surface of the cylindrical portion 43.
  • the magnet holder 41 is made of a cold-rolled steel plate (SPCC) having sufficient mechanical strength, forging steel, carbon fiber reinforced plastic (CFRP), or the like.
  • SPCC cold-rolled steel plate
  • CFRP carbon fiber reinforced plastic
  • the rotating shaft 11 is inserted into the through hole 44a of the fixing portion 44.
  • the fixed part 44 is fixed to the rotating shaft 11 arranged in the through hole 44a. That is, the magnet holder 41 is fixed to the rotating shaft 11 by the fixing unit 44.
  • the fixing portion 44 may be fixed to the rotating shaft 11 by spline connection or key connection using irregularities, welding, caulking, or the like. Thereby, the rotor 40 rotates integrally with the rotating shaft 11.
  • Bearings 21 and 22 of the bearing unit 20 are mounted radially outward of the fixing portion 44. Since the bearing unit 20 is fixed to the end face 32 of the housing 30 as described above, the rotating 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 at only one of two axially opposed ends thereof, whereby the rotor 40 is cantilevered on the rotating shaft 11.
  • the fixed portion 44 of the rotor 40 is rotatably supported at two different positions in the axial direction by the bearings 21 and 22 of the bearing unit 20. That is, the rotor 40 is rotatably supported at one of two axially opposed ends of the magnet holder 41 by the two bearings 21 and 22 spaced apart in the axial direction. Therefore, even when the rotor 40 has a structure in which the rotor 40 is cantilevered by the rotating shaft 11, stable rotation of the rotor 40 is realized. 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.
  • a clearance 22 between the outer ring 25 and the inner ring 26 and the ball 27 is provided between 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, on the side near the center of the rotor 40, even if vibration of the rotor 40 or vibration due to imbalance due to component tolerance acts on the bearing unit 20, the influence of the vibration or vibration is favorably absorbed. You.
  • the play size is increased by the preload in the bearing 22 near the center of the rotor 40 (the lower side in the figure), so that the vibration generated in the cantilever structure is absorbed by the play portion.
  • the preload may be either a fixed position preload or a constant pressure preload.
  • the outer races 25 of the bearing 21 and the bearing 22 are both joined to the holding member 23 by a method such as press fitting or bonding.
  • the inner races 26 of the bearing 21 and the bearing 22 are both joined to the rotating shaft 11 by a method such as press fitting or bonding.
  • Preload can be generated by arranging the outer ring 25 of the bearing 21 at a different position in the axial direction with respect to the inner ring 26 of the bearing 21, a preload can be generated. Preload can also be generated by arranging the outer ring 25 of the bearing 22 at a different position in the axial direction with respect to the inner ring 26 of the bearing 22.
  • a preload spring for example, a wave washer 24, is provided in the axial direction so that a preload is generated from a region between the bearing 22 and the bearing 21 toward the outer ring 25 of the bearing 22. 22 and the bearing 21 in the same area.
  • the inner rings 26 of the bearing 21 and the bearing 22 are both joined to the rotating shaft 11 by a method such as press fitting or bonding.
  • the outer ring 25 of the bearing 21 or the bearing 22 is disposed with a predetermined clearance with respect to the holding member 23. With such a configuration, the spring force of the preload spring acts on the outer ring 25 of the bearing 22 in a direction away from the bearing 21.
  • a spring force may be applied to the outer ring 25 of the bearing 22 as shown in FIG.
  • a spring force may be applied to the outer ring 25 of the bearing 21.
  • one of the inner rings 26 of the bearings 21 and 22 is arranged with a predetermined clearance with respect to the rotating shaft 11, and the outer ring 25 of the bearings 21 and 22 is pressed into the holding member 23 or a method such as adhesion is used. By joining together, preload may be applied to the two bearings.
  • the intermediate portion 45 has an annular inner shoulder 49a and an annular outer shoulder 49b.
  • the outer shoulder portion 49b is located outside the inner shoulder portion 49a in the radial direction of the intermediate portion 45.
  • the inner shoulder portion 49a and the outer shoulder portion 49b are separated from each other in the axial direction of the intermediate portion 45.
  • the cylindrical portion 43 and the fixed portion 44 partially overlap in the radial direction of the intermediate portion 45.
  • the cylindrical portion 43 protrudes outward in the axial direction from the base end of the fixing portion 44 (the lower end on the lower side in the figure).
  • the rotor 40 can be supported on the rotating shaft 11 at a position near the center of gravity of the rotor 40 as compared with the case where the intermediate portion 45 is provided in a flat shape without a step. Forty stable operations can be realized.
  • the rotor housing 40 has a bearing housing recess 46 that partially surrounds the bearing unit 20 at a position that surrounds the fixed portion 44 in the radial direction and is inward of the intermediate portion 45.
  • the coil accommodation concave portion accommodates a coil end 54 of a stator winding 51 of a stator 50 described later. 47 are formed.
  • These accommodation recesses 46 and 47 are arranged so as to be adjacent to each other inside and outside in the radial direction. That is, a part of the bearing unit 20 and the coil end 54 of the stator winding 51 are arranged so as to overlap inward and outward in the radial direction.
  • the axial length of the rotating electric machine 10 can be reduced.
  • the intermediate portion 45 is provided so as to project radially outward from the rotation shaft 11 side.
  • a contact avoiding portion that extends in the axial direction and that avoids contact of the stator winding 51 of the stator 50 with the coil end 54 is provided in the intermediate portion 45.
  • the intermediate portion 45 corresponds to the overhang portion.
  • the bending direction of the coil end 54 may be a direction in which the coil end 54 and the rotor 40 are assembled. 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.
  • the bending direction of the coil end on the side opposite to the coil end 54 may be arbitrary, but a shape bent outward with sufficient space is preferable in terms of manufacturing.
  • the magnet unit 42 as a magnet portion is constituted by a plurality of permanent magnets arranged inside the cylindrical portion 43 in the radial direction so that the polarity alternates along the circumferential direction. Thereby, the magnet unit 42 has a plurality of magnetic poles in the circumferential direction. However, details of the magnet unit 42 will be described later.
  • the stator 50 is provided radially inside the rotor 40.
  • the stator 50 has a stator winding 51 wound in a substantially cylindrical (annular) shape, and a stator core 52 as a base member disposed radially inward of the stator winding 51.
  • the line 51 is disposed so as to face the annular magnet unit 42 with a predetermined air gap interposed therebetween.
  • the stator winding 51 includes a plurality of phase windings. Each of the phase windings is configured by connecting a plurality of conductors arranged in a circumferential direction at a predetermined pitch.
  • the stator winding 51 is configured as a six-phase winding.
  • the stator core 52 is formed in an annular shape by a laminated steel sheet in which electromagnetic steel sheets as soft magnetic materials are laminated, and is assembled radially inside the stator winding 51.
  • 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
  • the stator core 52 corresponds to an armature core.
  • the stator winding 51 is a portion that overlaps the stator core 52 in the radial direction, and is a coil side portion 53 that is radially outside the stator core 52, and one end of the stator core 52 in the axial direction and the other. It has coil ends 54 and 55 projecting to the end sides, respectively.
  • the coil side portions 53 face the stator core 52 and the magnet unit 42 of the rotor 40 in the radial direction, respectively.
  • the inverter unit 60 has a unit base 61 fixed to the housing 30 by fasteners such as bolts, and a plurality of electric components 62 assembled to the unit base 61.
  • the unit base 61 is made of, for example, carbon fiber reinforced plastic (CFRP).
  • CFRP carbon fiber reinforced plastic
  • the unit base 61 has an end plate 63 fixed to the edge of the opening 33 of the housing 30 and a casing 64 provided integrally with the end plate 63 and extending in the axial direction.
  • the end plate 63 has a circular opening 65 at the center thereof, and a casing 64 is formed so as to rise from the peripheral edge of the opening 65.
  • the stator 50 is mounted on the outer peripheral surface of the casing 64. That is, the outer diameter of the casing 64 is the same as the inner diameter of the stator core 52 or slightly smaller than the inner diameter of the stator core 52.
  • the stator 50 and the unit base 61 are integrated by attaching the stator core 52 to the outside of the casing 64. 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 attached 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. Thereby, the displacement of the stator core 52 with respect to the unit base 61 in the circumferential direction or the axial direction is suppressed.
  • a radially inner side of the casing 64 is a housing space for housing the electric component 62, and the electric component 62 is arranged in the housing space so as to surround the rotating shaft 11.
  • the casing 64 has a role as an accommodation space forming part.
  • the electric component 62 includes a semiconductor module 66 constituting an inverter circuit, a control board 67, and a capacitor module 68.
  • the unit base 61 is provided radially inside the stator 50 and corresponds to a stator holder (armature holder) that holds the stator 50.
  • the housing 30 and the unit base 61 constitute a motor housing of the rotary electric machine 10.
  • the holding member 23 is fixed to the housing 30 on one side in the axial direction with the rotor 40 interposed therebetween, and the housing 30 and the unit base 61 are connected to each other on the other side.
  • the rotating electric machine 10 is mounted on a vehicle or the like by attaching a motor housing to the vehicle or the like.
  • FIG. 6 is an exploded view of the inverter unit 60 in addition to FIGS.
  • the casing 64 has a tubular portion 71 and an end face 72 provided at one of the opposite ends in the axial direction (the end on the bearing unit 20 side).
  • the opposite side of the end face 72 among both ends in the axial direction of the cylindrical portion 71 is entirely opened 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 into the hole 73.
  • the hole 73 is provided with a sealing material 171 that seals a gap between the hole 73 and the outer peripheral surface of the rotating shaft 11.
  • the sealant 171 may be a sliding seal made of, for example, a resin material.
  • the tubular portion 71 of the casing 64 serves as a partitioning portion between the rotor 40 and the stator 50 disposed radially outside the electrical component 62 disposed radially inward thereof.
  • the rotor 40 and the stator 50 and the electric component 62 are arranged inward and outward in the radial direction with the shape portion 71 interposed therebetween.
  • the electric component 62 is an electric component forming an inverter circuit, and has a powering function of rotating the rotor 40 by applying a current to each phase winding of the stator winding 51 in a predetermined order; And a power generation function of inputting a three-phase AC current flowing through the stator winding 51 with the rotation of the motor and outputting the generated power to the outside.
  • the electric component 62 may have only one of the powering function and the power generation function.
  • the power generation function is, for example, a regenerative function that outputs to the outside as regenerative power when the rotating electric machine 10 is used as a vehicle power source.
  • 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.
  • semiconductor modules 66 are arranged side by side in the circumferential direction.
  • the capacitor module 68 includes a plurality of smoothing capacitors 68a connected in parallel with each other.
  • the capacitor 68a is a laminated film capacitor in which a plurality of film capacitors are laminated, and has a trapezoidal cross section.
  • the capacitor module 68 is configured by arranging twelve capacitors 68a in a ring.
  • the capacitor 68a for example, a long film having a predetermined width formed by laminating a plurality of films is used, the film width direction is set to a trapezoidal height direction, and the upper and lower bases of the trapezoid alternate.
  • the long film is cut into an equal-leg trapezoidal shape so that the capacitor element is formed. Then, by attaching electrodes and the like to the capacitor element, the capacitor 68a is manufactured.
  • the semiconductor module 66 has a semiconductor switching element such as a MOSFET or an IGBT, and is formed in a substantially plate shape.
  • a semiconductor switching element such as a MOSFET or an IGBT
  • an inverter circuit is provided for each of the three-phase windings, a total of twelve semiconductor modules 66 are arranged in a ring.
  • the assembled semiconductor module group 66A is provided in the electric 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.
  • the heat generated in the semiconductor module 66 is transmitted to the end plate 63 via 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 in the outer peripheral surface side, that is, in the radial direction.
  • the cross-sectional shape of the cross section orthogonal to the axial direction is a regular dodecagon
  • the cross-sectional shape of the inner peripheral surface of the cylindrical portion 71 is circular.
  • Has a flat surface and the outer peripheral surface is a curved surface.
  • the spacer 69 may be provided integrally so as to be annularly continuous outside the semiconductor module group 66A in the radial direction.
  • the spacer 69 is a good heat conductor, for example, a metal such as aluminum, or a heat dissipation gel sheet.
  • the cross-sectional shape of the inner peripheral surface of the cylindrical portion 71 can be the same dodecagon as that of the capacitor module 68.
  • both the inner peripheral surface and the outer peripheral surface of the spacer 69 are preferably flat surfaces.
  • a cooling water passage 74 for flowing cooling water is formed in the cylindrical portion 71 of the casing 64, and heat generated in the semiconductor module 66 is supplied to the cooling water flowing through the cooling water passage 74. Is also released. That is, the casing 64 has a water cooling mechanism. As shown in FIGS. 3 and 4, the cooling water passage 74 is formed in an annular shape so as to surround the electric component 62 (the semiconductor module 66 and the capacitor module 68). The semiconductor module 66 is arranged along the inner peripheral surface of the cylindrical portion 71, and a cooling water passage 74 is provided at a position overlapping the semiconductor module 66 inward and outward in the radial direction.
  • stator 50 Since the stator 50 is disposed outside the tubular portion 71 and the electric component 62 is disposed inside, the heat of the stator 50 is transmitted to the tubular portion 71 from the outside, The heat of the electric 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 at the same time, and the heat of the heat generating member in the rotating electric machine 10 can be efficiently released.
  • the semiconductor module 66 that constitutes a part or all of the inverter circuit that operates the rotating electric machine by energizing the stator winding 51 is disposed outside the cylindrical portion 71 of the casing 64 in the radial direction.
  • the entirety of one semiconductor module 66 is arranged in a region surrounded by stator core 52.
  • the entirety of all the semiconductor modules 66 is arranged in a region surrounded by the stator core 52.
  • At least a part of the semiconductor module 66 is arranged in a region surrounded by the cooling water passage 74. Desirably, the entirety of all the semiconductor modules 66 is arranged in a region surrounded by the yoke 141.
  • the electric component 62 includes an insulating sheet 75 provided on one end face of the capacitor module 68 and a wiring module 76 provided on the other end face in the axial direction.
  • the capacitor module 68 has two end faces facing each other in the axial direction, that is, a first end face and a second end face.
  • the first end face of the capacitor module 68 near the bearing unit 20 is opposed to the end face 72 of the casing 64, and is superposed on the end face 72 with the insulating sheet 75 interposed therebetween.
  • a wiring module 76 is mounted on a second end face of the capacitor module 68 near the opening 65.
  • the wiring module 76 has a main body portion 76a made of a synthetic resin and having a circular plate shape, and a plurality of busbars 76b and 76c embedded therein.
  • the busbars 76b and 76c allow the semiconductor module 66 and the capacitor to be mounted.
  • An electrical connection is made with the module 68.
  • the semiconductor module 66 has a connection pin 66a extending from the axial end face, and the connection pin 66a is connected to the bus bar 76b on the radial outside of the main body portion 76a.
  • the bus bar 76c extends on the outer side of the main body 76a in the radial direction on the side opposite to the capacitor module 68, and is connected to the wiring member 79 at its tip (see FIG. 2).
  • the heat radiation path of the capacitor module 68 A path is formed 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. 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. Thereby, heat can be radiated from the end face of the capacitor module 68 other than the outer peripheral face where the semiconductor module 66 is provided. That is, not only the heat radiation in the radial direction but also the heat radiation in the axial direction are possible.
  • the capacitor module 68 has a hollow cylindrical shape and the rotating shaft 11 is disposed on the inner peripheral portion thereof with a predetermined gap interposed therebetween, the heat of the capacitor module 68 can be released 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 disc-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.
  • PCB printed circuit board
  • a control device 77 corresponding to a control unit including various ICs and a microcomputer is mounted. I have.
  • the control board 67 is fixed to the wiring module 76 by a fixture such as a screw.
  • the control board 67 has an insertion hole 67a at the center thereof, through which the rotating shaft 11 is inserted.
  • the wiring module 76 has a first surface and a second surface that face each other in the axial direction, that is, that face each other in the thickness direction.
  • the first surface faces the capacitor module 68.
  • the wiring module 76 has a control board 67 on the second surface.
  • the bus bar 76c of the wiring module 76 extends from one side of the both sides of the control board 67 to the other side.
  • the control board 67 may be provided with a notch for avoiding interference with the bus bar 76c. For example, a part of the outer edge of the circular control board 67 may be cut away.
  • the electric component 62 is generated in the inverter circuit.
  • Electromagnetic noise is suitably shielded. That is, in the inverter circuit, switching control in each semiconductor module 66 is performed using PWM control based on a predetermined carrier frequency, and electromagnetic noise may be generated by the switching control. It can be shielded suitably by the housing 30, the rotor 40, the stator 50, and the like outside in the radial direction of 62.
  • the semiconductor module 66 by arranging at least a part of the semiconductor module 66 in a region surrounded by the stator core 52 arranged radially outside the cylindrical portion 71 of the casing 64, the semiconductor module 66 and the stator winding As compared with a configuration in which the magnetic flux 51 is disposed without passing through the stator core 52, even if a magnetic flux is generated from the semiconductor module 66, the magnetic flux is less likely to affect the stator winding 51. Further, even if a magnetic flux is generated from the stator winding 51, the magnetic flux hardly affects the semiconductor module 66. It is more effective if the entire semiconductor module 66 is arranged in a region surrounded by the stator core 52 arranged radially outside the cylindrical portion 71 of the casing 64. Further, when at least a part of the semiconductor module 66 is surrounded by the cooling water passage 74, it is possible to obtain an effect that heat from the stator winding 51 and the magnet unit 42 does not easily reach the semiconductor module 66.
  • a through-hole 78 is formed near the end plate 63 in the cylindrical portion 71, through which 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 inserted.
  • the wiring member 79 is connected to the end of the stator winding 51 and the bus bar 76c of the wiring module 76 by crimping, welding, or the like.
  • the wiring member 79 is, for example, a bus bar, and its joint surface is desirably flattened.
  • the through holes 78 may be provided at one or a plurality of positions. In the present embodiment, the through holes 78 are provided at two positions. In the configuration in which the through holes 78 are provided at two locations, the winding terminals extending from the two sets of three-phase windings can be easily connected by the wiring members 79, respectively, which is suitable for performing multiphase connection. It has become.
  • the rotor 40 and the stator 50 are provided in this order from the outside in the radial direction as shown in FIG. 4, and the inverter unit 60 is provided inside the stator 50 in the radial direction.
  • 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. I have.
  • a region radially inward from the inner peripheral surface of the stator 50 on the radial inner side (that is, the inner peripheral surface of the stator core 52) is defined as a first region X1
  • the cross-sectional area of the first region X1 is larger than the cross-sectional area of the second region X2.
  • the volume of the first region X1 is larger than the volume of the second region X2.
  • a first region X1 radially inward from the inner peripheral surface of the magnetic circuit component assembly in the housing 30 is formed in the magnetic circuit component assembly in the radial direction.
  • a configuration of a stator in a rotating electric machine there is known a configuration in which a plurality of slots are provided in a circumferential direction on a stator core made of laminated steel sheets and forming an annular shape, and a stator winding is wound in the slots.
  • the stator core has a plurality of teeth extending in a radial direction at predetermined intervals from the yoke, and a slot is formed between adjacent teeth in the circumferential direction.
  • a plurality of layers of conductors are accommodated in the slot, for example, in the radial direction, and the conductors constitute a stator winding.
  • stator winding 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, and as a result, the rotating electric machine It is possible that the torque density is limited. That is, in the stator core, it is considered that the magnetic flux is generated by energizing the stator windings and concentrates on the teeth, thereby causing magnetic saturation.
  • FIG. 7 is a torque diagram showing the relationship between the ampere turn [AT] indicating the magnetomotive force of the stator winding and the torque density [Nm / L].
  • the dashed line indicates the characteristic in a general IPM rotor type rotating electric machine.
  • FIG. 7 in a general rotating electric machine, by increasing the magnetomotive force in the stator, magnetic saturation occurs at two places, ie, the teeth portion between the slots and the q-axis core portion. The increase in torque is limited.
  • the ampere-turn design value is limited by A1.
  • the following configuration is provided to the rotating electric machine 10 in order to eliminate the limitation caused by the magnetic saturation. That is, as a first contrivance, a slotless structure is employed in the stator 50 in order to eliminate magnetic saturation caused by teeth of the stator core in the stator, and in order to eliminate magnetic saturation occurring in the q-axis core portion of the IPM rotor. , SPM (Surface @ Permanent @ Magnet) rotor. According to the first device, the above two portions where magnetic saturation occurs can be eliminated, but it is conceivable that the torque in the low current region decreases (see the dashed line in FIG. 7).
  • a pole anisotropic structure is adopted in which the magnet magnetic path is lengthened and the magnetic force is increased in the magnet unit 42 of the rotor 40 in order to recover the torque reduction by increasing the magnetic flux of the SPM rotor. ing.
  • the coil side portion 53 of the stator winding 51 employs a flat conductor structure in which the radial thickness of the conductor in the stator 50 is reduced, thereby reducing torque reduction.
  • 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 increased.
  • the generation of radial eddy currents in the stator windings 51 can be suppressed because the flat conductive wire structure is thin in the radial direction.
  • the magnet having a high magnetic force is used. Concerns about possible large eddy current generation can also be improved.
  • a magnet unit having a magnetic flux density distribution close to a sine wave using a pole anisotropic structure is adopted. According to this, the torque can be increased by increasing the sine wave matching ratio by pulse control or the like described later, and eddy current loss (copper loss due to eddy current: eddy current loss) due to a gradual change in magnetic flux compared to the radial magnet. ) Can also be further suppressed.
  • the sine wave matching ratio can be determined by comparing a measured waveform of the surface magnetic flux density distribution measured by tracing the surface of the magnet with a magnetic flux probe and a 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 rotating electrical machine, to the amplitude of the actually measured waveform, that is, the amplitude of the fundamental wave plus other harmonic components, corresponds to the sine wave matching ratio.
  • the sine wave matching ratio increases, the waveform of the surface magnetic flux density distribution approaches a sine wave shape.
  • the surface magnetic flux density distribution may be estimated by a method other than the actual measurement, for example, an electromagnetic field analysis using Maxwell's equation.
  • the stator winding 51 has a wire conductor structure in which a plurality of wires are gathered and bundled. According to this, since the wires are connected in parallel, a large current can flow, and the generation of the eddy current generated in the conductors extending in the circumferential direction of the stator 50 in the flat conductor structure is reduced by the cross-sectional area of each of the wires. Can be more effectively suppressed than by reducing the thickness in the radial direction by the third device. And, by using a configuration in which a plurality of strands are twisted, the eddy current with respect to the magnetic flux generated by the right-handed screw rule in the direction of current flow can be offset with respect to the magnetomotive force from the conductor.
  • the torque is increased while the eddy current loss caused by the high magnetic force is suppressed while employing the magnet having the high magnetic force as the second device. Can be planned.
  • FIG. 8 is a cross-sectional view of the rotor 40 and the stator 50
  • 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.
  • FIG. 12 is a perspective view of the stator winding 51. 8 and 9, the magnetization directions of the magnets in the magnet unit 42 are indicated by arrows.
  • the stator core 52 is formed by laminating a plurality of electromagnetic steel sheets in the axial direction, and has a cylindrical shape having a predetermined thickness in the radial direction, and is located on the rotor 40 side.
  • the stator winding 51 is mounted radially outward.
  • the outer peripheral surface on the rotor 40 side is a conductive wire installation portion (conductor area).
  • the outer peripheral surface of the stator core 52 has a curved surface without irregularities, and a plurality of conductive wire groups 81 are arranged on the outer peripheral surface at predetermined intervals in the circumferential direction.
  • the stator core 52 functions as a back yoke which is a part of a magnetic circuit for rotating the rotor 40.
  • the teeth that is, the iron core
  • the teeth made of the soft magnetic material are not provided between the two conductive wire groups 81 that are adjacent in the circumferential direction (that is, the slotless structure).
  • a structure is such that the resin material of the sealing member 57 enters the gaps 56 between the conductive wire groups 81. That is, in the stator 50, the inter-conductor member provided between the respective conductor groups 81 in the circumferential direction is configured as the sealing member 57 which is a non-magnetic material.
  • each conductor group 81 is composed of two conductors 82 as described later, and only the non-magnetic material occupies between each two conductor groups 81 adjacent in the circumferential direction of the stator 50.
  • the non-magnetic material includes a non-magnetic gas such as air, a non-magnetic liquid, and the like in addition to the sealing member 57.
  • the sealing member 57 is also referred to as a conductor-to-conductor member.
  • the configuration in which the teeth are provided between the conductor groups 81 arranged 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 this is a configuration in which a part of the magnetic circuit, that is, a magnet magnetic path is formed between the magnetic circuits 81. In this regard, a 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-described magnetic circuit is not formed.
  • the stator winding (that is, the 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). 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 is a fixed phase functioning as one of the polyphases of the stator winding 51 (three phases in the embodiment: three phases of U phase, V phase and W phase or three phases of X phase, Y phase and Z phase). This is the circumferential length of a part of the stator winding 51 of the slave winding 51.
  • the thickness T2 is smaller than the total width dimension of the two conductive wire groups 81 existing in the width W2.
  • the cross-sectional shape of the stator winding 51 (more specifically, the conductive wire 82) is a perfect circle, an ellipse, or a polygon, among the cross-sections of the conductive wire 82 along the radial direction of the stator 50, In the section, the maximum length in the radial direction of the stator 50 may be W12, and in the section, the maximum length in the circumferential direction of the stator 50 may be W11.
  • the stator winding 51 is sealed with 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.
  • the sealing member 57 is provided between the conductive wire groups 81, that is, the gap 56 is filled with a synthetic resin material. And an insulating member interposed therebetween. That is, the sealing member 57 functions as an insulating member in the gap 56.
  • the sealing member 57 extends radially outside the stator core 52 in a range that includes all of the conductor groups 81, that is, in a range in which the radial thickness dimension is larger than the radial thickness dimension of each conductor group 81. Is provided.
  • 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 in a range including at least a part of the end face of the stator core 52 facing the axial direction.
  • the stator windings 51 are resin-sealed substantially at the ends of the phase windings of the respective phases, that is, substantially entirely except for connection terminals with the inverter circuit.
  • the sealing member 57 In the configuration in which the sealing member 57 is provided in a range including the end face of the stator core 52, the sealing member 57 can press the laminated steel sheet of the stator core 52 inward in the axial direction. Thereby, the laminated state of each steel plate can be maintained using the sealing member 57.
  • the inner peripheral surface of the stator core 52 is not resin-sealed in the present embodiment, the entire stator core 52 including the inner peripheral surface of the stator core 52 is resin-sealed instead. It may be a configuration.
  • the sealing member 57 is made of a highly heat-resistant fluororesin, epoxy resin, PPS resin, PEEK resin, LCP resin, silicon resin, PAI resin, PI resin, or the like. Preferably, it is configured. Further, considering the coefficient of linear expansion from the viewpoint of suppressing cracking due to the difference in expansion, it is preferable that the material is the same as the outer coating of the conductor of the stator winding 51. That is, a silicone resin whose linear expansion coefficient is generally twice or more that of another resin is desirably excluded.
  • a PPO resin, a phenol resin, and an FRP resin having a heat resistance of about 180 ° C. are also candidates. This is not the case in a field where the ambient temperature of the rotating electric machine can be regarded as being lower than 100 ° C.
  • the torque of the rotating electric machine 10 is proportional to the magnitude of the magnetic flux.
  • the maximum magnetic flux amount at the stator is limited depending on the saturation magnetic flux density at the teeth, but the stator core does not have teeth. In such a case, the maximum magnetic flux amount at the stator is not limited. Therefore, the configuration is advantageous in increasing the current flowing through the stator winding 51 to increase the torque of the rotating electric machine 10.
  • the use of a structure (slotless structure) without teeth in the stator 50 reduces the inductance of the stator 50.
  • the inductance of the stator of a general rotary electric machine in which a conductor is accommodated in each slot partitioned by a plurality of teeth is, for example, about 1 mH
  • the inductance of the stator 50 of the present embodiment is about 1 mH. It is reduced to about 5 to 60 ⁇ H.
  • the mechanical time constant Tm can be reduced by reducing the inductance of the stator 50 while using the rotating electric machine 10 having the outer rotor structure. That is, the mechanical time constant Tm can be reduced while increasing the torque.
  • the mechanical time constant Tm (J ⁇ L) / (Kt ⁇ Ke) In this case, it can be confirmed that the mechanical time constant Tm is reduced by reducing the inductance L.
  • Each conductor group 81 radially outside the stator core 52 is configured by arranging a plurality of conductors 82 having a flat rectangular cross section in a radial direction of the stator core 52.
  • Each conductive wire 82 is arranged in a direction that satisfies “radial dimension ⁇ circumferential dimension” in a cross section.
  • the thickness of each conductive wire group 81 in the radial direction is reduced.
  • the thickness of the conductor region is reduced in the radial direction, and the conductor region extends flat to the region where the teeth are conventionally formed, so that the conductor region has a flat conductor region structure.
  • each of the conductive wire group 81 and each of the conductive wires 82 are also referred to as a conductive member.
  • 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.
  • the conductor region / conductor non-occupied region in one circumferential direction of the stator winding is 1 or less.
  • each conductor group 81 is provided such that the conductor region is equal to the conductor non-occupied region or the conductor region is larger than the conductor non-occupied region.
  • the radial thickness of the conductor group 81 is smaller than the circumferential width of one phase in one magnetic pole. That is, in a configuration in which the conductor group 81 is formed of two layers of conductors 82 in the radial direction and two conductor groups 81 are provided in the circumferential direction for one phase in one magnetic pole, the radial thickness of each conductor 82 is reduced. Tc, when the width of the conductor 82 in the circumferential direction is Wc, the configuration is such that “Tc ⁇ 2 ⁇ Wc ⁇ 2”.
  • the conductor group 81 is formed of two layers of conductors 82 and one conductor group 81 is provided in one magnetic pole in the circumferential direction for one phase. It is good to be constituted so that it may become.
  • the conductor portions (conductor group 81) arranged at predetermined intervals in the circumferential direction in the stator winding 51 have a radial thickness that is larger than a circumferential width of one phase in one magnetic pole. It is small.
  • each conductor 82 has a thickness Tc in the radial direction smaller than a width Wc in the circumferential direction. Furthermore, the thickness (2Tc) in the radial direction of the wire group 81 composed of two layers of wires 82 in the radial direction, that is, the radial thickness (2Tc) of the wire group 81 is larger than the width Wc in the circumferential direction. Good to be small.
  • the torque of the rotating electric machine 10 is substantially inversely proportional to the radial thickness of the stator core 52 of the conductor group 81.
  • the configuration is advantageous in increasing the torque of the rotating electric machine 10.
  • 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
  • the flux linkage of the stator core 52 by the permanent magnet can be increased, and the torque can be increased.
  • the thickness of the conductor group 81 is reduced, even if the magnetic flux leaks from the conductor 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 a decrease in magnetic force due to magnetic flux leakage, to increase the linkage magnetic flux of the stator core 52 by the permanent magnet, and to increase the torque.
  • the conductor 82 (conductor) is made of a covered conductor in which the surface of a conductor (conductor body) 82a is covered with an insulating coating 82b, and between the conductors 82 that overlap each other in the radial direction, and between the conductor 82 and the stator core 52. In each case, insulation is ensured.
  • the insulating coating 82b is formed of an insulating member that is laminated separately from the coating of the element wire 86 described later if the element wire 86 is a self-fused coated wire or the coating of the element wire 86.
  • each of the phase windings constituted by the conductive wires 82 has an insulating property by the insulating coating 82b except for an exposed portion for connection.
  • the exposed portion is, for example, an input / output terminal portion or a neutral point portion in the case of a star connection.
  • the conductive wires 82 adjacent to each other in the radial direction are fixed to each other by using a resin fixing or a self-sealing coated wire. This suppresses dielectric breakdown, vibration, and sound due to the rubbing of the conductive wires 82.
  • the conductor 82a is configured as an aggregate of a plurality of wires 86. Specifically, as shown in FIG. 13, the conductor 82a is formed in a twisted yarn shape by twisting a plurality of strands 86. Further, as shown in FIG. 14, the strand 86 is configured as a composite in which thin fibrous conductive materials 87 are bundled.
  • 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 replaced by boron are used.
  • a vapor grown carbon fiber (VGCF) or the like can be used in addition to the CNT fiber, but it is preferable to use the CNT fiber.
  • the surface of the wire 86 is covered with a polymer insulating layer such as enamel.
  • the surface of the wire 86 is preferably covered with a so-called enamel coating made of a polyimide coating or an amide imide coating.
  • the conductor 82 forms an n-phase winding in the stator winding 51.
  • the strands 86 of the conductor 82 (that is, the conductor 82a) are adjacent to each other in a contact state.
  • the conducting wire 82 has, at one or more locations in the phase, a portion where the winding conductor is formed by twisting the plurality of strands 86, and the resistance between the twisted strands 86 is the strand 86 itself.
  • the wire aggregate is larger than the resistance value.
  • each two adjacent wires 86 have a first electrical resistivity in the adjacent direction, and if each of the wires 86 has a second electrical resistivity in its length direction, the first electrical resistivity
  • the ratio has a value larger than the second electric resistivity.
  • the conductor 82 may be formed by a plurality of strands 86, and may be a strand aggregate that covers the plurality of strands 86 with an insulating member having an extremely high first electrical resistivity.
  • the conductor 82a of the conductor 82 is constituted by a plurality of twisted strands 86.
  • the method of insulating the wires 86 is not limited to the above-described polymer insulating film, but may be a method of making the current less likely to flow between the twisted wires 86 using contact resistance. That is, if the resistance value between the twisted strands 86 is larger than the resistance value of the strand 86 itself, the above effect can be obtained by the potential difference generated due to the difference in the resistance value. .
  • the manufacturing facility for producing the strand 86 and the production facility for producing the stator 50 (armature) of the rotary electric machine 10 as separate non-continuous facilities, the travel time, the working interval, and the like make it possible to use the strand. 86 is oxidized and the contact resistance can be increased, which is preferable.
  • the conducting wire 82 has a flat rectangular shape in cross section, and is arranged in a plurality in the radial direction.
  • the conducting wire 82 is covered with a self-sealing covered wire including a fusion layer and an insulating layer.
  • a self-sealing covered wire including a fusion layer and an insulating layer.
  • the thickness of the insulating film 82b on the conductor 82 is, for example, 80 ⁇ m to 100 ⁇ m, and is thicker than the thickness of a commonly used conductor (5 to 40 ⁇ m), the insulation between the conductor 82 and the stator core 52 is formed. Even without paper or the like, the insulation between the two can be ensured.
  • the insulating coating 82b has a higher insulating performance than the insulating layer of the strand 86, and is configured to be able to insulate between the phases.
  • the thickness of the polymer insulating layer of the strand 86 is, for example, about 5 ⁇ m
  • the thickness of the insulating coating 82b of the conducting wire 82 is about 80 to 100 ⁇ m so that the interphase insulation can be suitably performed. Is desirable.
  • the conductor 82 may have a configuration in which a plurality of strands 86 are bundled without being twisted.
  • 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 a part of the entire length, and a plurality of strands 86 in the entire length.
  • any one of the bundled configurations may be used.
  • each of the conductors 82 constituting the conductor portion includes a plurality of strands 86 bundled together, and a wire aggregate in which the resistance value between the bundled strands is larger than the resistance value of the strand 86 itself. Has become.
  • Each conductive 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. .
  • a coil side portion 53 is formed by a straight portion 83 extending linearly in the axial direction of each of the conductors 82, and is located on both outer sides of the coil side portion 53 in the axial direction.
  • the coil ends 54 and 55 are formed by the projecting turn portions 84.
  • Each conductor 82 is configured as a series of corrugated conductors by alternately repeating a straight portion 83 and a turn portion 84.
  • the linear portions 83 are disposed at positions radially opposed to the magnet unit 42, and the linear portions 83 of the same phase, which are arranged at predetermined intervals at a position outside the magnet unit 42 in the axial direction, They are connected to each other by a turn part 84. Note that the straight portion 83 corresponds to a “magnet facing portion”.
  • the stator winding 51 is formed in an annular shape by distributed winding.
  • linear portions 83 are arranged in the circumferential direction at intervals corresponding to one pole pair of the magnet unit 42 for each phase, and in the coil ends 54 and 55, the linear portions 83 for each phase are arranged.
  • a turn portion 84 formed in a substantially V shape.
  • the straight portions 83 forming a pair corresponding to one pole pair have current directions opposite to each other.
  • the combination of the pair of linear portions 83 connected by the turn portion 84 is different between the one coil end 54 and the other coil end 55, and the connection at the coil ends 54, 55 is made in the circumferential direction.
  • the stator winding 51 is formed in a substantially cylindrical shape.
  • the stator winding 51 constitutes a winding for each phase using two pairs of conducting wires 82 for each phase, and one of the three windings (U Phase, V phase, W phase) and the other three-phase winding (X phase, Y phase, Z phase) are provided in two layers inside and outside in the radial direction.
  • the linear portions 83 are arranged so as to overlap in two layers adjacent in the radial direction, and at the coil ends 54 and 55, the linear portions 83 which overlap in the radial direction are arranged.
  • the turn portion 84 is configured to extend in the circumferential direction in directions opposite to each other in the circumferential direction. In other words, in each of the radially adjacent conductors 82, the directions of the turn portions 84 are opposite to each other except for the end of the stator winding 51.
  • FIGS. 15A and 15B are diagrams showing the form of each conductor 82 in the n-th layer.
  • FIG. 15A shows the shape of each conductor 82 viewed from the side of the stator winding 51.
  • FIG. 15B shows the shape of the conductive wire 82 as viewed from one axial side of the stator winding 51.
  • D1, D2, D3, the positions where the conductor groups 81 are arranged are indicated as D1, D2, D3,.
  • only three conductive wires 82 are shown, which are a first conductive wire 82_A, a second conductive wire 82_B, and a third conductive wire 82_C.
  • the straight portions 83 are arranged at the position of the nth layer, that is, at the same position in the radial direction, and the straight portions 83 separated from each other by six positions (3 ⁇ m pairs) in the circumferential direction. They are connected to each other by a turn part 84.
  • the straight portions 83 are connected to each other by one turn 84.
  • a pair of straight portions 83 are arranged at D ⁇ b> 1 and D ⁇ b> 7, respectively, and the pair of straight portions 83 are connected by an inverted V-shaped turn portion 84.
  • the other conductors 82_B and 82_C are arranged in the same n-th layer with their circumferential positions shifted one by one.
  • the turn portions 84 may interfere with each other. For this reason, in the present embodiment, an interference avoiding portion in which a part thereof is radially offset is formed in the turn portion 84 of each of the conductive wires 82_A to 82_C.
  • the turn portion 84 of each of the conductors 82_A to 82_C is formed by a single inclined portion 84a which is a portion extending in the circumferential direction on the same circle (first circle), and the same circle from the inclined portion 84a. Also shifts radially inward (upward in FIG. 15 (b)) to reach another circle (second circle), the top portion 84b, the inclined portion 84c extending in the circumferential direction on the second circle, and the first circle. And a return portion 84d that returns to the second circle.
  • the top portion 84b, the inclined portion 84c, and the return portion 84d correspond to an interference avoiding portion.
  • the inclined portion 84c may be configured to shift radially outward with respect to the inclined portion 84a.
  • the turn portion 84 of each of the conductors 82_A to 82_C has a slope portion 84a on one side and a slope portion 84c on the other side on both sides of the top portion 84b, which is a central position in the circumferential direction.
  • the radial positions of the inclined portions 84a and 84c are different from each other.
  • the turn portion 84 of the first conductive wire 82 ⁇ / b> _A extends in the circumferential direction from the position D ⁇ b> 1 of the n-layer as a starting point, and bends in the radial direction (for example, radially inward) at the top portion 84 b which is the central position in the circumferential direction.
  • the radial direction for example, radially inward
  • the return portion 84d By turning again in the circumferential direction, it extends again in the circumferential direction, and further turns again in the radial direction (for example, radially outward) at the return portion 84d, thereby reaching the D7 position of the n-layer, which is the end point position. I have.
  • one of the inclined portions 84a is vertically arranged in order from the top in the order of the first conductor 82_A ⁇ the second conductor 82_B ⁇ the third conductor 82_C, and each of the conductors 82_A ⁇ 82_C is turned upside down, and the other inclined portions 84c are arranged vertically from the top in the order of the third conductor 82_C ⁇ the second conductor 82_B ⁇ the first conductor 82_A. Therefore, the conductors 82_A to 82_C can be arranged in the circumferential direction without interfering with each other.
  • a turn portion 84 connected to the radially inner straight portion 83 of the plurality of linear portions 83 and a radially outer straight portion 83 are formed. It is preferable that the turn portions 84 connected to the straight portions 83 are arranged further apart from each other in the radial direction than the straight portions 83. Further, when a plurality of layers of the conductive wires 82 are bent to the same side in the radial direction near the end of the turn portion 84, that is, near the boundary with the linear portion 83, the insulation between the conductive wires 82 of the adjacent layers is caused by the interference. Should not be impaired.
  • the conductive wires 82 overlapping in the radial direction are each bent in the radial direction at the return portion 84d of the turn portion 84.
  • the radius of curvature of the bent portion may be different between the conductor 82 of the n-th layer and the conductor 82 of the (n + 1) -th layer.
  • the radius of curvature R1 of the conductive wire 82 on the radially inner side (nth layer) is made smaller than the radius of curvature R2 of the conductive wire 82 on the radially outer side (n + 1th layer).
  • the amount of shift in the radial direction be different between the n-th conductive wire 82 and the (n + 1) -th conductive wire 82.
  • the shift amount S1 of the radially inner (n-th layer) conductive wire 82 is made larger than the shift amount S2 of the radially outer (n + 1-th layer) conductive wire 82.
  • the permanent magnet used in this embodiment is a sintered magnet obtained by sintering and solidifying a granular magnetic material, and has a specific coercive force Hcj on the JH curve of 400 [kA / m] or more.
  • the residual magnetic flux density Br is 1.0 [T] or more.
  • the magnet unit 42 has a saturation magnetic flux density Js of 1.2 [T] or more, a crystal grain size of 10 [ ⁇ m] or less, and Js ⁇ ⁇ is 1 when the orientation ratio is ⁇ . 0.0 [T] or more.
  • the magnet unit 42 is supplemented below.
  • the magnet unit 42 (magnet) is characterized in that 2.15 [T] ⁇ Js ⁇ 1.2 [T].
  • examples of the magnet used for the magnet unit 42 include NdFe11TiN, Nd2Fe14B, Sm2Fe17N3, and a FeNi magnet having an L10 type crystal.
  • configurations such as SmCo5, FePt, Dy2Fe14B, and CoPt, which are generally called samakoba, cannot be used.
  • Dy2Fe14B and Nd2Fe14B generally use heavy rare earth dysprosium like Dy2Fe14B and Dy2Fe14B.
  • a rotating electric machine operated at a temperature outside the range of human activity for example, 60 ° C. or more, which is higher than the temperature in the desert
  • a motor application for a vehicle in which the temperature in a vehicle is close to 80 ° C. in summer it is desirable to include components of FeNi and Sm2Fe17N3 having a small temperature dependence coefficient. This is due to the temperature-dependent coefficient in the motor operation from the temperature range near ⁇ 40 ° C. in Northern Europe, which is within the range of human activity, to 60 ° C. or more, which exceeds the desert temperature described above, or to the heat-resistant temperature of the coil enamel coating of about 180 to 240 ° C.
  • the magnet unit 42 is characterized in that the particle size in the fine powder state before orientation is 10 ⁇ m or less and the single domain particle size or more using the above-described magnet composition.
  • the coercive force is increased by reducing the size of powder particles to the order of several hundreds of nm.
  • powders that have been made as fine as possible have been used in recent years.
  • the particle size is too small, the BH product of the magnet decreases due to oxidation or the like.
  • the size of the particle diameter described here is the size of the particle diameter in a fine powder state in the orientation step in the magnet manufacturing process.
  • each of the first magnet 91 and the second magnet 92 of the magnet unit 42 is a sintered magnet formed by so-called sintering of magnetic powder baked at a high temperature.
  • the saturation magnetization Js of the magnet unit 42 is 1.2 T or more
  • the crystal grain sizes of the first magnet 91 and the second magnet 92 are 10 ⁇ m or less
  • the orientation ratio is ⁇
  • Js ⁇ ⁇ is It is performed so as to satisfy the condition of 1.0 T (tesla) or more.
  • Each of the first magnet 91 and the second magnet 92 is sintered so as to satisfy the following conditions.
  • the orientation is performed in the orientation process in the manufacturing process, so that the orientation is different from the definition of the magnetic force direction in the isotropic magnet magnetization process.
  • the saturation magnetization Js of the magnet unit 42 of the present embodiment is 1.2 T or more
  • the orientation ratio ⁇ of the first magnet 91 and the second magnet 92 is so high that Jr ⁇ Js ⁇ ⁇ ⁇ 1.0 [T].
  • the orientation ratio is set. Note that the orientation ratio ⁇ here refers to, for example, in each of the first magnet 91 or the second magnet 92, there are six easy axes, and five of them have the same direction, that is, the direction A10.
  • the first magnet 91 and the second magnet 92 are formed by sintering, but if the above conditions are satisfied, the first magnet 91 and the second magnet 92 may be formed by another method. .
  • a method of forming an MQ3 magnet or the like can be adopted.
  • the permanent magnet whose easy axis of magnetization is controlled by the orientation is used. Therefore, the magnetic circuit length inside the magnet is set to be equal to the magnetic circuit length of a linearly oriented magnet that conventionally outputs 1.0 [T] or more. In comparison, it can be longer. In other words, a magnetic circuit length per pole pair can be achieved with a small amount of magnets, and the reversible demagnetization range is maintained even when exposed to severe high-temperature conditions, compared to a design using conventional linearly-oriented magnets. Can be. In addition, the present inventor has found a configuration in which characteristics similar to those of a polar anisotropic magnet can be obtained even when a conventional magnet is used.
  • the axis of easy magnetization refers to a crystal orientation that is easily magnetized in a magnet.
  • the direction of the axis of easy magnetization in the magnet is a direction in which the degree of orientation indicating the degree of alignment of the direction of the axis of easy magnetization is 50% or more, or a direction in which the orientation of the magnet is average.
  • the magnet unit 42 has an annular shape and is provided inside the magnet holder 41 (specifically, inside the cylindrical portion 43 in the radial direction).
  • the magnet unit 42 is a polar anisotropic magnet and has a first magnet 91 and a second magnet 92 having 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 forming an N pole in a portion near the stator winding 51
  • the second magnet 92 is a magnet forming an S pole in a portion near the stator winding 51.
  • the first magnet 91 and the second magnet 92 are permanent magnets made of a rare earth magnet such as a neodymium magnet.
  • each of the magnets 91 and 92 has a d-axis (direct-axis), which is the center of the magnetic pole, and a magnetic pole boundary between the N pole and the S pole in a known dq coordinate system (in other words, the magnetic flux density). Is 0 Tesla) and the magnetization direction extends in an arc shape with respect to the q-axis (quadrature-axis).
  • the magnetization direction is the radial direction of the annular magnet unit 42 on the d-axis side
  • the magnetization direction of the annular magnet unit 42 is the circumferential direction on the q-axis side.
  • 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.
  • the first portion 250 is closer to the d-axis than the second portion 260
  • 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 easy axis 300 of the first portion 250 is more parallel to the d axis than the direction of the easy axis 310 of the second portion 260.
  • the magnet unit 42 is configured such that the angle ⁇ 11 between the easy axis 300 of the first portion 250 and the d axis is smaller than the angle ⁇ 12 between the easy axis 310 of the second portion 260 and the q axis. I have.
  • the angle ⁇ 11 is an angle formed between the d axis and the easy axis 300 when the direction from the stator 50 (armature) toward the magnet unit 42 is positive on the d axis.
  • the angle ⁇ 12 is an angle formed between the q axis and the easy axis 310 when the direction from the stator 50 (armature) toward the magnet unit 42 is positive on the q axis. Note that both the angle ⁇ 11 and the angle ⁇ 12 are 90 ° or less in the present embodiment.
  • each of the easy axes 300 and 310 has the following definition.
  • the cosine of the angle ⁇ between the direction A11 and the direction B11 is obtained.
  • ) is defined as the easy axis 300 or the easy axis 310.
  • each of the magnets 91 and 92 has a different direction of the axis of easy magnetization on the d-axis side (portion closer to the d-axis) and on the q-axis side (portion closer to the q-axis).
  • the direction of the easy axis is close to the direction parallel to the d-axis
  • the direction of the easy axis of magnetization is close to the direction orthogonal to the q-axis on the q-axis side.
  • An arc-shaped magnet magnetic path is formed in accordance with the direction of the axis of easy magnetization.
  • the easy axis may be oriented parallel to the d axis on the d-axis side, and the easy axis may be orthogonal to the q axis on the q-axis side.
  • the stator-side outer surface of the magnets 91 and 92 on the stator 50 side (the lower side in FIG. 9) and the end surface on the q-axis side in the circumferential direction form a magnetic flux.
  • It is a magnetic flux acting surface which is an inflow / outflow surface, and a magnet magnetic path is formed so as to connect those magnetic flux acting surfaces (an outer surface on the stator side and an end surface on the q-axis side).
  • the magnetic flux flows in an arc between the adjacent N and S poles by the magnets 91 and 92, so that the magnet magnetic path is longer than, for example, a radial anisotropic magnet. Therefore, as shown in FIG. 17, the magnetic flux density distribution becomes close to a sine wave. As a result, unlike the magnetic flux density distribution of the radial anisotropic magnet shown as a comparative example in FIG. 18, the magnetic flux can be concentrated on the center side of the magnetic pole, and the torque of the rotating electric machine 10 can be increased. Further, in the magnet unit 42 of the present embodiment, it can be confirmed that there is a difference in the magnetic flux density distribution as compared with the conventional Halbach array magnet.
  • the horizontal axis represents the electrical angle
  • the vertical axis represents the magnetic flux density.
  • 17 and 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.
  • the magnet magnetic flux on the d-axis is strengthened, and the change in magnetic flux near the q-axis is suppressed.
  • the magnets 91 and 92 in which the surface magnetic flux changes gradually from the q axis to the d axis in each magnetic pole.
  • the sine wave matching ratio of the magnetic flux density distribution may be, for example, 40% or more. In this way, the amount of magnetic flux in the center portion of the waveform can be reliably improved as compared with the case of using a radially oriented magnet or a parallelly oriented magnet having a sine wave matching ratio of about 30%. Further, when the sine wave matching ratio is 60% or more, the amount of magnetic flux at the center portion of the waveform can be reliably improved as compared with a magnetic flux concentration array such as a Halbach array.
  • the magnetic flux density changes sharply near the q-axis.
  • the change in the magnetic flux density becomes steeper, the eddy current generated in the stator winding 51 increases. Further, the magnetic flux change on the stator winding 51 side also becomes steep.
  • the magnetic flux density distribution has a magnetic flux waveform close to a sine wave. For this reason, near the q-axis, the change in the magnetic flux density is smaller than the change in the magnetic flux density of the radial anisotropic magnet. Thereby, generation of eddy current can be suppressed.
  • a magnetic flux is generated in a direction orthogonal to the magnetic flux acting surface 280 on the stator 50 near the d-axis of each of the magnets 91 and 92 (that is, the center of the magnetic pole).
  • the shape of the arc increases as the distance from the d-axis increases. Further, the more the magnetic flux is perpendicular to the magnetic flux acting surface, the stronger the magnetic flux becomes.
  • the stator 50 can receive a strong magnet magnetic flux from the rotor 40.
  • the stator 50 is provided with a cylindrical stator core 52 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 surfaces of the magnets 91 and 92 is attracted to the stator core 52 and orbits while using the stator core 52 as a part of the magnetic path. In this case, the direction and path of the magnet magnetic flux can be optimized.
  • the inverter unit 60 has a unit base 61 and an electric component 62 as shown in FIG. 6, and each operation process including a process of assembling the unit base 61 and the electric component 62 will be described.
  • an assembly including the stator 50 and the inverter unit 60 is referred to as a first unit
  • an assembly including the bearing unit 20, the housing 30, and the rotor 40 is referred to as a second unit.
  • This manufacturing process A first step of mounting the electrical component 62 inside the unit base 61 in the radial direction; A second step of mounting the unit base 61 on the radially inner side of the stator 50 to produce a first unit; A third step of manufacturing the second unit by inserting the fixing portion 44 of the rotor 40 into the bearing unit 20 assembled in the housing 30; A fourth step of mounting the first unit radially inside the second unit; A fifth step of fastening and fixing the housing 30 and the unit base 61; have.
  • the order of execution of these steps is first step ⁇ second step ⁇ third step ⁇ fourth step ⁇ fifth step.
  • the assemblies are assembled. Easy handling and complete inspection of each unit can be realized, and a reasonable assembly line can be constructed. Therefore, it is possible to easily cope with multi-product production.
  • a good heat conductor having good heat conduction is adhered to at least one of the radially inner side of the unit base 61 and the radially outer side of the electric component 62 by coating, bonding, or the like. It is preferable to mount the electric component 62 on the unit base 61. Thus, heat generated by the semiconductor module 66 can be effectively transmitted to the unit base 61.
  • the rotor 40 may be inserted while the coaxial relationship between the housing 30 and the rotor 40 is maintained. 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 with reference to the inner peripheral surface of the housing 30. Using the jig, the housing 30 and the rotor 40 are assembled while sliding either the housing 30 or the rotor 40 along the jig. This makes it possible to mount a heavy component without applying an unbalanced load to the bearing unit 20, and the reliability of the bearing unit 20 is improved.
  • the fourth step it is preferable to carry out the assembly of the first unit and the second unit while maintaining the coaxiality of the two units.
  • a jig that determines the position of the inner peripheral surface of the unit base 61 with reference to the inner peripheral surface of the fixing portion 44 of the rotor 40 is used, and the first unit and the second unit are moved along the jig. Assemble these units while sliding any of them. As a result, it is possible to assemble the rotor 40 and the stator 50 while preventing mutual interference between the extremely small gaps. Defective products can be eliminated.
  • the order of the above steps may be the second step ⁇ the third step ⁇ the fourth step ⁇ the fifth step ⁇ the first step.
  • the delicate electric component 62 is assembled last, and the stress on the electric component 62 in the assembling process can be minimized.
  • FIG. 19 is an electric circuit diagram of a control system of the rotating electric machine 10
  • FIG. 20 is a functional block diagram illustrating a control process performed by the control device 110.
  • the stator winding 51 includes a U-phase winding, a V-phase winding, and a W-phase winding.
  • the phase winding 51b includes an X-phase winding, a Y-phase winding, and a Z-phase winding.
  • a first inverter 101 and a second inverter 102 each corresponding to a 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 the same number of upper and lower arms as the number of phases of the phase windings, and the switches (semiconductor switching elements) provided on each arm are turned on and off to turn the stator windings 51 on and off. 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 by, for example, an assembled battery in which a plurality of cells are connected in series.
  • Each switch of the inverters 101 and 102 corresponds 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. Based on various detection information in the rotating electric machine 10 and requests for powering drive and power generation, the control of the power supply is performed by turning on and off the switches in the inverters 101 and 102. carry out. Control device 110 corresponds to control device 77 shown in FIG.
  • the detection information of the rotating electric 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 energized current of each phase detected by Control device 110 generates and outputs an operation signal for operating each switch of inverters 101 and 102.
  • the power generation request is, for example, a request for regenerative driving when the rotating electric machine 10 is used as a vehicle power source.
  • the first inverter 101 includes a series connection of an upper arm switch Sp and a lower arm switch Sn in three phases including 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 phase windings are star-connected (Y connection), and the other ends of the 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 including an X phase, a Y phase, and a 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 phase windings are star-connected (Y connection), and the other ends of the phase windings are connected to each other at a neutral point.
  • FIG. 20 shows a current feedback control process for controlling the U, V, and W phase currents, and a current feedback control process for controlling the X, Y, and Z phase currents.
  • the control process on the U, V, and W phases will be described first.
  • a current command value setting unit 111 uses a torque-dq map and based on a powering torque command value or a power generation torque command value for the rotating electric machine 10 and an electric angular velocity ⁇ obtained by time-differentiating the electric angle ⁇ . , A d-axis current command value and a q-axis current command value are set.
  • the current command value setting unit 111 is provided in common on the U, V, and W phase sides and the X, Y, and Z phase sides.
  • the power generation torque command value is, for example, a regenerative torque command value when the rotating electric machine 10 is used as a vehicle power source.
  • the dq conversion unit 112 converts a current detection value (three phase currents) obtained by a current sensor provided for each phase into a quadrature 2 with a field direction (direction of an axis of a magnetic field, or field direction) as a d-axis. It is converted into a d-axis current and a q-axis current which are components of the three-dimensional rotation 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 a 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 a q-axis current command value. In each of these feedback control units 113 and 114, the command voltage is calculated using the PI feedback method based on the deviation of the d-axis current and the q-axis current from the current command value.
  • the three-phase converter 115 converts d-axis and q-axis command voltages into U-phase, V-phase, and W-phase command voltages.
  • Each of the units 111 to 115 is a feedback control unit that performs feedback control of the fundamental wave current based on the dq conversion theory, and the U-phase, V-phase, and W-phase command voltages are feedback control values.
  • the operation signal generation unit 116 generates an operation signal for 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 performs a PWM control based on a magnitude comparison between a signal obtained by standardizing a three-phase command voltage with a power supply voltage and a carrier signal such as a triangular wave signal, and thereby switches the upper and lower arms in each phase. An operation signal (duty signal) is generated.
  • the same configuration is also provided on the X, Y, and Z phase sides.
  • the dq conversion unit 122 outputs a current detection value (three phase currents) obtained by a current sensor provided for each phase to the field direction. It is converted into a d-axis current and a q-axis current, which are components of an orthogonal two-dimensional rotating coordinate system with the d axis.
  • the d-axis current feedback control unit 123 calculates a d-axis command voltage
  • the q-axis current feedback control unit 124 calculates a q-axis command voltage.
  • the three-phase converter 125 converts d-axis and q-axis command voltages into X-phase, Y-phase, and Z-phase command voltages.
  • the operation signal generation unit 126 generates an operation signal for the second inverter 102 based on the three-phase command voltage.
  • the operation signal generation unit 126 performs a PWM control based on a magnitude comparison between a signal obtained by standardizing a three-phase command voltage with a power supply voltage and a carrier signal such as a triangular wave signal, and thereby switches the upper and lower arms in each phase.
  • An operation signal (duty signal) is generated.
  • the driver 117 turns on and off the three-phase switches Sp and Sn of the inverters 101 and 102 based on the switch operation signals generated by the operation signal generation units 116 and 126.
  • This process is used mainly for the purpose of increasing the output of the rotating electric machine 10 and reducing the loss under operating conditions in which the output voltage of each of the inverters 101 and 102 becomes large, such as in a high rotation region and a high output region.
  • the control device 110 selects and executes one of the torque feedback control process and the current feedback control process based on the operating conditions of the rotating electric machine 10.
  • FIG. 21 shows a torque feedback control process corresponding to the U, V, and W phases and a torque feedback control process corresponding to the X, Y, and Z phases.
  • the same components as those in FIG. 20 are denoted by the same reference numerals, and description thereof will be omitted.
  • the control process on the U, V, and W phases will be described first.
  • the voltage amplitude calculation unit 127 is a command value for 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 electrical angular velocity ⁇ obtained by time-differentiating the electrical angle ⁇ . Calculate the voltage amplitude command.
  • the torque estimation unit 128a calculates a torque estimation 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. Note that the torque estimating 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.
  • the torque feedback control unit 129a calculates a voltage phase command, which is a command value of a voltage vector phase, as an operation amount for performing feedback control of a torque estimation value to a powering torque command value or a power generation torque command value.
  • the torque feedback control unit 129a calculates a voltage phase command using a PI feedback method based on the deviation of the estimated torque value from the powering torque command value or the generated torque command value.
  • the operation signal generation unit 130a generates an operation signal for the first inverter 101 based on the voltage amplitude command, the voltage phase command, and the electrical angle ⁇ . 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 ⁇ , and standardizes the calculated three-phase command voltage with the power supply voltage. And PWM control based on a magnitude comparison between the signal and a carrier signal such as a triangular wave signal to generate switch operation signals for the upper and lower arms in each phase.
  • a carrier signal such as a triangular wave signal
  • the operation signal generation unit 130a is based on a pulse pattern information, a voltage amplitude command, a voltage phase command, and an electrical angle ⁇ , which are map information in which the voltage amplitude command, the voltage phase command, the electric angle ⁇ and the switch operation signal are related.
  • a switch operation signal may be generated.
  • the X-, Y-, and Z-phase sides also have the same configuration, and the torque estimating unit 128b determines the X, Y, and Z-axis currents based on the d-axis current and the q-axis current converted by the dq An estimated torque value corresponding to the Z phase is calculated.
  • the torque feedback control unit 129b calculates a voltage phase command as an operation amount for feedback-controlling the torque estimation value to the powering torque command value or the power generation torque command value.
  • the torque feedback control unit 129b calculates the voltage phase command using the PI feedback method based on the deviation of the estimated torque value from the powering torque command value or the generated torque command value.
  • the operation signal generator 130b generates an operation signal for the second inverter 102 based on the voltage amplitude command, the voltage phase command, and the electrical angle ⁇ . 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 ⁇ , and standardizes the calculated three-phase command voltage with the power supply voltage. And PWM control based on a magnitude comparison between the signal and a carrier signal such as a triangular wave signal to generate switch operation signals for the upper and lower arms in each phase. The driver 117 turns on and 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.
  • the operation signal generation unit 130b is based on the voltage amplitude command, the voltage phase command, the pulse pattern information that is the map information associated with the electrical angle ⁇ and the switch operation signal, the voltage amplitude command, the voltage phase command, and the electrical angle ⁇ .
  • a switch operation signal may be generated.
  • the following three measures are taken as measures against electrolytic corrosion.
  • the first countermeasure against electric erosion is a countermeasure against electric erosion by reducing the inductance with the coreless stator 50 and making the magnet magnetic flux of the magnet unit 42 gentle.
  • the second countermeasure against electric corrosion is a countermeasure against electric corrosion by using a cantilever structure of the rotating shaft with the bearings 21 and 22.
  • the third countermeasure against electrolytic corrosion is a countermeasure against electrolytic corrosion caused by molding the annular stator winding 51 together with the stator core 52 using a molding material. The details of each of these measures will be described individually below.
  • the stator 50 is made of teethless between the conductor groups 81 in the circumferential direction, and sealed between each conductor group 81 by a nonmagnetic material instead of the teeth (iron core).
  • the member 57 is provided (see FIG. 10).
  • the inductance of the stator 50 can be reduced.
  • the d-axis inductance is equal to or less than the q-axis inductance.
  • the magnets 91 and 92 are configured such that the orientation of the easy axis of magnetization is parallel to the d-axis on the d-axis side as compared to the q-axis side (see FIG. 9).
  • the magnetic flux on the d-axis is strengthened, and the change in the surface magnetic flux (increase / decrease in magnetic flux) from the q-axis to the d-axis becomes gentle at each magnetic pole. Therefore, a rapid voltage change due to the switching imbalance is suppressed, and the configuration can contribute to suppressing electrolytic corrosion.
  • the bearings 21 and 22 are arranged so as to be biased to one side in the axial direction with respect to the axial center of the rotor 40 (see FIG. 2).
  • the influence of electrolytic corrosion can be reduced as compared with a configuration in which a plurality of bearings are provided on both sides of the rotor in the axial direction.
  • a closed circuit that passes through the rotor, the stator, and each bearing is generated as high-frequency magnetic flux is generated.
  • the rotating electric machine 10 has the following configuration in association with the configuration for one-side arrangement of the bearings 21 and 22.
  • a contact avoiding portion that extends in the axial direction and avoids contact with the stator 50 is provided at an intermediate portion 45 that projects in the radial direction of the rotor 40 (see FIG. 2).
  • the length of the closed circuit can be increased to increase the circuit resistance. Thereby, it is possible to suppress the electrolytic corrosion of the bearings 21 and 22.
  • the holding member 23 of the bearing unit 20 is fixed to the housing 30 on one side in the axial direction with the rotor 40 interposed therebetween, and the housing 30 and the unit base 61 (stator holder) are connected to each other on the other side. (See FIG. 2).
  • the unit base 61 since the unit base 61 is connected to the rotating shaft 11 via the housing 30, the unit base 61 can be arranged at a position electrically separated from the rotating shaft 11. If 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 further electrically separated. Thereby, the electrolytic corrosion of the bearings 21 and 22 can be appropriately suppressed.
  • the shaft voltage acting on the bearings 21 and 22 is reduced by arranging the bearings 21 and 22 on one side or the like. Further, the potential difference between the rotor 40 and the stator 50 is reduced. Therefore, the potential difference acting on the bearings 21 and 22 can be reduced without using conductive grease in the bearings 21 and 22. Since the conductive grease generally contains fine particles such as carbon, it is considered that sound is generated. In this regard, in this embodiment, the bearings 21 and 22 are configured to use non-conductive grease. For this reason, it is possible to suppress the inconvenience of generating noise in the bearings 21 and 22. For example, when it is applied to an electric vehicle such as an electric vehicle, it is considered that a countermeasure against the noise of the rotating electric machine 10 is required. However, the countermeasure against the noise can be suitably implemented.
  • the stator winding 51 is molded together with the stator core 52 with a molding material to suppress the displacement of the stator winding 51 in the stator 50 (see FIG. 11). ).
  • the stator winding 51 is molded together with the stator core 52 so that the displacement of the conductor wire of the stator winding 51 is suppressed. Therefore, it is possible to suppress the distortion of the magnetic flux due to the displacement of the stator winding 51 and the occurrence of electrolytic corrosion of the bearings 21 and 22 due to the distortion.
  • 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 a case where the unit base 61 is made of, for example, aluminum. As a result, a suitable countermeasure against electric corrosion is possible.
  • CFRP carbon fiber reinforced plastic
  • the magnet unit 42 is configured using a magnet array called a Halbach array. That is, the magnet unit 42 includes the first magnet 131 having the magnetization direction (the direction of the magnetization vector) in the radial direction and the second magnet 132 having the magnetization direction (the direction of the magnetization vector) in the circumferential direction.
  • the first magnets 131 are arranged at predetermined intervals in the circumferential direction, and the second magnets 132 are arranged 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 a rare earth magnet such as a neodymium magnet.
  • the first magnets 131 are circumferentially separated from each other such that the poles on the side facing the stator 50 (inside in the radial direction) alternately become N poles and S poles.
  • 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 each of the magnets 131 and 132 is preferably a soft magnetic core made of a soft magnetic material, and functions as a back core.
  • the magnet unit 42 of the second embodiment also has the same relationship of the easy axis to the d-axis and the q-axis in the dq coordinate system as in the first embodiment.
  • 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.
  • the magnetic body 133 may be made of an electromagnetic steel sheet, soft iron, or a powdered iron core material.
  • 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).
  • the radial thickness of the integrated body in a state where the first magnet 131 and the magnetic body 133 are integrated is the same as the radial thickness of the second magnet 132.
  • the thickness of the first magnet 131 in the radial direction is smaller than that of the second magnet 132 by the amount of the magnetic body 133.
  • the magnets 131 and 132 and the magnetic body 133 are fixed to each other by, for example, an adhesive.
  • the radial outside of the first magnet 131 is on the opposite side to the stator 50, and the magnetic body 133 is located on the opposite side (anti- On the stator side).
  • a key 134 is formed on the outer periphery of the magnetic body 133 as a protrusion protruding radially outward, that is, toward the cylindrical portion 43 of the magnet holder 41. Further, a key groove 135 is formed on the inner peripheral surface of the cylindrical portion 43 as a concave portion for accommodating the key 134 of the magnetic body 133.
  • the protruding shape of the key 134 and the groove shape of the key groove 135 are the same, and the same number of key grooves 135 as the keys 134 are formed corresponding to the keys 134 formed on each magnetic body 133.
  • the key 134 and the key groove 135 may be provided in any of the cylindrical portion 43 of the magnet holder 41 and the magnetic member 133, and conversely, on the outer peripheral portion of the magnetic member 133.
  • the magnetic flux density in the first magnet 131 can be increased by alternately arranging the first magnets 131 and the second magnets 132. Therefore, in the magnet unit 42, the magnetic flux is concentrated on one side, and the magnetic flux on the side closer to the stator 50 can be enhanced.
  • the magnet unit 42 of the present embodiment has a configuration in which a portion of the first magnet 131 where demagnetization is likely to occur is replaced with a magnetic body 133.
  • FIGS. 24A and 24B are diagrams specifically showing the flow of magnetic flux in the magnet unit 42.
  • FIG. 24A shows a conventional configuration in which the magnet unit 42 does not have the magnetic body 133.
  • FIG. 24B shows a case where the configuration of the present embodiment having the magnetic body 133 in the magnet unit 42 is used.
  • the cylindrical portion 43 and the magnet unit 42 of the magnet holder 41 are linearly developed, and the lower side of the figure is the stator side, and the upper side is the anti-stator. Side.
  • 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.
  • the magnetic flux acting surface of the second magnet 132 is in contact with the side surface of the first magnet 131.
  • the magnetic flux F1 entering the contact surface with the first magnet 131 through the outer path of the second magnet 132 and the magnetic flux F2 of the second magnet 132 substantially parallel to the cylindrical portion 43 pass through the cylindrical portion 43.
  • a combined magnetic flux with the attracting magnetic flux is generated. Therefore, there is a concern that magnetic saturation may partially occur near the contact surface between the first magnet 131 and the second magnet 132 in the cylindrical portion 43.
  • the magnetic body 133 is provided between the magnetic flux acting surface of the first magnet 131 and the inner peripheral surface of the cylindrical portion 43 on the side opposite to the stator 50 of the first magnet 131. 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 the proof strength against demagnetization is improved.
  • FIG. 24B unlike FIG. 24A, F2 that promotes magnetic saturation can be eliminated. Thereby, the permeance of the entire magnetic circuit can be effectively improved. With this configuration, the magnetic circuit characteristics can be maintained even under severe high-temperature conditions.
  • the magnet magnetic path passing inside the magnet is longer. Therefore, the magnet permeance increases, the magnetic force can be increased, and the torque can be increased. Further, since the magnetic flux is concentrated at the center of the d-axis, the sine wave matching ratio can be increased. In particular, when the current waveform is changed to a sine wave or a trapezoidal wave by the PWM control, or a switching IC with 120-degree conduction is used, the torque can be more effectively increased.
  • the radial thickness of the stator core 52 may be 1 / or larger than ⁇ of the radial thickness of the magnet unit 42.
  • the radial thickness of the stator core 52 is preferably equal to or more than ⁇ of the radial thickness of the first magnet 131 provided at the center of the magnetic pole in the magnet unit 42.
  • the radial thickness of the stator core 52 may be smaller than the radial thickness of the magnet unit 42.
  • the magnetic flux of the magnet is about 1 [T]
  • the saturation magnetic flux density of the stator core 52 is 2 [T]
  • the magnetic flux can be increased in proportion to the thickness of the magnet that handles the magnetic flux in the circumferential direction.
  • the magnetic flux flowing through the stator core 52 does not exceed the magnetic flux in the circumferential direction. 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, if the thickness of the stator core 52 is set to half or more of the thickness of the magnet, magnetic saturation does not occur.
  • a small and lightweight rotating electric machine can be provided.
  • the demagnetizing field from the stator 50 acts on the magnet magnetic flux, the magnet magnetic 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 kept suitably high.
  • the outer peripheral surface of the stator core 52 is formed into a curved surface without irregularities, and the plurality of conductive wire groups 81 are arranged at predetermined intervals on the outer peripheral surface.
  • the stator core 52 includes an annular yoke 141 provided on the opposite side (lower side in the figure) to the rotor 40 on both radial sides of the stator winding 51, A projection 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 at predetermined intervals on the radially outer side of the yoke 141, that is, on the rotor 40 side.
  • Each conductor group 81 of the stator winding 51 is engaged with the protrusion 142 in the circumferential direction, and is arranged side by side in the circumferential direction while using the protrusion 142 as a positioning portion of the conductor group 81.
  • the protrusion 142 corresponds to a “member between conductive wires”.
  • the projection 142 has a thickness in the radial direction from the yoke 141, in other words, as shown in FIG. 25, the projection 142 extends from the inner side surface 320 adjacent to the yoke 141 of the linear portion 83 in the radial direction of the yoke 141.
  • the distance W to the apex is smaller than 1/2 (H1 in the figure) of the radial thickness of the linear portion 83 radially adjacent to the yoke 141 among the linear portions 83 in the radially inner and outer layers. It has a configuration.
  • the dimension (thickness) T1 of the conductive wire group 81 (conductive member) in the radial direction of the stator winding 51 (stator core 52) (twice the thickness of the conductive wire 82, in other words, the stator core of the conductive wire group 81)
  • the non-magnetic member (sealing member 57) may occupy three-quarters of the range (the shortest distance between the surface 320 in contact with 52 and the surface 330 of the conductor group 81 facing the rotor 40).
  • the protrusions 142 do not function as teeth between the conductive wire groups 81 (that is, the linear portions 83) that are adjacent in the circumferential direction, and no magnetic path is formed by the teeth. .
  • the protrusions 142 may not be provided entirely between the conductor groups 81 arranged in the circumferential direction, but may be provided between at least one set of conductor groups 81 adjacent in the circumferential direction.
  • the protrusions 142 may be provided at regular intervals in a predetermined number between the conductive wire groups 81 in the circumferential direction.
  • the shape of the protrusion 142 may be an arbitrary shape such as a rectangular shape or an arc shape.
  • a single linear portion 83 may be provided on the outer peripheral surface of the stator core 52. Therefore, in a broad sense, the thickness of the projection 142 in the radial direction from the yoke 141 may be smaller than half the thickness of the straight portion 83 in the radial direction.
  • the protrusion 142 is positioned within the range of the virtual circle. It is preferable to have a shape that protrudes from the yoke 141, in other words, a shape that does not protrude radially outward (ie, toward the rotor 40) from the virtual circle.
  • the thickness of the protrusion 142 in the radial direction is limited and does not function as a tooth between the linear portions 83 adjacent in the circumferential direction. Is provided, adjacent linear portions 83 can be brought closer to each other. Thereby, the cross-sectional area of the conductor 82a can be increased, and the heat generated due to the energization of the stator winding 51 can be reduced. In such a configuration, magnetic saturation can be eliminated by the absence of teeth, and the current flowing through the stator winding 51 can be increased. In this case, it is possible to suitably cope with an increase in the amount of heat generated with an increase in the supplied current.
  • the turn portion 84 is shifted in the radial direction and has an interference avoiding portion that avoids interference with another turn portion 84, the different turn portions 84 are separated from each other in the radial direction. Can be arranged. Thereby, the heat radiation of the turn portion 84 can be improved. As described above, it is possible to optimize the heat radiation performance of the stator 50.
  • the radial thickness of the protrusion 142 is determined as shown in FIG. H1. Specifically, if the yoke 141 and the magnet unit 42 are separated from each other by 2 mm or more, the radial thickness of the protrusion 142 may be H1 or more in FIG.
  • the straight portion 83 in the radial direction exceeds 2 mm and the conductor group 81 is formed of two layers of conductors 82 inside and outside the radial direction, the straight portion 83 not adjacent to the yoke 141, That is, the protrusion 142 may be provided in a range from the yoke 141 to a half position of the second-layer conductive wire 82.
  • the radial thickness of the protrusion 142 is up to “H1 ⁇ 3/2”, the effect can be obtained to a considerable extent by increasing the conductor cross-sectional area in the conductor group 81.
  • the stator core 52 may have the configuration shown in FIG. Although the sealing member 57 is omitted in FIG. 26, the sealing member 57 may be provided. In FIG. 26, for convenience, the magnet unit 42 and the stator core 52 are linearly developed and shown.
  • the stator 50 has a protrusion 142 as a conductor-to-conductor member between the conductors 82 (that is, the straight portions 83) adjacent in the circumferential direction.
  • the stator winding 51 When the stator winding 51 is energized, the stator 50 functions magnetically together with one of the magnetic poles (N-pole or S-pole) of the magnet unit 42 and forms a part 350 extending in the circumferential direction of the stator 50.
  • the length of the portion 350 in the circumferential direction of the stator 50 is Wn
  • the total width of the protrusions 142 existing in this length range Wn (that is, the total dimension of the stator 50 in the circumferential direction) is defined as Wn.
  • the saturation magnetic flux density of the projection 142 is Bs
  • the circumferential width of one pole of the magnet unit 42 is Wm
  • the residual magnetic flux density of the magnet unit 42 is Br.
  • the range Wn is set so as to include a plurality of conductor groups 81 that are adjacent in the circumferential direction and include a plurality of conductor groups 81 whose excitation timings overlap. At this time, it is preferable to set the center of the gap 56 of the conductive wire group 81 as a reference (boundary) when setting the range Wn. For example, in the case of the configuration illustrated in FIG. 26, the fourth conductor group 81 up to the fourth from the shortest distance from the magnetic pole center of the N pole in the circumferential direction corresponds to the plurality of conductor groups 81. Then, the range Wn is set to include the four conductive wire groups 81. At this time, the end (start point and end point) of the range Wn is the center of the gap 56.
  • the three-phase winding of the stator winding 51 is a distributed winding, and in the stator winding 51, the number of the protrusions 142, The number of the gaps 56 between the conductor groups 81 is “the number of phases ⁇ Q”.
  • Q is the number of one-phase conductive wires 82 that comes into contact with stator core 52.
  • the protrusions 142 are formed as a magnetic material satisfying the above-described relationship (1).
  • the total width dimension Wt is also a circumferential dimension of a portion where relative magnetic permeability can be larger than 1 in one pole. Further, in consideration of a margin, the total width dimension Wt may be set to the circumferential width dimension of the projection 142 at one magnetic pole.
  • distributed winding refers to a period of one pole pair of magnetic poles (N pole and S pole) and one pole pair of the stator winding 51.
  • the one pole pair of the stator winding 51 here includes two straight portions 83 and a turn portion 84 in which currents flow in opposite directions and are electrically connected by a turn portion 84. If the above conditions are satisfied, even a short-pitch winding (Short Pitch Winding) is regarded as an equivalent of a distributed winding of a full-pitch winding.
  • concentrated winding means that the width of one pole pair of magnetic poles is different from the width of one pole pair of the stator winding 51.
  • concentrated winding three conductor groups 81 for one magnetic pole pair, three conductor groups 81 for two magnetic pole pairs, nine conductor groups 81 for four magnetic pole pairs, and 5 There is one in which the conductor group 81 has nine relations to one magnetic pole pair.
  • the stator windings 51 are concentrated windings, when the three-phase windings of the stator windings 51 are energized in a predetermined order, the stator windings 51 for two phases are excited. As a result, the projections 142 for two phases are excited. Therefore, in the range of one pole of the magnet unit 42, the circumferential width Wt of the protrusion 142 that is excited when the stator winding 51 is energized is “A ⁇ 2”. After the width Wt is defined in this manner, the protrusion 142 is formed of a magnetic material satisfying the relationship (1).
  • A is the sum of the widths of the protrusions 142 in the circumferential direction of the stator 50 in the region surrounded by the conductor group 81 of the same phase.
  • Wm in the concentrated winding is equivalent 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 conductive wire group 81”.
  • the protrusion 142 in the stator core 52 may be a magnetic material that satisfies the relationship of Wt ⁇ 1 / ⁇ Wm.
  • the conductor 82 may be arranged in the circumferential direction of the stator core 52 so that the outer coating 182 between the conductors 82 contacts.
  • Wt can be regarded as 0 or the thickness of the outer layer coating 182 of the two conducting wires 82 in contact with each other.
  • the inter-conductor member protrusion 142 that is unreasonably small with respect to the magnetic flux on the rotor 40 side is provided.
  • the rotor 40 is a flat surface magnet type rotor having low inductance and does not have saliency in terms of magnetoresistance.
  • the inductance of the stator 50 can be reduced, and the occurrence of magnetic flux distortion due to the shift of the switching timing of the stator winding 51 is suppressed, and thus the electrolytic corrosion of the bearings 21 and 22 is suppressed. .
  • a tooth-like portion 143 is provided on the outer peripheral surface side (the upper surface side in the drawing) of the stator core 52 as an inter-conductor member.
  • the teeth 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 conductor group 81 in the radial direction.
  • the side surface of the toothed portion 143 is in contact with each conductor 82 of the conductor group 81.
  • a gap may be provided between the tooth-shaped portion 143 and each conductive wire 82.
  • the tooth-shaped portion 143 has a limitation on the width in the circumferential direction, and has pole teeth (stator teeth) that are unreasonably thin with respect to the amount of magnets. With such a configuration, the tooth-shaped portion 143 is surely saturated by the magnetic flux at 1.8 T or more, and the inductance can be reduced due to a decrease in permeance.
  • the magnetic flux on the magnet unit side is, for example, “Sm ⁇ Br”.
  • the surface area of each tooth 143 on the rotor side is St
  • the number of conductors 82 per phase is m
  • the tooth windings 143 for two phases are excited within one pole by the current flowing through the stator winding 51.
  • 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 size of the tooth-shaped portion 143 so that the relationship of
  • the circumferential width of one pole of the magnet unit 42 is Wm
  • the circumferential width of the toothed part 143 is Wst.
  • the above equation (2) is replaced by an equation (3).
  • the inductance is reduced by setting the width Wst of the toothed portion 143 to be smaller than 1 / of the width Wm of one pole of the magnet unit 42. If the number m is 1, the width Wst of the toothed portion 143 may be smaller than 1 / of the width Wm of one pole of the magnet unit 42.
  • the sealing member 57 that covers the stator windings 51 is provided in a range that includes all of the conductor groups 81 outside the stator core 52 in the radial direction, that is, the thickness in the radial direction is equal to the diameter of each conductor group 81.
  • the thickness is set to be larger than the thickness in the direction, the thickness may be changed.
  • the sealing member 57 is provided so that a part of the conductive wire 82 protrudes.
  • the sealing member 57 is configured to be provided in a state in which a part of the conductive wire 82 that is the radially outermost in the conductive wire group 81 is exposed to the radially outer side, that is, to the stator 50 side.
  • the thickness of the sealing member 57 in the radial direction is preferably equal to or smaller than the thickness of the conductor group 81 in the radial direction.
  • the configuration may be such that each conductive wire group 81 is not sealed by the sealing member 57. That is, the configuration is such that the sealing member 57 that covers the stator winding 51 is not used. In this case, there is no gap between the conductors between the conductor groups 81 arranged in the circumferential direction, and there is a gap. In short, the configuration is such that no inter-conductor member is provided between the conductor groups 81 arranged in the circumferential direction.
  • the inter-wire member of the stator 50 is made of a non-magnetic material
  • a material other than resin can be used as the non-magnetic material.
  • a metallic nonmagnetic material such as SUS304, which is an austenitic stainless steel, may be used.
  • the stator 50 may not have the stator core 52.
  • the stator 50 is constituted by the stator winding 51 shown in FIG.
  • the stator winding 51 may be sealed with a sealing material.
  • the stator 50 may include an annular winding holding portion made of a nonmagnetic material such as a synthetic resin, instead of the stator core 52 made of a soft magnetic material.
  • the plurality of magnets 91 and 92 arranged in the circumferential direction are used as the magnet unit 42 of the rotor 40.
  • the magnet unit 42 is an annular permanent magnet.
  • a configuration using a magnet may be used.
  • an annular magnet 95 is fixed radially inside the cylindrical portion 43 of the magnet holder 41.
  • the annular magnet 95 is provided with a plurality of magnetic poles having alternating polarities in the circumferential direction, and the magnet is integrally formed on both the d-axis and the q-axis.
  • the annular magnet 95 is formed with an arc-shaped magnet magnetic path in which the direction of orientation is radial in the d-axis of each magnetic pole and circumferential in the q-axis between the magnetic poles.
  • the easy axis of magnetization is oriented parallel to or nearly parallel to the d axis in a portion near the d axis, and the easy axis of magnetization is orthogonal to the q axis or in the q axis in a portion near the q axis. It is sufficient that the orientation is made so as to form an arc-shaped magnet magnetic path that is nearly orthogonal.
  • Modification 8 In this modification, a part of the control method of the control device 110 is changed. In the present modification, mainly, differences from the configuration described in the first embodiment will be described.
  • the operation signal generator 116 includes a carrier generator 116a and U, V, and W phase comparators 116bU, 116bV, and 116bW.
  • the carrier generator 116a generates and outputs a triangular wave signal as the carrier signal SigC.
  • the U, V, and W phase comparators 116bU, 116bV, and 116bW receive the carrier signal SigC generated by the carrier generation unit 116a and the U, V, and W phase command voltages calculated by the three-phase conversion unit 115. You.
  • the U-, V-, and W-phase command voltages are, for example, sinusoidal waveforms, and are out of phase by 120 ° in electrical angle.
  • the U, V, W phase comparators 116bU, 116bV, 116bW control the U, V, W phase command voltage and the carrier signal SigC by PWM (pulse width modulation) based on a magnitude comparison between the U, V, W phase voltage and the carrier signal SigC. , V, and W-phase operation signals for the switches Sp and Sn of the upper arm and the lower arm.
  • the operation signal generation unit 116 performs each of the U, V, and W phases by PWM control based on a magnitude comparison between a signal obtained by standardizing the U, V, and W phase command voltages by the power supply voltage and a carrier signal.
  • An operation signal for the switches Sp and Sn is generated.
  • the driver 117 turns on and off the U, V, and W phase switches Sp and Sn in the first inverter 101 based on the operation signal generated by the operation signal generation unit 116.
  • the control device 110 performs a process of changing the carrier frequency fc of the carrier signal SigC, that is, the switching frequency of each of the switches Sp and Sn.
  • the carrier frequency fc is set high in a low torque region or a high rotation region of the rotating electric machine 10, and set low in a high torque region of the rotating electric machine 10. This setting is made in order to suppress a decrease in the controllability of the current flowing through each phase winding.
  • control device 110 changes carrier frequency fc.
  • a process of changing the carrier frequency fc will be described with reference to FIG. This process is repeatedly executed by the control device 110, for example, at a predetermined control cycle, as the process of the operation signal generation unit 116.
  • Step S10 it is determined whether or not the current flowing through each phase winding 51a is included in the low current region.
  • This process is a process for determining that the current torque of the rotating electric machine 10 is in the low torque region.
  • the following first and second methods can be used as a method for determining whether or not the pixel is included in the low current region.
  • an estimated torque value of the rotating electric machine 10 is calculated.
  • the torque threshold may be set to, for example, 1 / of the starting torque (also referred to as a constraint torque) of the rotating electric machine 10.
  • the speed threshold may be set to, for example, the rotation speed when the maximum torque of the rotating electric machine 10 is the torque threshold.
  • step S10 If a negative determination is made in step S10, it is determined that the current is in the high current region, and the process proceeds to step S11.
  • step S11 the carrier frequency fc is set to the first frequency fL.
  • step S10 If an affirmative determination is made in step S10, the process proceeds to step S12, and the carrier frequency fc is set to the second frequency fH higher than the first frequency fL.
  • the carrier frequency fc is set higher when the current flowing through each phase winding is included in the low current region than 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, a decrease in current controllability can be suppressed.
  • the carrier frequency fc when the current flowing through each phase winding is included in the high current region, the carrier frequency fc is set lower than when the current is included in the low current region.
  • the amplitude of the current flowing through the winding is larger than in the low current region, so that the increase in the current ripple due to the lower inductance has little effect on the current controllability. Therefore, the carrier frequency fc can be set lower in the high current region than in the low current region, and the switching loss of each of the inverters 101 and 102 can be reduced.
  • 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. Is also good.
  • the carrier frequency fc When the carrier frequency fc is set to the second frequency fH and a negative determination is made in step S10, the carrier frequency fc may be gradually changed from the second frequency fH to the first frequency fL. .
  • a switch operation signal may be generated by space vector modulation (SVM) control instead of ⁇ PWM control. Even in this case, the change of the switching frequency described above can be applied.
  • SVM space vector modulation
  • FIG. 33A is a diagram illustrating electrical connection between first and second conductive wires 88a and 88b, which are two pairs of conductive wires.
  • first and second conductive wires 88a and 88b may be connected in series as shown in FIG.
  • FIG. 34 shows a configuration in which first to fourth conductive wires 88a to 88d, which are four pairs of conductive wires, are stacked.
  • the first to fourth conductive wires 88a to 88d are arranged in the radial direction in the order of the first, second, third, and fourth conductive wires 88a, 88b, 88c, and 88d from the side closer to the stator core 52. .
  • the third and fourth conductors 88c and 88d are connected in parallel, a first conductor 88a is connected to one end of the parallel connection body, and a second conductor is connected to the other end. 88b may be connected.
  • the connection is made in parallel, the current density of the conductive wires connected in parallel can be reduced, and the heat generation during energization can be suppressed. Therefore, in a 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 conductive wires 88a and 88b that are not connected in parallel abut on the unit base 61.
  • the third and fourth conductive wires 88c and 88d arranged on the stator core 52 side and connected in parallel are arranged on the side opposite to the stator core side. Thereby, the cooling performance of each of the conductors 88a to 88d in the multilayer conductor structure can be equalized.
  • the thickness of the conductor group 81 including the first to fourth conductors 88a to 88d in the radial direction may be smaller than the circumferential width of one phase in one magnetic pole.
  • the rotating electric machine 10 may have an inner rotor structure (adduction structure).
  • the stator 50 may be provided radially outside the housing 30 and the rotor 40 may be provided radially inside the housing 30.
  • the inverter unit 60 may be provided on one or both of the axial ends of the stator 50 and the rotor 40.
  • FIG. 35 is a cross-sectional view of the rotor 40 and the stator 50
  • FIG. 36 is an enlarged view of a part of the rotor 40 and the stator 50 shown in FIG.
  • the configuration shown in FIGS. 35 and 36 based on the inner rotor structure is different from the configuration shown in FIGS. 8 and 9 based on the outer rotor structure in that the rotor 40 and the stator 50 are reversed inside and outside the radial direction. Except for, the configuration is the same.
  • the stator 50 has a stator winding 51 having a flat conductive wire structure and a stator core 52 having no teeth.
  • the stator winding 51 is mounted radially inside the stator core 52.
  • the stator core 52 has any one of the following configurations, similarly to the case of the outer rotor structure.
  • an inter-conductor member is provided between the respective conductor portions in the circumferential direction, and as the inter-conductor member, the circumferential width of the inter-conductor member at one magnetic pole is Wt, and the saturation of the inter-conductor member is achieved.
  • the magnetic flux density is Bs
  • the circumferential width of the magnet unit at one magnetic pole is Wm
  • the residual magnetic flux density of the magnet unit is Br
  • a magnetic material that satisfies Wt ⁇ Bs ⁇ Wm ⁇ Br is used.
  • an inter-conductor member is provided between the conductor portions in the circumferential direction, and a non-magnetic material is used as the inter-conductor member.
  • the stator 50 has a configuration in which no inter-conductor member is provided between the respective conductor portions in the circumferential direction.
  • the magnet units 42 and 91 are oriented such that the direction of the easy axis of magnetization is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, compared to the q-axis side, which is the boundary of the magnetic poles. It is configured using Details such as the magnetization direction of each of the magnets 91 and 92 are as described above. It is also possible to use an annular magnet 95 (see FIG. 30) in the magnet unit 42.
  • FIG. 37 is a longitudinal sectional view of the rotating 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.
  • an annular stator 50 is fixed inside a housing 30, and a rotor 40 is rotatably provided inside the stator 50 with a predetermined air gap interposed therebetween.
  • each of the bearings 21 and 22 is disposed so as to be biased toward one of the axial directions with respect to the axial center of the rotor 40, whereby the rotor 40 is cantilevered.
  • the inverter unit 60 is provided inside the magnet holder 41 of the rotor 40.
  • FIG. 38 shows another configuration of the rotating electric machine 10 having the inner rotor structure.
  • a rotating shaft 11 is rotatably supported by bearings 21 and 22 in a housing 30, and a rotor 40 is fixed to the rotating shaft 11.
  • each of the bearings 21 and 22 is arranged so as to be biased toward one of the axial directions with respect to the axial center of the rotor 40.
  • the rotor 40 has a magnet holder 41 and a magnet unit 42.
  • the rotating electric machine 10 of FIG. 38 is different from the rotating electric machine 10 of FIG. 37 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 radially inside the magnet unit 42.
  • the stator 50 has a stator winding 51 and a stator core 52 and is attached to the housing 30.
  • FIG. 39 is an exploded perspective view of the rotating electric machine 200
  • FIG. 40 is a side sectional view of the rotating electric machine 200.
  • the vertical direction is shown based on the state of FIGS. 39 and 40.
  • the rotating electric machine 200 is rotatably disposed inside the stator core 201 and a stator 203 having an annular stator core 201 and a polyphase stator winding 202. And a rotator 204.
  • the stator 203 corresponds to an armature
  • the rotor 204 corresponds to a field element.
  • the stator core 201 is formed by laminating a number of silicon steel plates, and a stator winding 202 is attached to the stator core 201.
  • the rotor 204 has a rotor core and a plurality of permanent magnets as magnet units. A plurality of magnet insertion holes are provided in the rotor core at equal intervals in the circumferential direction.
  • a permanent magnet that is magnetized so that the magnetization direction changes alternately for each adjacent magnetic pole is mounted.
  • the permanent magnet of the magnet unit may have a Halbach array as described with reference to FIG. 23 or a configuration similar thereto.
  • 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 center of the magnetic pole and the q-axis which is the boundary of the magnetic pole as described in FIGS. It is preferable to have anisotropic characteristics.
  • the stator 203 may have any of the following configurations.
  • an inter-conductor member is provided between the respective conductor portions in the circumferential direction, and as the inter-conductor member, the circumferential width of the inter-conductor member at one magnetic pole is Wt, and the saturation of the inter-conductor member is achieved.
  • the magnetic flux density is Bs
  • the circumferential width of the magnet unit at one magnetic pole is Wm
  • the residual magnetic flux density of the magnet unit is Br
  • a magnetic material that satisfies Wt ⁇ Bs ⁇ Wm ⁇ Br is used.
  • stator 203 In the stator 203, an inter-conductor member is provided between the conductor portions in the circumferential direction, and a non-magnetic material is used as the inter-conductor member.
  • the stator 203 has a configuration in which no inter-conductor member is provided between the respective conductor portions in the circumferential direction.
  • the magnet unit was oriented such that the direction of the easy axis of magnetization was parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, compared to the q-axis side, which is the boundary of the magnetic poles. It is configured using a plurality of magnets.
  • a ring-shaped inverter case 211 is provided at one axial end of the rotary electric machine 200. Inverter case 211 is arranged such that the lower surface of the case is in contact with the upper surface of stator core 201.
  • a plurality of power modules 212 constituting an inverter circuit, a smoothing capacitor 213 for suppressing pulsation (ripple) of voltage and current generated by a switching operation of a 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 that is a rotation speed sensor of the rotor 204.
  • the power module 212 has an IGBT or a diode that is a semiconductor switching element.
  • a power connector 217 connected to a DC circuit of a battery mounted on the vehicle, and a signal connector 218 used for transferring various signals between the rotating electric machine 200 and the vehicle-side control device are provided on the periphery of the inverter case 211. Is provided.
  • the inverter case 211 is covered with a top cover 219. DC power from the vehicle-mounted battery is input via the power connector 217, converted into AC by switching of the power module 212, and sent to the stator winding 202 of each phase.
  • a bearing unit 221 for rotatably holding the rotating shaft of the rotor 204 and an annular rear case 222 for accommodating the bearing unit 221 are provided on the opposite sides of the stator core 201 in the axial direction opposite to the inverter case 211. Is provided.
  • the bearing unit 221 has, for example, a pair of bearings, and is arranged so as to be deviated to one side in the axial direction with respect to the axial center of the rotor 204.
  • a configuration in which a plurality of bearings of the bearing unit 221 are provided separately on both sides in the axial direction of the stator core 201 and the rotating shaft is supported at both ends by the respective bearings may be adopted.
  • the rotating electrical machine 200 is mounted on the vehicle side by fixing the rear case 222 to the mounting portion such as a gear case or a transmission of the vehicle by bolting.
  • a cooling channel 211a for flowing a coolant is formed in the inverter case 211.
  • the cooling channel 211 a is formed by closing a space recessed annularly from the lower surface of the inverter case 211 with the upper surface of the stator core 201.
  • the cooling passage 211a is formed so as to surround the coil end of the stator winding 202.
  • the module case 212a of the power module 212 is inserted into the cooling channel 211a.
  • a cooling channel 222 a is also formed in the rear case 222 so as to surround the coil end of the stator winding 202.
  • the cooling channel 222 a is formed by closing a space recessed annularly from the upper surface of the rear case 222 with the lower surface of the stator core 201.
  • FIG. 41 shows a configuration of a rotary armature type rotary electric machine 230.
  • bearings 232 are fixed to the housings 231a and 231b, respectively, and the rotating shaft 233 is rotatably supported by the bearings 232.
  • the bearing 232 is, for example, an oil-impregnated bearing made of a porous metal containing oil.
  • a rotor 234 as an armature is fixed to the rotation shaft 233.
  • the rotor 234 has a rotor core 235 and a multi-phase rotor winding 236 fixed to an outer peripheral portion thereof.
  • the rotor core 235 has a slotless structure
  • the rotor winding 236 has a flat conductor 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.
  • 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 231a, and a magnet unit 239 fixed to the inner peripheral side of the stator core 238.
  • the magnet unit 239 includes a plurality of magnetic poles having polarities alternated in the circumferential direction.
  • the magnet unit 239 has a magnetic pole boundary q on the d-axis side that is the center of the magnetic pole. The orientation is made such that the direction of the easy axis of magnetization is parallel to the d-axis as compared to the axis side.
  • the magnet unit 239 has an oriented sintered neodymium magnet, and its intrinsic coercive force is 400 [kA / m] or more and the residual magnetic flux density is 1.0 [T] or more.
  • the rotating electric machine 230 of this example is a brushless coreless motor having two poles and three coils, the rotor winding 236 is divided into three, and the magnet unit 239 has two poles.
  • the number of poles and the number of coils of the brushed motor varies depending on the application, such as 2: 3, 4:10, and 4:21.
  • a commutator 241 is fixed to the rotating shaft 233, and a plurality of brushes 242 are arranged radially outside.
  • the commutator 241 is electrically connected to the rotor winding 236 via a conductor 243 embedded in the rotating shaft 233.
  • the direct current flows into and out of the rotor winding 236 through the commutator 241, the brush 242, and the conducting 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 directly connected to a DC power supply such as a storage battery via electrical wiring, or may be connected to a DC power supply via a terminal block or the like.
  • a resin washer 244 as a sealing material is provided between the bearing 232 and the commutator 241 on the rotating shaft 233.
  • the resin washer 244 suppresses oil that has oozed from the bearing 232 that is an oil-impregnated bearing from flowing out to the commutator 241 side.
  • each of the conductors 82 may be configured to have a plurality of insulating coatings inside and outside.
  • a plurality of conductive wires (element wires) with an insulating coating may be bundled into one and covered with an outer coating to form the conductive wire 82.
  • the insulating coating of the element wire forms the inner insulating coating
  • the outer coating forms the outer insulating coating.
  • the insulating ability of the outer insulating coat among the plurality of insulating coats in the conductive wire 82 be higher than the insulating ability of the inner insulating coat.
  • the thickness of the outer insulating coating is made larger than the thickness of the inner insulating coating.
  • the thickness of the outer insulating coating is 100 ⁇ m, and the thickness of the inner insulating coating is 40 ⁇ m.
  • a material having a lower dielectric constant than the inner insulating film may be used as the outer insulating film. At least one of these may be applied.
  • the strands may be configured as an aggregate of a plurality of conductive materials.
  • the outer insulating coating and the inner insulating coating may have a configuration in which at least one of the coefficient of linear expansion (linear expansion coefficient) and the adhesive strength is different.
  • FIG. 42 shows a configuration of the conductor 82 in this modification.
  • a conductive wire 82 includes a plurality of (four in the figure) strands 181, an outer layer coating 182 (outer insulating coating) made of, for example, resin 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 strand 181 has a conductive portion 181a made of a copper material and a conductor film 181b (an inner insulating film) made of an insulating material. When viewed as a stator winding, the outer layers 182 insulate the phases.
  • the strand 181 may be configured as an aggregate of a plurality of conductive materials.
  • the intermediate layer 183 has a higher linear expansion coefficient than the conductor coating 181b of the strand 181 and a lower linear expansion coefficient than the outer coating 182. That is, in the conductor 82, the coefficient of linear expansion is higher toward the outside.
  • the outer layer coating 182 has a higher linear expansion coefficient than the conductor coating 181b, but by providing an intermediate layer 183 having an intermediate linear expansion coefficient between them, the intermediate layer 183 functions as a cushion material. In addition, simultaneous cracking on the outer layer side and the inner layer side can be prevented.
  • the conductive portion 181a and the conductive film 181b are bonded to the wire 181 and the conductive film 181b and the intermediate layer 183, and the intermediate layer 183 and the outer layer film 182 are bonded to each other.
  • the bonding strength is weaker toward the outside of the conducting wire 82. That is, the adhesive strength between the conductive portion 181a and the conductive coating 181b is lower than the adhesive strength between the conductive coating 181b and the intermediate layer 183, and the adhesive strength between the intermediate layer 183 and the outer coating 182.
  • the latter (outer side) is preferably weaker or equivalent. It should be noted that the magnitude of the adhesive strength between the coatings can be grasped, for example, from the tensile strength and the like required when the two coatings are peeled off.
  • the bonding strength of the conductive wire 82 as described above, it is possible to suppress the occurrence of cracks (co-cracking) on both the inner layer side and the outer layer side even if an internal / external temperature difference occurs due to heat generation or cooling. .
  • heat generation and temperature change of the rotating electric machine mainly occur as copper loss generated from the conductive portion 181a of the wire 181 and iron loss generated from within the iron core.
  • the conductive layer 181a is transmitted from the outside of the conductive portion 181a or the conductive wire 82, and the intermediate layer 183 does not necessarily have a heat source.
  • the intermediate layer 183 since the intermediate layer 183 has an adhesive force that can serve as a cushion for both, simultaneous cracking can be prevented. Therefore, suitable use is possible even when used in a field having a high withstand voltage or a large temperature change such as a vehicle application.
  • the strand 181 may be, for example, an enameled wire, and in such a case, has a resin coating layer (conductor coating 181b) of PA, PI, PAI or the like. Further, it is desirable that the outer layer coating 182 outside the wire 181 be made of the same PA, PI, PAI or the like, and be thick. Thereby, the destruction of the coating film due to the difference in linear expansion coefficient is suppressed.
  • the outer layer coating 182 has a dielectric constant such as PPS, PEEK, fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, or LCP, which is different from the corresponding material such as PA, PI, PAI by thickening the corresponding material.
  • the adhesive 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 on the wire 181 is determined by the adhesive strength between the copper wire and the enamel coating on the wire 181. It is desirable that it be weaker. This suppresses a phenomenon in which the enamel coating and the two types of coatings are destroyed at a time.
  • the thermal stress or impact stress is applied first to the outer layer coating 182.
  • the thermal stress and the impact stress can be reduced by providing a portion where the coatings are not bonded. That is, the insulating structure is formed by providing a gap between the element wire (enameled wire) and the void, and arranging fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, and LCP.
  • the outermost layer fixed as a final step around the stator winding, which is responsible for mechanical strength, fixing, and the like, for the conductor 82 having the above-described configuration, is formed of epoxy, PPS, PEEK, LCP, or the like. It is preferable to use a resin having properties such as a dielectric constant and a linear expansion coefficient close to those of an enamel coating.
  • resin potting with urethane or silicon is generally performed, but the resin has a coefficient of linear expansion that is nearly twice as large as that of other resins, and generates thermal stress that can shear the resin. Therefore, it is not suitable for use at 60 V or higher where strict insulation regulations are used internationally.
  • the final insulation process that is easily made by injection molding or the like using epoxy, PPS, PEEK, LCP, or the like, the above-described requirements can be achieved.
  • the radial distance DM between the armature side surface of the magnet unit 42 in the radial direction and the axis 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. The distance DM may be set to 50 mm or more.
  • a rotary electric machine having a slotless structure As a rotary electric machine having a slotless structure, a small-sized electric machine whose output is used for a model whose output is several tens of watts to several hundreds of watts is known.
  • the applicant of the present application has not grasped an example in which a slotless structure is generally employed in a large-scale rotating electric machine for industrial use exceeding 10 kW. The present applicant has examined the reason.
  • the rotating electric machines are a brush motor, a cage induction motor, a permanent magnet synchronous motor, and a reluctance motor.
  • a magnetic field generated by a stator winding on a primary side is received by an iron core of a rotor on a secondary side, and an induced current is intensively applied to a cage-type conductor to form a reaction magnetic field.
  • This is the principle of generating torque. For this reason, from the viewpoint of miniaturization and high efficiency of the device, it is not always advisable to eliminate the iron core on both the stator side and the rotor side.
  • the reluctance motor is a motor that utilizes the reluctance change of the iron core, and it is not desirable to eliminate the iron core in principle.
  • IPMs i.e., embedded magnet type rotors
  • IPMs embedded magnet type rotors
  • the IPM has a characteristic of having both a magnet torque and a reluctance torque, and is operated while the ratio of those torques is appropriately adjusted by inverter control. Therefore, the IPM is a small-sized motor having excellent controllability.
  • the torque on the rotor surface that generates the magnet torque and the reluctance torque is calculated by calculating the distance DM in the radial direction between the surface of the magnet unit on the armature side in the radial direction and the axis of the rotor, that is, FIG. 43 shows the radius of the stator core of a general inner rotor taken along the horizontal axis.
  • the potential of the magnet torque is determined by the strength of the magnetic field generated by the permanent magnet, whereas the reluctance torque is expressed by inductance, particularly q, as shown in the following equation (eq2).
  • the magnitude of the shaft inductance determines its potential.
  • Magnet torque k ⁇ ⁇ ⁇ Iq (eq1)
  • Reluctance torque k ⁇ (Lq-Ld) ⁇ Iq ⁇ Id ⁇ ⁇ ⁇ ⁇ (eq2)
  • the magnetic field intensity generated by the permanent magnet that is, the amount of magnetic flux ⁇ is proportional to the total area of the permanent magnet on the surface facing the stator. In the case of a cylindrical rotor, it is the surface area of the cylinder. Strictly speaking, since there are an N pole and an S pole, it is proportional to the area occupied by half of the cylindrical surface.
  • the surface area of a cylinder is proportional to the radius of the cylinder and the length of the cylinder. That is, if the length of the cylinder is constant, it is proportional to the radius of the cylinder.
  • the inductance Lq of the winding depends on the shape of the iron core but has low sensitivity, and is rather proportional to the square of the number of turns of the stator winding.
  • ⁇ is the magnetic permeability of the magnetic circuit
  • N is the number of turns
  • S is the cross-sectional area of the magnetic circuit
  • ⁇ is the effective length of the magnetic circuit
  • the inductance L ⁇ ⁇ N ⁇ 2 ⁇ S / ⁇ . Since the number of windings 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. 44, the slot area is proportional to the product a ⁇ b of the circumferential length a and the radial length b since the shape of the slot is substantially rectangular.
  • the circumferential length of the slot increases in proportion to the diameter of the cylinder, because the larger the diameter of the cylinder, the larger it becomes.
  • the radial length dimension of the slot is directly proportional to the diameter of the cylinder. That is, the slot area is proportional to the square of the diameter of the cylinder.
  • the performance of the rotating electric machine is determined by how large a current can flow, and the performance depends on 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. 43 is a diagram plotting the relationship between the magnet torque and the reluctance torque and DM.
  • the magnet torque increases linearly with DM, and the reluctance torque increases quadratically with DM.
  • the DM is relatively small, the magnet torque is dominant, and the reluctance torque is dominant as the stator core radius increases.
  • the radial distance DM between the surface of the magnet unit on the armature side in the radial direction and the axis of the rotor is 50 mm or more. May be.
  • the straight line portion 83 of the conducting wire 82 may be provided in a single layer in the radial direction.
  • the number of the layers may be arbitrary, and three, four, five, six, or the like may be provided.
  • the rotating shaft 11 is provided so as to protrude at both the one end side and the other end side of the rotary electric machine 10 in the axial direction. Is also good.
  • the rotating shaft 11 may be provided so as to extend outward in the axial direction with a portion supported by the bearing unit 20 in a cantilevered manner as an end.
  • the internal space of the inverter unit 60 since the rotation shaft 11 does not protrude into the inverter unit 60, the internal space of the inverter unit 60, more specifically, the internal space of the tubular portion 71 can be used more widely.
  • the bearings 21 and 22 are configured to use the non-conductive grease.
  • the configuration may be changed and the bearings 21 and 22 may be configured to use the conductive grease.
  • a configuration is used in which conductive grease containing metal particles, carbon particles, or the like is included.
  • a configuration for rotatably supporting the rotating shaft 11 a configuration may be adopted in which bearings are provided at two locations on one end side and the other end side of the rotor 40 in the axial direction.
  • bearings are provided at two locations, one end side and the other end side, with the inverter unit 60 interposed therebetween.
  • the intermediate portion 45 of the magnet holder 41 in the rotor 40 has the inner shoulder 49a and the outer shoulder 49b of emotion.
  • these shoulders 49a and 49b are eliminated and the rotor 40 is flat. It may be configured to have various surfaces.
  • the conductor 82 a in the conductor 82 of the stator winding 51 is configured as an aggregate of the plurality of wires 86, but this is changed, and a rectangular conductor having a rectangular cross section is used as the conductor 82. It may be configured. Further, a configuration may be used in which a round conductor having a circular cross section or an elliptical cross section is used as the conductor 82.
  • the inverter unit 60 is provided radially inside the stator 50.
  • the inverter unit 60 may not be provided radially inside the stator 50. .
  • the configuration may be such that the housing 30 is not provided.
  • the rotor 40, the stator 50, and the like may be held in a part of a wheel or another vehicle part.
  • FIG. 45 is a perspective view showing a wheel 400 having an in-wheel motor structure and its peripheral structure
  • FIG. 46 is a longitudinal sectional view of the wheel 400 and its peripheral structure
  • FIG. 47 is an exploded perspective view of the wheel 400. is there.
  • Each of these figures is a perspective view of the wheel 400 as viewed from the inside of the vehicle.
  • the in-wheel motor structure of the present embodiment can be applied in various forms. For example, in a vehicle having two wheels before and after the vehicle, two wheels on the vehicle front side and two wheels on the vehicle rear side are used.
  • the in-wheel motor structure of this embodiment can be applied to two wheels or four wheels before and after the vehicle.
  • application to a vehicle in which at least one of the front and rear of the vehicle is one wheel is also possible.
  • the in-wheel motor is an example of application as a vehicle drive unit.
  • a wheel 400 is, for example, a tire 401 which is a well-known pneumatic tire, a wheel 402 fixed to an inner peripheral side of the tire 401, and a wheel 402 fixed to an inner peripheral side of the wheel 402.
  • the rotating electric machine 500 has a fixed portion that is a portion including a stator (stator) and a rotating portion that is a portion including a rotor (rotor).
  • the fixed portion is fixed to the vehicle body side, and the rotating portion is
  • the tire 401 and the wheel 402 are fixed to the wheel 402, and the rotation of the rotating unit rotates the tire 401 and the wheel 402.
  • the detailed configuration of the rotating electric machine 500 including the fixed part and the rotating part will be described later.
  • a suspension device that holds the wheel 400 with respect to a vehicle body (not shown), a steering device that changes the direction of the wheel 400, and a brake device that brakes the wheel 400. Have been.
  • the suspension device is an independent suspension type, and any type of application such as a trailing arm type, a strut type, a wishbone type, and a multi-link type is applicable.
  • the suspension device the lower arm 411 is provided so as to extend toward the center of the vehicle body, and the suspension arm 412 and the spring 413 are provided so as to extend vertically.
  • the suspension arm 412 may be configured as, for example, a shock absorber. However, detailed illustration thereof is omitted.
  • the lower arm 411 and the suspension arm 412 are each connected to the vehicle body side, and are also connected to a disk-shaped base plate 405 fixed to a fixed portion of the rotating electric machine 500. As shown in FIG. 46, a lower arm 411 and a suspension arm 412 are supported coaxially on the rotating electric machine 500 side (base plate 405 side) by support shafts 414 and 415.
  • a rack device 421 and a tie rod 422 are provided as a steering device, and the rack device 421 is connected to the base plate 405 on the rotary electric machine 500 side via the tie rod 422.
  • the tie rod 422 moves in the left-right direction of the vehicle.
  • the wheel 400 rotates about the support shafts 414 and 415 of the lower arm 411 and the suspension arm 412, and the direction of the wheel is changed.
  • Disc brakes and drum brakes are preferably used as the brake device.
  • a disk rotor 431 fixed to the rotating shaft 501 of the rotating electric machine 500 and a brake caliper 432 fixed to the base plate 405 on the rotating electric machine 500 side are provided as brake devices.
  • the brake pad is operated by hydraulic pressure or the like. When the brake pad is pressed against the disk rotor 431, a braking force is generated by friction, and the rotation of the wheel 400 is stopped.
  • An accommodation duct 440 for accommodating the electric wiring H1 extending from the rotary electric machine 500 and the cooling pipe H2 is attached to the wheel 400.
  • the accommodation duct 440 is provided to extend along the end face of the rotating electric machine 500 from an end on the fixed portion side of the rotating electric machine 500 and to avoid the suspension arm 412, and is fixed to the suspension arm 412 in that state.
  • the connection portion of the suspension duct 440 of the suspension arm 412 has a fixed positional relationship with the base plate 405. Therefore, it is possible to suppress the stress generated in the electric wiring H1 and the cooling pipe H2 due to the vibration of the vehicle and the like.
  • the electric wiring H1 is connected to a vehicle-mounted power supply unit and a vehicle-mounted ECU (not shown), and the cooling pipe H2 is connected to a radiator (not shown).
  • the rotating electric machine 500 has excellent operation efficiency and output as compared with a motor of a vehicle drive unit having a reduction gear as in the related art. That is, if the rotary electric machine 500 is used for an application that can realize a practical price by reducing costs compared to the conventional technology, it may be used as a motor for applications other than the vehicle drive unit. Even in such a case, excellent performance is exhibited as in the case where the present invention is applied to an in-wheel motor.
  • the operation efficiency refers to an index used at the time of a test in a driving mode for deriving the fuel efficiency of the vehicle.
  • FIGS. 48 to 51 show an outline of the rotating electric machine 500.
  • FIG. FIG. 48 is a side view of rotating electric machine 500 as viewed from the protruding side (inside of the vehicle) of rotating shaft 501
  • FIG. 49 is a longitudinal sectional view of rotating electric machine 500 (sectional view taken along line 49-49 in FIG. 48).
  • 50 is a cross-sectional view of rotary electric machine 500 (a cross-sectional view taken along line 50-50 in FIG. 49)
  • FIG. 51 is an exploded cross-sectional view in which the components of rotary electric machine 500 are disassembled.
  • the circumferential direction may be a clockwise direction starting from an arbitrary point on the cross section 49 or a counterclockwise direction. 49, the right side is the outside of the vehicle and the left side is the inside of the vehicle. In other words, in the vehicle mounted state, a rotor 510 described later is disposed outside the vehicle body with respect to the rotor cover 670.
  • the rotary electric machine 500 is an outer rotor type surface magnet type rotary electric machine.
  • the rotating electric machine 500 roughly includes a rotor 510, a stator 520, an inverter unit 530, a bearing 560, and a rotor cover 670. Each of these members is coaxially arranged with respect to a rotating shaft 501 provided integrally with the rotor 510, and is assembled in a predetermined order in the axial direction to constitute the rotating electric machine 500.
  • the rotor 510 and the stator 520 each have a cylindrical shape, and are arranged to face each other with an air gap therebetween.
  • the rotor 510 rotates integrally with the rotation shaft 501
  • the rotor 510 rotates radially outside the stator 520.
  • the rotor 510 corresponds to a “field element”
  • the stator 520 corresponds to an “armature”.
  • the rotor 510 has a substantially cylindrical rotor carrier 511 and an annular magnet unit 512 fixed to the rotor carrier 511.
  • the rotating shaft 501 is fixed to the rotor carrier 511.
  • the rotor carrier 511 has a cylindrical portion 513.
  • a magnet unit 512 is fixed to the inner peripheral surface of the cylindrical portion 513. That is, the magnet unit 512 is provided so as to be surrounded by the cylindrical portion 513 of the rotor carrier 511 from the outside in the radial direction.
  • the cylindrical portion 513 has a first end and a second end that are opposed in the axial direction. The first end is located in a direction outside the vehicle body, and the second end is located in a direction in which the base plate 405 exists.
  • an end plate 514 is continuously provided at a first end of the cylindrical portion 513. That is, the cylindrical portion 513 and the end plate 514 have an integral structure.
  • the second end of the cylindrical portion 513 is open.
  • the rotor carrier 511 is formed of, for example, a cold-rolled steel plate (SPCC or SPHC having a plate thickness greater than SPCC) having sufficient mechanical strength, forging steel, carbon fiber reinforced plastic (CFRP), or the like.
  • SPCC cold-rolled steel plate
  • CFRP carbon fiber reinforced plastic
  • the axis length of the rotating shaft 501 is longer than the axial dimension of the rotor carrier 511. In other words, the rotating shaft 501 protrudes toward the open end side (inward of the vehicle) of the rotor carrier 511, and the above-described brake device or the like is attached to the protruding end.
  • a through hole 514a is formed in the center of the end plate 514 of the rotor carrier 511.
  • the rotating shaft 501 is fixed to the rotor carrier 511 while being inserted through the through hole 514a of the end plate 514.
  • the rotating shaft 501 has a flange 502 extending in a direction intersecting (orthogonal) in the axial direction at a portion to which the rotor carrier 511 is fixed, and the flange and an end surface of the end plate 514 are surface-joined.
  • the rotating shaft 501 is fixed to the rotor carrier 511.
  • the wheel 402 is fixed by using a fastener such as a bolt that stands upright from the flange 502 of the rotating shaft 501 toward the outside of the vehicle.
  • the magnet unit 512 is composed of a plurality of permanent magnets arranged so that the polarity alternates along the circumferential direction of the rotor 510. Thereby, the magnet unit 512 has a plurality of magnetic poles in the circumferential direction.
  • the permanent magnet is fixed to the rotor carrier 511 by, for example, bonding.
  • the magnet unit 512 has the configuration described as the magnet unit 42 in FIGS. 8 and 9 of the first embodiment, has a specific coercive force of 400 [kA / m] or more as a permanent magnet, and has a residual magnetic flux. It is configured using a sintered neodymium magnet having a density Br of 1.0 [T] or more.
  • the magnet unit 512 is a polar anisotropic magnet and has a first magnet 91 and a second magnet 92 having polarities different from each other, similarly to the magnet unit 42 in FIG. 9 and the like.
  • the directions of the axes of easy magnetization of the magnets 91 and 92 are different between the d-axis side (portion closer to the d-axis) and the q-axis side (portion near the q-axis).
  • the direction of the easy axis is closer to the direction parallel to the d axis on the d-axis side, and the direction of the easy axis is closer to the direction orthogonal to the q axis on the q-axis side.
  • An arc-shaped magnet magnetic path is formed by an orientation corresponding to the direction of the easy axis of magnetization.
  • the easy axis may be oriented parallel to the d axis on the d-axis side, and the easy axis may be orthogonal to the q axis on the q-axis side.
  • the magnet unit 512 is configured such that the direction of the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared to the q-axis side, which is the magnetic pole boundary. .
  • the magnet magnetic flux on the d-axis is strengthened, and the change in magnetic flux near the q-axis is suppressed. Accordingly, it is possible to suitably realize the magnets 91 and 92 in which the surface magnetic flux changes gradually from the q axis to the d axis in each magnetic pole.
  • the magnet unit 512 the configuration of the magnet unit 42 shown in FIGS. 22 and 23 or the configuration of the magnet unit 42 shown in FIG. 30 can be used.
  • the magnet unit 512 has a rotor core (back yoke) formed by stacking a plurality of electromagnetic steel sheets in the axial direction on the side of the cylindrical portion 513 of the rotor carrier 511, that is, on the outer peripheral surface side. Is also good. That is, it is possible to provide a configuration in which a rotor core is provided radially inside the cylindrical portion 513 of the rotor carrier 511, and permanent magnets (magnets 91 and 92) are provided radially inside the rotor core.
  • a rotor core back yoke
  • the cylindrical portion 513 of the rotor carrier 511 is formed with concave portions 513a at predetermined circumferential intervals so as to extend in the axial direction.
  • the concave portion 513a is formed by, for example, press working.
  • a convex portion 513b is formed on the inner peripheral surface side of the cylindrical portion 513 at a position behind the concave portion 513a.
  • a concave portion 512a is formed on the outer peripheral surface side of the magnet unit 512 in conformity with the convex portion 513b of the cylindrical portion 513, and the convex portion 513b of the cylindrical portion 513 enters the concave portion 512a, thereby forming the magnet unit 512.
  • the convex portion 513b on the rotor carrier 511 side functions as a rotation preventing portion of the magnet unit 512.
  • the method of forming the convex portion 513b may be other than press working, and is arbitrary.
  • the directions of the magnet magnetic paths in the magnet unit 512 are indicated by arrows.
  • the magnet magnetic path extends in an arc shape so as to straddle the q axis, which is the magnetic pole boundary, and is oriented parallel to or nearly parallel to the d axis at the d axis, which is the center of the magnetic pole.
  • the magnet unit 512 has recesses 512b formed on the inner peripheral surface thereof at positions corresponding to the q axis. In this case, in the magnet unit 512, the length of the magnet magnetic path differs between the side closer to the stator 520 (the lower side in the figure) and the side farther (the upper side in the figure), and the side closer to the stator 520 has the magnet magnetic path.
  • the path length is short, and a concave portion 512b is formed at a position where the magnet magnetic path length is the shortest. That is, in consideration of the fact that it is difficult for the magnet unit 512 to generate a sufficient magnet magnetic flux in a place where the magnet magnetic path length is short, the magnet is deleted in a place where the magnet magnetic flux is weak.
  • the effective magnetic flux density Bd of the magnet increases as the length of the magnetic circuit passing through the inside of the magnet increases.
  • the permeance coefficient Pc and the effective magnetic flux density Bd of the magnet are such that if one of them becomes higher, the other becomes higher.
  • the permeance coefficient Pc which is an index of the height of the effective magnetic flux density Bd of the magnets.
  • the intersection of the permeance line corresponding to the shape of the magnet and the demagnetization curve is the operating point, and the magnetic flux density at that operating point is the effective magnetic flux density Bd of the magnet.
  • the rotating electric machine 500 of the present embodiment has a configuration in which the iron amount of the stator 520 is reduced, and in such a configuration, a method of setting a magnetic circuit across the q-axis is extremely effective.
  • the concave portion 512b of the magnet unit 512 can be used as an air passage extending in the axial direction. Therefore, the air cooling performance can be improved.
  • the stator 520 has a stator winding 521 and a stator core 522.
  • FIG. 53 is an exploded perspective view showing the stator winding 521 and the stator core 522.
  • the stator winding 521 is composed of a plurality of phase windings formed in a substantially cylindrical (annular) shape, and a stator core 522 as a base member is assembled radially inside the stator winding 521. I have.
  • the stator winding 521 is configured as a three-phase winding by using U-phase, V-phase, and W-phase windings. Each phase winding is composed of two layers of conductive wires 523 in the radial direction.
  • the stator 520 is characterized in that it has a slotless structure and a flat conductive wire structure of the stator winding 521 similarly to the stator 50 described above. It has a similar or similar configuration.
  • the configuration of the stator core 522 will be described.
  • the stator core 522 has a cylindrical shape in which a plurality of electromagnetic steel sheets are laminated in the axial direction and has a predetermined thickness in the radial direction, similarly to the stator core 52 described above.
  • a stator winding 521 is mounted radially outward on the rotor 510 side.
  • the outer peripheral surface of the stator core 522 has a curved surface without irregularities, and in a state where the stator winding 521 is assembled, the conductor 523 constituting the stator winding 521 is provided on the outer peripheral surface of the stator core 522. They are arranged side by side in the circumferential direction.
  • the stator core 522 functions as a back core.
  • the stator 520 uses one of the following (A) to (C).
  • an inter-conductor member is provided between the conductors 523 in the circumferential direction, and as the inter-conductor member, the circumferential width of the inter-conductor member at one magnetic pole is Wt, and the saturation of the inter-conductor member is achieved.
  • the magnetic flux density is Bs
  • the width in the circumferential direction of the magnet unit 512 at one magnetic pole is Wm
  • the residual magnetic flux density of the magnet unit 512 is Br
  • a magnetic material having a relationship of Wt ⁇ Bs ⁇ Wm ⁇ Br is used. I have.
  • stator 520 In the stator 520, an inter-conductor member is provided between the conductors 523 in the circumferential direction, and a non-magnetic material is used as the inter-conductor member.
  • the stator 520 is configured such that no inter-conductor member is provided between the respective conductors 523 in the circumferential direction.
  • the inductance is smaller than that of a general electric rotating machine having a tooth structure in which teeth (iron cores) for establishing a magnetic path are provided between the conductors as stator windings. Reduced. Specifically, the inductance can be reduced to 1/10 or less. In this case, since the impedance decreases as the inductance decreases, the rotating electric machine 500 can increase the output power with respect to the input power, and can contribute to an increase in torque. In addition, it is possible to provide a rotating electric machine having a higher output than a rotating electric machine using an embedded magnet type rotor that performs torque output using the voltage of the impedance component (in other words, utilizes reluctance torque). ing.
  • the stator winding 521 is integrally molded together with the stator core 522 by a molding material (insulating member) made of resin or the like, and a molding material is provided between the conductors 523 arranged in the circumferential direction. It has a configuration that intervenes.
  • the stator 520 of the present embodiment corresponds to the configuration (B) of the above (A) to (C).
  • the conductors 523 adjacent to each other in the circumferential direction are arranged such that their end faces in the circumferential direction abut each other or are arranged close to each other with a small space therebetween. Is also good.
  • the stator core 522 is adjusted according to the direction of the conductor 523 in the axial direction, that is, according to the skew angle of the stator winding 521 having, for example, a skew structure. It is preferable that a protrusion is provided on the outer peripheral surface.
  • FIG. 54 is a front view showing the stator winding 521 developed in a plane.
  • FIG. 54 (a) shows each conductor 523 located in the outer layer in the radial direction
  • FIG. 54 (b) shows the diameter.
  • Each conductor 523 located on the inner layer in the direction is shown.
  • the stator winding 521 is formed in an annular shape by distributed winding.
  • a conductive material is wound around two layers in the radially inner and outer layers, and skews in different directions are given to each of the conductive wires 523 on the inner layer side and the outer layer side (FIG. 54A).
  • Each conductor 523 is mutually insulated from each other.
  • the conductor 523 may be configured as an aggregate of a plurality of strands 86 (see FIG. 13). Further, for example, two conductors 523 having the same phase and the same energizing direction are provided side by side in the circumferential direction.
  • two conductive layers 523 in two layers in the radial direction and two in the circumferential direction constitute one conductive part having the same phase, and one conductive part is formed in each magnetic pole. Is provided.
  • the radial thickness is smaller than the circumferential width of one phase in one magnetic pole, and that the stator winding 521 has a flat conductive wire structure.
  • the stator winding 521 it is preferable that two conductors 523 in two layers in the radial direction and four conductors 523 in the circumferential direction (ie, a total of eight conductors) 523 constitute one conductor part in the same phase.
  • the width in the circumferential direction may be larger than the thickness in the radial direction.
  • the stator winding 51 shown in FIG. 12 as the stator winding 521. However, in this case, it is necessary to secure a space for accommodating the coil end of the stator winding in the rotor carrier 511.
  • the conductors 523 are arranged in the circumferential direction by being inclined at a predetermined angle on the coil side 525 overlapping the stator core 522 inward and outward with respect to the stator core 522, and are arranged axially outside the stator core 522.
  • the inward inversion in the axial direction (returning) is performed, and a continuous connection is made.
  • FIG. 54A shows a range to be the coil side 525 and a range to be the coil end 526, respectively.
  • the conductor 523 on the inner layer side and the conductor 523 on the outer layer side are connected to each other at a coil end 526, so that the conductor 523 is connected to the coil end 526 each time the conductor 523 is inverted in the axial direction (every time it is folded).
  • the inner layer and the outer layer are alternately switched.
  • the stator winding 521 has a configuration in which the inner and outer layers are switched in accordance with the reversal of the current direction in each of the conductors 523 that are continuous in the circumferential direction.
  • skew angle ⁇ s1 in the central region and the skew angle ⁇ s2 in the end region are different, and the skew angle ⁇ s1 is smaller than the skew angle ⁇ s2.
  • the end region is defined in a range including the coil side 525.
  • the skew angle ⁇ s1 and the skew angle ⁇ s2 are inclination angles at which the respective conductors 523 are inclined with respect to the axial direction.
  • the skew angle ⁇ s1 in the central region may be determined in an appropriate angle range for reducing harmonic components of magnetic flux generated by the conduction of the stator winding 521.
  • the skew angle of each conductor 523 in the stator winding 521 is made different between the center region and the end region, and the skew angle ⁇ s1 in the center region is made smaller than the skew angle ⁇ s2 in the end region, so that the coil end 526 is reduced.
  • the winding coefficient of the stator winding 521 can be increased. In other words, it is possible to shorten the length of the coil end 526, that is, the length of the conductive wire that protrudes from the stator core 522 in the axial direction, while securing a desired winding coefficient. Thus, torque can be improved while reducing the size of rotating electric machine 500.
  • the skew angle ⁇ s1 of the central region will be described.
  • the energization of the stator winding 521 generates an X-order harmonic component.
  • X 2 ⁇ S ⁇ m.
  • the present applicant disclosed that the X-order harmonic component is a component constituting a composite wave of the X-1 order harmonic component and the X + 1 order harmonic component, and therefore the X-1 order harmonic component or X + 1 Attention was paid to the fact that X-order harmonic components can be reduced by reducing at least one of the following harmonic components. Based on this attention, the present applicant sets the skew angle ⁇ s1 in the electrical angle range of “360 ° / (X + 1) to 360 ° / (X ⁇ 1)” to obtain the X-order harmonic component. Can be reduced.
  • the NS alternate magnet flux can be positively linked in the central region, and the winding coefficient of the stator winding 521 is increased. be able to.
  • the skew angle ⁇ s2 in the end region is larger than the skew angle ⁇ s1 in the central region described above.
  • the angle range of the skew angle ⁇ s2 is “ ⁇ s1 ⁇ s2 ⁇ 90 °”.
  • the inner conductor 523 and the outer conductor 523 may be connected to each other by welding or bonding between ends of the respective conductors 523, or may be connected by bending.
  • the end of each phase winding is electrically connected to a power converter (inverter) via a bus bar or the like on one side (that is, one end in the axial direction) of the coil ends 526 on both sides in the axial direction. Is connected. Therefore, here, a configuration in which the conductors are connected to each other at the coil end 526 while distinguishing the coil end 526 on the bus bar connection side and the coil end 526 on the opposite side will be described.
  • each conductor 523 is connected by welding at the coil end 526 on the bus bar connection side, and each conductor 523 is connected by means other than welding at the coil end 526 on the opposite side.
  • welding for example, connection by bending a conductive wire can be considered.
  • the bus bar is connected to the end of each phase winding by welding. Therefore, by adopting a configuration in which the conductive wires 523 are connected to each other by welding at the same coil end 526, each welded portion can be performed in a series of steps, and the working efficiency can be improved.
  • each conductor 523 is connected by means other than welding at the coil end 526 on the bus bar connection side, and each conductor 523 is connected by welding at the opposite coil end 526.
  • the conductors 523 are connected by welding at the coil end 526 on the bus bar connection side, a sufficient separation distance between the bus bar and the coil end 526 is required to avoid contact between the welded portion and the bus bar.
  • the distance between the bus bar and the coil end 526 can be reduced. Thereby, the regulation on the length of the stator winding 521 or the bus bar in the axial direction can be relaxed.
  • each of the conductive wires prepared before welding may have a short wire length, and the working efficiency can be improved by reducing the number of bending steps.
  • 4A fourth configuration is such that the conductors 523 are connected by means other than welding at the coil ends 526 on both axial sides.
  • the portion of the stator winding 521 where welding is performed can be reduced as much as possible, and concerns about the occurrence of insulation delamination in the welding process can be reduced.
  • the band-shaped winding In the process of manufacturing the annular stator winding 521, it is preferable that a band-shaped winding arranged in a plane is manufactured, and then the band-shaped winding is formed into a ring shape. In this case, it is preferable to perform welding between the conductors at the coil end 526 as necessary in the state of the flat band-shaped winding.
  • the band-shaped winding When the flat band-shaped winding is formed into an annular shape, the band-shaped winding may be formed into an annular shape by using a cylindrical jig having the same diameter as that of the stator core 522 so as to be wound around the cylindrical jig. Alternatively, a band-shaped winding may be wound directly around the stator core 522.
  • the configuration of the stator winding 521 can be changed as follows.
  • the configuration may be such that the skew angles of the central region and the end region are the same.
  • the ends of the in-phase conductive wires 523 that are adjacent in the circumferential direction are connected to each other by connecting wires extending in a direction orthogonal to the axial direction. It may be.
  • the number of layers of the stator windings 521 may be 2 ⁇ n layers (n is a natural number), and the stator windings 521 may be four layers, six layers, etc. other than two layers.
  • FIGS. 56 and 57 are exploded cross-sectional views of the inverter unit 530.
  • each member shown in FIG. 56 is shown as two subassemblies.
  • the inverter unit 530 includes an inverter housing 531, a plurality of electric modules 532 mounted on the inverter housing 531, and a bus bar module 533 for electrically connecting the electric modules 532.
  • the inverter housing 531 has a cylindrical outer wall member 541, an inner wall member 542 having an outer diameter smaller than the outer wall member 541, and a radially inner side of the outer wall member 541, and a shaft of the inner wall member 542. And a boss forming member 543 fixed to one end in the direction.
  • These members 541 to 543 are preferably made of a conductive material, for example, carbon fiber reinforced plastic (CFRP).
  • CFRP carbon fiber reinforced plastic
  • the inverter housing 531 is configured such that an outer wall member 541 and an inner wall member 542 are overlapped inside and outside in the radial direction and combined, and a boss forming member 543 is attached to one end side of the inner wall member 542 in the axial direction.
  • the assembled state is the state shown in FIG.
  • a stator core 522 is fixed radially outside the outer wall member 541 of the inverter housing 531.
  • the stator 520 and the inverter unit 530 are integrated.
  • a plurality of recesses 541a, 541b, 541c are formed on the inner peripheral surface of the outer wall member 541, and a plurality of recesses 542a, 542b, 542c are formed on the outer peripheral surface of the inner wall member 542.
  • the outer wall member 541 and the inner wall member 542 are assembled with each other, so that three hollow portions 544a, 544b, and 544c are formed therebetween (see FIG. 57).
  • the central hollow portion 544b is used as a cooling water passage 545 through which cooling water as a coolant flows.
  • seal members 546 are accommodated in the hollow portions 544a and 544c on both sides of the hollow portion 544b (cooling water passage 545).
  • the hollow portion 544b (cooling water passage 545) is hermetically sealed by the sealing material 546.
  • the cooling water passage 545 will be described later in detail.
  • the boss forming member 543 is provided with a disk ring-shaped end plate 547 and a boss portion 548 protruding from the end plate 547 toward the inside of the housing.
  • the boss 548 is provided in a hollow cylindrical shape.
  • the boss forming member 543 is the second end of the first end of the inner wall member 542 in the axial direction and the second end on the protruding side of the rotating shaft 501 (that is, inside the vehicle) opposed thereto. It is fixed to.
  • the base plate 405 is fixed to the inverter housing 531 (more specifically, the end plate 547 of the boss forming member 543).
  • the inverter housing 531 is configured to have a double peripheral wall in the radial direction with the axis as the center.
  • the outer peripheral wall is formed by the outer wall member 541 and the inner wall member 542, and the inner peripheral wall is formed. Is formed by the boss portion 548.
  • the outer peripheral wall formed by the outer wall member 541 and the inner wall member 542 is also referred to as “outer peripheral wall WA1”, and the inner peripheral wall formed by the boss 548 is also referred to as “inner peripheral wall WA2”.
  • an annular space is formed between the outer peripheral wall WA1 and the inner peripheral wall WA2, and a plurality of electric modules 532 are arranged in the annular space in the circumferential direction.
  • the electric module 532 is fixed to the inner peripheral surface of the inner wall member 542 by bonding, screwing, or the like.
  • the inverter housing 531 corresponds to a “housing member”, and the electric module 532 corresponds to an “electric component”.
  • a bearing 560 is housed inside the inner peripheral wall WA2 (the boss 548), and the rotating shaft 501 is rotatably supported by the bearing 560.
  • the bearing 560 is a hub bearing that rotatably supports the wheel 400 at the center of the wheel.
  • the bearing 560 is provided at a position axially overlapping the rotor 510, the stator 520, and the inverter unit 530.
  • the magnet unit 512 can be made thinner in accordance with the orientation in the rotor 510, and the slotless structure or the flat conductor structure is adopted in the stator 520, so that the magnetic circuit unit is formed.
  • the magnetic circuit unit, the inverter unit 530, and the bearing 560 can be arranged in a state of being stacked in the radial direction.
  • the boss portion 548 serves as a bearing holding portion that holds the bearing 560 inside.
  • the bearing 560 is, for example, a radial ball bearing, and has a cylindrical inner ring 561, an outer ring 562 that has a cylindrical shape larger in diameter than the inner ring 561, and is disposed radially outside the inner ring 561, and the inner ring 561 and the outer ring 561. And a plurality of balls 563 arranged between them.
  • the bearing 560 is fixed to the inverter housing 531 by attaching the outer ring 562 to the boss forming member 543, and the inner ring 561 is fixed to the rotating shaft 501.
  • Each of the inner ring 561, the outer ring 562, and the ball 563 is made of a metal material such as carbon steel.
  • the inner ring 561 of the bearing 560 has a cylindrical portion 561a that accommodates the rotary shaft 501, and a flange 561b that extends from one axial end of the cylindrical portion 561a in a direction intersecting (orthogonal) in the axial direction. .
  • the flange 561b is a portion that comes into contact with the end plate 514 of the rotor carrier 511 from the inside, and is sandwiched between the flange 502 of the rotary shaft 501 and the flange 561b of the inner ring 561 when the bearing 560 is mounted on the rotary shaft 501. In this state, the rotor carrier 511 is held.
  • the flange 502 of the rotary shaft 501 and the flange 561b of the inner ring 561 have the same angle of intersection with respect to the axial direction (both are right angles in this embodiment), and are sandwiched between these flanges 502 and 561b. In this state, the rotor carrier 511 is held.
  • the angle of the rotor carrier 511 with respect to the rotation shaft 501 can be maintained at an appropriate angle, and the parallelism of the magnet unit 512 with respect to the rotation shaft 501 can be improved. Can be kept. Thereby, even in a configuration in which the rotor carrier 511 is expanded in the radial direction, resistance to vibration and the like can be increased.
  • the plurality of electric modules 532 are obtained by dividing electric components such as a semiconductor switching element and a smoothing capacitor constituting a power converter into a plurality of parts and individually modularizing the electric parts.
  • the electric module 532 is a power element.
  • a switch module 532A having a semiconductor switching element and a capacitor module 532B having a smoothing capacitor are included.
  • a plurality of spacers 549 having a flat surface for attaching the electric module 532 are fixed to the inner peripheral surface of the inner wall member 542, and the electric module 532 is attached to the spacer 549.
  • the electric module 532 is fixed to a flat surface.
  • the spacer 549 is interposed between the inner wall member 542 and the electric module 532 is not essential, and the inner wall surface of the inner wall member 542 may be flattened or the mounting surface of the electric module 532 may be curved to form an inner wall. It is also possible to attach the electrical module 532 directly to the member 542. Further, the electric module 532 can be fixed to the inverter housing 531 in a state where the electric module 532 is not in contact with the inner peripheral surface of the inner wall member 542. For example, the electric module 532 is fixed to the end plate 547 of the boss forming member 543.
  • the switch module 532A can be fixed to the inner peripheral surface of the inner wall member 542 in a contact state, and the capacitor module 532B can be fixed to the inner peripheral surface of the inner wall member 542 in a non-contact state.
  • the outer peripheral wall WA1 and the spacer 549 correspond to a “cylindrical portion”.
  • the outer peripheral wall WA1 corresponds to a “cylindrical portion”.
  • the outer peripheral wall WA1 of the inverter housing 531 has the cooling water passage 545 through which the cooling water as the coolant flows, and the electric modules 532 are cooled by the cooling water flowing through the cooling water passage 545. It has become.
  • the cooling water passage 545 is provided in an annular shape along the outer peripheral wall WA ⁇ b> 1, and the cooling water flowing in the cooling water passage 545 flows from the upstream side to the downstream side while passing through each electric module 532.
  • the cooling water passage 545 is provided in an annular shape so as to overlap with each of the electric modules 532 inside and outside in the radial direction and surround each of the electric modules 532.
  • the inner wall member 542 is provided with an inlet passage 571 through which the cooling water flows into the cooling water passage 545 and an outlet passage 572 through which the cooling water flows out from the cooling water passage 545.
  • the plurality of electric modules 532 are fixed to the inner peripheral surface of the inner wall member 542. In such a configuration, the interval between the electric modules adjacent in the circumferential direction is expanded by one place more than the other, and the expansion is performed.
  • a part of the inner wall member 542 is protruded radially inward from the part thus formed to form a protruding part 573.
  • An inlet passage 571 and an outlet passage 572 are provided on the protruding portion 573 so as to be arranged side by side in the radial direction.
  • FIG. 58 shows an arrangement state of each electric module 532 in the inverter housing 531.
  • FIG. 58 is the same vertical sectional view as FIG.
  • the electric modules 532 are arranged side by side in the circumferential direction with the interval between the electric modules in the circumferential direction being the first interval INT1 or the second interval INT2.
  • the second interval INT2 is a wider interval than the first interval INT1.
  • Each of the intervals INT1 and INT2 is, for example, a distance between the center positions of two electric modules 532 adjacent in the circumferential direction.
  • the interval between the electric modules adjacent to each other in the circumferential direction without sandwiching the protruding portion 573 is the first interval INT1
  • the interval between the electric modules adjacent to each other in the circumferential direction across the protruding portion 573 is the second interval INT2. ing. That is, the interval between the electric modules adjacent in the circumferential direction is partially expanded, and the protruding portion 573 is provided at, for example, a central portion of the expanded interval (second interval INT2).
  • Each of the intervals INT1 and INT2 may be the distance of an arc between the center positions of two electric modules 532 adjacent to each other in the circumferential direction on the same circle centered on the rotation shaft 501.
  • the interval between the electric modules in the circumferential direction may be defined by angular intervals ⁇ i1 and ⁇ i2 about the rotation axis 501 ( ⁇ i1 ⁇ i2).
  • the electric modules 532 arranged at the first interval INT1 are arranged so as to be separated from each other in a circumferential direction (non-contact state). 532 may be arranged in contact with each other in the circumferential direction.
  • the end plate 547 of the boss forming member 543 is provided with a water passage port 574 in which the passage ends of the entrance passage 571 and the exit passage 572 are formed.
  • a circulation path 575 for circulating cooling water is connected to the inlet passage 571 and the outlet passage 572.
  • the circulation path 575 includes a cooling water pipe.
  • a pump 576 and a radiator 577 are provided in the circulation path 575, and the cooling water circulates through the cooling water passage 545 and the circulation path 575 as the pump 576 is driven.
  • the pump 576 is an electric pump.
  • the radiator 577 is, for example, a radiator that releases heat of cooling water to the atmosphere.
  • stator 520 is disposed outside the outer peripheral wall WA1, and the electric module 532 is disposed inside, the stator 520 is disposed on the outer peripheral wall WA1 from outside. While the heat is transmitted, the heat of the electric module 532 is transmitted from the inside. In this case, the stator 520 and the electric module 532 can be simultaneously cooled by the cooling water flowing through the cooling water passage 545, and the heat of the heat-generating components in the rotating electric machine 500 can be efficiently released.
  • the stator winding 521 includes a U-phase winding, a V-phase winding, and a W-phase winding
  • the inverter 600 is connected to the stator winding 521.
  • the inverter 600 is configured by a full bridge circuit having the same number of upper and lower arms as the number of phases, and a series connection including an upper arm switch 601 and a lower arm switch 602 is provided for each phase. These switches 601 and 602 are turned on and off by the drive circuit 603, and the windings of each phase are energized by the on and off.
  • Each of the switches 601 and 602 is configured by a semiconductor switching element such as a MOSFET or an IGBT.
  • the upper and lower arms of each phase are connected in parallel with a series connection of the switches 601 and 602 with a charge supply capacitor 604 for supplying charges required for switching to the switches 601 and 602.
  • the control device 607 includes a microcomputer including a CPU and various memories, and performs energization control by turning on and off the switches 601 and 602 based on various detection information in the rotating electric machine 500 and requests for powering drive and power generation. .
  • the control device 607 performs on / off control of the switches 601 and 602 by, for example, PWM control at a predetermined switching frequency (carrier frequency) or rectangular wave control.
  • Control device 607 may be a built-in control device built into rotating electric machine 500 or an external control device provided outside rotating electric machine 500.
  • the electric time constant is small because the inductance of the stator 520 is reduced, and the switching frequency (carrier frequency) is small under the condition that the electric time constant is small. ) And a high switching speed.
  • the charge supply capacitor 604 is connected in parallel with the series connection of the switches 601 and 602 of each phase, the wiring inductance is reduced, and even if the switching speed is increased, the proper surge can be achieved. Countermeasures become possible.
  • the high potential side terminal of the inverter 600 is connected to the positive terminal of the DC power supply 605, and the low potential side terminal is connected to the negative terminal (ground) of the DC power supply 605. Further, a smoothing capacitor 606 is connected to the high-potential side terminal and the low-potential side terminal of the inverter 600 in parallel with the DC power supply 605.
  • the switch module 532A has switches 601 and 602 (semiconductor switching elements), a driving circuit 603 (specifically, an electric element forming the driving circuit 603), and a capacitor 604 for supplying electric charges, as heat-generating components. Further, the capacitor module 532B has a smoothing capacitor 606 as a heat-generating component.
  • FIG. 60 shows a specific configuration example of the switch module 532A.
  • the switch module 532A has a module case 611 as an accommodation case, and switches 601 and 602 for one phase accommodated in the module case 611, a drive circuit 603, and a charge supply And the capacitor 604.
  • the drive circuit 603 is configured as a dedicated IC or a circuit board and provided in the switch module 532A.
  • the module case 611 is made of, for example, an insulating material such as a resin, and is fixed to the outer peripheral wall WA1 with its side surface in contact with the inner peripheral surface of the inner wall member 542 of the inverter unit 530.
  • the module case 611 is filled with a molding material such as a resin.
  • the switches 601 and 602 and the drive circuit 603, and the switches 601 and 602 and the capacitor 604 are electrically connected by wiring 612, respectively. More specifically, the switch module 532A is attached to the outer peripheral wall WA1 via the spacer 549, but illustration of the spacer 549 is omitted.
  • the switch module 532A In a state where the switch module 532A is fixed to the outer peripheral wall WA1, the side closer to the outer peripheral wall WA1 in the switch module 532A, that is, the side closer to the cooling water passage 545, has higher cooling performance, and accordingly, the switches 601, 602 according to the cooling performance.
  • the drive circuit 603 and the capacitor 604 are arranged in an order. Specifically, when the heat generation amount is compared, the order of the switches 601 and 602, the capacitor 604, and the drive circuit 603 is in descending order. Therefore, according to the order of the heat generation amount, the switches from the side closer to the outer peripheral wall WA1 are switched. These are arranged in the order of 601, 602, capacitor 604, and drive circuit 603. Note that the contact surface of the switch module 532A may be smaller than the contactable surface on the inner peripheral surface of the inner wall member 542.
  • the capacitor module 532B is configured by housing the capacitor 606 in a module case having the same shape and size as the switch module 532A. Similarly to the switch module 532A, the capacitor module 532B is fixed to the outer peripheral wall WA1 with the side surface of the module case 611 in contact with the inner peripheral surface of the inner wall member 542 of the inverter housing 531.
  • the switch module 532A and the capacitor module 532B do not necessarily have to be arranged concentrically on the radially inner side of the outer peripheral wall WA1 of the inverter housing 531.
  • a configuration in which the switch module 532A is disposed radially inward of the capacitor module 532B, or a configuration in which the switch module 532A is disposed in the opposite direction may be employed.
  • Each electric module 532 may have a configuration in which cooling water is drawn into the inside of the module and cooling by the cooling water is performed inside the module.
  • the water cooling structure of the switch module 532A will be described with reference to FIGS.
  • FIG. 61A is a longitudinal sectional view showing a sectional structure of the switch module 532A in a direction crossing the outer peripheral wall WA1
  • FIG. 61B is a sectional view taken along line 61B-61B of FIG. 61A. .
  • the switch module 532A includes a module case 611, switches 601 and 602 for one phase, a drive circuit 603, and a capacitor 604, as in FIG.
  • a cooling device including a pair of piping portions 621 and 622 and a cooler 623 is provided.
  • a pair of piping portions 621 and 622 are provided with an inflow-side piping portion 621 through which cooling water flows from the cooling water passage 545 of the outer peripheral wall WA1 to the cooler 623, and a cooling water flow from the cooler 623 to the cooling water passage 545.
  • a piping portion 622 on the outflow side through which the water flows out.
  • the cooler 623 is provided in accordance with an object to be cooled, and a single-stage or multiple-stage cooler 623 is used in the cooling device.
  • two-stage coolers 623 are provided in a direction away from the cooling water passage 545, that is, in a radial direction of the inverter unit 530, so as to be separated from each other. Cooling water is supplied to the respective coolers 623 via the sections 621 and 622.
  • the cooler 623 has a hollow inside, for example. However, an inner fin may be provided inside the cooler 623.
  • the outer peripheral wall WA1 side of the first-stage cooler 623 is a place where electric components to be cooled are arranged, and these places are (2), (1) and (3) in order from the one having the highest cooling performance.
  • the cooling performance is highest at a place between the two coolers 623, and at a place adjacent to any one of the coolers 623, the cooling performance is higher near the outer peripheral wall WA1 (cooling water passage 545). ing. Taking this into account, in the configuration shown in FIGS.
  • the switches 601 and 602 are disposed between (2) the first-stage and second-stage coolers 623, and the capacitor 604 is provided as ( 1)
  • the drive circuit 603 is disposed on the outer peripheral wall WA1 side of the first-stage cooler 623, and the drive circuit 603 is disposed on the (3) non-outer peripheral wall side of the second-stage cooler 623.
  • the drive circuit 603 and the capacitor 604 may be arranged in reverse.
  • the switches 601 and 602 and the drive circuit 603, and the switches 601 and 602 and the capacitor 604 are electrically connected by the wiring 612, respectively. Further, since the switches 601 and 602 are located between the driving circuit 603 and the capacitor 604, a wiring 612 extending from the switches 601 and 602 to the driving circuit 603 and a wiring 612 extending from the switches 601 and 602 to the capacitor 604. Are relations extending in opposite directions.
  • the pair of piping portions 621 and 622 are arranged in the circumferential direction, that is, on the upstream side and downstream side of the cooling water passage 545, and the inflow side piping portion located on the upstream side. Cooling water flows into the cooler 623 from 621, and then flows out from the outflow-side pipe portion 622 located on the downstream side.
  • the cooling water passage 545 is provided at a position between the inflow side pipe portion 621 and the outflow side pipe portion 621 when viewed in the circumferential direction. It is good to provide the regulation part 624 which regulates the flow of flow.
  • the regulating section 624 may be a blocking section that blocks the cooling water passage 545 or a throttle section that reduces the passage area of the cooling water passage 545.
  • FIG. 62 shows another cooling structure of the switch module 532A.
  • FIG. 62A is a longitudinal sectional view showing a sectional structure of the switch module 532A in a direction crossing the outer peripheral wall WA1
  • FIG. 62B is a sectional view taken along line 62B-62B of FIG. 62A. .
  • FIGS. 62A and 62B The configuration shown in FIGS. 62A and 62B is different from the configuration shown in FIGS. 61A and 61B in that the arrangement of the pair of piping portions 621 and 622 in the cooling device is different. Are arranged in the axial direction. Further, as shown in FIG. 62 (c), the cooling water passage 545 is formed such that a passage portion communicating with the inflow side piping portion 621 and a passage portion communicating with the outflow side piping portion 622 are separated in the axial direction. These passage portions are communicated with each other through the respective pipe portions 621 and 622 and the respective coolers 623.
  • the following configuration can be used as the switch module 532A.
  • the cooler 623 is changed from two stages to one stage as compared with the configuration in FIG. 61 (a).
  • the place where the cooling performance is highest in the module case 611 is different from that in FIG. 61A, and the place on the outer peripheral wall WA1 side is the most out of both sides in the radial direction of the cooler 623 (left and right sides in the figure).
  • the cooling performance is high, and then the cooling performance decreases in the order of the location on the side opposite to the outer peripheral wall of the cooler 623 and the location away from the cooler 623. Taking this into account, in the configuration shown in FIG.
  • the switches 601 and 602 are arranged on the outer circumferential wall WA1 side of the radially opposite sides (both in the left and right directions in the figure) of the cooler 623, and the condenser 604 is provided.
  • the drive circuit 603 is disposed at a location away from the cooler 623, and on a side opposite to the outer peripheral wall of the cooler 623.
  • the switch module 532A it is also possible to change the configuration in which the switches 601 and 602 for one phase, the drive circuit 603, and the capacitor 604 are accommodated in the module case 611.
  • the module case 611 may be configured to accommodate the switches 601 and 602 for one phase and one of the drive circuit 603 and the capacitor 604.
  • a pair of piping portions 621 and 622 and a two-stage cooler 623 are provided in the module case 611, and the switches 601 and 602 are connected to the first-stage and second-stage coolers 623.
  • the cooler 623 or the drive circuit 603 is arranged on the outer peripheral wall WA1 side of the first-stage cooler 623. Further, the switches 601 and 602 and the driving circuit 603 may be integrated into a semiconductor module, and the semiconductor module and the capacitor 604 may be housed in the module case 611.
  • FIG. 63B in the switch module 532A, at least one of the coolers 623 arranged on both sides of the switches 601 and 602, a capacitor is arranged on the opposite side to the switches 601 and 602. It is good to be. That is, a configuration in which the capacitor 604 is disposed only on one of the outer peripheral wall WA1 side of the first-stage cooler 623 and an opposite peripheral wall side of the second-stage cooler 623, or a configuration in which the capacitor 604 is disposed on both sides. It is possible.
  • the switch module 532A of the switch module 532A and the capacitor module 532B is configured to draw cooling water from the cooling water passage 545 into the module.
  • the configuration may be changed so that the cooling water is drawn into the both modules 532A and 532B from the cooling water passage 545.
  • each electric module 532 it is possible to cool each electric module 532 by putting cooling water directly on the outer surface of each electric module 532.
  • cooling water is applied to the outer surface of the electric module 532.
  • a configuration in which a part of the electric module 532 is immersed in the cooling water passage 545 or a configuration in which the cooling water passage 545 is expanded in the radial direction as compared with the configuration in FIG. A configuration in which the substrate is immersed in the substrate is conceivable.
  • the cooling performance can be further improved by providing fins in the immersed module case 611 (the immersion portion of the module case 611).
  • the electric module 532 includes a switch module 532A and a capacitor module 532B. In consideration of this point, the arrangement of the electric modules 532 in the inverter housing 531 can be devised.
  • a plurality of switch modules 532A are arranged in the circumferential direction without being dispersed, and are arranged on the upstream side of the cooling water passage 545, that is, on the side close to the inlet passage 571.
  • the cooling water flowing from the inlet passage 571 is used first for cooling the three switch modules 532A, and thereafter for cooling the respective capacitor modules 532B.
  • a pair of piping portions 621 and 622 are arranged in the axial direction as in FIGS. 62 (a) and 62 (b).
  • the present invention is not limited to this.
  • a pair of piping portions 621 and 622 may be arranged side by side in the circumferential direction.
  • FIG. 66 is a sectional view taken along line 66-66 of FIG. 49
  • FIG. 67 is a sectional view taken along line 67-67 of FIG.
  • FIG. 68 is a perspective view showing the bus bar module 533 alone.
  • the configuration relating to the electrical connection of each electric module 532 and the bus bar module 533 will be described with reference to these drawings.
  • the circumferential direction of the protrusion 573 provided on the inner wall member 542 (that is, the protrusion 573 provided with the inlet passage 571 and the outlet passage 572 leading to the cooling water passage 545).
  • Three switch modules 532A are arranged side by side in the circumferential direction, and six capacitor modules 532B are also arranged next to it in the circumferential direction.
  • the inside of the outer peripheral wall WA ⁇ b> 1 is equally divided in the circumferential direction into ten (that is, the number of modules + 1) regions, and one electric module 532 is arranged in each of the nine regions.
  • a protrusion 573 is provided in the remaining one region.
  • the three switch modules 532A are a U-phase module, a V-phase module, and a W-phase module.
  • each electric module 532 (switch module 532A and capacitor module 532B) has a plurality of module terminals 615 extending from the module case 611.
  • the module terminal 615 is a module input / output terminal for performing electric input / output in each electric module 532.
  • the module terminal 615 is provided so as to extend in the axial direction. More specifically, the module terminal 615 is provided so as to extend from the module case 611 toward the back side (outside of the vehicle) of the rotor carrier 511 (FIG. 51). reference).
  • the module terminals 615 of each electric module 532 are connected to the bus bar module 533, respectively.
  • the number of module terminals 615 is different between the switch module 532A and the capacitor module 532B.
  • the switch module 532A has four module terminals 615, and the capacitor module 532B has two module terminals 615.
  • the bus bar module 533 has an annular portion 631 having an annular shape and extends from the annular portion 631 to enable connection with an external device such as a power supply device or an ECU (electronic control device). It has three external connection terminals 632 and a winding connection terminal 633 connected to the winding end of each phase in the stator winding 521.
  • the bus bar module 533 corresponds to a “terminal module”.
  • the annular portion 631 is arranged radially inside the outer peripheral wall WA1 in the inverter housing 531 and at one position in the axial direction of each electric module 532.
  • the annular portion 631 has an annular main body formed of, for example, an insulating member such as a resin, and a plurality of busbars embedded therein.
  • the plurality of bus bars are connected to the module terminal 615 of each electric module 532, each external connection terminal 632, and each phase winding of the stator winding 521. The details will be described later.
  • the external connection terminal 632 includes a high-potential-side power terminal 632A and a low-potential-side power terminal 632B connected to the power supply device, and one signal terminal 632C connected to the external ECU.
  • These external connection terminals 632 (632 A to 632 C) are arranged in a line in the circumferential direction and are provided so as to extend in the axial direction inside the annular portion 631 in the radial direction.
  • FIG. 51 when the bus bar module 533 and the electric modules 532 are assembled to the inverter housing 531, one end of the external connection terminal 632 projects from the end plate 547 of the boss forming member 543. .
  • an end plate 547 of the boss forming member 543 is provided with an insertion hole 547a, and a cylindrical grommet 635 is attached to the insertion hole 547a.
  • the external connection terminal 632 is provided with the 635 inserted.
  • the grommet 635 also functions as a sealed connector.
  • the winding connection terminal 633 is a terminal connected to the winding end of each phase of the stator winding 521, and is provided so as to extend radially outward from the annular portion 631.
  • the winding connection terminal 633 includes a winding connection terminal 633U connected to an end of the U-phase winding of the stator winding 521, a winding connection terminal 633V connected to an end of the V-phase winding, and a W-phase winding. It has a winding connection terminal 633W connected to each end of the wire.
  • a current sensor 634 for detecting the current (U-phase current, V-phase current, W-phase current) flowing through each of the winding connection terminals 633 and each phase winding may be provided (see FIG. 70).
  • the current sensor 634 may be disposed outside the electric module 532 and around each winding connection terminal 633, or may be disposed inside the electric module 532.
  • FIG. 69 is a diagram showing each electric module 532 in a developed form, and schematically showing an electrical connection state between each electric module 532 and the bus bar module 533.
  • FIG. 70 is a diagram schematically showing a connection between each electric module 532 and the bus bar module 533 in a state where each electric module 532 is arranged in an annular shape.
  • a path for power transmission is indicated by a solid line
  • a path of a signal transmission system is indicated by a chain line.
  • FIG. 70 shows only the power transmission path.
  • the bus bar module 533 has a first bus bar 641, a second bus bar 642, and a third bus bar 643 as power transmission bus bars.
  • the first bus bar 641 is connected to the power terminal 632A on the high potential side
  • the second bus bar 642 is connected to the power terminal 632B on the low potential side.
  • the three third bus bars 643 are connected to the U-phase winding connection terminal 633U, the V-phase winding connection terminal 633V, and the W-phase winding connection terminal 633W, respectively.
  • the winding connection terminal 633 and the third bus bar 643 are parts that easily generate heat by the operation of the rotating electric machine 10. Therefore, a terminal block (not shown) may be interposed between the winding connection terminal 633 and the third bus bar 643, and this terminal block may be brought into contact with the inverter housing 531 having the cooling water passage 545. Alternatively, the winding connection terminal 633 and the third bus bar 643 may be bent into a crank shape so that the winding connection terminal 633 and the third bus bar 643 abut on the inverter housing 531 having the cooling water passage 545.
  • first busbar 641 and the second busbar 642 are shown as annular busbars, but these busbars 641 and 642 do not necessarily have to be connected in an annular shape.
  • the portion may be formed in a substantially C-shape with interruption.
  • each winding connection terminal 633U, 633V, 633W may be individually connected to the switch module 532A corresponding to each phase, each switch module 532A (actually, without the bus bar module 533) is directly connected. It may be configured to be connected to the module terminal 615).
  • each switch module 532A has four module terminals 615 including a positive terminal, a negative terminal, a winding terminal, and a signal terminal.
  • the positive terminal is connected to the first bus bar 641
  • the negative terminal is connected to the second bus bar 642
  • the winding terminal is connected to the third bus bar 643.
  • the bus bar module 533 has a fourth bus bar 644 as a signal transmission bus bar.
  • the signal terminal of each switch module 532A is connected to the fourth bus bar 644, and the fourth bus bar 644 is connected to the signal terminal 632C.
  • a control signal for each switch module 532A is input from an external ECU via a signal terminal 632C. That is, the switches 601 and 602 in each switch module 532A are turned on / off by the control signal input via the signal terminal 632C. Therefore, each switch module 532A is configured to be connected to the signal terminal 632C without passing through a control device built in the rotating electric machine on the way.
  • a control device is built in the rotating electric machine, and a control signal from the control device is input to each switch module 532A. Such a configuration is shown in FIG.
  • control board 651 on which a control device 652 is mounted, and the control device 652 is connected to each switch module 532A. Further, a signal terminal 632C is connected to the control device 652.
  • the control device 652 inputs a command signal related to powering or power generation from, for example, an external ECU that is a higher-level control device, and appropriately turns on and off the switches 601 and 602 of each switch module 532A based on the command signal.
  • control board 651 may be disposed outside the vehicle (the back side of the rotor carrier 511) from the bus bar module 533.
  • a control board 651 may be disposed between each electric module 532 and the end plate 547 of the boss forming member 543.
  • the control board 651 may be arranged so that at least a part of each control module 532 overlaps in the axial direction.
  • Each capacitor module 532B has two module terminals 615 each including a positive terminal and a negative terminal.
  • the positive terminal is connected to the first bus bar 641, and the negative terminal is connected to the second bus bar 642. Have been.
  • a protrusion 573 having a cooling water inlet passage 571 and an outlet passage 572 is provided in the inverter housing 531 at a position aligned with each electric module 532 in the circumferential direction.
  • An external connection terminal 632 is provided so as to be radially adjacent to the protrusion 573.
  • the protrusion 573 and the external connection terminal 632 are provided at the same angular position in the circumferential direction.
  • the external connection terminal 632 is provided at a position radially inside the protruding portion 573.
  • a water channel port 574 and an external connection terminal 632 are provided on the end plate 547 of the boss forming member 543 in a radial direction (see FIG. 48).
  • the cooling pipe H2 is connected to the water channel port 574, and the electric wiring H1 is connected to the external connection terminal 632.
  • the electric wiring H1 and the cooling Pipe H2 is housed in the housing duct 440.
  • the three switch modules 532A are arranged in the inverter housing 531 next to the external connection terminals 632 in the circumferential direction, and the six capacitor modules 532B are arranged next to the external connection terminals 632 in the circumferential direction.
  • the configuration has been described, this may be changed.
  • a configuration may be adopted in which three switch modules 532A are arranged side by side at a position farthest from the external connection terminal 632, that is, at a position on the opposite side of the rotary shaft 501.
  • the switch modules 532A can be distributed and arranged such that the capacitor modules 532B are arranged on both sides of each switch module 532A.
  • each switch module 532A is arranged at a position farthest from the external connection terminal 632, that is, a position on the opposite side of the rotary shaft 501, the mutual inductance between the external connection terminal 632 and each switch module 532A is obtained. Can be suppressed.
  • a resolver 660 for detecting the electrical angle ⁇ of the rotating electric machine 500 is provided in the inverter housing 531.
  • the resolver 660 is an electromagnetic induction type sensor, and includes a resolver rotor 661 fixed to the rotating shaft 501 and a resolver stator 662 arranged to face the resolver rotor 661 radially outward.
  • the resolver rotor 661 has a disk ring shape, and is provided coaxially with the rotary shaft 501 with the rotary shaft 501 inserted therethrough.
  • the resolver stator 662 includes an annular stator core 663 and a stator coil 664 wound around a plurality of teeth formed on the stator core 663.
  • the stator coil 664 includes a one-phase excitation coil and a two-phase output coil.
  • the excitation coil of the stator coil 664 is excited by a sine wave excitation signal, and the magnetic flux generated in the excitation coil by the excitation signal links the pair of output coils.
  • the relative arrangement relationship between the excitation coil and the pair of output coils changes periodically according to the rotation angle of the resolver rotor 661 (that is, the rotation angle of the rotation shaft 501).
  • the number of magnetic fluxes changes periodically.
  • the pair of output coils and the exciting coil are arranged such that the phases of voltages generated in the pair of output coils are shifted from each other by ⁇ / 2.
  • the output voltage of each of the pair of output coils becomes a modulated wave obtained by modulating the excitation signal with each of the modulated waves sin ⁇ and cos ⁇ . More specifically, if the excitation signal is “sin ⁇ t”, the modulated waves are “sin ⁇ ⁇ sin ⁇ t” and “cos ⁇ ⁇ sin ⁇ t”, respectively.
  • the resolver 660 has a resolver digital converter.
  • the resolver digital converter calculates the electrical angle ⁇ by detection based on the generated modulated wave and the excitation signal.
  • the resolver 660 is connected to the signal terminal 632C, and the calculation result of the resolver digital converter is output to an external device via the signal terminal 632C. If the rotating electric machine 500 has a built-in control device, a calculation result of the resolver digital converter is input to the control device.
  • the boss portion 548 of the boss forming member 543 constituting the inverter housing 531 has a hollow cylindrical shape, and the inner peripheral side of the boss portion 548 has a direction perpendicular to the axial direction.
  • a protruding portion 548a is formed to extend.
  • the resolver stator 662 is fixed by screws or the like in a state where the resolver stator 662 is in contact with the protruding portion 548a in the axial direction.
  • a bearing 560 is provided on one side in the axial direction with the protrusion 548a interposed therebetween, and a resolver 660 is provided coaxially on the other side.
  • a protrusion 548a is provided on one side of the resolver 660 in the axial direction, and a disc ring-shaped housing cover 666 for closing the accommodation space of the resolver 660 is provided on the other side. Is attached.
  • the housing cover 666 is made of a conductive material such as carbon fiber reinforced plastic (CFRP).
  • a hole 666a through which the rotating shaft 501 is inserted is formed at the center of the housing cover 666.
  • a seal member 667 for closing a gap between the rotary shaft 501 and the outer peripheral surface is provided in the hole 666a.
  • the sealer 667 seals the resolver housing space.
  • the seal member 667 may be a sliding seal made of, for example, a resin material.
  • the space in which the resolver 660 is housed is a space surrounded by an annular boss portion 548 in the boss forming member 543 and is axially sandwiched between the bearing 560 and the housing cover 666.
  • the periphery of the resolver 660 is conductive. Surrounded by material. Thereby, the influence of the electromagnetic noise on the resolver 660 can be suppressed.
  • the inverter housing 531 has the double outer peripheral wall WA1 and the inner peripheral wall WA2 (see FIG. 57), and the outside of the double peripheral wall (outside the outer peripheral wall WA1).
  • a stator 520 is arranged, an electric module 532 is arranged between the double peripheral walls (between WA1 and WA2), and a resolver 660 is arranged inside the double peripheral wall (inside the inner peripheral wall WA2).
  • the inverter housing 531 is a conductive member
  • the stator 520 and the resolver 660 are arranged so as to be separated by a conductive partition (in this embodiment, particularly, a double conductive partition). The generation of mutual magnetic interference between the child 520 (magnetic circuit side) and the resolver 660 can be suitably suppressed.
  • the rotor carrier 511 is open on one side in the axial direction, and a substantially disk-shaped rotor cover 670 is attached to the open end.
  • the rotor cover 670 may be fixed to the rotor carrier 511 by any joining method such as welding, bonding, or screwing. It is more preferable that the rotor cover 670 has a portion that is set to be smaller than the inner circumference of the rotor carrier 511 so that the movement of the magnet unit 512 in the axial direction can be suppressed.
  • Rotor cover 670 has an outer diameter that matches the outer diameter of rotor carrier 511, and an inner diameter that is slightly larger than the outer diameter of inverter housing 531. The outer diameter of the inverter housing 531 and the inner diameter of the stator 520 are the same.
  • the stator 520 is fixed radially outside the inverter housing 531, and at the joint portion where the stator 520 and the inverter housing 531 are joined to each other, the inverter housing 531 is pivoted with respect to the stator 520. Projecting in the direction.
  • a rotor cover 670 is attached so as to surround the protruding portion of the inverter housing 531.
  • a seal member 671 for closing a gap between the inner peripheral end surface of the rotor cover 670 and the outer peripheral surface of the inverter housing 531 is provided.
  • the housing space of the magnet unit 512 and the stator 520 is sealed by the sealing material 671.
  • the sealing material 671 is preferably a sliding seal made of, for example, a resin material.
  • the outer peripheral wall WA1 of the inverter housing 531 is disposed radially inside the magnetic circuit portion including the magnet unit 512 and the stator winding 521, and the cooling water passage 545 is formed in the outer peripheral wall WA1.
  • a plurality of electric modules 532 are arranged radially inside the outer peripheral wall WA1 in the circumferential direction along the outer peripheral wall WA1. Accordingly, the magnetic circuit portion, the cooling water passage 545, and the power converter can be arranged so as to be stacked in the radial direction of the rotating electric machine 500, and efficient component arrangement can be achieved while reducing the size in the axial direction. Becomes Further, the plurality of electric modules 532 constituting the power converter can be efficiently cooled. As a result, in the rotating electric machine 500, high efficiency and downsizing can be realized.
  • the electric module 532 (the switch module 532A and the capacitor module 532B) having heat-generating components such as a semiconductor switching element and a capacitor is provided so as to be in contact with the inner peripheral surface of the outer peripheral wall WA1. Thereby, the heat in each electric module 532 is transmitted to the outer peripheral wall WA1, and the electric module 532 is appropriately cooled by heat exchange on the outer peripheral wall WA1.
  • the coolers 623 are arranged on both sides of the switches 601 and 602, respectively, and at least one of the coolers 623 on both sides of the switches 601 and 602 is opposite to the switches 601 and 602.
  • the configuration is such that the capacitor 604 is arranged. Thereby, the cooling performance of the switches 601 and 602 can be improved, and the cooling performance of the capacitor 604 can be also improved.
  • the coolers 623 are arranged on both sides of the switches 601 and 602, respectively, and one of the coolers 623 on both sides of the switches 601 and 602 is driven in the opposite side to the switches 601 and 602.
  • the circuit 603 is arranged, and the condenser 604 is arranged on the other cooler 623 on the side opposite to the switches 601 and 602.
  • the cooling water flows into the module from the cooling water passage 545, and the semiconductor switching element and the like are cooled by the cooling water.
  • the switch module 532A is cooled by the heat exchange with the cooling water inside the module in addition to the heat exchange with the cooling water at the outer peripheral wall WA1. Thereby, the cooling effect of the switch module 532A can be enhanced.
  • the switch module 532A is arranged on the upstream side near the inlet passage 571 of the cooling water passage 545, and the condenser module 532B is connected to the switch module 532A. It is configured to be arranged on the downstream side. In this case, assuming that the temperature of the cooling water flowing through the cooling water passage 545 is lower toward the upstream side, it is possible to realize a configuration in which the switch module 532A is preferentially cooled.
  • the inlet passage 571 and the outlet passage 572 of the cooling water passage 545 can be suitably formed in a portion that is radially inward of the outer peripheral wall WA1. That is, in order to enhance the cooling performance, it is necessary to secure a circulation amount of the refrigerant, and for that purpose, it is conceivable to increase the opening areas of the inlet passage 571 and the outlet passage 572.
  • the entrance passage 571 and the exit passage 572 having desired sizes can be suitably formed.
  • the external connection terminals 632 of the bus bar module 533 are arranged at positions radially in line with the protruding portions 573 on the radially inner side of the outer peripheral wall WA1. That is, the external connection terminals 632 are arranged together with the protruding portions 573 at portions where the space between the electric modules adjacent in the circumferential direction is increased (a portion corresponding to the second space INT2). Thereby, the external connection terminals 632 can be suitably arranged while avoiding interference with each electric module 532.
  • the stator 520 is fixed radially outside the outer peripheral wall WA1, and a plurality of electric modules 532 are arranged radially inside.
  • the heat of the stator 520 is transmitted to the outer peripheral wall WA1 from the radial outside, and the heat of the electric module 532 is transmitted from the radial inner side.
  • the stator 520 and the electric module 532 can be simultaneously cooled by the cooling water flowing through the cooling water passage 545, and the heat of the heat generating member in the rotating electric machine 500 can be efficiently released.
  • the electric module 532 on the radially inner side and the stator winding 521 on the radially outer side with the outer peripheral wall WA1 interposed therebetween are electrically connected by the winding connection terminals 633 of the bus bar module 533.
  • the winding connection terminal 633 is provided at a position axially separated from the cooling water passage 545. Accordingly, even if the cooling water passage 545 is formed in an annular shape in the outer peripheral wall WA1, that is, even if the inside and the outside of the outer peripheral wall WA1 are separated by the cooling water passage 545, the electric module 532 and the stator winding 521 are formed. Can be suitably connected.
  • the rotating electric machine 500 of the present embodiment by reducing or eliminating the teeth (iron core) between the conductors 523 arranged in the circumferential direction on the stator 520, torque limitation caused by magnetic saturation occurring between the conductors 523 is reduced. And suppress the torque reduction by making the conducting wire 523 flat and thin. In this case, even if the outer diameter of the rotating electric machine 500 is the same, it is possible to expand the radially inner region of the magnetic circuit unit by making the stator 520 thinner, and use the inner region to perform cooling.
  • the outer peripheral wall WA1 having the water passage 545 and the plurality of electric modules 532 provided radially inside the outer peripheral wall WA1 can be suitably arranged.
  • the magnet flux in the magnet unit 512 is concentrated on the d-axis side so that the magnet flux in the d-axis is strengthened, and the torque can be increased accordingly.
  • the radial thickness of the magnet unit 512 can be reduced (thinned), the radially inner region of the magnetic circuit unit can be expanded, and the inner region is used.
  • the outer peripheral wall WA1 having the cooling water passage 545 and the plurality of electric modules 532 provided radially inside the outer peripheral wall WA1 can be suitably arranged.
  • the bearing 560 and the resolver 660 can be suitably arranged in the radial direction.
  • the wheel 400 using the rotating electric machine 500 as an in-wheel motor is mounted on the vehicle body via a base plate 405 fixed to the inverter housing 531 and a mounting mechanism such as a suspension device.
  • a mounting mechanism such as a suspension device.
  • the electric module 532 and the bus bar module 533 are arranged radially inside the outer peripheral wall WA1 of the inverter unit 530, and the electric module 532 and the bus bar are arranged radially inward and outward across the outer peripheral wall WA1.
  • a module 533 and a stator 520 are arranged, respectively.
  • the position of the bus bar module 533 with respect to the electric module 532 can be arbitrarily set.
  • a winding connection line for example, a winding connection terminal 633 used for the connection is connected.
  • the guidance position can be set arbitrarily.
  • the position of the bus bar module 533 with respect to the electric module 532 is ( ⁇ 1) such that the bus bar module 533 is located outside the electric module 532 in the axial direction, that is, on the rotor carrier 511 side, ( ⁇ 2) a configuration in which the bus bar module 533 is located on the vehicle inner side of the electric module 532 in the axial direction, that is, on the front side on the rotor carrier 511 side; Can be considered.
  • ( ⁇ 1) a configuration in which the winding connection line is guided on the vehicle outside in the axial direction, that is, on the back side on the rotor carrier 511 side; ( ⁇ 2) a configuration in which the winding connection line is guided on the vehicle inside in the axial direction, that is, on the near side of the rotor carrier 511 side; Can be considered.
  • FIGS. 72A to 72D are simplified longitudinal sectional views showing the configuration of the rotating electric machine 500.
  • the winding connection line 637 is an electric wiring that connects each phase winding of the stator winding 521 to the bus bar module 533, and corresponds to, for example, the winding connection terminal 633 described above.
  • ( ⁇ 1) is employed as the position of the bus bar module 533 with respect to the electric module 532, and ( ⁇ 1) is employed as the position for guiding the winding connection line 637. That is, the electric module 532 and the bus bar module 533, the stator winding 521, and the bus bar module 533 are all connected outside the vehicle (on the rear side of the rotor carrier 511). This corresponds to the configuration shown in FIG.
  • the cooling water passage 545 can be provided on the outer peripheral wall WA1 without fear of interference with the winding connection line 637. Further, the winding connection line 637 connecting the stator winding 521 and the bus bar module 533 can be easily realized.
  • ( ⁇ 1) is used as the position of the bus bar module 533 with respect to the electric module 532
  • ( ⁇ 2) is used as the position for guiding the winding connection line 637. That is, the electric module 532 and the bus bar module 533 are connected outside the vehicle (the back side of the rotor carrier 511), and the stator winding 521 and the bus bar module 533 are connected inside the vehicle (the front side of the rotor carrier 511). It is configured to be connected by.
  • the cooling water passage 545 can be provided on the outer peripheral wall WA1 without fear of interference with the winding connection line 637.
  • the position ( ⁇ 2) is used as the position of the bus bar module 533 with respect to the electric module 532
  • the position ( ⁇ 1) is used as the position for guiding the winding connection line 637. That is, the electric module 532 and the bus bar module 533 are connected inside the vehicle (front side of the rotor carrier 511), and the stator winding 521 and the bus bar module 533 are connected outside the vehicle (rear side of the rotor carrier 511). It is configured to be connected by.
  • the above ( ⁇ 2) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above ( ⁇ 2) is adopted as the position for guiding the winding connection line 637. That is, the electric module 532 and the busbar module 533, the stator winding 521, and the busbar module 533 are all connected inside the vehicle (on the front side of the rotor carrier 511).
  • the bus bar module 533 is disposed inside the vehicle (on the front side of the rotor carrier 511), so that an attempt is made to temporarily add an electric component such as a fan motor. In such a case, the wiring may be facilitated. In addition, the bus bar module 533 can be brought closer to the resolver 660 disposed on the vehicle inner side than the bearing, and wiring to the resolver 660 may be facilitated.
  • FIGS. 73A to 73C are configuration diagrams showing an example of a mounting structure of the resolver rotor 661 to the rotating body.
  • the resolver 660 is provided in a closed space surrounded by the rotor carrier 511, the inverter housing 531 and the like, and protected from external water or mud.
  • the bearing 560 has the same configuration as that of FIG.
  • the bearing 560 has a different configuration from that of FIG. 49 and is arranged at a position away from the end plate 514 of the rotor carrier 511.
  • the resolver stator 662 is not shown, for example, the boss 548 of the boss forming member 543 may be extended to the outer peripheral side of the resolver rotor 661 or in the vicinity thereof, and the resolver stator 662 may be fixed to the boss 548. .
  • the resolver rotor 661 is attached to the inner ring 561 of the bearing 560. Specifically, the resolver rotor 661 is provided on the axial end face of the flange 561b of the inner race 561, or is provided on the axial end face of the cylindrical portion 561a of the inner race 561.
  • the resolver rotor 661 is attached to the rotor carrier 511. Specifically, a resolver rotor 661 is provided on the inner surface of the end plate 514 in the rotor carrier 511. Alternatively, in a configuration in which the rotor carrier 511 has the cylindrical portion 515 extending along the rotation axis 501 from the inner peripheral edge of the end plate 514, the resolver rotor 661 is provided on the outer peripheral surface of the cylindrical portion 515 of the rotor carrier 511. ing. In the latter case, the resolver rotor 661 is disposed between the end plate 514 of the rotor carrier 511 and the bearing 560.
  • the resolver rotor 661 is attached to the rotating shaft 501. Specifically, the resolver rotor 661 is provided between the end plate 514 of the rotor carrier 511 and the bearing 560 on the rotating shaft 501, or the resolver rotor 661 is opposite to the rotor carrier 511 across the bearing 560 on the rotating shaft 501. Located on the side.
  • FIGS. 74A and 74B are simplified longitudinal sectional views showing the configuration of the rotating electric machine 500, and the same reference numerals are given to the already described components in FIG.
  • the configuration illustrated in FIG. 74A substantially corresponds to the configuration described in FIG. 49 and the like
  • the configuration illustrated in FIG. 74B is a configuration in which a part of the configuration illustrated in FIG. Is equivalent to
  • the rotor cover 670 fixed to the open end of the rotor carrier 511 is provided so as to surround the outer peripheral wall WA1 of the inverter housing 531. That is, the end surface on the inner diameter side of the rotor cover 670 faces the outer peripheral surface of the outer peripheral wall WA1, and the sealing material 671 is provided between the both.
  • a housing cover 666 is attached to a hollow portion of the boss 548 of the inverter housing 531, and a seal member 667 is provided between the housing cover 666 and the rotating shaft 501.
  • the external connection terminals 632 constituting the bus bar module 533 extend through the inverter housing 531 to the inside of the vehicle (the lower side in the figure).
  • an inlet passage 571 and an outlet passage 572 communicating with the cooling water passage 545 are formed in the inverter housing 531, and a water passage port 574 including the passage ends of the inlet passage 571 and the outlet passage 572 is formed.
  • annular convex portion 681 is formed on the inverter housing 531 (specifically, the boss forming member 543) so as to extend on the protruding side of the rotary shaft 501 (inside the vehicle).
  • a rotor cover 670 is provided so as to surround the protrusion 681 of the inverter housing 531. That is, the end surface on the inner diameter side of the rotor cover 670 faces the outer peripheral surface of the convex portion 681, and the sealing material 671 is provided between them.
  • the external connection terminals 632 constituting the bus bar module 533 extend through the boss portion 548 of the inverter housing 531 into the hollow region of the boss portion 548, and penetrate the housing cover 666 to the inside of the vehicle (the lower side in the figure). Extends to.
  • an inlet passage 571 and an outlet passage 572 that communicate with the cooling water passage 545 are formed in the inverter housing 531, and the inlet passage 571 and the outlet passage 572 extend to a hollow region of the boss 548, and It extends to the inside of the vehicle (the lower side in the figure) from the housing cover 666 via the 682.
  • a pipe portion extending from the housing cover 666 to the inside of the vehicle is a water channel port 574.
  • the rotor carrier 511 and the rotor cover 670 are connected to the inverter while maintaining the hermeticity of the inner space of the rotor carrier 511 and the rotor cover 670.
  • the housing 531 can be suitably rotated.
  • the inner diameter of the rotor cover 670 is smaller than that of the configuration of FIG. 74 (a). Therefore, the inverter housing 531 and the rotor cover 670 are provided in the axial direction doubly at a position inside the vehicle with respect to the electric module 532, and the inconvenience due to electromagnetic noise that is a concern in the electric module 532 is suppressed. can do.
  • the sliding diameter of the sealing material 671 is reduced, so that mechanical loss at the rotating sliding portion can be suppressed.
  • FIG. 75 shows a modification of the stator winding 521.
  • the stator winding 521 is made of a conductive wire having a rectangular cross section, and is wound by wave winding with the long side of the conductive wire extending in the circumferential direction.
  • the conductors 523 of each phase which become the coil side in the stator winding 521, are arranged at a predetermined pitch interval for each phase and are connected to each other at the coil end.
  • the conductors 523 that are adjacent to each other in the circumferential direction on the coil side have circumferential end faces that abut against each other or are arranged close to each other with a small interval.
  • the conductive wire is bent in the radial direction in each phase at the coil end. More specifically, the stator winding 521 (conductive wire) is bent radially inward at different positions in the axial direction for each phase, whereby the U-phase, V-phase, and W-phase windings are formed. Are avoided. In the illustrated configuration, the conductors are bent radially inward at right angles for each phase, with the phases differing by the thickness of the conductors in each phase winding. In each of the conductors 523 arranged in the circumferential direction, the length between both ends in the axial direction may be the same.
  • stator 520 When the stator 520 is manufactured by assembling the stator core 522 with the stator winding 521, a part of the annular shape in the stator winding 521 is disconnected and disconnected (that is, the stator winding 521 is used). After the stator core 522 is assembled on the inner peripheral side of the stator winding 521, the separated portions may be connected to each other to form the stator winding 521 in an annular shape.
  • stator core 522 is divided into a plurality (for example, three or more) in the circumferential direction, and the plurality of divided core pieces are provided on the inner peripheral side of the stator winding 521 formed in an annular shape. Can be assembled.
  • the inlet passage 571 and the outlet passage 572 of the cooling water passage 545 are provided at one place, but this configuration is changed so that the inlet passage 571 and the outlet
  • the passage 572 and the passage 572 may be provided at different positions in the circumferential direction.
  • a configuration in which the entrance passage 571 and the exit passage 572 are provided at positions different by 180 degrees in the circumferential direction, or a configuration in which at least one of the entrance passage 571 and the exit passage 572 is provided in plurality may be employed.
  • the rotating shaft 501 is configured to protrude on one side in the axial direction of the rotating electric machine 500.
  • this may be changed, and the rotating shaft 501 may be configured to protrude in both axial directions.
  • a preferable configuration can be realized in a vehicle in which at least one of the front and rear sides of the vehicle has one wheel.
  • an inner rotor type rotating electric machine can be used as the rotating electric machine 500 used for the wheel 400.
  • FIG. 76 is a front view showing the entire main part of rotating electric machine 700
  • FIG. 77 is a longitudinal sectional view of rotating electric machine 700
  • FIG. 78 is an exploded sectional view showing components of rotating electric machine 700 in an exploded manner. It is.
  • the rotating electric machine 700 is an outer rotor type surface magnet type rotating electric machine.
  • the rotating electric machine 700 is roughly provided with a rotating electric machine main body having a rotor 710, a stator 720, and a stator holder 760.
  • the rotating electric machine main body is provided in a state housed in the housing, but the illustration of the housing is omitted here.
  • Each member of the rotating electrical machine main body is coaxially arranged with respect to a rotating shaft 701 provided integrally with the rotor 710, and is assembled in a predetermined order in the axial direction to configure the rotating electrical machine 700. .
  • the rotating shaft 701 is rotatably supported by a pair of bearings 702 and 703 provided inside the stator holder 760 in the radial direction.
  • the rotation of the rotating shaft 701 causes, for example, the axle of the vehicle to rotate.
  • the rotating electric machine 700 can be mounted on a vehicle by fixing the stator holder 760 to a vehicle body frame or the like.
  • the rotor 710 and the stator 720 each have a cylindrical shape, and are arranged radially opposite each other with an air gap therebetween.
  • the rotor 710 rotates integrally with the rotation shaft 701
  • the rotor 710 rotates radially outside the stator 720.
  • the rotor 710 corresponds to a “field element”
  • the stator 720 corresponds to an “armature”.
  • the rotor 710 has a substantially cylindrical rotor carrier 711 and an annular magnet unit 712 fixed to the rotor carrier 711.
  • the rotor carrier 711 has a cylindrical portion 713 having a cylindrical shape, and an end plate portion 714 provided at one axial end of the cylindrical portion 713, and is configured by integrating them. ing.
  • an annular upright portion 714a extending in the axial direction may be provided at the outer edge of the end plate portion 714, and the tubular portion 713 may be fixed to the upright portion 714a.
  • the cylindrical portion 713 and the end plate portion 714 can be formed as an integral product instead of being separate bodies.
  • the rotor carrier 711 functions as a magnet holding member, and the magnet unit 712 is fixed to the inside of the cylindrical portion 713 in the radial direction in a ring shape.
  • a through hole 714b is formed at the center of the end plate portion 714, and the rotating shaft 701 is fixed to the end plate portion 714 by a fastener such as a bolt (not shown) in a state of being inserted through the through hole 714b.
  • the rotating shaft 701 has a flange 701a extending in a direction crossing (orthogonal to) the axial direction, and the rotor carrier 711 is attached to the rotating shaft 701 in a state where the flange 701a and the end plate portion 714 are surface-joined. Has been fixed.
  • the magnet unit 712 is constituted by a plurality of permanent magnets arranged so that the polarity alternates along the circumferential direction of the rotor 710.
  • the magnet unit 712 corresponds to a “magnet part”.
  • the magnet unit 712 has a plurality of magnetic poles in the circumferential direction.
  • the magnet unit 712 has the configuration described as the magnet unit 42 in FIGS. 8 and 9 of the first embodiment, and has a specific coercive force of 400 [kA / m] or more as a permanent magnet and a residual magnetic flux. It is configured using a sintered neodymium magnet having a density Br of 1.0 [T] or more.
  • the magnet unit 712 has a first magnet 91 and a second magnet 92 which are polar anisotropic magnets and have different polarities, respectively, similarly to the magnet unit 42 in FIG. 9 and the like.
  • the directions of the axes of easy magnetization of the magnets 91 and 92 are different between the d-axis side (portion closer to the d-axis) and the q-axis side (portion near the q-axis).
  • the direction of the easy axis is closer to the direction parallel to the d axis on the d-axis side, and the direction of the easy axis is closer to the direction orthogonal to the q axis on the q-axis side.
  • An arc-shaped magnet magnetic path is formed by an orientation corresponding to the direction of the easy axis of magnetization.
  • the easy axis may be oriented parallel to the d axis on the d-axis side, and the easy axis may be orthogonal to the q axis on the q-axis side.
  • the magnet unit 712 is configured such that the direction of the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared to the q-axis side, which is the magnetic pole boundary. .
  • the configuration of the magnet unit 42 shown in FIGS. 22 and 23 or the configuration of the magnet unit 42 shown in FIG. 30 can be used.
  • the stator 720 has a stator winding 721 and a stator core 722.
  • 79 is a perspective view of the stator 720
  • FIG. 80 is a plan view of the stator 720
  • FIG. 81 is a longitudinal sectional view of the stator 720
  • FIG. 82 is a perspective view of the stator core 722.
  • the stator core 722 is formed by laminating a core sheet made of a magnetic steel sheet, which is a magnetic material, in the axial direction, and has a cylindrical shape having a predetermined thickness in the radial direction.
  • the stator winding 721 is mounted on the outer side in the radial direction.
  • the outer peripheral surface of the stator core 722 has a curved shape without irregularities in the circumferential direction.
  • the constituent wire portions 734 are arranged side by side in the circumferential direction.
  • the stator core 722 functions as a back core.
  • the stator core 722 is composed of a plurality of divided cores 724 divided in the circumferential direction, and the plurality of divided cores 724 are integrated in a state where the divided cores 724 are in contact with each other at their circumferential end surfaces.
  • a projection 725 extending in the axial direction is provided on the inner peripheral surface of each split core 724, and in a state where the split cores 724 are integrated in an annular shape, the inner peripheral surface of the stator core 722 is provided in the circumferential direction. In this configuration, the protrusions 725 are provided at predetermined intervals.
  • the divided cores 724 are preferably connected to each other by fitting, and the divided cores 724 that are adjacent to each other in the circumferential direction are formed by press-fitting a concave portion and a convex portion provided on the circumferential end surface of the divided core 724. It may be fixed to each other.
  • stator core 722 may be configured as a cylindrical molded product instead of the configuration in which the plurality of split cores 724 are integrated.
  • the stator core 722 may be formed by stacking a plurality of core sheets punched and formed in an annular plate shape in the axial direction.
  • the stator core 722 may use a helical core structure in which a belt-shaped core sheet is formed in an annular shape and stacked in the axial direction.
  • the stator 720 may use any of the following (A) to (C).
  • an inter-conductor member is provided between the conductor portions 734 in the circumferential direction, and as the inter-conductor member, the circumferential width of the inter-conductor member at one magnetic pole is Wt,
  • the saturation magnetic flux density is Bs
  • the circumferential width of the magnet unit 712 at one magnetic pole is Wm
  • the residual magnetic flux density of the magnet unit 712 is Br
  • a magnetic material having a relationship of Wt ⁇ Bs ⁇ Wm ⁇ Br is used. ing.
  • stator 720 In the stator 720, an inter-conductor member is provided between the conductor portions 734 in the circumferential direction, and a non-magnetic material is used as the inter-conductor member.
  • the stator 720 has a configuration in which no inter-conductor member is provided between the conductor portions 734 in the circumferential direction.
  • stator winding 721 is integrally molded with the stator core 722 by a molding material (insulating member) made of resin or the like, the molding material is interposed between the conductors 734 arranged in the circumferential direction.
  • the stator 720 corresponds to the configuration (B) of the above (A) to (C).
  • the conductor portions 734 adjacent in the circumferential direction are arranged such that their end faces in the circumferential direction abut on each other or are arranged close to each other with a small space therebetween. You may.
  • the stator core 722 has a teethless structure having no teeth as a part thereof, and the stator winding 721 is integrated with the teethless stator core 722.
  • the stator core 722 has a cylindrical shape, and the stator winding 721 is attached to the outer peripheral side of the stator core 722.
  • the outer peripheral surface of the stator core 722 has a protrusion (width or protrusion height) of a size (width or protrusion height) satisfying the above-mentioned rule (A) at predetermined intervals in the circumferential direction. Should be provided.
  • the stator winding 721 has a plurality of phase windings, and the phase windings of each phase are arranged in a predetermined order in the circumferential direction.
  • the stator winding 721 has a three-phase winding by using U-phase, V-phase, and W-phase windings.
  • the stator winding 721 is constituted by a single-layer conductive wire portion 734 inside and outside in the radial direction in each phase winding.
  • the stator winding 721 has a plurality of partial windings 731U, 731V, 731W for each phase as a phase winding of each phase, and the partial windings 731U, 731V, 731W are circumferentially arranged in a predetermined order. It is constituted by being arranged in.
  • FIG. 83 is a circuit diagram showing electrical connection of partial windings 731U, 731V, 731W of each phase in stator winding 721.
  • one partial winding for each phase is star-connected (Y-connected).
  • a plurality of star-connected three-phase windings are connected in parallel.
  • the partial windings 731U, 731V, 731W of each phase are each formed by lapping a conductive wire.
  • Each of the partial windings 731U, 731V, 731W is assembled to the stator core 722 and electrically connected to each other by a connecting member such as a bus bar, thereby forming the stator winding 721.
  • the partial windings 731U, 731V, 731W of each phase are collectively referred to as a partial winding 731.
  • the number of magnetic poles is 12 (that is, the number of magnetic pole pairs is 6), but the number is arbitrary.
  • the stator winding 721 has a coil side CS radially aligned with the stator core 722 and a coil end CE located axially outside the coil side CS.
  • the coil ends CE are provided on both ends in the axial direction of the stator winding 721, respectively.
  • the coil side CS is a portion including a magnet facing portion radially facing the magnet unit 712 of the rotor 710, and the coil end CE includes a winding in the same phase on the outer side in the axial direction than the coil side CS in the circumferential direction. This is the orbital part that is orbited.
  • FIG. 84 (a) is a perspective view showing a partial winding 731U, 731V, 731W of each phase one by one extracted from the stator winding 721, and FIG. It is a front view which shows the partial winding 731U, 731V, 731W.
  • FIG. 85 is a perspective view showing only the U-phase partial winding 731U of the three-phase partial windings, and
  • FIG. 86 is a cross-sectional view of the rotor 710 and the stator 720.
  • the partial windings 731U, 731V, 731W of each phase are respectively composed of a pair of intermediate conductor groups 732 which are portions corresponding to the coil side CS, and the intermediate conductor group 732. And a crossover portion 733 that is a portion that is axially outward and includes the coil end CE.
  • Each of the partial windings 731U, 731V, 731W is arranged such that, for each phase, the intermediate conductor groups 732 are arranged in the coil side CS in the circumferential direction, and the crossover portions 733 overlap in the coil end CE in the axial direction. ing.
  • the partial winding 731U is formed by looping the conductor CR multiple times, and has a pair of intermediate conductor groups 732 separated in the circumferential direction. , And a pair of crossover portions 733 that are separated in the axial direction.
  • the number of turns of the partial winding 731 is three. However, the number of turns may be other than three.
  • the pair of intermediate conductor groups 732 are formed such that the conductor CR is linearly extended in the axial direction (vertical direction in the drawing).
  • the pair of transition portions 733 are provided so as to extend from both axial ends of each intermediate conductor group 732 in a direction orthogonal to the axial direction.
  • the conductor CR is a plastically deformable rectangular conductor having a rectangular cross section, and the partial winding 731U is manufactured by molding using, for example, a mold or a jig.
  • Each of the pair of intermediate conductor groups 732 is configured by arranging three conductors CR in the circumferential direction, and the intermediate conductor group 732 of the partial windings 731V and 731W of the other phase can be arranged between the pair of intermediate conductor groups 732.
  • the same number of conductors CR as the number of turns of the partial winding 731 are arranged in the circumferential direction.
  • the three conductors CR arranged in the circumferential direction in each intermediate conductor group 732 correspond to the coil side conductor 734 facing the magnetic pole in the radial direction. Since the pair of intermediate conductor groups 732 in each of the partial windings 731 are separated from each other, six (3 ⁇ 2) conductor wires CR of the other two phases are arranged between them. It has a configuration.
  • FIG. 86 shows the relationship between the phase windings of each phase and the magnetic poles of the rotor 710.
  • dots are attached to the U-phase winding of the three-phase winding, that is, the intermediate conductor group 732 of the U-phase partial winding 731U.
  • an intermediate conductor group 732 of one phase is provided for each magnetic pole arranged in the circumferential direction.
  • the pair of intermediate conductor groups 732 are provided on two magnetic poles adjacent in the circumferential direction.
  • the pair of transition portions 733 is a portion that connects the pair of intermediate conductor groups 732 in a ring shape, and the transition portion 733 on the upper side of the figure is configured by arranging two conductor wires CR.
  • the crossover portion 733B on the lower side of the figure is configured by arranging three conductive wires CR.
  • One of the crossover portions 733 on both sides in the axial direction is provided with winding ends 735 and 736 of the partial winding 731U by one end and the other end of the conductive wire CR.
  • the pair of transition portions 733 are bent toward the same side in the radial direction (in this example, all radially inward), and the bent shape allows the partial windings 731 of the phases adjacent to each other in the circumferential direction to be formed. Interference is avoided. That is, the pair of transition portions 733 function as an interference avoiding unit.
  • each transition portion 733 is radially bent so as to face the axial end surface of the stator core 722.
  • the radial dimension from the intermediate conductor group 732 to the tip of the transition portion 733 may be equal to or less than the radial thickness of the stator core 722.
  • the radial dimension from the intermediate conductor group 732 to the tip of the crossover portion 733 may be equal to or less than the radial thickness of the stator core 722.
  • the transition portion 733 of each partial winding 731 is bent radially inward at the coil end CE in a direction perpendicular to the axial direction. In this case, it is possible to minimize the protrusion height of the coil end CE in the axial direction.
  • the crossing portion 733 may be bent at an angle other than perpendicular to the axial direction.
  • the crossover portions 733 of the respective partial windings 731 are preferably arranged at different positions in at least one of the radial direction and the axial direction so as to avoid mutual interference.
  • the V-phase partial winding 731V and the W-phase partial winding 731W are different from the U-phase partial winding 731U in the axial length between the pair of bridging portions 733 and the radial length of the bridging portion 733. Except for this point, they have substantially the same configuration.
  • the axial length between the pair of transition portions 733 of each partial winding 731 is increased, and the radial length of the transition portion 733 is increased. It is getting shorter.
  • the U-phase partial winding 731U is the innermost (core end face side) in the axial direction
  • the V-phase part is A winding 731V and a W-phase partial winding 731W are further disposed outside the winding 731V.
  • the axial length of the intermediate conductor group 732 may be different from each other by the thickness of the conductor CR.
  • each of the partial windings 731U, 731V, 731W of each phase is configured such that the entire length of the conductive wire CR is substantially equal.
  • the partial windings 731U, 731V, 731W of each phase are arranged so as to be shifted in the circumferential direction by an electrical angle of 60 degrees ( ⁇ / 3). .
  • a three-phase winding corresponding to one magnetic pole pair is formed by the partial windings 731U, 731V, and 731W for each phase.
  • a three-phase winding is formed for each magnetic pole pair, and six three-phase windings (for six magnetic pole pairs) are arranged in the circumferential direction.
  • each partial winding 731 of each phase Since the partial windings 731U, 731V, 731W of each phase are arranged at positions shifted by 60 electrical degrees in the circumferential direction for each phase, each partial winding 731 of each phase, that is, three windings The winding assembly having one magnetic pole pair as one unit is formed using the partial windings 731.
  • the partial windings 731 of each phase are preferably arranged at positions shifted by 180 / n degrees in electrical angle in the circumferential direction for each phase. .
  • FIG. 87 is a perspective view showing a state where all of the partial windings 731U, 731V, 731W of each phase are assembled to the stator core 722.
  • the partial windings 731U, 731V, and 731W of each phase are formed by winding the conductive wire CR a plurality of times in a state of straddling two magnetic poles adjacent in the circumferential direction.
  • the wire 721 is configured by arranging the partial windings 731 of each phase in a predetermined order in the circumferential direction.
  • the winding ends 735 and 736 are configured to protrude in the same axial direction.
  • Each of the partial windings 731 has a configuration in which the radial thickness of the conductive wire in the coil side CS is smaller than the circumferential width of one phase in one magnetic pole (ie, a flat conductive wire structure). Good to be.
  • the conductor CR is preferably a bundled wire formed by bundling a plurality of strands (thin wires).
  • FIG. 88 illustrating a cross-sectional structure of the conductive wire CR.
  • the conductive wire CR is a rectangular conductive wire having a substantially rectangular cross section, and includes a plurality of (six in the figure) strands 741 and a resin, for example, made of resin surrounding the plurality of strands 741. It has an outer coating 742 (outer insulating layer) and an intermediate layer 743 filled around each element wire 741 in the outer coating 742.
  • the wire 741 has a configuration in which a conductor portion 741a made of a copper material is covered with a conductor coating 741b (wire insulation layer) made of an insulating material.
  • the conductor CR has a plurality of insulating coatings in the inner and outer multilayers
  • the outer coating 742 is an outer insulating coating
  • the intermediate layer 743 is an intermediate insulating coating
  • the conductor coating 741b of the strand 741 is provided. Is an inner insulating coating.
  • the conductor CR is preferably a wire aggregate in which a plurality of wires 741 are bundled and the resistance value between the bundled wires is larger than the resistance value of the wire 741 itself.
  • the strand 741 may be configured as an aggregate of a plurality of conductive materials.
  • the outer layer coating 742 has a larger thickness dimension than the conductor coating 741b.
  • the thickness of the outer layer coating 742 which is the interphase insulating layer, is larger than the conductor coating 741b of the strand 741, the resistance to high voltage can be enhanced. That is, in the conductor CR, the insulating ability of the outer insulating coating among the plurality of insulating coatings is higher than the insulating ability of the inner insulating coating. In this case, for example, it can be suitably used even in a voltage band that requires a withstand voltage larger than the general thickness of the conductive wire (5 to 40 ⁇ m).
  • the conductor CR has an outer coating 742 as an insulating coating on the outer peripheral portion.
  • the conductors CR adjacent to each other in the circumferential direction are insulated from each other by the outer coating 742. I have.
  • insulation is secured by the outer layer coating 742 of the conductor CR in the middle conductor group 732. Is done. Therefore, in the stator core 722 using the teethless structure, the insulation of the stator winding 721 can be appropriately realized.
  • connection structure in the partial windings 731U, 731V, 731W of each phase will be described with reference to FIGS. 84 (a), (b) and FIG.
  • Each of the partial windings 731U, 731V, and 731W of each phase has winding ends 735 and 736.
  • One of the winding ends 735 is a conductor end for neutral point connection, and the other winding end 735 is the other winding end.
  • the wire end 736 is a wire end for power input / output.
  • a neutral point bus bar 737 is connected to the winding end 735 of each phase.
  • the neutral point bus bar 737 is provided for each partial winding 731 of each phase, that is, one for each of the three partial windings 731.
  • the neutral bus bar 737 is provided for the stator winding 721.
  • a total of six neutral point bus bars 737 are provided.
  • Neutral point bus bar 737 is provided at a position axially overlapping transition portion 733 of stator winding 721.
  • power bus bars 751, 752, and 753 for inputting and outputting power to and from the partial winding 731 of each phase are connected to the winding end portion 736 of each phase.
  • Each of the power bus bars 751 to 753 of each phase has a circular ring shape, and has connection terminals 754, 755, 756.
  • connection terminals 754 to 756 By connecting the connection terminals 754 to 756 to an inverter via a harness (not shown), power can be input to and output from the stator winding 721.
  • Each of the power bus bars 751 to 753 of each phase has an annular portion of the same size, overlaps with the transition portion 733 of the stator winding 721 in the axial direction, and has a radial direction more than the neutral point bus bar 737. It is provided at a position on the inside (see FIG. 80).
  • Partial windings 731 of different phases are connected to each other by neutral point bus bar 737, and partial windings 731 of same phase are connected to each other by power bus bars 751 to 753.
  • the neutral bus bar 737 and the power bus bars 751 to 753 correspond to connection members.
  • one unit of a winding assembly (a winding assembly for one magnetic pole pair) is formed using the partial windings 731 for each phase, as described above.
  • Neutral point bus bars 737 are individually connected to the winding assemblies. This makes it possible to easily connect the partial windings 731 of each phase by the neutral point bus bar 737 for each magnetic pole pair, thereby facilitating welding work of the neutral point bus bar 737 and the like. It has become.
  • FIG. 90 is a diagram schematically showing the connection state of the U-phase partial winding 731U among the three-phase partial windings 731U, 731V, 731W.
  • a plurality of partial windings 731U arranged in the circumferential direction are shown in plan development, and a power bus bar 751 is connected to one winding end 736 of each partial winding 731U. I have.
  • intermediate conductor groups 732 of the other two-phase partial windings 731V and 731W are arranged between the intermediate conductor groups 732 of the partial winding 731U in the circumferential direction.
  • the partial winding 731 of each phase has an intermediate conductor group 732 composed of three coil side conductors 734 connected in series for each magnetic pole. In-phase currents flow in the conducting wire group 732 in the same phase. That is, in each of the partial windings 731, a current flows separately to the three coil side conductor portions 734 for each magnetic pole. Further, considering that the conductor CR constituting the partial winding 731U is a bundle of a plurality of (six in this example) strands 741, each of the magnetic poles is divided into 18 strands 741. Electric current flows.
  • each of the partial windings 731 is configured by wrapping the conducting wire CR in multiple layers, the in-phase coil side conducting wire portions 734 are connected in series, and the occurrence of circulating current is suppressed. Therefore, for example, circulating current can be suppressed without using a stranded wire in which a plurality of strands are twisted as the conductive wire CR. As described above, in the rotating electric machine 700, the loss due to the eddy current and the circulating current can be reduced.
  • a sintered magnet having a specific coercive force of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] or more is used as a permanent magnet in the rotor 710.
  • the magnetic flux of the magnet is increased.
  • the stator core 722 has a teethless structure, the magnet magnetic flux generated by the magnet unit 712 is directly linked to the stator winding 721, and the concern of eddy current generation increases. I have.
  • each of the partial windings 731 is formed by overlappingly winding the conductive wire CR a plurality of times while straddling two magnetic poles adjacent to each other in the circumferential direction, the linkage flux is reduced by the stator winding 721. (Specifically, even if it acts directly on the partial winding 731), the generation of the eddy current in the stator winding 721 can be suppressed.
  • the current flowing for each magnetic pole can be further divided and flown. As a result, a more preferable configuration for suppressing the eddy current can be realized.
  • one intermediate conductor group 732 of the pair of intermediate conductor groups 732 in the other-phase partial winding 731 is arranged between the pair of intermediate conductor groups 732, so that the intermediate conductor of each phase is arranged.
  • the groups 732 can be suitably arranged in the circumferential direction. Further, since the transition portions 733 on both sides in the axial direction are bent in a direction extending in the radial direction, interference between the partial windings 731 adjacent in the circumferential direction can be preferably avoided.
  • the connection state of the stator winding 721 can be easily changed.
  • a different configuration according to the type of the rotating electric machine 700 can be achieved by simply changing the connection partner of the neutral bus bar 737 and the power bus bars 751 to 753 while keeping the assembled state of the respective partial windings 731 to the stator core 722 unchanged.
  • the stator winding 721 can be easily realized.
  • the neutral point bus bar 737 and the power bus bars 751 to 753 are provided so as to extend in the circumferential direction along the coil end CE on one of the axial sides of the stator 720, the circumferential lengths are different. In the case where different types of busbars are used, it is possible to easily deal with changes in the busbars.
  • the stator winding 721 is disposed radially outward, that is, the rotor 710 outside the coil side conductor 734 in the axial direction. Is provided.
  • the configuration related to the protrusion 771 will be described.
  • FIG. 91 is a cross-sectional view showing a part of a vertical cross-section of rotating electric machine 700 in an enlarged manner.
  • the coil side conductive wire portion 734 of the stator winding 721 and the magnet unit 712 of the rotor 710 are opposed to each other in a radially separated state, and an air gap G is formed therebetween.
  • a protrusion 771 is provided at a position axially outside the air gap G.
  • the protruding portion 771 functions as a barrier that suppresses entry of foreign matter into the air gap G when viewed from the axial direction. Therefore, in the stator 720 in which the stator winding 721 is mounted on the outer peripheral side of the cylindrical stator core 722, that is, in the stator 720 having the teethless structure, the stator winding 721 is closer to the rotor 710. Even if it is arranged at a position, it is possible to suppress the intrusion of foreign matter into the air gap G, and furthermore, to suppress the adverse effect on the operation of the rotary electric machine 700 due to the intrusion of foreign matter. It is preferable that D1> D2, where D1 is the radial width of the air gap G and D2 is the shortest distance between the protrusion 771 and the magnet unit 712.
  • the protruding portion 771 is provided so as to protrude in an arc shape outward in the radial direction. More specifically, the stator winding 721 is bent in the radial direction so as to face the axial end face of the stator core 722 at the coil end CE, and at the bent portion, on the side opposite to the stator core 722 ( That is, the protruding portion 771 is provided so as to bulge in the direction opposite to the bending direction.
  • the bending radius of the conducting wire CR (the radius at the center of the conducting wire CR) may be, for example, 5 mm or more.
  • the radially bent portion of the stator winding 721 is provided with the protruding portion 771 so as to bulge in a direction opposite to the bending direction. It is easy to secure a sufficient bending radius in order to achieve reduction. This makes it possible to reduce the load on the stator windings 721 and to achieve a configuration suitable for suppressing the entry of foreign matter into the air gap G.
  • the rotor carrier 711 of the rotor 710 is configured to be divided into a cylindrical portion 713 and an end plate portion 714, and the rotor carrier 711 is provided on the inner peripheral side of the magnet unit 712 of the rotor 710. After assembling the stator 720, the end plate portion 714 may be fixed to the cylindrical portion 713 of the rotor carrier 711.
  • the position of the conductor wire height in the axial direction at the coil end CE differs for each phase winding of each phase. Therefore, the axial position of the protrusion 771 differs for each phase.
  • the axial position of the projecting portion 771 is different for each phase, and the stepped position when viewed in the axial direction is different. Has become.
  • the projections 771 in the phase windings of the respective phases have the same axial position, the projections 771 are arranged in a line in a direction orthogonal to the axial direction, and are discharged from the air gap G. There is a concern that the air may evenly hit the rising portion of the protruding portion 771, which may cause deterioration of the insulating film of the conductive wire CR.
  • the air discharged from the air gap G is appropriately discharged, and there is a concern that the insulation of the conductor CR may be deteriorated. Will be resolved.
  • the coil side conducting wire portions 734 arranged in the circumferential direction may be molded with a molding material in a range including the projecting portion 771.
  • the stator winding 721 is molded with a synthetic resin as a molding material in a state where the stator winding 721 is assembled to the stator core 722.
  • a resin layer 773 is formed between the coil side conductive wire portion 734 and the projecting portion 771. Also, comparing the coil side conductive wire portion 734, which is a straight line portion, with the projecting portion 771, the distance (radial distance) from the conductive wire CR to the stator core 722 is different in each of these portions.
  • a pool portion 774 Inside (stator core 722 side) is a pool portion 774 in which synthetic resin is stored.
  • the pool portion 774 serves as a heat sink, the transfer of heat between the side of the coil side conductive wire portion 734 and the side of the coil end CE is suppressed.
  • the coil side conductors 734 arranged in the circumferential direction are molded with a synthetic resin (molding material), whereas the portion corresponding to the coil end CE is molded with a synthetic resin. It is good to have no configuration. In this case, by exposing the winding portion of the coil end CE, air cooling can be promoted.
  • stator holder 760 as the stator holding member will be described with reference to FIG.
  • the stator holder 760 has an outer housing 761 and an inner housing 762 provided radially inward thereof. These housings 761 and 762 are made of, for example, an iron-based material, and are coupled so as to be coaxial with each other. Note that the inner housing 762 is a bearing holding member that holds the bearings 702 and 703, and therefore is preferably formed of an iron-based material. However, the outer housing 761 is formed of aluminum or the like as a conductor. Is also good.
  • the outer housing 761 has a cylindrical portion 763 assembled inside the stator core 722 in the radial direction, and a flange 764 provided at one axial end of the cylindrical portion 763.
  • the rotating electric machine 700 is attached to the vehicle body by fixing the flange 764 to, for example, a frame or the like on the vehicle body side.
  • the cylindrical portion 763 is provided with a refrigerant passage 765 through which a refrigerant such as cooling water flows in a ring shape.
  • a concave portion is provided on the outer peripheral surface of the cylindrical portion 763 so as to be able to engage with the protrusion 725 formed on the inner peripheral surface of the stator core 722.
  • the inner housing 762 has a cylindrical portion 766 and an end plate portion 767, and is fixed to the inner peripheral side of the outer housing 761 by the end plate portion 767.
  • the cylindrical portion 766 is concentric with the cylindrical portion 763 and has a smaller diameter than the cylindrical portion 763, and has a configuration in which the cylindrical portions 766 and 766 are connected to each other (that is, connected) by an end plate portion 767. . More specifically, the cylindrical portion 763 of the outer housing 761 and the cylindrical portion 766 of the inner housing 762 face inward and outward in the radial direction, and one end of the cylindrical portion 766 in the axial direction (the lower end in the drawing) is the first end.
  • the cylindrical portion 766a is also referred to as an outer cylindrical portion 763, and the cylindrical portion 766 is also referred to as an inner cylindrical portion 766.
  • the first end 766a of the first end 766a and the second end 766b of the inner cylindrical portion 766 is the rotor carrier.
  • An end of the end plate 711 on the end plate portion 714 side and a second end 766b are ends on the opposite end plate portion side (ends on the opposite side of the end plate portion 714).
  • An end plate 767 is provided on the second end 766b on the side of the unit.
  • a rotating shaft 701 is inserted radially inside the inner cylindrical portion 766, and a pair of bearings 702 and 703 that rotatably support the rotating shaft 701 are accommodated therein.
  • the bearings 702 and 703 are, for example, radial ball bearings having an outer ring, an inner ring, and a plurality of balls disposed therebetween, and are arranged side by side in the axial direction.
  • the outer cylindrical portion 763 corresponds to a “first cylindrical portion”
  • the inner cylindrical portion 766 corresponds to a “second cylindrical portion”.
  • the end plate portion 767 corresponds to a “joining portion”.
  • the outer cylindrical portion 763 and the inner cylindrical portion 766 face inward and outward in the radial direction, and a plurality of electric modules 768 are fixed in an annular space formed therebetween.
  • Each electric module 768 is obtained by individually modularizing electric components such as a semiconductor switching element and a smoothing capacitor constituting a power converter (inverter), and is arranged in a circumferential direction along the inner peripheral surface of the outer cylindrical portion 763. Are located.
  • the electric module 768 is cooled by the refrigerant flowing through the refrigerant passage 765.
  • the energization of the phase winding of each phase in the stator winding 721 is switched for each phase by the inverter as the power converter.
  • the inverter For the configuration of the inverter, refer to the configuration of the inverter 600 in FIG. 59, for example.
  • a semiconductor switching element provided for each phase is switched at a predetermined switching frequency, so that phase windings of each phase are energized at phases shifted by 120 electrical degrees.
  • the teeth are not provided or the magnetic members are weakly provided as the members between the conductors in the stator 720. Compared to the configuration in which the magnetic path is formed in the teeth, it is conceivable that the occurrence of unintended current due to the electromotive force and the problem of electrolytic corrosion of the bearings 702 and 703 due to the electromotive force may be concerned.
  • the outer cylindrical portion 763 that is assembled radially inside the stator 720 (that is, radially inside the stator core 722) is integrated with the outer cylindrical portion 763.
  • An inner cylindrical portion 766 is provided at a position radially inner than the outer cylindrical portion 763, and a pair of bearings 702 and 703 are provided on the inner peripheral side of the inner cylindrical portion 766 (between the inner cylindrical portion 766 and the rotation shaft 701). It was configured to be provided side by side in the axial direction. As a result, the potential difference between the pair of bearings 702 and 703 can be eliminated, and the occurrence of electrolytic corrosion in the bearings 702 and 703 can be suppressed.
  • the first end 766a (the end on the end plate 714 side of the rotor carrier 711) and the second end 766b (the opposite end) on both sides in the axial direction of the inner cylindrical portion 766 in the stator holder 760.
  • the inner cylindrical portion 766 is connected to the outer cylindrical portion 763 via the end plate portion 767 on the side of the second end portion 766b with respect to the end portion on the side of the end plate portion.
  • one side in the axial direction is closed by the end plate portion 714 of the rotor carrier 711, and the other side is stator holder 760.
  • a closed space can be formed on the inner peripheral side of the stator 720, surrounding the rotating shaft 701 and being closed on both sides in the axial direction.
  • the magnetic circuit unit including the rotor 710 and the stator 720 and the pair of bearings 702 and 703 are arranged so as to be radially inward and outward, respectively, so that the rotating electric machine 700 can be downsized.
  • a preferable configuration can be realized when a power converter (inverter) and other electric devices are provided integrally with the rotating electric machine 700.
  • a rotary electric machine 700 shown in FIG. 93 is an outer rotor type rotary electric machine, in which a rotor 710 is radially outside, a stator 720 is radially inside, and the rotor 710 and the stator 720 are arranged to face each other in the radial direction. It has become.
  • the stator holder 760 includes an outer cylindrical portion 763 assembled radially inside the stator core 722, an inner cylindrical portion 766 smaller in diameter than the outer cylindrical portion 763, and an end plate portion connecting the cylindrical portions 763 and 766. 767.
  • the first end 766a (the end on the end plate 714 side of the rotor carrier 711), which is on both sides in the axial direction of the inner cylindrical portion 766, and the second end 766b on the opposite side (the end on the opposite end plate side).
  • the inner cylindrical portion 766 is connected to the outer cylindrical portion 763 via an end plate portion 767 on the side of the first end portion 766a. That is, in the configuration of FIG. 93, the end plate portion 714 of the rotor carrier 711 and the end plate portion 767 of the stator holder 760 are provided on the same side as viewed in the axial direction.
  • the end plate portion 714 of the rotor carrier 711 and the end plate of the stator holder 760 are provided on one side in the axial direction.
  • the portion 767 By providing the portion 767, the other side in the axial direction of the annular space is opened.
  • a transmission 780 is attached to the annular space from the opposite side of the end plates 714 and 767 in the axial direction.
  • a part of the rotating electric machine 700 may be changed to have a configuration shown in FIG.
  • a rotating electric machine 700 shown in FIG. 94 is an inner-rotor-type rotating electric machine, in which a rotor 710 is radially inward, a stator 720 is radially outward, and the rotor 710 and the stator 720 are arranged to face each other in the radial direction. It has become.
  • the stator holder 760 includes an outer cylindrical portion 763 assembled radially outside the stator core 722, an inner cylindrical portion 766 smaller in diameter than the outer cylindrical portion 763, and an end plate portion connecting the cylindrical portions 763 and 766. 767.
  • a plurality of electric modules 768 are fixed to the outer peripheral side of the inner cylindrical portion 766.
  • the first end 766a (the end on the end plate 714 side of the rotor carrier 711), which is on both sides in the axial direction of the inner cylindrical portion 766, and the second end 766b on the opposite side (the end on the opposite end plate side).
  • the inner cylindrical portion 766 is connected to the outer cylindrical portion 763 via an end plate portion 767 on the side of the second end portion 766b. That is, in the configuration of FIG. 94, the end plate portion 714 of the rotor carrier 711 and the end plate portion 767 of the stator holder 760 are provided on opposite sides when viewed in the axial direction.
  • one axial side is formed by the end plate portion 714 of the rotor carrier 711.
  • the rotor 710 can be closed and the other side can be closed by the end plate portion 767 of the stator holder 760, and a space surrounding the rotating shaft 701 and closed on both sides in the axial direction can be formed on the inner peripheral side of the rotor 710.
  • an electric device such as a power converter (inverter) is provided integrally with the rotating electric machine 700.
  • the stator winding 721 in the rotating electric machine 700 may have a configuration having two-phase windings (U-phase winding and V-phase winding).
  • the partial winding 731 may have a configuration in which one intermediate conductor group 732 in the other one-phase partial winding 731 is arranged between the pair of intermediate conductor groups 732.
  • the stator core 722 used in the rotating electric machine 700 may have a protrusion (for example, a tooth) extending from the back yoke. Also in this case, it is sufficient that the partial winding 731 is assembled to the stator core 722 to the back yoke.
  • the rotating electric machine is not limited to the star-connection type, but may be a ⁇ -connection type.
  • the disclosure in this specification is not limited to the illustrated embodiment.
  • the disclosure includes the illustrated embodiments and variations based thereon based on those skilled in the art.
  • 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 may have additional parts that can be added to the embodiments.
  • the disclosure includes embodiments in which parts and / or elements are omitted.
  • the disclosure encompasses the replacement or combination of parts and / or elements between one embodiment and another.
  • the disclosed technical scope is not limited to the description of the embodiments. Some of the disclosed technical ranges are indicated by the description of the claims, and should be construed to include all modifications within the scope and meaning equivalent to the description of the claims.

Abstract

A rotating electrical machine 700 is provided with: a rotor (710) having a magnet portion (712) including a plurality of magnetic poles having polarities that alternate in a circumferential direction; a cylindrical stator (720) having a multiphase stator winding (721); a stator holding member (760) having a first cylinder portion (763) assembled on a radially inner side of the stator; and a pair of bearings (702, 703) for rotatably supporting a rotating shaft (701) of the rotor. The stator holding member includes a second cylinder portion (766) which is concentric with the first cylinder portion and has a smaller diameter than the first cylinder portion, and a joining portion (767) joining the first cylinder portion and the second cylinder portion, wherein the rotating shaft is inserted through the second cylinder portion, and the pair of bearings are provided side-by-side in the axial direction between the second cylinder portion and the rotating shaft.

Description

回転電機Rotating electric machine 関連出願の相互参照Cross-reference of related applications
　本出願は、２０１８年７月２５日に出願された日本出願番号２０１８－１３９８４６号と、２０１９年６月１４日に出願された日本出願番号２０１９－１１１５９５号に基づくもので、ここにその記載内容を援用する。 This application is based on Japanese Patent Application No. 2018-139846 filed on July 25, 2018 and Japanese Application No. 2019-1111595 filed on June 14, 2019, the contents of which are described herein. Invite.
　この明細書における開示は、回転電機に関する。 開 示 The disclosure in this specification relates to a rotating electric machine.
　車両等に搭載される回転電機として、一般に永久磁石を有する回転子と、多相の固定子巻線を有する固定子とを備える構成が知られている。また、回転電機の制御システムとして、スイッチング制御により固定子巻線に対する通電を制御する構成が知られている。 As a rotating electric machine mounted on a vehicle or the like, a configuration including a rotor having a permanent magnet and a stator having a multi-phase stator winding is generally known. Further, as a control system of a rotating electric machine, a configuration in which energization to a stator winding is controlled by switching control is known.
　ここで、回転電機では、回転軸に発生する軸電流により軸受で電食が生じることが懸念されており、例えば特許文献１では、回転子における外側鉄心と内側鉄心との間に誘電体層を設ける構成としている。そして、その誘電体層により、外側鉄心と内側鉄心との間の静電容量を調整することにより、軸受の電食を抑制するようにしている。 Here, in a rotating electric machine, there is a concern that electric corrosion may occur in a bearing due to a shaft current generated in a rotating shaft. For example, in Patent Document 1, a dielectric layer is provided between an outer core and an inner core in a rotor. It is configured to be provided. The dielectric layer adjusts the capacitance between the outer iron core and the inner iron core to suppress electrolytic corrosion of the bearing.
特開２０１６－１２９４３９号公報JP 2016-129439 A
　しかしながら、上記特許文献１に記載された構成では、回転子において外側鉄心と内側鉄心との間に誘電体層を設ける構成であることから、構成が特殊なものになっており、コストが嵩むこと等が懸念される。軸受の電食を抑制する上では技術改善の余地があると考えられる。 However, the configuration described in Patent Document 1 is a configuration in which the dielectric layer is provided between the outer core and the inner core in the rotor, so that the configuration is special, and the cost increases. And so on. It is considered that there is room for technical improvement in suppressing electrolytic corrosion of bearings.
　本開示は、上記事情に鑑みてなされたものであり、回転電機における軸受の電食を好適に抑制することを目的とする。 The present disclosure has been made in view of the above circumstances, and has an object to appropriately suppress electrolytic corrosion of a bearing in a rotating electric machine.
　この明細書における開示された複数の態様は、それぞれの目的を達成するために、互いに異なる技術的手段を採用する。この明細書に開示される目的、特徴、および効果は、後続の詳細な説明、および添付の図面を参照することによってより明確になる。 複数 The embodiments disclosed in this specification employ technical means different from each other in order to achieve the respective objects. The objects, features, and advantages disclosed in this specification will become more apparent with reference to the following detailed description and the accompanying drawings.
　手段１は、
　周方向に極性が交互となる複数の磁極を含む磁石部を有する回転子と、
　多相の固定子巻線を有する筒状の固定子と、
　前記固定子の径方向内側又は径方向外側に組み付けられる第１円筒部を有する固定子保持部材と、
　前記回転子の回転軸を回転可能に支持する一対の軸受と、を備える回転電機であって、
　前記固定子保持部材は、前記第１円筒部と同心でかつ該第１円筒部よりも小径の第２円筒部と、前記第１円筒部と前記第２円筒部とを繋ぐ繋ぎ部とを有し、
　前記第２円筒部内には前記回転軸が挿通されており、前記第２円筒部と前記回転軸との間に、前記一対の軸受が軸方向に並べて設けられている。 Means 1
A rotor having a magnet portion including a plurality of magnetic poles having alternating polarities in the circumferential direction,
A cylindrical stator having a multi-phase stator winding;
A stator holding member having a first cylindrical portion assembled radially inward or radially outward of the stator;
A pair of bearings rotatably supporting a rotating shaft of the rotor, and
The stator holding member has a second cylindrical portion concentric with the first cylindrical portion and smaller in diameter than the first cylindrical portion, and a connecting portion connecting the first cylindrical portion and the second cylindrical portion. And
The rotating shaft is inserted into the second cylindrical portion, and the pair of bearings are provided between the second cylindrical portion and the rotating shaft in the axial direction.
　多相の固定子巻線を有する回転電機では、各相の相巻線の通電が相ごとに切り替えられる際に、相間のスイッチングタイミングの差に起因して、回転軸を支持する一対の軸受間に電流が流れ、それに伴い軸受において電食が生じることが懸念される。この点、上記構成では、固定子保持部材において、固定子の径方向内側又は径方向外側に組み付けられる第１円筒部に一体的に、かつ第１円筒部よりも径方向内側となる位置に第２円筒部を設け、その第２円筒部と回転軸との間に一対の軸受を軸方向に並べて設けるようにした。本構成によれば、一対の軸受間における電位差を無くし、ひいては電食の発生を抑制することができる。 In a rotating electric machine having a multi-phase stator winding, when energization of each phase winding is switched for each phase, a difference in switching timing between the phases causes a difference between a pair of bearings supporting the rotating shaft. There is a concern that current may flow through the bearings, causing electrolytic corrosion in the bearings. In this regard, in the above configuration, in the stator holding member, the stator holding member is integrated with the first cylindrical portion assembled radially inward or radially outward of the stator and at a position radially inward from the first cylindrical portion. Two cylindrical portions are provided, and a pair of bearings are arranged between the second cylindrical portion and the rotating shaft in the axial direction. According to this configuration, it is possible to eliminate the potential difference between the pair of bearings, and to suppress the occurrence of electrolytic corrosion.
　手段２では、手段１において、前記固定子巻線は、前記磁石部に対向する位置で周方向に所定間隔で配置される導線部を有し、前記固定子において、周方向における前記各導線部の間に導線間部材を設け、かつその導線間部材として、１磁極における前記導線間部材の周方向の幅寸法をＷｔ、前記導線間部材の飽和磁束密度をＢｓ、１磁極における前記磁石部の周方向の幅寸法をＷｍ、前記磁石部の残留磁束密度をＢｒとした場合に、Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒの関係となる磁性材料、若しくは非磁性材料を用いる構成か、又は周方向における前記各導線部の間に導線間部材を設けていない構成となっている。 According to Means 2, in the Means 1, the stator winding has a conductor portion arranged at a predetermined interval in a circumferential direction at a position facing the magnet portion, and in the stator, the respective conductor portions in a circumferential direction are provided. The width of the circumferential portion of the inter-wire member at one magnetic pole is Wt, the saturation magnetic flux density of the inter-wire member is Bs, and the magnet portion of the magnetic pole at one magnetic pole is provided as the inter-wire member. When the width in the circumferential direction is Wm and the residual magnetic flux density of the magnet portion is Br, a configuration using a magnetic material or a non-magnetic material satisfying a relation of Wt × Bs ≦ Wm × Br, or The configuration is such that no inter-conductor member is provided between the conductor portions.
　本手段の回転電機では、固定子において、導線間部材としてのティースが設けられていないか又は磁気的に脆弱に設けられている構成となっており、導線間部材としての各ティースに磁気経路が形成される構成に比べて、起電力による意図しない電流の発生やそれに伴う軸受の電食の問題が一層懸念されることが考えられる。この点、上記のとおり固定子保持部材の第２円筒部と回転軸との間に一対の軸受を軸方向に並べて設ける構成とすることで、軸受での電食の発生を好適に抑制することができる。 In the rotating electric machine of the present means, the teeth are not provided or are magnetically weakly provided as members between conductors in the stator, and a magnetic path is provided for each tooth as a member between conductors. It is considered that the unintended current generation due to the electromotive force and the problem of the electrolytic corrosion of the bearing caused by the electromotive force are more concerned than the configuration formed. In this regard, as described above, by providing a pair of bearings arranged in the axial direction between the second cylindrical portion of the stator holding member and the rotating shaft, it is possible to preferably suppress the occurrence of electrolytic corrosion in the bearings. Can be.
　手段３では、手段１又は２において、前記回転子を径方向外側、前記固定子を径方向内側とし、これら回転子及び固定子を径方向に対向配置したアウタロータ式の回転電機であって、前記回転子は、前記磁石部を保持する磁石保持部材を有し、前記磁石保持部材は、前記磁石部が固定された筒状部と、前記回転軸から前記筒状部まで径方向に延びる端板部とを有しており、前記固定子保持部材において前記第２円筒部は、前記第１円筒部に対して径方向に対向するように設けられており、軸方向において前記第２円筒部の前記端板部側の第１端部とその逆側の第２端部とのうち前記第２端部の側に前記繋ぎ部が繋がっている。 Means 3 is the outer rotor type rotating electric machine according to means 1 or 2, wherein the rotor is radially outside and the stator is radially inside, and the rotor and the stator are radially opposed to each other. The rotor has a magnet holding member that holds the magnet portion, and the magnet holding member has a tubular portion to which the magnet portion is fixed, and an end plate that extends radially from the rotation axis to the tubular portion. And the second cylindrical portion of the stator holding member is provided so as to radially oppose the first cylindrical portion, and the second cylindrical portion of the second cylindrical portion in the axial direction. The connecting portion is connected to the second end portion of the first end portion on the end plate portion side and the second end portion on the opposite side.
　アウタロータ式の回転電機において、固定子保持部材の第１円筒部と第２円筒部とを径方向に対向させ、第２円筒部の軸方向両側である第１端部（磁石保持部材の端板部側の端部）と第２端部（反端板部側の端部）とのうち第２端部の側に繋ぎ部を繋げる構成とした。この構成では、固定子保持部材の第１円筒部と第２円筒部との間に形成される環状空間において、軸方向の一方側を磁石保持部材の端板部により閉じ、他方側を固定子保持部材の繋ぎ部により閉じることができ、固定子の内周側に、回転軸を囲み、かつ軸方向両側に閉じた空間を形成できる。これにより、回転子及び固定子を含む磁気回路部と一対の軸受とを径方向内外となるようにそれぞれ配置して、回転電機をコンパクト化することが可能となる。また、例えば回転電機に対して電力変換器（インバータ）等の電気装置を一体的に設ける上で好適な構成を実現できる。 In an outer rotor type rotating electric machine, a first cylindrical portion and a second cylindrical portion of a stator holding member are radially opposed to each other, and a first end portion (an end plate of a magnet holding member) on both axial sides of the second cylindrical portion. (The end on the part side) and the second end (the end on the side opposite to the end plate part), the connecting part is connected to the second end. In this configuration, in the annular space formed between the first cylindrical portion and the second cylindrical portion of the stator holding member, one side in the axial direction is closed by the end plate portion of the magnet holding member, and the other side is the stator. It can be closed by the connecting portion of the holding member, and a closed space can be formed on the inner peripheral side of the stator, surrounding the rotating shaft and closed on both sides in the axial direction. This makes it possible to reduce the size of the rotating electric machine by arranging the magnetic circuit section including the rotor and the stator and the pair of bearings so as to be radially inward and outward. In addition, for example, a preferable configuration can be realized when an electric device such as a power converter (inverter) is integrally provided with the rotating electric machine.
　例えば、固定子保持部材において第１円筒部と第２円筒部との間の環状空間に、固定子巻線における各相の相巻線に接続されるスイッチング素子を有し、かつそれら各相の相巻線の通電を行わせる電力変換器が設けられているとよい。 For example, the switching element connected to the phase winding of each phase in the stator winding is provided in the annular space between the first cylindrical portion and the second cylindrical portion in the stator holding member, and A power converter for energizing the phase windings may be provided.
　手段４では、手段１又は２において、前記回転子を径方向外側、前記固定子を径方向内側とし、これら回転子及び固定子を径方向に対向配置したアウタロータ式の回転電機であって、前記回転子は、前記磁石部を保持する磁石保持部材を有し、前記磁石保持部材は、前記磁石部が固定された筒状部と、前記回転軸から前記筒状部まで径方向に延びる端板部とを有しており、前記固定子保持部材において前記第２円筒部は、前記第１円筒部に対して径方向に対向するように設けられており、軸方向において前記第２円筒部の前記端板部側の第１端部とその逆側の第２端部とのうち前記第１端部の側に前記繋ぎ部が繋がっている。 Means 4 is the outer rotor type rotating electric machine according to the means 1 or 2, wherein the rotor is radially outside and the stator is radially inside, and the rotor and the stator are radially opposed to each other. The rotor has a magnet holding member that holds the magnet portion, and the magnet holding member has a tubular portion to which the magnet portion is fixed, and an end plate that extends radially from the rotation axis to the tubular portion. And the second cylindrical portion of the stator holding member is provided so as to radially oppose the first cylindrical portion, and the second cylindrical portion of the second cylindrical portion in the axial direction. The connecting portion is connected to the first end side of the first end portion on the end plate portion side and the second end portion on the opposite side.
　アウタロータ式の回転電機において、固定子保持部材の第１円筒部と第２円筒部とを径方向に対向させ、第２円筒部の軸方向両側である第１端部（磁石保持部材の端板部側の端部）と第２端部（反端板部側の端部）とのうち第１端部の側に繋ぎ部を繋げる構成とした。この構成では、固定子保持部材の第１円筒部と第２円筒部との間に形成される環状空間において、その軸方向の一方側に、磁石保持部材の端板部と固定子保持部材の繋ぎ部とが設けられることで、当該環状空間の軸方向他方側が開放される構成となっている。これにより、回転子及び固定子を含む磁気回路部と一対の軸受とを径方向内外となるようにそれぞれ配置して、回転電機をコンパクト化することが可能となる。また、例えば回転電機に対して一体的に変速装置等を設ける場合において、固定子保持部材の第１円筒部と第２円筒部との間の環状空間に対して軸方向一方から変速装置等を組み付けることが可能になっている。 In an outer rotor type rotating electric machine, a first cylindrical portion and a second cylindrical portion of a stator holding member are radially opposed to each other, and a first end portion (an end plate of a magnet holding member) on both axial sides of the second cylindrical portion. (The end on the part side) and the second end (the end on the side opposite to the end plate part), the connecting part is connected to the first end side. In this configuration, in the annular space formed between the first cylindrical portion and the second cylindrical portion of the stator holding member, the end plate portion of the magnet holding member and the stator holding member By providing the connecting portion, the other side in the axial direction of the annular space is opened. This makes it possible to reduce the size of the rotating electric machine by arranging the magnetic circuit section including the rotor and the stator and the pair of bearings so as to be radially inward and outward. Further, for example, in the case where a transmission or the like is provided integrally with the rotating electric machine, the transmission or the like is axially disposed from one side in the annular space between the first cylindrical portion and the second cylindrical portion of the stator holding member. It is possible to assemble.
　手段５では、手段１又は２において、前記回転子を径方向内側、前記固定子を径方向外側とし、これら回転子及び固定子を径方向に対向配置したインナロータ式の回転電機であって、前記回転子は、前記磁石部を保持する磁石保持部材を有し、前記磁石保持部材は、前記磁石部が固定された筒状部と、前記回転軸から前記筒状部まで径方向に延びる端板部とを有しており、前記固定子保持部材において前記第２円筒部は、前記筒状部の径方向内側に、当該筒状部に対して径方向に対向するように設けられており、軸方向において前記第２円筒部の前記端板部側の第１端部とその逆側の第２端部とのうち前記第２端部の側に前記繋ぎ部が繋がっている。 Means 5 is the inner rotor type rotating electric machine according to means 1 or 2, wherein the rotor is radially inward, the stator is radially outward, and the rotor and the stator are radially opposed to each other. The rotor has a magnet holding member that holds the magnet portion, and the magnet holding member has a tubular portion to which the magnet portion is fixed, and an end plate that extends radially from the rotation axis to the tubular portion. And the second cylindrical portion in the stator holding member is provided radially inward of the cylindrical portion so as to radially face the cylindrical portion, In the axial direction, the connecting portion is connected to the second end portion of the first end portion of the second cylindrical portion on the end plate portion side and the second end portion on the opposite side.
　インナロータ式の回転電機において、固定子保持部材の第２円筒部と磁石保持部材の筒状部とを径方向に対向させ、第２円筒部の軸方向両側である第１端部（磁石保持部材の端板部側の端部）と第２端部（反端板部側の端部）とのうち第２端部の側に繋ぎ部を繋げる構成とした。この構成では、固定子保持部材の第２円筒部と磁石保持部材の筒状部との間に形成される環状空間において、軸方向の一方側を磁石保持部材の端板部により閉じ、他方側を固定子保持部材の繋ぎ部により閉じることができ、回転子の内周側に、回転軸を囲み、かつ軸方向両側に閉じた空間を形成できる。これにより、回転子及び固定子を含む磁気回路部と一対の軸受とを径方向内外となるようにそれぞれ配置して、回転電機をコンパクト化することが可能となる。また、例えば回転電機に対して電力変換器（インバータ）等の電気装置を一体的に設ける上で好適な構成を実現できる。 In the rotating electric machine of the inner rotor type, the second cylindrical portion of the stator holding member and the cylindrical portion of the magnet holding member are radially opposed to each other, and the first end portion (the magnet holding member) on both axial sides of the second cylindrical portion. The end portion on the side of the end plate portion) and the second end portion (end portion on the side opposite to the end plate portion) are connected to the connecting portion on the side of the second end portion. In this configuration, in the annular space formed between the second cylindrical portion of the stator holding member and the cylindrical portion of the magnet holding member, one side in the axial direction is closed by the end plate portion of the magnet holding member, and the other side is closed. Can be closed by the connecting portion of the stator holding member, and a closed space can be formed on the inner peripheral side of the rotor, surrounding the rotating shaft and closed on both sides in the axial direction. This makes it possible to reduce the size of the rotating electric machine by arranging the magnetic circuit section including the rotor and the stator and the pair of bearings so as to be radially inward and outward. In addition, for example, a preferable configuration can be realized when an electric device such as a power converter (inverter) is integrally provided with the rotating electric machine.
　本開示についての上記目的およびその他の目的、特徴や利点は、添付の図面を参照しながら下記の詳細な記述により、より明確になる。その図面は、
図１は、回転電機の縦断面斜視図であり、 図２は、回転電機の縦断面図であり、 図３は、図２のIII－III線断面図であり、 図４は、図３の一部を拡大して示す断面図であり、 図５は、回転電機の分解図であり、 図６は、インバータユニットの分解図であり、 図７は、固定子巻線のアンペアターンとトルク密度との関係を示すトルク線図であり、 図８は、回転子及び固定子の横断面図であり、 図９は、図８の一部を拡大して示す図であり、 図１０は、固定子の横断面図であり、 図１１は、固定子の縦断面図であり、 図１２は、固定子巻線の斜視図であり、 図１３は、導線の構成を示す斜視図であり、 図１４は、素線の構成を示す模式図であり、 図１５は、ｎ層目における各導線の形態を示す図であり、 図１６は、ｎ層目とｎ＋１層目の各導線を示す側面図であり、 図１７は、実施形態の磁石について電気角と磁束密度との関係を示す図であり、 図１８は、比較例の磁石について電気角と磁束密度との関係を示す図であり、 図１９は、回転電機の制御システムの電気回路図であり、 図２０は、制御装置による電流フィードバック制御処理を示す機能ブロック図であり、 図２１は、制御装置によるトルクフィードバック制御処理を示す機能ブロック図であり、 図２２は、第２実施形態における回転子及び固定子の横断面図であり、 図２３は、図２２の一部を拡大して示す図であり、 図２４は、磁石ユニットにおける磁束の流れを具体的に示す図であり、 図２５は、変形例１における固定子の断面図であり、 図２６は、変形例１における固定子の断面図であり、 図２７は、変形例２における固定子の断面図であり、 図２８は、変形例３における固定子の断面図であり、 図２９は、変形例４における固定子の断面図であり、 図３０は、変形例７における回転子及び固定子の横断面図であり、 図３１は、変形例８において操作信号生成部の処理の一部を示す機能ブロック図であり、 図３２は、キャリア周波数変更処理の手順を示すフローチャートであり、 図３３は、変形例９において導線群を構成する各導線の接続形態を示す図であり、 図３４は、変形例９において４対の導線が積層配置されている構成を示す図であり、 図３５は、変形例１０においてインナロータ型の回転子及び固定子の横断面図であり、 図３６は、図３５の一部を拡大して示す図であり、 図３７は、インナロータ型の回転電機の縦断面図であり、 図３８は、インナロータ型の回転電機の概略構成を示す縦断面図であり、 図３９は、変形例１１においてインナロータ構造の回転電機の構成を示す図であり、 図４０は、変形例１１においてインナロータ構造の回転電機の構成を示す図であり、 図４１は、変形例１２において回転電機子形の回転電機の構成を示す図であり、 図４２は、変形例１４における導線の構成を示す断面図であり、 図４３は、リラクタンストルク、磁石トルク及びＤＭの関係を示す図であり、 図４４は、ティースを示す図であり、 図４５は、インホイールモータ構造の車輪及びその周辺構造を示す斜視図であり、 図４６は、車輪及びその周辺構造の縦断面図であり、 図４７は、車輪の分解斜視図であり、 図４８は、回転電機を回転軸の突出側から見た側面図であり、 図４９は、図４８の４９－４９線断面図であり、 図５０は、図４９の５０－５０線断面図であり、 図５１は、回転電機の分解断面図であり、 図５２は、回転子の部分断面図であり、 図５３は、固定子巻線及び固定子コアの斜視図であり、 図５４は、固定子巻線を平面状に展開して示す正面図であり、 図５５は、導線のスキューを示す図であり、 図５６は、インバータユニットの分解断面図であり、 図５７は、インバータユニットの分解断面図であり、 図５８は、インバータハウジングでの各電気モジュールの配置の状態を示す図であり、 図５９は、電力変換器の電気的構成を示す回路図であり、 図６０は、スイッチモジュールの冷却構造例を示す図であり、 図６１は、スイッチモジュールの冷却構造例を示す図であり、 図６２は、スイッチモジュールの冷却構造例を示す図であり、 図６３は、スイッチモジュールの冷却構造例を示す図であり、 図６４は、スイッチモジュールの冷却構造例を示す図であり、 図６５は、冷却水通路に対する各電気モジュールの配列順序を示す図であり、 図６６は、図４９の６６－６６線断面図であり、 図６７は、図４９の６７－６７線断面図であり、 図６８は、バスバーモジュールを単体で示す斜視図であり、 図６９は、各電気モジュールとバスバーモジュールとの電気的な接続状態を示す図であり、 図７０は、各電気モジュールとバスバーモジュールとの電気的な接続状態を示す図であり、 図７１は、各電気モジュールとバスバーモジュールとの電気的な接続状態を示す図であり、 図７２は、インホイールモータにおける変形例１を説明するための構成図であり、 図７３は、インホイールモータにおける変形例２を説明するための構成図であり、 図７４は、インホイールモータにおける変形例３を説明するための構成図であり、 図７５は、インホイールモータにおける変形例４を説明するための構成図であり、 図７６は、変形例１５における回転電機の要部全体を示す正面図であり、 図７７は、回転電機の縦断面図であり、 図７８は、回転電機の構成要素を分解して示す分解断面図であり、 図７９は、固定子の斜視図であり、 図８０は、固定子の平面図であり、 図８１は、固定子の縦断面図であり、 図８２は、固定子コアの斜視図であり、 図８３は、各相の部分巻線の接続状態を示す回路図であり、 図８４は、（ａ）は、固定子巻線から各相１つずつの部分巻線を抽出して示す斜視図、（ｂ）は、それら各相１つずつの部分巻線を示す正面図であり、 図８５は、３相の部分巻線のうちＵ相の部分巻線のみを示す斜視図であり、 図８６は、各相の相巻線と回転子の磁極との関係を示す図であり、 図８７は、固定子コアに対して、各相の部分巻線の全てを組み付けた状態を示す斜視図であり、 図８８は、導線材の断面構造を示す図であり、 図８９は、固定子において電力バスバーを分解して示す斜視図であり、 図９０は、Ｕ相の各部分巻線について互いの接続状態を示す図であり、 図９１は、回転電機の縦断面の一部を拡大して示す断面図であり、 図９２は、固定子ホルダの縦断面図であり、 図９３は、変形例１５の別例における回転電機を示す縦断面図であり、 図９４は、変形例１５の別例における回転電機を示す縦断面図である。 The above and other objects, features and advantages of the present disclosure will become more apparent from the following detailed description with reference to the accompanying drawings. The drawing is
FIG. 1 is a vertical sectional perspective view of a rotating electric machine, FIG. 2 is a longitudinal sectional view of the rotating electric machine, FIG. 3 is a sectional view taken along line III-III of FIG. FIG. 4 is an enlarged sectional view showing a part of FIG. FIG. 5 is an exploded view of the rotating electric machine, FIG. 6 is an exploded view of the inverter unit, FIG. 7 is a torque diagram showing the relationship between the ampere turn of the stator winding and the torque density. FIG. 8 is a cross-sectional view of the rotor and the stator, FIG. 9 is an enlarged view of a part of FIG. FIG. 10 is a cross-sectional view of the stator, FIG. 11 is a longitudinal sectional view of the stator, FIG. 12 is a perspective view of a stator winding, FIG. 13 is a perspective view showing a configuration of a conductor, FIG. 14 is a schematic diagram showing a configuration of a strand, FIG. 15 is a diagram showing the form of each lead in the n-th layer, FIG. 16 is a side view showing the respective conductors of the n-th layer and the (n + 1) -th layer. FIG. 17 is a diagram illustrating a relationship between an electric angle and a 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 the control system of the rotating electric machine, FIG. 20 is a functional block diagram illustrating a current feedback control process performed by the control device. FIG. 21 is a functional block diagram illustrating a torque feedback control process performed by the control device. FIG. 22 is a cross-sectional view of the rotor and the stator according to the second embodiment, FIG. 23 is a diagram showing a part of FIG. 22 in an enlarged manner. FIG. 24 is a diagram specifically showing the flow of magnetic flux in the magnet unit. FIG. 25 is a cross-sectional view of the stator according to the first modification. FIG. 26 is a cross-sectional view of the stator according to the first modification. FIG. 27 is a cross-sectional view of a stator according to a second modification. FIG. 28 is a cross-sectional view of a stator according to a third modification; FIG. 29 is a cross-sectional view of a stator according to a fourth modification; FIG. 30 is a cross-sectional view of the rotor and the stator in Modification Example 7, FIG. 31 is a functional block diagram illustrating a part of the processing of the operation signal generation unit in Modification Example 8. FIG. 32 is a flowchart illustrating a procedure of a carrier frequency change process. FIG. 33 is a diagram illustrating a connection form of each of the conductors forming the conductor group in Modification Example 9. FIG. 34 is a diagram illustrating a configuration in which four pairs of conductive wires are stacked and arranged in Modification Example 9. FIG. 35 is a cross-sectional view of an inner rotor type rotor and a stator in Modification Example 10, FIG. 36 is an enlarged view of a part of FIG. FIG. 37 is a longitudinal sectional view of an inner rotor type rotating electric machine, FIG. 38 is a longitudinal sectional view showing a schematic configuration of an inner rotor type rotating electric machine, FIG. 39 is a diagram illustrating a configuration of a rotating electric machine having an inner rotor structure in Modification Example 11. FIG. 40 is a diagram illustrating a configuration of a rotating electric machine having an inner rotor structure in Modification Example 11. FIG. 41 is a diagram illustrating a configuration of a rotary armature type rotary electric machine according to Modification Example 12. FIG. 42 is a cross-sectional view illustrating a configuration of a conductor according to Modification Example 14. FIG. 43 is a diagram showing a relationship between reluctance torque, magnet torque and DM, FIG. 44 shows teeth. FIG. 45 is a perspective view showing a wheel having an in-wheel motor structure and a peripheral structure thereof. FIG. 46 is a longitudinal sectional view of the wheel and its peripheral structure, FIG. 47 is an exploded perspective view of wheels. FIG. 48 is a side view of the rotating electric machine viewed from a protruding side of the rotating shaft, FIG. 49 is a sectional view taken along line 49-49 of FIG. FIG. 50 is a sectional view taken along line 50-50 of FIG. FIG. 51 is an exploded sectional view of the rotating electric machine, FIG. 52 is a partial cross-sectional view of the rotor, FIG. 53 is a perspective view of a stator winding and a stator core, FIG. 54 is a front view showing a stator winding developed in a plane. FIG. 55 is a diagram showing the skew of the conductor, FIG. 56 is an exploded sectional view of the inverter unit, FIG. 57 is an exploded sectional view of the inverter unit, FIG. 58 is a diagram showing a state of arrangement of each electric module in the inverter housing; FIG. 59 is a circuit diagram showing an electrical configuration of the power converter. FIG. 60 is a diagram illustrating an example of a cooling structure of a switch module. FIG. 61 is a diagram illustrating an example of a cooling structure of a switch module; FIG. 62 is a diagram illustrating an example of a cooling structure of a switch module. FIG. 63 is a diagram illustrating an example of a cooling structure of a switch module; FIG. 64 is a diagram illustrating an example of a cooling structure of the switch module. FIG. 65 is a diagram showing an arrangement order of each electric module with respect to the cooling water passage; FIG. 66 is a sectional view taken along line 66-66 of FIG. FIG. 67 is a sectional view taken along line 67-67 of FIG. FIG. 68 is a perspective view showing the bus bar module alone; FIG. 69 is a diagram showing an electrical connection state between each electric module and a bus bar module; FIG. 70 is a diagram showing an electrical connection state between each electric module and a bus bar module; FIG. 71 is a diagram showing an electrical connection state between each electric module and a bus bar module; FIG. 72 is a configuration diagram for explaining a first modification of the in-wheel motor. FIG. 73 is a configuration diagram for describing a second modification of the in-wheel motor. FIG. 74 is a configuration diagram for explaining a third modification of the in-wheel motor. FIG. 75 is a configuration diagram for explaining a fourth modification of the in-wheel motor. FIG. 76 is a front view showing the entire main part of the rotary electric machine according to Modification Example 15. FIG. 77 is a longitudinal sectional view of the rotating electric machine, FIG. 78 is an exploded sectional view showing components of the rotating electric machine in an exploded manner. FIG. 79 is a perspective view of a stator, FIG. 80 is a plan view of the stator, FIG. 81 is a longitudinal sectional view of the stator; FIG. 82 is a perspective view of a stator core; FIG. 83 is a circuit diagram showing a connection state of partial windings of each phase. 84 (a) is a perspective view showing one partial winding of each phase extracted from the stator winding, and FIG. 84 (b) is a front view showing one partial winding of each phase. And FIG. 85 is a perspective view showing only the U-phase partial winding among the three-phase partial windings. FIG. 86 is a diagram showing the relationship between the phase winding of each phase and the magnetic poles of the rotor, FIG. 87 is a perspective view showing a state where all the partial windings of each phase are assembled to the stator core; FIG. 88 is a diagram showing a cross-sectional structure of a conductive wire, FIG. 89 is an exploded perspective view showing a power bus bar in the stator. FIG. 90 is a diagram showing a connection state of each of the U-phase partial windings, FIG. 91 is a cross-sectional view showing a part of a longitudinal section of the rotating electric machine in an enlarged manner. FIG. 92 is a longitudinal sectional view of the stator holder; FIG. 93 is a longitudinal sectional view showing a rotating electric machine according to another example of Modification Example 15. FIG. 94 is a vertical cross-sectional view showing a rotating electric machine according to another example of the fifteenth modification.
　図面を参照しながら、複数の実施形態を説明する。複数の実施形態において、機能的におよび／または構造的に対応する部分および／または関連付けられる部分には同一の参照符号、または百以上の位が異なる参照符号が付される場合がある。対応する部分および／又は関連付けられる部分については、他の実施形態の説明を参照することができる。 複数 A plurality of embodiments will be described with reference to the drawings. In embodiments, functionally and / or structurally corresponding parts and / or associated parts may be provided with the same reference signs or reference signs that differ by more than a hundred places. For corresponding parts and / or associated parts, the description of the other embodiments can be referred to.
　本実施形態における回転電機は、例えば車両動力源として用いられるものとなっている。ただし、回転電機は、産業用、車両用、家電用、ＯＡ機器用、遊技機用などとして広く用いられることが可能となっている。なお、以下の各実施形態相互において、互いに同一又は均等である部分には、図中、同一符号を付しており、同一符号の部分についてはその説明を援用する。 The rotating electric machine according to the present embodiment is used, for example, as a vehicle power source. However, rotating electric machines can be widely used for industrial use, vehicles, home appliances, OA equipment, gaming machines, and the like. In the following embodiments, parts that are the same or equivalent to each other are given the same reference numerals in the drawings, and the description of the parts with the same reference numerals is used.
　（第１実施形態）
　本実施形態に係る回転電機１０は、同期式多相交流モータであり、アウタロータ構造（外転構造）のものとなっている。回転電機１０の概要を図１乃至図５に示す。図１は、回転電機１０の縦断面斜視図であり、図２は、回転電機１０の回転軸１１に沿う方向での縦断面図であり、図３は、回転軸１１に直交する方向での回転電機１０の横断面図（図２のIII－III線断面図）であり、図４は、図３の一部を拡大して示す断面図であり、図５は、回転電機１０の分解図である。なお、図３では、図示の都合上、回転軸１１を除き、切断面を示すハッチングを省略している。以下の記載では、回転軸１１が延びる方向を軸方向とし、回転軸１１の中心から放射状に延びる方向を径方向とし、回転軸１１を中心として円周状に延びる方向を周方向としている。 (1st Embodiment)
The rotating electric machine 10 according to the present embodiment is a synchronous polyphase AC motor and has an outer rotor structure (eternal rotation structure). The outline of the rotating electric machine 10 is shown in FIGS. 1 is a vertical cross-sectional perspective view of the rotary electric machine 10, FIG. 2 is a vertical cross-sectional view of the rotary electric machine 10 in a direction along a rotation axis 11, and FIG. 3 is a cross-sectional view of the rotary electric machine 10 (a cross-sectional view taken along line III-III in FIG. 2). FIG. 4 is a cross-sectional view illustrating a part of FIG. 3 in an enlarged manner. It is. In FIG. 3, hatching indicating a cut surface is omitted except for the rotation shaft 11 for convenience of illustration. In the following description, the direction in which the rotating shaft 11 extends is defined as the axial direction, the direction radially extending from the center of the rotating shaft 11 is defined as the radial direction, and the direction extending circumferentially around the rotating shaft 11 is defined as the circumferential direction.
　回転電機１０は、大別して、軸受ユニット２０と、ハウジング３０と、回転子４０と、固定子５０と、インバータユニット６０とを備えている。これら各部材は、いずれも回転軸１１と共に同軸上に配置され、所定順序で軸方向に組み付けられることで回転電機１０が構成されている。本実施形態の回転電機１０は、「界磁子」としての回転子４０と、「電機子」としての固定子５０とを有する構成となっており、回転界磁形の回転電機として具体化されるものとなっている。 The rotating 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 arranged coaxially with the rotating shaft 11 and assembled in a predetermined order in the axial direction to form the rotating electric machine 10. The rotating electric machine 10 of the present embodiment has a configuration having a rotor 40 as a “field element” and a stator 50 as an “armature”, and is embodied as a rotating field type rotating electric machine. It has become something.
　軸受ユニット２０は、軸方向に互いに離間して配置される２つの軸受２１，２２と、その軸受２１，２２を保持する保持部材２３とを有している。軸受２１，２２は、例えばラジアル玉軸受であり、それぞれ外輪２５と、内輪２６と、それら外輪２５及び内輪２６の間に配置された複数の玉２７とを有している。保持部材２３は円筒状をなしており、その径方向内側に軸受２１，２２が組み付けられている。そして、軸受２１，２２の径方向内側に、回転軸１１及び回転子４０が回転自在に支持されている。軸受２１，２２により、回転軸１１を回転可能に支持する一組の軸受が構成されている。 The bearing unit 20 has two bearings 21 and 22 that are arranged apart from each other in the axial direction, and a holding member 23 that holds the bearings 21 and 22. The bearings 21 and 22 are, for example, radial ball bearings, each of which has an outer ring 25, an inner ring 26, and a plurality of balls 27 arranged between the outer ring 25 and the inner ring 26. The holding member 23 has a cylindrical shape, and bearings 21 and 22 are attached to the inside in the radial direction. The rotating shaft 11 and the rotor 40 are rotatably supported inside the bearings 21 and 22 in the radial direction. The bearings 21 and 22 constitute a set of bearings that rotatably support the rotating shaft 11.
　各軸受２１，２２では、不図示のリテーナにより玉２７が保持され、その状態で各玉同士のピッチが保たれている。軸受２１，２２は、リテーナの軸方向上下部に封止部材を有し、その内部に非導電性グリース（例えば非導電性のウレア系グリース）が充填されている。また、内輪２６の位置がスペーサにより機械的に保持され、内側から上下方向に凸となる定圧予圧が施されている。 で は In each of the bearings 21 and 22, the ball 27 is 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 upper and lower portions in the axial direction of the retainer, and are filled with non-conductive grease (for example, non-conductive urea grease). Further, the position of the inner ring 26 is mechanically held by a spacer, and a constant-pressure preload that is vertically convex from the inside is applied.
　ハウジング３０は、円筒状をなす周壁３１を有する。周壁３１は、その軸方向に対向する第１端と第２端を有する。周壁３１は、第１端に端面３２と有するとともに、第２端に開口３３を有する。開口３３は、第２端の全体において開放されている。端面３２には、その中央に円形の孔３４が形成されており、その孔３４に挿通させた状態で、ネジやリベット等の固定具により軸受ユニット２０が固定されている。また、ハウジング３０内、すなわち周壁３１及び端面３２により区画された内部スペースには、中空円筒状の回転子４０と中空円筒状の固定子５０とが収容されている。本実施形態では回転電機１０がアウタロータ式であり、ハウジング３０内には、筒状をなす回転子４０の径方向内側に固定子５０が配置されている。回転子４０は、軸方向において端面３２の側で回転軸１１に片持ち支持されている。 The housing 30 has a cylindrical peripheral wall 31. The peripheral wall 31 has a first end and a second end that face each other 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 to the end face 32 by a fixing tool such as a screw or a rivet while being inserted through the hole 34. 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 rotating electric machine 10 is of an outer rotor type, and a stator 50 is disposed inside a housing 30 in a radial direction of a cylindrical rotor 40. The rotor 40 is cantilevered by the rotating shaft 11 on the end face 32 side in the axial direction.
　回転子４０は、中空筒状に形成された磁石ホルダ４１と、その磁石ホルダ４１の径方向内側に設けられた環状の磁石ユニット４２とを有している。磁石ホルダ４１は、略カップ状をなし、磁石保持部材としての機能を有する。磁石ホルダ４１は、円筒状をなす円筒部４３と、同じく円筒状をなしかつ円筒部４３よりも小径の固定部（attachment）４４と、それら円筒部４３及び固定部４４を繋ぐ部位となる中間部４５とを有している。円筒部４３の内周面に磁石ユニット４２が取り付けられている。 The rotor 40 has a magnet holder 41 formed in a hollow cylindrical shape, and an annular magnet unit 42 provided radially inside 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 includes a cylindrical portion 43 having a cylindrical shape, a fixed portion (attachment) 44 also having a cylindrical shape and a smaller diameter than the cylindrical portion 43, and an intermediate portion serving as a portion connecting the cylindrical portion 43 and the fixed portion 44. 45. The magnet unit 42 is mounted on the inner peripheral surface of the cylindrical portion 43.
　なお、磁石ホルダ４１は、機械強度が充分な冷間圧延鋼板（ＳＰＣＣ）や、鍛造用鋼、炭素繊維強化プラスチック（ＣＦＲＰ）等により構成されている。 The magnet holder 41 is made of a cold-rolled steel plate (SPCC) having sufficient mechanical strength, forging steel, carbon fiber reinforced plastic (CFRP), or the like.
　固定部４４の貫通孔４４ａには回転軸１１が挿通される。貫通孔４４ａ内に配置された回転軸１１に対して固定部４４が固定されている。つまり、固定部４４により、回転軸１１に対して磁石ホルダ４１が固定されている。なお、固定部４４は、凹凸を利用したスプライン結合やキー結合、溶接、又はかしめ等により回転軸１１に対して固定されているとよい。これにより、回転子４０が回転軸１１と一体に回転する。 回 転 The rotating shaft 11 is inserted into the through hole 44a of the fixing portion 44. The fixed part 44 is fixed to the rotating shaft 11 arranged in the through hole 44a. That is, the magnet holder 41 is fixed to the rotating shaft 11 by the fixing unit 44. The fixing portion 44 may be fixed to the rotating shaft 11 by spline connection or key connection using irregularities, welding, caulking, or the like. Thereby, the rotor 40 rotates integrally with the rotating shaft 11.
　また、固定部４４の径方向外側には、軸受ユニット２０の軸受２１，２２が組み付けられている。上述のとおり軸受ユニット２０はハウジング３０の端面３２に固定されているため、回転軸１１及び回転子４０は、ハウジング３０に回転可能に支持されるものとなっている。これにより、ハウジング３０内において回転子４０が回転自在となっている。 軸 受 Bearings 21 and 22 of the bearing unit 20 are mounted radially outward of the fixing portion 44. Since the bearing unit 20 is fixed to the end face 32 of the housing 30 as described above, the rotating shaft 11 and the rotor 40 are rotatably supported by the housing 30. Thereby, the rotor 40 is rotatable in the housing 30.
　回転子４０には、その軸方向に対向する二つの端部の一方にのみ固定部４４が設けられており、これにより、回転子４０が回転軸１１に片持ち支持されている。ここで、回転子４０の固定部４４は、軸受ユニット２０の軸受２１，２２により、軸方向に異なる２位置で回転可能に支持されている。すなわち、回転子４０は、磁石ホルダ４１の、その軸方向に対向する二つの端部の一方において、その軸方向に離間する二つの軸受２１，２２により回転可能に支持されている。そのため、回転子４０が回転軸１１に片持ち支持される構造であっても、回転子４０の安定回転が実現されるようになっている。この場合、回転子４０の軸方向中心位置に対して片側にずれた位置で、回転子４０が軸受２１，２２により支持されている。 固定 The rotor 40 is provided with a fixing portion 44 at only one of two axially opposed ends thereof, whereby the rotor 40 is cantilevered on the rotating shaft 11. Here, the fixed portion 44 of the rotor 40 is rotatably supported at two different positions in the axial direction by the bearings 21 and 22 of the bearing unit 20. That is, the rotor 40 is rotatably supported at one of two axially opposed ends of the magnet holder 41 by the two bearings 21 and 22 spaced apart in the axial direction. Therefore, even when the rotor 40 has a structure in which the rotor 40 is cantilevered by the rotating shaft 11, stable rotation of the rotor 40 is realized. 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.
　また、軸受ユニット２０において回転子４０の中心寄り（図の下側）の軸受２２と、その逆側（図の上側）の軸受２１とは、外輪２５及び内輪２６と玉２７との間の隙間寸法が相違しており、例えば回転子４０の中心寄りの軸受２２の方が、その逆側の軸受２１よりも隙間寸法が大きいものとなっている。この場合、回転子４０の中心寄りの側において、回転子４０の振れや、部品公差に起因するインバランスによる振動が軸受ユニット２０に作用しても、その振れや振動の影響が良好に吸収される。具体的には、回転子４０の中心寄り（図の下側）の軸受２２において予圧により遊び寸法（隙間寸法）を大きくしていることで、片持ち構造において生じる振動がその遊び部分により吸収される。前記予圧は、定位置予圧、又は定圧予圧のいずれであっても良い。定位置予圧の場合、軸受２１と軸受２２の外輪２５はいずれも保持部材２３に対して、圧入、又は接着等の方法を用いて接合されている。また、軸受２１と軸受２２の内輪２６はいずれも回転軸１１に対して、圧入、又は接着等の方法を用いて接合されている。ここで軸受２１の外輪２５を軸受２１の内輪２６に対して軸方向に異なる位置に配置する事で予圧を発生させることができる。軸受２２の外輪２５を軸受２２の内輪２６に対して軸方向に異なる位置に配置する事でも予圧を発生させることができる。 Further, in the bearing unit 20, a clearance 22 between the outer ring 25 and the inner ring 26 and the ball 27 is provided between 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, on the side near the center of the rotor 40, even if vibration of the rotor 40 or vibration due to imbalance due to component tolerance acts on the bearing unit 20, the influence of the vibration or vibration is favorably absorbed. You. Specifically, the play size (gap size) is increased by the preload in the bearing 22 near the center of the rotor 40 (the lower side in the figure), so that the vibration generated in the cantilever structure is absorbed by the play portion. You. The preload may be either a fixed position preload or a constant pressure preload. In the case of the fixed position preload, the outer races 25 of the bearing 21 and the bearing 22 are both joined to the holding member 23 by a method such as press fitting or bonding. The inner races 26 of the bearing 21 and the bearing 22 are both joined to the rotating shaft 11 by a method such as press fitting or bonding. Here, by arranging the outer ring 25 of the bearing 21 at a different position in the axial direction with respect to the inner ring 26 of the bearing 21, a preload can be generated. Preload can also be generated by arranging the outer ring 25 of the bearing 22 at a different position in the axial direction with respect to the inner ring 26 of the bearing 22.
　また定圧予圧を採用する場合には、軸方向において、軸受２２と軸受２１に挟まれた領域から軸受２２の外輪２５に向けて予圧が発生する様に予圧用バネ、例えばウェーブワッシャ２４等を軸受２２と軸受２１に挟まれた同領域に配置する。この場合も、軸受２１と軸受２２の内輪２６はいずれも回転軸１１に対して、圧入、又は接着等の方法を用いて接合されている。軸受２１、又は軸受２２の外輪２５は、保持部材２３に対して所定のクリアランスを介して配置される。このような構成とすることで、軸受２２の外輪２５には軸受２１から離れる方向に予圧用バネのバネ力が作用する。そして、この力が回転軸１１を伝わることで、軸受２１の内輪２６を軸受２２の方向に押し付ける力が作用する。これにより、軸受２１，２２ともに、外輪２５と内輪２６の軸方向の位置がずれ、前述した定位置予圧と同様に２つのベアリングに予圧を掛けることができる。 When a constant-pressure preload is employed, a preload spring, for example, a wave washer 24, is provided in the axial direction so that a preload is generated from a region between the bearing 22 and the bearing 21 toward the outer ring 25 of the bearing 22. 22 and the bearing 21 in the same area. Also in this case, the inner rings 26 of the bearing 21 and the bearing 22 are both joined to the rotating shaft 11 by a method such as press fitting or bonding. The outer ring 25 of the bearing 21 or the bearing 22 is disposed with a predetermined clearance with respect to the holding member 23. With such a configuration, the spring force of the preload spring acts on the outer ring 25 of the bearing 22 in a direction away from the bearing 21. Then, when this force is transmitted through the rotating shaft 11, a force acts on the inner ring 26 of the bearing 21 in the direction of the bearing 22. As a result, the positions of the outer race 25 and the inner race 26 in the bearings 21 and 22 are shifted in the axial direction, so that preload can be applied to the two bearings in the same manner as the above-described fixed position preload.
　なお、定圧予圧を発生させる際には、必ずしも図２に示す様に軸受２２の外輪２５にバネ力を印加する必要は無い。例えば、軸受２１の外輪２５にバネ力を印加しても良い。また軸受２１，２２のいずれかの内輪２６を回転軸１１に対して所定のクリアランスを介して配置し、軸受２１，２２の外輪２５を保持部材２３に対して圧入、又は接着等の方法を用いて接合することで、２つのベアリングに予圧を掛けても良い。 When generating the 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. In addition, one of the inner rings 26 of the bearings 21 and 22 is arranged with a predetermined clearance with respect to the rotating shaft 11, and the outer ring 25 of the bearings 21 and 22 is pressed into the holding member 23 or a method such as adhesion is used. By joining together, preload may be applied to the two bearings.
　更には、軸受２１の内輪２６が軸受２２に対して離れるように力を作用させる場合には、軸受２２の内輪２６も軸受２１に対して離れるように力を作用させる方が良い。逆に、軸受２１の内輪２６が軸受２２に対して近づくように力を作用させる場合には、軸受２２の内輪２６も軸受２１に対して近づくように力を作用させる方が良い。 Furthermore, when a force is applied so that the inner ring 26 of the bearing 21 separates from the bearing 22, it is better to apply a force so that the inner ring 26 of the bearing 22 also separates from the bearing 21. Conversely, when a force is applied so that the inner ring 26 of the bearing 21 approaches the bearing 22, it is better to apply the force such that the inner ring 26 of the bearing 22 also approaches the bearing 21.
　なお、本回転電機１０を車両動力源等の目的で車両に適用する場合には、予圧を発生させる機構に対して予圧の発生方向の成分を持つ振動が加わる可能性や、予圧を印加する対象物に掛る重力の方向が変動してしまう可能性がある。その為、本回転電機１０を車両に適用する場合には、定位置予圧を採用することが望ましい。 When the rotary electric machine 10 is applied to a vehicle for the purpose of a vehicle power source or the like, there is a possibility that vibration having a component in a direction of generation of the preload may be applied to a mechanism that generates the preload, or a target to which the preload is applied. The direction of gravity applied to an object may change. Therefore, when the present rotating electric machine 10 is applied to a vehicle, it is desirable to employ a fixed position preload.
　また、中間部４５は、環状の内側肩部４９ａと環状の外側肩部４９ｂを有する。外側肩部４９ｂは、中間部４５の径方向において内側肩部４９ａの外側に位置している。内側肩部４９ａと外側肩部４９ｂは、中間部４５の軸方向において互いに離間している。これにより、中間部４５の径方向において、円筒部４３と固定部４４とは部分的に重複している。つまり、固定部４４の基端部（図の下側の奥側端部）よりも軸方向外側に、円筒部４３が突出するものとなっている。本構成では、中間部４５が段差無しで平板状に設けられる場合に比べて、回転子４０の重心近くの位置で、回転軸１１に対して回転子４０を支持させることが可能となり、回転子４０の安定動作が実現できるものとなっている。 中間 The intermediate portion 45 has an annular inner shoulder 49a and an annular outer shoulder 49b. The outer shoulder portion 49b is located outside the inner shoulder portion 49a in the radial direction of the intermediate portion 45. The inner shoulder portion 49a and the outer shoulder portion 49b are separated from each other in the axial direction of the intermediate portion 45. Thus, the cylindrical portion 43 and the fixed portion 44 partially overlap in the radial direction of the intermediate portion 45. In other words, the cylindrical portion 43 protrudes outward in the axial direction from the base end of the fixing portion 44 (the lower end on the lower side in the figure). In this configuration, the rotor 40 can be supported on the rotating shaft 11 at a position near the center of gravity of the rotor 40 as compared with the case where the intermediate portion 45 is provided in a flat shape without a step. Forty stable operations can be realized.
　上述した中間部４５の構成によれば、回転子４０には、径方向において固定部４４を囲みかつ中間部４５の内寄りとなる位置に、軸受ユニット２０の一部を収容する軸受収容凹部４６が環状に形成されるとともに、径方向において軸受収容凹部４６を囲みかつ中間部４５の外寄りとなる位置に、後述する固定子５０の固定子巻線５１のコイルエンド５４を収容するコイル収容凹部４７が形成されている。そして、これら各収容凹部４６，４７が、径方向の内外で隣り合うように配置されるようになっている。つまり、軸受ユニット２０の一部と、固定子巻線５１のコイルエンド５４とが径方向内外に重複するように配置されている。これにより、回転電機１０において軸方向の長さ寸法の短縮が可能となっている。 According to the configuration of the intermediate portion 45 described above, the rotor housing 40 has a bearing housing recess 46 that partially surrounds the bearing unit 20 at a position that surrounds the fixed portion 44 in the radial direction and is inward of the intermediate portion 45. Is formed in a ring shape, and encloses the bearing accommodation concave portion 46 in the radial direction and is located outside of the intermediate portion 45. The coil accommodation concave portion accommodates a coil end 54 of a stator winding 51 of a stator 50 described later. 47 are formed. These accommodation recesses 46 and 47 are arranged so as to be adjacent to each other inside and outside in the radial direction. That is, a part of the bearing unit 20 and the coil end 54 of the stator winding 51 are arranged so as to overlap inward and outward in the radial direction. Thus, the axial length of the rotating electric machine 10 can be reduced.
　中間部４５は、回転軸１１側から径方向外側に張り出すように設けられている。そして、その中間部４５に、軸方向に延び、固定子５０の固定子巻線５１のコイルエンド５４に対する接触を回避する接触回避部が設けられている。中間部４５が張出部に相当する。 The intermediate portion 45 is provided so as to project radially outward from the rotation shaft 11 side. A contact avoiding portion that extends in the axial direction and that avoids contact of the stator winding 51 of the stator 50 with the coil end 54 is provided in the intermediate portion 45. The intermediate portion 45 corresponds to the overhang portion.
　コイルエンド５４は、径方向の内側又は外側に曲げられることで、そのコイルエンド５４の軸方向寸法を小さくすることができ、固定子５０の軸長を短縮することが可能である。コイルエンド５４の曲げ方向は、回転子４０との組み付けを考慮したものであるとよい。回転子４０の径方向内側に固定子５０を組み付けることを想定すると、その回転子４０に対する挿入先端側では、コイルエンド５４が径方向内側に曲げられるとよい。コイルエンド５４の反対側のコイルエンドの曲げ方向は任意でよいが、空間的に余裕のある外側に曲げた形状が製造上好ましい。 By bending the coil end 54 inward or outward in the radial direction, 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 a direction in which the coil end 54 and the rotor 40 are assembled. 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. The bending direction of the coil end on the side opposite to the coil end 54 may be arbitrary, but a shape bent outward with sufficient space is preferable in terms of manufacturing.
　また、磁石部としての磁石ユニット４２は、円筒部４３の径方向内側において、周方向に沿って極性が交互に変わるように配置された複数の永久磁石により構成されている。これにより、磁石ユニット４２は、周方向に複数の磁極を有する。ただし、磁石ユニット４２の詳細については後述する。 磁石 The magnet unit 42 as a magnet portion is constituted by a plurality of permanent magnets arranged inside the cylindrical portion 43 in the radial direction so that the polarity alternates along the circumferential direction. Thereby, the magnet unit 42 has a plurality of magnetic poles in the circumferential direction. However, details of the magnet unit 42 will be described later.
　固定子５０は、回転子４０の径方向内側に設けられている。固定子５０は、略筒状（環状）に巻回形成された固定子巻線５１と、その径方向内側に配置されたベース部材としての固定子コア５２とを有しており、固定子巻線５１が、所定のエアギャップを挟んで円環状の磁石ユニット４２に対向するように配置されている。固定子巻線５１は複数の相巻線よりなる。それら各相巻線は、周方向に配列された複数の導線が所定ピッチで互いに接続されることで構成されている。本実施形態では、Ｕ相、Ｖ相及びＷ相の３相巻線と、Ｘ相、Ｙ相及びＺ相の３相巻線とを用い、それら３相の巻線を２つ用いることで、固定子巻線５１が６相の相巻線として構成されている。 The stator 50 is provided radially inside the rotor 40. The stator 50 has a stator winding 51 wound in a substantially cylindrical (annular) shape, and a stator core 52 as a base member disposed radially inward of the stator winding 51. The line 51 is disposed so as to face the annular magnet unit 42 with a predetermined air gap interposed therebetween. The stator winding 51 includes a plurality of phase windings. Each of the phase windings is configured by connecting a plurality of conductors arranged in a circumferential direction at a predetermined pitch. In this embodiment, three-phase windings of U-phase, V-phase, and W-phase and three-phase windings of X-phase, Y-phase, and Z-phase are used, and by using two of these three-phase windings, The stator winding 51 is configured as a six-phase winding.
　固定子コア５２は、軟磁性材である電磁鋼板が積層された積層鋼板により円環状に形成されており、固定子巻線５１の径方向内側に組み付けられている。電磁鋼板は、例えば鉄に数％程度（例えば３％）の珪素を添加した珪素鋼板である。固定子巻線５１が電機子巻線に相当し、固定子コア５２が電機子コアに相当する。 The stator core 52 is formed in an annular shape by a laminated steel sheet in which electromagnetic steel sheets as soft magnetic materials are laminated, and is assembled radially inside the stator winding 51. 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.
　固定子巻線５１は、径方向において固定子コア５２に重複する部分であり、かつ固定子コア５２の径方向外側となるコイルサイド部５３と、軸方向において固定子コア５２の一端側及び他端側にそれぞれ張り出すコイルエンド５４，５５とを有している。コイルサイド部５３は、径方向において固定子コア５２と回転子４０の磁石ユニット４２にそれぞれ対向している。回転子４０の内側に固定子５０が配置された状態では、軸方向両側のコイルエンド５４，５５のうち軸受ユニット２０の側（図の上側）となるコイルエンド５４が、回転子４０の磁石ホルダ４１により形成されたコイル収容凹部４７に収容されている。ただし、固定子５０の詳細については後述する。 The stator winding 51 is a portion that overlaps the stator core 52 in the radial direction, and is a coil side portion 53 that is radially outside the stator core 52, and one end of the stator core 52 in the axial direction and the other. It has coil ends 54 and 55 projecting to the end sides, respectively. The coil side portions 53 face the stator core 52 and the magnet unit 42 of the rotor 40 in the radial direction, respectively. When the stator 50 is disposed inside the rotor 40, the coil end 54 on the bearing unit 20 side (upper side in the drawing) of the coil ends 54 and 55 on both axial sides is a magnet holder of the rotor 40. It is housed in a coil housing recess 47 formed by 41. However, details of the stator 50 will be described later.
　インバータユニット６０は、ハウジング３０に対してボルト等の締結具により固定されるユニットベース６１と、そのユニットベース６１に組み付けられる複数の電気コンポーネント６２とを有している。ユニットベース６１は、例えば炭素繊維強化プラスチック（ＣＦＲＰ）により構成されている。ユニットベース６１は、ハウジング３０の開口３３の縁に対して固定されるエンドプレート６３と、そのエンドプレート６３に一体に設けられ、軸方向に延びるケーシング６４とを有している。エンドプレート６３は、その中心部に円形の開口６５を有しており、開口６５の周縁部から起立するようにしてケーシング６４が形成されている。 The inverter unit 60 has a unit base 61 fixed to the housing 30 by fasteners such as bolts, and a plurality of electric components 62 assembled to the unit base 61. The unit base 61 is made of, for example, 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 a casing 64 provided integrally with the end plate 63 and extending in the axial direction. The end plate 63 has a circular opening 65 at the center thereof, and a casing 64 is formed so as to rise from the peripheral edge of the opening 65.
　ケーシング６４の外周面には固定子５０が組み付けられている。つまり、ケーシング６４の外径寸法は、固定子コア５２の内径寸法と同じか、又は固定子コア５２の内径寸法よりも僅かに小さい寸法になっている。ケーシング６４の外側に固定子コア５２が組み付けられることで、固定子５０とユニットベース６１とが一体化されている。また、ユニットベース６１がハウジング３０に固定されることからすると、ケーシング６４に固定子コア５２が組み付けられた状態では、固定子５０がハウジング３０に対して一体化された状態となっている。 固定 The stator 50 is mounted on the outer peripheral surface of the casing 64. That is, the outer diameter of the casing 64 is the same as the inner diameter of the stator core 52 or slightly smaller than the inner diameter of the stator core 52. The stator 50 and the unit base 61 are integrated by attaching the stator core 52 to the outside of the casing 64. 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 attached to the casing 64.
　なお、固定子コア５２は、ユニットベース６１に対して接着、焼きばめ、圧入等により組み付けられているとよい。これにより、ユニットベース６１側に対する固定子コア５２の周方向又は軸方向の位置ずれが抑制される。 The stator core 52 may be assembled to the unit base 61 by bonding, shrink fitting, press fitting, or the like. Thereby, the displacement of the stator core 52 with respect to the unit base 61 in the circumferential direction or the axial direction is suppressed.
　また、ケーシング６４の径方向内側は、電気コンポーネント６２を収容する収容空間となっており、その収容空間には、回転軸１１を囲むようにして電気コンポーネント６２が配置されている。ケーシング６４は、収容空間形成部としての役目を有している。電気コンポーネント６２は、インバータ回路を構成する半導体モジュール６６や、制御基板６７、コンデンサモジュール６８を具備する構成となっている。 A radially inner side of the casing 64 is a housing space for housing the electric component 62, and the electric component 62 is arranged in the housing space so as to surround the rotating shaft 11. The casing 64 has a role as an accommodation space forming part. The electric component 62 includes a semiconductor module 66 constituting an inverter circuit, a control board 67, and a capacitor module 68.
　なお、ユニットベース６１が、固定子５０の径方向内側に設けられ、固定子５０を保持する固定子ホルダ（電機子ホルダ）に相当する。ハウジング３０及びユニットベース６１により、回転電機１０のモータハウジングが構成されている。このモータハウジングでは、回転子４０を挟んで軸方向の一方側においてハウジング３０に対して保持部材２３が固定されるとともに、他方側においてハウジング３０及びユニットベース６１が互いに結合されている。例えば電気自動車である電動車両等においては、その車両等の側にモータハウジングが取り付けられることで、回転電機１０が車両等に装着される。 The unit base 61 is provided radially inside the stator 50 and corresponds to a stator holder (armature holder) that holds 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 in the axial direction with the rotor 40 interposed therebetween, and the housing 30 and the unit base 61 are connected to each other on the other side. For example, in an electric vehicle such as an electric vehicle, the rotating electric machine 10 is mounted on a vehicle or the like by attaching a motor housing to the vehicle or the like.
　ここで、上記図１～図５に加え、インバータユニット６０の分解図である図６を用いて、インバータユニット６０の構成をさらに説明する。 Here, the configuration of the inverter unit 60 will be further described with reference to FIG. 6 which is an exploded view of the inverter unit 60 in addition to FIGS.
　ユニットベース６１において、ケーシング６４は、筒状部７１と、その軸方向において対向する両端の一方（軸受ユニット２０側の端部）に設けられた端面７２とを有している。筒状部７１の軸方向両端部のうち端面７２の反対側は、エンドプレート６３の開口６５を通じて全面的に開放されている。端面７２には、その中央に円形の孔７３が形成されており、その孔７３に回転軸１１が挿通可能となっている。孔７３には、回転軸１１の外周面との間の空隙を封鎖するシール材１７１が設けられている。シール材１７１は、例えば樹脂材料よりなる摺動シールであるとよい。 In the unit base 61, the casing 64 has a tubular portion 71 and an end face 72 provided at one of the opposite ends in the axial direction (the end on the bearing unit 20 side). The opposite side of the end face 72 among both ends in the axial direction of the cylindrical portion 71 is entirely opened 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 into the hole 73. The hole 73 is provided with a sealing material 171 that seals a gap between the hole 73 and the outer peripheral surface of the rotating shaft 11. The sealant 171 may be a sliding seal made of, for example, a resin material.
　ケーシング６４の筒状部７１は、その径方向外側に配置される回転子４０及び固定子５０と、その径方向内側に配置される電気コンポーネント６２との間を仕切る仕切り部となっており、筒状部７１を挟んで径方向内外に、回転子４０及び固定子５０と電気コンポーネント６２とが並ぶようにそれぞれ配置されている。 The tubular portion 71 of the casing 64 serves as a partitioning portion between the rotor 40 and the stator 50 disposed radially outside the electrical component 62 disposed radially inward thereof. The rotor 40 and the stator 50 and the electric component 62 are arranged inward and outward in the radial direction with the shape portion 71 interposed therebetween.
　また、電気コンポーネント６２は、インバータ回路を構成する電気部品であり、固定子巻線５１の各相巻線に対して所定順序で電流を流して回転子４０を回転させる力行機能と、回転軸１１の回転に伴い固定子巻線５１に流れる３相交流電流を入力し、発電電力として外部に出力する発電機能とを有している。なお、電気コンポーネント６２は、力行機能と発電機能とのうちいずれか一方のみを有するものであってもよい。発電機能は、例えば回転電機１０が車両用動力源として用いられる場合、回生電力として外部に出力する回生機能である。 The electric component 62 is an electric component forming an inverter circuit, and has a powering function of rotating the rotor 40 by applying a current to each phase winding of the stator winding 51 in a predetermined order; And a power generation function of inputting a three-phase AC current flowing through the stator winding 51 with the rotation of the motor and outputting the generated power to the outside. The electric component 62 may have only one of the powering function and the power generation function. The power generation function is, for example, a regenerative function that outputs to the outside as regenerative power when the rotating electric machine 10 is used as a vehicle power source.
　電気コンポーネント６２の具体的な構成として、図４に示すように、回転軸１１の周りには、中空円筒状をなすコンデンサモジュール６８が設けられており、そのコンデンサモジュール６８の外周面上に、複数の半導体モジュール６６が周方向に並べて配置されている。コンデンサモジュール６８は、互いに並列接続された平滑用のコンデンサ６８ａを複数備えている。具体的には、コンデンサ６８ａは、複数枚のフィルムコンデンサが積層されてなる積層型フィルムコンデンサであり、横断面が台形状をなしている。コンデンサモジュール６８は、１２個のコンデンサ６８ａが環状に並べて配置されることで構成されている。 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. Of semiconductor modules 66 are arranged side by side in the circumferential direction. The capacitor module 68 includes a plurality of smoothing capacitors 68a connected in parallel with each other. Specifically, the capacitor 68a is a laminated film capacitor in which a plurality of film capacitors are laminated, and has a trapezoidal cross section. The capacitor module 68 is configured by arranging twelve capacitors 68a in a ring.
　なお、コンデンサ６８ａの製造過程においては、例えば、複数のフィルムが積層されてなる所定幅の長尺フィルムを用い、フィルム幅方向を台形高さ方向とし、かつ台形の上底と下底とが交互になるように長尺フィルムが等脚台形状に切断されることにより、コンデンサ素子が作られる。そして、そのコンデンサ素子に電極等を取り付けることでコンデンサ６８ａが作製される。 In the manufacturing process of the capacitor 68a, for example, a long film having a predetermined width formed by laminating a plurality of films is used, the film width direction is set to a trapezoidal height direction, and the upper and lower bases of the trapezoid alternate. The long film is cut into an equal-leg trapezoidal shape so that the capacitor element is formed. Then, by attaching electrodes and the like to the capacitor element, the capacitor 68a is manufactured.
　半導体モジュール６６は、例えばＭＯＳＦＥＴやＩＧＢＴ等の半導体スイッチング素子を有し、略板状に形成されている。本実施形態では、回転電機１０が２組の３相巻線を備えており、その３相巻線ごとにインバータ回路が設けられていることから、計１２個の半導体モジュール６６を環状に並べて形成された半導体モジュール群６６Ａが電気コンポーネント６２に設けられている。 The semiconductor module 66 has a semiconductor switching element such as a MOSFET or an IGBT, and is formed in a substantially plate shape. In the present embodiment, since the rotating electric machine 10 includes two sets of three-phase windings and an inverter circuit is provided for each of the three-phase windings, a total of twelve semiconductor modules 66 are arranged in a ring. The assembled semiconductor module group 66A is provided in the electric component 62.
　半導体モジュール６６は、ケーシング６４の筒状部７１とコンデンサモジュール６８との間に挟まれた状態で配置されている。半導体モジュール群６６Ａの外周面は筒状部７１の内周面に当接し、半導体モジュール群６６Ａの内周面はコンデンサモジュール６８の外周面に当接している。この場合、半導体モジュール６６で生じた熱は、ケーシング６４を介してエンドプレート６３に伝わり、エンドプレート６３から放出される。 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 transmitted to the end plate 63 via the casing 64 and is released from the end plate 63.
　半導体モジュール群６６Ａは、外周面側、すなわち径方向において半導体モジュール６６と筒状部７１との間にスペーサ６９を有しているとよい。この場合、コンデンサモジュール６８では軸方向に直交する横断面の断面形状が正１２角形である一方、筒状部７１の内周面の横断面形状が円形であるため、スペーサ６９は、内周面が平坦面、外周面が曲面となっている。スペーサ６９は、半導体モジュール群６６Ａの径方向外側において円環状に連なるように一体に設けられていてもよい。スペーサ６９は、良熱伝導体であり、例えばアルミニウム等の金属、又は放熱ゲルシート等であるとよい。なお、筒状部７１の内周面の横断面形状をコンデンサモジュール６８と同じ１２角形にすることも可能である。この場合、スペーサ６９の内周面及び外周面がいずれも平坦面であるとよい。 The semiconductor module group 66A preferably has a spacer 69 between the semiconductor module 66 and the cylindrical portion 71 in 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. Has a flat surface and the outer peripheral surface is a curved surface. The spacer 69 may be provided integrally so as to be annularly continuous outside the semiconductor module group 66A in the radial direction. The spacer 69 is a good heat conductor, for example, a metal such as aluminum, or a heat dissipation gel sheet. Note that the cross-sectional shape of the inner peripheral surface of the cylindrical portion 71 can be the same dodecagon as that of the capacitor module 68. In this case, both the inner peripheral surface and the outer peripheral surface of the spacer 69 are preferably flat surfaces.
　また、本実施形態では、ケーシング６４の筒状部７１に、冷却水を流通させる冷却水通路７４が形成されており、半導体モジュール６６で生じた熱は、冷却水通路７４を流れる冷却水に対しても放出される。つまり、ケーシング６４は水冷機構を備えている。図３や図４に示すように、冷却水通路７４は、電気コンポーネント６２（半導体モジュール６６及びコンデンサモジュール６８）を囲むように環状に形成されている。半導体モジュール６６は筒状部７１の内周面に沿って配置されており、その半導体モジュール６６に対して径方向内外に重なる位置に冷却水通路７４が設けられている。 Further, in the present embodiment, a cooling water passage 74 for flowing cooling water is formed in the cylindrical portion 71 of the casing 64, and heat generated in the semiconductor module 66 is supplied to the cooling water flowing through the cooling water passage 74. Is also released. That is, the casing 64 has a water cooling mechanism. As shown in FIGS. 3 and 4, the cooling water passage 74 is formed in an annular shape so as to surround the electric component 62 (the semiconductor module 66 and the capacitor module 68). The semiconductor module 66 is arranged along the inner peripheral surface of the cylindrical portion 71, and a cooling water passage 74 is provided at a position overlapping the semiconductor module 66 inward and outward in the radial direction.
　筒状部７１の外側には固定子５０が配置され、内側には電気コンポーネント６２が配置されていることから、筒状部７１に対しては、その外側から固定子５０の熱が伝わるとともに、内側から電気コンポーネント６２の熱（例えば半導体モジュール６６の熱）が伝わることになる。この場合、固定子５０と半導体モジュール６６とを同時に冷やすことが可能となっており、回転電機１０における発熱部材の熱を効率良く放出することができる。 Since the stator 50 is disposed outside the tubular portion 71 and the electric component 62 is disposed inside, the heat of the stator 50 is transmitted to the tubular portion 71 from the outside, The heat of the electric 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 at the same time, and the heat of the heat generating member in the rotating electric machine 10 can be efficiently released.
　更に、固定子巻線５１への通電を行うことで回転電機を動作させるインバータ回路の一部、又は全部を構成する半導体モジュール６６の少なくとも一部が、ケーシング６４の筒状部７１の径方向外側に配置された固定子コア５２に囲まれた領域内に配置されている。望ましくは、１つの半導体モジュール６６の全体が固定子コア５２に囲まれた領域内に配置されている。更に、望ましくは、全ての半導体モジュール６６の全体が固定子コア５２に囲まれた領域内に配置されている。 Furthermore, at least a part of the semiconductor module 66 that constitutes a part or all of the inverter circuit that operates the rotating electric machine by energizing the stator winding 51 is disposed outside the cylindrical portion 71 of the casing 64 in the radial direction. Are arranged in a region surrounded by the stator core 52 arranged in the above. Desirably, the entirety of one semiconductor module 66 is arranged in a region surrounded by stator core 52. Further, desirably, the entirety of all the semiconductor modules 66 is arranged in a region surrounded by the stator core 52.
　また、半導体モジュール６６の少なくとも一部が、冷却水通路７４により囲まれた領域内に配置されている。望ましくは、全ての半導体モジュール６６の全体がヨーク１４１に囲まれた領域内に配置されている。 少 な く と も At least a part of the semiconductor module 66 is arranged in a region surrounded by the cooling water passage 74. Desirably, the entirety of all the semiconductor modules 66 is arranged in a region surrounded by the yoke 141.
　また、電気コンポーネント６２は、軸方向において、コンデンサモジュール６８の一方の端面に設けられた絶縁シート７５と、他方の端面に設けられた配線モジュール７６とを備えている。この場合、コンデンサモジュール６８は、その軸方向に対向した二つの端面、すなわち第１端面と第２端面を有している。コンデンサモジュール６８の軸受ユニット２０に近い第１端面は、ケーシング６４の端面７２に対向しており、絶縁シート７５を挟んだ状態で端面７２に重ね合わされている。また、コンデンサモジュール６８の開口６５に近い第２端面には、配線モジュール７６が組み付けられている。 {Circle around (2)} The electric component 62 includes an insulating sheet 75 provided on one end face of the capacitor module 68 and a wiring module 76 provided on the other end face in the axial direction. In this case, the capacitor module 68 has two end faces facing each other in the axial direction, that is, a first end face and a second end face. The first end face of the capacitor module 68 near the bearing unit 20 is opposed to the end face 72 of the casing 64, and is superposed on the end face 72 with the insulating sheet 75 interposed therebetween. A wiring module 76 is mounted on a second end face of the capacitor module 68 near the opening 65.
　配線モジュール７６は、合成樹脂材よりなり円形板状をなす本体部７６ａと、その内部に埋設された複数のバスバー７６ｂ，７６ｃを有しており、そのバスバー７６ｂ，７６ｃにより、半導体モジュール６６やコンデンサモジュール６８と電気的接続がなされている。具体的には、半導体モジュール６６は、その軸方向端面から延びる接続ピン６６ａを有しており、その接続ピン６６ａが、本体部７６ａの径方向外側においてバスバー７６ｂに接続されている。また、バスバー７６ｃは、本体部７６ａの径方向外側においてコンデンサモジュール６８とは反対側に延びており、その先端部にて配線部材７９に接続されるようになっている（図２参照）。 The wiring module 76 has a main body portion 76a made of a synthetic resin and having a circular plate shape, and a plurality of busbars 76b and 76c embedded therein. The busbars 76b and 76c allow the semiconductor module 66 and the capacitor to be mounted. An electrical connection is made with the module 68. Specifically, the semiconductor module 66 has a connection pin 66a extending from the axial end face, and the connection pin 66a is connected to the bus bar 76b on the radial outside of the main body portion 76a. The bus bar 76c extends on the outer side of the main body 76a in the radial direction on the side opposite to the capacitor module 68, and is connected to the wiring member 79 at its tip (see FIG. 2).
　上記のとおりコンデンサモジュール６８の軸方向に対向する第１端面に絶縁シート７５が設けられ、かつコンデンサモジュール６８の第２端面に配線モジュール７６が設けられた構成によれば、コンデンサモジュール６８の放熱経路として、コンデンサモジュール６８の第１端面および第２端面から端面７２及び筒状部７１に至る経路が形成される。すなわち、第１端面から端面７２への経路と、第２端面から筒状部７１へ至る経路が形成される。これにより、コンデンサモジュール６８において半導体モジュール６６が設けられた外周面以外の端面部からの放熱が可能になっている。つまり、径方向への放熱だけでなく、軸方向への放熱も可能となっている。 As described above, 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 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 is formed 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. 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. Thereby, heat can be radiated from the end face of the capacitor module 68 other than the outer peripheral face where the semiconductor module 66 is provided. That is, not only the heat radiation in the radial direction but also the heat radiation in the axial direction are possible.
　また、コンデンサモジュール６８は中空円筒状をなし、その内周部には所定の隙間を介在させて回転軸１１が配置されることから、コンデンサモジュール６８の熱はその中空部からも放出可能となっている。この場合、回転軸１１の回転により空気の流れが生じることにより、その冷却効果が高められるようになっている。 Further, since the capacitor module 68 has a hollow cylindrical shape and the rotating shaft 11 is disposed on the inner peripheral portion thereof with a predetermined gap interposed therebetween, the heat of the capacitor module 68 can be released 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.
　配線モジュール７６には、円板状の制御基板６７が取り付けられている。制御基板６７は、所定の配線パターンが形成されたプリントサーキットボード（ＰＣＢ）を有しており、そのボード上には各種ＩＣや、マイコン等からなる制御部に相当する制御装置７７が実装されている。制御基板６７は、ネジ等の固定具により配線モジュール７６に固定されている。制御基板６７は、その中央部に、回転軸１１を挿通させる挿通孔６７ａを有している。 円 A disc-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. On the board, a control device 77 corresponding to a control unit including various ICs and a microcomputer is mounted. I have. The control board 67 is fixed to the wiring module 76 by a fixture such as a screw. The control board 67 has an insertion hole 67a at the center thereof, through which the rotating shaft 11 is inserted.
　なお、配線モジュール７６は、軸方向に互いに対向する、すなわち、その厚み方向において互いに対向する第１面と第２面を有する。第１面は、コンデンサモジュール６８に面する。配線モジュール７６は、その第２面に、制御基板６７を設けている。制御基板６７の両面の一方側から他方側に配線モジュール７６のバスバー７６ｃが延びる構成となっている。かかる構成において、制御基板６７には、バスバー７６ｃとの干渉を回避する切欠が設けられているとよい。例えば、円形状をなす制御基板６７の外縁部の一部が切り欠かれているとよい。 The wiring module 76 has a first surface and a second surface that face each other in the axial direction, that is, that face each other in the thickness direction. The first surface faces the capacitor module 68. The wiring module 76 has a control board 67 on the second surface. The bus bar 76c of the wiring module 76 extends from one side of the both sides of the control board 67 to the other side. In such a configuration, the control board 67 may be provided with a notch for avoiding interference with the bus bar 76c. For example, a part of the outer edge of the circular control board 67 may be cut away.
　上述のとおり、ケーシング６４に囲まれた空間内に電気コンポーネント６２が収容され、その外側に、ハウジング３０、回転子４０及び固定子５０が層状に設けられている構成によれば、インバータ回路で生じる電磁ノイズが好適にシールドされるようになっている。すなわち、インバータ回路では、所定のキャリア周波数によるＰＷＭ制御を利用して各半導体モジュール６６でのスイッチング制御が行われ、そのスイッチング制御により電磁ノイズが生じることが考えられるが、その電磁ノイズを、電気コンポーネント６２の径方向外側のハウジング３０、回転子４０、固定子５０等により好適にシールドできる。 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 outside the space, the electric component 62 is generated in the inverter circuit. Electromagnetic noise is suitably shielded. That is, in the inverter circuit, switching control in each semiconductor module 66 is performed using PWM control based on a predetermined carrier frequency, and electromagnetic noise may be generated by the switching control. It can be shielded suitably by the housing 30, the rotor 40, the stator 50, and the like outside in the radial direction of 62.
　更に、半導体モジュール６６の少なくとも一部が、ケーシング６４の筒状部７１の径方向外側に配置された固定子コア５２に囲まれた領域内に配置することで、半導体モジュール６６と固定子巻線５１とが固定子コア５２を介さずに配置されている構成に比べて、半導体モジュール６６から磁束が発生したとしても、固定子巻線５１に影響を与えにくい。また、固定子巻線５１から磁束が発生したとしても、半導体モジュール６６に影響を与えにくい。なお、半導体モジュール６６の全体が、ケーシング６４の筒状部７１の径方向外側に配置された固定子コア５２に囲まれた領域内に配置されると更に効果的である。また、半導体モジュール６６の少なくとも一部が、冷却水通路７４により囲まれている場合、固定子巻線５１や磁石ユニット４２からの発熱が半導体モジュール６６に届きにくいという効果を得ることができる。 Furthermore, by arranging at least a part of the semiconductor module 66 in a region surrounded by the stator core 52 arranged radially outside the cylindrical portion 71 of the casing 64, the semiconductor module 66 and the stator winding As compared with a configuration in which the magnetic flux 51 is disposed without passing through the stator core 52, even if a magnetic flux is generated from the semiconductor module 66, the magnetic flux is less likely to affect the stator winding 51. Further, even if a magnetic flux is generated from the stator winding 51, the magnetic flux hardly affects the semiconductor module 66. It is more effective if the entire semiconductor module 66 is arranged in a region surrounded by the stator core 52 arranged radially outside the cylindrical portion 71 of the casing 64. Further, when at least a part of the semiconductor module 66 is surrounded by the cooling water passage 74, it is possible to obtain an effect that heat from the stator winding 51 and the magnet unit 42 does not easily reach the semiconductor module 66.
　筒状部７１においてエンドプレート６３の付近には、その外側の固定子５０と内側の電気コンポーネント６２とを電気的に接続する配線部材７９（図２参照）を挿通させる貫通孔７８が形成されている。図２に示すように、配線部材７９は、圧着、溶接などにより、固定子巻線５１の端部と配線モジュール７６のバスバー７６ｃとにそれぞれ接続されている。配線部材７９は、例えばバスバーであり、その接合面は平たく潰されていることが望ましい。貫通孔７８は、１カ所又は複数箇所に設けられているとよく、本実施形態では２カ所に貫通孔７８が設けられている。２カ所に貫通孔７８が設けられる構成では、２組の３相巻線から延びる巻線端子を、それぞれ配線部材７９により容易に結線することが可能となり、多相結線を行う上で好適なものとなっている。 A through-hole 78 is formed near the end plate 63 in the cylindrical portion 71, through which 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 inserted. I have. As shown in FIG. 2, the wiring member 79 is connected to the end of the stator winding 51 and the bus bar 76c of the wiring module 76 by crimping, welding, or the like. The wiring member 79 is, for example, a bus bar, and its joint surface is desirably flattened. The through holes 78 may be provided at one or a plurality of positions. In the present embodiment, the through holes 78 are provided at two positions. In the configuration in which the through holes 78 are provided at two locations, the winding terminals extending from the two sets of three-phase windings can be easily connected by the wiring members 79, respectively, which is suitable for performing multiphase connection. It has become.
　上述のとおりハウジング３０内には、図４に示すように径方向外側から順に回転子４０、固定子５０が設けられ、固定子５０の径方向内側にインバータユニット６０が設けられている。ここで、ハウジング３０の内周面の半径をｄとした場合に、回転子４０の回転中心からｄ×０．７０５の距離よりも径方向外側に回転子４０と固定子５０とが配置されている。この場合、回転子４０及び固定子５０のうち径方向内側の固定子５０の内周面（すなわち固定子コア５２の内周面）から径方向内側となる領域を第１領域Ｘ１、径方向において固定子５０の内周面からハウジング３０までの間の領域を第２領域Ｘ２とすると、第１領域Ｘ１の横断面の面積は、第２領域Ｘ２の横断面の面積よりも大きい構成となっている。また、径方向において回転子４０の磁石ユニット４２及び固定子巻線５１が重複する範囲で見て、第１領域Ｘ１の容積が第２領域Ｘ２の容積よりも大きい構成となっている。 As described above, in the housing 30, the rotor 40 and the stator 50 are provided in this order from the outside in the radial direction as shown in FIG. 4, and the inverter unit 60 is provided inside the stator 50 in the radial direction. Here, assuming that 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. I have. In this case, of the rotor 40 and the stator 50, a region radially inward from the inner peripheral surface of the stator 50 on the radial inner side (that is, the inner peripheral surface of the stator core 52) is defined as a first region X1, Assuming that a region between the inner peripheral surface of the stator 50 and the housing 30 is the second region X2, the cross-sectional area of the first region X1 is larger than the cross-sectional area of the second region X2. I have. Further, when viewed in a range where the magnet unit 42 of the rotor 40 and the stator winding 51 overlap in the radial direction, the volume of the first region X1 is larger than the volume of the second region X2.
　なお、回転子４０及び固定子５０を磁気回路コンポーネントアッセンブリとすると、ハウジング３０内において、その磁気回路コンポーネントアッセンブリの内周面から径方向内側となる第１領域Ｘ１が、径方向において磁気回路コンポーネントアッセンブリの内周面からハウジング３０までの間の第２領域Ｘ２よりも容積が大きい構成となっている。 Assuming that the rotor 40 and the stator 50 are magnetic circuit component assemblies, a first region X1 radially inward from the inner peripheral surface of the magnetic circuit component assembly in the housing 30 is formed in the magnetic circuit component assembly in the radial direction. Has a larger volume than the second region X2 between the inner peripheral surface and the housing 30.
　次いで、回転子４０及び固定子５０の構成をより詳しく説明する。 Next, the configurations of the rotor 40 and the stator 50 will be described in more detail.
　一般に、回転電機における固定子の構成として、積層鋼板よりなりかつ円環状をなす固定子コアに周方向に複数のスロットを設け、そのスロット内に固定子巻線を巻装するものが知られている。具体的には、固定子コアは、ヨークから所定間隔で径方向に延びる複数のティースを有しており、周方向に隣り合うティース間にスロットが形成されている。そして、スロット内に、例えば径方向に複数層の導線が収容され、その導線により固定子巻線が構成されている。 Generally, as a configuration of a stator in a rotating electric machine, there is known a configuration in which a plurality of slots are provided in a circumferential direction on a stator core made of laminated steel sheets and forming an annular shape, and a stator winding is wound in the slots. I have. Specifically, the stator core has a plurality of teeth extending in a radial direction at predetermined intervals from the yoke, and a slot is formed between adjacent teeth in the circumferential direction. A plurality of layers of conductors are accommodated in the slot, for example, in the radial direction, and the conductors constitute a stator winding.
　ただし、上述した固定子構造では、固定子巻線の通電時において、固定子巻線の起磁力が増加するのに伴い固定子コアのティース部分で磁気飽和が生じ、それに起因して回転電機のトルク密度が制限されることが考えられる。つまり、固定子コアにおいて、固定子巻線の通電により生じた回転磁束がティースに集中することで、磁気飽和が生じると考えられる。 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, and as a result, the rotating electric machine It is possible that the torque density is limited. That is, in the stator core, it is considered that the magnetic flux is generated by energizing the stator windings and concentrates on the teeth, thereby causing magnetic saturation.
　また、一般的に、回転電機におけるＩＰＭ（Interior Permanent Magnet）ロータの構成として、永久磁石がｄ－ｑ座標系におけるｄ軸に配置され、ｑ軸にロータコアが配置されたものが知られている。このような場合、ｄ軸近傍の固定子巻線が励磁されることで、フレミングの法則により固定子から回転子のｑ軸に励磁磁束が流入される。そしてこれにより、回転子のｑ軸コア部分に、広範囲の磁気飽和が生じると考えられる。 In general, as a configuration of an IPM (Interior @ Permanent @ Magnet) rotor in a rotating electric machine, a configuration in which a permanent magnet is arranged on a d-axis in a dq coordinate system and a rotor core is arranged on a q-axis is known. In such a case, when the stator winding near the d-axis is excited, the excitation magnetic flux flows from the stator to the q-axis of the rotor according to Fleming's law. It is considered that this causes a wide range of magnetic saturation in the q-axis core portion of the rotor.
　図７は、固定子巻線の起磁力を示すアンペアターン［ＡＴ］とトルク密度［Ｎｍ／Ｌ］との関係を示すトルク線図である。破線が一般的なＩＰＭロータ型の回転電機における特性を示す。図７に示すように、一般的な回転電機では、固定子において起磁力を増加させていくことにより、スロット間のティース部分及びｑ軸コア部分の２カ所で磁気飽和が生じ、それが原因でトルクの増加が制限されてしまう。このように、当該一般的な回転電機では、アンペアターン設計値がＡ１で制限されることになる。 FIG. 7 is a torque diagram showing the relationship between the ampere turn [AT] indicating the magnetomotive force of the stator winding and the torque density [Nm / L]. The dashed line indicates the characteristic in a general IPM rotor type rotating electric machine. As shown in FIG. 7, in a general rotating electric machine, by increasing the magnetomotive force in the stator, magnetic saturation occurs at two places, ie, the teeth portion between the slots and the q-axis core portion. The increase in torque is limited. As described above, in the general rotating electric machine, the ampere-turn design value is limited by A1.
　そこで本実施形態では、磁気飽和に起因する制限を解消すべく、回転電機１０において、以下に示す構成を付与するものとしている。すなわち、第１の工夫として、固定子において固定子コアのティースで生じる磁気飽和をなくすべく、固定子５０においてスロットレス構造を採用し、かつＩＰＭロータのｑ軸コア部分で生じる磁気飽和をなくすべく、ＳＰＭ（Surface Permanent Magnet）ロータを採用している。第１の工夫によれば、磁気飽和が生じる上記２カ所の部分をなくすことができるが、低電流域でのトルクが減少することが考えられる（図７の一点鎖線参照）。そのため、第２の工夫として、ＳＰＭロータの磁束増強を図ることでトルク減少を挽回すべく、回転子４０の磁石ユニット４２において磁石磁路を長くして磁力を高めた極異方構造を採用している。 Therefore, in the present embodiment, the following configuration is provided to the rotating electric machine 10 in order to eliminate the limitation caused by the magnetic saturation. That is, as a first contrivance, a slotless structure is employed in the stator 50 in order to eliminate magnetic saturation caused by teeth of the stator core in the stator, and in order to eliminate magnetic saturation occurring in the q-axis core portion of the IPM rotor. , SPM (Surface @ Permanent @ Magnet) rotor. According to the first device, the above two portions where magnetic saturation occurs can be eliminated, but it is conceivable that the torque in the low current region decreases (see the dashed line in FIG. 7). Therefore, as a second contrivance, a pole anisotropic structure is adopted in which the magnet magnetic path is lengthened and the magnetic force is increased in the magnet unit 42 of the rotor 40 in order to recover the torque reduction by increasing the magnetic flux of the SPM rotor. ing.
　また、第３の工夫として、固定子巻線５１のコイルサイド部５３において導線の固定子５０における径方向厚さを小さくした扁平導線構造を採用してトルク減少の挽回を図っている。ここで、上述の磁力を高めた極異方構造によって、磁石ユニット４２に対向する固定子巻線５１には、より大きな渦電流が発生することが考えられる。しかしながら、第３の工夫によれば、径方向に薄い扁平導線構造のため、固定子巻線５１における径方向の渦電流の発生を抑制することができる。このように、これら第１～第３の各構成によれば、図７に実線で示すように、磁力の高い磁石を採用してトルク特性の大幅な改善を見込みつつも、磁力の高い磁石ゆえに生じ得る大きい渦電流発生の懸念も改善できるものとなっている。 As a third device, the coil side portion 53 of the stator winding 51 employs a flat conductor structure in which the radial thickness of the conductor in the stator 50 is reduced, thereby reducing torque reduction. 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 increased. However, according to the third device, the generation of radial eddy currents in the stator windings 51 can be suppressed because the flat conductive wire structure is thin in the radial direction. As described above, according to each of the first to third configurations, as shown by the solid line in FIG. 7, while a magnet having a high magnetic force is employed to greatly improve the torque characteristics, the magnet having a high magnetic force is used. Concerns about possible large eddy current generation can also be improved.
　さらに、第４の工夫として、極異方構造を利用し正弦波に近い磁束密度分布を有する磁石ユニットを採用している。これによれば、後述するパルス制御等によって正弦波整合率を高めてトルク増強を図ることができるとともに、ラジアル磁石と比べ緩やかな磁束変化のため渦電流損（渦電流による銅損：eddy current loss）もまた更に抑制することができるのである。 Furthermore, as a fourth device, a magnet unit having a magnetic flux density distribution close to a sine wave using a pole anisotropic structure is adopted. According to this, the torque can be increased by increasing the sine wave matching ratio by pulse control or the like described later, and eddy current loss (copper loss due to eddy current: eddy current loss) due to a gradual change in magnetic flux compared to the radial magnet. ) Can also be further suppressed.
　以下、正弦波整合率について説明する。正弦波整合率は、磁石の表面を磁束プローブでなぞる等して計測した表面磁束密度分布の実測波形と周期及びピーク値が同じ正弦波との比較から求める事ができる。そして、回転電機の基本波である１次波形の振幅が、実測波形の振幅、即ち基本波に他の高調波成分を加えた振幅に対して、占める割合が正弦波整合率に相当する。正弦波整合率が高くなると、表面磁束密度分布の波形が正弦波形状に近づいていく。そして、正弦波整合率を向上させた磁石を備えた回転電機に対して、インバータから１次の正弦波の電流を供給すると、磁石の表面磁束密度分布の波形が正弦波形状に近い事と相まって、大きなトルクを発生させることができる。なお、表面磁束密度分布は実測以外の方法、例えばマクスウェルの方程式を用いた電磁界解析によって推定しても良い。 正弦 Hereinafter, the sine wave matching ratio will be described. The sine wave matching ratio can be determined by comparing a measured waveform of the surface magnetic flux density distribution measured by tracing the surface of the magnet with a magnetic flux probe and a 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 rotating electrical machine, to the amplitude of the actually measured waveform, that is, the amplitude of the fundamental wave plus other harmonic components, corresponds to the sine wave matching ratio. As the sine wave matching ratio increases, the waveform of the surface magnetic flux density distribution approaches a sine wave shape. When a primary sine-wave current is supplied from a inverter to a rotating electric machine having a magnet with an improved sine-wave matching ratio, the waveform of the surface magnetic flux density distribution of the magnet is close to a sine-wave shape. , A large torque can be generated. The surface magnetic flux density distribution may be estimated by a method other than the actual measurement, for example, an electromagnetic field analysis using Maxwell's equation.
　また、第５の工夫として、固定子巻線５１を複数の素線を寄せ集めて束ねた素線導体構造としている。これによれば、素線が並列結線されているため、大電流が流せるとともに、扁平導線構造で固定子５０の周方向に広がった導線で発生する渦電流の発生を、素線それぞれの断面積が小さくなるため、第３の工夫による径方向に薄くする以上に効果的に抑制することができる。そして、複数の素線を撚り合わせた構成にすることで、導体からの起磁力に対しては、電流通電方向に対して右ネジの法則で発生する磁束に対する渦電流を相殺することができる。 (5) As a fifth measure, the stator winding 51 has a wire conductor structure in which a plurality of wires are gathered and bundled. According to this, since the wires are connected in parallel, a large current can flow, and the generation of the eddy current generated in the conductors extending in the circumferential direction of the stator 50 in the flat conductor structure is reduced by the cross-sectional area of each of the wires. Can be more effectively suppressed than by reducing the thickness in the radial direction by the third device. And, by using a configuration in which a plurality of strands are twisted, the eddy current with respect to the magnetic flux generated by the right-handed screw rule in the direction of current flow can be offset with respect to the magnetomotive force from the conductor.
　このように、第４の工夫、第５の工夫をさらに加えると、第２の工夫である磁力の高い磁石を採用しながら、さらにその高い磁力に起因する渦電流損を抑制しながらトルク増強を図ることができる。 As described above, when the fourth device and the fifth device are further added, the torque is increased while the eddy current loss caused by the high magnetic force is suppressed while employing the magnet having the high magnetic force as the second device. Can be planned.
　以下に、上述した固定子５０のスロットレス構造、固定子巻線５１の扁平導線構造、及び磁石ユニット４２の極異方構造について個別に説明を加える。ここではまずは、固定子５０におけるスロットレス構造と固定子巻線５１の扁平導線構造とを説明する。図８は、回転子４０及び固定子５０の横断面図であり、図９は、図８に示す回転子４０及び固定子５０の一部を拡大して示す図である。図１０は、図１１のＸ‐Ｘ線に沿った固定子５０の横断面を示す断面図であり、図１１は、固定子５０の縦断面を示す断面図である。また、図１２は、固定子巻線５１の斜視図である。なお、図８及び図９には、磁石ユニット４２における磁石の磁化方向を矢印にて示している。 ス ロ ッ ト Hereinafter, the slotless structure of the stator 50, the flat conductor structure of the stator winding 51, and the pole anisotropic structure of the magnet unit 42 will be individually described. First, the slotless structure of the stator 50 and the flat conductor structure of the stator winding 51 will be described. FIG. 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. FIG. 12 is a perspective view of the stator winding 51. 8 and 9, the magnetization directions of the magnets in the magnet unit 42 are indicated by arrows.
　図８乃至図１１に示すように、固定子コア５２は、軸方向に複数の電磁鋼板が積層され、かつ径方向に所定の厚さを有する円筒状をなしており、回転子４０側となる径方向外側に固定子巻線５１が組み付けられるものとなっている。固定子コア５２において、回転子４０側の外周面が導線設置部（導体エリア）となっている。固定子コア５２の外周面は凹凸のない曲面状をなしており、その外周面において周方向に所定間隔で複数の導線群８１が配置されている。固定子コア５２は、回転子４０を回転させるための磁気回路の一部となるバックヨークとして機能する。この場合、周方向に隣り合う各２つの導線群８１の間には軟磁性材からなるティース（つまり、鉄心）が設けられていない構成（つまり、スロットレス構造）となっている。本実施形態において、それら各導線群８１の間隙５６には、封止部材５７の樹脂材料が入り込む構造となっている。つまり、固定子５０において、周方向における各導線群８１の間に設けられる導線間部材が、非磁性材料である封止部材５７として構成されている。封止部材５７の封止前の状態で言えば、固定子コア５２の径方向外側には、それぞれ導線間領域である間隙５６を隔てて周方向に所定間隔で導線群８１が配置されており、これによりスロットレス構造の固定子５０が構築されている。言い換えれば、各導線群８１は、後述するように二つの導線（conductor）８２からなり、固定子５０の周方向に隣り合う各二つの導線群８１の間は、非磁性材のみが占有している。この非磁性材とは、封止部材５７以外に空気などの非磁性気体や非磁性液体などをも含む。なお、以下において、封止部材５７は導線間部材（conductor-to- conductor member）ともいう。 As shown in FIGS. 8 to 11, the stator core 52 is formed by laminating a plurality of electromagnetic steel sheets in the axial direction, and has a cylindrical shape having a predetermined thickness in the radial direction, and is located on the rotor 40 side. The stator winding 51 is mounted radially outward. In the stator core 52, the outer peripheral surface on the rotor 40 side is a conductive wire installation portion (conductor area). The outer peripheral surface of the stator core 52 has a curved surface without irregularities, and a plurality of conductive wire groups 81 are arranged on the outer peripheral surface at predetermined intervals in the circumferential direction. The stator core 52 functions as a back yoke which is a part of a magnetic circuit for rotating the rotor 40. In this case, the teeth (that is, the iron core) made of the soft magnetic material are not provided between the two conductive wire groups 81 that are adjacent in the circumferential direction (that is, the slotless structure). In the present embodiment, a structure is such that the resin material of the sealing member 57 enters the gaps 56 between the conductive wire groups 81. That is, in the stator 50, the inter-conductor member provided between the respective conductor groups 81 in the circumferential direction is configured as the sealing member 57 which is a non-magnetic material. Speaking of the state before the sealing of the sealing member 57, on the radially outer side of the stator core 52, the conductor groups 81 are arranged at predetermined intervals in the circumferential direction with a gap 56 being a region between the conductors. Thus, a stator 50 having a slotless structure is constructed. In other words, each conductor group 81 is composed of two conductors 82 as described later, and only the non-magnetic material occupies between each two conductor groups 81 adjacent in the circumferential direction of the stator 50. I have. The non-magnetic material includes a non-magnetic gas such as air, a non-magnetic liquid, and the like in addition to the sealing member 57. In the following, the sealing member 57 is also referred to as a conductor-to-conductor member.
　なお、周方向に並ぶ各導線群８１の間においてティースが設けられている構成とは、ティースが、径方向に所定厚さを有し、かつ周方向に所定幅を有することで、各導線群８１の間に磁気回路の一部、すなわち磁石磁路を形成する構成であると言える。この点において、各導線群８１の間にティースが設けられていない構成とは、上記の磁気回路の形成がなされていない構成であると言える。 Note that the configuration in which the teeth are provided between the conductor groups 81 arranged 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 this is a configuration in which a part of the magnetic circuit, that is, a magnet magnetic path is formed between the magnetic circuits 81. In this regard, a 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-described magnetic circuit is not formed.
　図１０に示すように、固定子巻線（すなわち電機子巻線）５１は、所定の厚みＴ２（以下、第１寸法とも言う）と幅Ｗ２（以下、第２寸法とも言う）を有するように形成されている。厚みＴ２は、固定子巻線５１の径方向において互いに対向する外側面と内側面との間の最短距離である。幅Ｗ２は、固定子巻線５１の多相（実施例では３相：Ｕ相、Ｖ相及びＷ相の３相あるいはＸ相、Ｙ相及びＺ相の３相）の一つとして機能する固定子巻線５１の一部分の固定子巻線５１の周方向の長さである。具体的には、図１０において、周方向に隣り合う２つの導線群８１が３相の内の一つである例えばＵ相として機能する場合、周方向において当該２つの導線群８１の端から端までの幅Ｗ２である。そして、厚みＴ２は幅Ｗ２より小さくなっている。 As shown in FIG. 10, the stator winding (that is, the 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). 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 is a fixed phase functioning as one of the polyphases of the stator winding 51 (three phases in the embodiment: three phases of U phase, V phase and W phase or three phases of X phase, Y phase and Z phase). This is the circumferential length of a part of the stator winding 51 of the slave winding 51. Specifically, in FIG. 10, when two conductor groups 81 adjacent to each other in the circumferential direction function as one of three phases, for example, a U-phase, the two conductor groups 81 in the circumferential direction end to end. Up to W2. The thickness T2 is smaller than the width W2.
　なお、厚みＴ２は、幅Ｗ２内に存在する２つの導線群８１の合計幅寸法より小さいことが好ましい。また、仮に固定子巻線５１（より詳しくは導線８２）の断面形状が真円形状や楕円形状、又は多角形形状である場合、固定子５０の径方向に沿った導線８２の断面のうち、その断面において固定子５０の径方向の最大の長さをＷ１２、同断面のうち固定子５０の周方向の最大の長さをＷ１１としても良い。 厚 み In addition, it is preferable that the thickness T2 is smaller than the total width dimension of the two conductive wire groups 81 existing in the width W2. If the cross-sectional shape of the stator winding 51 (more specifically, the conductive wire 82) is a perfect circle, an ellipse, or a polygon, among the cross-sections of the conductive wire 82 along the radial direction of the stator 50, In the section, the maximum length in the radial direction of the stator 50 may be W12, and in the section, the maximum length in the circumferential direction of the stator 50 may be W11.
　図１０及び図１１に示すように、固定子巻線５１は、封止材（モールド材）としての合成樹脂材からなる封止部材５７により封止されている。つまり、固定子巻線５１は、固定子コア５２と共にモールド材によりモールドされている。なお樹脂は、非磁性体、又は非磁性体の均等物としてＢｓ＝０と看做すことができる。 As shown in FIGS. 10 and 11, the stator winding 51 is sealed with 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. The resin can be regarded as Bs = 0 as a non-magnetic material or an equivalent of the non-magnetic material.
　図１０の横断面で見れば、封止部材５７は、各導線群８１の間、すなわち間隙５６に合成樹脂材が充填されて設けられており、封止部材５７により、各導線群８１の間に絶縁部材が介在する構成となっている。つまり、間隙５６において封止部材５７が絶縁部材として機能する。封止部材５７は、固定子コア５２の径方向外側において、各導線群８１を全て含む範囲、すなわち径方向の厚さ寸法が各導線群８１の径方向の厚さ寸法よりも大きくなる範囲で設けられている。 10, the sealing member 57 is provided between the conductive wire groups 81, that is, the gap 56 is filled with a synthetic resin material. And an insulating member interposed therebetween. That is, the sealing member 57 functions as an insulating member in the gap 56. The sealing member 57 extends radially outside the stator core 52 in a range that includes all of the conductor groups 81, that is, in a range in which the radial thickness dimension is larger than the radial thickness dimension of each conductor group 81. Is provided.
　また、図１１の縦断面で見れば、封止部材５７は、固定子巻線５１のターン部８４を含む範囲で設けられている。固定子巻線５１の径方向内側では、固定子コア５２の軸方向に対向する端面の少なくとも一部を含む範囲で封止部材５７が設けられている。この場合、固定子巻線５１は、各相の相巻線の端部、すなわちインバータ回路との接続端子を除く略全体で樹脂封止されている。 In addition, as 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. On the radially inner side of the stator winding 51, a sealing member 57 is provided in a range including at least a part of the end face of the stator core 52 facing the axial direction. In this case, the stator windings 51 are resin-sealed substantially at the ends of the phase windings of the respective phases, that is, substantially entirely except for connection terminals with the inverter circuit.
　封止部材５７が固定子コア５２の端面を含む範囲で設けられた構成では、封止部材５７により、固定子コア５２の積層鋼板を軸方向内側に押さえ付けることができる。これにより、封止部材５７を用いて、各鋼板の積層状態を保持することができる。なお、本実施形態では、固定子コア５２の内周面を樹脂封止していないが、これに代えて、固定子コア５２の内周面を含む固定子コア５２の全体を樹脂封止する構成であってもよい。 In the configuration in which the sealing member 57 is provided in a range including the end face of the stator core 52, the sealing member 57 can press the laminated steel sheet of the stator core 52 inward in the axial direction. Thereby, the laminated state of each steel plate can be maintained using the sealing member 57. Although the inner peripheral surface of the stator core 52 is not resin-sealed in the present embodiment, the entire stator core 52 including the inner peripheral surface of the stator core 52 is resin-sealed instead. It may be a configuration.
　回転電機１０が車両動力源として使用される場合には、封止部材５７が、高耐熱のフッ素樹脂や、エポキシ樹脂、ＰＰＳ樹脂、ＰＥＥＫ樹脂、ＬＣＰ樹脂、シリコン樹脂、ＰＡＩ樹脂、ＰＩ樹脂等により構成されていることが好ましい。また、膨張差による割れ抑制の観点から線膨張係数を考えると、固定子巻線５１の導線の外被膜と同じ材質であることが望ましい。すなわち、線膨張係数が、一般的に他樹脂の倍以上であるシリコン樹脂は望ましくは除外される。なお、電気車両の如く、燃焼を利用した機関を持たない電気製品においては、１８０℃程度の耐熱性を持つＰＰＯ樹脂やフェノール樹脂、ＦＲＰ樹脂も候補となる。回転電機の周囲温度が１００℃未満と見做せる分野においては、この限りではない。 When the rotating electric machine 10 is used as a vehicle power source, the sealing member 57 is made of a highly heat-resistant fluororesin, epoxy resin, PPS resin, PEEK resin, LCP resin, silicon resin, PAI resin, PI resin, or the like. Preferably, it is configured. Further, considering the coefficient of linear expansion from the viewpoint of suppressing cracking due to the difference in expansion, it is preferable that the material is the same as the outer coating of the conductor of the stator winding 51. That is, a silicone resin whose linear expansion coefficient is generally twice or more that of another resin is desirably excluded. In addition, in an electric product such as an electric vehicle that does not have an engine using combustion, a PPO resin, a phenol resin, and an FRP resin having a heat resistance of about 180 ° C. are also candidates. This is not the case in a field where the ambient temperature of the rotating electric machine can be regarded as being lower than 100 ° C.
　回転電機１０のトルクは磁束の大きさに比例する。ここで、固定子コアがティースを有している場合には、固定子での最大磁束量がティースでの飽和磁束密度に依存して制限されるが、固定子コアがティースを有していない場合には、固定子での最大磁束量が制限されない。そのため、固定子巻線５１に対する通電電流を増加して回転電機１０のトルク増加を図る上で、有利な構成となっている。 ト ル ク The torque of the rotating electric machine 10 is proportional to the magnitude of the magnetic flux. Here, when the stator core has teeth, the maximum magnetic flux amount at the stator is limited depending on the saturation magnetic flux density at the teeth, but the stator core does not have teeth. In such a case, the maximum magnetic flux amount at the stator is not limited. Therefore, the configuration is advantageous in increasing the current flowing through the stator winding 51 to increase the torque of the rotating electric machine 10.
　本実施形態では、固定子５０においてティースを無くした構造（スロットレス構造）を用いたことにより、固定子５０のインダクタンスが低減される。具体的には、複数のティースにより仕切られた各スロットに導線が収容される一般的な回転電機の固定子ではインダクタンスが例えば１ｍＨ前後であるのに対し、本実施形態の固定子５０ではインダクタンスが５～６０μＨ程度に低減される。本実施形態では、アウタロータ構造の回転電機１０としつつも、固定子５０のインダクタンス低減により機械的時定数Ｔｍを下げることが可能となっている。つまり、高トルク化を図りつつ、機械的時定数Ｔｍの低減が可能となっている。なお、イナーシャをＪ、インダクタンスをＬ、トルク定数をＫｔ、逆起電力定数をＫｅとすると、機械的時定数Ｔｍは、次式により算出される。
Ｔｍ＝（Ｊ×Ｌ）／（Ｋｔ×Ｋｅ）
この場合、インダクタンスＬの低減により機械的時定数Ｔｍが低減されることが確認できる。 In the present embodiment, the use of a structure (slotless structure) without teeth in the stator 50 reduces the inductance of the stator 50. Specifically, the inductance of the stator of a general rotary electric machine in which a conductor is accommodated in each slot partitioned by a plurality of teeth is, for example, about 1 mH, whereas the inductance of the stator 50 of the present embodiment is about 1 mH. 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 rotating electric machine 10 having the outer rotor structure. That is, the mechanical time constant Tm can be reduced while increasing the torque. When 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 reducing the inductance L.
　固定子コア５２の径方向外側における各導線群８１は、断面が扁平矩形状をなす複数の導線８２が固定子コア５２の径方向に並べて配置されて構成されている。各導線８２は、横断面において「径方向寸法＜周方向寸法」となる向きで配置されている。これにより、各導線群８１において径方向の薄肉化が図られている。また、径方向の薄肉化を図るとともに、導体領域が、ティースが従来あった領域まで平らに延び、扁平導線領域構造となっている。これにより、薄肉化により断面積が小さくなることで懸念される導線の発熱量の増加を、周方向に扁平化して導体の断面積を稼ぐことで抑えている。なお、複数の導線を周方向に並べ、かつそれらを並列結線とする構成であっても、導体被膜分の導体断面積低下は起こるものの、同じ理屈に依る効果が得られる。なお、以下において、導線群８１のそれぞれ、および導線８２のそれぞれを、伝導部材（conductive member）とも言う。 各 Each conductor group 81 radially outside the stator core 52 is configured by arranging a plurality of conductors 82 having a flat rectangular cross section in a radial direction of the stator core 52. Each conductive wire 82 is arranged in a direction that satisfies “radial dimension <circumferential dimension” in a cross section. Thus, the thickness of each conductive wire group 81 in the radial direction is reduced. In addition, the thickness of the conductor region is reduced in the radial direction, and the conductor region extends flat to the region where the teeth are conventionally formed, so that the conductor region has a flat conductor region structure. As a result, an increase in the calorific value of the conductor, which may be caused by a reduction in 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. Note that, even in a configuration in which a plurality of conductors are arranged in the circumferential direction and are connected in parallel, an effect based on the same theory can be obtained, although the conductor cross-sectional area is reduced by the conductor coating. In the following, each of the conductive wire group 81 and each of the conductive wires 82 are also referred to as a conductive member.
　スロットがないことから、本実施形態における固定子巻線５１では、その周方向の一周における固定子巻線５１が占める導体領域を、固定子巻線５１が存在しない導体非占有領域より大きく設計することができる。なお、従来の車両用回転電機は、固定子巻線の周方向の一周における導体領域／導体非占有領域は１以下であるのが当然であった。一方、本実施形態では、導体領域が導体非占有領域と同等又は導体領域が導体非占有領域よりも大きくなるようにして、各導線群８１が設けられている。ここで、図１０に示すように、周方向において導線８２（つまり、後述する直線部８３）が配置された導線領域をＷＡ、隣り合う導線８２の間となる導線間領域をＷＢとすると、導線領域ＷＡは、導線間領域ＷＢより周方向において大きいものとなっている。 Since there is no slot, in the stator winding 51 of 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 rotating electrical machine for a vehicle, it is natural that the conductor region / conductor non-occupied region in one circumferential direction of the stator winding is 1 or less. On the other hand, in the present embodiment, each conductor group 81 is provided such that the conductor region is equal to the conductor non-occupied region or the conductor region is larger than the conductor non-occupied region. Here, as shown in FIG. 10, assuming that a conductor region in which the conductor 82 (that is, a straight line portion 83 described later) is disposed in the circumferential direction is WA and a region between conductors between adjacent conductors 82 is WB, The area WA is larger in the circumferential direction than the inter-wire area WB.
　固定子巻線５１における導線群８１の構成として、その導線群８１の径方向の厚さ寸法は、１磁極内における１相分の周方向の幅寸法よりも小さいものとなっている。すなわち、導線群８１が径方向に２層の導線８２よりなり、かつ１磁極内に１相につき周方向に２つの導線群８１が設けられる構成では、各導線８２の径方向の厚さ寸法をＴｃ、各導線８２の周方向の幅寸法をＷｃとした場合に、「Ｔｃ×２＜Ｗｃ×２」となるように構成されている。なお、他の構成として、導線群８１が２層の導線８２よりなり、かつ１磁極内に１相につき周方向に１つの導線群８１が設けられる構成では、「Ｔｃ×２＜Ｗｃ」の関係となるように構成されるとよい。要するに、固定子巻線５１において周方向に所定間隔で配置される導線部（導線群８１）は、その径方向の厚さ寸法が、１磁極内における１相分の周方向の幅寸法よりも小さいものとなっている。 構成 As the configuration of the conductor group 81 in the stator winding 51, the radial thickness of the conductor group 81 is smaller than the circumferential width of one phase in one magnetic pole. That is, in a configuration in which the conductor group 81 is formed of two layers of conductors 82 in the radial direction and two conductor groups 81 are provided in the circumferential direction for one phase in one magnetic pole, the radial thickness of each conductor 82 is reduced. Tc, when the width of the conductor 82 in the circumferential direction is Wc, the configuration is such that “Tc × 2 <Wc × 2”. As another configuration, in a configuration in which the conductor group 81 is formed of two layers of conductors 82 and one conductor group 81 is provided in one magnetic pole in the circumferential direction for one phase, the relation of “Tc × 2 <Wc” is satisfied. It is good to be constituted so that it may become. In short, the conductor portions (conductor group 81) arranged at predetermined intervals in the circumferential direction in the stator winding 51 have a radial thickness that is larger than a circumferential width of one phase in one magnetic pole. It is small.
　言い換えると、１本１本の各導線８２は、径方向の厚さ寸法Ｔｃが周方向の幅寸法Ｗｃよりも小さいとよい。またさらに、径方向に２層の導線８２よりなる導線群８１の径方向の厚さ寸法（２Ｔｃ）、すなわち導線群８１の径方向の厚さ寸法（２Ｔｃ）が周方向の幅寸法Ｗｃよりも小さいとよい。 In other words, it is preferable that each conductor 82 has a thickness Tc in the radial direction smaller than a width Wc in the circumferential direction. Furthermore, the thickness (2Tc) in the radial direction of the wire group 81 composed of two layers of wires 82 in the radial direction, that is, the radial thickness (2Tc) of the wire group 81 is larger than the width Wc in the circumferential direction. Good to be small.
　回転電機１０のトルクは、導線群８１の固定子コア５２の径方向の厚さに略反比例する。この点、固定子コア５２の径方向外側において導線群８１の厚さを薄くしたことにより、回転電機１０のトルク増加を図る上で有利な構成となっている。その理由としては、回転子４０の磁石ユニット４２から固定子コア５２までの距離（つまり鉄の無い部分の距離）を小さくして磁気抵抗を下げることができるためである。これによれば、永久磁石による固定子コア５２の鎖交磁束を大きくすることができ、トルクを増強することができる。 ト ル ク The torque of the rotating electric machine 10 is substantially inversely proportional to the radial thickness of the stator core 52 of the conductor group 81. In this regard, by reducing the thickness of the conductive wire group 81 on the radially outer side of the stator core 52, the configuration is advantageous in increasing the torque of the rotating electric machine 10. The reason is that 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) can be reduced to reduce the magnetic resistance. According to this, the flux linkage of the stator core 52 by the permanent magnet can be increased, and the torque can be increased.
　また、導線群８１の厚さを薄くしたことにより、導線群８１から磁束が漏れても固定子コア５２に回収されやすくなり、磁束がトルク向上のために有効に利用されずに外部に漏れることを抑制することができる。つまり、磁束漏れにより磁力が低下することを抑制でき、永久磁石による固定子コア５２の鎖交磁束を大きくして、トルクを増強することができる。 In addition, since the thickness of the conductor group 81 is reduced, even if the magnetic flux leaks from the conductor 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 a decrease in magnetic force due to magnetic flux leakage, to increase the linkage magnetic flux of the stator core 52 by the permanent magnet, and to increase the torque.
　導線８２(conductor)は、導体(conductor body)８２ａの表面が絶縁被膜８２ｂにより被覆された被覆導線よりなり、径方向に互いに重なる導線８２同士の間、及び導線８２と固定子コア５２との間においてそれぞれ絶縁性が確保されている。この絶縁被膜８２ｂは、後述する素線８６が自己融着被覆線であるならその被膜、又は、素線８６の被膜とは別に重ねられた絶縁部材で構成されている。なお、導線８２により構成される各相巻線は、接続のための露出部分を除き、絶縁被膜８２ｂによる絶縁性が保持されるものとなっている。露出部分としては、例えば、入出力端子部や、星形結線とする場合の中性点部分である。導線群８１では、樹脂固着や自己融着被覆線を用いて、径方向に隣り合う各導線８２が相互に固着されている。これにより、導線８２同士が擦れ合うことによる絶縁破壊や、振動、音が抑制される。 The conductor 82 (conductor) is made of a covered conductor in which the surface of a conductor (conductor body) 82a is covered with an insulating coating 82b, and between the conductors 82 that overlap each other in the radial direction, and between the conductor 82 and the stator core 52. In each case, insulation is ensured. The insulating coating 82b is formed of an insulating member that is laminated separately from the coating of the element wire 86 described later if the element wire 86 is a self-fused coated wire or the coating of the element wire 86. In addition, each of the phase windings constituted by the conductive wires 82 has an insulating property by the insulating coating 82b except for an exposed portion for connection. The exposed portion is, for example, an input / output terminal portion or a neutral point portion in the case of a star connection. In the conductive wire group 81, the conductive wires 82 adjacent to each other in the radial direction are fixed to each other by using a resin fixing or a self-sealing coated wire. This suppresses dielectric breakdown, vibration, and sound due to the rubbing of the conductive wires 82.
　本実施形態では、導体８２ａが複数の素線(wire)８６の集合体として構成されている。具体的には、図１３に示すように、導体８２ａは、複数の素線８６を撚ることで撚糸状に形成されている。また、図１４に示すように、素線８６は、細い繊維状の導電材８７を束ねた複合体として構成されている。例えば、素線８６はＣＮＴ（カーボンナノチューブ）繊維の複合体であり、ＣＮＴ繊維として、炭素の少なくとも一部をホウ素で置換したホウ素含有微細繊維を含む繊維が用いられている。炭素系微細繊維としては、ＣＮＴ繊維以外に、気相成長法炭素繊維（ＶＧＣＦ）等を用いることができるが、ＣＮＴ繊維を用いることが好ましい。なお、素線８６の表面は、エナメルなどの高分子絶縁層で覆われている。また、素線８６の表面は、ポリイミドの被膜やアミドイミドの被膜からなる、いわゆるエナメル被膜で覆われていることが好ましい。 In the present embodiment, the conductor 82a is configured as an aggregate of a plurality of wires 86. Specifically, as shown in FIG. 13, the conductor 82a is formed in a twisted yarn shape by twisting a plurality of strands 86. Further, as shown in FIG. 14, the strand 86 is configured as a composite in which thin fibrous conductive materials 87 are bundled. 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 replaced by boron are used. As the carbon-based fine fiber, a vapor grown carbon fiber (VGCF) or the like can be used in addition to the CNT fiber, but it is preferable to use the CNT fiber. The surface of the wire 86 is covered with a polymer insulating layer such as enamel. The surface of the wire 86 is preferably covered with a so-called enamel coating made of a polyimide coating or an amide imide coating.
　導線８２は、固定子巻線５１においてｎ相の巻線を構成する。そして導線８２（すなわち、導体８２ａ）の各々の素線８６は、互いに接触状態で隣接している。導線８２は、巻線導体が、複数の素線８６が撚られて形成される部位を、相内の１か所以上に持つとともに、撚られた素線８６間の抵抗値が素線８６そのものの抵抗値よりも大きい素線集合体となっている。言い換えると、隣接する各２つの素線８６はその隣接する方向において第１電気抵抗率を有し、素線８６の各々はその長さ方向において第２電気抵抗率を有する場合、第１電気抵抗率は第２電気抵抗率より大きい値になっている。なお、導線８２が複数の素線８６により形成されるとともに、第１電気抵抗率が極めて高い絶縁部材により複数の素線８６を覆う素線集合体となっていても良い。また、導線８２の導体８２ａは、撚り合わされた複数の素線８６により構成されている。 The conductor 82 forms an n-phase winding in the stator winding 51. The strands 86 of the conductor 82 (that is, the conductor 82a) are adjacent to each other in a contact state. The conducting wire 82 has, at one or more locations in the phase, a portion where the winding conductor is formed by twisting the plurality of strands 86, and the resistance between the twisted strands 86 is the strand 86 itself. The wire aggregate is larger than the resistance value. In other words, each two adjacent wires 86 have a first electrical resistivity in the adjacent direction, and if each of the wires 86 has a second electrical resistivity in its length direction, the first electrical resistivity The ratio has a value larger than the second electric resistivity. In addition, the conductor 82 may be formed by a plurality of strands 86, and may be a strand aggregate that covers the plurality of strands 86 with an insulating member having an extremely high first electrical resistivity. The conductor 82a of the conductor 82 is constituted by a plurality of twisted strands 86.
　上記の導体８２ａでは、複数の素線８６が撚り合わされて構成されているため、各素線８６での渦電流の発生が抑えられ、導体８２ａにおける渦電流の低減を図ることができる。また、各素線８６が捻られていることで、１本の素線８６において磁界の印加方向が互いに逆になる部位が生じて逆起電圧が相殺される。そのため、やはり渦電流の低減を図ることができる。特に、素線８６を繊維状の導電材８７により構成することで、細線化することと捻り回数を格段に増やすこととが可能になり、渦電流をより好適に低減することができる。 た め Since the plurality of strands 86 are twisted in the conductor 82a, generation of eddy current in each strand 86 is suppressed, and eddy current in the conductor 82a can be reduced. Further, since the strands 86 are twisted, portions where directions of applying the magnetic field are opposite to each other are generated in one strand 86, and the back electromotive voltage is canceled. Therefore, the eddy current can be reduced. In particular, by forming the wire 86 from the fibrous conductive material 87, it is possible to make the wire thinner and to remarkably increase the number of twists, so that the eddy current can be more suitably reduced.
　なお、ここでいう素線８６同士の絶縁方法は、前述の高分子絶縁膜に限定されず、接触抵抗を利用し撚られた素線８６間で電流を流れにくくする方法であってもよい。すなわち撚られた素線８６間の抵抗値が、素線８６そのものの抵抗値よりも大きい関係になっていれば、抵抗値の差に起因して発生する電位差により、上記効果を得ることができる。たとえば、素線８６を作成する製造設備と、回転電機１０の固定子５０（電機子）を作成する製造設備とを別の非連続の設備として用いることで、移動時間や作業間隔などから素線８６が酸化し、接触抵抗を増やすことができ、好適である。 The method of insulating the wires 86 is not limited to the above-described polymer insulating film, but may be a method of making the current less likely to flow between the twisted wires 86 using contact resistance. That is, if the resistance value between the twisted strands 86 is larger than the resistance value of the strand 86 itself, the above effect can be obtained by the potential difference generated due to the difference in the resistance value. . For example, by using the manufacturing facility for producing the strand 86 and the production facility for producing the stator 50 (armature) of the rotary electric machine 10 as separate non-continuous facilities, the travel time, the working interval, and the like make it possible to use the strand. 86 is oxidized and the contact resistance can be increased, which is preferable.
　上述のとおり導線８２は、断面が扁平矩形状をなし、径方向に複数並べて配置されるものとなっており、例えば融着層と絶縁層とを備えた自己融着被覆線で被覆された複数の素線８６を撚った状態で集合させ、その融着層同士を融着させることで形状を維持している。なお、融着層を備えない素線や自己融着被覆線の素線を撚った状態で合成樹脂等により所望の形状に固めて成形してもよい。導線８２における絶縁被膜８２ｂの厚さを例えば８０μｍ～１００μｍとし、一般に使用される導線の被膜厚さ（５～４０μｍ）よりも厚肉とした場合、導線８２と固定子コア５２との間に絶縁紙等を介在させることをしなくても、これら両者の間の絶縁性が確保することができる。 As described above, the conducting wire 82 has a flat rectangular shape in cross section, and is arranged in a plurality in the radial direction. For example, the conducting wire 82 is covered with a self-sealing covered wire including a fusion layer and an insulating layer. Are assembled in a twisted state, and the fusion layers are fused together to maintain the shape. In addition, you may shape | mold in the state which twisted the strand which does not have a fusion | melting layer, or the strand of a self-fusion | bonding coating wire with a synthetic resin etc. to a desired shape. If the thickness of the insulating film 82b on the conductor 82 is, for example, 80 μm to 100 μm, and is thicker than the thickness of a commonly used conductor (5 to 40 μm), the insulation between the conductor 82 and the stator core 52 is formed. Even without paper or the like, the insulation between the two can be ensured.
　また、絶縁被膜８２ｂは、素線８６の絶縁層よりも高い絶縁性能を有し、相間を絶縁することができるように構成されていることが望ましい。例えば、素線８６の高分子絶縁層の厚さを例えば５μｍ程度にした場合、導線８２の絶縁被膜８２ｂの厚さを８０μｍ～１００μｍ程度にして、相間の絶縁を好適に実施できるようにすることが望ましい。 絶 縁 Further, it is desirable that the insulating coating 82b has a higher insulating performance than the insulating layer of the strand 86, and is configured to be able 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 82b of the conducting wire 82 is about 80 to 100 μm so that the interphase insulation can be suitably performed. Is desirable.
　また、導線８２は、複数の素線８６が撚られることなく束ねられている構成であってもよい。つまり、導線８２は、その全長において複数の素線８６が撚られている構成、全長のうち一部で複数の素線８６が撚られている構成、全長において複数の素線８６が撚られることなく束ねられている構成のいずれかであればよい。まとめると、導線部を構成する各導線８２は、複数の素線８６が束ねられているとともに、束ねられた素線間の抵抗値が素線８６そのものの抵抗値よりも大きい素線集合体となっている。 The conductor 82 may have a configuration in which a plurality of strands 86 are bundled without being twisted. In other words, 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 a part of the entire length, and a plurality of strands 86 in the entire length. Instead, any one of the bundled configurations may be used. In summary, each of the conductors 82 constituting the conductor portion includes a plurality of strands 86 bundled together, and a wire aggregate in which the resistance value between the bundled strands is larger than the resistance value of the strand 86 itself. Has become.
　各導線８２は、固定子巻線５１の周方向に所定の配置パターンで配置されるように折り曲げ形成されており、これにより、固定子巻線５１として相ごとの相巻線が形成されている。図１２に示すように、固定子巻線５１では、各導線８２のうち軸方向に直線状に延びる直線部８３によりコイルサイド部５３が形成され、軸方向においてコイルサイド部５３よりも両外側に突出するターン部８４によりコイルエンド５４，５５が形成されている。各導線８２は、直線部８３とターン部８４とが交互に繰り返されることにより、波巻状の一連の導線として構成されている。直線部８３は、磁石ユニット４２に対して径方向に対向する位置に配置されており、磁石ユニット４２の軸方向外側となる位置において所定間隔を隔てて配置される同相の直線部８３同士が、ターン部８４により互いに接続されている。なお、直線部８３が「磁石対向部」に相当する。 Each conductive 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, a coil side portion 53 is formed by a straight portion 83 extending linearly in the axial direction of each of the conductors 82, and is located on both outer sides of the coil side portion 53 in the axial direction. The coil ends 54 and 55 are formed by the projecting turn portions 84. Each conductor 82 is configured as a series of corrugated conductors by alternately repeating a straight portion 83 and a turn portion 84. The linear portions 83 are disposed at positions radially opposed to the magnet unit 42, and the linear portions 83 of the same phase, which are arranged at predetermined intervals at a position outside the magnet unit 42 in the axial direction, They are connected to each other by a turn part 84. Note that the straight portion 83 corresponds to a “magnet facing portion”.
　本実施形態では、固定子巻線５１が分布巻きにより円環状に巻回形成されている。この場合、コイルサイド部５３では、相ごとに、磁石ユニット４２の１極対に対応する間隔で周方向に直線部８３が配置され、コイルエンド５４，５５では、相ごとの各直線部８３が、略Ｖ字状に形成されたターン部８４により互いに接続されている。１極対に対応して対となる各直線部８３は、それぞれ電流の向きが互いに逆になるものとなっている。また、一方のコイルエンド５４と他方のコイルエンド５５とでは、ターン部８４により接続される一対の直線部８３の組み合わせがそれぞれ相違しており、そのコイルエンド５４，５５での接続が周方向に繰り返されることにより、固定子巻線５１が略円筒状に形成されている。 In the present embodiment, the stator winding 51 is formed in an annular shape by distributed winding. In this case, in the coil side portion 53, linear portions 83 are arranged in the circumferential direction at intervals corresponding to one pole pair of the magnet unit 42 for each phase, and in the coil ends 54 and 55, the linear portions 83 for each phase are arranged. , Are connected to each other by a turn portion 84 formed in a substantially V shape. The straight portions 83 forming a pair corresponding to one pole pair have current directions opposite to each other. Also, the combination of the pair of linear portions 83 connected by the turn portion 84 is different between the one coil end 54 and the other coil end 55, and the connection at the coil ends 54, 55 is made in the circumferential direction. By repeating, the stator winding 51 is formed in a substantially cylindrical shape.
　より具体的には、固定子巻線５１は、各相２対ずつの導線８２を用いて相ごとの巻線を構成しており、固定子巻線５１のうち一方の３相巻線（Ｕ相、Ｖ相、Ｗ相）と他方の３相巻線（Ｘ相、Ｙ相、Ｚ相）とが径方向内外の２層に設けられるものとなっている。この場合、固定子巻線５１の相数をＳ（実施例の場合は６）、導線８２の一相あたりの数をｍとすれば、極対ごとに２×Ｓ×ｍ＝２Ｓｍ個の導線８２が形成されることになる。本実施形態では、相数Ｓが６、数ｍが４であり、８極対（１６極）の回転電機であることから、６×４×８＝１９２の導線８２が固定子コア５２の周方向に配置されている。 More specifically, the stator winding 51 constitutes a winding for each phase using two pairs of conducting wires 82 for each phase, and one of the three windings (U Phase, V phase, W phase) and the other three-phase winding (X phase, Y phase, Z phase) are provided in two layers inside and outside in the radial direction. In this case, if the number of phases of the stator winding 51 is S (six in the embodiment) and the number of conductors 82 per phase is m, 2 × S × m = 2Sm conductors for each pole pair 82 will be formed. In the present embodiment, since the number of phases S is 6, the number m is 4, and the rotating electric machine has 8 pole pairs (16 poles), 6 × 4 × 8 = 192 conductors 82 are formed around the stator core 52. It is arranged in the direction.
　図１２に示す固定子巻線５１では、コイルサイド部５３において、径方向に隣接する２層で直線部８３が重ねて配置されるとともに、コイルエンド５４，５５において、径方向に重なる各直線部８３から、互いに周方向逆となる向きでターン部８４が周方向に延びる構成となっている。つまり、径方向に隣り合う各導線８２では、固定子巻線５１の端部を除き、ターン部８４の向きが互いに逆となっている。 In the stator winding 51 shown in FIG. 12, in the coil side portion 53, the linear portions 83 are arranged so as to overlap in two layers adjacent in the radial direction, and at the coil ends 54 and 55, the linear portions 83 which overlap in the radial direction are arranged. From 83, the turn portion 84 is configured to extend in the circumferential direction in directions opposite to each other in the circumferential direction. In other words, in each of the radially adjacent conductors 82, the directions of the turn portions 84 are opposite to each other except for the end of the stator winding 51.
　ここで、固定子巻線５１における導線８２の巻回構造を具体的に説明する。本実施形態では、波巻にて形成された複数の導線８２を、径方向に隣接する複数層（例えば２層）に重ねて設ける構成としている。図１５（ａ）、図１５（ｂ）は、ｎ層目における各導線８２の形態を示す図であり、図１５（ａ）には、固定子巻線５１の側方から見た導線８２の形状を示し、図１５（ｂ）には、固定子巻線５１の軸方向一側から見た導線８２の形状を示している。なお、図１５（ａ）、図１５（ｂ）では、導線群８１が配置される位置をそれぞれＤ１，Ｄ２，Ｄ３，…と示している。また、説明の便宜上、３本の導線８２のみを示しており、それを第１導線８２＿Ａ、第２導線８２＿Ｂ、第３導線８２＿Ｃとしている。 Here, the winding structure of the conductor wire 82 in the stator winding 51 will be specifically described. In the present embodiment, a plurality of conducting wires 82 formed by a wave winding are provided so as to overlap with a plurality of layers (for example, two layers) adjacent in the radial direction. FIGS. 15A and 15B are diagrams showing the form of each conductor 82 in the n-th layer. FIG. 15A shows the shape of each conductor 82 viewed from the side of the stator winding 51. FIG. 15B shows the shape of the conductive wire 82 as viewed from one axial side of the stator winding 51. 15 (a) and FIG. 15 (b), the positions where the conductor groups 81 are arranged are indicated as D1, D2, D3,. Also, for convenience of explanation, only three conductive wires 82 are shown, which are a first conductive wire 82_A, a second conductive wire 82_B, and a third conductive wire 82_C.
　各導線８２＿Ａ～８２＿Ｃでは、直線部８３が、いずれもｎ層目の位置、すなわち径方向において同じ位置に配置され、周方向に６位置（３×ｍ対分）ずつ離れた直線部８３同士がターン部８４により互いに接続されている。換言すると、各導線８２＿Ａ～８２＿Ｃでは、いずれも回転子４０の軸心を中心とする同一の円上において、固定子巻線５１の周方向に隣接して並ぶ７個の直線部８３の両端の二つが一つのターン部８４により互いに接続されている。例えば第１導線８２＿Ａでは、一対の直線部８３がＤ１，Ｄ７にそれぞれ配置され、その一対の直線部８３同士が、逆Ｖ字状のターン部８４により接続されている。また、他の導線８２＿Ｂ，８２＿Ｃは、同じｎ層目において周方向の位置を１つずつずらしてそれぞれ配置されている。この場合、各導線８２＿Ａ～８２＿Ｃは、いずれも同じ層に配置されるため、ターン部８４が互いに干渉することが考えられる。そのため本実施形態では、各導線８２＿Ａ～８２＿Ｃのターン部８４に、その一部を径方向にオフセットした干渉回避部を形成することとしている。 In each of the conductors 82_A to 82_C, the straight portions 83 are arranged at the position of the nth layer, that is, at the same position in the radial direction, and the straight portions 83 separated from each other by six positions (3 × m pairs) in the circumferential direction. They are connected to each other by a turn part 84. In other words, in each of the conductors 82_A to 82_C, on both ends of the seven linear portions 83 adjacent to each other in the circumferential direction of the stator winding 51 on the same circle centered on the axis of the rotor 40. The two are connected to each other by one turn 84. For example, in the first conductive wire 82 </ b> _A, a pair of straight portions 83 are arranged at D <b> 1 and D <b> 7, respectively, and the pair of straight portions 83 are connected by an inverted V-shaped turn portion 84. The other conductors 82_B and 82_C are arranged in the same n-th layer with their circumferential positions shifted one by one. In this case, since each of the conductive wires 82_A to 82_C is disposed in the same layer, the turn portions 84 may interfere with each other. For this reason, in the present embodiment, an interference avoiding portion in which a part thereof is radially offset is formed in the turn portion 84 of each of the conductive wires 82_A to 82_C.
　具体的には、各導線８２＿Ａ～８２＿Ｃのターン部８４は、同一の円（第１の円）上で周方向に延びる部分である１つの傾斜部８４ａと、傾斜部８４ａからその同一の円よりも径方向内側（図１５（ｂ）において上側）にシフトし、別の円（第２の円）に達する頂部８４ｂ、第２の円上で周方向に延びる傾斜部８４ｃ及び第１の円から第２の円に戻る戻り部８４ｄとを有している。頂部８４ｂ、傾斜部８４ｃ及び戻り部８４ｄが干渉回避部に相当する。なお、傾斜部８４ｃは、傾斜部８４ａに対して径方向外側にシフトする構成であってもよい。 Specifically, the turn portion 84 of each of the conductors 82_A to 82_C is formed by a single inclined portion 84a which is a portion extending in the circumferential direction on the same circle (first circle), and the same circle from the inclined portion 84a. Also shifts radially inward (upward in FIG. 15 (b)) to reach another circle (second circle), the top portion 84b, the inclined portion 84c extending in the circumferential direction on the second circle, and the first circle. And a return portion 84d that returns to the second circle. The top portion 84b, the inclined portion 84c, and the return portion 84d correspond to an interference avoiding portion. Note that the inclined portion 84c may be configured to shift radially outward with respect to the inclined portion 84a.
　つまり、各導線８２＿Ａ～８２＿Ｃのターン部８４は、周方向の中央位置である頂部８４ｂを挟んでその両側に、一方側の傾斜部８４ａと他方側の傾斜部８４ｃとを有しており、それら各傾斜部８４ａ，８４ｃの径方向の位置（図１５（ａ）では紙面前後方向の位置、図１５（ｂ）では上下方向の位置）が互いに相違するものとなっている。例えば第１導線８２＿Ａのターン部８４は、ｎ層のＤ１位置を始点位置として周方向に沿って延び、周方向の中央位置である頂部８４ｂで径方向（例えば径方向内側）に曲がった後、周方向に再度曲がることで、再び周方向に沿って延び、さらに戻り部８４ｄで再び径方向（例えば径方向外側）に曲がることで、終点位置であるｎ層のＤ７位置に達する構成となっている。 That is, the turn portion 84 of each of the conductors 82_A to 82_C has a slope portion 84a on one side and a slope portion 84c on the other side on both sides of the top portion 84b, which is a central position in the circumferential direction. The radial positions of the inclined portions 84a and 84c (positions in the front-rear direction in FIG. 15A, positions in the up-down direction in FIG. 15B) are different from each other. For example, the turn portion 84 of the first conductive wire 82 </ b> _A extends in the circumferential direction from the position D <b> 1 of the n-layer as a starting point, and bends in the radial direction (for example, radially inward) at the top portion 84 b which is the central position in the circumferential direction. By turning again in the circumferential direction, it extends again in the circumferential direction, and further turns again in the radial direction (for example, radially outward) at the return portion 84d, thereby reaching the D7 position of the n-layer, which is the end point position. I have.
　上記構成によれば、導線８２＿Ａ～８２＿Ｃでは、一方の各傾斜部８４ａが、上から第１導線８２＿Ａ→第２導線８２＿Ｂ→第３導線８２＿Ｃの順に上下に並ぶとともに、頂部８４ｂで各導線８２＿Ａ～８２＿Ｃの上下が入れ替わり、他方の各傾斜部８４ｃが、上から第３導線８２＿Ｃ→第２導線８２＿Ｂ→第１導線８２＿Ａの順に上下に並ぶ構成となっている。そのため、各導線８２＿Ａ～８２＿Ｃが互いに干渉することなく周方向に配置できるようになっている。 According to the above configuration, in each of the conductors 82_A to 82_C, one of the inclined portions 84a is vertically arranged in order from the top in the order of the first conductor 82_A → the second conductor 82_B → the third conductor 82_C, and each of the conductors 82_A ～ 82_C is turned upside down, and the other inclined portions 84c are arranged vertically from the top in the order of the third conductor 82_C → the second conductor 82_B → the first conductor 82_A. Therefore, the conductors 82_A to 82_C can be arranged in the circumferential direction without interfering with each other.
　ここで、複数の導線８２を径方向に重ねて導線群８１とする構成において、複数層の各直線部８３のうち径方向内側の直線部８３に接続されたターン部８４と、径方向外側の直線部８３に接続されたターン部８４とが、それら各直線部８３同士よりも径方向に離して配置されているとよい。また、ターン部８４の端部、すなわち直線部８３との境界部付近で、複数層の導線８２が径方向の同じ側に曲げられる場合に、その隣り合う層の導線８２同士の干渉により絶縁性が損なわれることが生じないようにするとよい。 Here, in a configuration in which a plurality of conductive wires 82 are superposed in the radial direction to form a conductive wire group 81, a turn portion 84 connected to the radially inner straight portion 83 of the plurality of linear portions 83 and a radially outer straight portion 83 are formed. It is preferable that the turn portions 84 connected to the straight portions 83 are arranged further apart from each other in the radial direction than the straight portions 83. Further, when a plurality of layers of the conductive wires 82 are bent to the same side in the radial direction near the end of the turn portion 84, that is, near the boundary with the linear portion 83, the insulation between the conductive wires 82 of the adjacent layers is caused by the interference. Should not be impaired.
　例えば図１５（ａ）、図１５（ｂ）のＤ７～Ｄ９では、径方向に重なる各導線８２が、ターン部８４の戻り部８４ｄでそれぞれ径方向に曲げられる。この場合、図１６に示すように、ｎ層目の導線８２とｎ＋１層目の導線８２とで、曲がり部の曲率半径を相違させるとよい。具体的には、径方向内側（ｎ層目）の導線８２の曲率半径Ｒ１を、径方向外側（ｎ＋１層目）の導線８２の曲率半径Ｒ２よりも小さくする。 For example, in D7 to D9 of FIGS. 15A and 15B, the conductive wires 82 overlapping in the radial direction are each bent in the radial direction at the return portion 84d of the turn portion 84. In this case, as shown in FIG. 16, the radius of curvature of the bent portion may be different between the conductor 82 of the n-th layer and the conductor 82 of the (n + 1) -th layer. Specifically, the radius of curvature R1 of the conductive wire 82 on the radially inner side (nth layer) is made smaller than the radius of curvature R2 of the conductive wire 82 on the radially outer side (n + 1th layer).
　また、ｎ層目の導線８２とｎ＋１層目の導線８２とで、径方向のシフト量を相違させるとよい。具体的には、径方向内側（ｎ層目）の導線８２のシフト量Ｓ１を、径方向外側（ｎ＋１層目）の導線８２のシフト量Ｓ２よりも大きくする。 シ フ ト Further, it is preferable that the amount of shift in the radial direction be 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) conductive wire 82 is made larger than the shift amount S2 of the radially outer (n + 1-th layer) conductive wire 82.
　上記構成により、径方向に重なる各導線８２が同じ向きに曲げられる場合であっても、各導線８２の相互干渉を好適に回避することができる。これにより、良好な絶縁性が得られることとなる。 According to the above configuration, even when the conductive wires 82 overlapping in the radial direction are bent in the same direction, mutual interference between the conductive wires 82 can be preferably avoided. Thereby, good insulating properties are obtained.
　次に、回転子４０における磁石ユニット４２の構造について説明する。本実施形態では、磁石ユニット４２が永久磁石からなり、残留磁束密度Ｂｒ＝１．０［Ｔ］、固有保磁力Ｈｃｊ＝４００［ｋＡ／ｍ］以上のものを想定している。要は、本実施形態で用いる永久磁石は、粒状の磁性材料を焼結して成型固化した焼結磁石であり、Ｊ－Ｈ曲線上の固有保磁力Ｈｃｊは４００［ｋＡ／ｍ］以上であり、かつ残留磁束密度Ｂｒは１．０［Ｔ］以上である。５０００～１００００［ＡＴ］が相間励磁により掛かる場合、１極対、すなわちＮ極とＳ極の磁気的長さ、言い換えれば、Ｎ極とＳ極間の磁束が流れる経路のうち、磁石内を通る長さが２５［ｍｍ］の永久磁石を使えば、Ｈｃｊ＝１００００［Ａ］となり、減磁をしないことが伺える。 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 made of a permanent magnet and has a residual magnetic flux density Br = 1.0 [T] and a specific coercive force Hcj = 400 [kA / m] or more. In short, the permanent magnet used in this embodiment is a sintered magnet obtained by sintering and solidifying a granular magnetic material, and has a specific coercive force Hcj on the JH curve of 400 [kA / m] or more. And the residual magnetic flux density Br is 1.0 [T] or more. When 5,000 to 10,000 [AT] is applied by the inter-phase excitation, the magnetic length of one pole pair, that is, the north pole and the south pole, in other words, the magnetic flux between the north pole and the south pole flows through the magnet. If a permanent magnet having a length of 25 [mm] is used, Hcj = 10000 [A], which indicates that demagnetization does not occur.
　また換言すれば、磁石ユニット４２は、飽和磁束密度Ｊｓが１．２［Ｔ］以上で、かつ結晶粒径が１０［μｍ］以下であり、配向率をαとした場合にＪｓ×αが１．０［Ｔ］以上であるものとなっている。 In other words, the magnet unit 42 has a saturation magnetic flux density Js of 1.2 [T] or more, a crystal grain size of 10 [μm] or less, and Js × α is 1 when the orientation ratio is α. 0.0 [T] or more.
　以下に磁石ユニット４２について補足する。磁石ユニット４２（磁石）は、２．１５［Ｔ］≧Ｊｓ≧１．２［Ｔ］であることが特徴である。言い換えれば、磁石ユニット４２に用いられる磁石として、NdFe11TiN、Nd2Fe14B、Sm2Fe17N3、L10型結晶を有するFeNi磁石などが挙げられる。なお、通例サマコバと言われるSmCo5や、FePt、Dy2Fe14B、CoPtなどの構成は使うことができない。注意としては、同型の化合物、例えばDy2Fe14BとNd2Fe14Bのように、一般的に、重希土類であるディスプロシウムを利用して、ネオジウムの高いＪｓ特性を少しだけ失いながらも、Dyの持つ高い保磁力を持たせた磁石でも２．１５［Ｔ］≧Ｊｓ≧１．２［Ｔ］を満たす場合があり、この場合も採用可能である。このような場合は、例えば([Nd1-xDyx]2Fe14B)と呼ぶこととする。更に、異なる組成の２種類以上の磁石、例えば、FeNiプラスSm2Fe17N3というように２種類以上の材料からなる磁石でも、達成が可能であるし、例えば、Ｊｓ＝１．６［Ｔ］と、Ｊｓに余裕のあるNd2Fe14Bの磁石に、Ｊｓ＜１［Ｔ］の、例えばDy2Fe14Bを少量混ぜ、保磁力を増加させた混合磁石などでも達成が可能である。 (4) The magnet unit 42 is supplemented below. The magnet unit 42 (magnet) is characterized in that 2.15 [T] ≧ Js ≧ 1.2 [T]. In other words, examples of the magnet used for the magnet unit 42 include NdFe11TiN, Nd2Fe14B, Sm2Fe17N3, and a FeNi magnet having an L10 type crystal. It should be noted that configurations such as SmCo5, FePt, Dy2Fe14B, and CoPt, which are generally called samakoba, cannot be used. It should be noted that Dy2Fe14B and Nd2Fe14B generally use heavy rare earth dysprosium like Dy2Fe14B and Dy2Fe14B. May satisfy 2.15 [T] ≧ Js ≧ 1.2 [T], and this case is also applicable. In such a case, it is referred to as ([Nd1-xDyx] 2Fe14B), for example. Furthermore, two or more magnets having different compositions, for example, magnets made of two or more materials such as FeNi plus Sm2Fe17N3 can be achieved. For example, Js = 1.6 [T] and Js This can be achieved even by a mixed magnet having a coercive force increased by mixing a small amount of Js <1 [T], for example, Dy2Fe14B, with a marginal Nd2Fe14B magnet.
　また、人間の活動範囲外の温度、例えば砂漠の温度を超える６０℃以上で動作されるような回転電機、例えば、夏においておけば車中温度が８０℃近くなる車両用モータ用途などにおいては、特に温度依存係数の小さい、FeNi、Sm2Fe17N3の成分を含むことが望ましい。これは、人間の活動範囲内である北欧の－４０℃近い温度状態から、先述の砂漠温度を超える６０℃以上、又はコイルエナメル被膜の耐熱温度１８０～２４０℃程度までのモータ動作において温度依存係数によって大きくモータ特性を異ならせるため、同一のモータドライバでの最適制御などが困難となるためである。前記L10型結晶を有するFeNi、又はSm2Fe17N3などを用いれば、Nd2Fe14Bと比べ、半分以下の温度依存係数を所持しているその特性から、モータドライバの負担を好適に減らすことができる。 In addition, in a rotating electric machine operated at a temperature outside the range of human activity, for example, 60 ° C. or more, which is higher than the temperature in the desert, for example, in a motor application for a vehicle in which the temperature in a vehicle is close to 80 ° C. in summer, In particular, it is desirable to include components of FeNi and Sm2Fe17N3 having a small temperature dependence coefficient. This is due to the temperature-dependent coefficient in the motor operation from the temperature range near −40 ° C. in Northern Europe, which is within the range of human activity, to 60 ° C. or more, which exceeds the desert temperature described above, or to the heat-resistant temperature of the coil enamel coating of about 180 to 240 ° C. This is because the motor characteristics are greatly different from each other, which makes it difficult to perform optimal control and the like with the same motor driver. If FeNi or Sm2Fe17N3 having the L10 type crystal is used, the load on the motor driver can be reduced appropriately because of its characteristic that it has a temperature dependence coefficient of half or less as compared with Nd2Fe14B.
　加えて、磁石ユニット４２は、前記磁石配合を用いて、配向以前の微粉体状態の粒子径の大きさが１０μｍ以下、単磁区粒子径以上としていることを特徴としている。磁石では、粉体の粒子を数百ｎｍオーダまで微細化することにより保磁力が大きくなるため、近年では、できるだけ微細化された粉体が使用されている。ただし、細かくしすぎると、酸化などにより磁石のＢＨ積が落ちてしまうため、単磁区粒子径以上が好ましい。単磁区粒子径までの粒子径であれば、微細化により保磁力が上昇することが知られている。なお、ここで述べてきた粒子径の大きさは、磁石の製造工程でいうところの配向工程の際の微粉体状態の粒子径の大きさである。 (4) 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 domain particle size or more using the above-described magnet composition. In magnets, the coercive force is increased by reducing the size of powder particles to the order of several hundreds of nm. In recent years, powders that have been made as fine as possible have been used in recent years. However, if the particle size is too small, the BH product of the magnet decreases due to oxidation or the like. It is known that when the particle diameter is up to a single magnetic domain particle diameter, the coercive force increases due to miniaturization. The size of the particle diameter described here is the size of the particle diameter in a fine powder state in the orientation step in the magnet manufacturing process.
　更に、磁石ユニット４２の第１磁石９１と第２磁石９２の各々は、磁性粉末を高温で焼き固めた、いわゆる焼結により形成された焼結磁石である。この焼結は、磁石ユニット４２の飽和磁化Ｊｓが１．２Ｔ以上で、第１磁石９１および第２磁石９２の結晶粒径が１０μｍ以下であり、配向率をαとした場合、Ｊｓ×αが１．０Ｔ（テスラ）以上の条件を満足するよう行われる。また、第１磁石９１と第２磁石９２の各々は、以下の条件を満足するように焼結されている。そして、その製造過程において配向工程にて配向が行われることにより、等方性磁石の着磁工程による磁力方向の定義とは異なり、配向率（orientation ratio）を持つ。本実施形態の磁石ユニット４２の飽和磁化Ｊｓが１．２Ｔ以上で、第１磁石９１と第２磁石９２の配向率αが、Ｊｒ≧Ｊｓ×α≧１．０［Ｔ］となるように高い配向率を設定されている。なお、ここで言う配向率αとは、第１磁石９１又は第２磁石９２の各々において、例えば、磁化容易軸が６つあり、そのうちの５つが同じ方向である方向Ａ１０を向き、残りの一つが方向Ａ１０に対して９０度傾いた方向Ｂ１０を向いている場合、α＝５／６であり、残りの一つが方向Ａ１０に対して４５度傾いた方向Ｂ１０を向いている場合には、残りの一つの方向Ａ１０を向く成分はｃｏｓ４５°＝０．７０７であるため、α＝（５＋０．７０７）／６となる。本実施例では焼結により第１磁石９１と第２磁石９２を形成しているが、上記条件が満足されれば、第１磁石９１と第２磁石９２は他の方法により成形してもよい。例えば、ＭＱ３磁石などを形成する方法を採用することができる。 {Circle around (1)} Further, each of the first magnet 91 and the second magnet 92 of the magnet unit 42 is a sintered magnet formed by so-called sintering of magnetic powder baked 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 sizes of the first magnet 91 and the second magnet 92 are 10 μm or less, and the orientation ratio is α, Js × α is It is performed so as to satisfy the condition of 1.0 T (tesla) or more. Each of the first magnet 91 and the second magnet 92 is sintered so as to satisfy the following conditions. The orientation is performed in the orientation process in the manufacturing process, so that the orientation is different from the definition of the magnetic force direction in the isotropic magnet magnetization process. When the saturation magnetization Js of the magnet unit 42 of the present embodiment is 1.2 T or more, the orientation ratio α of the first magnet 91 and the second magnet 92 is so high that Jr ≧ Js × α ≧ 1.0 [T]. The orientation ratio is set. Note that the orientation ratio α here refers to, for example, in each of the first magnet 91 or the second magnet 92, there are six easy axes, and five of them have the same direction, that is, the direction A10. Α = 5/6 when one of them faces the direction B10 inclined at 90 degrees to the direction A10, and when one of the other faces the direction B10 inclined at 45 degrees to the direction A10, Since the component facing one direction A10 is cos45 ° = 0.707, α = (5 + 0.707) / 6. In the present embodiment, the first magnet 91 and the second magnet 92 are formed by sintering, but if the above conditions are satisfied, the first magnet 91 and the second magnet 92 may be formed by another method. . For example, a method of forming an MQ3 magnet or the like can be adopted.
　本実施形態においては、配向により磁化容易軸をコントロールした永久磁石を利用しているから、その磁石内部の磁気回路長を、従来１．０［Ｔ］以上を出す直線配向磁石の磁気回路長と比べて、長くすることができる。すなわち、１極対あたりの磁気回路長を、少ない磁石量で達成できる他、従来の直線配向磁石を利用した設計と比べ、過酷な高熱条件に曝されても、その可逆減磁範囲を保つことができる。また、本願開示者は、従来技術の磁石を用いても、極異方性磁石と近しい特性を得られる構成を見いだした。 In this embodiment, the permanent magnet whose easy axis of magnetization is controlled by the orientation is used. Therefore, the magnetic circuit length inside the magnet is set to be equal to the magnetic circuit length of a linearly oriented magnet that conventionally outputs 1.0 [T] or more. In comparison, it can be longer. In other words, a magnetic circuit length per pole pair can be achieved with a small amount of magnets, and the reversible demagnetization range is maintained even when exposed to severe high-temperature conditions, compared to a design using conventional linearly-oriented magnets. Can be. In addition, the present inventor has found a configuration in which characteristics similar to those of a polar anisotropic magnet can be obtained even when a conventional magnet is used.
　なお、磁化容易軸は、磁石において磁化されやすい結晶方位のことをいう。磁石における磁化容易軸の向きとは、磁化容易軸の方向が揃っている程度を示す配向率が５０％以上となる方向、又は、その磁石の配向の平均となる方向である。 容易 The axis of easy magnetization refers to a crystal orientation that is easily magnetized in a magnet. The direction of the axis of easy magnetization in the magnet is a direction in which the degree of orientation indicating the degree of alignment of the direction of the axis of easy magnetization is 50% or more, or a direction in which the orientation of the magnet is average.
　図８及び図９に示すように、磁石ユニット４２は、円環状をなしており、磁石ホルダ４１の内側（詳しくは円筒部４３の径方向内側）に設けられている。磁石ユニット４２は、それぞれ極異方性磁石でありかつ極性が互いに異なる第１磁石９１及び第２磁石９２を有している。第１磁石９１及び第２磁石９２は周方向に交互に配置されている。第１磁石９１は、固定子巻線５１に近い部分においてＮ極を形成する磁石であり、第２磁石９２は、固定子巻線５１に近い部分においてＳ極を形成する磁石である。第１磁石９１及び第２磁石９２は、例えばネオジム磁石等の希土類磁石からなる永久磁石である。 As shown in FIGS. 8 and 9, the magnet unit 42 has an annular shape and is provided inside the magnet holder 41 (specifically, inside the cylindrical portion 43 in the radial direction). The magnet unit 42 is a polar anisotropic magnet and has a first magnet 91 and a second magnet 92 having 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 forming an N pole in a portion near the stator winding 51, and the second magnet 92 is a magnet forming an S pole in a portion near the stator winding 51. The first magnet 91 and the second magnet 92 are permanent magnets made of a rare earth magnet such as a neodymium magnet.
　各磁石９１，９２では、図９に示すように、公知のｄ－ｑ座標系において磁極中心であるｄ軸(direct-axis)とＮ極とＳ極の磁極境界である（言い換えれば、磁束密度が０テスラである）ｑ軸(quadrature-axis)との間において磁化方向が円弧状に延びている。各磁石９１，９２それぞれにおいて、ｄ軸側では磁化方向が円環状の磁石ユニット４２の径方向とされ、ｑ軸側では円環状の磁石ユニット４２の磁化方向が周方向とされている。以下、更に詳細に説明する。磁石９１，９２のそれぞれは、図９に示すように、第１部分２５０と、磁石ユニット４２の周方向において第１部分２５０の両側に位置する二つの第２部分２６０とを有する。言い換えれば、第１部分２５０は、第２部分２６０よりｄ軸に近く、第２部分２６０は、第１部分２５０よりｑ軸に近い。そして、第１部分２５０の磁化容易軸３００の方向は、第２部分２６０の磁化容易軸３１０の方向よりもｄ軸に対してより平行となるように磁石ユニット４２が構成されている。言い換えれば、第１部分２５０の磁化容易軸３００がｄ軸となす角度θ１１が、第２部分２６０の磁化容易軸３１０がｑ軸となす角度θ１２よりも小さくなるように磁石ユニット４２が構成されている。 As shown in FIG. 9, each of the magnets 91 and 92 has a d-axis (direct-axis), which is the center of the magnetic pole, and a magnetic pole boundary between the N pole and the S pole in a known dq coordinate system (in other words, the magnetic flux density). Is 0 Tesla) and the magnetization direction extends in an arc shape with respect to the q-axis (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. Hereinafter, this will be described in more detail. As shown in FIG. 9, 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. 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 easy axis 300 of the first portion 250 is more parallel to the d axis than the direction of the easy axis 310 of the second portion 260. In other words, the magnet unit 42 is configured such that the angle θ11 between the easy axis 300 of the first portion 250 and the d axis is smaller than the angle θ12 between the easy axis 310 of the second portion 260 and the q axis. I have.
　より詳細には、角度θ１１は、ｄ軸において固定子５０（電機子）から磁石ユニット４２に向かう方向を正とした時に、ｄ軸と磁化容易軸３００とがなす角度である。角度θ１２は、ｑ軸において固定子５０（電機子）から磁石ユニット４２に向かう方向を正とした時に、ｑ軸と磁化容易軸３１０とがなす角度である。なお角度θ１１及び角度θ１２共に、本実施形態では９０°以下である。ここでいう、磁化容易軸３００，３１０のそれぞれは、以下の定義による。磁石９１，９２のそれぞれの部分において、一つの磁化容易軸が方向Ａ１１を向き、もう一つの磁化容易軸が方向Ｂ１１を向いているとした場合、方向Ａ１１と方向Ｂ１１の成す角度θのコサインの絶対値（｜ｃｏｓθ｜）を磁化容易軸３００或いは磁化容易軸３１０とする。 More specifically, the angle θ11 is an angle formed between the d axis and the easy axis 300 when the direction from the stator 50 (armature) toward the magnet unit 42 is positive on the d axis. The angle θ12 is an angle formed between the q axis and the easy axis 310 when the direction from the stator 50 (armature) toward the magnet unit 42 is positive on the q axis. Note that both the angle θ11 and the angle θ12 are 90 ° or less in the present embodiment. Here, each of the easy axes 300 and 310 has the following definition. In each part of the magnets 91 and 92, when one easy axis of magnetization is oriented in the direction A11 and the other easy axis is oriented in the direction B11, the cosine of the angle θ between the direction A11 and the direction B11 is obtained. The absolute value (| cos θ |) is defined as the easy axis 300 or the easy axis 310.
　すなわち、各磁石９１，９２のそれぞれは、ｄ軸側（ｄ軸寄りの部分）とｑ軸側（ｑ軸寄りの部分）とで磁化容易軸の向きが相違しており、ｄ軸側では磁化容易軸の向きがｄ軸に平行な方向に近い向きとなり、ｑ軸側では磁化容易軸の向きがｑ軸に直交する方向に近い向きとなっている。そして、この磁化容易軸の向きに応じて円弧状の磁石磁路が形成されている。なお、各磁石９１，９２において、ｄ軸側では磁化容易軸をｄ軸に平行な向きとし、ｑ軸側では磁化容易軸をｑ軸に直交する向きとしてもよい。 That is, each of the magnets 91 and 92 has a different direction of the axis of easy magnetization on the d-axis side (portion closer to the d-axis) and on the q-axis side (portion closer to the q-axis). The direction of the easy axis is close to the direction parallel to the d-axis, and the direction of the easy axis of magnetization is close to the direction orthogonal to the q-axis on the q-axis side. An arc-shaped magnet magnetic path is formed in accordance with the direction of the axis of easy magnetization. In each of the magnets 91 and 92, the easy axis may be oriented parallel to the d axis on the d-axis side, and the easy axis may be orthogonal to the q axis on the q-axis side.
　また、磁石９１，９２では、各磁石９１，９２の周面のうち固定子５０側（図９の下側）となる固定子側外面と、周方向においてｑ軸側の端面とが、磁束の流入流出面である磁束作用面となっており、それらの磁束作用面（固定子側外面及びｑ軸側の端面）を繋ぐように磁石磁路が形成されている。 In the magnets 91 and 92, the stator-side outer surface of the magnets 91 and 92 on the stator 50 side (the lower side in FIG. 9) and the end surface on the q-axis side in the circumferential direction form a magnetic flux. It is a magnetic flux acting surface which is an inflow / outflow surface, and a magnet magnetic path is formed so as to connect those magnetic flux acting surfaces (an outer surface on the stator side and an end surface on the q-axis side).
　磁石ユニット４２では、各磁石９１，９２により、隣接するＮ，Ｓ極間を円弧状に磁束が流れるため、例えばラジアル異方性磁石に比べて磁石磁路が長くなっている。このため、図１７に示すように、磁束密度分布が正弦波に近いものとなる。その結果、図１８に比較例として示すラジアル異方性磁石の磁束密度分布とは異なり、磁極の中心側に磁束を集中させることができ、回転電機１０のトルクを高めることができる。また、本実施形態の磁石ユニット４２では、従来のハルバッハ配列の磁石と比べても、磁束密度分布の差異があることが確認できる。なお、図１７及び図１８において、横軸は電気角を示し、縦軸は磁束密度を示す。また、図１７及び図１８において、横軸の９０°はｄ軸（すなわち磁極中心）を示し、横軸の０°，１８０°はｑ軸を示す。 (4) In the magnet unit 42, the magnetic flux flows in an arc between the adjacent N and S poles by the magnets 91 and 92, so that the magnet magnetic path is longer than, for example, a radial anisotropic magnet. Therefore, as shown in FIG. 17, the magnetic flux density distribution becomes close to a sine wave. As a result, unlike the magnetic flux density distribution of the radial anisotropic magnet shown as a comparative example in FIG. 18, the magnetic flux can be concentrated on the center side of the magnetic pole, and the torque of the rotating electric machine 10 can be increased. Further, in the magnet unit 42 of the present embodiment, it can be confirmed that there is a difference in the magnetic flux density distribution as compared with the conventional Halbach array magnet. 17 and 18, the horizontal axis represents the electrical angle, and the vertical axis represents the magnetic flux density. 17 and 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.
　つまり、上記構成の各磁石９１，９２によれば、ｄ軸での磁石磁束が強化され、かつｑ軸付近での磁束変化が抑えられる。これにより、各磁極においてｑ軸からｄ軸にかけての表面磁束変化がなだらかになる磁石９１，９２を好適に実現することができる。 That is, according to the magnets 91 and 92 having the above-described configuration, the magnet magnetic flux on the d-axis is strengthened, and the change in magnetic flux near the q-axis is suppressed. Thereby, it is possible to suitably realize the magnets 91 and 92 in which the surface magnetic flux changes gradually from the q axis to the d axis in each magnetic pole.
　磁束密度分布の正弦波整合率は、例えば４０％以上の値とされていればよい。このようにすれば、正弦波整合率が３０％程度であるラジアル配向磁石、パラレル配向磁石を用いる場合に比べ、確実に波形中央部分の磁束量を向上させることができる。また、正弦波整合率を６０％以上とすれば、ハルバッハ配列のような磁束集中配列と比べ、確実に波形中央部分の磁束量を向上させることができる。 正弦 The sine wave matching ratio of the magnetic flux density distribution may be, for example, 40% or more. In this way, the amount of magnetic flux in the center portion of the waveform can be reliably improved as compared with the case of using a radially oriented magnet or a parallelly oriented magnet having a sine wave matching ratio of about 30%. Further, when the sine wave matching ratio is 60% or more, the amount of magnetic flux at the center portion of the waveform can be reliably improved as compared with a magnetic flux concentration array such as a Halbach array.
　図１８に示すラジアル異方性磁石では、ｑ軸付近において磁束密度が急峻に変化する。磁束密度の変化が急峻なほど、固定子巻線５１に発生する渦電流が増加してしまう。また、固定子巻線５１側での磁束変化も急峻となる。これに対し、本実施形態では、磁束密度分布が正弦波に近い磁束波形となる。このため、ｑ軸付近において、磁束密度の変化が、ラジアル異方性磁石の磁束密度の変化よりも小さい。これにより、渦電流の発生を抑制することができる。 で は In the radial anisotropic magnet shown in FIG. 18, the magnetic flux density changes sharply near the q-axis. As the change in the magnetic flux density becomes steeper, the eddy current generated in the stator winding 51 increases. Further, the magnetic flux change on the stator winding 51 side also becomes steep. On the other hand, in the present embodiment, the magnetic flux density distribution has a magnetic flux waveform close to a sine wave. For this reason, near the q-axis, the change in the magnetic flux density is smaller than the change in the magnetic flux density of the radial anisotropic magnet. Thereby, generation of eddy current can be suppressed.
　磁石ユニット４２では、各磁石９１，９２のｄ軸付近（すなわち磁極中心）において、固定子５０側の磁束作用面２８０に直交する向きで磁束が生じ、その磁束は、固定子５０側の磁束作用面２８０から離れるほど、ｄ軸から離れるような円弧状をなす。また、磁束作用面に直交する磁束であるほど、強い磁束となる。この点において、本実施形態の回転電機１０では、上述のとおり各導線群８１を径方向に薄くしたため、導線群８１の径方向の中心位置が磁石ユニット４２の磁束作用面に近づくことになり、固定子５０において回転子４０から強い磁石磁束を受けることができる。 In the magnet unit 42, a magnetic flux is generated in a direction orthogonal to the magnetic flux acting surface 280 on the stator 50 near the d-axis of each of the magnets 91 and 92 (that is, the center of the magnetic pole). As the distance from the surface 280 increases, the shape of the arc increases as the distance from the d-axis increases. Further, the more the magnetic flux is perpendicular to the magnetic flux acting surface, the stronger the magnetic flux becomes. In this regard, in the rotating electric machine 10 of the present embodiment, since the conductor groups 81 are thinned in the radial direction as described above, the radial center position of the conductor groups 81 approaches the magnetic flux acting surface of the magnet unit 42, The stator 50 can receive a strong magnet magnetic flux from the rotor 40.
　また、固定子５０には、固定子巻線５１の径方向内側、すなわち固定子巻線５１を挟んで回転子４０の逆側に円筒状の固定子コア５２が設けられている。そのため、各磁石９１，９２の磁束作用面から延びる磁束は、固定子コア５２に引きつけられ、固定子コア５２を磁路の一部として用いつつ周回する。この場合、磁石磁束の向き及び経路を適正化することができる。 固定 Further, the stator 50 is provided with a cylindrical stator core 52 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 surfaces of the magnets 91 and 92 is attracted to the stator core 52 and orbits while using the stator core 52 as a part of the magnetic path. In this case, the direction and path of the magnet magnetic flux can be optimized.
　以下に、回転電機１０の製造方法として、図５に示す軸受ユニット２０、ハウジング３０、回転子４０、固定子５０及びインバータユニット６０についての組み付け手順について説明する。なお、インバータユニット６０は、図６に示すようにユニットベース６１と電気コンポーネント６２とを有しており、それらユニットベース６１及び電気コンポーネント６２の組み付け工程を含む各作業工程を説明する。以下の説明では、固定子５０及びインバータユニット６０よりなる組立品を第１ユニット、軸受ユニット２０、ハウジング３０及び回転子４０よりなる組立品を第２ユニットとしている。 Hereinafter, as a method of manufacturing the rotary electric machine 10, a procedure for assembling 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. The inverter unit 60 has a unit base 61 and an electric component 62 as shown in FIG. 6, and each operation process including a process of assembling the unit base 61 and the electric component 62 will be described. In the following description, an assembly including the stator 50 and the inverter unit 60 is referred to as a first unit, and an assembly including the bearing unit 20, the housing 30, and the rotor 40 is referred to as a second unit.
　本製造工程は、
・ユニットベース６１の径方向内側に電気コンポーネント６２を装着する第１工程と、
・固定子５０の径方向内側にユニットベース６１を装着して第１ユニットを製作する第２工程と、
・ハウジング３０に組み付けられた軸受ユニット２０に、回転子４０の固定部４４を挿入して第２ユニットを製作する第３工程と、
・第２ユニットの径方向内側に第１ユニットを装着する第４工程と、
・ハウジング３０とユニットベース６１とを締結固定する第５工程と、
を有している。これら各工程の実施順序は、第１工程→第２工程→第３工程→第４工程→第５工程である。 This manufacturing process
A first step of mounting the electrical component 62 inside the unit base 61 in the radial direction;
A second step of mounting the unit base 61 on the radially inner side of the stator 50 to produce a first unit;
A third step of manufacturing the second unit by inserting the fixing portion 44 of the rotor 40 into the bearing unit 20 assembled in the housing 30;
A fourth step of mounting the first unit radially inside the second unit;
A fifth step of fastening and fixing the housing 30 and the unit base 61;
have. The order of execution of these steps is first step → second step → third step → fourth step → fifth step.
　上記の製造方法によれば、軸受ユニット２０、ハウジング３０、回転子４０、固定子５０及びインバータユニット６０を複数の組立品（サブアセンブリ）として組み立てた後に、それら組立品同士を組み付けるようにしたため、ハンドリングのし易さやユニット毎の検査完結などを実現でき、合理的な組み立てラインの構築が可能となる。したがって、多品種生産にも容易に対応が可能となる。 According to the manufacturing method described above, 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 (subassemblies), the assemblies are assembled. Easy handling and complete inspection of each unit can be realized, and a reasonable assembly line can be constructed. Therefore, it is possible to easily cope with multi-product production.
　第１工程では、ユニットベース６１の径方向内側及び電気コンポーネント６２の径方向外部の少なくともいずれかに、熱伝導が良好な良熱伝導体を塗布や接着等により付着させておき、その状態で、ユニットベース６１に対して電気コンポーネント６２を装着するとよい。これにより、半導体モジュール６６の発熱をユニットベース６１に対して効果的に伝達させることが可能となる。 In the first step, a good heat conductor having good heat conduction is adhered to at least one of the radially inner side of the unit base 61 and the radially outer side of the electric component 62 by coating, bonding, or the like. It is preferable to mount the electric component 62 on the unit base 61. Thus, heat generated by the semiconductor module 66 can be effectively transmitted to the unit base 61.
　第３工程では、ハウジング３０と回転子４０との同軸を維持しながら、回転子４０の挿入作業を実施するとよい。具体的には、例えばハウジング３０の内周面を基準として回転子４０の外周面（磁石ホルダ４１の外周面）又は回転子４０の内周面（磁石ユニット４２の内周面）の位置を定める治具を用い、その治具に沿ってハウジング３０及び回転子４０のいずれかをスライドさせながら、ハウジング３０と回転子４０との組み付けを実施する。これにより、軸受ユニット２０に偏荷重を掛けることなく重量部品を組み付けることが可能となり、軸受ユニット２０の信頼性が向上する。 で は In the third step, the rotor 40 may be inserted while the coaxial relationship between the housing 30 and the rotor 40 is maintained. 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 with reference to the inner peripheral surface of the housing 30. Using the jig, the housing 30 and the rotor 40 are assembled while sliding either the housing 30 or the rotor 40 along the jig. This makes it possible to mount a heavy component without applying an unbalanced load to the bearing unit 20, and the reliability of the bearing unit 20 is improved.
　第４工程では、第１ユニットと第２ユニットとの同軸を維持しながら、それら両ユニットの組み付けを実施するとよい。具体的には、例えば回転子４０の固定部４４の内周面を基準としてユニットベース６１の内周面の位置を定める治具を用い、その治具に沿って第１ユニット及び第２ユニットのいずれかをスライドさせながら、これら各ユニットの組み付けを実施する。これにより、回転子４０と固定子５０との極少隙間間での互いの干渉を防止しながら組み付けることが可能となるため、固定子巻線５１へのダメージや永久磁石の欠け等、組み付け起因の不良品の撲滅が可能となる。 ４ In the fourth step, it is preferable to carry out the assembly of the first unit and the second unit while maintaining the coaxiality of the two units. Specifically, for example, a jig that determines the position of the inner peripheral surface of the unit base 61 with reference to the inner peripheral surface of the fixing portion 44 of the rotor 40 is used, and the first unit and the second unit are moved along the jig. Assemble these units while sliding any of them. As a result, it is possible to assemble the rotor 40 and the stator 50 while preventing mutual interference between the extremely small gaps. Defective products can be eliminated.
　上記各工程の順序を、第２工程→第３工程→第４工程→第５工程→第１工程とすることも可能である。この場合、デリケートな電気コンポーネント６２を最後に組み付けることになり、組み付け工程内での電気コンポーネント６２へのストレスを最小限にとどめることができる。 順序 The order of the above steps may be the second step → the third step → the fourth step → the fifth step → the first step. In this case, the delicate electric component 62 is assembled last, and the stress on the electric component 62 in the assembling process can be minimized.
　次に、回転電機１０を制御する制御システムの構成について説明する。図１９は、回転電機１０の制御システムの電気回路図であり、図２０は、制御装置１１０による制御処理を示す機能ブロック図である。 Next, the configuration of a control system that controls the rotating electric machine 10 will be described. FIG. 19 is an electric circuit diagram of a control system of the rotating electric machine 10, and FIG. 20 is a functional block diagram illustrating a control process performed by the control device 110.
　図１９では、固定子巻線５１として２組の３相巻線５１ａ，５１ｂが示されており、３相巻線５１ａはＵ相巻線、Ｖ相巻線及びＷ相巻線よりなり、３相巻線５１ｂはＸ相巻線、Ｙ相巻線及びＺ相巻線よりなる。３相巻線５１ａ，５１ｂごとに、電力変換器に相当する第１インバータ１０１と第２インバータ１０２とがそれぞれ設けられている。インバータ１０１，１０２は、相巻線の相数と同数の上下アームを有するフルブリッジ回路により構成されており、各アームに設けられたスイッチ（半導体スイッチング素子）のオンオフにより、固定子巻線５１の各相巻線において通電電流が調整される。 In FIG. 19, two sets of three-phase windings 51a and 51b are shown as the stator winding 51. The three-phase winding 51a includes a U-phase winding, a V-phase winding, and a W-phase winding. The phase winding 51b includes an X-phase winding, a Y-phase winding, and a Z-phase winding. A first inverter 101 and a second inverter 102 each corresponding to a 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 the same number of upper and lower arms as the number of phases of the phase windings, and the switches (semiconductor switching elements) provided on each arm are turned on and off to turn the stator windings 51 on and off. The conduction current is adjusted in each phase winding.
　各インバータ１０１，１０２には、直流電源１０３と平滑用のコンデンサ１０４とが並列に接続されている。直流電源１０３は、例えば複数の単電池が直列接続された組電池により構成されている。なお、インバータ１０１，１０２の各スイッチが、図１等に示す半導体モジュール６６に相当し、コンデンサ１０４が、図１等に示すコンデンサモジュール６８に相当する。 直流 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 by, for example, an assembled battery in which a plurality of cells are connected in series. Each switch of the inverters 101 and 102 corresponds 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.
　制御装置１１０は、ＣＰＵや各種メモリからなるマイコンを備えており、回転電機１０における各種の検出情報や、力行駆動及び発電の要求に基づいて、インバータ１０１，１０２における各スイッチのオンオフにより通電制御を実施する。制御装置１１０が、図６に示す制御装置７７に相当する。回転電機１０の検出情報には、例えば、レゾルバ等の角度検出器により検出される回転子４０の回転角度（電気角情報）や、電圧センサにより検出される電源電圧（インバータ入力電圧）、電流センサにより検出される各相の通電電流が含まれる。制御装置１１０は、インバータ１０１，１０２の各スイッチを操作する操作信号を生成して出力する。なお、発電の要求は、例えば回転電機１０が車両用動力源として用いられる場合、回生駆動の要求である。 The control device 110 includes a microcomputer including a CPU and various memories. Based on various detection information in the rotating electric machine 10 and requests for powering drive and power generation, the control of the power supply is performed by turning on and off the switches in the inverters 101 and 102. carry out. Control device 110 corresponds to control device 77 shown in FIG. The detection information of the rotating electric 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 energized current of each phase detected by Control device 110 generates and outputs an operation signal for operating each switch of inverters 101 and 102. The power generation request is, for example, a request for regenerative driving when the rotating electric machine 10 is used as a vehicle power source.
　第１インバータ１０１は、Ｕ相、Ｖ相及びＷ相からなる３相において上アームスイッチＳｐと下アームスイッチＳｎとの直列接続体をそれぞれ備えている。各相の上アームスイッチＳｐの高電位側端子は直流電源１０３の正極端子に接続され、各相の下アームスイッチＳｎの低電位側端子は直流電源１０３の負極端子（グランド）に接続されている。各相の上アームスイッチＳｐと下アームスイッチＳｎとの間の中間接続点には、それぞれＵ相巻線、Ｖ相巻線、Ｗ相巻線の一端が接続されている。これら各相巻線は星形結線（Ｙ結線）されており、各相巻線の他端は中性点にて互いに接続されている。 The first inverter 101 includes a series connection of an upper arm switch Sp and a lower arm switch Sn in three phases including 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 phase windings are star-connected (Y connection), and the other ends of the phase windings are connected to each other at a neutral point.
　第２インバータ１０２は、第１インバータ１０１と同様の構成を有しており、Ｘ相、Ｙ相及びＺ相からなる３相において上アームスイッチＳｐと下アームスイッチＳｎとの直列接続体をそれぞれ備えている。各相の上アームスイッチＳｐの高電位側端子は直流電源１０３の正極端子に接続され、各相の下アームスイッチＳｎの低電位側端子は直流電源１０３の負極端子（グランド）に接続されている。各相の上アームスイッチＳｐと下アームスイッチＳｎとの間の中間接続点には、それぞれＸ相巻線、Ｙ相巻線、Ｚ相巻線の一端が接続されている。これら各相巻線は星形結線（Ｙ結線）されており、各相巻線の他端は中性点で互いに接続されている。 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 including an X phase, a Y phase, and a 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 phase windings are star-connected (Y connection), and the other ends of the phase windings are connected to each other at a neutral point.
　図２０には、Ｕ，Ｖ，Ｗ相の各相電流を制御する電流フィードバック制御処理と、Ｘ，Ｙ，Ｚ相の各相電流を制御する電流フィードバック制御処理とが示されている。ここではまず、Ｕ，Ｖ，Ｗ相側の制御処理について説明する。 FIG. 20 shows a current feedback control process for controlling the U, V, and W phase currents, and a current feedback control process for controlling the X, Y, and Z phase currents. Here, the control process on the U, V, and W phases will be described first.
　図２０において、電流指令値設定部１１１は、トルク－ｄｑマップを用い、回転電機１０に対する力行トルク指令値又は発電トルク指令値や、電気角θを時間微分して得られる電気角速度ωに基づいて、ｄ軸の電流指令値とｑ軸の電流指令値とを設定する。なお、電流指令値設定部１１１は、Ｕ，Ｖ，Ｗ相側及びＸ，Ｙ，Ｚ相側において共通に設けられている。なお、発電トルク指令値は、例えば回転電機１０が車両用動力源として用いられる場合、回生トルク指令値である。 20, a current command value setting unit 111 uses a torque-dq map and based on a powering torque command value or a power generation torque command value for the rotating electric machine 10 and an electric angular velocity ω obtained by time-differentiating the electric angle θ. , A d-axis current command value and a q-axis current command value are set. The current command value setting unit 111 is provided in common on the U, V, and W phase sides and the X, Y, and Z phase sides. The power generation torque command value is, for example, a regenerative torque command value when the rotating electric machine 10 is used as a vehicle power source.
　ｄｑ変換部１１２は、相ごとに設けられた電流センサによる電流検出値（３つの相電流）を、界磁方向(direction of an axis of a magnetic field,or field direction)をｄ軸とする直交２次元回転座標系の成分であるｄ軸電流とｑ軸電流とに変換する。 The dq conversion unit 112 converts a current detection value (three phase currents) obtained by a current sensor provided for each phase into a quadrature 2 with a field direction (direction of an axis of a magnetic field, or field direction) as a d-axis. It is converted into a d-axis current and a q-axis current which are components of the three-dimensional rotation coordinate system.
　ｄ軸電流フィードバック制御部１１３は、ｄ軸電流をｄ軸の電流指令値にフィードバック制御するための操作量としてｄ軸の指令電圧を算出する。また、ｑ軸電流フィードバック制御部１１４は、ｑ軸電流をｑ軸の電流指令値にフィードバック制御するための操作量としてｑ軸の指令電圧を算出する。これら各フィードバック制御部１１３，１１４では、ｄ軸電流及びｑ軸電流の電流指令値に対する偏差に基づき、ＰＩフィードバック手法を用いて指令電圧が算出される。 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 a 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 a q-axis current command value. In each of these feedback control units 113 and 114, the command voltage is calculated using the PI feedback method based on the deviation of the d-axis current and the q-axis current from the current command value.
　３相変換部１１５は、ｄ軸及びｑ軸の指令電圧を、Ｕ相、Ｖ相及びＷ相の指令電圧に変換する。なお、上記の各部１１１～１１５が、ｄｑ変換理論による基本波電流のフィードバック制御を実施するフィードバック制御部であり、Ｕ相、Ｖ相及びＷ相の指令電圧がフィードバック制御値である。 The three-phase converter 115 converts d-axis and q-axis command voltages into U-phase, V-phase, and W-phase command voltages. Each of the units 111 to 115 is a feedback control unit that performs feedback control of the fundamental wave current based on the dq conversion theory, and the U-phase, V-phase, and W-phase command voltages are feedback control values.
　そして、操作信号生成部１１６は、周知の三角波キャリア比較方式を用い、３相の指令電圧に基づいて、第１インバータ１０１の操作信号を生成する。具体的には、操作信号生成部１１６は、３相の指令電圧を電源電圧で規格化した信号と、三角波信号等のキャリア信号との大小比較に基づくＰＷＭ制御により、各相における上下アームのスイッチ操作信号（デューティ信号）を生成する。 Then, the operation signal generation unit 116 generates an operation signal for 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 performs a PWM control based on a magnitude comparison between a signal obtained by standardizing a three-phase command voltage with a power supply voltage and a carrier signal such as a triangular wave signal, and thereby switches the upper and lower arms in each phase. An operation signal (duty signal) is generated.
　また、Ｘ，Ｙ，Ｚ相側においても同様の構成を有しており、ｄｑ変換部１２２は、相ごとに設けられた電流センサによる電流検出値（３つの相電流）を、界磁方向をｄ軸とする直交２次元回転座標系の成分であるｄ軸電流とｑ軸電流とに変換する。 The same configuration is also provided on the X, Y, and Z phase sides. The dq conversion unit 122 outputs a current detection value (three phase currents) obtained by a current sensor provided for each phase to the field direction. It is converted into a d-axis current and a q-axis current, which are components of an orthogonal two-dimensional rotating coordinate system with the d axis.
　ｄ軸電流フィードバック制御部１２３はｄ軸の指令電圧を算出し、ｑ軸電流フィードバック制御部１２４はｑ軸の指令電圧を算出する。３相変換部１２５は、ｄ軸及びｑ軸の指令電圧を、Ｘ相、Ｙ相及びＺ相の指令電圧に変換する。そして、操作信号生成部１２６は、３相の指令電圧に基づいて、第２インバータ１０２の操作信号を生成する。具体的には、操作信号生成部１２６は、３相の指令電圧を電源電圧で規格化した信号と、三角波信号等のキャリア信号との大小比較に基づくＰＷＭ制御により、各相における上下アームのスイッチ操作信号（デューティ信号）を生成する。 The d-axis current feedback control unit 123 calculates a d-axis command voltage, and the q-axis current feedback control unit 124 calculates a q-axis command voltage. The three-phase converter 125 converts 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 for the second inverter 102 based on the three-phase command voltage. Specifically, the operation signal generation unit 126 performs a PWM control based on a magnitude comparison between a signal obtained by standardizing a three-phase command voltage with a power supply voltage and a carrier signal such as a triangular wave signal, and thereby switches the upper and lower arms in each phase. An operation signal (duty signal) is generated.
　ドライバ１１７は、操作信号生成部１１６，１２６にて生成されたスイッチ操作信号に基づいて、各インバータ１０１，１０２における各３相のスイッチＳｐ，Ｓｎをオンオフさせる。 The driver 117 turns on and off the three-phase switches Sp and Sn of the inverters 101 and 102 based on the switch operation signals generated by the operation signal generation units 116 and 126.
　続いて、トルクフィードバック制御処理について説明する。この処理は、例えば高回転領域及び高出力領域等、各インバータ１０１，１０２の出力電圧が大きくなる運転条件において、主に回転電機１０の高出力化や損失低減の目的で用いられる。制御装置１１０は、回転電機１０の運転条件に基づいて、トルクフィードバック制御処理及び電流フィードバック制御処理のいずれか一方の処理を選択して実行する。 Next, the torque feedback control process will be described. This process is used mainly for the purpose of increasing the output of the rotating electric machine 10 and reducing the loss under operating conditions in which the output voltage of each of the inverters 101 and 102 becomes large, such as in a high rotation region and a high output region. The control device 110 selects and executes one of the torque feedback control process and the current feedback control process based on the operating conditions of the rotating electric machine 10.
　図２１には、Ｕ，Ｖ，Ｗ相に対応するトルクフィードバック制御処理と、Ｘ，Ｙ，Ｚ相に対応するトルクフィードバック制御処理とが示されている。なお、図２１において、図２０と同じ構成については、同じ符号を付して説明を省略する。ここではまず、Ｕ，Ｖ，Ｗ相側の制御処理について説明する。 FIG. 21 shows a torque feedback control process corresponding to the U, V, and W phases and a torque feedback control process corresponding to the X, Y, and Z phases. In FIG. 21, the same components as those in FIG. 20 are denoted by the same reference numerals, and description thereof will be omitted. Here, the control process on the U, V, and W phases will be described first.
　電圧振幅算出部１２７は、回転電機１０に対する力行トルク指令値又は発電トルク指令値と、電気角θを時間微分して得られる電気角速度ωとに基づいて、電圧ベクトルの大きさの指令値である電圧振幅指令を算出する。 The voltage amplitude calculation unit 127 is a command value for 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 electrical angular velocity ω obtained by time-differentiating the electrical angle θ. Calculate the voltage amplitude command.
　トルク推定部１２８ａは、ｄｑ変換部１１２により変換されたｄ軸電流とｑ軸電流とに基づいて、Ｕ，Ｖ，Ｗ相に対応するトルク推定値を算出する。なお、トルク推定部１２８ａは、ｄ軸電流、ｑ軸電流及び電圧振幅指令が関係付けられたマップ情報に基づいて、電圧振幅指令を算出すればよい。 The torque estimation unit 128a calculates a torque estimation 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. Note that the torque estimating 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.
　トルクフィードバック制御部１２９ａは、力行トルク指令値又は発電トルク指令値にトルク推定値をフィードバック制御するための操作量として、電圧ベクトルの位相の指令値である電圧位相指令を算出する。トルクフィードバック制御部１２９ａでは、力行トルク指令値又は発電トルク指令値に対するトルク推定値の偏差に基づき、ＰＩフィードバック手法を用いて電圧位相指令が算出される。 The torque feedback control unit 129a calculates a voltage phase command, which is a command value of a voltage vector phase, as an operation amount for performing feedback control of a torque estimation value to a powering torque command value or a power generation torque command value. The torque feedback control unit 129a calculates a voltage phase command using a PI feedback method based on the deviation of the estimated torque value from the powering torque command value or the generated torque command value.
　操作信号生成部１３０ａは、電圧振幅指令、電圧位相指令及び電気角θに基づいて、第１インバータ１０１の操作信号を生成する。具体的には、操作信号生成部１３０ａは、電圧振幅指令、電圧位相指令及び電気角θに基づいて３相の指令電圧を算出し、算出した３相の指令電圧を電源電圧で規格化した信号と、三角波信号等のキャリア信号との大小比較に基づくＰＷＭ制御により、各相における上下アームのスイッチ操作信号を生成する。 The operation signal generation unit 130a generates an operation signal for 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 standardizes the calculated three-phase command voltage with the power supply voltage. And PWM control based on a magnitude comparison between the signal and a carrier signal such as a triangular wave signal to generate switch operation signals for the upper and lower arms in each phase.
　ちなみに、操作信号生成部１３０ａは、電圧振幅指令、電圧位相指令、電気角θ及びスイッチ操作信号が関係付けられたマップ情報であるパルスパターン情報、電圧振幅指令、電圧位相指令並びに電気角θに基づいて、スイッチ操作信号を生成してもよい。 Incidentally, the operation signal generation unit 130a is based on a pulse pattern information, a voltage amplitude command, a voltage phase command, and an electrical angle θ, which are map information in which the voltage amplitude command, the voltage phase command, the electric angle θ and the switch operation signal are related. Thus, a switch operation signal may be generated.
　また、Ｘ，Ｙ，Ｚ相側においても同様の構成を有しており、トルク推定部１２８ｂは、ｄｑ変換部１２２により変換されたｄ軸電流とｑ軸電流とに基づいて、Ｘ，Ｙ，Ｚ相に対応するトルク推定値を算出する。 The X-, Y-, and Z-phase sides also have the same configuration, and the torque estimating unit 128b determines the X, Y, and Z-axis currents based on the d-axis current and the q-axis current converted by the dq An estimated torque value corresponding to the Z phase is calculated.
　トルクフィードバック制御部１２９ｂは、力行トルク指令値又は発電トルク指令値にトルク推定値をフィードバック制御するための操作量として、電圧位相指令を算出する。トルクフィードバック制御部１２９ｂでは、力行トルク指令値又は発電トルク指令値に対するトルク推定値の偏差に基づき、ＰＩフィードバック手法を用いて電圧位相指令が算出される。 The torque feedback control unit 129b calculates a voltage phase command as an operation amount for feedback-controlling the torque estimation value to the powering torque command value or the power generation torque command value. The torque feedback control unit 129b calculates the voltage phase command using the PI feedback method based on the deviation of the estimated torque value from the powering torque command value or the generated torque command value.
　操作信号生成部１３０ｂは、電圧振幅指令、電圧位相指令及び電気角θに基づいて、第２インバータ１０２の操作信号を生成する。具体的には、操作信号生成部１３０ｂは、電圧振幅指令、電圧位相指令及び電気角θに基づいて３相の指令電圧を算出し、算出した３相の指令電圧を電源電圧で規格化した信号と、三角波信号等のキャリア信号との大小比較に基づくＰＷＭ制御により、各相における上下アームのスイッチ操作信号を生成する。ドライバ１１７は、操作信号生成部１３０ａ，１３０ｂにて生成されたスイッチ操作信号に基づいて、各インバータ１０１，１０２における各３相のスイッチＳｐ，Ｓｎをオンオフさせる。 The operation signal generator 130b generates an operation signal for 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 standardizes the calculated three-phase command voltage with the power supply voltage. And PWM control based on a magnitude comparison between the signal and a carrier signal such as a triangular wave signal to generate switch operation signals for the upper and lower arms in each phase. The driver 117 turns on and 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.
　ちなみに、操作信号生成部１３０ｂは、電圧振幅指令、電圧位相指令、電気角θ及びスイッチ操作信号が関係付けられたマップ情報であるパルスパターン情報、電圧振幅指令、電圧位相指令並びに電気角θに基づいて、スイッチ操作信号を生成してもよい。 Incidentally, the operation signal generation unit 130b is based on the voltage amplitude command, the voltage phase command, the pulse pattern information that is the map information associated with the electrical angle θ and the switch operation signal, the voltage amplitude command, the voltage phase command, and the electrical angle θ. Thus, a switch operation signal may be generated.
　ところで、回転電機１０においては、軸電流の発生に伴い軸受２１，２２の電食が生じることが懸念されている。例えば固定子巻線５１の通電がスイッチングにより切り替えられる際に、スイッチングタイミングの微小なずれ（スイッチングの不均衡）により磁束の歪みが生じ、それに起因して、回転軸１１を支持する軸受２１，２２において電食が生じることが懸念される。磁束の歪みは固定子５０のインダクタンスに応じて生じ、その磁束の歪みにより生じる軸方向の起電圧によって、軸受２１，２２内での絶縁破壊が起こり電食が進行する。 By the way, in the rotating electric machine 10, there is a concern that the corrosion of the bearings 21 and 22 may occur with the generation of the shaft current. For example, when the energization of the stator winding 51 is switched by switching, a slight shift in switching timing (switching imbalance) causes distortion of magnetic flux, and as a result, bearings 21 and 22 supporting the rotating shaft 11 are caused. It is feared that electrolytic corrosion will occur in the case. The distortion of the magnetic flux is generated in accordance with the inductance of the stator 50, and the axial electromotive voltage generated by the distortion of the magnetic flux causes dielectric breakdown in the bearings 21 and 22, and the electrolytic corrosion proceeds.
　この点本実施形態では、電食対策として、以下に示す３つの対策を講じている。第１の電食対策は、固定子５０のコアレス化に伴いインダクタンスを低減したこと、及び磁石ユニット４２の磁石磁束をなだらかにしたことによる電食抑制対策である。第２の電食対策は、回転軸を軸受２１，２２による片持ち構造としたことによる電食抑制対策である。第３の電食対策は、円環状の固定子巻線５１を固定子コア５２と共にモールド材によりモールドしたことによる電食抑制対策である。以下には、これら各対策の詳細を個々に説明する。 In this regard, in the present embodiment, the following three measures are taken as measures against electrolytic corrosion. The first countermeasure against electric erosion is a countermeasure against electric erosion by reducing the inductance with the coreless stator 50 and making the magnet magnetic flux of the magnet unit 42 gentle. The second countermeasure against electric corrosion is a countermeasure against electric corrosion by using a cantilever structure of the rotating shaft with the bearings 21 and 22. The third countermeasure against electrolytic corrosion is a countermeasure against electrolytic corrosion caused by molding the annular stator winding 51 together with the stator core 52 using a molding material. The details of each of these measures will be described individually below.
　まず第１の電食対策では、固定子５０において、周方向における各導線群８１の間をティースレスとし、各導線群８１の間に、ティース（鉄心）の代わりに非磁性材料よりなる封止部材５７を設ける構成としている（図１０参照）。これにより、固定子５０のインダクタンス低減が可能となっている。固定子５０におけるインダクタンス低減を図ることで、仮に固定子巻線５１の通電時にスイッチングタイミングのずれが生じても、そのスイッチングタイミングのずれに起因する磁束歪みの発生を抑制し、ひいては軸受２１，２２の電食抑制が可能になっている。なお、ｄ軸のインダクタンスがｑ軸のインダクタンス以下になっているとよい。 First, in the first countermeasures against electrolytic corrosion, the stator 50 is made of teethless between the conductor groups 81 in the circumferential direction, and sealed between each conductor group 81 by a nonmagnetic material instead of the teeth (iron core). The member 57 is provided (see FIG. 10). Thereby, the inductance of the stator 50 can be reduced. By reducing the inductance in the stator 50, even if a switching timing shift occurs when the stator windings 51 are energized, the occurrence of magnetic flux distortion due to the switching timing shift is suppressed, and the bearings 21 and 22 are further reduced. It is possible to suppress the electric erosion. It is preferable that the d-axis inductance is equal to or less than the q-axis inductance.
　また、磁石９１，９２において、ｄ軸側においてｑ軸側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされた構成とした（図９参照）。これにより、ｄ軸での磁石磁束が強化され、各磁極においてｑ軸からｄ軸にかけての表面磁束変化（磁束の増減）がなだらかになる。そのため、スイッチング不均衡に起因する急激な電圧変化が抑制され、ひいては電食抑制に寄与できる構成となっている。 Also, the magnets 91 and 92 are configured such that the orientation of the easy axis of magnetization 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 magnetic flux on the d-axis is strengthened, and the change in the surface magnetic flux (increase / decrease in magnetic flux) from the q-axis to the d-axis becomes gentle at each magnetic pole. Therefore, a rapid voltage change due to the switching imbalance is suppressed, and the configuration can contribute to suppressing electrolytic corrosion.
　第２の電食対策では、回転電機１０において、各軸受２１，２２を、回転子４０の軸方向中央に対して軸方向のいずれか一方側に偏って配置している（図２参照）。これにより、複数の軸受が軸方向において回転子を挟んで両側にそれぞれ設けられる構成と比べて、電食の影響を軽減できる。つまり、回転子を複数の軸受により両持ち支持する構成では、高周波磁束の発生に伴い回転子、固定子及び各軸受（すなわち、回転子を挟んで軸方向両側の各軸受）を通る閉回路が形成され、軸電流により軸受の電食が懸念される。これに対し、回転子４０を複数の軸受２１，２２により片持ち支持する構成では上記閉回路が形成されず、軸受の電食が抑制される。 In the second countermeasure against electrolytic corrosion, in the rotating electric machine 10, the bearings 21 and 22 are arranged so as 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 electrolytic corrosion can be reduced as compared with a configuration in which a plurality of bearings are provided on both sides of the rotor in the axial direction. In other words, in a configuration in which the rotor is supported at both ends by a plurality of bearings, a closed circuit that passes through the rotor, the stator, and each bearing (that is, each bearing on both sides in the axial direction with the rotor interposed therebetween) is generated as high-frequency magnetic flux is generated. It is formed, and there is a concern that the shaft current causes electrolytic corrosion of the bearing. On the other hand, in a configuration in which the rotor 40 is cantilevered by the plurality of bearings 21 and 22, the closed circuit is not formed, and the electrolytic corrosion of the bearing is suppressed.
　また、回転電機１０は、軸受２１，２２の片側配置のための構成に絡み、以下の構成を有する。磁石ホルダ４１において、回転子４０の径方向に張り出す中間部４５に、軸方向に延びて固定子５０に対する接触を回避する接触回避部が設けられている（図２参照）。この場合、磁石ホルダ４１を経由して軸電流の閉回路が形成される場合にあっては、閉回路長を長くしてその回路抵抗を大きくすることが可能となる。これにより、軸受２１，２２の電食の抑制を図ることができる。 回 転 In addition, the rotating electric machine 10 has the following configuration in association with the 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 and avoids contact with the stator 50 is provided at an intermediate portion 45 that projects in the radial direction of the rotor 40 (see FIG. 2). In this case, when a closed circuit of the shaft current is formed via the magnet holder 41, the length of the closed circuit can be increased to increase the circuit resistance. Thereby, it is possible to suppress the electrolytic corrosion of the bearings 21 and 22.
　回転子４０を挟んで軸方向の一方側においてハウジング３０に対して軸受ユニット２０の保持部材２３が固定されるとともに、他方側においてハウジング３０及びユニットベース６１（固定子ホルダ）が互いに結合されている（図２参照）。本構成によれば、回転軸１１の軸方向においてその軸方向の片側に各軸受２１，２２を偏って配置する構成を好適に実現することができる。また本構成では、ユニットベース６１がハウジング３０を介して回転軸１１に繋がる構成となるため、ユニットベース６１を、回転軸１１から電気的に離れた位置に配置することができる。なお、ユニットベース６１とハウジング３０との間に樹脂等の絶縁部材を介在させれば、ユニットベース６１と回転軸１１とが電気的に一層離れた構成となる。これにより、軸受２１，２２の電食を適正に抑制することができる。 The holding member 23 of the bearing unit 20 is fixed to the housing 30 on one side in the axial direction with the rotor 40 interposed therebetween, and the housing 30 and the unit base 61 (stator holder) are connected to each other on the other side. (See FIG. 2). According to the present configuration, it is possible to suitably realize a configuration in which the bearings 21 and 22 are biased on one side in the axial direction of the rotating shaft 11. Further, in this configuration, since the unit base 61 is connected to the rotating shaft 11 via the housing 30, the unit base 61 can be arranged at a position electrically separated from the rotating shaft 11. If 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 further electrically separated. Thereby, the electrolytic corrosion of the bearings 21 and 22 can be appropriately suppressed.
　本実施形態の回転電機１０では、各軸受２１，２２の片側配置等により、軸受２１，２２に作用する軸電圧が低減されている。また、回転子４０と固定子５０との間の電位差が低減されている。そのため、軸受２１，２２において導電性グリースを用いなくても、軸受２１，２２に作用する電位差の低減が可能になっている。導電性グリースは、一般的にカーボンなどの細かい粒子を含むため音鳴りが生じることが考えられる。この点、本実施形態では、軸受２１，２２において非導電性グリースを用いる構成としている。そのため、軸受２１，２２において音鳴りが生じる不都合を抑制できる。例えば電気自動車などの電動車両への適用時には回転電機１０の音鳴り対策が必要になると考えられるが、その音鳴り対策を好適に実施することが可能となる。 回 転 In the rotating electric machine 10 of the present embodiment, the shaft voltage acting on the bearings 21 and 22 is reduced by arranging the bearings 21 and 22 on one side or the like. Further, the potential difference between the rotor 40 and the stator 50 is reduced. Therefore, the potential difference acting on the bearings 21 and 22 can be reduced without using conductive grease in the bearings 21 and 22. Since the conductive grease generally contains fine particles such as carbon, it is considered that sound is generated. In this regard, in this embodiment, the bearings 21 and 22 are configured to use non-conductive grease. For this reason, it is possible to suppress the inconvenience of generating noise in the bearings 21 and 22. For example, when it is applied to an electric vehicle such as an electric vehicle, it is considered that a countermeasure against the noise of the rotating electric machine 10 is required. However, the countermeasure against the noise can be suitably implemented.
　第３の電食対策では、固定子巻線５１を固定子コア５２と共にモールド材によりモールドすることで、固定子５０での固定子巻線５１の位置ずれを抑制する構成としている（図１１参照）。特に本実施形態の回転電機１０では、固定子巻線５１における周方向の各導線群８１の間に導線間部材（ティース）を有していないため、固定子巻線５１における位置ずれ生じる懸念が考えられるが、固定子巻線５１を固定子コア５２と共にモールドすることにより、固定子巻線５１の導線位置にずれが抑制される。したがって、固定子巻線５１の位置ずれによる磁束の歪みや、それに起因する軸受２１，２２の電食の発生を抑制することができる。 In the third countermeasure against electrolytic corrosion, the stator winding 51 is molded together with the stator core 52 with a molding material to suppress the displacement of the stator winding 51 in the stator 50 (see FIG. 11). ). In particular, in the rotating electric machine 10 of the present embodiment, since there is no inter-conductor member (teeth) between the respective conductor groups 81 in the circumferential direction of the stator winding 51, there is a concern that a displacement may occur in the stator winding 51. It is conceivable that the stator winding 51 is molded together with the stator core 52 so that the displacement of the conductor wire of the stator winding 51 is suppressed. Therefore, it is possible to suppress the distortion of the magnetic flux due to the displacement of the stator winding 51 and the occurrence of electrolytic corrosion of the bearings 21 and 22 due to the distortion.
　なお、固定子コア５２を固定するハウジング部材としてのユニットベース６１を、炭素繊維強化プラスチック（ＣＦＲＰ）により構成したため、例えばアルミ等により構成する場合に比べて、ユニットベース６１への放電が抑制され、ひいては好適な電食対策が可能となっている。 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 a case where the unit base 61 is made of, for example, aluminum. As a result, a suitable countermeasure against electric corrosion is possible.
　その他、軸受２１，２２の電食対策として、外輪２５及び内輪２６の少なくともいずれかをセラミックス材により構成する、又は、外輪２５の外側に絶縁スリーブを設ける等の構成を用いることも可能である。 In addition, as a countermeasure 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.
　以下に、他の実施形態を第１実施形態との相違点を中心に説明する。 Hereinafter, another embodiment will be described focusing on differences from the first embodiment.
　（第２実施形態）
　本実施形態では、回転子４０における磁石ユニット４２の極異方構造を変更しており、以下に詳しく説明する。 (2nd Embodiment)
In the present embodiment, the pole anisotropic structure of the magnet unit 42 in the rotor 40 is changed, and will be described in detail below.
　図２２及び図２３に示すように、磁石ユニット４２は、ハルバッハ配列と称される磁石配列を用いて構成されている。すなわち、磁石ユニット４２は、磁化方向（磁化ベクトルの向き）を径方向とする第１磁石１３１と、磁化方向（磁化ベクトルの向き）を周方向とする第２磁石１３２とを有しており、周方向に所定間隔で第１磁石１３１が配置されるとともに、周方向において隣り合う第１磁石１３１の間となる位置に第２磁石１３２が配置されている。第１磁石１３１及び第２磁石１３２は、例えばネオジム磁石等の希土類磁石からなる永久磁石である。 及 び As shown in FIGS. 22 and 23, the magnet unit 42 is configured using a magnet array called a Halbach array. That is, the magnet unit 42 includes the first magnet 131 having the magnetization direction (the direction of the magnetization vector) in the radial direction and the second magnet 132 having the magnetization direction (the direction of the magnetization vector) in the circumferential direction. The first magnets 131 are arranged at predetermined intervals in the circumferential direction, and the second magnets 132 are arranged 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 a rare earth magnet such as a neodymium magnet.
　第１磁石１３１は、固定子５０に対向する側（径方向内側）の極が交互にＮ極、Ｓ極となるように周方向に互いに離間して配置されている。また、第２磁石１３２は、各第１磁石１３１の隣において周方向に極性が交互となるように配置されている。これら各磁石１３１，１３２を囲うように設けられる円筒部４３は、軟磁性材料よりなる軟磁性体コアであるとよく、バックコアとして機能する。なお、この第２実施形態の磁石ユニット４２も、ｄ－ｑ座標系において、ｄ軸やｑ軸に対する磁化容易軸の関係は上記第１実施形態と同じである。 The first magnets 131 are circumferentially separated from each other such that the poles on the side facing the stator 50 (inside in the radial direction) alternately become N poles and S poles. 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 each of the magnets 131 and 132 is preferably a soft magnetic core made of a soft magnetic material, and functions as a back core. The magnet unit 42 of the second embodiment also has the same relationship of the easy axis to the d-axis and the q-axis in the dq coordinate system as in the first embodiment.
　また、第１磁石１３１の径方向外側、すなわち磁石ホルダ４１の円筒部４３の側には、軟磁性材料よりなる磁性体１３３が配置されている。例えば磁性体１３３は、電磁鋼板や軟鉄、圧粉鉄心材料により構成されているとよい。この場合、磁性体１３３の周方向の長さは第１磁石１３１の周方向の長さ（特に第１磁石１３１の外周部の周方向の長さ）と同じである。また、第１磁石１３１と磁性体１３３とを一体化した状態でのその一体物の径方向の厚さは、第２磁石１３２の径方向の厚さと同じである。換言すれば、第１磁石１３１は第２磁石１３２よりも磁性体１３３の分だけ径方向の厚さが薄くなっている。各磁石１３１，１３２と磁性体１３３とは、例えば接着剤により相互に固着されている。磁石ユニット４２において第１磁石１３１の径方向外側は、固定子５０とは反対側であり、磁性体１３３は、径方向における第１磁石１３１の両側のうち、固定子５０とは反対側（反固定子側）に設けられている。 磁性 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 an electromagnetic steel sheet, soft iron, or a powdered iron 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). Further, the radial thickness of the integrated body in a state where the first magnet 131 and the magnetic body 133 are integrated is the same as the radial thickness of the second magnet 132. In other words, the thickness of the first magnet 131 in the radial direction is smaller than that of the second magnet 132 by the amount of the magnetic body 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 radial outside of the first magnet 131 is on the opposite side to the stator 50, and the magnetic body 133 is located on the opposite side (anti- On the stator side).
　磁性体１３３の外周部には、径方向外側、すなわち磁石ホルダ４１の円筒部４３の側に突出する凸部としてのキー１３４が形成されている。また、円筒部４３の内周面には、磁性体１３３のキー１３４を収容する凹部としてのキー溝１３５が形成されている。キー１３４の突出形状とキー溝１３５の溝形状とは同じであり、各磁性体１３３に形成されたキー１３４に対応して、キー１３４と同数のキー溝１３５が形成されている。キー１３４及びキー溝１３５の係合により、第１磁石１３１及び第２磁石１３２と磁石ホルダ４１との周方向（回転方向）の位置ずれが抑制されている。なお、キー１３４及びキー溝１３５（凸部及び凹部）を、磁石ホルダ４１の円筒部４３及び磁性体１３３のいずれに設けるかは任意でよく、上記とは逆に、磁性体１３３の外周部にキー溝１３５を設けるとともに、磁石ホルダ４１の円筒部４３の内周部にキー１３４を設けることも可能である。 キ ー A key 134 is formed on the outer periphery of the magnetic body 133 as a protrusion protruding radially outward, that is, toward the cylindrical portion 43 of the magnet holder 41. Further, a key groove 135 is formed on the inner peripheral surface of the cylindrical portion 43 as a concave portion for accommodating the key 134 of the magnetic body 133. The protruding shape of the key 134 and the groove shape of the key groove 135 are the same, and the same number of key grooves 135 as 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, the positional displacement of the first magnet 131 and the second magnet 132 and the magnet holder 41 in the circumferential direction (rotation direction) is suppressed. The key 134 and the key groove 135 (convex portion and concave portion) may be provided in any of the cylindrical portion 43 of the magnet holder 41 and the magnetic member 133, and conversely, on the outer peripheral portion of the magnetic member 133. In addition to providing the key groove 135, it is also possible to provide the key 134 on the inner peripheral portion of the cylindrical portion 43 of the magnet holder 41.
　ここで、磁石ユニット４２では、第１磁石１３１と第２磁石１３２とを交互に配列することにより、第１磁石１３１での磁束密度を大きくすることが可能となっている。そのため、磁石ユニット４２において、磁束の片面集中を生じさせ、固定子５０寄りの側での磁束強化を図ることができる。 Here, in the magnet unit 42, the magnetic flux density in the first magnet 131 can be increased by alternately arranging the first magnets 131 and the second magnets 132. Therefore, in the magnet unit 42, the magnetic flux is concentrated on one side, and the magnetic flux on the side closer to the stator 50 can be enhanced.
　また、第１磁石１３１の径方向外側、すなわち反固定子側に磁性体１３３を配置したことにより、第１磁石１３１の径方向外側での部分的な磁気飽和を抑制でき、ひいては磁気飽和に起因して生じる第１磁石１３１の減磁を抑制できる。これにより、結果的に磁石ユニット４２の磁力を増加させることが可能となっている。本実施形態の磁石ユニット４２は、言うなれば、第１磁石１３１において減磁が生じ易い部分を磁性体１３３に置き換えた構成となっている。 Further, by arranging the magnetic body 133 radially outside the first magnet 131, that is, on the side opposite to the stator, it is possible to suppress partial magnetic saturation outside the first magnet 131 in the radial direction, and as a result, magnetic saturation occurs. The demagnetization of the first magnet 131 generated as a result can be suppressed. As a result, the magnetic force of the magnet unit 42 can be increased. In other words, the magnet unit 42 of the present embodiment has a configuration in which a portion of the first magnet 131 where demagnetization is likely to occur is replaced with a magnetic body 133.
　図２４（ａ）、図２４（ｂ）は、磁石ユニット４２における磁束の流れを具体的に示す図であり、図２４（ａ）は、磁石ユニット４２において磁性体１３３を有していない従来構成を用いた場合を示し、図２４（ｂ）は、磁石ユニット４２において磁性体１３３を有している本実施形態の構成を用いた場合を示している。なお、図２４（ａ）、図２４（ｂ）では、磁石ホルダ４１の円筒部４３及び磁石ユニット４２を直線状に展開して示しており、図の下側が固定子側、上側が反固定子側となっている。 FIGS. 24A and 24B are diagrams specifically showing the flow of magnetic flux in the magnet unit 42. FIG. 24A shows a conventional configuration in which the magnet unit 42 does not have the magnetic body 133. FIG. 24B shows a case where the configuration of the present embodiment having the magnetic body 133 in the magnet unit 42 is used. In FIGS. 24A and 24B, the cylindrical portion 43 and the magnet unit 42 of the magnet holder 41 are linearly developed, and the lower side of the figure is the stator side, and the upper side is the anti-stator. Side.
　図２４（ａ）の構成では、第１磁石１３１の磁束作用面と第２磁石１３２の側面とが、それぞれ円筒部４３の内周面に接触している。また、第２磁石１３２の磁束作用面が第１磁石１３１の側面に接触している。この場合、円筒部４３には、第２磁石１３２の外側経路を通って第１磁石１３１との接触面に入る磁束Ｆ１と、円筒部４３と略平行で、かつ第２磁石１３２の磁束Ｆ２を引きつける磁束との合成磁束が生じる。そのため、円筒部４３において第１磁石１３１と第２磁石１３２との接触面付近において、部分的に磁気飽和が生じることが懸念される。 In the configuration of FIG. 24A, 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. 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, the magnetic flux F1 entering the contact surface with the first magnet 131 through the outer path of the second magnet 132 and the magnetic flux F2 of the second magnet 132 substantially parallel to the cylindrical portion 43 pass through the cylindrical portion 43. A combined magnetic flux with the attracting magnetic flux is generated. Therefore, there is a concern that magnetic saturation may partially occur near the contact surface between the first magnet 131 and the second magnet 132 in the cylindrical portion 43.
　これに対し、図２４（ｂ）の構成では、第１磁石１３１の固定子５０とは反対側において第１磁石１３１の磁束作用面と円筒部４３の内周面との間に磁性体１３３が設けられているため、その磁性体１３３で磁束の通過が許容される。したがって、円筒部４３での磁気飽和を抑制でき、減磁に対する耐力が向上する。 On the other hand, in the configuration of FIG. 24B, the magnetic body 133 is provided between the magnetic flux acting surface of the first magnet 131 and the inner peripheral surface of the cylindrical portion 43 on the side opposite to the stator 50 of the first magnet 131. 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 the proof strength against demagnetization is improved.
　また、図２４（ｂ）の構成では、図２４（ａ）とは異なり、磁気飽和を促すＦ２を消すことができる。これにより、磁気回路全体のパーミアンスを効果的に向上させることができる。このように構成することで、その磁気回路特性を、過酷な高熱条件下でも保つことができる。 Furthermore, in the configuration of FIG. 24B, unlike FIG. 24A, F2 that promotes magnetic saturation can be eliminated. Thereby, the permeance of the entire magnetic circuit can be effectively improved. With this configuration, the magnetic circuit characteristics can be maintained even under severe high-temperature conditions.
　また、従来のＳＰＭロータにおけるラジアル磁石と比べて、磁石内部を通る磁石磁路が長くなる。そのため、磁石パーミアンスが上昇し、磁力を上げ、トルクを増強することができる。さらに、磁束がｄ軸の中央に集まることにより、正弦波整合率を高くすることができる。特に、ＰＷＭ制御により、電流波形を正弦波や台形波とする、又は１２０度通電のスイッチングＩＣを利用すると、より効果的にトルクを増強することができる。 磁石 In addition, compared to the radial magnet in the conventional SPM rotor, the magnet magnetic path passing inside the magnet is longer. Therefore, the magnet permeance increases, the magnetic force can be increased, and the torque can be increased. Further, since the magnetic flux is concentrated at the center of the d-axis, the sine wave matching ratio can be increased. In particular, when the current waveform is changed to a sine wave or a trapezoidal wave by the PWM control, or a switching IC with 120-degree conduction is used, the torque can be more effectively increased.
　なお、固定子コア５２が電磁鋼板により構成される場合において、固定子コア５２の径方向厚さは、磁石ユニット４２の径方向厚さの１／２、又は１／２よりも大きいとよい。例えば、固定子コア５２の径方向厚さは、磁石ユニット４２において磁極中心に設けられる第１磁石１３１の径方向厚さの１／２以上であるとよい。また、固定子コア５２の径方向厚さは、磁石ユニット４２の径方向厚さより小さいとよい。この場合、磁石磁束は約１［Ｔ］であり、固定子コア５２の飽和磁束密度は２［Ｔ］であるため、固定子コア５２の径方向厚さを、磁石ユニット４２の径方向厚さの１／２以上にすることで、固定子コア５２の内周側への磁束漏洩を防ぐことができる。 In the case where the stator core 52 is made of an electromagnetic steel plate, the radial thickness of the stator core 52 may be １ ／ or larger than 径 of the radial thickness of the magnet unit 42. For example, the radial thickness of the stator core 52 is preferably equal to or more than の of the radial thickness of the first magnet 131 provided at the center of the magnetic pole in 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, the magnetic flux of the magnet is about 1 [T], and the saturation magnetic flux density of the stator core 52 is 2 [T], so that the radial thickness of the stator core 52 is reduced by the radial thickness of the magnet unit 42. By not less than の of the above, it is possible to prevent magnetic flux leakage to the inner peripheral side of the stator core 52.
　ハルバッハ構造や極異方構造の磁石では、磁路が擬似円弧状になっているため、周方向の磁束を扱う磁石厚みに比例して、その磁束を上昇させることができる。こういった構成においては、固定子コア５２に流れる磁束は、周方向の磁束を超えることはないと考えられる。すなわち、磁石の磁束１［Ｔ］に対して飽和磁束密度２［Ｔ］の鉄系金属を利用した場合、固定子コア５２の厚みを磁石厚みの半分以上とすれば、磁気飽和せず好適に小型かつ軽量の回転電機を提供することができる。ここで、磁石磁束に対して固定子５０からの反磁界が作用するため、磁石磁束は一般的に０．９［Ｔ］以下となる。そのため、固定子コアは磁石の半分の厚みを持てば、その透磁率を好適に高く保つことができる。 (4) In a magnet having a Halbach structure or a very anisotropic structure, since the magnetic path has a pseudo-arc shape, 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 through the stator core 52 does not exceed the magnetic flux in the circumferential direction. 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, if the thickness of the stator core 52 is set to half or more of the thickness of the magnet, magnetic saturation does not occur. A small and lightweight rotating electric machine can be provided. Here, since the demagnetizing field from the stator 50 acts on the magnet magnetic flux, the magnet magnetic 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 kept suitably high.
　以下に、上述した構成の一部を変更した変形例について説明する。 Hereinafter, a modified example in which a part of the above-described configuration is changed will be described.
　（変形例１）
　上記実施形態では、固定子コア５２の外周面を凹凸のない曲面状とし、その外周面に所定間隔で複数の導線群８１を並べて配置する構成としたが、これを変更してもよい。例えば、図２５に示すように、固定子コア５２は、固定子巻線５１の径方向両側のうち回転子４０とは反対側（図の下側）に設けられた円環状のヨーク１４１と、そのヨーク１４１から、周方向に隣り合う直線部８３の間に向かって突出するように延びる突起部１４２とを有している。突起部１４２は、ヨーク１４１の径方向外側、すなわち回転子４０側に所定間隔で設けられている。固定子巻線５１の各導線群８１は、突起部１４２と周方向において係合しており、突起部１４２を導線群８１の位置決め部として用いつつ周方向に並べて配置されている。なお、突起部１４２が「導線間部材」に相当する。 (Modification 1)
In the above-described embodiment, the outer peripheral surface of the stator core 52 is formed into a curved surface without irregularities, and the plurality of conductive wire groups 81 are arranged at predetermined intervals on the outer peripheral surface. However, this may be changed. For example, as shown in FIG. 25, the stator core 52 includes an annular yoke 141 provided on the opposite side (lower side in the figure) to the rotor 40 on both radial sides of the stator winding 51, A projection 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 at predetermined intervals on the radially outer side of the yoke 141, that is, on the rotor 40 side. Each conductor group 81 of the stator winding 51 is engaged with the protrusion 142 in the circumferential direction, and is arranged side by side in the circumferential direction while using the protrusion 142 as a positioning portion of the conductor group 81. Note that the protrusion 142 corresponds to a “member between conductive wires”.
　突起部１４２は、ヨーク１４１からの径方向の厚さ寸法、言い換えれば、図２５に示すように、ヨーク１４１の径方向において、直線部８３のヨーク１４１に隣接する内側面３２０から突起部１４２の頂点までの距離Ｗが、径方向内外の複数層の直線部８３のうち、ヨーク１４１に径方向に隣接する直線部８３の径方向の厚さ寸法の１／２（図のＨ１）よりも小さい構成となっている。言い換えれば、固定子巻線５１（固定子コア５２）の径方向における導線群８１（伝導部材）の寸法（厚み）Ｔ１（導線８２の厚みの２倍、言い換えれば、導線群８１の固定子コア５２に接する面３２０と、導線群８１の回転子４０に向いた面３３０との最短距離）の４分の３の範囲は非磁性部材（封止部材５７）が占有していればよい。こうした突起部１４２の厚さ制限により、周方向に隣り合う導線群８１（すなわち直線部８３）の間において突起部１４２がティースとして機能せず、ティースによる磁路形成がなされないようになっている。突起部１４２は、周方向に並ぶ各導線群８１の間ごとに全て設けられていなくてもよく、周方向に隣り合う少なくとも１組の導線群８１の間に設けられていればよい。例えば、突起部１４２は、周方向において各導線群８１の間の所定数ごとに等間隔で設けられているとよい。突起部１４２の形状は、矩形状、円弧状など任意の形状でよい。 The projection 142 has a thickness in the radial direction from the yoke 141, in other words, as shown in FIG. 25, the projection 142 extends from the inner side surface 320 adjacent to the yoke 141 of the linear portion 83 in the radial direction of the yoke 141. The distance W to the apex is smaller than 1/2 (H1 in the figure) of the radial thickness of the linear portion 83 radially adjacent to the yoke 141 among the linear portions 83 in the radially inner and outer layers. It has a configuration. In other words, the dimension (thickness) T1 of the conductive wire group 81 (conductive member) in the radial direction of the stator winding 51 (stator core 52) (twice the thickness of the conductive wire 82, in other words, the stator core of the conductive wire group 81) The non-magnetic member (sealing member 57) may occupy three-quarters of the range (the shortest distance between the surface 320 in contact with 52 and the surface 330 of the conductor group 81 facing the rotor 40). Due to the thickness limitation of the protrusions 142, the protrusions 142 do not function as teeth between the conductive wire groups 81 (that is, the linear portions 83) that are adjacent in the circumferential direction, and no magnetic path is formed by the teeth. . The protrusions 142 may not be provided entirely between the conductor groups 81 arranged in the circumferential direction, but may be provided between at least one set of conductor groups 81 adjacent in the circumferential direction. For example, the protrusions 142 may be provided at regular intervals in a predetermined number between the conductive wire groups 81 in the circumferential direction. The shape of the protrusion 142 may be an arbitrary shape such as a rectangular shape or an arc shape.
　また、固定子コア５２の外周面では、直線部８３が一層で設けられていてもよい。したがって、広義には、突起部１４２におけるヨーク１４１からの径方向の厚さ寸法は、直線部８３における径方向の厚さ寸法の１／２よりも小さいものであればよい。 直線 Further, on the outer peripheral surface of the stator core 52, a single linear portion 83 may be provided. Therefore, in a broad sense, the thickness of the projection 142 in the radial direction from the yoke 141 may be smaller than half the thickness of the straight portion 83 in the radial direction.
　なお、回転軸１１の軸心を中心とし、かつヨーク１４１に径方向に隣接する直線部８３の径方向の中心位置を通る仮想円を想定すると、突起部１４２は、その仮想円の範囲内においてヨーク１４１から突出する形状、換言すれば仮想円よりも径方向外側（すなわち回転子４０側）に突出しない形状をなしているとよい。 In addition, assuming a virtual circle centered on the axis of the rotating shaft 11 and passing through the radial center position of the linear portion 83 radially adjacent to the yoke 141, the protrusion 142 is positioned within the range of the virtual circle. It is preferable to have a shape that protrudes from the yoke 141, in other words, a shape that does not protrude radially outward (ie, toward the rotor 40) from the virtual circle.
　上記構成によれば、突起部１４２は、径方向の厚さ寸法が制限されており、周方向に隣り合う直線部８３の間においてティースとして機能するものでないため、各直線部８３の間にティースが設けられている場合に比べて、隣り合う各直線部８３を近づけることができる。これにより、導体８２ａの断面積を大きくすることができ、固定子巻線５１の通電に伴い生じる発熱を低減することができる。かかる構成では、ティースがないことで磁気飽和の解消が可能となり、固定子巻線５１への通電電流を増大させることが可能となる。この場合において、その通電電流の増大に伴い発熱量が増えることに好適に対処することができる。また、固定子巻線５１では、ターン部８４が、径方向にシフトされ、他のターン部８４との干渉を回避する干渉回避部を有することから、異なるターン部８４同士を径方向に離して配置することができる。これにより、ターン部８４においても放熱性の向上を図ることができる。以上により、固定子５０での放熱性能を適正化することが可能になっている。 According to the above configuration, the thickness of the protrusion 142 in the radial direction is limited and does not function as a tooth between the linear portions 83 adjacent in the circumferential direction. Is provided, adjacent linear portions 83 can be brought closer to each other. Thereby, the cross-sectional area of the conductor 82a can be increased, and the heat generated due to the energization of the stator winding 51 can be reduced. In such a configuration, magnetic saturation can be eliminated by the absence of teeth, and the current flowing through the stator winding 51 can be increased. In this case, it is possible to suitably cope with an increase in the amount of heat generated with an increase in the supplied current. Further, in the stator winding 51, since the turn portion 84 is shifted in the radial direction and has an interference avoiding portion that avoids interference with another turn portion 84, the different turn portions 84 are separated from each other in the radial direction. Can be arranged. Thereby, the heat radiation of the turn portion 84 can be improved. As described above, it is possible to optimize the heat radiation performance of the stator 50.
　また、固定子コア５２のヨーク１４１と、回転子４０の磁石ユニット４２（すなわち各磁石９１，９２）とが所定距離以上離れていれば、突起部１４２の径方向の厚さ寸法は、図２５のＨ１に縛られるものではない。具体的には、ヨーク１４１と磁石ユニット４２とが２ｍｍ以上離れていれば、突起部１４２の径方向の厚さ寸法は、図２５のＨ１以上であってもよい。例えば、直線部８３の径方向厚み寸法が２ｍｍを越えており、かつ導線群８１が径方向内外の２層の導線８２により構成されている場合に、ヨーク１４１に隣接していない直線部８３、すなわちヨーク１４１から数えて２層目の導線８２の半分位置までの範囲で、突起部１４２が設けられていてもよい。この場合、突起部１４２の径方向厚さ寸法が「Ｈ１×３／２」までになっていれば、導線群８１における導体断面積を大きくすることで、前記効果を少なからず得ることはできる。 If the yoke 141 of the stator core 52 and the magnet unit 42 of the rotor 40 (that is, the magnets 91 and 92) are separated from each other by a predetermined distance or more, the radial thickness of the protrusion 142 is determined as shown in FIG. H1. Specifically, if the yoke 141 and the magnet unit 42 are separated from each other by 2 mm or more, the radial thickness of the protrusion 142 may be H1 or more in FIG. For example, when the thickness of the straight portion 83 in the radial direction exceeds 2 mm and the conductor group 81 is formed of two layers of conductors 82 inside and outside the radial direction, the straight portion 83 not adjacent to the yoke 141, That is, the protrusion 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 of the protrusion 142 is up to “H1 × 3/2”, the effect can be obtained to a considerable extent by increasing the conductor cross-sectional area in the conductor group 81.
　また、固定子コア５２は、図２６に示す構成であってもよい。なお、図２６では、封止部材５７を省略しているが、封止部材５７が設けられていてもよい。図２６では、便宜上、磁石ユニット４２及び固定子コア５２を直線状に展開して示している。 The stator core 52 may have the configuration shown in FIG. Although the sealing member 57 is omitted in FIG. 26, the sealing member 57 may be provided. In FIG. 26, for convenience, the magnet unit 42 and the stator core 52 are linearly developed and shown.
　図２６の構成では、固定子５０は、周方向に隣接する導線８２（すなわち直線部８３）の間に、導線間部材としての突起部１４２を有している。固定子５０は、固定子巻線５１が通電されると、磁石ユニット４２の磁極の一つ（Ｎ極、またはＳ極）とともに磁気的に機能し、固定子５０の周方向に延びる一部分３５０を有する。この部分３５０の固定子５０の周方向への長さをＷｎとすると、この長さ範囲Ｗｎに存在する突起部１４２の合計の幅（すなわち、固定子５０の周方向への合計の寸法）をＷｔとし、突起部１４２の飽和磁束密度をＢｓ、磁石ユニット４２の１極分の周方向の幅寸法をＷｍ、磁石ユニット４２の残留磁束密度をＢｒとする場合、突起部１４２は、
Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒ　　　…（１）
となる磁性材料により構成されている。 In the configuration of FIG. 26, the stator 50 has a protrusion 142 as a conductor-to-conductor member between the conductors 82 (that is, the straight portions 83) adjacent in the circumferential direction. When the stator winding 51 is energized, the stator 50 functions magnetically together with one of the magnetic poles (N-pole or S-pole) of the magnet unit 42 and forms a part 350 extending in the circumferential direction of the stator 50. Have. Assuming that the length of the portion 350 in the circumferential direction of the stator 50 is Wn, the total width of the protrusions 142 existing in this length range Wn (that is, the total dimension of the stator 50 in the circumferential direction) is defined as Wn. Wt, the saturation magnetic flux density of the projection 142 is Bs, the circumferential width of one pole of the magnet unit 42 is Wm, and the residual magnetic flux density of the magnet unit 42 is Br.
Wt × Bs ≦ Wm × Br (1)
And a magnetic material.
　なお、範囲Ｗｎは、周方向に隣接する複数の導線群８１であって、励磁時期が重複する複数の導線群８１を含むように設定される。その際、範囲Ｗｎを設定する際の基準（境界）として、導線群８１の間隙５６の中心を設定することが好ましい。例えば、図２６に例示する構成の場合、周方向においてＮ極の磁極中心からの距離が最も短いものから順番に、４番目までの導線群８１が、当該複数の導線群８１に相当する。そして、当該４つの導線群８１を含むように範囲Ｗｎが設定される。その際、範囲Ｗｎの端（起点と終点）が間隙５６の中心とされている。 The range Wn is set so as to include a plurality of conductor groups 81 that are adjacent in the circumferential direction and include a plurality of conductor groups 81 whose excitation timings overlap. At this time, it is preferable to set the center of the gap 56 of the conductive wire group 81 as a reference (boundary) when setting the range Wn. For example, in the case of the configuration illustrated in FIG. 26, the fourth conductor group 81 up to the fourth from the shortest distance from the magnetic pole center of the N pole in the circumferential direction corresponds to the plurality of conductor groups 81. Then, the range Wn is set to include the four conductive wire groups 81. At this time, the end (start point and end point) of the range Wn is the center of the gap 56.
　図２６において、範囲Ｗｎの両端には、それぞれ突起部１４２が半分ずつ含まれていることから、範囲Ｗｎには、合計４つ分の突起部１４２が含まれている。したがって、突起部１４２の幅（すなわち、固定子５０の周方向における突起部１４２の寸法、言い換えれば、隣接する導線群８１の間隔）をＡとすると、範囲Ｗｎに含まれる突起部１４２の合計の幅は、Ｗｔ＝１／２Ａ＋Ａ＋Ａ＋Ａ＋１／２Ａ＝４Ａとなる。 26. In FIG. 26, the projections 142 are included in both ends of the range Wn by half each. Therefore, the range Wn includes a total of four projections 142. Therefore, if 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 interval between the adjacent conductor groups 81) is A, the total of the protrusions 142 included in the range Wn is assumed. The width is Wt = 1 / 2A + A + A + A + 1 / 2A = 4A.
　詳しくは、本実施形態では、固定子巻線５１の３相巻線が分布巻であり、その固定子巻線５１では、磁石ユニット４２の１極に対して、突起部１４２の数、すなわち各導線群８１の間となる間隙５６の数が「相数×Ｑ」個となっている。ここでＱとは、１相の導線８２のうち固定子コア５２と接する数である。なお、導線８２が回転子４０の径方向に積層された導線群８１である場合には、１相の導線群８１の内周側の導線８２の数であるともいえる。この場合、固定子巻線５１の３相巻線が各相所定順序で通電されると、１極内において２相分の突起部１４２が励磁される。したがって、磁石ユニット４２の１極分の範囲において固定子巻線５１の通電により励磁される突起部１４２の周方向の合計幅寸法Ｗｔは、突起部１４２（つまり、間隙５６）の周方向の幅寸法をＡとすると、「励磁される相数×Ｑ×Ａ＝２×２×Ａ」となる。 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 protrusions 142, The number of the gaps 56 between the conductor groups 81 is “the number of phases × Q”. Here, Q is the number of one-phase conductive wires 82 that comes into contact with stator core 52. When the conductors 82 are the conductor groups 81 stacked in the radial direction of the rotor 40, the number of conductors 82 on the inner peripheral side of the one-phase conductor group 81 can be said. In this case, when the three-phase winding of the stator winding 51 is energized in a predetermined order for each phase, the projections 142 for two phases are excited within one pole. Therefore, the total circumferential width Wt of the protrusions 142 that is excited by energization of the stator winding 51 in the range of one pole of the magnet unit 42 is equal to the circumferential width of the protrusions 142 (that is, the gap 56). Assuming that the dimension is A, “the number of excited phases × Q × A = 2 × 2 × A” is obtained.
　そして、こうして合計幅寸法Ｗｔが規定された上で、固定子コア５２において、突起部１４２が、上記（１）の関係を満たす磁性材料として構成されている。なお、合計幅寸法Ｗｔは、１極内において比透磁率が１よりも大きくなりえる部分の周方向寸法でもある。また、余裕を考えて、合計幅寸法Ｗｔを、１磁極における突起部１４２の周方向の幅寸法としてもよい。具体的には、磁石ユニット４２の１極に対する突起部１４２の数が「相数×Ｑ」であることから、１磁極における突起部１４２の周方向の幅寸法（合計幅寸法Ｗｔ）を、「相数×Ｑ×Ａ＝３×２×Ａ＝６Ａ」としてもよい。 Then, after the total width dimension Wt is defined in this way, in the stator core 52, the protrusions 142 are formed as a magnetic material satisfying the above-described relationship (1). Note that the total width dimension Wt is also a circumferential dimension of a portion where relative magnetic permeability can be larger than 1 in one pole. Further, in consideration of a margin, the total width dimension Wt may be set to the circumferential width dimension of the projection 142 at one magnetic pole. Specifically, since the number of the projections 142 for one pole of the magnet unit 42 is “the number of phases × Q”, the circumferential width dimension (total width dimension Wt) of the projections 142 for one magnetic pole is set to “ The number of phases × Q × A = 3 × 2 × A = 6A ”.
　なお、ここでいう分布巻とは、磁極の１極対周期（Ｎ極とＳ極）で、固定子巻線５１の一極対があるものである。ここでいう固定子巻線５１の一極対は、電流が互いに逆方向に流れ、ターン部８４で電気的に接続された２つの直線部８３とターン部８４からなる。上記条件みたすものであれば、短節巻（Short Pitch Winding）であっても、全節巻（Full Pitch Winding）の分布巻の均等物とみなす。 分布 Note that the term “distributed winding” used herein refers to a period of one pole pair of magnetic poles (N pole and S pole) and one pole pair of the stator winding 51. The one pole pair of the stator winding 51 here includes two straight portions 83 and a turn portion 84 in which currents flow in opposite directions and are electrically connected by a turn portion 84. If the above conditions are satisfied, even a short-pitch winding (Short Pitch Winding) is regarded as an equivalent of a distributed winding of a full-pitch winding.
　次に、集中巻の場合の例を示す。ここでいう集中巻とは、磁極の１極対の幅と、固定子巻線５１の一極対の幅とが異なるものである。集中巻の一例としては、１つの磁極対に対して導線群８１が３つ、２つの磁極対に対して導線群８１が３つ、４つの磁極対に対して導線群８１が９つ、５つの磁極対に対して導線群８１が９つのような関係であるものが挙げられる。 Next, an example of concentrated winding is shown. The term “concentrated winding” as used herein means that the width of one pole pair of magnetic poles is different from the width of one pole pair of the stator winding 51. As an example of concentrated winding, three conductor groups 81 for one magnetic pole pair, three conductor groups 81 for two magnetic pole pairs, nine conductor groups 81 for four magnetic pole pairs, and 5 There is one in which the conductor group 81 has nine relations to one magnetic pole pair.
　ここで、固定子巻線５１を集中巻とする場合には、固定子巻線５１の３相巻線が所定順序で通電されると、２相分の固定子巻線５１が励磁される。その結果、２相分の突起部１４２が励磁される。したがって、磁石ユニット４２の１極分の範囲において固定子巻線５１の通電により励磁される突起部１４２の周方向の幅寸法Ｗｔは、「Ａ×２」となる。そして、こうして幅寸法Ｗｔが規定された上で、突起部１４２が、上記（１）の関係を満たす磁性材料として構成されている。なお、上記で示した集中巻の場合は、同一相の導線群８１に囲まれた領域において、固定子５０の周方向にある突起部１４２の幅の総和をＡとする。また、集中巻におけるＷｍは「磁石ユニット４２のエアギャップに対向する面の全周」×「相数」÷「導線群８１の分散数」に相当する。 Here, when the stator windings 51 are concentrated windings, when the three-phase windings of the stator windings 51 are energized in a predetermined order, the stator windings 51 for two phases are excited. As a result, the projections 142 for two phases are excited. Therefore, in the range of one pole of the magnet unit 42, the circumferential width Wt of the protrusion 142 that is excited when the stator winding 51 is energized is “A × 2”. After the width Wt is defined in this manner, the protrusion 142 is formed of a magnetic material satisfying the relationship (1). In the case of the concentrated winding described above, A is the sum of the widths of the protrusions 142 in the circumferential direction of the stator 50 in the region surrounded by the conductor group 81 of the same phase. Wm in the concentrated winding is equivalent 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 conductive wire group 81”.
　ちなみに、ネオジム磁石やサマリウムコバルト磁石、フェライト磁石といったＢＨ積が２０［ＭＧＯｅ（ｋＪ／ｍ^3）］以上の磁石ではＢｄ＝１．０強［Ｔ］、鉄ではＢｒ＝２．０強［Ｔ］である。そのため、高出力モータとしては、固定子コア５２において、突起部１４２が、Ｗｔ＜１／２×Ｗｍの関係を満たす磁性材料であればよい。 Incidentally, magnets having a BH product of 20 [MGOe (kJ / m ^ 3)] or more, such as neodymium magnets, samarium cobalt magnets, and ferrite magnets, have Bd = 1.0 or more [T], and iron has Br = 2.0 or more [T]. ]. Therefore, as the high-output motor, the protrusion 142 in the stator core 52 may be a magnetic material that satisfies the relationship of Wt <１ ／ × Wm.
　また、後述するように導線８２が外層被膜１８２を備える場合には、導線８２同士の外層被膜１８２が接触するように、導線８２を固定子コア５２の周方向に配置しても良い。この場合は、Ｗｔは、０又は接触する両導線８２の外層被膜１８２の厚さ、と看做すことができる。 In the case where the conductor 82 includes the outer coating 182 as described later, the conductor 82 may be arranged in the circumferential direction of the stator core 52 so that the outer coating 182 between the conductors 82 contacts. In this case, Wt can be regarded as 0 or the thickness of the outer layer coating 182 of the two conducting wires 82 in contact with each other.
　図２５や図２６の構成では、回転子４０側の磁石磁束に対して不相応に小さい導線間部材（突起部１４２）を有する構成となっている。なお、回転子４０は、インダクタンスが低くかつ平坦な表面磁石型ロータであり、磁気抵抗的に突極性を有していないものとなっている。かかる構成では、固定子５０のインダクタンス低減が可能となっており、固定子巻線５１のスイッチングタイミングのずれに起因する磁束歪みの発生が抑制され、ひいては軸受２１，２２の電食が抑制される。 や In the configuration of FIGS. 25 and 26, the inter-conductor member (protrusion 142) that is unreasonably small with respect to the magnetic flux on the rotor 40 side is provided. The rotor 40 is a flat surface magnet type rotor having low inductance and does not have saliency in terms of magnetoresistance. In such a configuration, the inductance of the stator 50 can be reduced, and the occurrence of magnetic flux distortion due to the shift of the switching timing of the stator winding 51 is suppressed, and thus the electrolytic corrosion of the bearings 21 and 22 is suppressed. .
　（変形例２）
　上記式（１）の関係を満たす導線間部材を用いる固定子５０として、以下の構成を採用することも可能である。図２７では、固定子コア５２の外周面側（図の上面側）に、導線間部材として歯状部１４３が設けられている。歯状部１４３は、ヨーク１４１から突出するようにして周方向に所定間隔で設けられており、径方向に導線群８１と同じ厚み寸法を有している。歯状部１４３の側面は導線群８１の各導線８２に接している。ただし、歯状部１４３と各導線８２との間に隙間があってもよい。 (Modification 2)
The following configuration can be adopted as the stator 50 using the inter-conductor member satisfying the relationship of the above equation (1). In FIG. 27, a tooth-like portion 143 is provided on the outer peripheral surface side (the upper surface side in the drawing) of the stator core 52 as an inter-conductor member. The teeth 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 conductor group 81 in the radial direction. The side surface of the toothed portion 143 is in contact with each conductor 82 of the conductor group 81. However, a gap may be provided between the tooth-shaped portion 143 and each conductive wire 82.
　歯状部１４３は、周方向における幅寸法に制限が付与されており、磁石量に対して不相応に細い極歯（ステータティース）を備えるものとなっている。かかる構成により、歯状部１４３は、１．８Ｔ以上で磁石磁束により確実に飽和し、パーミアンスの低下によりインダクタンスを下げることができる。 The tooth-shaped portion 143 has a limitation on the width in the circumferential direction, and has pole teeth (stator teeth) that are unreasonably thin with respect to the amount of magnets. With such a configuration, the tooth-shaped portion 143 is surely saturated by the magnetic flux at 1.8 T or more, and the inductance can be reduced due to a decrease in permeance.
　ここで、磁石ユニット４２において、固定子側における磁束作用面の１極あたりの表面積をＳｍ、磁石ユニット４２の残留磁束密度をＢｒとすると、磁石ユニット側の磁束は、例えば「Ｓｍ×Ｂｒ」となる。また、各歯状部１４３における回転子側の表面積をＳｔ、導線８２の一相あたりの数をｍとし、固定子巻線５１の通電により１極内において２相分の歯状部１４３が励磁されるとすると、固定子側の磁束は、例えば「Ｓｔ×ｍ×２×Ｂｓ」となる。この場合、
Ｓｔ×ｍ×２×Ｂｓ＜Ｓｍ×Ｂｒ　　　…（２）
の関係が成立するように歯状部１４３の寸法を制限することで、インダクタンスの低減が図られている。 Here, in the magnet unit 42, assuming that the surface area per pole of the magnetic flux acting surface on the stator side per pole is Sm and the residual magnetic flux density of the magnet unit 42 is Br, the magnetic flux on the magnet unit side is, for example, “Sm × Br”. Become. Also, the surface area of each tooth 143 on the rotor side is St, the number of conductors 82 per phase is m, and the tooth windings 143 for two phases are excited within one pole by the current flowing through the stator winding 51. Then, 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 size of the tooth-shaped portion 143 so that the relationship of
　なお、磁石ユニット４２と歯状部１４３とで軸方向の寸法が同一である場合、磁石ユニット４２の１極分の周方向の幅寸法をＷｍ、歯状部１４３の周方向の幅寸法をＷｓｔとすると、上記式（２）は、式（３）のように置き換えられる。
Ｗｓｔ×ｍ×２×Ｂｓ＜Ｗｍ×Ｂｒ　　　…（３）
　より具体的には、例えばＢｓ＝２Ｔ、Ｂｒ＝１Ｔであり、ｍ＝２であると想定すると、上記式（３）は、「Ｗｓｔ＜Ｗｍ／８」の関係となる。この場合、歯状部１４３の幅寸法Ｗｓｔを、磁石ユニット４２の１極分の幅寸法Ｗｍの１／８よりも小さくすることで、インダクタンスの低減が図られている。なお、数ｍが１であれば、歯状部１４３の幅寸法Ｗｓｔを、磁石ユニット４２の１極分の幅寸法Ｗｍの１／４よりも小さくするとよい。 When the magnet unit 42 and the toothed part 143 have the same axial dimension, the circumferential width of one pole of the magnet unit 42 is Wm, and the circumferential width of the toothed part 143 is Wst. Then, the above equation (2) is replaced by an equation (3).
Wst × m × 2 × Bs <Wm × Br (3)
More specifically, assuming that Bs = 2T, Br = 1T, and m = 2, the above equation (3) has a relationship of “Wst <Wm / 8”. In this case, the inductance is reduced by setting the width Wst of the toothed portion 143 to be smaller than １ ／ of the width Wm of one pole of the magnet unit 42. If the number m is 1, the width Wst of the toothed portion 143 may be smaller than １ ／ of the width Wm of one pole of the magnet unit 42.
　なお、上記式（３）において、「Ｗｓｔ×ｍ×２」は、磁石ユニット４２の１極分の範囲において固定子巻線５１の通電により励磁される歯状部１４３の周方向の幅寸法に相当する。 In the above equation (3), “Wst × m × 2” is the width in the circumferential direction of the tooth-shaped portion 143 that is excited when the stator winding 51 is energized in the range of one pole of the magnet unit 42. Equivalent to.
　図２７の構成では、上述した図２５，図２６の構成と同様に、回転子４０側の磁石磁束に対して不相応に小さい導線間部材（歯状部１４３）を有する構成となっている。かかる構成では、固定子５０のインダクタンス低減が可能となっており、固定子巻線５１のスイッチングタイミングのずれに起因する磁束歪みの発生が抑制され、ひいては軸受２１，２２の電食が抑制される。 In the configuration of FIG. 27, similarly to the configurations of FIGS. 25 and 26 described above, a configuration is provided in which the inter-wire member (tooth portion 143) is unreasonably 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 occurrence of magnetic flux distortion due to the shift of the switching timing of the stator winding 51 is suppressed, and thus the electrolytic corrosion of the bearings 21 and 22 is suppressed. .
　（変形例３）
　上記実施形態では、固定子巻線５１を覆う封止部材５７を、固定子コア５２の径方向外側において各導線群８１を全て含む範囲、すなわち径方向の厚さ寸法が各導線群８１の径方向の厚さ寸法よりも大きくなる範囲で設ける構成としたが、これを変更してもよい。例えば、図２８に示すように、封止部材５７を、導線８２の一部がはみ出すように設ける構成とする。より具体的には、封止部材５７を、導線群８１において最も径方向外側となる導線８２の一部を径方向外側、すなわち固定子５０側に露出させた状態で設ける構成とする。この場合、封止部材５７の径方向の厚さ寸法は、各導線群８１の径方向の厚さ寸法と同じ、又はその厚さ寸法よりも小さいとよい。 (Modification 3)
In the above-described embodiment, the sealing member 57 that covers the stator windings 51 is provided in a range that includes all of the conductor groups 81 outside the stator core 52 in the radial direction, that is, the thickness in the radial direction is equal to the diameter of each conductor group 81. Although the thickness is set to be larger than the thickness in the direction, the thickness may be changed. For example, as shown in FIG. 28, the sealing member 57 is provided so that a part of the conductive wire 82 protrudes. More specifically, the sealing member 57 is configured to be provided in a state in which a part of the conductive wire 82 that is the radially outermost in the conductive wire group 81 is exposed to the radially outer side, that is, to the stator 50 side. In this case, the thickness of the sealing member 57 in the radial direction is preferably equal to or smaller than the thickness of the conductor group 81 in the radial direction.
　（変形例４）
　図２９に示すように、固定子５０において、各導線群８１が封止部材５７により封止されていない構成としてもよい。つまり、固定子巻線５１を覆う封止部材５７を用いない構成とする。この場合、周方向に並ぶ各導線群８１の間に導線間部材が設けられず空隙となっている。要するに、周方向に並ぶ各導線群８１の間に導線間部材が設けられていない構成となっている。なお、空気を非磁性体、又は非磁性体の均等物としてＢｓ＝０と看做し、この空隙に空気を配置しても良い。 (Modification 4)
As shown in FIG. 29, in the stator 50, the configuration may be such that each conductive wire group 81 is not sealed by the sealing member 57. That is, the configuration is such that the sealing member 57 that covers the stator winding 51 is not used. In this case, there is no gap between the conductors between the conductor groups 81 arranged in the circumferential direction, and there is a gap. In short, the configuration is such that no inter-conductor member is provided between the conductor groups 81 arranged in the circumferential direction. Note that Bs = 0 may be regarded as air as a non-magnetic material or an equivalent of the non-magnetic material, and air may be arranged in this gap.
　（変形例５）
　固定子５０おける導線間部材を非磁性材料により構成する場合に、その非磁性材料として、樹脂以外の材料を用いることも可能である。例えば、オーステナイト系のステンレス鋼であるＳＵＳ３０４を用いる等、金属系の非磁性材料を用いてもよい。 (Modification 5)
When the inter-wire member of the stator 50 is made of a non-magnetic material, a material other than resin can be used as the non-magnetic material. For example, a metallic nonmagnetic material such as SUS304, which is an austenitic stainless steel, may be used.
　（変形例６）
　固定子５０が固定子コア５２を具備していない構成としてもよい。この場合、固定子５０は、図１２に示す固定子巻線５１により構成されることになる。なお、固定子コア５２を具備していない固定子５０において、固定子巻線５１を封止材により封止する構成としてもよい。又は、固定子５０が、軟磁性材からなる固定子コア５２に代えて、合成樹脂等の非磁性材からなる円環状の巻線保持部を備える構成であってもよい。 (Modification 6)
The stator 50 may not have the stator core 52. In this case, the stator 50 is constituted by the stator winding 51 shown in FIG. In the stator 50 having no stator core 52, the stator winding 51 may be sealed with a sealing material. Alternatively, the stator 50 may include an annular winding holding portion made of a nonmagnetic material such as a synthetic resin, instead of the stator core 52 made of a soft magnetic material.
　（変形例７）
　上記第１実施形態では、回転子４０の磁石ユニット４２として周方向に並べた複数の磁石９１，９２を用いる構成としたが、これを変更し、磁石ユニット４２として円環状の永久磁石である環状磁石を用いる構成としてもよい。具体的には、図３０に示すように、磁石ホルダ４１の円筒部４３の径方向内側に、環状磁石９５が固定されている。環状磁石９５には、周方向に極性が交互となる複数の磁極が設けられており、ｄ軸及びｑ軸のいずれにおいても一体的に磁石が形成されている。環状磁石９５には、各磁極のｄ軸において配向の向きが径方向となり、各磁極間のｑ軸において配向の向きが周方向となるような円弧状の磁石磁路が形成されている。 (Modification 7)
In the first embodiment, the plurality of magnets 91 and 92 arranged in the circumferential direction are used as the magnet unit 42 of the rotor 40. However, this is changed, and the magnet unit 42 is an annular permanent magnet. A configuration using a magnet may be used. Specifically, as shown in FIG. 30, an annular magnet 95 is fixed radially inside the cylindrical portion 43 of the magnet holder 41. The annular magnet 95 is provided with a plurality of magnetic poles having alternating polarities in the circumferential direction, and the magnet is integrally formed on both the d-axis and the q-axis. The annular magnet 95 is formed with an arc-shaped magnet magnetic path in which the direction of orientation is radial in the d-axis of each magnetic pole and circumferential in the q-axis between the magnetic poles.
　なお、環状磁石９５では、ｄ軸寄りの部分において磁化容易軸がｄ軸に平行又はｄ軸に平行に近い向きとなり、かつｑ軸寄りの部分において磁化容易軸がｑ軸に直交又はｑ軸に直交に近い向きとなる円弧状の磁石磁路が形成されるように配向がなされていればよい。 In the ring magnet 95, the easy axis of magnetization is oriented parallel to or nearly parallel to the d axis in a portion near the d axis, and the easy axis of magnetization is orthogonal to the q axis or in the q axis in a portion near the q axis. It is sufficient that the orientation is made so as to form an arc-shaped magnet magnetic path that is nearly orthogonal.
　（変形例８）
　本変形例では、制御装置１１０の制御手法の一部を変更している。本変形例では、主に、第１実施形態で説明した構成に対する相違部分について説明する。 (Modification 8)
In this modification, a part of the control method of the control device 110 is changed. In the present modification, mainly, differences from the configuration described in the first embodiment will be described.
　まず、図３１を用いて、図２０に示した操作信号生成部１１６，１２６及び図２１に示した操作信号生成部１３０ａ，１３０ｂ内の処理について説明する。なお、各操作信号生成部１１６，１２６，１３０ａ，１３０ｂにおける処理は基本的には同様である。このため、以下では、操作信号生成部１１６の処理を例にして説明する。 First, the processing in the operation signal generators 116 and 126 shown in FIG. 20 and the processing in the operation signal generators 130a and 130b shown in FIG. 21 will be described with reference to FIG. The processing in each of the operation signal generators 116, 126, 130a, and 130b is basically the same. Therefore, hereinafter, the processing of the operation signal generation unit 116 will be described as an example.
　操作信号生成部１１６は、キャリア生成部１１６ａと、Ｕ，Ｖ，Ｗ相比較器１１６ｂＵ，１１６ｂＶ，１１６ｂＷとを備えている。本実施形態において、キャリア生成部１１６ａは、キャリア信号ＳｉｇＣとして三角波信号を生成して出力する。 The operation signal generator 116 includes a carrier generator 116a and U, V, and W phase comparators 116bU, 116bV, and 116bW. In the present embodiment, the carrier generator 116a generates and outputs a triangular wave signal as the carrier signal SigC.
　Ｕ，Ｖ，Ｗ相比較器１１６ｂＵ，１１６ｂＶ，１１６ｂＷには、キャリア生成部１１６ａより生成されたキャリア信号ＳｉｇＣと、３相変換部１１５により算出されたＵ，Ｖ，Ｗ相指令電圧とが入力される。Ｕ，Ｖ，Ｗ相指令電圧は、例えば正弦波状の波形であり、電気角で位相が１２０°ずつずれている。 The U, V, and W phase comparators 116bU, 116bV, and 116bW receive the carrier signal SigC generated by the carrier generation unit 116a and the U, V, and W phase command voltages calculated by the three-phase conversion unit 115. You. The U-, V-, and W-phase command voltages are, for example, sinusoidal waveforms, and are out of phase by 120 ° in electrical angle.
　Ｕ，Ｖ，Ｗ相比較器１１６ｂＵ，１１６ｂＶ，１１６ｂＷは、Ｕ，Ｖ，Ｗ相指令電圧とキャリア信号ＳｉｇＣとの大小比較に基づくＰＷＭ（ＰＷＭ：pulse width modulation）制御により、第１インバータ１０１におけるＵ，Ｖ，Ｗ相の上アーム及び下アームの各スイッチＳｐ，Ｓｎの操作信号を生成する。具体的には、操作信号生成部１１６は、Ｕ，Ｖ，Ｗ相指令電圧を電源電圧で規格化した信号と、キャリア信号との大小比較に基づくＰＷＭ制御により、Ｕ，Ｖ，Ｗ相の各スイッチＳｐ，Ｓｎの操作信号を生成する。ドライバ１１７は、操作信号生成部１１６により生成された操作信号に基づいて、第１インバータ１０１におけるＵ，Ｖ，Ｗ相の各スイッチＳｐ，Ｓｎをオンオフさせる。 The U, V, W phase comparators 116bU, 116bV, 116bW control the U, V, W phase command voltage and the carrier signal SigC by PWM (pulse width modulation) based on a magnitude comparison between the U, V, W phase voltage and the carrier signal SigC. , V, and W-phase operation signals for the switches Sp and Sn of the upper arm and the lower arm. Specifically, the operation signal generation unit 116 performs each of the U, V, and W phases by PWM control based on a magnitude comparison between a signal obtained by standardizing the U, V, and W phase command voltages by the power supply voltage and a carrier signal. An operation signal for the switches Sp and Sn is generated. The driver 117 turns on and off the U, V, and W phase switches Sp and Sn in the first inverter 101 based on the operation signal generated by the operation signal generation unit 116.
　制御装置１１０は、キャリア信号ＳｉｇＣのキャリア周波数ｆｃ、すなわち各スイッチＳｐ，Ｓｎのスイッチング周波数を変更する処理を行う。キャリア周波数ｆｃは、回転電機１０の低トルク領域又は高回転領域において高く設定され、回転電機１０の高トルク領域において低く設定される。この設定は、各相巻線に流れる電流の制御性の低下を抑制するためになされる。 The control device 110 performs a process of changing the carrier frequency fc of the carrier signal SigC, that is, the switching frequency of each of the switches Sp and Sn. The carrier frequency fc is set high in a low torque region or a high rotation region of the rotating electric machine 10, and set low in a high torque region of the rotating electric machine 10. This setting is made in order to suppress a decrease in the controllability of the current flowing through each phase winding.
　つまり、固定子５０のコアレス化に伴い、固定子５０におけるインダクタンスの低減を図ることができる。ここで、インダクタンスが低くなると、回転電機１０の電気的時定数が小さくなる。その結果、各相巻線に流れる電流のリップルが増加して巻線に流れる電流の制御性が低下し、電流制御が発散する懸念がある。この制御性低下の影響は、巻線に流れる電流（例えば、電流の実効値）が高電流領域に含まれる場合よりも低電流領域に含まれる場合に顕著となり得る。この問題に対処すべく、本変形例において、制御装置１１０はキャリア周波数ｆｃを変更する。 In other words, with the coreless stator 50, the inductance of the stator 50 can be reduced. Here, when the inductance decreases, the electrical time constant of the rotating electric machine 10 decreases. As a result, there is a concern that the ripple of the current flowing through each phase winding increases, the controllability of the current flowing through the winding decreases, and current control diverges. The effect of the decrease in controllability may be more remarkable when the current flowing through the winding (for example, the effective value of the current) is included in the low current region than in the high current region. In order to address this problem, in the present modification, control device 110 changes carrier frequency fc.
　図３２を用いて、キャリア周波数ｆｃを変更する処理について説明する。この処理は、操作信号生成部１１６の処理として、制御装置１１０により、例えば所定の制御周期で繰り返し実行される。 A process of changing the carrier frequency fc will be described with reference to FIG. This process is repeatedly executed by the control device 110, for example, at a predetermined control cycle, as the process of the operation signal generation unit 116.
　ステップＳ１０では、各相の巻線５１ａに流れる電流が低電流領域に含まれているか否かを判定する。この処理は、回転電機１０の現在のトルクが低トルク領域であることを判定するための処理である。低電流領域に含まれているか否かの判定手法としては、例えば、以下の第１，第２の方法が挙げられる。 In Step S10, it is determined whether or not the current flowing through each phase winding 51a is included in the low current region. This process is a process for determining that the current torque of the rotating electric machine 10 is in the low torque region. For example, the following first and second methods can be used as a method for determining whether or not the pixel is included in the low current region.
　＜第１の方法＞
　ｄｑ変換部１１２により変換されたｄ軸電流とｑ軸電流とに基づいて、回転電機１０のトルク推定値を算出する。そして、算出したトルク推定値がトルク閾値未満であると判定した場合、巻線５１ａに流れる電流が低電流領域に含まれていると判定し、トルク推定値がトルク閾値以上であると判定した場合、高電流領域に含まれていると判定する。ここで、トルク閾値は、例えば、回転電機１０の起動トルク（拘束トルクともいう）の１／２に設定されていればよい。 <First method>
Based on the d-axis current and the q-axis current converted by the dq conversion unit 112, an estimated torque value of the rotating electric machine 10 is calculated. When 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 when it is determined that the torque estimated value is equal to or larger than the torque threshold. , Is included in the high current region. Here, the torque threshold may be set to, for example, １ ／ of the starting torque (also referred to as a constraint torque) of the rotating electric machine 10.
　＜第２の方法＞
　角度検出器により検出された回転子４０の回転角度が速度閾値以上であると判定した場合、巻線５１ａに流れる電流が低電流領域に含まれている、すなわち高回転領域であると判定する。ここで、速度閾値は、例えば、回転電機１０の最大トルクがトルク閾値となる場合の回転速度に設定されていればよい。 <Second method>
When 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, the rotation speed when the maximum torque of the rotating electric machine 10 is the torque threshold.
　ステップＳ１０において否定判定した場合には、高電流領域であると判定し、ステップＳ１１に進む。ステップＳ１１では、キャリア周波数ｆｃを第１周波数ｆＬに設定する。 場合 If a negative determination is made in step S10, it is determined that the current is in the high current region, and the process proceeds to step S11. In step S11, the carrier frequency fc is set to the first frequency fL.
　ステップＳ１０において肯定判定した場合には、ステップＳ１２に進み、キャリア周波数ｆｃを、第１周波数ｆＬよりも高い第２周波数ｆＨに設定する。 (4) If an affirmative determination is made in step S10, the process proceeds to step S12, and the carrier frequency fc is set to the second frequency fH higher than the first frequency fL.
　以上説明した本変形例によれば、各相巻線に流れる電流が高電流領域に含まれる場合よりも低電流領域に含まれる場合においてキャリア周波数ｆｃが高く設定される。このため、低電流領域において、スイッチＳｐ，Ｓｎのスイッチング周波数を高くすることができ、電流リップルの増加を抑制することができる。これにより、電流制御性の低下を抑制することができる。 According to the present modification described above, the carrier frequency fc is set higher when the current flowing through each phase winding is included in the low current region than 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, a decrease in current controllability can be suppressed.
　一方、各相巻線に流れる電流が高電流領域に含まれる場合、低電流領域に含まれる場合よりもキャリア周波数ｆｃが低く設定される。高電流領域においては、低電流領域よりも巻線に流れる電流の振幅が大きいため、インダクタンスが低くなったことに起因する電流リップルの増加が、電流制御性に及ぼす影響が小さい。このため、高電流領域においては、低電流領域よりもキャリア周波数ｆｃを低く設定することができ、各インバータ１０１，１０２のスイッチング損失を低減することができる。 On the other hand, when the current flowing through each phase winding is included in the high current region, the carrier frequency fc is set lower than when the current is included in the low current region. In the high current region, the amplitude of the current flowing through the winding is larger than in the low current region, so that the increase in the current ripple due to the lower inductance has little effect on the current controllability. Therefore, the carrier frequency fc can be set lower in the high current region than in the low current region, and the switching loss of each of the inverters 101 and 102 can be reduced.
　本変形例においては、以下に示す形態の実施が可能である。 変 形 In this modification, the following embodiment is possible.
　・キャリア周波数ｆｃが第１周波数ｆＬに設定されている場合において、図３２のステップＳ１０において肯定判定されたとき、キャリア周波数ｆｃを、第１周波数ｆＬから第２周波数ｆＨに向かって徐変させてもよい。 In the case where the carrier frequency fc is set to the first frequency fL, when the affirmative determination is made in step S10 of FIG. 32, the carrier frequency fc is gradually changed from the first frequency fL to the second frequency fH. Is also good.
　また、キャリア周波数ｆｃが第２周波数ｆＨに設定されている場合において、ステップＳ１０において否定判定されたとき、キャリア周波数ｆｃを、第２周波数ｆＨから第１周波数ｆＬに向かって徐変させてもよい。 When the carrier frequency fc is set to the second frequency fH and a negative determination is made in step S10, the carrier frequency fc may be gradually changed from the second frequency fH to the first frequency fL. .
　・ＰＷＭ制御に代えて、空間ベクトル変調（ＳＶＭ：space vector modulation）制御によりスイッチの操作信号が生成されてもよい。この場合であっても、上述したスイッチング周波数の変更を適用することができる。 A switch operation signal may be generated by space vector modulation (SVM) control instead of · PWM control. Even in this case, the change of the switching frequency described above can be applied.
　（変形例９）
　上記各実施形態では、導線群８１を構成する各相２対ずつの導線が、図３３（ａ）に示すように並列接続されていた。図３３（ａ）は、２対の導線である第１，第２導線８８ａ，８８ｂの電気的接続を示す図である。ここで、図３３（ａ）に示す構成に代えて、図３３（ｂ）に示すように、第１，第２導線８８ａ，８８ｂが直列接続されていてもよい。 (Modification 9)
In each of the above embodiments, two pairs of conductors of each phase constituting the conductor group 81 are connected in parallel as shown in FIG. FIG. 33A is a diagram illustrating electrical connection between first and second conductive wires 88a and 88b, which are two pairs of conductive wires. Here, instead of the configuration shown in FIG. 33A, the first and second conductive wires 88a and 88b may be connected in series as shown in FIG.
　また、３対以上の多層導線が径方向に積層配置されていてもよい。図３４に、４対の導線である第１～第４導線８８ａ～８８ｄが積層配置されている構成を示す。第１～第４導線８８ａ～８８ｄは、固定子コア５２に近い方から、第１，第２，第３，第４導線８８ａ，８８ｂ，８８ｃ，８８ｄの順に径方向に並んで配置されている。 Furthermore, three or more pairs of multilayer conductors may be stacked in the radial direction. FIG. 34 shows a configuration in which first to fourth conductive wires 88a to 88d, which are four pairs of conductive wires, are stacked. The first to fourth conductive wires 88a to 88d are arranged in the radial direction in the order of the first, second, third, and fourth conductive wires 88a, 88b, 88c, and 88d from the side closer to the stator core 52. .
　ここで、図３３（ｃ）に示すように、第３，第４導線８８ｃ，８８ｄが並列接続されるとともに、この並列接続体の一端に第１導線８８ａが接続され、他端に第２導線８８ｂが接続されていてもよい。並列接続にすると、その並列接続された導線の電流密度を低下させることができ、通電時の発熱を抑制できる。そのため、冷却水通路７４が形成されたハウジング（ユニットベース６１）に筒状の固定子巻線を組み付ける構成において、並列接続されていない第１，第２導線８８ａ，８８ｂがユニットベース６１に当接する固定子コア５２側に配置され、並列接続された第３，第４導線８８ｃ，８８ｄが反固定子コア側に配置されている構成とする。これにより、多層導線構造における各導線８８ａ～８８ｄの冷却性能を均等化することができる。 Here, as shown in FIG. 33C, the third and fourth conductors 88c and 88d are connected in parallel, a first conductor 88a is connected to one end of the parallel connection body, and a second conductor is connected to the other end. 88b may be connected. When the connection is made in parallel, the current density of the conductive wires connected in parallel can be reduced, and the heat generation during energization can be suppressed. Therefore, in a 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 conductive wires 88a and 88b that are not connected in parallel abut on the unit base 61. The third and fourth conductive wires 88c and 88d arranged on the stator core 52 side and connected in parallel are arranged on the side opposite to the stator core side. Thereby, the cooling performance of each of the conductors 88a to 88d in the multilayer conductor structure can be equalized.
　なお、第１～第４導線８８ａ～８８ｄからなる導線群８１の径方向の厚さ寸法は、１磁極内における１相分の周方向の幅寸法よりも小さいものとされていればよい。 The thickness of the conductor group 81 including the first to fourth conductors 88a to 88d in the radial direction may be smaller than the circumferential width of one phase in one magnetic pole.
　（変形例１０）
　回転電機１０をインナロータ構造（内転構造）としてもよい。この場合、例えばハウジング３０内において、径方向外側に固定子５０が設けられ、その径方向内側に回転子４０が設けられるとよい。また、固定子５０及び回転子４０の軸方向両端のうちその一方の側又はその両方の側にインバータユニット６０が設けられているとよい。図３５は、回転子４０及び固定子５０の横断面図であり、図３６は、図３５に示す回転子４０及び固定子５０の一部を拡大して示す図である。 (Modification 10)
The rotating electric machine 10 may have an inner rotor structure (adduction structure). In this case, for example, the stator 50 may be provided radially outside the housing 30 and the rotor 40 may be provided radially inside the housing 30. Further, the inverter unit 60 may be provided on one or both of the axial ends of the stator 50 and the rotor 40. FIG. 35 is a cross-sectional view of the rotor 40 and the stator 50, and FIG. 36 is an enlarged view of a part of the rotor 40 and the stator 50 shown in FIG.
　インナロータ構造を前提とする図３５及び図３６の構成は、アウタロータ構造を前提とする図８及び図９の構成に対して、回転子４０及び固定子５０が径方向内外で逆になっていることを除いて、同様の構成となっている。簡単に説明すると、固定子５０は、扁平導線構造の固定子巻線５１と、ティースを持たない固定子コア５２とを有している。固定子巻線５１は、固定子コア５２の径方向内側に組み付けられている。固定子コア５２は、アウタロータ構造の場合と同様に、以下のいずれかの構成を有する。
（Ａ）固定子５０において、周方向における各導線部の間に導線間部材を設け、かつその導線間部材として、１磁極における導線間部材の周方向の幅寸法をＷｔ、導線間部材の飽和磁束密度をＢｓ、１磁極における磁石ユニットの周方向の幅寸法をＷｍ、磁石ユニットの残留磁束密度をＢｒとした場合に、Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒの関係となる磁性材料を用いている。
（Ｂ）固定子５０において、周方向における各導線部の間に導線間部材を設け、かつその導線間部材として、非磁性材料を用いている。
（Ｃ）固定子５０において、周方向における各導線部の間に導線間部材を設けていない構成となっている。 The configuration shown in FIGS. 35 and 36 based on the inner rotor structure is different from the configuration shown in FIGS. 8 and 9 based on the outer rotor structure in that the rotor 40 and the stator 50 are reversed inside and outside the radial direction. Except for, the configuration is the same. In brief, the stator 50 has a stator winding 51 having a flat conductive wire structure and a stator core 52 having no teeth. The stator winding 51 is mounted radially inside the stator core 52. The stator core 52 has any one of the following configurations, similarly to the case of the outer rotor structure.
(A) In the stator 50, an inter-conductor member is provided between the respective conductor portions in the circumferential direction, and as the inter-conductor member, the circumferential width of the inter-conductor member at one magnetic pole is Wt, and the saturation of the inter-conductor member is achieved. When the magnetic flux density is Bs, the circumferential width of the magnet unit at one magnetic pole is Wm, and the residual magnetic flux density of the magnet unit is Br, a magnetic material that satisfies 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 non-magnetic material is used as the inter-conductor member.
(C) The stator 50 has a configuration in which no inter-conductor member is provided between the respective conductor portions in the circumferential direction.
　また、磁石ユニット４２の各磁石９１，９２についても同様である。つまり、磁石ユニット４２は、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされた磁石９１，９２を用いて構成されている。各磁石９１，９２における磁化方向等の詳細は既述のとおりである。磁石ユニット４２において環状磁石９５（図３０参照）を用いることも可能である。 The same applies to the magnets 91 and 92 of the magnet unit 42. That is, the magnet units 42 and 91 are oriented such that the direction of the easy axis of magnetization is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, compared to the q-axis side, which is the boundary of the magnetic poles. It is configured using Details such as the magnetization direction of each of the magnets 91 and 92 are as described above. It is also possible to use an annular magnet 95 (see FIG. 30) in the magnet unit 42.
　図３７は、インナロータ型とした場合における回転電機１０の縦断面図であり、これは既述の図２に対応する図面である。図２の構成との相違点を簡単に説明する。図３７において、ハウジング３０の内側には、環状の固定子５０が固定され、その固定子５０の内側には、所定のエアギャップを挟んで回転子４０が回転可能に設けられている。図２と同様に、各軸受２１，２２は、回転子４０の軸方向中央に対して軸方向のいずれか一方側に偏って配置されており、これにより、回転子４０が片持ち支持されている。また、回転子４０の磁石ホルダ４１の内側に、インバータユニット６０が設けられている。 FIG. 37 is a longitudinal sectional view of the rotating 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. 37, an annular stator 50 is fixed inside a housing 30, and a rotor 40 is rotatably provided inside the stator 50 with a predetermined air gap interposed therebetween. As in FIG. 2, each of the bearings 21 and 22 is disposed so as to be biased toward one of the axial directions with respect to the axial center of the rotor 40, whereby the rotor 40 is cantilevered. I have. The inverter unit 60 is provided inside the magnet holder 41 of the rotor 40.
　図３８には、インナロータ構造の回転電機１０として別の構成を示す。図３８において、ハウジング３０には、軸受２１，２２により回転軸１１が回転可能に支持されており、その回転軸１１に対して回転子４０が固定されている。図２等に示す構成と同様に、各軸受２１，２２は、回転子４０の軸方向中央に対して軸方向のいずれか一方側に偏って配置されている。回転子４０は、磁石ホルダ４１と磁石ユニット４２とを有している。 FIG. 38 shows another configuration of the rotating electric machine 10 having the inner rotor structure. In FIG. 38, a rotating shaft 11 is rotatably supported by bearings 21 and 22 in a housing 30, and a rotor 40 is fixed to the rotating shaft 11. As in the configuration shown in FIG. 2 and the like, each of the bearings 21 and 22 is arranged so as to be biased toward one of the axial directions with respect to the axial center of the rotor 40. The rotor 40 has a magnet holder 41 and a magnet unit 42.
　図３８の回転電機１０では、図３７の回転電機１０との相違点として、回転子４０の径方向内側にインバータユニット６０が設けられていない構成となっている。磁石ホルダ４１は、磁石ユニット４２の径方向内側となる位置で回転軸１１に連結されている。また、固定子５０は、固定子巻線５１と固定子コア５２とを有しており、ハウジング３０に対して取り付けられている。 38. The rotating electric machine 10 of FIG. 38 is different from the rotating electric machine 10 of FIG. 37 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 radially inside the magnet unit 42. Further, the stator 50 has a stator winding 51 and a stator core 52 and is attached to the housing 30.
　（変形例１１）
　インナロータ構造の回転電機として別の構成を以下に説明する。図３９は、回転電機２００の分解斜視図であり、図４０は、回転電機２００の側面断面図である。なおここでは、図３９及び図４０の状態を基準に上下方向を示すこととしている。 (Modification 11)
Another configuration as a rotating electric machine having an inner rotor structure will be described below. FIG. 39 is an exploded perspective view of the rotating electric machine 200, and FIG. 40 is a side sectional view of the rotating electric machine 200. Here, the vertical direction is shown based on the state of FIGS. 39 and 40.
　図３９及び図４０に示すように、回転電機２００は、環状の固定子コア２０１及び多相の固定子巻線２０２を有する固定子２０３と、固定子コア２０１の内側に回転自在に配設される回転子２０４とを備えている。固定子２０３が電機子に相当し、回転子２０４が界磁子に相当する。固定子コア２０１は、多数の珪素鋼板が積層されて構成されており、その固定子コア２０１に対して固定子巻線２０２が取り付けられている。図示は省略するが、回転子２０４は、回転子コアと、磁石ユニットとして複数の永久磁石とを有している。回転子コアには、円周方向に等間隔で複数の磁石挿入孔が設けられている。磁石挿入孔のそれぞれには、隣接する磁極毎に交互に磁化方向が変わるように磁化された永久磁石が装着されている。なお、磁石ユニットの永久磁石は、図２３で説明したようなハルバッハ配列又はそれに類する構成を有するものであるとよい。又は、磁石ユニットの永久磁石は、図９や図３０で説明したような磁極中心であるｄ軸と磁極境界であるｑ軸との間において配向方向（磁化方向）が円弧状に延びている極異方性の特性を備えるものであるとよい。 As shown in FIGS. 39 and 40, the rotating electric machine 200 is rotatably disposed inside the stator core 201 and a stator 203 having an annular stator core 201 and a polyphase stator winding 202. And a rotator 204. The stator 203 corresponds to an armature, and the rotor 204 corresponds to a field element. The stator core 201 is formed by laminating a number of silicon steel plates, and a stator winding 202 is attached to the stator core 201. Although not shown, the rotor 204 has a rotor core and a plurality of permanent magnets as magnet units. A plurality of magnet insertion holes are provided in the rotor core at equal intervals in the circumferential direction. In each of the magnet insertion holes, a permanent magnet that is magnetized so that the magnetization direction changes alternately for each adjacent magnetic pole is mounted. The permanent magnet of the magnet unit may have a Halbach array as described with reference to FIG. 23 or a configuration similar thereto. 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 center of the magnetic pole and the q-axis which is the boundary of the magnetic pole as described in FIGS. It is preferable to have anisotropic characteristics.
　ここで、固定子２０３は、以下のいずれかの構成であるとよい。
（Ａ）固定子２０３において、周方向における各導線部の間に導線間部材を設け、かつその導線間部材として、１磁極における導線間部材の周方向の幅寸法をＷｔ、導線間部材の飽和磁束密度をＢｓ、１磁極における磁石ユニットの周方向の幅寸法をＷｍ、磁石ユニットの残留磁束密度をＢｒとした場合に、Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒの関係となる磁性材料を用いている。
（Ｂ）固定子２０３において、周方向における各導線部の間に導線間部材を設け、かつその導線間部材として、非磁性材料を用いている。
（Ｃ）固定子２０３において、周方向における各導線部の間に導線間部材を設けていない構成となっている。 Here, the stator 203 may have any of the following configurations.
(A) In the stator 203, an inter-conductor member is provided between the respective conductor portions in the circumferential direction, and as the inter-conductor member, the circumferential width of the inter-conductor member at one magnetic pole is Wt, and the saturation of the inter-conductor member is achieved. When the magnetic flux density is Bs, the circumferential width of the magnet unit at one magnetic pole is Wm, and the residual magnetic flux density of the magnet unit is Br, a magnetic material that satisfies 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 non-magnetic material is used as the inter-conductor member.
(C) The stator 203 has a configuration in which no inter-conductor member is provided between the respective conductor portions in the circumferential direction.
　また、回転子２０４において、磁石ユニットは、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされた複数の磁石を用いて構成されている。 In the rotor 204, the magnet unit was oriented such that the direction of the easy axis of magnetization was parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, compared to the q-axis side, which is the boundary of the magnetic poles. It is configured using a plurality of magnets.
　回転電機２００の軸方向の一端側には、環状のインバータケース２１１が設けられている。インバータケース２１１は、ケース下面が固定子コア２０１の上面に接するように配置されている。インバータケース２１１内には、インバータ回路を構成する複数のパワーモジュール２１２と、半導体スイッチング素子のスイッチング動作により生じる電圧・電流の脈動（リップル）を抑制する平滑コンデンサ２１３と、制御部を有する制御基板２１４と、相電流を検出する電流センサ２１５と、回転子２０４の回転数センサであるレゾルバステータ２１６とが設けられている。パワーモジュール２１２は、半導体スイッチング素子であるＩＧＢＴやダイオードを有している。 環状 A ring-shaped inverter case 211 is provided at one axial end of the rotary electric machine 200. Inverter case 211 is arranged such that the lower surface of the case is in contact with the upper surface of stator core 201. In an inverter case 211, a plurality of power modules 212 constituting an inverter circuit, a smoothing capacitor 213 for suppressing pulsation (ripple) of voltage and current generated by a switching operation of a 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 that is a rotation speed sensor of the rotor 204. The power module 212 has an IGBT or a diode that is a semiconductor switching element.
　インバータケース２１１の周縁には、車両に搭載されるバッテリの直流回路と接続されるパワーコネクタ２１７と、回転電機２００側と車両側制御装置との間で各種信号の受け渡しに用いられる信号コネクタ２１８とが設けられている。インバータケース２１１はトップカバー２１９で覆われている。車載バッテリからの直流電力は、パワーコネクタ２１７を介して入力され、パワーモジュール２１２のスイッチングにより交流に変換されて各相の固定子巻線２０２に送られる。 A power connector 217 connected to a DC circuit of a battery mounted on the vehicle, and a signal connector 218 used for transferring various signals between the rotating electric machine 200 and the vehicle-side control device are provided on the periphery of the inverter case 211. Is provided. The inverter case 211 is covered with a top cover 219. DC power from the vehicle-mounted battery is input via the power connector 217, converted into AC by switching of the power module 212, and sent to the stator winding 202 of each phase.
　固定子コア２０１の軸方向両側のうちインバータケース２１１の反対側には、回転子２０４の回転軸を回転可能に保持する軸受ユニット２２１と、その軸受ユニット２２１を収容する環状のリアケース２２２とが設けられている。軸受ユニット２２１は、例えば２つ一組の軸受を有しており、回転子２０４の軸方向中央に対して軸方向のいずれか一方側に偏って配置されている。ただし、軸受ユニット２２１における複数の軸受を固定子コア２０１の軸方向両側に分散させて設け、それら各軸受により回転軸を両持ち支持する構成であってもよい。リアケース２２２が車両のギアケースや変速機などの取付部にボルト締結して固定されることで、回転電機２００が車両側に取り付けられるようになっている。 A bearing unit 221 for rotatably holding the rotating shaft of the rotor 204 and an annular rear case 222 for accommodating the bearing unit 221 are provided on the opposite sides of the stator core 201 in the axial direction opposite to the inverter case 211. Is provided. The bearing unit 221 has, for example, a pair of bearings, and is arranged so as to be deviated to one side in the axial direction with respect to the axial center of the rotor 204. However, a configuration in which a plurality of bearings of the bearing unit 221 are provided separately on both sides in the axial direction of the stator core 201 and the rotating shaft is supported at both ends by the respective bearings may be adopted. The rotating electrical machine 200 is mounted on the vehicle side by fixing the rear case 222 to the mounting portion such as a gear case or a transmission of the vehicle by bolting.
　インバータケース２１１内には、冷媒を流すための冷却流路２１１ａが形成されている。冷却流路２１１ａは、インバータケース２１１の下面から環状に凹設された空間を固定子コア２０１の上面で閉塞して形成されている。冷却流路２１１ａは、固定子巻線２０２のコイルエンドを囲むように形成されている。冷却流路２１１ａ内には、パワーモジュール２１２のモジュールケース２１２ａが挿入されている。リアケース２２２にも、固定子巻線２０２のコイルエンドを囲むように冷却流路２２２ａが形成されている。冷却流路２２２ａは、リアケース２２２の上面から環状に凹設された空間を固定子コア２０１の下面で閉塞して形成されている。 冷却 A cooling channel 211a for flowing a coolant is formed in the inverter case 211. The cooling channel 211 a is formed by closing a space recessed annularly from the lower surface of the inverter case 211 with the upper surface of the stator core 201. The cooling passage 211a is formed so as to surround the coil end of the stator winding 202. The module case 212a of the power module 212 is inserted into the cooling channel 211a. A cooling channel 222 a is also formed in the rear case 222 so as to surround the coil end of the stator winding 202. The cooling channel 222 a is formed by closing a space recessed annularly from the upper surface of the rear case 222 with the lower surface of the stator core 201.
　（変形例１２）
　これまでは、回転界磁形の回転電機にて具体化した構成を説明したが、これを変更し、回転電機子形の回転電機にて具体化することも可能である。図４１に、回転電機子形の回転電機２３０の構成を示す。 (Modification 12)
The configuration embodied in the rotating field type rotary electric machine has been described above, but it is also possible to change the configuration and embodied in a rotary armature type rotary electric machine. FIG. 41 shows a configuration of a rotary armature type rotary electric machine 230.
　図４１の回転電機２３０において、ハウジング２３１ａ，２３１ｂにはそれぞれ軸受２３２が固定され、その軸受２３２により回転軸２３３が回転自在に支持されている。軸受２３２は、例えば多孔質金属に油を含ませてなる含油軸受である。回転軸２３３には、電機子としての回転子２３４が固定されている。回転子２３４は、回転子コア２３５とその外周部に固定された多相の回転子巻線２３６とを有している。回転子２３４において、回転子コア２３５はスロットレス構造を有し、回転子巻線２３６は扁平導線構造を有している。つまり、回転子巻線２３６は、１相ごとの領域が径方向よりも周方向に長い扁平構造となっている。 In the rotating electric machine 230 of FIG. 41, bearings 232 are fixed to the housings 231a and 231b, respectively, and the rotating shaft 233 is rotatably supported by the bearings 232. The bearing 232 is, for example, an oil-impregnated bearing made of a porous metal containing oil. A rotor 234 as an armature is fixed to the rotation shaft 233. The rotor 234 has a rotor core 235 and a multi-phase rotor winding 236 fixed to an outer peripheral portion thereof. In the rotor 234, the rotor core 235 has a slotless structure, and the rotor winding 236 has a flat conductor 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.
　また、回転子２３４の径方向外側には、界磁子としての固定子２３７が設けられている。固定子２３７は、ハウジング２３１ａに固定された固定子コア２３８と、その固定子コア２３８の内周側に固定された磁石ユニット２３９とを有している。磁石ユニット２３９は、周方向に極性が交互となる複数の磁極を含む構成となっており、既述した磁石ユニット４２等と同様に、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされて構成されている。磁石ユニット２３９は、配向が行われた焼結ネオジム磁石を有しており、その固有保磁力は４００［ｋＡ／ｍ］以上、かつ残留磁束密度は１．０［Ｔ］以上となっている。 固定 Further, 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 231a, and a magnet unit 239 fixed to the inner peripheral side of the stator core 238. The magnet unit 239 includes a plurality of magnetic poles having polarities alternated in the circumferential direction. Like the magnet unit 42 described above, the magnet unit 239 has a magnetic pole boundary q on the d-axis side that is the center of the magnetic pole. The orientation is made such that the direction of the easy axis of magnetization is parallel to the d-axis as compared to the axis side. The magnet unit 239 has an oriented sintered neodymium magnet, and its intrinsic coercive force is 400 [kA / m] or more and the residual magnetic flux density is 1.0 [T] or more.
　本例の回転電機２３０は、２極３コイルのブラシ付コアレスモータであり、回転子巻線２３６は３つに分割され、磁石ユニット２３９は２極である。ブラシ付きモータの極数とコイル数は、２：３、４：１０、４：２１などその用途に応じて様々である。 The rotating electric machine 230 of this example is a brushless coreless motor having two poles and three coils, the rotor winding 236 is divided into three, and the magnet unit 239 has two poles. The number of poles and the number of coils of the brushed motor varies depending on the application, such as 2: 3, 4:10, and 4:21.
　回転軸２３３にはコミュテータ２４１が固定されており、その径方向外側には複数のブラシ２４２が配置されている。コミュテータ２４１は、回転軸２３３に埋め込まれた導線２４３を介して回転子巻線２３６に電気接続されている。これらコミュテータ２４１、ブラシ２４２、導線２４３を通じて、回転子巻線２３６に対する直流電流の流入及び流出が行われる。コミュテータ２４１は、回転子巻線２３６の相数に応じて周方向に適宜分割されて構成されている。なお、ブラシ２４２は、そのまま電気配線を介して蓄電池などの直流電源に接続されていてもよいし、端子台などを介して直流電源に接続されていてもよい。 コ A commutator 241 is fixed to the rotating shaft 233, and a plurality of brushes 242 are arranged radially outside. The commutator 241 is electrically connected to the rotor winding 236 via a conductor 243 embedded in the rotating shaft 233. The direct current flows into and out of the rotor winding 236 through the commutator 241, the brush 242, and the conducting 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 directly connected to a DC power supply such as a storage battery via electrical wiring, or may be connected to a DC power supply via a terminal block or the like.
　回転軸２３３には、軸受２３２とコミュテータ２４１との間に、シール材としての樹脂ワッシャ２４４が設けられている。樹脂ワッシャ２４４により、含油軸受である軸受２３２からしみ出た油がコミュテータ２４１側に流れ出ることが抑制される。 樹脂 A resin washer 244 as a sealing material is provided between the bearing 232 and the commutator 241 on the rotating shaft 233. The resin washer 244 suppresses oil that has oozed from the bearing 232 that is an oil-impregnated bearing from flowing out to the commutator 241 side.
　（変形例１３）
　回転電機１０の固定子巻線５１において、各導線８２を、内外に複数の絶縁被膜を有する構成としてもよい。例えば、絶縁被膜付きの複数の導線（素線）を１本に束ね、それを外層被膜により覆って導線８２を構成するとよい。この場合、素線の絶縁被膜が内側の絶縁被膜を構成し、外層被膜が外側の絶縁被膜を構成する。また特に、導線８２における複数の絶縁被膜のうち外側の絶縁被膜の絶縁能力を、内側の絶縁被膜の絶縁能力よりも高めておくとよい。具体的には、外側の絶縁被膜の厚さを、内側の絶縁被膜の厚さよりも厚くする。例えば、外側の絶縁被膜の厚さを１００μｍ、内側の絶縁被膜の厚さを４０μｍとする。又は、外側の絶縁被膜として、内側の絶縁被膜よりも誘電率の低い材料を用いるとよい。これらは少なくともいずれかが適用されればよい。なお、素線が、複数の導電材の集合体として構成されているとよい。 (Modification 13)
In the stator winding 51 of the rotating electric machine 10, each of the conductors 82 may be configured to have a plurality of insulating coatings inside and outside. For example, a plurality of conductive wires (element wires) with an insulating coating may be bundled into one and covered with an outer coating to form the conductive wire 82. In this case, the insulating coating of the element wire forms the inner insulating coating, and the outer coating forms the outer insulating coating. In particular, it is preferable that the insulating ability of the outer insulating coat among the plurality of insulating coats in the conductive wire 82 be higher than the insulating ability of the inner insulating coat. Specifically, the thickness of the outer insulating coating is made larger than the thickness of the inner insulating coating. For example, the thickness of the outer insulating coating is 100 μm, and the thickness of the inner insulating coating is 40 μm. Alternatively, a material having a lower dielectric constant than the inner insulating film may be used as the outer insulating film. At least one of these may be applied. Note that the strands may be configured as an aggregate of a plurality of conductive materials.
　上記のとおり導線８２における最外層の絶縁を強くすることにより、高電圧の車両用システムに用いる場合に好適なものとなる。また、気圧の低い高地などでも、回転電機１０の適正な駆動が可能となる。 (4) By strengthening the insulation of the outermost layer of the conductive wire 82 as described above, it becomes suitable for use in a high-voltage vehicle system. In addition, it is possible to appropriately drive the rotating electric machine 10 even at a high altitude where the atmospheric pressure is low.
　（変形例１４）
　内外に複数の絶縁被膜を有する導線８２において、外側の絶縁被膜と内側の絶縁被膜とで、線膨張率（線膨張係数）及び接着強さの少なくともいずれかが異なる構成としてもよい。本変形例における導線８２の構成を図４２に示す。 (Modification 14)
In the conductive wire 82 having a plurality of inner and outer insulating coatings, the outer insulating coating and the inner insulating coating may have a configuration in which at least one of the coefficient of linear expansion (linear expansion coefficient) and the adhesive strength is different. FIG. 42 shows a configuration of the conductor 82 in this modification.
　図４２において、導線８２は、複数（図では４本）の素線１８１と、その複数の素線１８１を囲む例えば樹脂製の外層被膜１８２（外側絶縁被膜）と、外層被膜１８２内において各素線１８１の周りに充填された中間層１８３（中間絶縁被膜）とを有している。素線１８１は、銅材よりなる導電部１８１ａと、絶縁材料よりなる導体被膜１８１ｂ（内側絶縁被膜）とを有している。固定子巻線として見れば、外層被膜１８２により相間が絶縁される。なお、素線１８１が、複数の導電材の集合体として構成されているとよい。 In FIG. 42, a conductive wire 82 includes a plurality of (four in the figure) strands 181, an outer layer coating 182 (outer insulating coating) made of, for example, resin 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 strand 181 has a conductive portion 181a made of a copper material and a conductor film 181b (an inner insulating film) made of an insulating material. When viewed as a stator winding, the outer layers 182 insulate the phases. Note that the strand 181 may be configured as an aggregate of a plurality of conductive materials.
　中間層１８３は、素線１８１の導体被膜１８１ｂよりも高い線膨張率を有し、かつ外層被膜１８２よりも低い線膨張率を有している。つまり、導線８２では、外側ほど線膨張率が高くなっている。一般的に、外層被膜１８２では導体被膜１８１ｂよりも線膨張係数が高いが、それらの間にその中間の線膨張率を有する中間層１８３を設けることにより、その中間層１８３がクッション材として機能し、外層側及び内層側での同時割れを防ぐことができる。 The intermediate layer 183 has a higher linear expansion coefficient than the conductor coating 181b of the strand 181 and a lower linear expansion coefficient than the outer coating 182. That is, in the conductor 82, the coefficient of linear expansion is higher toward the outside. Generally, the outer layer coating 182 has a higher linear expansion coefficient than the conductor coating 181b, but by providing an intermediate layer 183 having an intermediate linear expansion coefficient between them, the intermediate layer 183 functions as a cushion material. In addition, simultaneous cracking on the outer layer side and the inner layer side can be prevented.
　また、導線８２では、素線１８１において導電部１８１ａと導体被膜１８１ｂとが接着されるとともに、導体被膜１８１ｂと中間層１８３、中間層１８３と外層被膜１８２がそれぞれ接着されており、それら各接着部分では、導線８２の外側ほど、接着強さが弱くなっている。つまり、導電部１８１ａ及び導体被膜１８１ｂの接着強さは、導体被膜１８１ｂ及び中間層１８３の接着強さ、中間層１８３及び外層被膜１８２の接着強さよりも弱くなっている。また、導体被膜１８１ｂ及び中間層１８３の接着強さと、中間層１８３及び外層被膜１８２の接着強さとを比較すると、後者の方（外側の方）が弱いか、又は同等であるとよい。なお、各被膜同士の接着強さの大きさは、例えば２層の被膜を引き剥がす際に要する引っ張り強さ等により把握可能である。上記のごとく導線８２の接着強さが設定されていることで、発熱又は冷却による内外温度差が生じても、内層側及び外層側で共に割れが生じること（共割れ）を抑制することができる。 In the conductive wire 82, the conductive portion 181a and the conductive film 181b are bonded to the wire 181 and the conductive film 181b and the intermediate layer 183, and the intermediate layer 183 and the outer layer film 182 are bonded to each other. In the figure, the bonding strength is weaker toward the outside of the conducting wire 82. That is, the adhesive strength between the conductive portion 181a and the conductive coating 181b is lower than the adhesive strength between the conductive coating 181b and the intermediate layer 183, and the adhesive strength between the intermediate layer 183 and the outer coating 182. Further, comparing the adhesive strength between the conductor coating 181b and the intermediate layer 183 and the adhesive strength between the intermediate layer 183 and the outer coating 182, the latter (outer side) is preferably weaker or equivalent. It should be noted that the magnitude of the adhesive strength between the coatings can be grasped, for example, from the tensile strength and the like required when the two coatings are peeled off. By setting the bonding strength of the conductive wire 82 as described above, it is possible to suppress the occurrence of cracks (co-cracking) on both the inner layer side and the outer layer side even if an internal / external temperature difference occurs due to heat generation or cooling. .
　ここで、回転電機の発熱、温度変化は、主に素線１８１の導電部１８１ａから発熱される銅損と、鉄心内から発せられる鉄損として生じるが、それら２種類の損失は、導線８２内の導電部１８１ａ、又は導線８２の外部より伝わるものであり、中間層１８３に発熱源があるわけではない。この場合、中間層１８３が両方に対してクッションとなり得る接着力を持つことで、その同時割れを防ぐことができる。したがって、車両用途など、高耐圧又は温度変化の大きい分野での使用に際しても、好適なる使用が可能となる。 Here, heat generation and temperature change of the rotating electric machine mainly occur as copper loss generated from the conductive portion 181a of the wire 181 and iron loss generated from within the iron core. The conductive layer 181a is transmitted from the outside of the conductive portion 181a or the conductive wire 82, and the intermediate layer 183 does not necessarily have a heat source. In this case, since the intermediate layer 183 has an adhesive force that can serve as a cushion for both, simultaneous cracking can be prevented. Therefore, suitable use is possible even when used in a field having a high withstand voltage or a large temperature change such as a vehicle application.
　以下に補足する。素線１８１は、例えばエナメル線であってもよく、かかる場合にはＰＡ、ＰＩ、ＰＡＩ等の樹脂被膜層（導体被膜１８１ｂ）を有する。また、素線１８１より外側の外層被膜１８２は、同様のＰＡ、ＰＩ、ＰＡＩ等よりなり、かつ厚みが厚いものであることが望ましい。これにより、線膨張率差による被膜の破壊が抑えられる。なお、外層被膜１８２としては、ＰＡ、ＰＩ、ＰＡＩ等の前記材料を厚くして対応するものとは別に、ＰＰＳ、ＰＥＥＫ、フッ素、ポリカーボネート、シリコン、エポキシ、ポリエチレンナフタレート、ＬＣＰといった、誘電率がＰＩ、ＰＡＩよりも小さいものを使うことも回転機の導体密度を高めるためには望ましい。これらの樹脂であれば、導体被膜１８１ｂ同等のＰＩ，ＰＡＩ被膜よりも薄いか、導体被膜１８１ｂと同等の厚みであっても、その絶縁能力を高くすることができ、これにより導電部の占有率を高めることが可能となる。一般的には、上記樹脂は、誘電率がエナメル線の絶縁被膜より良好な絶縁を有している。当然、成形状態や、混ぜ物によって、その誘電率を悪くする例も存在する。中でも、ＰＰＳ、ＰＥＥＫは、その線膨張係数がエナメル被膜より一般的には大きいが、他樹脂よりも小さいため、第２層の外層被膜として適するのである。 補足 Supplement to the following. The strand 181 may be, for example, an enameled wire, and in such a case, has a resin coating layer (conductor coating 181b) of PA, PI, PAI or the like. Further, it is desirable that the outer layer coating 182 outside the wire 181 be made of the same PA, PI, PAI or the like, and be thick. Thereby, the destruction of the coating film due to the difference in linear expansion coefficient is suppressed. The outer layer coating 182 has a dielectric constant such as PPS, PEEK, fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, or LCP, which is different from the corresponding material such as PA, PI, PAI by thickening the corresponding material. It is also desirable to use a material smaller than PI and PAI in order to increase the conductor density of the rotating machine. With these resins, even if they are thinner than the PI and PAI coatings equivalent to the conductor coating 181b or have the same thickness as the conductor coating 181b, their insulating ability can be increased, thereby increasing the occupancy of the conductive portion. Can be increased. Generally, the resin has better insulation than the insulating coating of the enameled wire. Naturally, there is an example in which the dielectric constant is deteriorated depending on the molding state or the mixture. Above all, PPS and PEEK generally have a higher coefficient of linear expansion than the enamel coating, but are smaller than other resins, and thus are suitable as the outer coating of the second layer.
　また、素線１８１の外側における２種類の被膜（中間絶縁被膜、外側絶縁被膜）と素線１８１のエナメル被膜との接着強さは、素線１８１における銅線とエナメル被膜との間の接着強さよりも弱いことが望ましい。これにより、エナメル被膜と前記２種類の被膜とが一度に破壊される現象が抑制される。 The adhesive 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 on the wire 181 is determined by the adhesive strength between the copper wire and the enamel coating on the wire 181. It is desirable that it be weaker. This suppresses a phenomenon in which the enamel coating and the two types of coatings are destroyed at a time.
　固定子に水冷構造、液冷構造、空冷構造が付加されている場合には、基本的に、外層被膜１８２から先に熱応力や衝撃応力が掛かると考えられる。しかし、素線１８１の絶縁層と、前記２種類の被膜とが違う樹脂の場合でも、その被膜を接着しない部位を設けることにより、前記熱応力や衝撃応力を低減することができる。すなわち、素線（エナメル線）と空隙を設け、フッ素、ポリカーボネート、シリコン、エポキシ、ポリエチレンナフタレート、ＬＣＰを配置することで前記絶縁構造がなされる。この場合、エポキシなどからなる低誘電率で、かつ低線膨張係数からなる接着材を用いて、外層被膜と内層被膜とを接着することが望ましい。こうすることで、機械的強度だけでなく、導電部の振動による揺れなどによる摩擦による被膜破壊、または線膨張係数差による外層被膜の破壊を抑えることができる。 (4) When a water-cooled structure, a liquid-cooled structure, or an air-cooled structure is added to the stator, it is basically considered that thermal stress or impact stress is applied first to the outer layer coating 182. However, even when the insulating layer of the strand 181 and the two types of coatings are made of different resins, the thermal stress and the impact stress can be reduced by providing a portion where the coatings are not bonded. That is, the insulating structure is formed by providing a gap between the element wire (enameled wire) and the void, 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 made of epoxy or the like having a low dielectric constant and a low linear expansion coefficient. By doing so, it is possible to suppress not only the mechanical strength but also the destruction of the coating due to friction caused by the vibration of the conductive portion due to vibration or the destruction of the outer coating due to the difference in linear expansion coefficient.
　上記構成の導線８２に対しての、機械的強度、固定等を担う、一般的には固定子巻線周りの最終工程となる最外層固定としては、エポキシ、ＰＰＳ、ＰＥＥＫ、ＬＣＰなどの成形性が良く、誘電率、線膨張係数といった性質がエナメル被膜と近い性質をもった樹脂が好ましい。 The outermost layer fixed as a final step around the stator winding, which is responsible for mechanical strength, fixing, and the like, for the conductor 82 having the above-described configuration, is formed of epoxy, PPS, PEEK, LCP, or the like. It is preferable to use a resin having properties such as a dielectric constant and a linear expansion coefficient close to those of an enamel coating.
　一般的には、ウレタン、シリコンによる樹脂ポッティングが通例なされるが、前記樹脂においてはその線膨張係数がその他の樹脂と比べて倍近い差があり、樹脂をせん断し得る熱応力を発生する。そのため、厳しい絶縁規定が国際的に用いられる６０Ｖ以上の用途には不適である。この点、エポキシ、ＰＰＳ、ＰＥＥＫ、ＬＣＰなどにより射出成型等により容易に作られる最終絶縁工程によれば、上述の各要件を達成することが可能である。 樹脂 Generally, resin potting with urethane or silicon is generally performed, but the resin has a coefficient of linear expansion that is nearly twice as large as that of other resins, and generates thermal stress that can shear the resin. Therefore, it is not suitable for use at 60 V or higher where strict insulation regulations are used internationally. In this regard, according to the final insulation process that is easily made by injection molding or the like using epoxy, PPS, PEEK, LCP, or the like, the above-described requirements can be achieved.
　上記以外の変形例を以下に列記する。 変 形 Modifications other than the above are listed below.
　・磁石ユニット４２のうち径方向において電機子側の面と、回転子の軸心との径方向における距離ＤＭが５０ｍｍ以上とされていてもよい。具体的には、例えば、図４に示す磁石ユニット４２（具体的には、第１，第２磁石９１，９２）のうち径方向内側の面と、回転子４０の軸心との径方向における距離ＤＭが５０ｍｍ以上とされていてもよい。 (4) The radial distance DM between the armature side surface of the magnet unit 42 in the radial direction and the axis 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. The distance DM may be set to 50 mm or more.
　スロットレス構造の回転電機としては、その出力が数十Ｗから数百Ｗ級の模型用などに使用される小規模なものが知られている。そして、一般的には１０ｋＷを超すような工業用の大型の回転電機でスロットレス構造が採用された事例を本願開示者は把握していない。その理由について本願開示者は検討した。 As a rotary electric machine having a slotless structure, a small-sized electric machine whose output is used for a model whose output is several tens of watts to several hundreds of watts is known. In addition, the applicant of the present application has not grasped an example in which a slotless structure is generally employed in a large-scale rotating electric machine for industrial use exceeding 10 kW. The present applicant has examined the reason.
　近年主流の回転電機は、次の４種類に大別される。それら回転電機とは、ブラシ付きモータ、カゴ型誘導モータ、永久磁石式同期モータ及びリラクタンスモータである。 In recent years, the mainstream rotating electric machines are roughly classified into the following four types. The rotating electric machines are a brush motor, a cage induction motor, a permanent magnet synchronous motor, and a reluctance motor.
　ブラシ付きモータには、ブラシを介して励磁電流が供給される。このため、大型機のブラシ付きモータの場合、ブラシが大型化したり、メンテナンスが煩雑になったりしたりする。これにより、半導体技術の目覚ましい発達に伴い、誘導モータ等のブラシレスモータに置換されてきた経緯がある。一方、小型モータの世界では、低い慣性及び経済性の利点から、コアレスモータも多数世の中に供給されている。 励 Excitation current is supplied to the motor with brush via the brush. For this reason, in the case of a motor with a brush of a large machine, the brush becomes large or the maintenance becomes complicated. As a result, with the remarkable development of semiconductor technology, there has been a history of replacement with brushless motors such as induction motors. On the other hand, in the world of small motors, coreless motors are also supplied to many people due to the advantages of low inertia and economy.
　カゴ型誘導モータでは、１次側の固定子巻線で発生させる磁界を２次側の回転子の鉄心で受けてカゴ型導体に集中的に誘導電流を流して反作用磁界を形成することにより、トルクを発生させる原理である。このため、機器の小型高効率の観点からすれば、固定子側及び回転子側ともに鉄心をなくすことは必ずしも得策であるとは言えない。 In a cage-type induction motor, a magnetic field generated by a stator winding on a primary side is received by an iron core of a rotor on a secondary side, and an induced current is intensively applied to a cage-type conductor to form a reaction magnetic field. This is the principle of generating torque. For this reason, from the viewpoint of miniaturization and high efficiency of the device, it is not always advisable to eliminate the iron core on both the stator side and the rotor side.
　リラクタンスモータは、当に鉄心のリラクタンス変化を活用するモータであり、原理的に鉄心をなくすことは望ましくない。 (4) The reluctance motor is a motor that utilizes the reluctance change of the iron core, and it is not desirable to eliminate the iron core in principle.
　永久磁石式同期モータでは、近年ＩＰＭ（つまり埋め込み磁石型回転子）が主流であり、特に大型機においては、特殊事情がない限りＩＰＭである場合が多い。 In recent years, IPMs (i.e., embedded magnet type rotors) have become the mainstream among permanent magnet type synchronous motors, and especially in large machines, IPMs are often used unless there are special circumstances.
　ＩＰＭは、磁石トルク及びリラクタンストルクを併せ持つ特性を有しており、インバータ制御により、それらトルクの割合が適時調整されながら運転される。このため、ＩＰＭは小型で制御性に優れるモータである。 The IPM has a characteristic of having both a magnet torque and a reluctance torque, and is operated while the ratio of those torques is appropriately adjusted by inverter control. Therefore, the IPM is a small-sized motor having excellent controllability.
　本願開示者の分析により、磁石トルク及びリラクタンストルクを発生する回転子表面のトルクを、磁石ユニットのうち径方向において電機子側の面と、回転子の軸心との径方向における距離ＤＭ、すなわち、一般的なインナロータの固定子鉄心の半径を横軸にとって描くと図４３に示すものとなる。 According to the analysis of the present applicant, the torque on the rotor surface that generates the magnet torque and the reluctance torque is calculated by calculating the distance DM in the radial direction between the surface of the magnet unit on the armature side in the radial direction and the axis of the rotor, that is, FIG. 43 shows the radius of the stator core of a general inner rotor taken along the horizontal axis.
　磁石トルクは、下式（ｅｑ１）に示すように、永久磁石の発生する磁界強度によりそのポテンシャルが決定されるのに対し、リラクタンストルクは、下式（ｅｑ２）に示すように、インダクタンス、特にｑ軸インダクタンスの大きさがそのポテンシャルを決定する。 As shown in the following equation (eq1), the potential of the magnet torque is determined by the strength of the magnetic field generated by the permanent magnet, whereas the reluctance torque is expressed by inductance, particularly q, as shown in the following equation (eq2). The magnitude of the shaft inductance determines its potential.
　磁石トルク＝ｋ・Ψ・Ｉｑ　　　　　　　　　　　　・・・・・・・（ｅｑ１）
　リラクタンストルク＝ｋ・（Ｌｑ－Ｌｄ）・Ｉｑ・Ｉｄ　・・・・・（ｅｑ２）
　ここで、永久磁石の磁界強度と巻線のインダクタンスの大きさとをＤＭで比較してみた。永久磁石の発する磁界強度、すなわち磁束量Ψは、固定子と対向する面の永久磁石の総面積に比例する。円筒型の回転子であれば円筒の表面積になる。厳密には、Ｎ極とＳ極とが存在するので、円筒表面の半分の専有面積に比例する。円筒の表面積は、円筒の半径と、円筒長さとに比例する。つまり、円筒長さが一定であれば、円筒の半径に比例する。 Magnet torque = k · Ψ · Iq (eq1)
Reluctance torque = k · (Lq-Ld) · Iq · Id · · · · (eq2)
Here, the magnetic field strength of the permanent magnet and the magnitude of the inductance of the winding were compared by DM. The magnetic field intensity generated 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. In the case of a cylindrical rotor, it is the surface area of the cylinder. Strictly speaking, since there are an N pole and an S pole, it is proportional to the area occupied by half of the cylindrical surface. The surface area of a cylinder is proportional to the radius of the cylinder and the length of the cylinder. That is, if the length of the cylinder is constant, it is proportional to the radius of the cylinder.
　一方、巻線のインダクタンスＬｑは、鉄心形状に依存はするものの感度は低く、むしろ固定子巻線の巻数の２乗に比例するため、巻数の依存性が高い。なお、μを磁気回路の透磁率、Ｎを巻数、Ｓを磁気回路の断面積、δを磁気回路の有効長さとする場合、インダクタンスＬ＝μ・Ｎ＾２×Ｓ／δである。巻線の巻数は、巻線スペースの大きさに依存するため、円筒型モータであれば、固定子の巻線スペース、すなわちスロット面積に依存することになる。図４４に示すように、スロット面積は、スロットの形状が略四角形であるため、周方向の長さ寸法ａ及び径方向の長さ寸法ｂとの積ａ×ｂに比例する。 On the other hand, the inductance Lq of the winding depends on the shape of the iron core but has low sensitivity, and is rather proportional to the square of the number of turns of the stator winding. 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 windings 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. 44, the slot area is proportional to the product a × b of the circumferential length a and the radial length b since the shape of the slot is substantially rectangular.
　スロットの周方向の長さ寸法は、円筒の直径が大きいほど大きくなるため、円筒の直径に比例する。スロットの径方向の長さ寸法は、当に円筒の直径に比例する。つまり、スロット面積は、円筒の直径の２乗に比例する。また、上式（ｅｑ２）からも分かる通り、リラクタンストルクは、固定子電流の２乗に比例するため、いかに大電流を流せるかで回転電機の性能が決まり、その性能は固定子のスロット面積に依存する。以上より、円筒の長さが一定なら、リラクタンストルクは円筒の直径の２乗に比例する。このことを踏まえ、磁石トルク及びリラクタンストルクとＤＭとの関係性をプロットした図が図４３である。 周 The circumferential length of the slot increases in proportion to the diameter of the cylinder, because the larger the diameter of the cylinder, the larger it becomes. The radial length dimension of the slot is directly 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 electric machine is determined by how large a current can flow, and the performance depends on 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. 43 is a diagram plotting the relationship between the magnet torque and the reluctance torque and DM.
　図４３に示すように、磁石トルクはＤＭに対して直線的に増加し、リラクタンストルクはＤＭに対して２次関数的に増加する。ＤＭが比較的小さい場合は磁石トルクが支配的であり、固定子鉄心半径が大きくなるに連れてリラクタンストルクが支配的であることがわかる。本願開示者は、図４３における磁石トルク及びリラクタンストルクの交点が、所定の条件下において、おおよそ固定子鉄心半径＝５０ｍｍの近傍であるとの結論に至った。つまり、固定子鉄心半径が５０ｍｍを十分に超えるような１０ｋＷ級のモータでは、リラクタンストルクを活用することが現在の主流であるため鉄心を無くすことは困難であり、このことが大型機の分野においてスロットレス構造が採用されない理由の１つであると推定される。 磁石 As shown in FIG. 43, the magnet torque increases linearly with DM, and the reluctance torque increases quadratically with DM. When the DM is relatively small, the magnet torque is dominant, and the reluctance torque is dominant as the stator core radius increases. The inventor of the present application has concluded that the intersection of the magnet torque and the reluctance torque in FIG. 43 is approximately in the vicinity of the stator core radius = 50 mm under a predetermined condition. In other words, in a 10 kW class motor in which the stator core radius is well over 50 mm, it is difficult to eliminate the core because the current mainstream is to utilize the reluctance torque. This is presumed to be one of the reasons that the slotless structure is not adopted.
　固定子に鉄心が使用される回転電機の場合、鉄心の磁気飽和が常に課題となる。特にラジアルギャップ型の回転電機では、回転軸の縦断面形状は１磁極当たり扇型となり、機器内周側程磁路幅が狭くなりスロットを形成するティース部分の内周側寸法が回転電機の性能限界を決める。いかに高性能な永久磁石を使おうとも、この部分で磁気飽和が発生すると、永久磁石の性能を十分にひきだすことができない。この部分で磁気飽和を発生させないためには、内周径を大きく設計することになり結果的に機器の大型化に至ってしまうのである。 回 転 In the case of a rotating electric machine using an iron core for the stator, magnetic saturation of the iron core is always an issue. In particular, in the radial gap type rotating electric machine, the longitudinal section of the rotating shaft is fan-shaped per magnetic pole, and the magnetic path width becomes narrower toward the inner peripheral side of the device, and the inner peripheral side dimensions of the teeth forming the slots are the performance of the rotating electric machine. Set limits. No matter how high-performance a permanent magnet is used, if magnetic saturation occurs in this part, the performance of the permanent magnet cannot be fully exploited. In order to prevent magnetic saturation from occurring in this portion, the inner diameter must be designed to be large, resulting in an increase in the size of the device.
　例えば、分布巻の回転電機では、３相巻線であれば、１磁極あたり３つ乃至６つのティースで分担して磁束を流すのだが、周方向前方のティースに磁束が集中しがちであるため、３つ乃至６つのティースに均等に磁束が流れるわけではない。この場合、一部（例えば１つ又は２つ）のティースに集中的に磁束が流れながら、回転子の回転に伴って磁気飽和するティースも周方向に移動してゆく。これがスロットリップルを生む要因にもなる。 For example, in the case of a distributed winding rotary electric machine, in the case of a three-phase winding, three to six teeth per magnetic pole share the magnetic flux, but the magnetic flux tends to concentrate on the teeth in the circumferential front. The magnetic flux does not flow evenly in three to six teeth. In this case, magnetic flux intensively flows through some (for example, one or two) teeth, and the teeth that are magnetically saturated with the rotation of the rotor also move in the circumferential direction. This is also a factor that causes slot ripple.
　以上から、ＤＭが５０ｍｍ以上となるスロットレス構造の回転電機において、磁気飽和を解消するために、ティースを廃止したい。しかし、ティースが廃止されると、回転子及び固定子における磁気回路の磁気抵抗が増加し、回転電機のトルクが低下してしまう。磁気抵抗増加の理由としては、例えば、回転子と固定子との間のエアギャップが大きくなることがある。このため、上述したＤＭが５０ｍｍ以上となるスロットレス構造の回転電機において、トルクを増強することについて改善の余地がある。したがって、上述したＤＭが５０ｍｍ以上となるスロットレス構造の回転電機に、上述したトルクを増強できる構成を適用するメリットが大きい。 From the above, in the rotating electric machine of the slotless structure in which the DM becomes 50 mm or more, it is desired to eliminate the teeth in order to eliminate the magnetic saturation. However, when the teeth are abolished, the magnetic resistance of the magnetic circuit in the rotor and the stator increases, and the torque of the rotating electric machine decreases. As a reason for the increase in magnetic resistance, for example, an air gap between the rotor and the stator may be large. For this reason, there is room for improvement in increasing the torque in the above-mentioned slotless rotating electric machine in which the DM is 50 mm or more. Therefore, there is a great merit in applying the above-described configuration capable of increasing the torque to the rotating electric machine having the slotless structure in which the DM is 50 mm or more.
　なお、アウタロータ構造の回転電機に限らず、インナロータ構造の回転電機についても、磁石ユニットのうち径方向において電機子側の面と、回転子の軸心との径方向における距離ＤＭが５０ｍｍ以上とされていてもよい。 Not only for the rotating electric machine having the outer rotor structure but also for the rotating electric machine having the inner rotor structure, the radial distance DM between the surface of the magnet unit on the armature side in the radial direction and the axis of the rotor is 50 mm or more. May be.
　・回転電機１０の固定子巻線５１において、導線８２の直線部８３を径方向に単層で設ける構成としてもよい。また、径方向内外に複数層で直線部８３を配置する場合に、その層数は任意でよく、３層、４層、５層、６層等で設けてもよい。 In the stator winding 51 of the rotating electric machine 10, the straight line portion 83 of the conducting wire 82 may be provided in a single layer in the radial direction. When the linear portion 83 is arranged in a plurality of layers inside and outside in the radial direction, the number of the layers may be arbitrary, and three, four, five, six, or the like may be provided.
　・例えば図２の構成では、回転軸１１を、軸方向で回転電機１０の一端側及び他端側の両方に突出するように設けたが、これを変更し、一端側にのみ突出する構成としてもよい。この場合、回転軸１１は、軸受ユニット２０により片持ち支持される部分を端部とし、その軸方向外側に延びるように設けられるとよい。本構成では、インバータユニット６０の内部に回転軸１１が突出しない構成となるため、インバータユニット６０の内部空間、詳しくは筒状部７１の内部空間をより広く用いることができることとなる。 For example, in the configuration of FIG. 2, the rotating shaft 11 is provided so as to protrude at both the one end side and the other end side of the rotary electric machine 10 in the axial direction. Is also good. In this case, the rotating shaft 11 may be provided so as to extend outward in the axial direction with a portion supported by the bearing unit 20 in a cantilevered manner as an end. In this configuration, since the rotation shaft 11 does not protrude into the inverter unit 60, the internal space of the inverter unit 60, more specifically, the internal space of the tubular portion 71 can be used more widely.
　・上記構成の回転電機１０では、軸受２１，２２において非導電性グリースを用いる構成としたが、これを変更し、軸受２１，２２において導電性グリースを用いる構成としてもよい。例えば、金属粒子やカーボン粒子等が含まれた導電性グリースを用いる構成とする。 In the rotating electric machine 10 having the above-described configuration, the bearings 21 and 22 are configured to use the non-conductive grease. However, the configuration may be changed and the bearings 21 and 22 may be configured to use the conductive grease. For example, a configuration is used in which conductive grease containing metal particles, carbon particles, or the like is included.
　・回転軸１１を回転自在に支持する構成として、回転子４０の軸方向一端側及び他端側の２カ所に軸受を設ける構成としてもよい。この場合、図１の構成で言えば、インバータユニット６０を挟んで一端側及び他端側の２カ所に軸受が設けられるとよい。 (4) As a configuration for rotatably supporting the rotating shaft 11, a configuration may be adopted in which bearings are provided at two locations on one end side and the other end side of the rotor 40 in the axial direction. In this case, in the configuration of FIG. 1, it is preferable that bearings are provided at two locations, one end side and the other end side, with the inverter unit 60 interposed therebetween.
　・上記構成の回転電機１０では、回転子４０において磁石ホルダ４１の中間部４５が内側肩部４９ａと感情の外側肩部４９ｂを有する構成としたが、これらの肩部４９ａ，４９ｂを無くし、平坦な面を有する構成としてもよい。 In the rotating electric machine 10 having the above-described configuration, the intermediate portion 45 of the magnet holder 41 in the rotor 40 has the inner shoulder 49a and the outer shoulder 49b of emotion. However, these shoulders 49a and 49b are eliminated and the rotor 40 is flat. It may be configured to have various surfaces.
　・上記構成の回転電機１０では、固定子巻線５１の導線８２において導体８２ａを複数の素線８６の集合体として構成したが、これを変更し、導線８２として断面矩形状の角形導線を用いる構成としてもよい。また、導線８２として断面円形状又は断面楕円状の丸形導線を用いる構成としてもよい。 In the rotating electric machine 10 having the above-described configuration, the conductor 82 a in the conductor 82 of the stator winding 51 is configured as an aggregate of the plurality of wires 86, but this is changed, and a rectangular conductor having a rectangular cross section is used as the conductor 82. It may be configured. Further, a configuration may be used in which a round conductor having a circular cross section or an elliptical cross section is used as the conductor 82.
　・上記構成の回転電機１０では、固定子５０の径方向内側にインバータユニット６０を設ける構成としたが、これに代えて、固定子５０の径方向内側にインバータユニット６０を設けない構成としてもよい。この場合、固定子５０の径方向内側となる内部領域を空間としておくことが可能である。また、その内部領域に、インバータユニット６０とは異なる部品を配することが可能である。 In the rotating electric machine 10 having the above configuration, the inverter unit 60 is provided radially inside the stator 50. Alternatively, the inverter unit 60 may not be provided radially inside the stator 50. . In this case, it is possible to leave an internal region radially inside the stator 50 as a space. Further, it is possible to arrange components different from the inverter unit 60 in the internal area.
　・上記構成の回転電機１０において、ハウジング３０を具備しない構成としてもよい。この場合、例えばホイールや他の車両部品の一部において、回転子４０、固定子５０等が保持される構成であってもよい。 In the rotating electric machine 10 having the above-described configuration, the configuration may be such that the housing 30 is not provided. In this case, for example, the rotor 40, the stator 50, and the like may be held in a part of a wheel or another vehicle part.
　（車両用インホイールモータとしての実施形態）
　次に、回転電機を、車両の車輪に一体にインホイールモータとして設けた実施形態について説明する。図４５は、インホイールモータ構造の車輪４００及びその周辺構造を示す斜視図であり、図４６は、車輪４００及びその周辺構造の縦断面図であり、図４７は、車輪４００の分解斜視図である。これら各図は、いずれも車輪４００を車両内側から見た斜視図である。なお、車両においては、本実施形態のインホイールモータ構造を種々の形態で適用することが可能であり、例えば車両前後にそれぞれ２つの車輪を有する車両では、車両前側の２輪、車両後側の２輪、又は車両前後の４輪に本実施形態のインホイールモータ構造を適用することが可能である。ただし、車両前後の少なくとも一方が１輪である車両への適用も可能である。なお、インホイールモータは、車両用駆動ユニットとしての適用例である。 (Embodiment as in-wheel motor for vehicle)
Next, an embodiment in which the rotating electric machine is provided integrally with the wheels of the vehicle as an in-wheel motor will be described. 45 is a perspective view showing a wheel 400 having an in-wheel motor structure and its peripheral structure, FIG. 46 is a longitudinal sectional view of the wheel 400 and its peripheral structure, and FIG. 47 is an exploded perspective view of the wheel 400. is there. Each of these figures is a perspective view of the wheel 400 as viewed from the inside of the vehicle. Note that, in a vehicle, the in-wheel motor structure of the present embodiment can be applied in various forms. For example, in a vehicle having two wheels before and after the vehicle, two wheels on the vehicle front side and two wheels on the vehicle rear side are used. The in-wheel motor structure of this embodiment can be applied to two wheels or four wheels before and after the vehicle. However, application to a vehicle in which at least one of the front and rear of the vehicle is one wheel is also possible. Note that the in-wheel motor is an example of application as a vehicle drive unit.
　図４５～図４７に示すように、車輪４００は、例えば周知の空気入りタイヤであるタイヤ４０１と、タイヤ４０１の内周側に固定されたホイール４０２と、ホイール４０２の内周側に固定された回転電機５００とを備えている。回転電機５００は、固定子（ステータ）を含む部分である固定部と、回転子（ロータ）を含む部分である回転部とを有し、固定部が車体側に固定されるとともに、回転部がホイール４０２に固定されており、回転部の回転によりタイヤ４０１及びホイール４０２が回転する。なお、回転電機５００において固定部及び回転部を含む詳細な構成は後述する。 As shown in FIGS. 45 to 47, a wheel 400 is, for example, a tire 401 which is a well-known pneumatic tire, a wheel 402 fixed to an inner peripheral side of the tire 401, and a wheel 402 fixed to an inner peripheral side of the wheel 402. And a rotating electric machine 500. The rotating electric machine 500 has a fixed portion that is a portion including a stator (stator) and a rotating portion that is a portion including a rotor (rotor). The fixed portion is fixed to the vehicle body side, and the rotating portion is The tire 401 and the wheel 402 are fixed to the wheel 402, and the rotation of the rotating unit rotates the tire 401 and the wheel 402. The detailed configuration of the rotating electric machine 500 including the fixed part and the rotating part will be described later.
　また、車輪４００には、周辺装置として、不図示の車体に対して車輪４００を保持するサスペンション装置と、車輪４００の向きを可変とするステアリング装置と、車輪４００の制動を行うブレーキ装置とが取り付けられている。 Also mounted on the wheel 400 are, as peripheral devices, a suspension device that holds the wheel 400 with respect to a vehicle body (not shown), a steering device that changes the direction of the wheel 400, and a brake device that brakes the wheel 400. Have been.
　サスペンション装置は、独立懸架式サスペンションであり、例えばトレーリングアーム式、ストラット式、ウィッシュボーン式、マルチリンク式など任意の形式の適用が可能である。本実施形態では、サスペンション装置として、車体中央側に延びる向きでロアアーム４１１が設けられるとともに、上下方向に延びる向きでサスペンションアーム４１２及びスプリング４１３が設けられている。サスペンションアーム４１２は、例えばショックアブソーバとして構成されているとよい。ただしその詳細な図示は省略する。ロアアーム４１１及びサスペンションアーム４１２はそれぞれ、車体側に接続されるとともに、回転電機５００の固定部に固定された円板状のベースプレート４０５に接続されている。図４６に示すように、回転電機５００側（ベースプレート４０５側）には、ロアアーム４１１及びサスペンションアーム４１２が支持軸４１４，４１５により互いに同軸の状態で支持されている。 The suspension device is an independent suspension type, and any type of application such as a trailing arm type, a strut type, a wishbone type, and a multi-link type is applicable. In the present embodiment, as the suspension device, the lower arm 411 is provided so as to extend toward the center of the vehicle body, and the suspension arm 412 and the spring 413 are provided so as to extend vertically. The suspension arm 412 may be configured as, for example, a shock absorber. However, detailed illustration thereof is omitted. The lower arm 411 and the suspension arm 412 are each connected to the vehicle body side, and are also connected to a disk-shaped base plate 405 fixed to a fixed portion of the rotating electric machine 500. As shown in FIG. 46, a lower arm 411 and a suspension arm 412 are supported coaxially on the rotating electric machine 500 side (base plate 405 side) by support shafts 414 and 415.
　また、ステアリング装置としては、例えばラック＆ピニオン式構造、ボール＆ナット式構造の適用や、油圧式パワーステアリングシステム、電動式パワーステアリングシステムの適用が可能である。本実施形態では、ステアリング装置として、ラック装置４２１とタイロッド４２２とが設けられており、ラック装置４２１がタイロッド４２２を介して回転電機５００側のベースプレート４０５に接続されている。この場合、不図示のステアリングシャフトの回転に伴いラック装置４２１が作動すると、タイロッド４２２が車両左右方向に移動する。これにより、車輪４００が、ロアアーム４１１及びサスペンションアーム４１２の支持軸４１４，４１５を中心として回転し、車輪方向が変更される。 ス テ ア リ ン グ Further, as the steering device, for example, a rack & pinion type structure, a ball & nut type structure, a hydraulic power steering system, and an electric power steering system can be applied. In the present embodiment, a rack device 421 and a tie rod 422 are provided as a steering device, and the rack device 421 is connected to the base plate 405 on the rotary electric machine 500 side via the tie rod 422. In this case, when the rack device 421 operates according to the rotation of the steering shaft (not shown), the tie rod 422 moves in the left-right direction of the vehicle. As a result, the wheel 400 rotates about the support shafts 414 and 415 of the lower arm 411 and the suspension arm 412, and the direction of the wheel is changed.
　ブレーキ装置としては、ディスクブレーキやドラムブレーキの適用が好適である。本実施形態では、ブレーキ装置として、回転電機５００の回転軸５０１に固定されたディスクロータ４３１と、回転電機５００側のベースプレート４０５に固定されたブレーキキャリパ４３２とが設けられている。ブレーキキャリパ４３２ではブレーキパッドが油圧等により作動されるようになっており、ブレーキパッドがディスクロータ４３１に押し付けられることにより、摩擦による制動力を生じさせて車輪４００の回転が停止される。 デ ィ ス ク Disc brakes and drum brakes are preferably used as the brake device. In the present embodiment, a disk rotor 431 fixed to the rotating shaft 501 of the rotating electric machine 500 and a brake caliper 432 fixed to the base plate 405 on the rotating electric machine 500 side are provided as brake devices. In the brake caliper 432, the brake pad is operated by hydraulic pressure or the like. When the brake pad is pressed against the disk rotor 431, a braking force is generated by friction, and the rotation of the wheel 400 is stopped.
　また、車輪４００には、回転電機５００から延びる電気配線Ｈ１や冷却用配管Ｈ２を収容する収容ダクト４４０が取り付けられている。収容ダクト４４０は、回転電機５００の固定部側の端部から回転電機５００の端面に沿って延び、かつサスペンションアーム４１２を避けるように設けられ、その状態でサスペンションアーム４１２に固定されている。これにより、サスペンションアーム４１２における収容ダクト４４０の接続部位は、ベースプレート４０５との位置関係が固定されたものとなる。そのため、電気配線Ｈ１や冷却用配管Ｈ２において車両の振動などに起因して生じるストレスを抑制できるようになっている。なお、電気配線Ｈ１は、不図示の車載電源部や車載ＥＣＵに接続され、冷却用配管Ｈ２は、不図示のラジエータに接続される。 {Circle around (4)} An accommodation duct 440 for accommodating the electric wiring H1 extending from the rotary electric machine 500 and the cooling pipe H2 is attached to the wheel 400. The accommodation duct 440 is provided to extend along the end face of the rotating electric machine 500 from an end on the fixed portion side of the rotating electric machine 500 and to avoid the suspension arm 412, and is fixed to the suspension arm 412 in that state. Thus, the connection portion of the suspension duct 440 of the suspension arm 412 has a fixed positional relationship with the base plate 405. Therefore, it is possible to suppress the stress generated in the electric wiring H1 and the cooling pipe H2 due to the vibration of the vehicle and the like. The electric wiring H1 is connected to a vehicle-mounted power supply unit and a vehicle-mounted ECU (not shown), and the cooling pipe H2 is connected to a radiator (not shown).
　次に、インホイールモータとして用いられる回転電機５００の構成を詳細に説明する。本実施形態では、回転電機５００をインホイールモータに適用した事例を示している。回転電機５００は、従来技術のように減速機を擁した車両駆動ユニットのモータと比べて、優れた動作効率、出力を備える。すなわち、回転電機５００を従来技術に比べて、コストダウンにより実用的な価格を実現できるような用途に採用すれば、車両駆動ユニット以外の用途のモータとしても使ってもよい。そのような場合であっても、インホイールモータに適用した場合と同様に、優れた性能を発揮する。なお、動作効率とは、車両の燃費を導出する走行モードでの試験時の際に使われる指標を指す。 Next, the configuration of the rotating electric machine 500 used as the in-wheel motor will be described in detail. In the present embodiment, an example is shown in which the rotating electric machine 500 is applied to an in-wheel motor. The rotating electric machine 500 has excellent operation efficiency and output as compared with a motor of a vehicle drive unit having a reduction gear as in the related art. That is, if the rotary electric machine 500 is used for an application that can realize a practical price by reducing costs compared to the conventional technology, it may be used as a motor for applications other than the vehicle drive unit. Even in such a case, excellent performance is exhibited as in the case where the present invention is applied to an in-wheel motor. The operation efficiency refers to an index used at the time of a test in a driving mode for deriving the fuel efficiency of the vehicle.
　回転電機５００の概要を図４８～図５１に示す。図４８は、回転電機５００を回転軸５０１の突出側（車両内側）から見た側面図であり、図４９は、回転電機５００の縦断面図（図４８の４９－４９線断面図）であり、図５０は、回転電機５００の横断面図（図４９の５０－５０線断面図）であり、図５１は、回転電機５００の構成要素を分解した分解断面図である。以下の記載では、回転軸５０１が、図５１においては車体の外側方向に延びる方向を軸方向とし、回転軸５０１から放射状に延びる方向を径方向とし、図４８においては回転軸５０１の中央、言い換えれば回転部分の回転中心、を通る断面４９を作るために引いた中心線上の、回転部分の回転中心以外の任意の点より、円周状に延びる２つの方向をいずれも周方向としている。言い換えると、周方向は、断面４９上の任意の点を起点とした時計回りの方向、又は反時計回りの方向のいずれの方向であってもよい。また、車両搭載状態からすれば、図４９において右側が車両外側であり、左側が車両内側である。言い換えると、同車両搭載状態からすれば、後述する回転子５１０は、回転子カバー６７０よりも車体の外側方向に配置される。 FIGS. 48 to 51 show an outline of the rotating electric machine 500. FIG. FIG. 48 is a side view of rotating electric machine 500 as viewed from the protruding side (inside of the vehicle) of rotating shaft 501, and FIG. 49 is a longitudinal sectional view of rotating electric machine 500 (sectional view taken along line 49-49 in FIG. 48). 50 is a cross-sectional view of rotary electric machine 500 (a cross-sectional view taken along line 50-50 in FIG. 49), and FIG. 51 is an exploded cross-sectional view in which the components of rotary electric machine 500 are disassembled. In the following description, the direction in which the rotating shaft 501 extends outwardly of the vehicle body in FIG. 51 is defined as the axial direction, the direction radially extending from the rotating shaft 501 is defined as the radial direction, and in FIG. 48, the center of the rotating shaft 501, in other words, Two directions extending circumferentially from an arbitrary point other than the center of rotation of the rotating portion on a center line drawn to create a cross section 49 passing through the center of rotation of the rotating portion are defined as circumferential directions. In other words, the circumferential direction may be a clockwise direction starting from an arbitrary point on the cross section 49 or a counterclockwise direction. 49, the right side is the outside of the vehicle and the left side is the inside of the vehicle. In other words, in the vehicle mounted state, a rotor 510 described later is disposed outside the vehicle body with respect to the rotor cover 670.
　本実施形態に係る回転電機５００は、アウタロータ式の表面磁石型回転電機である。回転電機５００は、大別して、回転子５１０と、固定子５２０と、インバータユニット５３０と、軸受５６０と、回転子カバー６７０とを備えている。これら各部材は、いずれも回転子５１０に一体に設けられた回転軸５０１に対して同軸に配置され、所定順序で軸方向に組み付けられることで回転電機５００が構成されている。 回 転 The rotary electric machine 500 according to the present embodiment is an outer rotor type surface magnet type rotary electric machine. The rotating electric machine 500 roughly includes a rotor 510, a stator 520, an inverter unit 530, a bearing 560, and a rotor cover 670. Each of these members is coaxially arranged with respect to a rotating shaft 501 provided integrally with the rotor 510, and is assembled in a predetermined order in the axial direction to constitute the rotating electric machine 500.
　回転電機５００において、回転子５１０及び固定子５２０はそれぞれ円筒状をなしており、エアギャップを挟んで互いに対向配置されている。回転子５１０が回転軸５０１と共に一体回転することにより、固定子５２０の径方向外側にて回転子５１０が回転する。回転子５１０が「界磁子」に相当し、固定子５２０が「電機子」に相当する。 In the rotary electric machine 500, the rotor 510 and the stator 520 each have a cylindrical shape, and are arranged to face each other with an air gap therebetween. When the rotor 510 rotates integrally with the rotation shaft 501, the rotor 510 rotates radially outside the stator 520. The rotor 510 corresponds to a “field element”, and the stator 520 corresponds to an “armature”.
　回転子５１０は、略円筒状の回転子キャリア５１１と、その回転子キャリア５１１に固定された環状の磁石ユニット５１２とを有している。回転子キャリア５１１に回転軸５０１が固定されている。 The rotor 510 has a substantially cylindrical rotor carrier 511 and an annular magnet unit 512 fixed to the rotor carrier 511. The rotating shaft 501 is fixed to the rotor carrier 511.
　回転子キャリア５１１は、円筒部５１３を有している。円筒部５１３の内周面には磁石ユニット５１２が固定されている。つまり、磁石ユニット５１２は、回転子キャリア５１１の円筒部５１３に径方向外側から包囲された状態で設けられている。また、円筒部５１３は、その軸方向に対向する第１端と第２端とを有している。第１端は、車体の外側の方向に位置し、第２端は、ベースプレート４０５が存在する方向に位置する。回転子キャリア５１１において、円筒部５１３の第１端には端板５１４が連続して設けられている。すなわち円筒部５１３と端板５１４とは一体の構造である。円筒部５１３の第２端は開放されている。回転子キャリア５１１は、例えば機械強度が充分な冷間圧延鋼板（ＳＰＣＣやＳＰＣＣより板厚が厚いＳＰＨＣ）、鍛造用鋼、炭素繊維強化プラスチック（ＣＦＲＰ）などにより形成されている。 The rotor carrier 511 has a cylindrical portion 513. A magnet unit 512 is fixed to the inner peripheral surface of the cylindrical portion 513. That is, the magnet unit 512 is provided so as to be surrounded by the cylindrical portion 513 of the rotor carrier 511 from the outside in the radial direction. Further, the cylindrical portion 513 has a first end and a second end that are opposed in the axial direction. The first end is located in a direction outside the vehicle body, and the second end is located in a direction in which the base plate 405 exists. In the rotor carrier 511, an end plate 514 is continuously provided at a first end of the cylindrical portion 513. That is, the cylindrical portion 513 and the end plate 514 have an integral structure. The second end of the cylindrical portion 513 is open. The rotor carrier 511 is formed of, for example, a cold-rolled steel plate (SPCC or SPHC having a plate thickness greater than SPCC) having sufficient mechanical strength, forging steel, carbon fiber reinforced plastic (CFRP), or the like.
　回転軸５０１の軸長は、回転子キャリア５１１の軸方向の寸法よりも長い。言い換えると、回転軸５０１は、回転子キャリア５１１の開放端側（車両内側方向）に突出しており、その突出側の端部に、上述のブレーキ装置等が取り付けられるようになっている。 軸 The axis length of the rotating shaft 501 is longer than the axial dimension of the rotor carrier 511. In other words, the rotating shaft 501 protrudes toward the open end side (inward of the vehicle) of the rotor carrier 511, and the above-described brake device or the like is attached to the protruding end.
　回転子キャリア５１１の端板５１４にはその中央部に貫通孔５１４ａが形成されている。回転軸５０１は、端板５１４の貫通孔５１４ａに挿通された状態で、回転子キャリア５１１に固定されている。回転軸５０１は、回転子キャリア５１１が固定される部分に、軸方向に交差（直交）する向きに延びるフランジ５０２を有しており、そのフランジと端板５１４の車両外側の面とが面接合されている状態で、回転子キャリア５１１に対して回転軸５０１が固定されている。なお、車輪４００においては、回転軸５０１のフランジ５０２から車両外側方向に立設されたボルト等の締結具を用いてホイール４０２が固定されるようになっている。 貫通 A through hole 514a is formed in the center of the end plate 514 of the rotor carrier 511. The rotating shaft 501 is fixed to the rotor carrier 511 while being inserted through the through hole 514a of the end plate 514. The rotating shaft 501 has a flange 502 extending in a direction intersecting (orthogonal) in the axial direction at a portion to which the rotor carrier 511 is fixed, and the flange and an end surface of the end plate 514 are surface-joined. In this state, the rotating shaft 501 is fixed to the rotor carrier 511. In the wheel 400, the wheel 402 is fixed by using a fastener such as a bolt that stands upright from the flange 502 of the rotating shaft 501 toward the outside of the vehicle.
　また、磁石ユニット５１２は、回転子５１０の周方向に沿って極性が交互に変わるように配置された複数の永久磁石により構成されている。これにより、磁石ユニット５１２は、周方向に複数の磁極を有する。永久磁石は、例えば接着により回転子キャリア５１１に固定されている。磁石ユニット５１２は、第１実施形態の図８，図９において磁石ユニット４２として説明した構成を有しており、永久磁石として、固有保磁力が４００［ｋＡ／ｍ］以上であり、かつ残留磁束密度Ｂｒが１．０［Ｔ］以上である焼結ネオジム磁石を用いて構成されている。 The magnet unit 512 is composed of a plurality of permanent magnets arranged so that the polarity alternates along the circumferential direction of the rotor 510. Thereby, the magnet unit 512 has a plurality of magnetic poles in the circumferential direction. The permanent magnet is fixed to the rotor carrier 511 by, for example, bonding. The magnet unit 512 has the configuration described as the magnet unit 42 in FIGS. 8 and 9 of the first embodiment, has a specific coercive force of 400 [kA / m] or more as a permanent magnet, and has a residual magnetic flux. It is configured using a sintered neodymium magnet having a density Br of 1.0 [T] or more.
　磁石ユニット５１２は、図９等の磁石ユニット４２と同様に、それぞれ極異方性磁石でありかつ極性が互いに異なる第１磁石９１及び第２磁石９２を有している。図８及び図９で説明したように、各磁石９１，９２ではそれぞれ、ｄ軸側（ｄ軸寄りの部分）とｑ軸側（ｑ軸寄りの部分）とで磁化容易軸の向きが相違しており、ｄ軸側では磁化容易軸の向きがｄ軸に平行な方向に近い向きとなり、ｑ軸側では磁化容易軸の向きがｑ軸に直交する方向に近い向きとなっている。そして、この磁化容易軸の向きに応じた配向により円弧状の磁石磁路が形成されている。なお、各磁石９１，９２において、ｄ軸側では磁化容易軸をｄ軸に平行な向きとし、ｑ軸側では磁化容易軸をｑ軸に直交する向きとしてもよい。要するに、磁石ユニット５１２は、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされて構成されている。 The magnet unit 512 is a polar anisotropic magnet and has a first magnet 91 and a second magnet 92 having polarities different from each other, similarly to the magnet unit 42 in FIG. 9 and the like. As described with reference to FIGS. 8 and 9, the directions of the axes of easy magnetization of the magnets 91 and 92 are different between the d-axis side (portion closer to the d-axis) and the q-axis side (portion near the q-axis). The direction of the easy axis is closer to the direction parallel to the d axis on the d-axis side, and the direction of the easy axis is closer to the direction orthogonal to the q axis on the q-axis side. An arc-shaped magnet magnetic path is formed by an orientation corresponding to the direction of the easy axis of magnetization. In each of the magnets 91 and 92, the easy axis may be oriented parallel to the d axis on the d-axis side, and the easy axis may be orthogonal to the q axis on the q-axis side. In short, the magnet unit 512 is configured such that the direction of the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared to the q-axis side, which is the magnetic pole boundary. .
　各磁石９１，９２によれば、ｄ軸での磁石磁束が強化され、かつｑ軸付近での磁束変化が抑えられる。これにより、各磁極においてｑ軸からｄ軸にかけての表面磁束変化がなだらかになる磁石９１，９２を好適に実現できるものとなっている。磁石ユニット５１２として、図２２及び図２３に示す磁石ユニット４２の構成や、図３０に示す磁石ユニット４２の構成を用いることも可能である。 According to the magnets 91 and 92, the magnet magnetic flux on the d-axis is strengthened, and the change in magnetic flux near the q-axis is suppressed. Accordingly, it is possible to suitably realize the magnets 91 and 92 in which the surface magnetic flux changes gradually from the q axis to the d axis in each magnetic pole. As the magnet unit 512, the configuration of the magnet unit 42 shown in FIGS. 22 and 23 or the configuration of the magnet unit 42 shown in FIG. 30 can be used.
　なお、磁石ユニット５１２は、回転子キャリア５１１の円筒部５１３の側、すなわち外周面側に、複数の電磁鋼板が軸方向に積層されて構成された回転子コア（バックヨーク）を有していてもよい。つまり、回転子キャリア５１１の円筒部５１３の径方向内側に回転子コアを設けるとともに、その回転子コアの径方向内側に永久磁石（磁石９１，９２）を設ける構成とすることも可能である。 The magnet unit 512 has a rotor core (back yoke) formed by stacking a plurality of electromagnetic steel sheets in the axial direction on the side of the cylindrical portion 513 of the rotor carrier 511, that is, on the outer peripheral surface side. Is also good. That is, it is possible to provide a configuration in which a rotor core is provided radially inside the cylindrical portion 513 of the rotor carrier 511, and permanent magnets (magnets 91 and 92) are provided radially inside the rotor core.
　図４７に示すように、回転子キャリア５１１の円筒部５１３には、周方向の所定間隔にて、軸方向に延びる向きで凹部５１３ａが形成されている。この凹部５１３ａは例えばプレス加工により形成されており、図５２に示すように、円筒部５１３の内周面側には、凹部５１３ａの裏側となる位置に凸部５１３ｂが形成されている。一方、磁石ユニット５１２の外周面側には、円筒部５１３の凸部５１３ｂに合わせて凹部５１２ａが形成されており、その凹部５１２ａ内に円筒部５１３の凸部５１３ｂが入り込むことで、磁石ユニット５１２の周方向の位置ずれが抑制されるようになっている。つまり、回転子キャリア５１１側の凸部５１３ｂは、磁石ユニット５１２の回り止め部として機能する。なお、凸部５１３ｂの形成方法は、プレス加工以外であってもよく任意である。 凹 部 As shown in FIG. 47, the cylindrical portion 513 of the rotor carrier 511 is formed with concave portions 513a at predetermined circumferential intervals so as to extend in the axial direction. The concave portion 513a is formed by, for example, press working. As shown in FIG. 52, a convex portion 513b is formed on the inner peripheral surface side of the cylindrical portion 513 at a position behind the concave portion 513a. On the other hand, a concave portion 512a is formed on the outer peripheral surface side of the magnet unit 512 in conformity with the convex portion 513b of the cylindrical portion 513, and the convex portion 513b of the cylindrical portion 513 enters the concave portion 512a, thereby forming the magnet unit 512. In the circumferential direction is suppressed. That is, the convex portion 513b on the rotor carrier 511 side functions as a rotation preventing portion of the magnet unit 512. The method of forming the convex portion 513b may be other than press working, and is arbitrary.
　図５２には、磁石ユニット５１２における磁石磁路の方向が矢印により示されている。磁石磁路は、磁極境界であるｑ軸を跨ぐようにして円弧状に延び、かつ磁極中心であるｄ軸では、ｄ軸に平行又は平行に近い向きとなっている。磁石ユニット５１２には、その内周面側に、ｑ軸に相当する位置ごとに凹部５１２ｂが形成されている。この場合、磁石ユニット５１２では、固定子５２０に近い側（図の下側）と遠い側（図の上側）とで磁石磁路の長さが異なり、固定子５２０に近い側の方が磁石磁路長が短くなっており、その磁石磁路長が最短となる位置に凹部５１２ｂが形成されている。つまり、磁石ユニット５１２では磁石磁路長が短い場所において十分な磁石磁束を生じさせることが困難になることを考慮して、その磁石磁束の弱い場所で磁石を削除するようにしている。 In FIG. 52, the directions of the magnet magnetic paths in the magnet unit 512 are indicated by arrows. The magnet magnetic path extends in an arc shape so as to straddle the q axis, which is the magnetic pole boundary, and is oriented parallel to or nearly parallel to the d axis at the d axis, which is the center of the magnetic pole. The magnet unit 512 has recesses 512b formed on the inner peripheral surface thereof at positions corresponding to the q axis. In this case, in the magnet unit 512, the length of the magnet magnetic path differs between the side closer to the stator 520 (the lower side in the figure) and the side farther (the upper side in the figure), and the side closer to the stator 520 has the magnet magnetic path. The path length is short, and a concave portion 512b is formed at a position where the magnet magnetic path length is the shortest. That is, in consideration of the fact that it is difficult for the magnet unit 512 to generate a sufficient magnet magnetic flux in a place where the magnet magnetic path length is short, the magnet is deleted in a place where the magnet magnetic flux is weak.
　ここで、磁石の実効磁束密度Ｂｄは、磁石内部を通る磁気回路の長さが長いほど高くなる。また、パーミアンス係数Ｐｃと磁石の実効磁束密度Ｂｄとは、そのうち一方が高くなると他方が高くなる関係にある。上記図５２の構成によれば、磁石の実効磁束密度Ｂｄの高さの指標となるパーミアンス係数Ｐｃの低下を抑制しつつ、磁石量の削減を図ることができる。なお、Ｂ－Ｈ座標において、磁石の形状に応じたパーミアンス直線と減磁曲線との交点が動作点であり、その動作点の磁束密度が磁石の実効磁束密度Ｂｄである。本実施形態の回転電機５００では、固定子５２０の鉄量を少なくした構成としており、かかる構成においてｑ軸を跨いだ磁気回路を設定する手法は極めて有効である。 Here, the effective magnetic flux density Bd of the magnet increases as the length of the magnetic circuit passing through the inside of the magnet increases. In addition, the permeance coefficient Pc and the effective magnetic flux density Bd of the magnet are such that if one of them becomes higher, the other becomes higher. According to the configuration of FIG. 52, it is possible to reduce the amount of magnets while suppressing a decrease in the permeance coefficient Pc, which is an index of the height of the effective magnetic flux density Bd of the magnets. In the BH coordinates, the intersection of the permeance line corresponding to the shape of the magnet and the demagnetization curve is the operating point, and the magnetic flux density at that operating point is the effective magnetic flux density Bd of the magnet. The rotating electric machine 500 of the present embodiment has a configuration in which the iron amount of the stator 520 is reduced, and in such a configuration, a method of setting a magnetic circuit across the q-axis is extremely effective.
　また、磁石ユニット５１２の凹部５１２ｂは、軸方向に延びる空気通路として用いることができる。そのため、空冷性能を高めることも可能となる。 凹 部 Furthermore, the concave portion 512b of the magnet unit 512 can be used as an air passage extending in the axial direction. Therefore, the air cooling performance can be improved.
　次に、固定子５２０の構成を説明する。固定子５２０は、固定子巻線５２１と固定子コア５２２とを有している。図５３は、固定子巻線５２１と固定子コア５２２とを分解して示す斜視図である。 Next, the configuration of the stator 520 will be described. The stator 520 has a stator winding 521 and a stator core 522. FIG. 53 is an exploded perspective view showing the stator winding 521 and the stator core 522.
　固定子巻線５２１は、略筒状（環状）に巻回形成された複数の相巻線よりなり、その固定子巻線５２１の径方向内側にベース部材としての固定子コア５２２が組み付けられている。本実施形態では、Ｕ相、Ｖ相及びＷ相の相巻線を用いることで、固定子巻線５２１が３相の相巻線として構成されている。各相巻線は、径方向に内外２層の導線５２３により構成されている。固定子５２０は、既述の固定子５０と同様に、スロットレス構造と固定子巻線５２１の扁平導線構造とを有することを特徴としており、図８～図１６に示された固定子５０と同様又は類似の構成を有している。 The stator winding 521 is composed of a plurality of phase windings formed in a substantially cylindrical (annular) shape, and a stator core 522 as a base member is assembled radially inside the stator winding 521. I have. In the present embodiment, the stator winding 521 is configured as a three-phase winding by using U-phase, V-phase, and W-phase windings. Each phase winding is composed of two layers of conductive wires 523 in the radial direction. The stator 520 is characterized in that it has a slotless structure and a flat conductive wire structure of the stator winding 521 similarly to the stator 50 described above. It has a similar or similar configuration.
　固定子コア５２２の構成について説明する。固定子コア５２２は、既述の固定子コア５２と同様に、軸方向に複数の電磁鋼板が積層され、かつ径方向に所定の厚さを有する円筒状をなしており、固定子コア５２２において回転子５１０側となる径方向外側に固定子巻線５２１が組み付けられている。固定子コア５２２の外周面は凹凸のない曲面状をなしており、固定子巻線５２１が組み付けられた状態では、固定子コア５２２の外周面に、固定子巻線５２１を構成する導線５２３が周方向に並べて配置されている。固定子コア５２２はバックコアとして機能する。 The configuration of the stator core 522 will be described. The stator core 522 has a cylindrical shape in which a plurality of electromagnetic steel sheets are laminated in the axial direction and has a predetermined thickness in the radial direction, similarly to the stator core 52 described above. A stator winding 521 is mounted radially outward on the rotor 510 side. The outer peripheral surface of the stator core 522 has a curved surface without irregularities, and in a state where the stator winding 521 is assembled, the conductor 523 constituting the stator winding 521 is provided on the outer peripheral surface of the stator core 522. They are arranged side by side in the circumferential direction. The stator core 522 functions as a back core.
　固定子５２０は、以下の（Ａ）～（Ｃ）のいずれかを用いたものであるとよい。
（Ａ）固定子５２０において、周方向における各導線５２３の間に導線間部材を設け、かつその導線間部材として、１磁極における導線間部材の周方向の幅寸法をＷｔ、導線間部材の飽和磁束密度をＢｓ、１磁極における磁石ユニット５１２の周方向の幅寸法をＷｍ、磁石ユニット５１２の残留磁束密度をＢｒとした場合に、Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒの関係となる磁性材料を用いている。
（Ｂ）固定子５２０において、周方向における各導線５２３の間に導線間部材を設け、かつその導線間部材として、非磁性材料を用いている。
（Ｃ）固定子５２０において、周方向における各導線５２３の間に導線間部材を設けていない構成となっている。 It is preferable that the stator 520 uses one of the following (A) to (C).
(A) In the stator 520, an inter-conductor member is provided between the conductors 523 in the circumferential direction, and as the inter-conductor member, the circumferential width of the inter-conductor member at one magnetic pole is Wt, and the saturation of the inter-conductor member is achieved. When the magnetic flux density is Bs, the width in the circumferential direction of the magnet unit 512 at one magnetic pole is Wm, and the residual magnetic flux density of the magnet unit 512 is Br, a magnetic material having a relationship of Wt × Bs ≦ Wm × Br is used. I have.
(B) In the stator 520, an inter-conductor member is provided between the conductors 523 in the circumferential direction, and a non-magnetic material is used as the inter-conductor member.
(C) The stator 520 is configured such that no inter-conductor member is provided between the respective conductors 523 in the circumferential direction.
　こうした固定子５２０の構成によれば、固定子巻線としての各導線部の間に磁気経路を確立するためのティース（鉄心）が設けられる一般的なティース構造の回転電機に比べて、インダクタンスが低減される。具体的には、インダクタンスを１／１０以下にすることが可能となっている。この場合、インダクタンスの低下に伴いインピーダンスが低下することから、回転電機５００において入力電力に対する出力電力を大きくし、ひいてはトルク増加に貢献できるものとなっている。また、インピーダンス成分の電圧を利用してトルク出力を行う（言い換えればリラクタンストルクを利用する）埋込み磁石型回転子を用いた回転電機に比べて、大出力の回転電機を提供することが可能となっている。 According to the configuration of the stator 520, the inductance is smaller than that of a general electric rotating machine having a tooth structure in which teeth (iron cores) for establishing a magnetic path are provided between the conductors as stator windings. Reduced. Specifically, the inductance can be reduced to 1/10 or less. In this case, since the impedance decreases as the inductance decreases, the rotating electric machine 500 can increase the output power with respect to the input power, and can contribute to an increase in torque. In addition, it is possible to provide a rotating electric machine having a higher output than a rotating electric machine using an embedded magnet type rotor that performs torque output using the voltage of the impedance component (in other words, utilizes reluctance torque). ing.
　本実施形態では、固定子巻線５２１が、固定子コア５２２と共に樹脂等からなるモールド材（絶縁部材）により一体にモールドされており、周方向に並ぶ各導線５２３の間には、モールド材が介在する構成となっている。かかる構成からすると、本実施形態の固定子５２０は、上記（Ａ）～（Ｃ）のうち（Ｂ）の構成に相当する。また、周方向に隣り合う各導線５２３は、周方向の端面同士が互いに当接するか、又は微小な間隔を隔てて近接配置されており、この構成から言えば上記（Ｃ）の構成であってもよい。なお、上記（Ａ）の構成を採用する場合には、軸方向における導線５２３の向きに合わせて、すなわち例えばスキュー構造の固定子巻線５２１であればスキュー角度に合わせて、固定子コア５２２の外周面に突部が設けられているとよい。 In the present embodiment, the stator winding 521 is integrally molded together with the stator core 522 by a molding material (insulating member) made of resin or the like, and a molding material is provided between the conductors 523 arranged in the circumferential direction. It has a configuration that intervenes. With this configuration, the stator 520 of the present embodiment corresponds to the configuration (B) of the above (A) to (C). The conductors 523 adjacent to each other in the circumferential direction are arranged such that their end faces in the circumferential direction abut each other or are arranged close to each other with a small space therebetween. Is also good. In the case of adopting the configuration of (A), the stator core 522 is adjusted according to the direction of the conductor 523 in the axial direction, that is, according to the skew angle of the stator winding 521 having, for example, a skew structure. It is preferable that a protrusion is provided on the outer peripheral surface.
　次に、固定子巻線５２１の構成を、図５４を用いて説明する。図５４は、固定子巻線５２１を平面状に展開して示す正面図であり、図５４（ａ）には径方向において外層に位置する各導線５２３を示し、図５４（ｂ）には径方向において内層に位置する各導線５２３を示す。 Next, the configuration of the stator winding 521 will be described with reference to FIG. FIG. 54 is a front view showing the stator winding 521 developed in a plane. FIG. 54 (a) shows each conductor 523 located in the outer layer in the radial direction, and FIG. 54 (b) shows the diameter. Each conductor 523 located on the inner layer in the direction is shown.
　固定子巻線５２１は、分布巻きにより円環状に巻回形成されている。固定子巻線５２１では、径方向内外２層に導線材が巻回され、かつ内層側及び外層側の各導線５２３にて互いに異なる方向へのスキューが施されている（図５４（ａ）、図５４（ｂ）参照）。各導線５２３は、それぞれ相互に絶縁されている。導線５２３は、複数の素線８６の集合体として構成されているとよい（図１３参照）。また、同相でかつ通電方向を同じとする導線５２３が、周方向に例えば２本ずつ並べて設けられている。固定子巻線５２１では、径方向に２層かつ周方向に２本（すなわち計４本）の各導線５２３により同相の１つの導線部が構成され、その導線部が１磁極内で１つずつ設けられている。 The stator winding 521 is formed in an annular shape by distributed winding. In the stator winding 521, a conductive material is wound around two layers in the radially inner and outer layers, and skews in different directions are given to each of the conductive wires 523 on the inner layer side and the outer layer side (FIG. 54A). FIG. 54 (b)). Each conductor 523 is mutually insulated from each other. The conductor 523 may be configured as an aggregate of a plurality of strands 86 (see FIG. 13). Further, for example, two conductors 523 having the same phase and the same energizing direction are provided side by side in the circumferential direction. In the stator winding 521, two conductive layers 523 in two layers in the radial direction and two in the circumferential direction (that is, four in total) constitute one conductive part having the same phase, and one conductive part is formed in each magnetic pole. Is provided.
　導線部では、その径方向の厚さ寸法を、１磁極内における１相分の周方向の幅寸法よりも小さいものとし、これにより固定子巻線５２１を扁平導線構造とすることが望ましい。具体的には,例えば、固定子巻線５２１において、径方向に２層かつ周方向に４本（すなわち計８本）の各導線５２３により同相の１つの導線部を構成するとよい。又は、図５０に示す固定子巻線５２１の導線断面において、周方向の幅寸法が径方向の厚さ寸法よりも大きくなっているとよい。固定子巻線５２１として、図１２に示す固定子巻線５１を用いることも可能である。ただしこの場合には、回転子キャリア５１１内に固定子巻線のコイルエンドを収容するスペースを確保する必要がある。 In the conductive wire portion, it is desirable that the radial thickness is smaller than the circumferential width of one phase in one magnetic pole, and that the stator winding 521 has a flat conductive wire structure. Specifically, for example, in the stator winding 521, it is preferable that two conductors 523 in two layers in the radial direction and four conductors 523 in the circumferential direction (ie, a total of eight conductors) 523 constitute one conductor part in the same phase. Alternatively, in the conductor wire cross section of the stator winding 521 shown in FIG. 50, the width in the circumferential direction may be larger than the thickness in the radial direction. It is also possible to use the stator winding 51 shown in FIG. 12 as the stator winding 521. However, in this case, it is necessary to secure a space for accommodating the coil end of the stator winding in the rotor carrier 511.
　固定子巻線５２１では、固定子コア５２２に対して径方向内外に重なるコイルサイド５２５において所定角度で傾斜させて導線５２３が周方向に並べて配置されるとともに、固定子コア５２２よりも軸方向外側となる両側のコイルエンド５２６において軸方向内側への反転（折り返し）が行われて連続結線がなされている。図５４（ａ）には、コイルサイド５２５となる範囲とコイルエンド５２６となる範囲とがそれぞれ示されている。内層側の導線５２３と外層側の導線５２３とはコイルエンド５２６にて互いに接続されており、これにより、コイルエンド５２６で導線５２３が軸方向に反転される都度（折り返される都度）、導線５２３が内層側と外層側とで交互に切り替わるようになっている。要するに、固定子巻線５２１では、周方向に連続する各導線５２３において、電流の向きが反転するのに合わせて内外層の切り替えが行われる構成となっている。 In the stator winding 521, the conductors 523 are arranged in the circumferential direction by being inclined at a predetermined angle on the coil side 525 overlapping the stator core 522 inward and outward with respect to the stator core 522, and are arranged axially outside the stator core 522. At the coil ends 526 on both sides, the inward inversion in the axial direction (returning) is performed, and a continuous connection is made. FIG. 54A shows a range to be the coil side 525 and a range to be the coil end 526, respectively. The conductor 523 on the inner layer side and the conductor 523 on the outer layer side are connected to each other at a coil end 526, so that the conductor 523 is connected to the coil end 526 each time the conductor 523 is inverted in the axial direction (every time it is folded). The inner layer and the outer layer are alternately switched. In short, the stator winding 521 has a configuration in which the inner and outer layers are switched in accordance with the reversal of the current direction in each of the conductors 523 that are continuous in the circumferential direction.
　また、固定子巻線５２１では、軸方向の両端となる端部領域と、その端部領域に挟まれた中央領域とでスキュー角度が異なる２種類のスキューが施されている。すなわち、図５５に示すように、導線５２３において、中央領域のスキュー角度θｓ１と端部領域のスキュー角度θｓ２とが異なっており、スキュー角度θｓ１がスキュー角度θｓ２よりも小さくなる構成となっている。軸方向において、端部領域は、コイルサイド５２５を含む範囲で定められている。スキュー角度θｓ１，スキュー角度θｓ２は、軸方向に対して各導線５２３が傾斜している傾斜角度である。中央領域のスキュー角度θｓ１は、固定子巻線５２１の通電により生じる磁束の高調波成分を削減するのに適正な角度範囲で定められているとよい。 で は Further, in the stator winding 521, two types of skews having different skew angles are applied to an end region which is both ends in the axial direction and a central region sandwiched between the end regions. That is, as shown in FIG. 55, in the conductor 523, the skew angle θs1 in the central region and the skew angle θs2 in the end region are different, and the skew angle θs1 is smaller than the skew angle θs2. In the axial direction, the end region is defined in a range including the coil side 525. The skew angle θs1 and the skew angle θs2 are inclination angles at which the respective conductors 523 are inclined with respect to the axial direction. The skew angle θs1 in the central region may be determined in an appropriate angle range for reducing harmonic components of magnetic flux generated by the conduction of the stator winding 521.
　固定子巻線５２１における各導線５２３のスキュー角度を中央領域と端部領域とで相違させ、中央領域のスキュー角度θｓ１を端部領域のスキュー角度θｓ２よりも小さくすることで、コイルエンド５２６の縮小を図りつつも、固定子巻線５２１の巻線係数を大きくすることができる。言い換えれば、所望の巻線係数を確保しつつも、コイルエンド５２６の長さ、すなわち固定子コア５２２から軸方向にはみ出た部分の導線長を短くすることができる。これにより、回転電機５００の小型化を図りつつ、トルク向上を実現することができる。 The skew angle of each conductor 523 in the stator winding 521 is made different between the center region and the end region, and the skew angle θs1 in the center region is made smaller than the skew angle θs2 in the end region, so that the coil end 526 is reduced. , The winding coefficient of the stator winding 521 can be increased. In other words, it is possible to shorten the length of the coil end 526, that is, the length of the conductive wire that protrudes from the stator core 522 in the axial direction, while securing a desired winding coefficient. Thus, torque can be improved while reducing the size of rotating electric machine 500.
　ここで、中央領域のスキュー角度θｓ１としての適正範囲を説明する。固定子巻線５２１において１磁極内に導線５２３がＸ本配置されている場合には、固定子巻線５２１の通電によりＸ次の高調波成分が生じることが考えられる。相数をＳ、対数をｍとする場合、Ｘ＝２×Ｓ×ｍである。本願開示者は、Ｘ次の高調波成分が、Ｘ－１次の高調波成分とＸ＋１次の高調波成分との合成波を構成する成分であるため、Ｘ－１次の高調波成分又はＸ＋１次の高調波成分の少なくともいずれかを低減することにより、Ｘ次の高調波成分を低減できることに着目した。この着目を踏まえ、本願開示者は、電気角で「３６０°／（Ｘ＋１）～３６０°／（Ｘ－１）」の角度範囲内にスキュー角度θｓ１を設定することにより、Ｘ次の高調波成分を低減できることを見出した。 Here, an appropriate range as the skew angle θs1 of the central region will be described. When X conductors 523 are arranged within one magnetic pole in the stator winding 521, it is conceivable that the energization of the stator winding 521 generates an X-order harmonic component. When the number of phases is S and the logarithm is m, X = 2 × S × m. The present applicant disclosed that the X-order harmonic component is a component constituting a composite wave of the X-1 order harmonic component and the X + 1 order harmonic component, and therefore the X-1 order harmonic component or X + 1 Attention was paid to the fact that X-order harmonic components can be reduced by reducing at least one of the following harmonic components. Based on this attention, the present applicant sets the skew angle θs1 in the electrical angle range of “360 ° / (X + 1) to 360 ° / (X−1)” to obtain the X-order harmonic component. Can be reduced.
　例えばＳ＝３、ｍ＝２である場合、Ｘ＝１２次の高調波成分を低減すべく、「３６０°／１３～３６０°／１１」の角度範囲内にスキュー角度θｓ１を設定する。つまり、スキュー角度θｓ１は、２７．７°～３２．７°の範囲内の角度で設定されるとよい。 If, for example, S = 3 and m = 2, the skew angle θs1 is set within an angle range of “360 ° / 13 to 360 ° / 11” in order to reduce the X = 12th harmonic component. That is, the skew angle θs1 may be set to an angle in the range of 27.7 ° to 32.7 °.
　中央領域のスキュー角度θｓ１が上記のように設定されることにより、その中央領域において、ＮＳ交互の磁石磁束を積極的に鎖交させることができ、固定子巻線５２１の巻線係数を高くすることができる。 By setting the skew angle θs1 of the central region as described above, the NS alternate magnet flux can be positively linked in the central region, and the winding coefficient of the stator winding 521 is increased. be able to.
　端部領域のスキュー角度θｓ２は、上述した中央領域のスキュー角度θｓ１よりも大きい角度である。この場合、スキュー角度θｓ２の角度範囲は、「θｓ１＜θｓ２＜９０°」である。 The skew angle θs2 in the end region is larger than the skew angle θs1 in the central region described above. In this case, the angle range of the skew angle θs2 is “θs1 <θs2 <90 °”.
　また、固定子巻線５２１において、内層側の導線５２３と外層側の導線５２３とは、各導線５２３の端部どうしの溶接や接着により繋げられているか、又は折り曲げにより繋げられているとよい。固定子巻線５２１では、軸方向両側の各コイルエンド５２６のうち一方側（すなわち軸方向一端側）にて各相巻線の端部が電力変換器（インバータ）にバスバー等を介して電気的に接続される構成となっている。そのためここでは、バスバー接続側のコイルエンド５２６とその反対側のコイルエンド５２６とを区別しつつ、コイルエンド５２６において各導線同士が繋げられている構成を説明する。 In addition, in the stator winding 521, the inner conductor 523 and the outer conductor 523 may be connected to each other by welding or bonding between ends of the respective conductors 523, or may be connected by bending. In the stator winding 521, the end of each phase winding is electrically connected to a power converter (inverter) via a bus bar or the like on one side (that is, one end in the axial direction) of the coil ends 526 on both sides in the axial direction. Is connected. Therefore, here, a configuration in which the conductors are connected to each other at the coil end 526 while distinguishing the coil end 526 on the bus bar connection side and the coil end 526 on the opposite side will be described.
　第１の構成としては、バスバー接続側のコイルエンド５２６において各導線５２３を溶接にて繋げるとともに、その反対側のコイルエンド５２６において各導線５２３を溶接以外の手段にて繋げる構成とする。溶接以外の手段とは、例えば導線材の折り曲げによる繋ぎが考えられる。バスバー接続側のコイルエンド５２６では、各相巻線の端部にバスバーが溶接にて接続されることが想定される。そのため、それと同じコイルエンド５２６において各導線５２３を溶接にて繋げる構成とすることで、各溶接部を一連の工程で行わせることができ、作業効率の向上を図ることができる。 As a first configuration, each conductor 523 is connected by welding at the coil end 526 on the bus bar connection side, and each conductor 523 is connected by means other than welding at the coil end 526 on the opposite side. As means other than welding, for example, connection by bending a conductive wire can be considered. At the coil end 526 on the bus bar connection side, it is assumed that the bus bar is connected to the end of each phase winding by welding. Therefore, by adopting a configuration in which the conductive wires 523 are connected to each other by welding at the same coil end 526, each welded portion can be performed in a series of steps, and the working efficiency can be improved.
　第２の構成としては、バスバー接続側のコイルエンド５２６において各導線５２３を溶接以外の手段にて繋げるとともに、その反対側のコイルエンド５２６において各導線５２３を溶接にて繋げる構成とする。この場合、仮にバスバー接続側のコイルエンド５２６において各導線５２３を溶接にて繋げる構成であると、その溶接部とバスバーとの接触を避けるべく、バスバーとコイルエンド５２６との間の離間距離を十分に取る必要が生じるが、本構成とすることで、バスバーとコイルエンド５２６との間の離間距離を小さくすることができる。これにより、軸方向における固定子巻線５２１の長さ又はバスバーに関する規制を緩めることができる。 As a second configuration, each conductor 523 is connected by means other than welding at the coil end 526 on the bus bar connection side, and each conductor 523 is connected by welding at the opposite coil end 526. In this case, if the conductors 523 are connected by welding at the coil end 526 on the bus bar connection side, a sufficient separation distance between the bus bar and the coil end 526 is required to avoid contact between the welded portion and the bus bar. However, with this configuration, the distance between the bus bar and the coil end 526 can be reduced. Thereby, the regulation on the length of the stator winding 521 or the bus bar in the axial direction can be relaxed.
　第３の構成としては、軸方向両側のコイルエンド５２６において各導線５２３を溶接にて繋げる構成とする。この場合、溶接前に用意する導線材はいずれも短い線長のものでよく、曲げ工程の削減による作業効率の向上を図ることができる。 ３As a third configuration, the conductors 523 are connected by welding at the coil ends 526 on both sides in the axial direction. In this case, each of the conductive wires prepared before welding may have a short wire length, and the working efficiency can be improved by reducing the number of bending steps.
　第４の構成としては、軸方向両側のコイルエンド５２６において各導線５２３を溶接以外の手段にて繋げる構成とする。この場合、固定子巻線５２１において溶接が行われる部位を極力減らすことができ、溶接工程での絶縁剥離が生じることの懸念を低減できる。 ４A fourth configuration is such that the conductors 523 are connected by means other than welding at the coil ends 526 on both axial sides. In this case, the portion of the stator winding 521 where welding is performed can be reduced as much as possible, and concerns about the occurrence of insulation delamination in the welding process can be reduced.
　また、円環状の固定子巻線５２１を製作する工程において、平面状に整列された帯状巻線を製作し、その後にその帯状巻線を環状に成形するとよい。この場合、平面状の帯状巻線となっている状態で、必要に応じてコイルエンド５２６での導線同士の溶接を行うとよい。平面状の帯状巻線を環状に成形する際には、固定子コア５２２と同径の円柱治具を用いてその円柱治具に巻き付けるようにして帯状巻線を環状に成形するとよい。又は、帯状巻線を固定子コア５２２に直接巻き付けるようにしてよい。 In the process of manufacturing the annular stator winding 521, it is preferable that a band-shaped winding arranged in a plane is manufactured, and then the band-shaped winding is formed into a ring shape. In this case, it is preferable to perform welding between the conductors at the coil end 526 as necessary in the state of the flat band-shaped winding. When the flat band-shaped winding is formed into an annular shape, the band-shaped winding may be formed into an annular shape by using a cylindrical jig having the same diameter as that of the stator core 522 so as to be wound around the cylindrical jig. Alternatively, a band-shaped winding may be wound directly around the stator core 522.
　なお、固定子巻線５２１の構成を以下のように変更することも可能である。 The configuration of the stator winding 521 can be changed as follows.
　例えば、図５４（ａ），（ｂ）に示す固定子巻線５２１において、中央領域及び端部領域のスキュー角度を同一とする構成であってもよい。 For example, in the stator winding 521 shown in FIGS. 54A and 54B, the configuration may be such that the skew angles of the central region and the end region are the same.
　また、図５４（ａ），（ｂ）に示す固定子巻線５２１において、周方向に隣り合う同相の導線５２３の端部同士を、軸方向に直交する向きに延びる渡り線部により接続する構成であってもよい。 In the stator winding 521 shown in FIGS. 54A and 54B, the ends of the in-phase conductive wires 523 that are adjacent in the circumferential direction are connected to each other by connecting wires extending in a direction orthogonal to the axial direction. It may be.
　固定子巻線５２１の層数は、２×ｎ層（ｎは自然数）であればよく、固定子巻線５２１を、２層以外に４層、６層等にすることも可能である。 数 The number of layers of the stator windings 521 may be 2 × n layers (n is a natural number), and the stator windings 521 may be four layers, six layers, etc. other than two layers.
　次に、電力変換ユニットであるインバータユニット５３０について説明する。ここでは、インバータユニット５３０の分解断面図である図５６及び図５７を併せ用いて、インバータユニット５３０の構成を説明する。なお、図５７では、図５６に示す各部材を２つのサブアセンブリとして示している。 Next, the inverter unit 530 which is a power conversion unit will be described. Here, the configuration of the inverter unit 530 will be described with reference to FIGS. 56 and 57 which are exploded cross-sectional views of the inverter unit 530. In FIG. 57, each member shown in FIG. 56 is shown as two subassemblies.
　インバータユニット５３０は、インバータハウジング５３１と、そのインバータハウジング５３１に組み付けられる複数の電気モジュール５３２と、それら各電気モジュール５３２を電気的に接続するバスバーモジュール５３３とを有している。 The inverter unit 530 includes an inverter housing 531, a plurality of electric modules 532 mounted on the inverter housing 531, and a bus bar module 533 for electrically connecting the electric modules 532.
　インバータハウジング５３１は、円筒状をなす外壁部材５４１と、外周径が外壁部材５４１よりも小径の円筒状をなし、外壁部材５４１の径方向内側に配置される内壁部材５４２と、内壁部材５４２の軸方向一端側に固定されるボス形成部材５４３とを有している。これら各部材５４１～５４３は、導電性材料により構成されているとよく、例えば炭素繊維強化プラスチック（ＣＦＲＰ）により構成されている。インバータハウジング５３１は、外壁部材５４１と内壁部材５４２とが径方向内外に重ねて組み合わされ、かつ内壁部材５４２の軸方向一端側にボス形成部材５４３が組み付けられることで構成されている。その組み付け状態が図５７に示す状態である。 The inverter housing 531 has a cylindrical outer wall member 541, an inner wall member 542 having an outer diameter smaller than the outer wall member 541, and a radially inner side of the outer wall member 541, and a shaft of the inner wall member 542. And a boss forming member 543 fixed to one end in the direction. These members 541 to 543 are preferably made of a conductive material, for example, carbon fiber reinforced plastic (CFRP). The inverter housing 531 is configured such that an outer wall member 541 and an inner wall member 542 are overlapped inside and outside in the radial direction and combined, and a boss forming member 543 is attached to one end side of the inner wall member 542 in the axial direction. The assembled state is the state shown in FIG.
　インバータハウジング５３１の外壁部材５４１の径方向外側には固定子コア５２２が固定される。これにより、固定子５２０とインバータユニット５３０とが一体化されるようになっている。 固定 A stator core 522 is fixed radially outside the outer wall member 541 of the inverter housing 531. Thus, the stator 520 and the inverter unit 530 are integrated.
　図５６に示すように、外壁部材５４１には、その内周面に複数の凹部５４１ａ，５４１ｂ，５４１ｃが形成されるとともに、内壁部材５４２には、その外周面に複数の凹部５４２ａ，５４２ｂ，５４２ｃが形成されている。そして、外壁部材５４１及び内壁部材５４２が互いに組み付けられることにより、これら両者の間には３つの中空部５４４ａ，５４４ｂ，５４４ｃが形成されている（図５７参照）。このうち、中央の中空部５４４ｂは、冷媒としての冷却水を流通させる冷却水通路５４５として用いられる。また、中空部５４４ｂ（冷却水通路５４５）を挟んで両側の中空部５４４ａ，５４４ｃにはシール材５４６が収容されている。このシール材５４６により、中空部５４４ｂ（冷却水通路５４５）が密閉化されている。冷却水通路５４５については後で詳しく説明する。 As shown in FIG. 56, a plurality of recesses 541a, 541b, 541c are formed on the inner peripheral surface of the outer wall member 541, and a plurality of recesses 542a, 542b, 542c are formed on the outer peripheral surface of the inner wall member 542. Are formed. The outer wall member 541 and the inner wall member 542 are assembled with each other, so that three hollow portions 544a, 544b, and 544c are formed therebetween (see FIG. 57). Of these, the central hollow portion 544b is used as a cooling water passage 545 through which cooling water as a coolant flows. Further, seal members 546 are accommodated in the hollow portions 544a and 544c on both sides of the hollow portion 544b (cooling water passage 545). The hollow portion 544b (cooling water passage 545) is hermetically sealed by the sealing material 546. The cooling water passage 545 will be described later in detail.
　また、ボス形成部材５４３には、円板リング状の端板５４７と、その端板５４７からハウジング内部に向けて突出するボス部５４８とが設けられている。ボス部５４８は、中空筒状に設けられている。例えば図５１に示すように、ボス形成部材５４３は、軸方向における内壁部材５４２の第１端とそれに対向する回転軸５０１の突出側（すなわち車両内側）の第２端とのうち、第２端に固定されている。なお、図４５～図４７に示す車輪４００においては、インバータハウジング５３１（より詳しくはボス形成部材５４３の端板５４７）にベースプレート４０５が固定されるようになっている。 ボ ス Further, the boss forming member 543 is provided with a disk ring-shaped end plate 547 and a boss portion 548 protruding from the end plate 547 toward the inside of the housing. The boss 548 is provided in a hollow cylindrical shape. For example, as shown in FIG. 51, the boss forming member 543 is the second end of the first end of the inner wall member 542 in the axial direction and the second end on the protruding side of the rotating shaft 501 (that is, inside the vehicle) opposed thereto. It is fixed to. In the wheels 400 shown in FIGS. 45 to 47, the base plate 405 is fixed to the inverter housing 531 (more specifically, the end plate 547 of the boss forming member 543).
　インバータハウジング５３１は、軸心を中心として径方向に二重の周壁を有する構成となっており、その二重の周壁のうち外側の周壁が外壁部材５４１及び内壁部材５４２により形成され、内側の周壁がボス部５４８により形成されている。なお、以下の説明では、外壁部材５４１及び内壁部材５４２により形成された外側の周壁を「外側周壁ＷＡ１」、ボス部５４８により形成された内側の周壁を「内側周壁ＷＡ２」とも言う。 The inverter housing 531 is configured to have a double peripheral wall in the radial direction with the axis as the center. Of the double peripheral wall, the outer peripheral wall is formed by the outer wall member 541 and the inner wall member 542, and the inner peripheral wall is formed. Is formed by the boss portion 548. In the following description, the outer peripheral wall formed by the outer wall member 541 and the inner wall member 542 is also referred to as “outer peripheral wall WA1”, and the inner peripheral wall formed by the boss 548 is also referred to as “inner peripheral wall WA2”.
　インバータハウジング５３１には、外側周壁ＷＡ１と内側周壁ＷＡ２との間に環状空間が形成されており、その環状空間内に、周方向に並べて複数の電気モジュール５３２が配置されている。電気モジュール５３２は、接着やビス締め等により内壁部材５４２の内周面に固定されている。本実施形態では、インバータハウジング５３１が「ハウジング部材」に相当し、電気モジュール５３２が「電気部品」に相当する。 In the inverter housing 531, an annular space is formed between the outer peripheral wall WA1 and the inner peripheral wall WA2, and a plurality of electric modules 532 are arranged in the annular space in the circumferential direction. The electric module 532 is fixed to the inner peripheral surface of the inner wall member 542 by bonding, screwing, or the like. In the present embodiment, the inverter housing 531 corresponds to a “housing member”, and the electric module 532 corresponds to an “electric component”.
　内側周壁ＷＡ２（ボス部５４８）の内側には軸受５６０が収容されており、その軸受５６０により回転軸５０１が回転自在に支持されている。軸受５６０は、車輪中心部において車輪４００を回転可能に支えるハブベアリングである。軸受５６０は、回転子５１０や固定子５２０、インバータユニット５３０に対して軸方向に重複する位置に設けられている。本実施形態の回転電機５００では、回転子５１０において配向に伴い磁石ユニット５１２の薄型化が可能であること、固定子５２０においてスロットレス構造や扁平導線構造が採用されていることにより、磁気回路部の径方向の厚み寸法を縮小して、磁気回路部よりも径方向内側の中空空間を拡張することが可能となっている。これにより、径方向に積層された状態での磁気回路部やインバータユニット５３０、軸受５６０の配置が可能となっている。ボス部５４８は、その内側に軸受５６０を保持する軸受保持部となっている。 軸 受 A bearing 560 is housed inside the inner peripheral wall WA2 (the boss 548), and the rotating shaft 501 is rotatably supported by the bearing 560. The bearing 560 is a hub bearing that rotatably supports the wheel 400 at the center of the wheel. The bearing 560 is provided at a position axially overlapping the rotor 510, the stator 520, and the inverter unit 530. In the rotating electric machine 500 of the present embodiment, the magnet unit 512 can be made thinner in accordance with the orientation in the rotor 510, and the slotless structure or the flat conductor structure is adopted in the stator 520, so that the magnetic circuit unit is formed. It is possible to expand the hollow space radially inside the magnetic circuit portion by reducing the radial thickness of the magnetic circuit portion. Thus, the magnetic circuit unit, the inverter unit 530, and the bearing 560 can be arranged in a state of being stacked in the radial direction. The boss portion 548 serves as a bearing holding portion that holds the bearing 560 inside.
　軸受５６０は、例えばラジアル玉軸受であり、筒状をなす内輪５６１と、その内輪５６１よりも大径の筒状をなし内輪５６１の径方向外側に配置された外輪５６２と、それら内輪５６１及び外輪５６２の間に配置された複数の玉５６３とを有している。軸受５６０は、外輪５６２がボス形成部材５４３に組み付けられることでインバータハウジング５３１に固定されるとともに、内輪５６１が回転軸５０１に固定されている。これら内輪５６１、外輪５６２及び玉５６３は、いずれも炭素鋼等の金属材料よりなる。 The bearing 560 is, for example, a radial ball bearing, and has a cylindrical inner ring 561, an outer ring 562 that has a cylindrical shape larger in diameter than the inner ring 561, and is disposed radially outside the inner ring 561, and the inner ring 561 and the outer ring 561. And a plurality of balls 563 arranged between them. The bearing 560 is fixed to the inverter housing 531 by attaching the outer ring 562 to the boss forming member 543, and the inner ring 561 is fixed to the rotating shaft 501. Each of the inner ring 561, the outer ring 562, and the ball 563 is made of a metal material such as carbon steel.
　また、軸受５６０の内輪５６１は、回転軸５０１を収容する筒部５６１ａと、その筒部５６１ａの軸方向一端部から、軸方向に交差（直交）する向きに延びるフランジ５６１ｂとを有している。フランジ５６１ｂは、回転子キャリア５１１の端板５１４に内側から当接する部位であり、回転軸５０１に軸受５６０が組み付けられた状態では、回転軸５０１のフランジ５０２と内輪５６１のフランジ５６１ｂとにより挟まれた状態で、回転子キャリア５１１が保持されるようになっている。この場合、回転軸５０１のフランジ５０２及び内輪５６１のフランジ５６１ｂは、軸方向に対する交差の角度が互いに同じであり（本実施形態ではいずれも直角であり）、これら各フランジ５０２，５６１ｂの間に挟まれた状態で、回転子キャリア５１１が保持されている。 The inner ring 561 of the bearing 560 has a cylindrical portion 561a that accommodates the rotary shaft 501, and a flange 561b that extends from one axial end of the cylindrical portion 561a in a direction intersecting (orthogonal) in the axial direction. . The flange 561b is a portion that comes into contact with the end plate 514 of the rotor carrier 511 from the inside, and is sandwiched between the flange 502 of the rotary shaft 501 and the flange 561b of the inner ring 561 when the bearing 560 is mounted on the rotary shaft 501. In this state, the rotor carrier 511 is held. In this case, the flange 502 of the rotary shaft 501 and the flange 561b of the inner ring 561 have the same angle of intersection with respect to the axial direction (both are right angles in this embodiment), and are sandwiched between these flanges 502 and 561b. In this state, the rotor carrier 511 is held.
　軸受５６０の内輪５６１により回転子キャリア５１１を内側から支える構成によれば、回転軸５０１に対する回転子キャリア５１１の角度を適正角度に保持でき、ひいては回転軸５０１に対する磁石ユニット５１２の平行度を良好に保つことができる。これにより、回転子キャリア５１１を径方向に拡張した構成にあっても、振動等に対する耐性を高めることができる。 According to the configuration in which the rotor carrier 511 is supported from the inside by the inner ring 561 of the bearing 560, the angle of the rotor carrier 511 with respect to the rotation shaft 501 can be maintained at an appropriate angle, and the parallelism of the magnet unit 512 with respect to the rotation shaft 501 can be improved. Can be kept. Thereby, even in a configuration in which the rotor carrier 511 is expanded in the radial direction, resistance to vibration and the like can be increased.
　次に、インバータハウジング５３１内に収容される電気モジュール５３２について説明する。 Next, the electric module 532 housed in the inverter housing 531 will be described.
　複数の電気モジュール５３２は、電力変換器を構成する半導体スイッチング素子や平滑用コンデンサといった電気部品を、複数に分割して個々にモジュール化したものであり、その電気モジュール５３２には、パワー素子である半導体スイッチング素子を有するスイッチモジュール５３２Ａと、平滑用コンデンサを有するコンデンサモジュール５３２Ｂとが含まれている。 The plurality of electric modules 532 are obtained by dividing electric components such as a semiconductor switching element and a smoothing capacitor constituting a power converter into a plurality of parts and individually modularizing the electric parts. The electric module 532 is a power element. A switch module 532A having a semiconductor switching element and a capacitor module 532B having a smoothing capacitor are included.
　図４９及び図５０に示すように、内壁部材５４２の内周面には、電気モジュール５３２を取り付けるための平坦面を有する複数のスペーサ５４９が固定され、そのスペーサ５４９に電気モジュール５３２が取り付けられている。つまり、内壁部材５４２の内周面が曲面であるのに対し、電気モジュール５３２の取付面が平坦面であることから、スペーサ５４９により内壁部材５４２の内周面側に平坦面を形成し、その平坦面に電気モジュール５３２を固定する構成としている。 As shown in FIGS. 49 and 50, a plurality of spacers 549 having a flat surface for attaching the electric module 532 are fixed to the inner peripheral surface of the inner wall member 542, and the electric module 532 is attached to the spacer 549. I have. That is, since the inner peripheral surface of the inner wall member 542 is a curved surface, whereas the mounting surface of the electric module 532 is a flat surface, a flat surface is formed on the inner peripheral surface side of the inner wall member 542 by the spacer 549. The electric module 532 is fixed to a flat surface.
　なお、内壁部材５４２と電気モジュール５３２との間にスペーサ５４９を介在させる構成は必須ではなく、内壁部材５４２の内周面を平坦面にする、又は電気モジュール５３２の取付面を曲面することにより内壁部材５４２に対して電気モジュール５３２を直接取り付けることも可能である。また、内壁部材５４２の内周面に対して非接触の状態で、電気モジュール５３２をインバータハウジング５３１に固定することも可能である。例えば、ボス形成部材５４３の端板５４７に対して電気モジュール５３２を固定する。スイッチモジュール５３２Ａを内壁部材５４２の内周面に接触状態で固定するとともに、コンデンサモジュール５３２Ｂを内壁部材５４２の内周面に非接触状態で固定することも可能である。 Note that a configuration in which the spacer 549 is interposed between the inner wall member 542 and the electric module 532 is not essential, and the inner wall surface of the inner wall member 542 may be flattened or the mounting surface of the electric module 532 may be curved to form an inner wall. It is also possible to attach the electrical module 532 directly to the member 542. Further, the electric module 532 can be fixed to the inverter housing 531 in a state where the electric module 532 is not in contact with the inner peripheral surface of the inner wall member 542. For example, the electric module 532 is fixed to the end plate 547 of the boss forming member 543. The switch module 532A can be fixed to the inner peripheral surface of the inner wall member 542 in a contact state, and the capacitor module 532B can be fixed to the inner peripheral surface of the inner wall member 542 in a non-contact state.
　なお、内壁部材５４２の内周面にスペーサ５４９が設けられる場合、外側周壁ＷＡ１及びスペーサ５４９が「筒状部」に相当する。また、スペーサ５４９が用いられない場合、外側周壁ＷＡ１が「筒状部」に相当する。 When the spacer 549 is provided on the inner peripheral surface of the inner wall member 542, the outer peripheral wall WA1 and the spacer 549 correspond to a “cylindrical portion”. When the spacer 549 is not used, the outer peripheral wall WA1 corresponds to a “cylindrical portion”.
　上述したとおりインバータハウジング５３１の外側周壁ＷＡ１には、冷媒としての冷却水を流通させる冷却水通路５４５が形成されており、その冷却水通路５４５を流れる冷却水により各電気モジュール５３２が冷却されるようになっている。なお、冷媒として、冷却水に代えて冷却用オイルを用いることも可能である。冷却水通路５４５は、外側周壁ＷＡ１に沿って環状に設けられており、冷却水通路５４５内を流れる冷却水は、各電気モジュール５３２を経由しながら上流側から下流側に流通する。本実施形態では、冷却水通路５４５が、径方向内外に各電気モジュール５３２に重なり、かつこれら各電気モジュール５３２を囲むように環状に設けられている。 As described above, the outer peripheral wall WA1 of the inverter housing 531 has the cooling water passage 545 through which the cooling water as the coolant flows, and the electric modules 532 are cooled by the cooling water flowing through the cooling water passage 545. It has become. In addition, it is also possible to use cooling oil instead of cooling water as a refrigerant. The cooling water passage 545 is provided in an annular shape along the outer peripheral wall WA <b> 1, and the cooling water flowing in the cooling water passage 545 flows from the upstream side to the downstream side while passing through each electric module 532. In the present embodiment, the cooling water passage 545 is provided in an annular shape so as to overlap with each of the electric modules 532 inside and outside in the radial direction and surround each of the electric modules 532.
　内壁部材５４２には、冷却水通路５４５に冷却水を流入させる入口通路５７１と、冷却水通路５４５から冷却水を流出させる出口通路５７２とが設けられている。上述したように内壁部材５４２の内周面には複数の電気モジュール５３２が固定されており、かかる構成において、周方向に隣り合う電気モジュール間の間隔が１カ所だけ他よりも拡張され、その拡張された部分に、内壁部材５４２の一部が径方向内側に突出されて突出部５７３が形成されている。そして、その突出部５７３に、径方向に沿って横並びの状態で入口通路５７１及び出口通路５７２が設けられている。 The inner wall member 542 is provided with an inlet passage 571 through which the cooling water flows into the cooling water passage 545 and an outlet passage 572 through which the cooling water flows out from the cooling water passage 545. As described above, the plurality of electric modules 532 are fixed to the inner peripheral surface of the inner wall member 542. In such a configuration, the interval between the electric modules adjacent in the circumferential direction is expanded by one place more than the other, and the expansion is performed. A part of the inner wall member 542 is protruded radially inward from the part thus formed to form a protruding part 573. An inlet passage 571 and an outlet passage 572 are provided on the protruding portion 573 so as to be arranged side by side in the radial direction.
　インバータハウジング５３１での各電気モジュール５３２の配置の状態を図５８に示す。なお、図５８は、図５０と同一の縦断面図である。 FIG. 58 shows an arrangement state of each electric module 532 in the inverter housing 531. FIG. 58 is the same vertical sectional view as FIG.
　図５８に示すように、各電気モジュール５３２は、周方向における電気モジュール同士の間隔を、第１間隔ＩＮＴ１又は第２間隔ＩＮＴ２として周方向に並べて配置されている。第２間隔ＩＮＴ２は、第１間隔ＩＮＴ１よりも広い間隔である。各間隔ＩＮＴ１，ＩＮＴ２は、例えば周方向に隣り合う２つ電気モジュール５３２の中心位置同士の間の距離である。この場合、突出部５７３を挟まずに周方向に隣り合う電気モジュール同士の間隔は第１間隔ＩＮＴ１となり、突出部５７３を挟んで周方向に隣り合う電気モジュール同士の間隔は第２間隔ＩＮＴ２となっている。つまり、周方向に隣り合う電気モジュール同士の間隔が一部で拡げられており、その拡げられた間隔（第２間隔ＩＮＴ２）の例えば中央となる部分に突出部５７３が設けられている。 各 As shown in FIG. 58, the electric modules 532 are arranged side by side in the circumferential direction with the interval between the electric modules in the circumferential direction being the first interval INT1 or the second interval INT2. The second interval INT2 is a wider interval than the first interval INT1. Each of the intervals INT1 and INT2 is, for example, a distance between the center positions of two electric modules 532 adjacent in the circumferential direction. In this case, the interval between the electric modules adjacent to each other in the circumferential direction without sandwiching the protruding portion 573 is the first interval INT1, and the interval between the electric modules adjacent to each other in the circumferential direction across the protruding portion 573 is the second interval INT2. ing. That is, the interval between the electric modules adjacent in the circumferential direction is partially expanded, and the protruding portion 573 is provided at, for example, a central portion of the expanded interval (second interval INT2).
　各間隔ＩＮＴ１，ＩＮＴ２は、回転軸５０１を中心とする同一円上において、周方向に隣り合う２つ電気モジュール５３２の中心位置同士の間の円弧の距離であってもよい。又は、周方向における電気モジュール同士の間隔は、回転軸５０１を中心とする角度間隔θｉ１，θｉ２で定義されていてもよい（θｉ１＜θｉ２）。 Each of the intervals INT1 and INT2 may be the distance of an arc between the center positions of two electric modules 532 adjacent to each other in the circumferential direction on the same circle centered on the rotation shaft 501. Alternatively, the interval between the electric modules in the circumferential direction may be defined by angular intervals θi1 and θi2 about the rotation axis 501 (θi1 <θi2).
　なお、図５８に示す構成では、第１間隔ＩＮＴ１で並ぶ各電気モジュール５３２が周方向に互いに離間する状態（非接触の状態）で配置されているが、この構成に代えて、それら各電気モジュール５３２が周方向に互いに接触する状態で配置されていてもよい。 In the configuration shown in FIG. 58, the electric modules 532 arranged at the first interval INT1 are arranged so as to be separated from each other in a circumferential direction (non-contact state). 532 may be arranged in contact with each other in the circumferential direction.
　図４８に示すように、ボス形成部材５４３の端板５４７には、入口通路５７１及び出口通路５７２の通路端部が形成された水路ポート５７４が設けられている。入口通路５７１及び出口通路５７２には、冷却水を循環させる循環経路５７５が接続されるようになっている。循環経路５７５は冷却水配管よりなる。循環経路５７５にはポンプ５７６と放熱装置５７７とが設けられ、ポンプ５７６の駆動に伴い冷却水通路５４５と循環経路５７５とを通じて冷却水が循環する。ポンプ５７６は電動ポンプである。放熱装置５７７は、例えば冷却水の熱を大気放出するラジエータである。 水 As shown in FIG. 48, the end plate 547 of the boss forming member 543 is provided with a water passage port 574 in which the passage ends of the entrance passage 571 and the exit passage 572 are formed. A circulation path 575 for circulating cooling water is connected to the inlet passage 571 and the outlet passage 572. The circulation path 575 includes a cooling water pipe. A pump 576 and a radiator 577 are provided in the circulation path 575, and the cooling water circulates through the cooling water passage 545 and the circulation path 575 as the pump 576 is driven. The pump 576 is an electric pump. The radiator 577 is, for example, a radiator that releases heat of cooling water to the atmosphere.
　図５０に示すように、外側周壁ＷＡ１の外側には固定子５２０が配置され、内側には電気モジュール５３２が配置されていることから、外側周壁ＷＡ１に対しては、その外側から固定子５２０の熱が伝わるとともに、内側から電気モジュール５３２の熱が伝わることになる。この場合、冷却水通路５４５を流れる冷却水により固定子５２０と電気モジュール５３２とを同時に冷やすことが可能となっており、回転電機５００における発熱部品の熱を効率良く放出することができる。 As shown in FIG. 50, since the stator 520 is disposed outside the outer peripheral wall WA1, and the electric module 532 is disposed inside, the stator 520 is disposed on the outer peripheral wall WA1 from outside. While the heat is transmitted, the heat of the electric module 532 is transmitted from the inside. In this case, the stator 520 and the electric module 532 can be simultaneously cooled by the cooling water flowing through the cooling water passage 545, and the heat of the heat-generating components in the rotating electric machine 500 can be efficiently released.
　ここで、電力変換器の電気的構成を図５９を用いて説明する。 Here, the electrical configuration of the power converter will be described with reference to FIG.
　図５９に示すように、固定子巻線５２１はＵ相巻線、Ｖ相巻線及びＷ相巻線よりなり、その固定子巻線５２１にインバータ６００が接続されている。インバータ６００は、相数と同じ数の上下アームを有するフルブリッジ回路により構成されており、相ごとに上アームスイッチ６０１及び下アームスイッチ６０２からなる直列接続体が設けられている。これら各スイッチ６０１，６０２は駆動回路６０３によりそれぞれオンオフされ、そのオンオフにより各相の巻線が通電される。各スイッチ６０１，６０２は、例えばＭＯＳＦＥＴやＩＧＢＴ等の半導体スイッチング素子により構成されている。また、各相の上下アームには、スイッチ６０１，６０２の直列接続体に並列に、スイッチング時に要する電荷を各スイッチ６０１，６０２に供給する電荷供給用のコンデンサ６０４が接続されている。 As shown in FIG. 59, the stator winding 521 includes a U-phase winding, a V-phase winding, and a W-phase winding, and the inverter 600 is connected to the stator winding 521. The inverter 600 is configured by a full bridge circuit having the same number of upper and lower arms as the number of phases, and a series connection including an upper arm switch 601 and a lower arm switch 602 is provided for each phase. These switches 601 and 602 are turned on and off by the drive circuit 603, and the windings of each phase are energized by the on and off. Each of the switches 601 and 602 is configured by a semiconductor switching element such as a MOSFET or an IGBT. The upper and lower arms of each phase are connected in parallel with a series connection of the switches 601 and 602 with a charge supply capacitor 604 for supplying charges required for switching to the switches 601 and 602.
　制御装置６０７は、ＣＰＵや各種メモリからなるマイコンを備えており、回転電機５００における各種の検出情報や、力行駆動及び発電の要求に基づいて、各スイッチ６０１，６０２のオンオフにより通電制御を実施する。制御装置６０７は、例えば所定のスイッチング周波数（キャリア周波数）でのＰＷＭ制御や、矩形波制御により各スイッチ６０１，６０２のオンオフ制御を実施する。制御装置６０７は、回転電機５００に内蔵された内蔵制御装置であってもよいし、回転電機５００の外部に設けられた外部制御装置であってもよい。 The control device 607 includes a microcomputer including a CPU and various memories, and performs energization control by turning on and off the switches 601 and 602 based on various detection information in the rotating electric machine 500 and requests for powering drive and power generation. . The control device 607 performs on / off control of the switches 601 and 602 by, for example, PWM control at a predetermined switching frequency (carrier frequency) or rectangular wave control. Control device 607 may be a built-in control device built into rotating electric machine 500 or an external control device provided outside rotating electric machine 500.
　ちなみに、本実施形態の回転電機５００では、固定子５２０のインダクタンス低減が図られていることから電気的時定数が小さくなっており、その電気的時定数が小さい状況下では、スイッチング周波数（キャリア周波数）を高くし、かつスイッチング速度を速くすることが望ましい。この点において、各相のスイッチ６０１，６０２の直列接続体に並列に電荷供給用のコンデンサ６０４が接続されていることで配線インダクタンスが低くなり、スイッチング速度を速くした構成であっても適正なサージ対策が可能となる。 By the way, in the rotating electric machine 500 of the present embodiment, the electric time constant is small because the inductance of the stator 520 is reduced, and the switching frequency (carrier frequency) is small under the condition that the electric time constant is small. ) And a high switching speed. In this regard, since the charge supply capacitor 604 is connected in parallel with the series connection of the switches 601 and 602 of each phase, the wiring inductance is reduced, and even if the switching speed is increased, the proper surge can be achieved. Countermeasures become possible.
　インバータ６００の高電位側端子は直流電源６０５の正極端子に接続され、低電位側端子は直流電源６０５の負極端子（グランド）に接続されている。また、インバータ６００の高電位側端子及び低電位側端子には、直流電源６０５に並列に平滑用のコンデンサ６０６が接続されている。 (4) The high potential side terminal of the inverter 600 is connected to the positive terminal of the DC power supply 605, and the low potential side terminal is connected to the negative terminal (ground) of the DC power supply 605. Further, a smoothing capacitor 606 is connected to the high-potential side terminal and the low-potential side terminal of the inverter 600 in parallel with the DC power supply 605.
　スイッチモジュール５３２Ａは、発熱部品として各スイッチ６０１，６０２（半導体スイッチング素子）や、駆動回路６０３（具体的には駆動回路６０３を構成する電気素子）、電荷供給用のコンデンサ６０４を有している。また、コンデンサモジュール５３２Ｂは、発熱部品として平滑用のコンデンサ６０６を有している。スイッチモジュール５３２Ａの具体的な構成例を図６０に示す。 The switch module 532A has switches 601 and 602 (semiconductor switching elements), a driving circuit 603 (specifically, an electric element forming the driving circuit 603), and a capacitor 604 for supplying electric charges, as heat-generating components. Further, the capacitor module 532B has a smoothing capacitor 606 as a heat-generating component. FIG. 60 shows a specific configuration example of the switch module 532A.
　図６０に示すように、スイッチモジュール５３２Ａは、収容ケースとしてのモジュールケース６１１を有するとともに、そのモジュールケース６１１内に収容された１相分のスイッチ６０１，６０２と、駆動回路６０３と、電荷供給用のコンデンサ６０４とを有している。なお、駆動回路６０３は、専用ＩＣ又は回路基板として構成されてスイッチモジュール５３２Ａに設けられている。 As shown in FIG. 60, the switch module 532A has a module case 611 as an accommodation case, and switches 601 and 602 for one phase accommodated in the module case 611, a drive circuit 603, and a charge supply And the capacitor 604. Note that the drive circuit 603 is configured as a dedicated IC or a circuit board and provided in the switch module 532A.
　モジュールケース６１１は、例えば樹脂等の絶縁材料よりなり、その側面がインバータユニット５３０の内壁部材５４２の内周面に当接した状態で、外側周壁ＷＡ１に固定されている。モジュールケース６１１内には樹脂等のモールド材が充填されている。モジュールケース６１１内において、スイッチ６０１，６０２と駆動回路６０３、スイッチ６０１，６０２とコンデンサ６０４は、それぞれ配線６１２により電気的に接続されている。なお詳しくは、スイッチモジュール５３２Ａは、スペーサ５４９を介して外側周壁ＷＡ１に取り付けられるが、スペーサ５４９の図示を省略している。 The module case 611 is made of, for example, an insulating material such as a resin, and is fixed to the outer peripheral wall WA1 with its side surface in contact with the inner peripheral surface of the inner wall member 542 of the inverter unit 530. The module case 611 is filled with a molding material such as a resin. In the module case 611, the switches 601 and 602 and the drive circuit 603, and the switches 601 and 602 and the capacitor 604 are electrically connected by wiring 612, respectively. More specifically, the switch module 532A is attached to the outer peripheral wall WA1 via the spacer 549, but illustration of the spacer 549 is omitted.
　スイッチモジュール５３２Ａが外側周壁ＷＡ１に固定された状態では、スイッチモジュール５３２Ａにおいて外側周壁ＷＡ１に近い側、すなわち冷却水通路５４５に近い側ほど冷却性が高いため、その冷却性に応じてスイッチ６０１，６０２、駆動回路６０３及びコンデンサ６０４の配列の順序が定められている。具体的には、発熱量を比べると、大きいものからスイッチ６０１，６０２、コンデンサ６０４、駆動回路６０３の順序となるため、その発熱量の大きさ順序に合わせて、外側周壁ＷＡ１に近い側からスイッチ６０１，６０２、コンデンサ６０４、駆動回路６０３の順序でこれらが配置されている。なお、スイッチモジュール５３２Ａの接触面は、内壁部材５４２の内周面における接触可能面より小さいとよい。 In a state where the switch module 532A is fixed to the outer peripheral wall WA1, the side closer to the outer peripheral wall WA1 in the switch module 532A, that is, the side closer to the cooling water passage 545, has higher cooling performance, and accordingly, the switches 601, 602 according to the cooling performance. , The drive circuit 603 and the capacitor 604 are arranged in an order. Specifically, when the heat generation amount is compared, the order of the switches 601 and 602, the capacitor 604, and the drive circuit 603 is in descending order. Therefore, according to the order of the heat generation amount, the switches from the side closer to the outer peripheral wall WA1 are switched. These are arranged in the order of 601, 602, capacitor 604, and drive circuit 603. Note that the contact surface of the switch module 532A may be smaller than the contactable surface on the inner peripheral surface of the inner wall member 542.
　なお、コンデンサモジュール５３２Ｂについては詳細な図示を省略するが、コンデンサモジュール５３２Ｂでは、スイッチモジュール５３２Ａと同じ形状及び大きさのモジュールケース内に、コンデンサ６０６が収容されて構成されている。コンデンサモジュール５３２Ｂは、スイッチモジュール５３２Ａと同様に、モジュールケース６１１の側面がインバータハウジング５３１の内壁部材５４２の内周面に当接した状態で、外側周壁ＷＡ１に固定されている。 Although the detailed illustration of the capacitor module 532B is omitted, the capacitor module 532B is configured by housing the capacitor 606 in a module case having the same shape and size as the switch module 532A. Similarly to the switch module 532A, the capacitor module 532B is fixed to the outer peripheral wall WA1 with the side surface of the module case 611 in contact with the inner peripheral surface of the inner wall member 542 of the inverter housing 531.
　スイッチモジュール５３２Ａ及びコンデンサモジュール５３２Ｂは、インバータハウジング５３１の外側周壁ＷＡ１の径方向内側において必ずしも同心円上に並んでいなくてもよい。例えばスイッチモジュール５３２Ａがコンデンサモジュール５３２Ｂよりも径方向内側に配置される構成、又はその逆となるように配置される構成であってもよい。 The switch module 532A and the capacitor module 532B do not necessarily have to be arranged concentrically on the radially inner side of the outer peripheral wall WA1 of the inverter housing 531. For example, a configuration in which the switch module 532A is disposed radially inward of the capacitor module 532B, or a configuration in which the switch module 532A is disposed in the opposite direction may be employed.
　回転電機５００の駆動時には、スイッチモジュール５３２Ａ及びコンデンサモジュール５３２Ｂと冷却水通路５４５との間で、外側周壁ＷＡ１の内壁部材５４２を介して熱交換が行われる。これにより、スイッチモジュール５３２Ａ及びコンデンサモジュール５３２Ｂにおける冷却が行われる。 When the rotating electric machine 500 is driven, heat is exchanged between the switch module 532A and the capacitor module 532B and the cooling water passage 545 via the inner wall member 542 of the outer peripheral wall WA1. Thereby, cooling in the switch module 532A and the capacitor module 532B is performed.
　各電気モジュール５３２は、その内部に冷却水を引き込み、モジュール内部にて冷却水による冷却を行わせる構成であってもよい。ここでは、スイッチモジュール５３２Ａの水冷構造を、図６１（ａ），（ｂ）を用いて説明する。図６１（ａ）は、外側周壁ＷＡ１を横切る方向で、スイッチモジュール５３２Ａの断面構造を示す縦断面図であり、図６１（ｂ）は、図６１（ａ）の６１Ｂ－６１Ｂ線断面図である。 電 気 Each electric module 532 may have a configuration in which cooling water is drawn into the inside of the module and cooling by the cooling water is performed inside the module. Here, the water cooling structure of the switch module 532A will be described with reference to FIGS. FIG. 61A is a longitudinal sectional view showing a sectional structure of the switch module 532A in a direction crossing the outer peripheral wall WA1, and FIG. 61B is a sectional view taken along line 61B-61B of FIG. 61A. .
　図６１（ａ），（ｂ）に示すように、スイッチモジュール５３２Ａは、図６０と同様にモジュールケース６１１と、１相分のスイッチ６０１，６０２と、駆動回路６０３と、コンデンサ６０４とを有することに加え、一対の配管部６２１，６２２及び冷却器６２３からなる冷却装置を有している。冷却装置において、一対の配管部６２１，６２２は、外側周壁ＷＡ１の冷却水通路５４５から冷却器６２３へ冷却水を流入させる流入側の配管部６２１と、冷却器６２３から冷却水通路５４５へ冷却水を流出させる流出側の配管部６２２とからなる。冷却器６２３は、冷却対象物に応じて設けられ、冷却装置では１段又は複数段の冷却器６２３が用いられる。図６１（ａ），（ｂ）の構成では、冷却水通路５４５から離れる方向、すなわちインバータユニット５３０の径方向に、互いに離間した状態で２段の冷却器６２３が設けられており、一対の配管部６２１，６２２を介してそれら各冷却器６２３に対して冷却水が供給される。冷却器６２３は、例えば内部が空洞になっている。ただし、冷却器６２３の内部にインナフィンが設けられていてもよい。 As shown in FIGS. 61A and 61B, the switch module 532A includes a module case 611, switches 601 and 602 for one phase, a drive circuit 603, and a capacitor 604, as in FIG. In addition, a cooling device including a pair of piping portions 621 and 622 and a cooler 623 is provided. In the cooling device, a pair of piping portions 621 and 622 are provided with an inflow-side piping portion 621 through which cooling water flows from the cooling water passage 545 of the outer peripheral wall WA1 to the cooler 623, and a cooling water flow from the cooler 623 to the cooling water passage 545. And a piping portion 622 on the outflow side through which the water flows out. The cooler 623 is provided in accordance with an object to be cooled, and a single-stage or multiple-stage cooler 623 is used in the cooling device. In the configuration of FIGS. 61A and 61B, two-stage coolers 623 are provided in a direction away from the cooling water passage 545, that is, in a radial direction of the inverter unit 530, so as to be separated from each other. Cooling water is supplied to the respective coolers 623 via the sections 621 and 622. The cooler 623 has a hollow inside, for example. However, an inner fin may be provided inside the cooler 623.
　２段の冷却器６２３を備える構成では、（１）１段目の冷却器６２３の外側周壁ＷＡ１側、（２）１段目及び２段目の冷却器６２３の間、（３）２段目の冷却器６２３の反外側周壁側が、それぞれ冷却対象の電気部品を配置する場所であり、これら各場所は、冷却性能の高いものから順から（２）、（１）、（３）となっている。つまり、２つの冷却器６２３に挟まれた場所が最も冷却性能が高く、いずれか１つの冷却器６２３に隣接する場所では、外側周壁ＷＡ１（冷却水通路５４５）に近い方が冷却性能が高くなっている。これを加味し、図６１（ａ），（ｂ）に示す構成では、スイッチ６０１，６０２が、（２）１段目及び２段目の冷却器６２３の間に配置され、コンデンサ６０４が、（１）１段目の冷却器６２３の外側周壁ＷＡ１側に配置され、駆動回路６０３が、（３）２段目の冷却器６２３の反外側周壁側に配置されている。なお、図示しないが、駆動回路６０３とコンデンサ６０４とが逆の配置であってもよい。 In the configuration including the two-stage cooler 623, (1) the outer peripheral wall WA1 side of the first-stage cooler 623, (2) between the first-stage and second-stage coolers 623, (3) the second-stage cooler 623 The outer peripheral wall side of the cooler 623 is a place where electric components to be cooled are arranged, and these places are (2), (1) and (3) in order from the one having the highest cooling performance. I have. That is, the cooling performance is highest at a place between the two coolers 623, and at a place adjacent to any one of the coolers 623, the cooling performance is higher near the outer peripheral wall WA1 (cooling water passage 545). ing. Taking this into account, in the configuration shown in FIGS. 61A and 61B, the switches 601 and 602 are disposed between (2) the first-stage and second-stage coolers 623, and the capacitor 604 is provided as ( 1) The drive circuit 603 is disposed on the outer peripheral wall WA1 side of the first-stage cooler 623, and the drive circuit 603 is disposed on the (3) non-outer peripheral wall side of the second-stage cooler 623. Although not shown, the drive circuit 603 and the capacitor 604 may be arranged in reverse.
　いずれの場合であってもモジュールケース６１１内において、スイッチ６０１，６０２と駆動回路６０３、スイッチ６０１，６０２とコンデンサ６０４は、それぞれ配線６１２により電気的に接続されている。また、スイッチ６０１，６０２が駆動回路６０３とコンデンサ６０４との間に位置するため、スイッチ６０１，６０２から駆動回路６０３に向かって延びる配線６１２と、スイッチ６０１，６０２からコンデンサ６０４に向かって延びる配線６１２は互いに逆方向に延びる関係である。 In any case, in the module case 611, the switches 601 and 602 and the drive circuit 603, and the switches 601 and 602 and the capacitor 604 are electrically connected by the wiring 612, respectively. Further, since the switches 601 and 602 are located between the driving circuit 603 and the capacitor 604, a wiring 612 extending from the switches 601 and 602 to the driving circuit 603 and a wiring 612 extending from the switches 601 and 602 to the capacitor 604. Are relations extending in opposite directions.
　図６１（ｂ）に示すように、一対の配管部６２１，６２２は、周方向、すなわち冷却水通路５４５の上流側及び下流側に並べて配置されており、上流側に位置する流入側の配管部６２１から冷却器６２３に冷却水が流入され、その後、下流側に位置する流出側の配管部６２２から冷却水が流出される。なお、冷却装置への冷却水の流入を促すべく、冷却水通路５４５には、周方向に見て、流入側の配管部６２１と流出側の配管部６２１との間となる位置に、冷却水の流れを規制する規制部６２４が設けられているとよい。規制部６２４は、冷却水通路５４５を遮断する遮断部、又は冷却水通路５４５の通路面積を小さくする絞り部であるとよい。 As shown in FIG. 61 (b), the pair of piping portions 621 and 622 are arranged in the circumferential direction, that is, on the upstream side and downstream side of the cooling water passage 545, and the inflow side piping portion located on the upstream side. Cooling water flows into the cooler 623 from 621, and then flows out from the outflow-side pipe portion 622 located on the downstream side. In order to promote the inflow of the cooling water into the cooling device, the cooling water passage 545 is provided at a position between the inflow side pipe portion 621 and the outflow side pipe portion 621 when viewed in the circumferential direction. It is good to provide the regulation part 624 which regulates the flow of flow. The regulating section 624 may be a blocking section that blocks the cooling water passage 545 or a throttle section that reduces the passage area of the cooling water passage 545.
　図６２には、スイッチモジュール５３２Ａの別の冷却構造を示す。図６２（ａ）は、外側周壁ＷＡ１を横切る方向で、スイッチモジュール５３２Ａの断面構造を示す縦断面図であり、図６２（ｂ）は、図６２（ａ）の６２Ｂ－６２Ｂ線断面図である。 FIG. 62 shows another cooling structure of the switch module 532A. FIG. 62A is a longitudinal sectional view showing a sectional structure of the switch module 532A in a direction crossing the outer peripheral wall WA1, and FIG. 62B is a sectional view taken along line 62B-62B of FIG. 62A. .
　図６２（ａ），（ｂ）の構成では、上述した図６１（ａ），（ｂ）の構成との相違点として、冷却装置における一対の配管部６２１，６２２の配置が異なっており、一対の配管部６２１，６２２が軸方向に並べて配置されている。また、図６２（ｃ）に示すように、冷却水通路５４５は、流入側の配管部６２１に連通される通路部分と、流出側の配管部６２２に連通される通路部分とが軸方向に分離して設けられ、それら各通路部分が各配管部６２１，６２２及び各冷却器６２３を通じて連通されている。 The configuration shown in FIGS. 62A and 62B is different from the configuration shown in FIGS. 61A and 61B in that the arrangement of the pair of piping portions 621 and 622 in the cooling device is different. Are arranged in the axial direction. Further, as shown in FIG. 62 (c), the cooling water passage 545 is formed such that a passage portion communicating with the inflow side piping portion 621 and a passage portion communicating with the outflow side piping portion 622 are separated in the axial direction. These passage portions are communicated with each other through the respective pipe portions 621 and 622 and the respective coolers 623.
　その他に、スイッチモジュール５３２Ａとして、次の構成を用いることも可能である。 In addition, the following configuration can be used as the switch module 532A.
　図６３（ａ）に示す構成では、図６１（ａ）の構成と比べて、冷却器６２３が２段から１段に変更されている。この場合、モジュールケース６１１内において冷却性能の最も高い場所が図６１（ａ）とは異なっており、冷却器６２３の径方向両側（図の左右方向両側）のうち外側周壁ＷＡ１側の場所が最も冷却性能が高く、次いで、冷却器６２３の反外側周壁側の場所、冷却器６２３から離れた場所の順に冷却性能が低くなっている。これを加味し、図６３（ａ）に示す構成では、スイッチ６０１，６０２が、冷却器６２３の径方向両側（図の左右方向両側）のうち外側周壁ＷＡ１側の場所に配置され、コンデンサ６０４が、冷却器６２３の反外側周壁側の場所に配置され、駆動回路６０３が、冷却器６２３から離れた場所に配置されている。 構成 In the configuration shown in FIG. 63 (a), the cooler 623 is changed from two stages to one stage as compared with the configuration in FIG. 61 (a). In this case, the place where the cooling performance is highest in the module case 611 is different from that in FIG. 61A, and the place on the outer peripheral wall WA1 side is the most out of both sides in the radial direction of the cooler 623 (left and right sides in the figure). The cooling performance is high, and then the cooling performance decreases in the order of the location on the side opposite to the outer peripheral wall of the cooler 623 and the location away from the cooler 623. Taking this into account, in the configuration shown in FIG. 63 (a), the switches 601 and 602 are arranged on the outer circumferential wall WA1 side of the radially opposite sides (both in the left and right directions in the figure) of the cooler 623, and the condenser 604 is provided. The drive circuit 603 is disposed at a location away from the cooler 623, and on a side opposite to the outer peripheral wall of the cooler 623.
　また、スイッチモジュール５３２Ａにおいて、モジュールケース６１１内に１相分のスイッチ６０１，６０２と、駆動回路６０３と、コンデンサ６０４とを収容する構成を変更することも可能である。例えば、モジュールケース６１１内に１相分のスイッチ６０１，６０２と、駆動回路６０３及びコンデンサ６０４のいずれ一方とを収容する構成としてもよい。 In the switch module 532A, it is also possible to change the configuration in which the switches 601 and 602 for one phase, the drive circuit 603, and the capacitor 604 are accommodated in the module case 611. For example, the module case 611 may be configured to accommodate the switches 601 and 602 for one phase and one of the drive circuit 603 and the capacitor 604.
　図６３（ｂ）では、モジュールケース６１１内に、一対の配管部６２１，６２２と２段の冷却器６２３とを設けるとともに、スイッチ６０１，６０２を、１段目及び２段目の冷却器６２３の間に配置し、コンデンサ６０４又は駆動回路６０３を、１段目の冷却器６２３の外側周壁ＷＡ１側に配置する構成としている。また、スイッチ６０１，６０２と駆動回路６０３とを一体化して半導体モジュールとし、その半導体モジュールとコンデンサ６０４とを、モジュールケース６１１内に収容する構成とすることも可能である。 In FIG. 63B, a pair of piping portions 621 and 622 and a two-stage cooler 623 are provided in the module case 611, and the switches 601 and 602 are connected to the first-stage and second-stage coolers 623. The cooler 623 or the drive circuit 603 is arranged on the outer peripheral wall WA1 side of the first-stage cooler 623. Further, the switches 601 and 602 and the driving circuit 603 may be integrated into a semiconductor module, and the semiconductor module and the capacitor 604 may be housed in the module case 611.
　なお、図６３（ｂ）では、スイッチモジュール５３２Ａにおいて、スイッチ６０１，６０２を挟んで両側に配置される冷却器６２３のうち少なくとも一方の冷却器６２３においてスイッチ６０１，６０２とは逆側にコンデンサが配置されているとよい。すなわち、１段目の冷却器６２３の外側周壁ＷＡ１側と、２段目の冷却器６２３の反周壁側とのうち一方にのみコンデンサ６０４を配置する構成、又は両方にコンデンサ６０４を配置する構成が可能である。 In FIG. 63B, in the switch module 532A, at least one of the coolers 623 arranged on both sides of the switches 601 and 602, a capacitor is arranged on the opposite side to the switches 601 and 602. It is good to be. That is, a configuration in which the capacitor 604 is disposed only on one of the outer peripheral wall WA1 side of the first-stage cooler 623 and an opposite peripheral wall side of the second-stage cooler 623, or a configuration in which the capacitor 604 is disposed on both sides. It is possible.
　本実施形態では、スイッチモジュール５３２Ａとコンデンサモジュール５３２Ｂとのうちスイッチモジュール５３２Ａのみについて、冷却水通路５４５からモジュール内部に冷却水を引き込む構成としている。ただし、その構成を変更し、両方のモジュール５３２Ａ，５３２Ｂに、冷却水通路５４５から冷却水を引き込む構成としてもよい。 In the present embodiment, only the switch module 532A of the switch module 532A and the capacitor module 532B is configured to draw cooling water from the cooling water passage 545 into the module. However, the configuration may be changed so that the cooling water is drawn into the both modules 532A and 532B from the cooling water passage 545.
　また、各電気モジュール５３２の外面に冷却水を直接当てる状態にして、各電気モジュール５３２を冷却する構成とすることも可能である。例えば、図６４に示すように、外側周壁ＷＡ１に電気モジュール５３２を埋め込むことで、電気モジュール５３２の外面に冷却水を当てる構成とする。この場合、電気モジュール５３２の一部を冷却水通路５４５内に浸漬させる構成や、冷却水通路５４５を図５８等の構成よりも径方向に拡張して電気モジュール５３２の全てを冷却水通路５４５内に浸漬させる構成が考えられる。冷却水通路５４５内に電気モジュール５３２を浸漬させる場合、浸漬されるモジュールケース６１１（モジュールケース６１１の浸漬部分）にフィンを設けると、冷却性能を更に向上させることができる。 Also, it is possible to cool each electric module 532 by putting cooling water directly on the outer surface of each electric module 532. For example, as shown in FIG. 64, by embedding the electric module 532 in the outer peripheral wall WA <b> 1, cooling water is applied to the outer surface of the electric module 532. In this case, a configuration in which a part of the electric module 532 is immersed in the cooling water passage 545 or a configuration in which the cooling water passage 545 is expanded in the radial direction as compared with the configuration in FIG. A configuration in which the substrate is immersed in the substrate is conceivable. When the electric module 532 is immersed in the cooling water passage 545, the cooling performance can be further improved by providing fins in the immersed module case 611 (the immersion portion of the module case 611).
　また、電気モジュール５３２には、スイッチモジュール５３２Ａとコンデンサモジュール５３２Ｂとが含まれ、それら両者を比べた場合に発熱量に差異がある。この点を考慮して、インバータハウジング５３１における各電気モジュール５３２の配置を工夫することも可能である。 (4) The electric module 532 includes a switch module 532A and a capacitor module 532B. In consideration of this point, the arrangement of the electric modules 532 in the inverter housing 531 can be devised.
　例えば、図６５に示すように、複数個のスイッチモジュール５３２Ａを、分散させず周方向に並べ、かつ冷却水通路５４５の上流側、すなわち入口通路５７１に近い側に配置する。この場合、入口通路５７１から流入した冷却水は、先ずは３つのスイッチモジュール５３２Ａの冷却に用いられ、その後に各コンデンサモジュール５３２Ｂの冷却に用いられる。なお、図６５では、先の図６２（ａ），（ｂ）のように一対の配管部６２１，６２２が軸方向に並べて配置されているが、これに限らず、先の図６１（ａ），（ｂ）のように一対の配管部６２１，６２２が周方向に並べて配置されていてもよい。 For example, as shown in FIG. 65, a plurality of switch modules 532A are arranged in the circumferential direction without being dispersed, and are arranged on the upstream side of the cooling water passage 545, that is, on the side close to the inlet passage 571. In this case, the cooling water flowing from the inlet passage 571 is used first for cooling the three switch modules 532A, and thereafter for cooling the respective capacitor modules 532B. In FIG. 65, a pair of piping portions 621 and 622 are arranged in the axial direction as in FIGS. 62 (a) and 62 (b). However, the present invention is not limited to this. , (B), a pair of piping portions 621 and 622 may be arranged side by side in the circumferential direction.
　次に、各電気モジュール５３２及びバスバーモジュール５３３における電気的な接続に関する構成を説明する。図６６は、図４９の６６－６６線断面図であり、図６７は、図４９の６７－６７線断面図である。図６８は、バスバーモジュール５３３を単体で示す斜視図である。ここではこれら各図を併せ用いて、各電気モジュール５３２及びバスバーモジュール５３３の電気接続に関する構成を説明する。 Next, a configuration related to electrical connection in each electric module 532 and bus bar module 533 will be described. FIG. 66 is a sectional view taken along line 66-66 of FIG. 49, and FIG. 67 is a sectional view taken along line 67-67 of FIG. FIG. 68 is a perspective view showing the bus bar module 533 alone. Here, the configuration relating to the electrical connection of each electric module 532 and the bus bar module 533 will be described with reference to these drawings.
　図６６に示すように、インバータハウジング５３１には、内壁部材５４２に設けられた突出部５７３（すなわち、冷却水通路５４５に通じる入口通路５７１及び出口通路５７２が設けられた突出部５７３）の周方向に隣となる位置に、３つのスイッチモジュール５３２Ａが周方向に並べて配置されるとともに、さらにその隣に、６つのコンデンサモジュール５３２Ｂが周方向に並べて配置されている。その概要として、インバータハウジング５３１では、外側周壁ＷＡ１の内側が周方向に１０個（すなわち、モジュール数＋１）の領域に等分に分けられ、そのうち９つの領域にそれぞれ電気モジュール５３２が１つずつ配置されるとともに、残り１つの領域に突出部５７３が設けられている。３つのスイッチモジュール５３２Ａは、Ｕ相用モジュール、Ｖ相用モジュール、Ｗ相用モジュールである。 As shown in FIG. 66, in the inverter housing 531, the circumferential direction of the protrusion 573 provided on the inner wall member 542 (that is, the protrusion 573 provided with the inlet passage 571 and the outlet passage 572 leading to the cooling water passage 545). , Three switch modules 532A are arranged side by side in the circumferential direction, and six capacitor modules 532B are also arranged next to it in the circumferential direction. As an outline, in the inverter housing 531, the inside of the outer peripheral wall WA <b> 1 is equally divided in the circumferential direction into ten (that is, the number of modules + 1) regions, and one electric module 532 is arranged in each of the nine regions. In addition, a protrusion 573 is provided in the remaining one region. The three switch modules 532A are a U-phase module, a V-phase module, and a W-phase module.
　図６６や前述の図５６、図５７等に示すように、各電気モジュール５３２（スイッチモジュール５３２Ａ及びコンデンサモジュール５３２Ｂ）は、モジュールケース６１１から延びる複数のモジュール端子６１５を有している。モジュール端子６１５は、各電気モジュール５３２における電気的な入出力を行わせるモジュール入出力端子である。モジュール端子６１５は、軸方向に延びる向きで設けられており、より具体的には、モジュールケース６１１から回転子キャリア５１１の奥側（車両外側）に向けて延びるように設けられている（図５１参照）。 As shown in FIG. 66 and FIGS. 56 and 57 described above, each electric module 532 (switch module 532A and capacitor module 532B) has a plurality of module terminals 615 extending from the module case 611. The module terminal 615 is a module input / output terminal for performing electric input / output in each electric module 532. The module terminal 615 is provided so as to extend in the axial direction. More specifically, the module terminal 615 is provided so as to extend from the module case 611 toward the back side (outside of the vehicle) of the rotor carrier 511 (FIG. 51). reference).
　各電気モジュール５３２のモジュール端子６１５は、それぞれバスバーモジュール５３３に接続されている。モジュール端子６１５の数は、スイッチモジュール５３２Ａとコンデンサモジュール５３２Ｂとで異なっており、スイッチモジュール５３２Ａには４つのモジュール端子６１５が設けられ、コンデンサモジュール５３２Ｂには２つのモジュール端子６１５が設けられている。 The module terminals 615 of each electric module 532 are connected to the bus bar module 533, respectively. The number of module terminals 615 is different between the switch module 532A and the capacitor module 532B. The switch module 532A has four module terminals 615, and the capacitor module 532B has two module terminals 615.
　また、図６８に示すように、バスバーモジュール５３３は、円環状をなす環状部６３１と、その環状部６３１から延び、電源装置やＥＣＵ（電子制御装置）等の外部装置との接続を可能とする３本の外部接続端子６３２と、固定子巻線５２１における各相の巻線端部に接続される巻線接続端子６３３とを有している。バスバーモジュール５３３が「端子モジュール」に相当する。 As shown in FIG. 68, the bus bar module 533 has an annular portion 631 having an annular shape and extends from the annular portion 631 to enable connection with an external device such as a power supply device or an ECU (electronic control device). It has three external connection terminals 632 and a winding connection terminal 633 connected to the winding end of each phase in the stator winding 521. The bus bar module 533 corresponds to a “terminal module”.
　環状部６３１は、インバータハウジング５３１において外側周壁ＷＡ１の径方向内側であり、かつ各電気モジュール５３２の軸方向片側となる位置に配置されている。環状部６３１は、例えば樹脂等の絶縁部材により成形された円環状の本体部と、その内部に埋設された複数のバスバーとを有する。その複数のバスバーは、各電気モジュール５３２のモジュール端子６１５や、各外部接続端子６３２、固定子巻線５２１の各相巻線に接続されている。その詳細は後述する。 The annular portion 631 is arranged radially inside the outer peripheral wall WA1 in the inverter housing 531 and at one position in the axial direction of each electric module 532. The annular portion 631 has an annular main body formed of, for example, an insulating member such as a resin, and a plurality of busbars embedded therein. The plurality of bus bars are connected to the module terminal 615 of each electric module 532, each external connection terminal 632, and each phase winding of the stator winding 521. The details will be described later.
　外部接続端子６３２は、電源装置に接続される高電位側の電力端子６３２Ａ及び低電位側の電力端子６３２Ｂと、外部ＥＣＵに接続される１本の信号端子６３２Ｃとからなる。これら各外部接続端子６３２（６３２Ａ～６３２Ｃ）は、周方向に一列に並び、かつ環状部６３１の径方向内側において軸方向に延びるように設けられている。図５１に示すように、バスバーモジュール５３３が各電気モジュール５３２と共にインバータハウジング５３１に組み付けられた状態では、外部接続端子６３２の一端がボス形成部材５４３の端板５４７から突出するように構成されている。具体的には、図５６、図５７に示すように、ボス形成部材５４３の端板５４７には挿通孔５４７ａが設けられており、その挿通孔５４７ａに円筒状のグロメット６３５が取り付けられるとともに、グロメット６３５を挿通させた状態で外部接続端子６３２が設けられている。グロメット６３５は、密閉コネクタとしても機能する。 The external connection terminal 632 includes a high-potential-side power terminal 632A and a low-potential-side power terminal 632B connected to the power supply device, and one signal terminal 632C connected to the external ECU. These external connection terminals 632 (632 A to 632 C) are arranged in a line in the circumferential direction and are provided so as to extend in the axial direction inside the annular portion 631 in the radial direction. As shown in FIG. 51, when the bus bar module 533 and the electric modules 532 are assembled to the inverter housing 531, one end of the external connection terminal 632 projects from the end plate 547 of the boss forming member 543. . Specifically, as shown in FIGS. 56 and 57, an end plate 547 of the boss forming member 543 is provided with an insertion hole 547a, and a cylindrical grommet 635 is attached to the insertion hole 547a. The external connection terminal 632 is provided with the 635 inserted. The grommet 635 also functions as a sealed connector.
　巻線接続端子６３３は、固定子巻線５２１の各相の巻線端部に接続される端子であり、環状部６３１から径方向外側に延びるように設けられている。巻線接続端子６３３は、固定子巻線５２１におけるＵ相巻線の端部に接続される巻線接続端子６３３Ｕ、Ｖ相巻線の端部に接続される巻線接続端子６３３Ｖ、Ｗ相巻線の端部にそれぞれ接続に接続される巻線接続端子６３３Ｗを有する。これらの各巻線接続端子６３３、各相巻線に流れる電流（Ｕ相電流、Ｖ相電流、Ｗ相電流）を検出する電流センサ６３４が設けられているとよい（図７０参照）。 The winding connection terminal 633 is a terminal connected to the winding end of each phase of the stator winding 521, and is provided so as to extend radially outward from the annular portion 631. The winding connection terminal 633 includes a winding connection terminal 633U connected to an end of the U-phase winding of the stator winding 521, a winding connection terminal 633V connected to an end of the V-phase winding, and a W-phase winding. It has a winding connection terminal 633W connected to each end of the wire. A current sensor 634 for detecting the current (U-phase current, V-phase current, W-phase current) flowing through each of the winding connection terminals 633 and each phase winding may be provided (see FIG. 70).
　なお、電流センサ６３４は、電気モジュール５３２の外部であって、各巻線接続端子６３３の周辺に配置されてもよいし、電気モジュール５３２の内部に配置されてもよい。 The current sensor 634 may be disposed outside the electric module 532 and around each winding connection terminal 633, or may be disposed inside the electric module 532.
　ここで、各電気モジュール５３２とバスバーモジュール５３３との接続を、図６９及び図７０を用いてより具体的に説明する。図６９は、各電気モジュール５３２を平面状に展開して示すとともに、それら各電気モジュール５３２とバスバーモジュール５３３との電気的な接続状態を模式的に示す図である。図７０は、各電気モジュール５３２を円環状に配置した状態での各電気モジュール５３２とバスバーモジュール５３３との接続を模式的に示す図である。なお、図６９には、電力伝送用の経路を実線で示し、信号伝送系の経路を一点鎖線で示している。図７０には、電力伝送用の経路のみを示している。 Here, the connection between each electric module 532 and the bus bar module 533 will be described more specifically with reference to FIGS. FIG. 69 is a diagram showing each electric module 532 in a developed form, and schematically showing an electrical connection state between each electric module 532 and the bus bar module 533. FIG. 70 is a diagram schematically showing a connection between each electric module 532 and the bus bar module 533 in a state where each electric module 532 is arranged in an annular shape. In FIG. 69, a path for power transmission is indicated by a solid line, and a path of a signal transmission system is indicated by a chain line. FIG. 70 shows only the power transmission path.
　バスバーモジュール５３３は、電力伝送用のバスバーとして、第１バスバー６４１と第２バスバー６４２と第３バスバー６４３とを有している。このうち第１バスバー６４１が高電位側の電力端子６３２Ａに接続され、第２バスバー６４２が低電位側の電力端子６３２Ｂに接続されている。また、３つの第３バスバー６４３が、Ｕ相の巻線接続端子６３３Ｕ、Ｖ相の巻線接続端子６３３Ｖ、Ｗ相の巻線接続端子６３３Ｗにそれぞれ接続されている。 The bus bar module 533 has a first bus bar 641, a second bus bar 642, and a third bus bar 643 as power transmission bus bars. Among them, the first bus bar 641 is connected to the power terminal 632A on the high potential side, and the second bus bar 642 is connected to the power terminal 632B on the low potential side. The three third bus bars 643 are connected to the U-phase winding connection terminal 633U, the V-phase winding connection terminal 633V, and the W-phase winding connection terminal 633W, respectively.
　また、巻線接続端子６３３や第３バスバー６４３は、回転電機１０の動作により発熱しやすい部位である。このため、巻線接続端子６３３と第３バスバー６４３との間に図示しない端子台を介在させるとともに、この端子台を、冷却水通路５４５を有するインバータハウジング５３１に当接させてもよい。又は、巻線接続端子６３３や第３バスバー６４３をクランク状に曲げることで、巻線接続端子６３３や第３バスバー６４３を冷却水通路５４５を有するインバータハウジング５３１に当接させてもよい。 (4) The winding connection terminal 633 and the third bus bar 643 are parts that easily generate heat by the operation of the rotating electric machine 10. Therefore, a terminal block (not shown) may be interposed between the winding connection terminal 633 and the third bus bar 643, and this terminal block may be brought into contact with the inverter housing 531 having the cooling water passage 545. Alternatively, the winding connection terminal 633 and the third bus bar 643 may be bent into a crank shape so that the winding connection terminal 633 and the third bus bar 643 abut on the inverter housing 531 having the cooling water passage 545.
　このような構成であれば、巻線接続端子６３３や第３バスバー６４３で発生した熱を冷却水通路５４５内の冷却水に放熱することができる。 With such a configuration, heat generated in the winding connection terminal 633 and the third bus bar 643 can be radiated to the cooling water in the cooling water passage 545.
　なお、図７０では、第１バスバー６４１及び第２バスバー６４２を、円環形状をなすバスバーとして示すが、これら各バスバー６４１，６４２は必ずしも円環形状で繋がっていなくてもよく、周方向の一部が途切れた略Ｃ字状をなしていてもよい。また、各巻線接続端子６３３Ｕ，６３３Ｖ，６３３Ｗは、各相に対応するスイッチモジュール５３２Ａに個々に接続されればよいため、バスバーモジュール５３３を介することなく、直接的に各スイッチモジュール５３２Ａ（実際にはモジュール端子６１５）に接続される構成であってもよい。 In FIG. 70, the first busbar 641 and the second busbar 642 are shown as annular busbars, but these busbars 641 and 642 do not necessarily have to be connected in an annular shape. The portion may be formed in a substantially C-shape with interruption. Further, since each winding connection terminal 633U, 633V, 633W may be individually connected to the switch module 532A corresponding to each phase, each switch module 532A (actually, without the bus bar module 533) is directly connected. It may be configured to be connected to the module terminal 615).
　一方、各スイッチモジュール５３２Ａは、正極側端子、負極側端子、巻線用端子及び信号用端子からなる４つのモジュール端子６１５を有している。このうち正極側端子は第１バスバー６４１に接続され、負極側端子は第２バスバー６４２に接続され、巻線用端子は第３バスバー６４３に接続されている。 On the other hand, each switch module 532A has four module terminals 615 including a positive terminal, a negative terminal, a winding terminal, and a signal terminal. The positive terminal is connected to the first bus bar 641, the negative terminal is connected to the second bus bar 642, and the winding terminal is connected to the third bus bar 643.
　また、バスバーモジュール５３３は、信号伝送系のバスバーとして第４バスバー６４４を有している。各スイッチモジュール５３２Ａの信号用端子が第４バスバー６４４に接続されるとともに、その第４バスバー６４４が信号端子６３２Ｃに接続されている。 The bus bar module 533 has a fourth bus bar 644 as a signal transmission bus bar. The signal terminal of each switch module 532A is connected to the fourth bus bar 644, and the fourth bus bar 644 is connected to the signal terminal 632C.
　本実施形態では、各スイッチモジュール５３２Ａに対する制御信号を信号端子６３２Ｃを介して外部ＥＣＵから入力する構成としている。つまり、各スイッチモジュール５３２Ａ内の各スイッチ６０１，６０２は、信号端子６３２Ｃを介して入力される制御信号によりオンオフする。そのため、各スイッチモジュール５３２Ａが、途中で回転電機内蔵の制御装置を経由することなく信号端子６３２Ｃに対して接続される構成となっている。ただし、この構成を変更し、回転電機に制御装置を内蔵させ、その制御装置からの制御信号が各スイッチモジュール５３２Ａに入力される構成とすることも可能である。かかる構成を図７１に示す。 In this embodiment, a control signal for each switch module 532A is input from an external ECU via a signal terminal 632C. That is, the switches 601 and 602 in each switch module 532A are turned on / off by the control signal input via the signal terminal 632C. Therefore, each switch module 532A is configured to be connected to the signal terminal 632C without passing through a control device built in the rotating electric machine on the way. However, by changing this configuration, it is also possible to adopt a configuration in which a control device is built in the rotating electric machine, and a control signal from the control device is input to each switch module 532A. Such a configuration is shown in FIG.
　図７１の構成では、制御装置６５２が実装された制御基板６５１を有し、その制御装置６５２が各スイッチモジュール５３２Ａに接続されている。また、制御装置６５２には信号端子６３２Ｃが接続されている。この場合、制御装置６５２は、例えば上位制御装置である外部ＥＣＵから力行又は発電に関する指令信号を入力し、その指令信号に基づいて各スイッチモジュール５３２Ａのスイッチ６０１，６０２を適宜オンオフさせる。 In the configuration of FIG. 71, there is a control board 651 on which a control device 652 is mounted, and the control device 652 is connected to each switch module 532A. Further, a signal terminal 632C is connected to the control device 652. In this case, the control device 652 inputs a command signal related to powering or power generation from, for example, an external ECU that is a higher-level control device, and appropriately turns on and off the switches 601 and 602 of each switch module 532A based on the command signal.
　インバータユニット５３０においては、バスバーモジュール５３３よりも車両外側（回転子キャリア５１１の奥側）に制御基板６５１が配置されるとよい。又は、各電気モジュール５３２とボス形成部材５４３の端板５４７との間に制御基板６５１が配置されるとよい。制御基板６５１は、各電気モジュール５３２に対して少なくとも一部が軸方向に重複するように配置されるとよい。 In the inverter unit 530, the control board 651 may be disposed outside the vehicle (the back side of the rotor carrier 511) from the bus bar module 533. Alternatively, a control board 651 may be disposed between each electric module 532 and the end plate 547 of the boss forming member 543. The control board 651 may be arranged so that at least a part of each control module 532 overlaps in the axial direction.
　また、各コンデンサモジュール５３２Ｂは、正極側端子及び負極側端子からなる２つのモジュール端子６１５を有しており、正極側端子は第１バスバー６４１に接続され、負極側端子は第２バスバー６４２に接続されている。 Each capacitor module 532B has two module terminals 615 each including a positive terminal and a negative terminal. The positive terminal is connected to the first bus bar 641, and the negative terminal is connected to the second bus bar 642. Have been.
　図４９及び図５０に示すように、インバータハウジング５３１内には、周方向に各電気モジュール５３２と並ぶ位置に、冷却水の入口通路５７１及び出口通路５７２を有する突出部５７３が設けられるとともに、その突出部５７３に対して径方向に隣り合うようにして外部接続端子６３２が設けられている。換言すれば、突出部５７３と外部接続端子６３２とが、周方向に同じ角度位置に設けられている。本実施形態では、突出部５７３の径方向内側の位置に外部接続端子６３２が設けられている。また、インバータハウジング５３１の車両内側から見れば、ボス形成部材５４３の端板５４７に、径方向に並べて水路ポート５７４と外部接続端子６３２とが設けられている（図４８参照）。 As shown in FIG. 49 and FIG. 50, a protrusion 573 having a cooling water inlet passage 571 and an outlet passage 572 is provided in the inverter housing 531 at a position aligned with each electric module 532 in the circumferential direction. An external connection terminal 632 is provided so as to be radially adjacent to the protrusion 573. In other words, the protrusion 573 and the external connection terminal 632 are provided at the same angular position in the circumferential direction. In the present embodiment, the external connection terminal 632 is provided at a position radially inside the protruding portion 573. Further, when viewed from the inside of the vehicle of the inverter housing 531, a water channel port 574 and an external connection terminal 632 are provided on the end plate 547 of the boss forming member 543 in a radial direction (see FIG. 48).
　この場合、複数の電気モジュール５３２と共に突出部５７３及び外部接続端子６３２を周方向に並べて配置したことにより、インバータユニット５３０としての小型化、ひいては回転電機５００としての小型化が可能となっている。 In this case, by arranging the protrusions 573 and the external connection terminals 632 in the circumferential direction along with the plurality of electric modules 532, it is possible to reduce the size of the inverter unit 530, and further, the size of the rotating electric machine 500.
　車輪４００の構造を示す図４５及び図４７で見ると、水路ポート５７４に冷却用配管Ｈ２が接続されるとともに、外部接続端子６３２に電気配線Ｈ１が接続され、その状態で、電気配線Ｈ１及び冷却用配管Ｈ２が収容ダクト４４０に収容されている。 45 and 47 showing the structure of the wheel 400, the cooling pipe H2 is connected to the water channel port 574, and the electric wiring H1 is connected to the external connection terminal 632. In this state, the electric wiring H1 and the cooling Pipe H2 is housed in the housing duct 440.
　なお、上記構成では、インバータハウジング５３１内において外部接続端子６３２の隣に、３つのスイッチモジュール５３２Ａを周方向に並べて配置するととともに、さらにその隣に、６つのコンデンサモジュール５３２Ｂを周方向に並べて配置する構成としたが、これを変更してもよい。例えば、外部接続端子６３２から最も離れた位置、すなわち回転軸５０１を挟んで反対側となる位置に、３つのスイッチモジュール５３２Ａを並べて配置する構成としてもよい。また、各スイッチモジュール５３２Ａの両隣にコンデンサモジュール５３２Ｂが配置されるように、各スイッチモジュール５３２Ａを分散配置することも可能である。 In the above configuration, the three switch modules 532A are arranged in the inverter housing 531 next to the external connection terminals 632 in the circumferential direction, and the six capacitor modules 532B are arranged next to the external connection terminals 632 in the circumferential direction. Although the configuration has been described, this may be changed. For example, a configuration may be adopted in which three switch modules 532A are arranged side by side at a position farthest from the external connection terminal 632, that is, at a position on the opposite side of the rotary shaft 501. Also, the switch modules 532A can be distributed and arranged such that the capacitor modules 532B are arranged on both sides of each switch module 532A.
　外部接続端子６３２から最も離れた位置、すなわち回転軸５０１を挟んで反対側となる位置に各スイッチモジュール５３２Ａを配置する構成とすれば、外部接続端子６３２と各スイッチモジュール５３２Ａとの間における相互インダクタンスに起因する誤動作等を抑制できる。 If each switch module 532A is arranged at a position farthest from the external connection terminal 632, that is, a position on the opposite side of the rotary shaft 501, the mutual inductance between the external connection terminal 632 and each switch module 532A is obtained. Can be suppressed.
　次に、回転角度センサとして設けられるレゾルバ６６０に関する構成を説明する。 Next, the configuration of the resolver 660 provided as a rotation angle sensor will be described.
　図４９～図５１に示すように、インバータハウジング５３１には、回転電機５００の電気角θを検出するレゾルバ６６０が設けられている。レゾルバ６６０は、電磁誘導式センサであり、回転軸５０１に固定されたレゾルバロータ６６１と、そのレゾルバロータ６６１の径方向外側に対向配置されたレゾルバステータ６６２とを備えている。レゾルバロータ６６１は、円板リング状をなしており、回転軸５０１を挿通させた状態で、回転軸５０１に同軸で設けられている。レゾルバステータ６６２は、円環状をなすステータコア６６３と、ステータコア６６３に形成された複数のティースに巻回されたステータコイル６６４とを備えている。ステータコイル６６４には、１相の励磁コイルと２相の出力コイルとが含まれている。 イ ン バ ー タ As shown in FIGS. 49 to 51, a resolver 660 for detecting the electrical angle θ of the rotating electric machine 500 is provided in the inverter housing 531. The resolver 660 is an electromagnetic induction type sensor, and includes a resolver rotor 661 fixed to the rotating shaft 501 and a resolver stator 662 arranged to face the resolver rotor 661 radially outward. The resolver rotor 661 has a disk ring shape, and is provided coaxially with the rotary shaft 501 with the rotary shaft 501 inserted therethrough. The resolver stator 662 includes an annular stator core 663 and a stator coil 664 wound around a plurality of teeth formed on the stator core 663. The stator coil 664 includes a one-phase excitation coil and a two-phase output coil.
　ステータコイル６６４の励磁コイルは、正弦波状の励磁信号によって励磁され、励磁信号によって励磁コイルに生じた磁束は、一対の出力コイルを鎖交する。この際、励磁コイルと一対の出力コイルとの相対的な配置関係がレゾルバロータ６６１の回転角（すなわち回転軸５０１の回転角）に応じて周期的に変化するため、一対の出力コイルを鎖交する磁束数は周期的に変化する。本実施形態では、一対の出力コイルのそれぞれに生じる電圧の位相が互いにπ／２だけずれるように一対の出力コイルと励磁コイルとが配置されている。これにより、一対の出力コイルそれぞれの出力電圧は、励磁信号を変調波ｓｉｎθ、ｃｏｓθのそれぞれによって変調した被変調波となる。より具体的には、励磁信号を「ｓｉｎΩｔ」とすると、被変調波はそれぞれ「ｓｉｎθ×ｓｉｎΩｔ」，「ｃｏｓθ×ｓｉｎΩｔ」となる。 (4) The excitation coil of the stator coil 664 is excited by a sine wave excitation signal, and the magnetic flux generated in the excitation coil by the excitation signal links the pair of output coils. At this time, the relative arrangement relationship between the excitation coil and the pair of output coils changes periodically according to the rotation angle of the resolver rotor 661 (that is, the rotation angle of the rotation shaft 501). The number of magnetic fluxes changes periodically. In the present embodiment, the pair of output coils and the exciting coil are arranged such that the phases of voltages generated in the pair of output coils are shifted from each other by π / 2. As a result, the output voltage of each of the pair of output coils becomes a modulated wave obtained by modulating the excitation signal with each of the modulated waves sin θ and cos θ. More specifically, if the excitation signal is “sinΩt”, the modulated waves are “sinθ × sinΩt” and “cosθ × sinΩt”, respectively.
　レゾルバ６６０はレゾルバデジタルコンバータを有している。レゾルバデジタルコンバータは、生成された被変調波及び励磁信号に基づく検波によって電気角θを算出する。例えばレゾルバ６６０は信号端子６３２Ｃに接続されており、レゾルバデジタルコンバータの算出結果は、信号端子６３２Ｃを介して外部装置に出力される。また、回転電機５００に制御装置が内蔵されている場合には、その制御装置にレゾルバデジタルコンバータの算出結果が入力される。 The resolver 660 has a resolver digital converter. The resolver digital converter calculates the electrical angle θ by detection based on the generated modulated wave and the excitation signal. For example, the resolver 660 is connected to the signal terminal 632C, and the calculation result of the resolver digital converter is output to an external device via the signal terminal 632C. If the rotating electric machine 500 has a built-in control device, a calculation result of the resolver digital converter is input to the control device.
　ここで、インバータハウジング５３１におけるレゾルバ６６０の組み付け構造について説明する。 Here, the assembly structure of the resolver 660 in the inverter housing 531 will be described.
　図４９及び図５１に示すように、インバータハウジング５３１を構成するボス形成部材５４３のボス部５４８は中空筒状をなしており、そのボス部５４８の内周側には、軸方向に直交する向きに延びる突出部５４８ａが形成されている。そして、この突出部５４８ａに軸方向に当接した状態で、ネジ等によりレゾルバステータ６６２が固定されている。ボス部５４８内には、突出部５４８ａを挟んで軸方向の一方側に軸受５６０が設けられるとともに、他方側にレゾルバ６６０が同軸で設けられている。 As shown in FIGS. 49 and 51, the boss portion 548 of the boss forming member 543 constituting the inverter housing 531 has a hollow cylindrical shape, and the inner peripheral side of the boss portion 548 has a direction perpendicular to the axial direction. A protruding portion 548a is formed to extend. The resolver stator 662 is fixed by screws or the like in a state where the resolver stator 662 is in contact with the protruding portion 548a in the axial direction. In the boss 548, a bearing 560 is provided on one side in the axial direction with the protrusion 548a interposed therebetween, and a resolver 660 is provided coaxially on the other side.
　また、ボス部５４８の中空部には、軸方向においてレゾルバ６６０の一方の側に突出部５４８ａが設けられるとともに、他方の側に、レゾルバ６６０の収容空間を閉鎖する円板リング状のハウジングカバー６６６が取り付けられている。ハウジングカバー６６６は、炭素繊維強化プラスチック（ＣＦＲＰ）等の導電性材料により構成されている。ハウジングカバー６６６の中央部には、回転軸５０１を挿通させる孔６６６ａが形成されている。孔６６６ａ内には、回転軸５０１の外周面との間の空隙を封鎖するシール材６６７が設けられている。シール材６６７により、レゾルバ収容空間が密閉されている。シール材６６７は、例えば樹脂材料よりなる摺動シールであるとよい。 In the hollow portion of the boss portion 548, a protrusion 548a is provided on one side of the resolver 660 in the axial direction, and a disc ring-shaped housing cover 666 for closing the accommodation space of the resolver 660 is provided on the other side. Is attached. The housing cover 666 is made of a conductive material such as carbon fiber reinforced plastic (CFRP). A hole 666a through which the rotating shaft 501 is inserted is formed at the center of the housing cover 666. In the hole 666a, a seal member 667 for closing a gap between the rotary shaft 501 and the outer peripheral surface is provided. The sealer 667 seals the resolver housing space. The seal member 667 may be a sliding seal made of, for example, a resin material.
　レゾルバ６６０が収容される空間は、ボス形成部材５４３において円環状をなすボス部５４８に囲まれ、かつ軸方向が軸受５６０とハウジングカバー６６６とにより挟まれた空間であり、レゾルバ６６０の周囲は導電材料により囲まれている。これにより、レゾルバ６６０に対する電磁ノイズの影響を抑制できるようになっている。 The space in which the resolver 660 is housed is a space surrounded by an annular boss portion 548 in the boss forming member 543 and is axially sandwiched between the bearing 560 and the housing cover 666. The periphery of the resolver 660 is conductive. Surrounded by material. Thereby, the influence of the electromagnetic noise on the resolver 660 can be suppressed.
　また、上述したとおりインバータハウジング５３１は、二重となる外側周壁ＷＡ１と内側周壁ＷＡ２とを有しており（図５７参照）、その二重となる周壁の外側（外側周壁ＷＡ１の外側）には固定子５２０が配置され、二重の周壁の間（ＷＡ１，ＷＡ２の間）には電気モジュール５３２が配置され、二重の周壁の内側（内側周壁ＷＡ２の内側）にはレゾルバ６６０が配置されている。インバータハウジング５３１は導電性部材であるため、固定子５２０とレゾルバ６６０とは、導電性の隔壁（本実施形態では特に二重の導電性隔壁）を隔てて配置されるようになっており、固定子５２０側（磁気回路側）とレゾルバ６６０とについて相互の磁気干渉の発生を好適に抑制できるものとなっている。 Further, as described above, the inverter housing 531 has the double outer peripheral wall WA1 and the inner peripheral wall WA2 (see FIG. 57), and the outside of the double peripheral wall (outside the outer peripheral wall WA1). A stator 520 is arranged, an electric module 532 is arranged between the double peripheral walls (between WA1 and WA2), and a resolver 660 is arranged inside the double peripheral wall (inside the inner peripheral wall WA2). I have. Since the inverter housing 531 is a conductive member, the stator 520 and the resolver 660 are arranged so as to be separated by a conductive partition (in this embodiment, particularly, a double conductive partition). The generation of mutual magnetic interference between the child 520 (magnetic circuit side) and the resolver 660 can be suitably suppressed.
　次に、回転子キャリア５１１の開放端部の側に設けられる回転子カバー６７０について説明する。 Next, the rotor cover 670 provided on the open end side of the rotor carrier 511 will be described.
　図４９及び図５１に示すように、回転子キャリア５１１は軸方向の一方側が開放されており、その開放端部に、略円板リング状の回転子カバー６７０が取り付けられている。回転子カバー６７０は、溶接や接着、ビス止め等の任意の接合手法により回転子キャリア５１１に対して固定されているとよい。回転子カバー６７０が、磁石ユニット５１２の軸方向への移動を抑制できるように回転子キャリア５１１の内周よりも小さめに寸法設定されている部位を持つとなおよい。回転子カバー６７０は、その外径寸法が、回転子キャリア５１１の外径寸法に一致し、内径寸法が、インバータハウジング５３１の外径寸法よりも僅かに大きい寸法となっている。なお、インバータハウジング５３１の外径寸法と固定子５２０の内径寸法とは同じである。 及 び As shown in FIGS. 49 and 51, the rotor carrier 511 is open on one side in the axial direction, and a substantially disk-shaped rotor cover 670 is attached to the open end. The rotor cover 670 may be fixed to the rotor carrier 511 by any joining method such as welding, bonding, or screwing. It is more preferable that the rotor cover 670 has a portion that is set to be smaller than the inner circumference of the rotor carrier 511 so that the movement of the magnet unit 512 in the axial direction can be suppressed. Rotor cover 670 has an outer diameter that matches the outer diameter of rotor carrier 511, and an inner diameter that is slightly larger than the outer diameter of inverter housing 531. The outer diameter of the inverter housing 531 and the inner diameter of the stator 520 are the same.
　上述したとおりインバータハウジング５３１の径方向外側には固定子５２０が固定されており、それら固定子５２０及びインバータハウジング５３１が互いに接合されている接合部分では、固定子５２０に対してインバータハウジング５３１が軸方向に突出している。そして、インバータハウジング５３１の突出部分を囲むように回転子カバー６７０が取り付けられている。この場合、回転子カバー６７０の内周側の端面とインバータハウジング５３１の外周面との間には、それらの間の隙間を封鎖するシール材６７１が設けられている。シール材６７１により、磁石ユニット５１２及び固定子５２０の収容空間が密閉されている。シール材６７１は、例えば樹脂材料よりなる摺動シールであるとよい。 As described above, the stator 520 is fixed radially outside the inverter housing 531, and at the joint portion where the stator 520 and the inverter housing 531 are joined to each other, the inverter housing 531 is pivoted with respect to the stator 520. Projecting in the direction. A rotor cover 670 is attached so as to surround the protruding portion of the inverter housing 531. In this case, a seal member 671 for closing a gap between the inner peripheral end surface of the rotor cover 670 and the outer peripheral surface of the inverter housing 531 is provided. The housing space of the magnet unit 512 and the stator 520 is sealed by the sealing material 671. The sealing material 671 is preferably a sliding seal made of, for example, a resin material.
　以上詳述した本実施形態によれば、以下の優れた効果が得られる。 According to the embodiment described in detail above, the following excellent effects can be obtained.
　回転電機５００において、磁石ユニット５１２及び固定子巻線５２１よりなる磁気回路部の径方向内側に、インバータハウジング５３１の外側周壁ＷＡ１を配置し、その外側周壁ＷＡ１に冷却水通路５４５を形成した。また、外側周壁ＷＡ１の径方向内側に、その外側周壁ＷＡ１に沿って周方向に複数の電気モジュール５３２を配置する構成とした。これにより、回転電機５００の径方向に積層されるようにして磁気回路部、冷却水通路５４５、電力変換器を配置でき、軸方向における寸法の縮小化を図りつつ、効率の良い部品配置が可能となる。また、電力変換器を構成する複数の電気モジュール５３２について効率良く冷却を行わせることができる。その結果、回転電機５００において、高効率かつ小型化が実現可能となる。 In the rotary electric machine 500, the outer peripheral wall WA1 of the inverter housing 531 is disposed radially inside the magnetic circuit portion including the magnet unit 512 and the stator winding 521, and the cooling water passage 545 is formed in the outer peripheral wall WA1. In addition, a plurality of electric modules 532 are arranged radially inside the outer peripheral wall WA1 in the circumferential direction along the outer peripheral wall WA1. Accordingly, the magnetic circuit portion, the cooling water passage 545, and the power converter can be arranged so as to be stacked in the radial direction of the rotating electric machine 500, and efficient component arrangement can be achieved while reducing the size in the axial direction. Becomes Further, the plurality of electric modules 532 constituting the power converter can be efficiently cooled. As a result, in the rotating electric machine 500, high efficiency and downsizing can be realized.
　半導体スイッチング素子やコンデンサ等の発熱部品を有する電気モジュール５３２（スイッチモジュール５３２Ａ、コンデンサモジュール５３２Ｂ）を、外側周壁ＷＡ１の内周面に接した状態で設ける構成とした。これにより、各電気モジュール５３２における熱が外側周壁ＷＡ１に伝達され、その外側周壁ＷＡ１での熱交換により電気モジュール５３２が好適に冷却される。 (4) The electric module 532 (the switch module 532A and the capacitor module 532B) having heat-generating components such as a semiconductor switching element and a capacitor is provided so as to be in contact with the inner peripheral surface of the outer peripheral wall WA1. Thereby, the heat in each electric module 532 is transmitted to the outer peripheral wall WA1, and the electric module 532 is appropriately cooled by heat exchange on the outer peripheral wall WA1.
　スイッチモジュール５３２Ａにおいて、スイッチ６０１，６０２を挟んで両側に冷却器６２３をそれぞれ配置するとともに、スイッチ６０１，６０２の両側の冷却器６２３のうち少なくとも一方の冷却器においてスイッチ６０１，６０２とは逆側にコンデンサ６０４を配置する構成とした。これにより、スイッチ６０１，６０２に対する冷却性能を高めることができるとともに、コンデンサ６０４の冷却性能も高めることができる。 In the switch module 532A, the coolers 623 are arranged on both sides of the switches 601 and 602, respectively, and at least one of the coolers 623 on both sides of the switches 601 and 602 is opposite to the switches 601 and 602. The configuration is such that the capacitor 604 is arranged. Thereby, the cooling performance of the switches 601 and 602 can be improved, and the cooling performance of the capacitor 604 can be also improved.
　スイッチモジュール５３２Ａにおいて、スイッチ６０１，６０２を挟んで両側に冷却器６２３をそれぞれ配置するとともに、スイッチ６０１，６０２の両側の冷却器６２３のうち一方の冷却器においてスイッチ６０１，６０２とは逆側に駆動回路６０３を配置し、他方の冷却器６２３においてスイッチ６０１，６０２とは逆側にコンデンサ６０４を配置する構成とした。これにより、スイッチ６０１，６０２に対する冷却性能を高めることができるとともに、駆動回路６０３とコンデンサ６０４についても冷却性能も高めることができる。 In the switch module 532A, the coolers 623 are arranged on both sides of the switches 601 and 602, respectively, and one of the coolers 623 on both sides of the switches 601 and 602 is driven in the opposite side to the switches 601 and 602. The circuit 603 is arranged, and the condenser 604 is arranged on the other cooler 623 on the side opposite to the switches 601 and 602. Thus, the cooling performance of the switches 601 and 602 can be improved, and the cooling performance of the drive circuit 603 and the capacitor 604 can also be improved.
　例えばスイッチモジュール５３２Ａにおいて、冷却水通路５４５からモジュール内部に冷却水を流入させ、その冷却水により半導体スイッチング素子等を冷却する構成とした。この場合、スイッチモジュール５３２Ａは、外側周壁ＷＡ１での冷却水による熱交換に加えて、モジュール内部での冷却水による熱交換により冷却される。これにより、スイッチモジュール５３２Ａの冷却効果を高めることができる。 {For example, in the switch module 532A, the cooling water flows into the module from the cooling water passage 545, and the semiconductor switching element and the like are cooled by the cooling water. In this case, the switch module 532A is cooled by the heat exchange with the cooling water inside the module in addition to the heat exchange with the cooling water at the outer peripheral wall WA1. Thereby, the cooling effect of the switch module 532A can be enhanced.
　冷却水通路５４５に対して外部の循環経路５７５から冷却水を流入させる冷却システムにおいて、スイッチモジュール５３２Ａを冷却水通路５４５の入口通路５７１に近い上流側に配置するとともに、コンデンサモジュール５３２Ｂをスイッチモジュール５３２Ａよりも下流側に配置する構成とした。この場合、冷却水通路５４５を流れる冷却水が上流側ほど低温であることを想定すれば、スイッチモジュール５３２Ａを優先的に冷却する構成を実現することが可能になる。 In the cooling system in which the cooling water flows from the external circulation path 575 into the cooling water passage 545, the switch module 532A is arranged on the upstream side near the inlet passage 571 of the cooling water passage 545, and the condenser module 532B is connected to the switch module 532A. It is configured to be arranged on the downstream side. In this case, assuming that the temperature of the cooling water flowing through the cooling water passage 545 is lower toward the upstream side, it is possible to realize a configuration in which the switch module 532A is preferentially cooled.
　周方向に隣り合う電気モジュール同士の間隔を一部で拡げ、その拡げた間隔（第２間隔ＩＮＴ２）となる部分に、入口通路５７１及び出口通路５７２を有する突出部５７３を設ける構成とした。これにより、外側周壁ＷＡ１の径方向内側となる部分に、冷却水通路５４５の入口通路５７１及び出口通路５７２を好適に形成することができる。つまり、冷却性能を高めるには冷媒の流通量を確保する必要があり、そのためには入口通路５７１及び出口通路５７２の開口面積を大きくすることが考えられる。この点、上記のとおり電気モジュール同士の間隔を一部で拡げて突出部５７３を設けることにより、所望とする大きさの入口通路５７１及び出口通路５７２を好適に形成することができる。 (4) The interval between the electric modules adjacent to each other in the circumferential direction is partially increased, and a protruding portion 573 having an inlet passage 571 and an outlet passage 572 is provided in a portion corresponding to the expanded interval (second interval INT2). Thus, the inlet passage 571 and the outlet passage 572 of the cooling water passage 545 can be suitably formed in a portion that is radially inward of the outer peripheral wall WA1. That is, in order to enhance the cooling performance, it is necessary to secure a circulation amount of the refrigerant, and for that purpose, it is conceivable to increase the opening areas of the inlet passage 571 and the outlet passage 572. In this regard, as described above, by providing the projecting portion 573 by partially expanding the interval between the electric modules, the entrance passage 571 and the exit passage 572 having desired sizes can be suitably formed.
　バスバーモジュール５３３の外部接続端子６３２を、外側周壁ＷＡ１の径方向内側において突出部５７３に径方向に並ぶ位置に配置するようにした。つまり、外部接続端子６３２を、周方向に隣り合う電気モジュール同士の間隔が拡げられた部分（第２間隔ＩＮＴ２に相当する部分）に突出部５７３と共に配置するようにした。これにより、各電気モジュール５３２との干渉を避けつつ、外部接続端子６３２を好適に配置することができる。 (4) The external connection terminals 632 of the bus bar module 533 are arranged at positions radially in line with the protruding portions 573 on the radially inner side of the outer peripheral wall WA1. That is, the external connection terminals 632 are arranged together with the protruding portions 573 at portions where the space between the electric modules adjacent in the circumferential direction is increased (a portion corresponding to the second space INT2). Thereby, the external connection terminals 632 can be suitably arranged while avoiding interference with each electric module 532.
　アウタロータ式の回転電機５００において、外側周壁ＷＡ１の径方向外側に固定子５２０を固定し、かつ径方向内側に複数の電気モジュール５３２を配置する構成とした。これにより、外側周壁ＷＡ１に対して、その径方向外側から固定子５２０の熱が伝わるとともに、径方向内側から電気モジュール５３２の熱が伝わることになる。この場合、固定子５２０と電気モジュール５３２とを，冷却水通路５４５を流れる冷却水により同時に冷やすことが可能となり、回転電機５００における発熱部材の熱を効率良く放出することができる。 In the outer rotor type rotary electric machine 500, the stator 520 is fixed radially outside the outer peripheral wall WA1, and a plurality of electric modules 532 are arranged radially inside. Thus, the heat of the stator 520 is transmitted to the outer peripheral wall WA1 from the radial outside, and the heat of the electric module 532 is transmitted from the radial inner side. In this case, the stator 520 and the electric module 532 can be simultaneously cooled by the cooling water flowing through the cooling water passage 545, and the heat of the heat generating member in the rotating electric machine 500 can be efficiently released.
　外側周壁ＷＡ１を挟んで径方向内側の電気モジュール５３２と径方向外側の固定子巻線５２１とを、バスバーモジュール５３３の巻線接続端子６３３により電気的に接続する構成とした。またこの場合、巻線接続端子６３３を、冷却水通路５４５に対して軸方向に離れた位置に設ける構成とした。これにより、外側周壁ＷＡ１において環状に冷却水通路５４５が形成される構成、すなわち外側周壁ＷＡ１の内外が冷却水通路５４５により分断されている構成であっても、電気モジュール５３２と固定子巻線５２１とを好適に接続することができる。 (4) The electric module 532 on the radially inner side and the stator winding 521 on the radially outer side with the outer peripheral wall WA1 interposed therebetween are electrically connected by the winding connection terminals 633 of the bus bar module 533. In this case, the winding connection terminal 633 is provided at a position axially separated from the cooling water passage 545. Accordingly, even if the cooling water passage 545 is formed in an annular shape in the outer peripheral wall WA1, that is, even if the inside and the outside of the outer peripheral wall WA1 are separated by the cooling water passage 545, the electric module 532 and the stator winding 521 are formed. Can be suitably connected.
　本実施形態の回転電機５００では、固定子５２０において周方向に並ぶ各導線５２３の間のティース（鉄心）を小さくする又は無くすことで、それら各導線５２３の間で生じる磁気飽和に起因するトルク制限を抑制するとともに、導線５２３を扁平薄型にすることでトルク低下を抑制するものとしている。この場合、仮に回転電機５００の外径寸法が同じであっても、固定子５２０の薄型化により磁気回路部の径方向内側の領域を拡張することが可能となり、その内側領域を用いて、冷却水通路５４５を有する外側周壁ＷＡ１や、外側周壁ＷＡ１の径方向内側に設けられた複数の電気モジュール５３２を好適に配置することができる。 In the rotating electric machine 500 of the present embodiment, by reducing or eliminating the teeth (iron core) between the conductors 523 arranged in the circumferential direction on the stator 520, torque limitation caused by magnetic saturation occurring between the conductors 523 is reduced. And suppress the torque reduction by making the conducting wire 523 flat and thin. In this case, even if the outer diameter of the rotating electric machine 500 is the same, it is possible to expand the radially inner region of the magnetic circuit unit by making the stator 520 thinner, and use the inner region to perform cooling. The outer peripheral wall WA1 having the water passage 545 and the plurality of electric modules 532 provided radially inside the outer peripheral wall WA1 can be suitably arranged.
　本実施形態の回転電機５００では、磁石ユニット５１２において磁石磁束がｄ軸側に集まることでｄ軸での磁石磁束が強化され、それに伴うトルク増強が可能となっている。この場合、磁石ユニット５１２において径方向の厚さ寸法の縮小化（薄型化）が可能になることに伴い、磁気回路部の径方向内側の領域を拡張することが可能となり、その内側領域を用いて、冷却水通路５４５を有する外側周壁ＷＡ１や、外側周壁ＷＡ１の径方向内側に設けられた複数の電気モジュール５３２を好適に配置することができる。 In the rotating electric machine 500 of the present embodiment, the magnet flux in the magnet unit 512 is concentrated on the d-axis side so that the magnet flux in the d-axis is strengthened, and the torque can be increased accordingly. In this case, since the radial thickness of the magnet unit 512 can be reduced (thinned), the radially inner region of the magnetic circuit unit can be expanded, and the inner region is used. Thus, the outer peripheral wall WA1 having the cooling water passage 545 and the plurality of electric modules 532 provided radially inside the outer peripheral wall WA1 can be suitably arranged.
　また、磁気回路部、外側周壁ＷＡ１、複数の電気モジュール５３２だけでなく、軸受５６０やレゾルバ６６０についても同様に、径方向に好適に配置することができる。 Also, not only the magnetic circuit portion, the outer peripheral wall WA1, and the plurality of electric modules 532, but also the bearing 560 and the resolver 660 can be suitably arranged in the radial direction.
　回転電機５００をインホイールモータとして用いた車輪４００は、インバータハウジング５３１に固定されたベースプレート４０５と、サスペンション装置等の装着機構とを介して車体に装着される。ここで、回転電機５００では小型化が実現されていることから、車体への組み付けを想定しても省スペース化が可能となる。そのため、車両においてバッテリ等の電源装置の設置領域を拡大したり、車室スペースを拡張したりする上で有利な構成を実現できる。 The wheel 400 using the rotating electric machine 500 as an in-wheel motor is mounted on the vehicle body via a base plate 405 fixed to the inverter housing 531 and a mounting mechanism such as a suspension device. Here, since the rotating electric machine 500 is downsized, it is possible to save space even when assembling to a vehicle body. Therefore, it is possible to realize an advantageous configuration for expanding the installation area of a power supply device such as a battery in a vehicle or expanding the cabin space.
　以下に、インホイールモータに関する変形例を説明する。 Hereinafter, a modification of the in-wheel motor will be described.
　（インホイールモータにおける変形例１）
　回転電機５００では、インバータユニット５３０の外側周壁ＷＡ１の径方向内側に、電気モジュール５３２及びバスバーモジュール５３３が配置されるとともに、外側周壁ＷＡ１を隔てて径方向の内側及び外側に、電気モジュール５３２及びバスバーモジュール５３３と、固定子５２０とがそれぞれ配置されている。かかる構成において、電気モジュール５３２に対するバスバーモジュール５３３の位置は任意に設定可能である。また、外側周壁ＷＡ１を径方向に横切って固定子巻線５２１の各相巻線とバスバーモジュール５３３とを接続する場合において、その接続に用いられる巻線接続線（例えば巻線接続端子６３３）を案内する位置は任意に設定可能である。 (Modification 1 of in-wheel motor)
In the rotary electric machine 500, the electric module 532 and the bus bar module 533 are arranged radially inside the outer peripheral wall WA1 of the inverter unit 530, and the electric module 532 and the bus bar are arranged radially inward and outward across the outer peripheral wall WA1. A module 533 and a stator 520 are arranged, respectively. In such a configuration, the position of the bus bar module 533 with respect to the electric module 532 can be arbitrarily set. When connecting each phase winding of the stator winding 521 to the bus bar module 533 across the outer peripheral wall WA1 in the radial direction, a winding connection line (for example, a winding connection terminal 633) used for the connection is connected. The guidance position can be set arbitrarily.
　すなわち、電気モジュール５３２に対するバスバーモジュール５３３の位置としては、（α１）バスバーモジュール５３３を、軸方向において電気モジュール５３２よりも車両外側、すなわち回転子キャリア５１１側の奥側とする構成と、
（α２）バスバーモジュール５３３を、軸方向において電気モジュール５３２よりも車両内側、すなわち回転子キャリア５１１側の手前側とする構成と、
が考えられる。 That is, the position of the bus bar module 533 with respect to the electric module 532 is (α1) such that the bus bar module 533 is located outside the electric module 532 in the axial direction, that is, on the rotor carrier 511 side,
(Α2) a configuration in which the bus bar module 533 is located on the vehicle inner side of the electric module 532 in the axial direction, that is, on the front side on the rotor carrier 511 side;
Can be considered.
　また、巻線接続線を案内する位置としては、
（β１）巻線接続線を、軸方向において車両外側、すなわち回転子キャリア５１１側の奥側で案内する構成と、
（β２）巻線接続線を、軸方向において車両内側、すなわち回転子キャリア５１１側の手前側で案内する構成と、
が考えられる。 Also, as the position for guiding the winding connection line,
(Β1) a configuration in which the winding connection line is guided on the vehicle outside in the axial direction, that is, on the back side on the rotor carrier 511 side;
(Β2) a configuration in which the winding connection line is guided on the vehicle inside in the axial direction, that is, on the near side of the rotor carrier 511 side;
Can be considered.
　以下には、電気モジュール５３２、バスバーモジュール５３３及び巻線接続線の配置に関する４つの構成例を、図７２（ａ）～（ｄ）を用いて説明する。図７２（ａ）～（ｄ）は、回転電機５００の構成を簡略化して示す縦断面図であり、同図には、既に説明した構成に同じ符号が付されている。巻線接続線６３７は、固定子巻線５２１の各相巻線とバスバーモジュール５３３とを接続する電気配線であり、例えば既述の巻線接続端子６３３がこれに相当する。 (4) Four configuration examples regarding the arrangement of the electric module 532, the bus bar module 533, and the winding connection line will be described below with reference to FIGS. 72 (a) to 72 (d). FIGS. 72A to 72D are simplified longitudinal sectional views showing the configuration of the rotating electric machine 500. In FIG. 72, the same reference numerals are given to the already described components. The winding connection line 637 is an electric wiring that connects each phase winding of the stator winding 521 to the bus bar module 533, and corresponds to, for example, the winding connection terminal 633 described above.
　図７２（ａ）の構成では、電気モジュール５３２に対するバスバーモジュール５３３の位置として上記（α１）を採用するとともに、巻線接続線６３７を案内する位置として上記（β１）を採用している。つまり、電気モジュール５３２及びバスバーモジュール５３３、固定子巻線５２１及びバスバーモジュール５３３がいずれも車両外側（回転子キャリア５１１の奥側）で接続される構成となっている。なおこれは、図４９に示す構成に相当する。 構成 In the configuration of FIG. 72A, (α1) is employed as the position of the bus bar module 533 with respect to the electric module 532, and (β1) is employed as the position for guiding the winding connection line 637. That is, the electric module 532 and the bus bar module 533, the stator winding 521, and the bus bar module 533 are all connected outside the vehicle (on the rear side of the rotor carrier 511). This corresponds to the configuration shown in FIG.
　本構成によれば、外側周壁ＷＡ１において、巻線接続線６３７との干渉を懸念することなく冷却水通路５４５を設けることができる。また、固定子巻線５２１とバスバーモジュール５３３とを接続する巻線接続線６３７を簡易に実現できる。 According to this configuration, the cooling water passage 545 can be provided on the outer peripheral wall WA1 without fear of interference with the winding connection line 637. Further, the winding connection line 637 connecting the stator winding 521 and the bus bar module 533 can be easily realized.
　図７２（ｂ）の構成では、電気モジュール５３２に対するバスバーモジュール５３３の位置として上記（α１）を採用するとともに、巻線接続線６３７を案内する位置として上記（β２）を採用している。つまり、電気モジュール５３２とバスバーモジュール５３３とが車両外側（回転子キャリア５１１の奥側）で接続されるとともに、固定子巻線５２１とバスバーモジュール５３３とが車両内側（回転子キャリア５１１の手前側）で接続される構成となっている。 72 (b), (α1) is used as the position of the bus bar module 533 with respect to the electric module 532, and (β2) is used as the position for guiding the winding connection line 637. That is, the electric module 532 and the bus bar module 533 are connected outside the vehicle (the back side of the rotor carrier 511), and the stator winding 521 and the bus bar module 533 are connected inside the vehicle (the front side of the rotor carrier 511). It is configured to be connected by.
　本構成によれば、外側周壁ＷＡ１において、巻線接続線６３７との干渉を懸念することなく冷却水通路５４５を設けることができる。 According to this configuration, the cooling water passage 545 can be provided on the outer peripheral wall WA1 without fear of interference with the winding connection line 637.
　図７２（ｃ）の構成では、電気モジュール５３２に対するバスバーモジュール５３３の位置として上記（α２）を採用するとともに、巻線接続線６３７を案内する位置として上記（β１）を採用している。つまり、電気モジュール５３２とバスバーモジュール５３３とが車両内側（回転子キャリア５１１の手前側）で接続されるとともに、固定子巻線５２１とバスバーモジュール５３３とが車両外側（回転子キャリア５１１の奥側）で接続される構成となっている。 72 (c), the position (α2) is used as the position of the bus bar module 533 with respect to the electric module 532, and the position (β1) is used as the position for guiding the winding connection line 637. That is, the electric module 532 and the bus bar module 533 are connected inside the vehicle (front side of the rotor carrier 511), and the stator winding 521 and the bus bar module 533 are connected outside the vehicle (rear side of the rotor carrier 511). It is configured to be connected by.
　図７２（ｄ）の構成では、電気モジュール５３２に対するバスバーモジュール５３３の位置として上記（α２）を採用するとともに、巻線接続線６３７を案内する位置として上記（β２）を採用している。つまり、電気モジュール５３２及びバスバーモジュール５３３、固定子巻線５２１及びバスバーモジュール５３３がいずれも車両内側（回転子キャリア５１１の手前側）で接続される構成となっている。 72 (d), the above (α2) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above (β2) is adopted as the position for guiding the winding connection line 637. That is, the electric module 532 and the busbar module 533, the stator winding 521, and the busbar module 533 are all connected inside the vehicle (on the front side of the rotor carrier 511).
　図７２（ｃ）、図７２（ｄ）の構成によれば、バスバーモジュール５３３が車両内側（回転子キャリア５１１の手前側）に配置されることで、仮にファンモータなどの電気部品を追加しようとする場合に、その配線が容易となることが考えられる。また、軸受よりも車両内側に配置されるレゾルバ６６０に対してバスバーモジュール５３３を近づけることが可能になり、レゾルバ６６０に対する配線が容易になることも考えられる。 According to the configuration of FIGS. 72 (c) and 72 (d), the bus bar module 533 is disposed inside the vehicle (on the front side of the rotor carrier 511), so that an attempt is made to temporarily add an electric component such as a fan motor. In such a case, the wiring may be facilitated. In addition, the bus bar module 533 can be brought closer to the resolver 660 disposed on the vehicle inner side than the bearing, and wiring to the resolver 660 may be facilitated.
　（インホイールモータにおける変形例２）
　以下に、レゾルバロータ６６１の取付構造の変形例を説明する。すなわち、回転軸５０１、回転子キャリア５１１及び軸受５６０の内輪５６１は一体的に回転する回転体であり、その回転体に対するレゾルバロータ６６１の取付構造の変形例について以下に説明する。 (Modification 2 of in-wheel motor)
Hereinafter, a modified example of the mounting structure of the resolver rotor 661 will be described. That is, the rotating shaft 501, the rotor carrier 511, and the inner ring 561 of the bearing 560 are a rotating body that rotates integrally, and a modified example of the mounting structure of the resolver rotor 661 to the rotating body will be described below.
　図７３（ａ）～（ｃ）は、上記回転体に対するレゾルバロータ６６１の取付構造例を示す構成図である。いずれの構成においても、レゾルバ６６０は、回転子キャリア５１１及びインバータハウジング５３１等により囲まれ、外部からの被水や被泥等から防護された密閉空間に設けられている。図７３（ａ）～（ｃ）のうち図７３（ａ）では、軸受５６０を、図４９と同じ構成としている。また、図７３（ｂ）、図７３（ｃ）では、軸受５６０を、図４９とは異なる構成とし、かつ回転子キャリア５１１の端板５１４から離れた位置に配置している。これら各図には、レゾルバロータ６６１の取付場所としてそれぞれ２カ所を例示している。なお、レゾルバステータ６６２については図示されていないが、例えばボス形成部材５４３のボス部５４８をレゾルバロータ６６１の外周側又はその付近まで延ばし、そのボス部５４８にレゾルバステータ６６２が固定されていればよい。 FIGS. 73A to 73C are configuration diagrams showing an example of a mounting structure of the resolver rotor 661 to the rotating body. In any of the configurations, the resolver 660 is provided in a closed space surrounded by the rotor carrier 511, the inverter housing 531 and the like, and protected from external water or mud. 73 (a) of FIGS. 73 (a) to 73 (c), the bearing 560 has the same configuration as that of FIG. Further, in FIGS. 73 (b) and 73 (c), the bearing 560 has a different configuration from that of FIG. 49 and is arranged at a position away from the end plate 514 of the rotor carrier 511. In each of these figures, two locations are illustrated as mounting locations of the resolver rotor 661. Although the resolver stator 662 is not shown, for example, the boss 548 of the boss forming member 543 may be extended to the outer peripheral side of the resolver rotor 661 or in the vicinity thereof, and the resolver stator 662 may be fixed to the boss 548. .
　図７３（ａ）の構成では、軸受５６０の内輪５６１にレゾルバロータ６６１が取り付けられている。具体的には、レゾルバロータ６６１が、内輪５６１のフランジ５６１ｂの軸方向端面に設けられているか、又は内輪５６１の筒部５６１ａの軸方向端面に設けられている。 で は In the configuration of FIG. 73A, the resolver rotor 661 is attached to the inner ring 561 of the bearing 560. Specifically, the resolver rotor 661 is provided on the axial end face of the flange 561b of the inner race 561, or is provided on the axial end face of the cylindrical portion 561a of the inner race 561.
　図７３（ｂ）の構成では、回転子キャリア５１１にレゾルバロータ６６１が取り付けられている。具体的には、レゾルバロータ６６１が、回転子キャリア５１１において端板５１４の内面に設けられている。又は、回転子キャリア５１１が、端板５１４の内周縁部から回転軸５０１に沿って延びる筒部５１５を有する構成において、レゾルバロータ６６１が、回転子キャリア５１１の筒部５１５の外周面に設けられている。後者の場合、レゾルバロータ６６１は、回転子キャリア５１１の端板５１４と軸受５６０との間に配置されている。 で は In the configuration of FIG. 73 (b), the resolver rotor 661 is attached to the rotor carrier 511. Specifically, a resolver rotor 661 is provided on the inner surface of the end plate 514 in the rotor carrier 511. Alternatively, in a configuration in which the rotor carrier 511 has the cylindrical portion 515 extending along the rotation axis 501 from the inner peripheral edge of the end plate 514, the resolver rotor 661 is provided on the outer peripheral surface of the cylindrical portion 515 of the rotor carrier 511. ing. In the latter case, the resolver rotor 661 is disposed between the end plate 514 of the rotor carrier 511 and the bearing 560.
　図７３（ｃ）の構成では、回転軸５０１にレゾルバロータ６６１が取り付けられている。具体的には、レゾルバロータ６６１が、回転軸５０１において回転子キャリア５１１の端板５１４と軸受５６０との間に設けられているか、又は回転軸５０１において軸受５６０を挟んで回転子キャリア５１１の反対側に配置されている。 で は In the configuration of FIG. 73 (c), the resolver rotor 661 is attached to the rotating shaft 501. Specifically, the resolver rotor 661 is provided between the end plate 514 of the rotor carrier 511 and the bearing 560 on the rotating shaft 501, or the resolver rotor 661 is opposite to the rotor carrier 511 across the bearing 560 on the rotating shaft 501. Located on the side.
　（インホイールモータにおける変形例３）
　以下に、インバータハウジング５３１及び回転子カバー６７０の変形例を図７４を用いて説明する。図７４（ａ）、図７４（ｂ）は、回転電機５００の構成を簡略化して示す縦断面図であり、同図には、既に説明した構成に同じ符号が付されている。なお、図７４（ａ）に示す構成は、実質的に図４９等で説明した構成に相当し、図７４（ｂ）に示す構成は、図７４（ａ）の構成の一部を変更した構成に相当する。 (Modification 3 of in-wheel motor)
Hereinafter, a modified example of the inverter housing 531 and the rotor cover 670 will be described with reference to FIG. FIGS. 74A and 74B are simplified longitudinal sectional views showing the configuration of the rotating electric machine 500, and the same reference numerals are given to the already described components in FIG. The configuration illustrated in FIG. 74A substantially corresponds to the configuration described in FIG. 49 and the like, and the configuration illustrated in FIG. 74B is a configuration in which a part of the configuration illustrated in FIG. Is equivalent to
　図７４（ａ）に示す構成では、回転子キャリア５１１の開放端部に固定された回転子カバー６７０が、インバータハウジング５３１の外側周壁ＷＡ１を囲むように設けられている。つまり、回転子カバー６７０の内径側の端面が外側周壁ＷＡ１の外周面に対向しており、それら両者の間にシール材６７１が設けられている。また、インバータハウジング５３１のボス部５４８の中空部にはハウジングカバー６６６が取り付けられ、そのハウジングカバー６６６と回転軸５０１との間にシール材６６７が設けられている。バスバーモジュール５３３を構成する外部接続端子６３２は、インバータハウジング５３１を貫通して車両内側（図の下側）に延びている。 In the configuration shown in FIG. 74A, the rotor cover 670 fixed to the open end of the rotor carrier 511 is provided so as to surround the outer peripheral wall WA1 of the inverter housing 531. That is, the end surface on the inner diameter side of the rotor cover 670 faces the outer peripheral surface of the outer peripheral wall WA1, and the sealing material 671 is provided between the both. A housing cover 666 is attached to a hollow portion of the boss 548 of the inverter housing 531, and a seal member 667 is provided between the housing cover 666 and the rotating shaft 501. The external connection terminals 632 constituting the bus bar module 533 extend through the inverter housing 531 to the inside of the vehicle (the lower side in the figure).
　また、インバータハウジング５３１には、冷却水通路５４５に連通する入口通路５７１及び出口通路５７２が形成されるとともに、それら入口通路５７１及び出口通路５７２の通路端部を含む水路ポート５７４が形成されている。 In addition, an inlet passage 571 and an outlet passage 572 communicating with the cooling water passage 545 are formed in the inverter housing 531, and a water passage port 574 including the passage ends of the inlet passage 571 and the outlet passage 572 is formed. .
　これに対して、図７４（ｂ）に示す構成では、インバータハウジング５３１（詳しくはボス形成部材５４３）に、回転軸５０１の突出側（車両内側）に延びる環状の凸部６８１が形成されており、回転子カバー６７０が、インバータハウジング５３１の凸部６８１を囲むように設けられている。つまり、回転子カバー６７０の内径側の端面が凸部６８１の外周面に対向しており、それら両者の間にシール材６７１が設けられている。また、バスバーモジュール５３３を構成する外部接続端子６３２は、インバータハウジング５３１のボス部５４８を貫通してボス部５４８の中空領域に延びるとともに、ハウジングカバー６６６を貫通して車両内側（図の下側）に延びている。 On the other hand, in the configuration shown in FIG. 74 (b), an annular convex portion 681 is formed on the inverter housing 531 (specifically, the boss forming member 543) so as to extend on the protruding side of the rotary shaft 501 (inside the vehicle). , A rotor cover 670 is provided so as to surround the protrusion 681 of the inverter housing 531. That is, the end surface on the inner diameter side of the rotor cover 670 faces the outer peripheral surface of the convex portion 681, and the sealing material 671 is provided between them. The external connection terminals 632 constituting the bus bar module 533 extend through the boss portion 548 of the inverter housing 531 into the hollow region of the boss portion 548, and penetrate the housing cover 666 to the inside of the vehicle (the lower side in the figure). Extends to.
　また、インバータハウジング５３１には、冷却水通路５４５に連通する入口通路５７１及び出口通路５７２が形成されており、それら入口通路５７１及び出口通路５７２は、ボス部５４８の中空領域に延び、かつ中継配管６８２を介してハウジングカバー６６６よりも車両内側（図の下側）に延びている。本構成では、ハウジングカバー６６６から車両内側に延びる配管部分が水路ポート５７４となっている。 In addition, an inlet passage 571 and an outlet passage 572 that communicate with the cooling water passage 545 are formed in the inverter housing 531, and the inlet passage 571 and the outlet passage 572 extend to a hollow region of the boss 548, and It extends to the inside of the vehicle (the lower side in the figure) from the housing cover 666 via the 682. In this configuration, a pipe portion extending from the housing cover 666 to the inside of the vehicle is a water channel port 574.
　図７４（ａ）、図７４（ｂ）の各構成によれば、回転子キャリア５１１及び回転子カバー６７０の内部空間の密閉性を保持しつつ、これら回転子キャリア５１１及び回転子カバー６７０をインバータハウジング５３１に対して好適に回転させることができる。 According to the respective configurations of FIGS. 74A and 74B, the rotor carrier 511 and the rotor cover 670 are connected to the inverter while maintaining the hermeticity of the inner space of the rotor carrier 511 and the rotor cover 670. The housing 531 can be suitably rotated.
　また特に、図７４（ｂ）の構成によれば、図７４（ａ）の構成に比べて、回転子カバー６７０の内径が小さくなっている。そのため、電気モジュール５３２よりも車両内側となる位置に、インバータハウジング５３１と回転子カバー６７０とが軸方向に二重に設けられるようになり、電気モジュール５３２にて懸念される電磁ノイズによる不都合を抑制することができる。また、回転子カバー６７０の内径を小さくすることによりシール材６７１の摺動径が小さくなり、回転摺動部分における機械的ロスを抑制することができる。 In particular, according to the configuration of FIG. 74 (b), the inner diameter of the rotor cover 670 is smaller than that of the configuration of FIG. 74 (a). Therefore, the inverter housing 531 and the rotor cover 670 are provided in the axial direction doubly at a position inside the vehicle with respect to the electric module 532, and the inconvenience due to electromagnetic noise that is a concern in the electric module 532 is suppressed. can do. In addition, by reducing the inner diameter of the rotor cover 670, the sliding diameter of the sealing material 671 is reduced, so that mechanical loss at the rotating sliding portion can be suppressed.
　（インホイールモータにおける変形例４）
　以下に、固定子巻線５２１の変形例を説明する。図７５に、固定子巻線５２１に関する変形例を示す。 (Modification 4 of in-wheel motor)
Hereinafter, a modified example of the stator winding 521 will be described. FIG. 75 shows a modification of the stator winding 521.
　図７５に示すように、固定子巻線５２１は、横断面が矩形状をなす導線材を用い、その導線材の長辺が周方向に延びる向きにして波巻により巻回されている。この場合、固定子巻線５２１においてコイルサイドとなる各相の導線５２３は、相ごとに所定ピッチ間隔で配置されるとともに、コイルエンドで互いに接続されている。コイルサイドにおいて周方向に隣り合う各導線５２３は、周方向の端面同士が互いに当接するか、又は微小な間隔を隔てて近接配置されている。 固定 As shown in FIG. 75, the stator winding 521 is made of a conductive wire having a rectangular cross section, and is wound by wave winding with the long side of the conductive wire extending in the circumferential direction. In this case, the conductors 523 of each phase, which become the coil side in the stator winding 521, are arranged at a predetermined pitch interval for each phase and are connected to each other at the coil end. The conductors 523 that are adjacent to each other in the circumferential direction on the coil side have circumferential end faces that abut against each other or are arranged close to each other with a small interval.
　また、固定子巻線５２１では、コイルエンドにおいて相ごとに導線材が径方向に折り曲げられている。より詳しくは、固定子巻線５２１（導線材）は、軸方向において相ごとに異なる位置にて径方向内側に折り曲げられており、これにより、Ｕ相、Ｖ相及びＷ相の各相巻線における互いの干渉が回避されている。図示の構成では、各相巻線で導線材の厚み分だけ異ならせて、相ごとに導線材が径方向内側に直角に折り曲げられている。周方向に並ぶ各導線５２３において軸方向の両端間の長さ寸法は各導線５２３で同じであるとよい。 In the stator winding 521, the conductive wire is bent in the radial direction in each phase at the coil end. More specifically, the stator winding 521 (conductive wire) is bent radially inward at different positions in the axial direction for each phase, whereby the U-phase, V-phase, and W-phase windings are formed. Are avoided. In the illustrated configuration, the conductors are bent radially inward at right angles for each phase, with the phases differing by the thickness of the conductors in each phase winding. In each of the conductors 523 arranged in the circumferential direction, the length between both ends in the axial direction may be the same.
　なお、固定子巻線５２１に固定子コア５２２を組み付けて固定子５２０を製作する際には、固定子巻線５２１において円環状の一部を非接続として切り離しておき（すなわち、固定子巻線５２１を略Ｃ字状にしておき）、固定子巻線５２１の内周側に固定子コア５２２を組み付けた後に、切り離し部分を互いに接続させて固定子巻線５２１を円環状にするとよい。 When the stator 520 is manufactured by assembling the stator core 522 with the stator winding 521, a part of the annular shape in the stator winding 521 is disconnected and disconnected (that is, the stator winding 521 is used). After the stator core 522 is assembled on the inner peripheral side of the stator winding 521, the separated portions may be connected to each other to form the stator winding 521 in an annular shape.
　上記以外に、固定子コア５２２を周方向にて複数（例えば３つ以上）に分割しておき、円環状に形成された固定子巻線５２１の内周側に、複数に分割されたコア片を組み付けるようにすることも可能である。 In addition to the above, the stator core 522 is divided into a plurality (for example, three or more) in the circumferential direction, and the plurality of divided core pieces are provided on the inner peripheral side of the stator winding 521 formed in an annular shape. Can be assembled.
　（他の変形例）
　・例えば図５０に示すように、回転電機５００では、冷却水通路５４５の入口通路５７１と出口通路５７２とが一カ所にまとめて設けられているが、この構成を変更し、入口通路５７１と出口通路５７２とが周方向に異なる位置にそれぞれ設けられていてもよい。例えば、入口通路５７１と出口通路５７２とを周方向に１８０度異なる位置に設ける構成や、入口通路５７１及び出口通路５７２の少なくともいずれかを複数設ける構成であってもよい。 (Other modifications)
For example, as shown in FIG. 50, in the rotating electric machine 500, the inlet passage 571 and the outlet passage 572 of the cooling water passage 545 are provided at one place, but this configuration is changed so that the inlet passage 571 and the outlet The passage 572 and the passage 572 may be provided at different positions in the circumferential direction. For example, a configuration in which the entrance passage 571 and the exit passage 572 are provided at positions different by 180 degrees in the circumferential direction, or a configuration in which at least one of the entrance passage 571 and the exit passage 572 is provided in plurality may be employed.
　・上記実施形態の車輪４００では、回転電機５００の軸方向の片側に回転軸５０１を突出させる構成としたが、これを変更し、軸方向の両方に回転軸５０１を突出させる構成としてもよい。これにより、例えば車両前後の少なくとも一方が１輪となる車両において好適な構成を実現できる。 In the wheel 400 of the above embodiment, the rotating shaft 501 is configured to protrude on one side in the axial direction of the rotating electric machine 500. However, this may be changed, and the rotating shaft 501 may be configured to protrude in both axial directions. Thereby, for example, a preferable configuration can be realized in a vehicle in which at least one of the front and rear sides of the vehicle has one wheel.
　・車輪４００に用いられる回転電機５００として、インナロータ式の回転電機を用いることも可能である。 As the rotating electric machine 500 used for the wheel 400, an inner rotor type rotating electric machine can be used.
　（変形例１５）
　次に、本変形例における回転電機７００について説明する。回転電機７００は、例えば車両の駆動用ユニットとして用いられる。回転電機７００の概要を図７６～図７８に示す。図７６は、回転電機７００の要部全体を示す正面図であり、図７７は、回転電機７００の縦断面図であり、図７８は、回転電機７００の構成要素を分解して示す分解断面図である。 (Modification 15)
Next, the rotating electric machine 700 according to the present modification will be described. The rotating electric machine 700 is used, for example, as a driving unit of a vehicle. The outline of the rotating electric machine 700 is shown in FIGS. FIG. 76 is a front view showing the entire main part of rotating electric machine 700, FIG. 77 is a longitudinal sectional view of rotating electric machine 700, and FIG. 78 is an exploded sectional view showing components of rotating electric machine 700 in an exploded manner. It is.
　回転電機７００は、アウタロータ式の表面磁石型回転電機である。回転電機７００は、大別して、回転子７１０、固定子７２０及び固定子ホルダ７６０を有する回転電機本体を備えている。なお、回転電機７００では、ハウジングに収容された状態で回転電機本体が設けられているが、ここではハウジングの図示を省略している。回転電機本体の各部材はいずれも、回転子７１０に一体に設けられた回転軸７０１に対して同軸に配置されており、所定順序で軸方向に組み付けられることで回転電機７００が構成されている。回転軸７０１は、固定子ホルダ７６０の径方向内側に設けられた一対の軸受７０２，７０３により回転可能に支持されている。回転軸７０１の回転により、例えば車両の車軸が回転する。回転電機７００は、固定子ホルダ７６０が車体フレーム等に固定されることにより車両に搭載可能となっている。 The rotating electric machine 700 is an outer rotor type surface magnet type rotating electric machine. The rotating electric machine 700 is roughly provided with a rotating electric machine main body having a rotor 710, a stator 720, and a stator holder 760. In the rotating electric machine 700, the rotating electric machine main body is provided in a state housed in the housing, but the illustration of the housing is omitted here. Each member of the rotating electrical machine main body is coaxially arranged with respect to a rotating shaft 701 provided integrally with the rotor 710, and is assembled in a predetermined order in the axial direction to configure the rotating electrical machine 700. . The rotating shaft 701 is rotatably supported by a pair of bearings 702 and 703 provided inside the stator holder 760 in the radial direction. The rotation of the rotating shaft 701 causes, for example, the axle of the vehicle to rotate. The rotating electric machine 700 can be mounted on a vehicle by fixing the stator holder 760 to a vehicle body frame or the like.
　回転電機７００において、回転子７１０及び固定子７２０はそれぞれ円筒状をなしており、エアギャップを挟んで径方向に対向配置されている。回転子７１０が回転軸７０１と共に一体回転することにより、固定子７２０の径方向外側にて回転子７１０が回転する。回転子７１０が「界磁子」に相当し、固定子７２０が「電機子」に相当する。 In the rotating electric machine 700, the rotor 710 and the stator 720 each have a cylindrical shape, and are arranged radially opposite each other with an air gap therebetween. When the rotor 710 rotates integrally with the rotation shaft 701, the rotor 710 rotates radially outside the stator 720. The rotor 710 corresponds to a “field element”, and the stator 720 corresponds to an “armature”.
　回転子７１０は、略円筒状の回転子キャリア７１１と、その回転子キャリア７１１に固定された環状の磁石ユニット７１２とを有している。回転子キャリア７１１は、円筒状をなす筒状部７１３と、その筒状部７１３の軸方向一端に設けられた端板部７１４とを有しており、それらが一体化されることで構成されている。例えば、端板部７１４の外縁部に、軸方向に延びる環状の起立部７１４ａを設け、その起立部７１４ａに対して筒状部７１３が固定されているとよい。なお、筒状部７１３と端板部７１４とを別体でなく、一体成形物とすることも可能である。 The rotor 710 has a substantially cylindrical rotor carrier 711 and an annular magnet unit 712 fixed to the rotor carrier 711. The rotor carrier 711 has a cylindrical portion 713 having a cylindrical shape, and an end plate portion 714 provided at one axial end of the cylindrical portion 713, and is configured by integrating them. ing. For example, an annular upright portion 714a extending in the axial direction may be provided at the outer edge of the end plate portion 714, and the tubular portion 713 may be fixed to the upright portion 714a. Note that the cylindrical portion 713 and the end plate portion 714 can be formed as an integral product instead of being separate bodies.
　回転子キャリア７１１は、磁石保持部材として機能し、筒状部７１３の径方向内側に環状に磁石ユニット７１２が固定されている。端板部７１４の中央部には貫通孔７１４ｂが形成されており、その貫通孔７１４ｂに挿通された状態で、図示しないボルト等の締結具により端板部７１４に回転軸７０１が固定されている。回転軸７０１は、軸方向に交差（直交）する向きに延びるフランジ７０１ａを有しており、そのフランジ７０１ａと端板部７１４とが面接合されている状態で、回転軸７０１に回転子キャリア７１１が固定されている。 The rotor carrier 711 functions as a magnet holding member, and the magnet unit 712 is fixed to the inside of the cylindrical portion 713 in the radial direction in a ring shape. A through hole 714b is formed at the center of the end plate portion 714, and the rotating shaft 701 is fixed to the end plate portion 714 by a fastener such as a bolt (not shown) in a state of being inserted through the through hole 714b. . The rotating shaft 701 has a flange 701a extending in a direction crossing (orthogonal to) the axial direction, and the rotor carrier 711 is attached to the rotating shaft 701 in a state where the flange 701a and the end plate portion 714 are surface-joined. Has been fixed.
　磁石ユニット７１２は、回転子７１０の周方向に沿って極性が交互に変わるように配置された複数の永久磁石により構成されている。磁石ユニット７１２が「磁石部」に相当する。これにより、磁石ユニット７１２は、周方向に複数の磁極を有する。磁石ユニット７１２は、第１実施形態の図８，図９において磁石ユニット４２として説明した構成を有しており、永久磁石として、固有保磁力が４００［ｋＡ／ｍ］以上であり、かつ残留磁束密度Ｂｒが１．０［Ｔ］以上である焼結ネオジム磁石を用いて構成されている。 The magnet unit 712 is constituted by a plurality of permanent magnets arranged so that the polarity alternates along the circumferential direction of the rotor 710. The magnet unit 712 corresponds to a “magnet part”. Thereby, the magnet unit 712 has a plurality of magnetic poles in the circumferential direction. The magnet unit 712 has the configuration described as the magnet unit 42 in FIGS. 8 and 9 of the first embodiment, and has a specific coercive force of 400 [kA / m] or more as a permanent magnet and a residual magnetic flux. It is configured using a sintered neodymium magnet having a density Br of 1.0 [T] or more.
　磁石ユニット７１２は、図９等の磁石ユニット４２と同様に、それぞれ極異方性磁石でありかつ極性が互いに異なる第１磁石９１及び第２磁石９２を有している。図８及び図９で説明したように、各磁石９１，９２ではそれぞれ、ｄ軸側（ｄ軸寄りの部分）とｑ軸側（ｑ軸寄りの部分）とで磁化容易軸の向きが相違しており、ｄ軸側では磁化容易軸の向きがｄ軸に平行な方向に近い向きとなり、ｑ軸側では磁化容易軸の向きがｑ軸に直交する方向に近い向きとなっている。そして、この磁化容易軸の向きに応じた配向により円弧状の磁石磁路が形成されている。なお、各磁石９１，９２において、ｄ軸側では磁化容易軸をｄ軸に平行な向きとし、ｑ軸側では磁化容易軸をｑ軸に直交する向きとしてもよい。要するに、磁石ユニット７１２は、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされて構成されている。なお、磁石ユニット７１２として、図２２及び図２３に示す磁石ユニット４２の構成や、図３０に示す磁石ユニット４２の構成を用いることも可能である。 The magnet unit 712 has a first magnet 91 and a second magnet 92 which are polar anisotropic magnets and have different polarities, respectively, similarly to the magnet unit 42 in FIG. 9 and the like. As described with reference to FIGS. 8 and 9, the directions of the axes of easy magnetization of the magnets 91 and 92 are different between the d-axis side (portion closer to the d-axis) and the q-axis side (portion near the q-axis). The direction of the easy axis is closer to the direction parallel to the d axis on the d-axis side, and the direction of the easy axis is closer to the direction orthogonal to the q axis on the q-axis side. An arc-shaped magnet magnetic path is formed by an orientation corresponding to the direction of the easy axis of magnetization. In each of the magnets 91 and 92, the easy axis may be oriented parallel to the d axis on the d-axis side, and the easy axis may be orthogonal to the q axis on the q-axis side. In short, the magnet unit 712 is configured such that the direction of the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared to the q-axis side, which is the magnetic pole boundary. . As the magnet unit 712, the configuration of the magnet unit 42 shown in FIGS. 22 and 23 or the configuration of the magnet unit 42 shown in FIG. 30 can be used.
　次に、固定子７２０の構成を説明する。 Next, the configuration of the stator 720 will be described.
　固定子７２０は、固定子巻線７２１と固定子コア７２２とを有している。図７９は、固定子７２０の斜視図であり、図８０は、固定子７２０の平面図であり、図８１は、固定子７２０の縦断面図であり、図８２は、固定子コア７２２の斜視図である。 The stator 720 has a stator winding 721 and a stator core 722. 79 is a perspective view of the stator 720, FIG. 80 is a plan view of the stator 720, FIG. 81 is a longitudinal sectional view of the stator 720, and FIG. 82 is a perspective view of the stator core 722. FIG.
　固定子コア７２２は、磁性体である電磁鋼板からなるコアシートが軸方向に積層され、かつ径方向に所定の厚さを有する円筒状をなしており、固定子コア７２２において回転子７１０側となる径方向外側に固定子巻線７２１が組み付けられている。固定子コア７２２の外周面は周方向に凹凸のない曲面状をなしており、固定子巻線７２１が組み付けられた状態では、固定子コア７２２の外周面に沿って、固定子巻線７２１を構成する導線部７３４が周方向に並べて配置されるようになっている。固定子コア７２２はバックコアとして機能する。 The stator core 722 is formed by laminating a core sheet made of a magnetic steel sheet, which is a magnetic material, in the axial direction, and has a cylindrical shape having a predetermined thickness in the radial direction. The stator winding 721 is mounted on the outer side in the radial direction. The outer peripheral surface of the stator core 722 has a curved shape without irregularities in the circumferential direction. When the stator winding 721 is assembled, the stator winding 721 is formed along the outer peripheral surface of the stator core 722. The constituent wire portions 734 are arranged side by side in the circumferential direction. The stator core 722 functions as a back core.
　固定子コア７２２は、周方向に分割された複数の分割コア７２４よりなり、複数の分割コア７２４が、その周方向端面どうしで互いに当接した状態で一体化されることで構成されている。各分割コア７２４の内周面には軸方向に延びる突起部７２５が設けられており、各分割コア７２４を円環状に一体化した状態では、固定子コア７２２の内周面に、周方向に所定間隔で突起部７２５が設けられる構成となっている。図示は省略するが、各分割コア７２４は嵌め合いにより互いに結合されているとよく、分割コア７２４の周方向端面に設けた凹部及び凸部の圧入より、周方向に隣り合う分割コア７２４どうしが互いに固定されているとよい。 The stator core 722 is composed of a plurality of divided cores 724 divided in the circumferential direction, and the plurality of divided cores 724 are integrated in a state where the divided cores 724 are in contact with each other at their circumferential end surfaces. A projection 725 extending in the axial direction is provided on the inner peripheral surface of each split core 724, and in a state where the split cores 724 are integrated in an annular shape, the inner peripheral surface of the stator core 722 is provided in the circumferential direction. In this configuration, the protrusions 725 are provided at predetermined intervals. Although not shown, the divided cores 724 are preferably connected to each other by fitting, and the divided cores 724 that are adjacent to each other in the circumferential direction are formed by press-fitting a concave portion and a convex portion provided on the circumferential end surface of the divided core 724. It may be fixed to each other.
　なお、固定子コア７２２は、複数の分割コア７２４を一体化した構成でなく、円筒状の成形物として構成されていてもよい。例えば、固定子コア７２２は、円環板状に打ち抜き形成された複数枚のコアシートが軸方向に積層されて構成されるものであるとよい。又は、固定子コア７２２は、帯状のコアシートが環状に巻回形成されるとともに軸方向に積層されたヘリカルコア構造を用いたものであるとよい。 Note that the stator core 722 may be configured as a cylindrical molded product instead of the configuration in which the plurality of split cores 724 are integrated. For example, the stator core 722 may be formed by stacking a plurality of core sheets punched and formed in an annular plate shape in the axial direction. Alternatively, the stator core 722 may use a helical core structure in which a belt-shaped core sheet is formed in an annular shape and stacked in the axial direction.
　固定子７２０は、以下の（Ａ）～（Ｃ）のいずれかを用いたものであるとよい。
（Ａ）固定子７２０において、周方向における各導線部７３４の間に導線間部材を設け、かつその導線間部材として、１磁極における導線間部材の周方向の幅寸法をＷｔ、導線間部材の飽和磁束密度をＢｓ、１磁極における磁石ユニット７１２の周方向の幅寸法をＷｍ、磁石ユニット７１２の残留磁束密度をＢｒとした場合に、Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒの関係となる磁性材料を用いている。
（Ｂ）固定子７２０において、周方向における各導線部７３４の間に導線間部材を設け、かつその導線間部材として、非磁性材料を用いている。
（Ｃ）固定子７２０において、周方向における各導線部７３４の間に導線間部材を設けていない構成となっている。 The stator 720 may use any of the following (A) to (C).
(A) In the stator 720, an inter-conductor member is provided between the conductor portions 734 in the circumferential direction, and as the inter-conductor member, the circumferential width of the inter-conductor member at one magnetic pole is Wt, When the saturation magnetic flux density is Bs, the circumferential width of the magnet unit 712 at one magnetic pole is Wm, and the residual magnetic flux density of the magnet unit 712 is Br, a magnetic material having a relationship of Wt × Bs ≦ Wm × Br is used. ing.
(B) In the stator 720, an inter-conductor member is provided between the conductor portions 734 in the circumferential direction, and a non-magnetic material is used as the inter-conductor member.
(C) The stator 720 has a configuration in which no inter-conductor member is provided between the conductor portions 734 in the circumferential direction.
　例えば、固定子巻線７２１が、固定子コア７２２と共に樹脂等からなるモールド材（絶縁部材）により一体にモールドされている場合には、周方向に並ぶ各導線部７３４の間にモールド材が介在する。かかる場合、固定子７２０は、上記（Ａ）～（Ｃ）のうち（Ｂ）の構成に相当するものとなる。また、周方向に隣り合う各導線部７３４は、周方向の端面どうしが互いに当接するか、又は微小な間隔を隔てて近接配置されており、この構成から言えば上記（Ｃ）の構成であってもよい。いずれにしろ、固定子コア７２２は、その一部としてティースを有していないティースレス構造となっており、ティースレスの固定子コア７２２に対して固定子巻線７２１が一体化されている。要するに、固定子コア７２２は円筒状をなし、固定子コア７２２の外周側に固定子巻線７２１が組み付けられている。なお、上記（Ａ）の構成を採用する場合には、固定子コア７２２の外周面に、周方向の所定間隔で上記（Ａ）の規定を満たす大きさ（幅又は突出高さ）の突部が設けられているとよい。 For example, when the stator winding 721 is integrally molded with the stator core 722 by a molding material (insulating member) made of resin or the like, the molding material is interposed between the conductors 734 arranged in the circumferential direction. I do. In such a case, the stator 720 corresponds to the configuration (B) of the above (A) to (C). In addition, the conductor portions 734 adjacent in the circumferential direction are arranged such that their end faces in the circumferential direction abut on each other or are arranged close to each other with a small space therebetween. You may. In any case, the stator core 722 has a teethless structure having no teeth as a part thereof, and the stator winding 721 is integrated with the teethless stator core 722. In short, the stator core 722 has a cylindrical shape, and the stator winding 721 is attached to the outer peripheral side of the stator core 722. In the case of adopting the configuration (A), the outer peripheral surface of the stator core 722 has a protrusion (width or protrusion height) of a size (width or protrusion height) satisfying the above-mentioned rule (A) at predetermined intervals in the circumferential direction. Should be provided.
　固定子巻線７２１は、複数の相巻線を有し、各相の相巻線が周方向に所定順序で配置されている。本例では、Ｕ相、Ｖ相及びＷ相の相巻線を用いることで、固定子巻線７２１が３相の相巻線を有する構成となっている。固定子巻線７２１は、各相巻線において径方向内外に１層の導線部７３４により構成されている。 The stator winding 721 has a plurality of phase windings, and the phase windings of each phase are arranged in a predetermined order in the circumferential direction. In this example, the stator winding 721 has a three-phase winding by using U-phase, V-phase, and W-phase windings. The stator winding 721 is constituted by a single-layer conductive wire portion 734 inside and outside in the radial direction in each phase winding.
　固定子巻線７２１は、各相の相巻線として、相ごとに複数の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗを有しており、それら各部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗを所定順序で周方向に配置することで構成されている。 The stator winding 721 has a plurality of partial windings 731U, 731V, 731W for each phase as a phase winding of each phase, and the partial windings 731U, 731V, 731W are circumferentially arranged in a predetermined order. It is constituted by being arranged in.
　図８３は、固定子巻線７２１において各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗの電気的接続を示す回路図である。図８３に示すように、本例の固定子巻線７２１では、各相１つずつの部分巻線が星形結線(Ｙ結線)されている。そして、星形結線された複数の３相巻線が並列に接続されている。 FIG. 83 is a circuit diagram showing electrical connection of partial windings 731U, 731V, 731W of each phase in stator winding 721. As shown in FIG. 83, in the stator winding 721 of the present example, one partial winding for each phase is star-connected (Y-connected). A plurality of star-connected three-phase windings are connected in parallel.
　各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗは、それぞれ導線材を重ね巻することにより構成されている。そして、それら各部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗが、それぞれ固定子コア７２２に組み付けられ、かつバスバー等の接続部材により電気的にそれぞれ接続されることで、固定子巻線７２１が構成されている。なお以下の説明では、各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗをまとめて、部分巻線７３１とも称する。本例では、磁極数を１２（すなわち磁極対数を６）としているが、その数は任意である。 部分 The partial windings 731U, 731V, 731W of each phase are each formed by lapping a conductive wire. Each of the partial windings 731U, 731V, 731W is assembled to the stator core 722 and electrically connected to each other by a connecting member such as a bus bar, thereby forming the stator winding 721. . In the following description, the partial windings 731U, 731V, 731W of each phase are collectively referred to as a partial winding 731. In this example, the number of magnetic poles is 12 (that is, the number of magnetic pole pairs is 6), but the number is arbitrary.
　図８１に示すように、固定子巻線７２１は、固定子コア７２２と径方向に並ぶコイルサイドＣＳと、そのコイルサイドＣＳよりも軸方向外側となるコイルエンドＣＥとを有している。コイルエンドＣＥは、固定子巻線７２１の軸方向両端側にそれぞれ設けられている。なお、コイルサイドＣＳは、回転子７１０の磁石ユニット７１２に径方向に対向する磁石対向部を含む部分であり、コイルエンドＣＥは、コイルサイドＣＳよりも軸方向外側において同相の巻線を周方向に周回させる周回部分である。 固定 As shown in FIG. 81, the stator winding 721 has a coil side CS radially aligned with the stator core 722 and a coil end CE located axially outside the coil side CS. The coil ends CE are provided on both ends in the axial direction of the stator winding 721, respectively. Note that the coil side CS is a portion including a magnet facing portion radially facing the magnet unit 712 of the rotor 710, and the coil end CE includes a winding in the same phase on the outer side in the axial direction than the coil side CS in the circumferential direction. This is the orbital part that is orbited.
　図８４（ａ）は、固定子巻線７２１から各相１つずつの部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗを抽出して示す斜視図であり、図８４（ｂ）は、それら各相１つずつの部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗを示す正面図である。また、図８５は、３相の部分巻線のうちＵ相の部分巻線７３１Ｕのみを示す斜視図であり、図８６は、回転子７１０及び固定子７２０の横断面図である。 FIG. 84 (a) is a perspective view showing a partial winding 731U, 731V, 731W of each phase one by one extracted from the stator winding 721, and FIG. It is a front view which shows the partial winding 731U, 731V, 731W. FIG. 85 is a perspective view showing only the U-phase partial winding 731U of the three-phase partial windings, and FIG. 86 is a cross-sectional view of the rotor 710 and the stator 720.
　図８４（ａ），（ｂ）に示すように、各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗは、それぞれコイルサイドＣＳに相当する部分である一対の中間導線群７３２と、その中間導線群７３２よりも軸方向外側であり、コイルエンドＣＥを含む部分である渡り部７３３とを有している。そして、各部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗは、相ごとに、コイルサイドＣＳにおいて各中間導線群７３２が周方向に並び、かつコイルエンドＣＥにおいて渡り部７３３が軸方向に重なるようにして配置されている。 As shown in FIGS. 84 (a) and 84 (b), the partial windings 731U, 731V, 731W of each phase are respectively composed of a pair of intermediate conductor groups 732 which are portions corresponding to the coil side CS, and the intermediate conductor group 732. And a crossover portion 733 that is a portion that is axially outward and includes the coil end CE. Each of the partial windings 731U, 731V, 731W is arranged such that, for each phase, the intermediate conductor groups 732 are arranged in the coil side CS in the circumferential direction, and the crossover portions 733 overlap in the coil end CE in the axial direction. ing.
　より詳しくは、図８５に示すように、部分巻線７３１Ｕは、導線材ＣＲを、複数回、環状に周回させることで形成されており、周方向に離れた一対の中間導線群７３２を有するとともに、軸方向に離れた一対の渡り部７３３を有している。本例では、部分巻線７３１の巻数は３である。ただし、巻数は３以外であってもよい。 More specifically, as shown in FIG. 85, the partial winding 731U is formed by looping the conductor CR multiple times, and has a pair of intermediate conductor groups 732 separated in the circumferential direction. , And a pair of crossover portions 733 that are separated in the axial direction. In this example, the number of turns of the partial winding 731 is three. However, the number of turns may be other than three.
　一対の中間導線群７３２は、それぞれ導線材ＣＲが軸方向（図の上下方向）に直線状に延びるようにして形成されている。また、一対の渡り部７３３は、各中間導線群７３２の軸方向両端から、軸方向に直交する方向に延びるように設けられている。導線材ＣＲは、横断面が矩形状をなす塑性変形可能な平角導線であり、例えば成形型や治具等を用いた成形により、部分巻線７３１Ｕが作製されるようになっている。 The pair of intermediate conductor groups 732 are formed such that the conductor CR is linearly extended in the axial direction (vertical direction in the drawing). The pair of transition portions 733 are provided so as to extend from both axial ends of each intermediate conductor group 732 in a direction orthogonal to the axial direction. The conductor CR is a plastically deformable rectangular conductor having a rectangular cross section, and the partial winding 731U is manufactured by molding using, for example, a mold or a jig.
　一対の中間導線群７３２は、それぞれ周方向に３本分の導線材ＣＲを並べて構成され、一対の中間導線群７３２の間に他相の部分巻線７３１Ｖ，７３１Ｗの中間導線群７３２を配置可能にすべく、周方向に所定間隔を離して設けられている。本例では、中間導線群７３２ごとに、部分巻線７３１の巻数と同数の導線材ＣＲが周方向に並べて配置されている。各中間導線群７３２において周方向に並ぶ３本分の導線材ＣＲが、径方向に磁極に対向するコイルサイド導線部７３４に相当する。そして、各部分巻線７３１における一対の中間導線群７３２を互いに離間させていることにより、それらの間に、他２相の６本分（３本分×２）の導線材ＣＲが配置される構成としている。 Each of the pair of intermediate conductor groups 732 is configured by arranging three conductors CR in the circumferential direction, and the intermediate conductor group 732 of the partial windings 731V and 731W of the other phase can be arranged between the pair of intermediate conductor groups 732. Are provided at a predetermined interval in the circumferential direction. In this example, for each intermediate conductor group 732, the same number of conductors CR as the number of turns of the partial winding 731 are arranged in the circumferential direction. The three conductors CR arranged in the circumferential direction in each intermediate conductor group 732 correspond to the coil side conductor 734 facing the magnetic pole in the radial direction. Since the pair of intermediate conductor groups 732 in each of the partial windings 731 are separated from each other, six (3 × 2) conductor wires CR of the other two phases are arranged between them. It has a configuration.
　図８６には、各相の相巻線と回転子７１０の磁極との関係が示されている。なお、同図では便宜上、３相の相巻線のうちＵ相の相巻線、すなわちＵ相の部分巻線７３１Ｕの中間導線群７３２にドットを付している。図８６では、周方向に並ぶ磁極ごとに各相１つずつの中間導線群７３２が配置されるように設けられている。各部分巻線７３１が一対の中間導線群７３２を有することから言えば、各部分巻線７３１において一対の中間導線群７３２は、周方向に隣り合う２つの磁極にそれぞれ設けられている。 FIG. 86 shows the relationship between the phase windings of each phase and the magnetic poles of the rotor 710. In the figure, for convenience, dots are attached to the U-phase winding of the three-phase winding, that is, the intermediate conductor group 732 of the U-phase partial winding 731U. In FIG. 86, an intermediate conductor group 732 of one phase is provided for each magnetic pole arranged in the circumferential direction. Speaking of the fact that each partial winding 731 has a pair of intermediate conductor groups 732, in each partial winding 731, the pair of intermediate conductor groups 732 are provided on two magnetic poles adjacent in the circumferential direction.
　また、図８５に示すように、一対の渡り部７３３は、一対の中間導線群７３２を環状に接続する部分であり、図の上側の渡り部７３３は、２本分の導線材ＣＲを並べて構成され、図の下側の渡り部７３３Ｂは、３本分の導線材ＣＲを並べて構成されている。これら軸方向両側の渡り部７３３のうち一方の渡り部７３３には、導線材ＣＲの一端部及び他端部により部分巻線７３１Ｕの巻線端部７３５，７３６が設けられている。 As shown in FIG. 85, the pair of transition portions 733 is a portion that connects the pair of intermediate conductor groups 732 in a ring shape, and the transition portion 733 on the upper side of the figure is configured by arranging two conductor wires CR. The crossover portion 733B on the lower side of the figure is configured by arranging three conductive wires CR. One of the crossover portions 733 on both sides in the axial direction is provided with winding ends 735 and 736 of the partial winding 731U by one end and the other end of the conductive wire CR.
　一対の渡り部７３３は、径方向に同じ側（本例ではいずれも径方向内側）に向けて屈曲成形されており、この屈曲形状により、周方向に隣り合う各相の部分巻線７３１どうしの干渉が回避されるようになっている。すなわち、一対の渡り部７３３は、干渉回避部として機能する。固定子コア７２２との関係で言えば、各渡り部７３３は、固定子コア７２２の軸方向端面に対向するように径方向に折り曲げられている。各渡り部７３３において、中間導線群７３２から渡り部７３３の先端までの径方向寸法が固定子コア７２２の径方向の厚さ寸法以下であるとよい。ただし、一対の渡り部７３３において少なくとも一方の渡り部７３３について、中間導線群７３２から渡り部７３３の先端までの径方向寸法が固定子コア７２２の径方向の厚さ寸法以下であるとよい。 The pair of transition portions 733 are bent toward the same side in the radial direction (in this example, all radially inward), and the bent shape allows the partial windings 731 of the phases adjacent to each other in the circumferential direction to be formed. Interference is avoided. That is, the pair of transition portions 733 function as an interference avoiding unit. In terms of the relationship with the stator core 722, each transition portion 733 is radially bent so as to face the axial end surface of the stator core 722. In each of the transition portions 733, the radial dimension from the intermediate conductor group 732 to the tip of the transition portion 733 may be equal to or less than the radial thickness of the stator core 722. However, for at least one of the pair of crossover portions 733, the radial dimension from the intermediate conductor group 732 to the tip of the crossover portion 733 may be equal to or less than the radial thickness of the stator core 722.
　本例では、各部分巻線７３１の渡り部７３３は、コイルエンドＣＥにおいて径方向内側に向けて軸方向に垂直に折り曲げられている。この場合、軸方向におけるコイルエンドＣＥの突出高さを極力小さくすることが可能となっている。ただし、渡り部７３３を、軸方向に対して垂直以外となる角度で折り曲げる構成であってもよい。各部分巻線７３１の渡り部７３３は、径方向及び軸方向の少なくともいずれかに互いに異なる位置に配置されることで互いの干渉が回避されるものであるとよい。 In the present example, the transition portion 733 of each partial winding 731 is bent radially inward at the coil end CE in a direction perpendicular to the axial direction. In this case, it is possible to minimize the protrusion height of the coil end CE in the axial direction. However, the crossing portion 733 may be bent at an angle other than perpendicular to the axial direction. The crossover portions 733 of the respective partial windings 731 are preferably arranged at different positions in at least one of the radial direction and the axial direction so as to avoid mutual interference.
　Ｖ相の部分巻線７３１Ｖ、Ｗ相の部分巻線７３１Ｗは、Ｕ相の部分巻線７３１Ｕと比べて、一対の渡り部７３３の間の軸方向長さと渡り部７３３の径方向長さとが相違する点を除いて、略同じ構成を有している。本例では、Ｕ相、Ｖ相、Ｗ相の順で、各部分巻線７３１における一対の渡り部７３３の間の軸方向長さが長くなっているとともに、渡り部７３３の径方向長さが短くなっている。各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗを固定子コア７２２に組み付けた状態では、軸方向において、Ｕ相の部分巻線７３１Ｕが最も内側（コア端面側）となり、その外側にＶ相の部分巻線７３１Ｖ、さらにその外側にＷ相の部分巻線７３１Ｗが配置される。各部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗにおいて、中間導線群７３２の軸方向の長さは導線材ＣＲの厚み分だけ互いに異なっているとよい。 The V-phase partial winding 731V and the W-phase partial winding 731W are different from the U-phase partial winding 731U in the axial length between the pair of bridging portions 733 and the radial length of the bridging portion 733. Except for this point, they have substantially the same configuration. In this example, in the order of the U-phase, the V-phase, and the W-phase, the axial length between the pair of transition portions 733 of each partial winding 731 is increased, and the radial length of the transition portion 733 is increased. It is getting shorter. When the partial windings 731U, 731V, 731W of each phase are assembled to the stator core 722, the U-phase partial winding 731U is the innermost (core end face side) in the axial direction, and the V-phase part is A winding 731V and a W-phase partial winding 731W are further disposed outside the winding 731V. In each of the partial windings 731U, 731V, 731W, the axial length of the intermediate conductor group 732 may be different from each other by the thickness of the conductor CR.
　なお、各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗにおいて、その軸方向寸法は、Ｕ相が最も短く、かつＷ相が最も長いのに対し、径方向寸法は、Ｕ相が最も長く、かつＷ相が最も短い構成となっている。そのため、各部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗは、導線材ＣＲの全長が概ね等しくなるような構成となっている。 In the partial windings 731U, 731V, 731W of each phase, the axial dimension is the shortest in the U phase and the longest in the W phase, while the radial dimension is the longest in the U phase and the W dimension. It has the shortest phase. Therefore, each of the partial windings 731U, 731V, 731W is configured such that the entire length of the conductive wire CR is substantially equal.
　図８４（ａ）、（ｂ）や図８６に示すように、各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗは、電気角で６０度（π／３）ずつ周方向にずらして配置されている。これにより、各相１つずつの部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗにより１磁極対分の３相巻線が構成されている。この場合、固定子巻線７２１の全体で言えば、１磁極対ごとに３相巻線が構成され、その３相巻線が周方向に６つ（６磁極対分）並べて設けられている。 As shown in FIGS. 84 (a), (b) and FIG. 86, the partial windings 731U, 731V, 731W of each phase are arranged so as to be shifted in the circumferential direction by an electrical angle of 60 degrees (π / 3). . Thus, a three-phase winding corresponding to one magnetic pole pair is formed by the partial windings 731U, 731V, and 731W for each phase. In this case, speaking of the entire stator winding 721, a three-phase winding is formed for each magnetic pole pair, and six three-phase windings (for six magnetic pole pairs) are arranged in the circumferential direction.
　各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗを、相ごとに電気角で６０度ずつ周方向にずらした位置にそれぞれ配置するようにしたため、各相１つずつの部分巻線７３１、すなわち３個の部分巻線７３１を用いて、１磁極対分を１単位とする巻線アセンブリが形成されるようになっている。なお、固定子巻線７２１の相数をｎとする場合、各相の部分巻線７３１は、相ごとに電気角で１８０／ｎ度ずつ周方向にずらした位置にそれぞれ配置されているとよい。 Since the partial windings 731U, 731V, 731W of each phase are arranged at positions shifted by 60 electrical degrees in the circumferential direction for each phase, each partial winding 731 of each phase, that is, three windings The winding assembly having one magnetic pole pair as one unit is formed using the partial windings 731. When the number of phases of the stator winding 721 is n, the partial windings 731 of each phase are preferably arranged at positions shifted by 180 / n degrees in electrical angle in the circumferential direction for each phase. .
　図８７は、固定子コア７２２に対して、各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗの全てを組み付けた状態を示す斜視図である。図８７において、各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗは、周方向に隣り合う２つの磁極を跨ぐ状態で、導線材ＣＲを複数回、重ね巻することで形成されており、固定子巻線７２１は、各相の部分巻線７３１を所定順序で周方向に並べて配置することにより構成されている。また、各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗでは、巻線端部７３５，７３６がそれぞれ軸方向の同じ向きに突き出る構成となっている。 FIG. 87 is a perspective view showing a state where all of the partial windings 731U, 731V, 731W of each phase are assembled to the stator core 722. In FIG. 87, the partial windings 731U, 731V, and 731W of each phase are formed by winding the conductive wire CR a plurality of times in a state of straddling two magnetic poles adjacent in the circumferential direction. The wire 721 is configured by arranging the partial windings 731 of each phase in a predetermined order in the circumferential direction. In the partial windings 731U, 731V, and 731W of each phase, the winding ends 735 and 736 are configured to protrude in the same axial direction.
　各部分巻線７３１は、コイルサイドＣＳにおいて、径方向の導線厚さ寸法が、１磁極内における１相分の周方向の幅寸法よりも小さくなっている構成（すなわち扁平導線構造）を有しているとよい。また、導線材ＣＲは、複数の素線（細線）が１本に束ねられて構成された束線であるとよい。以下に、導線材ＣＲの断面構造を示す図８８を用いて、導線材ＣＲの構成を補足説明する。 Each of the partial windings 731 has a configuration in which the radial thickness of the conductive wire in the coil side CS is smaller than the circumferential width of one phase in one magnetic pole (ie, a flat conductive wire structure). Good to be. Further, the conductor CR is preferably a bundled wire formed by bundling a plurality of strands (thin wires). Hereinafter, the configuration of the conductive wire CR will be additionally described with reference to FIG. 88 illustrating a cross-sectional structure of the conductive wire CR.
　図８８に示すように、導線材ＣＲは、横断面が略矩形状をなす角形導線であり、複数（図では６本）の素線７４１と、その複数の素線７４１を囲む例えば樹脂製の外層被膜７４２（外側絶縁層）と、外層被膜７４２内において各素線７４１の周りに充填された中間層７４３とを有している。また、素線７４１は、銅材よりなる導体部７４１ａを、絶縁材料よりなる導体被膜７４１ｂ（素線絶縁層）で被覆する構成となっている。この場合、導線材ＣＲは、内外多層に複数の絶縁被膜を有するものとなっており、外層被膜７４２が外側絶縁被膜であり、中間層７４３が中間絶縁被膜であり、素線７４１の導体被膜７４１ｂが内側絶縁被膜である。固定子巻線７２１として見れば、少なくとも外層被膜７４２により相間が絶縁される。導線材ＣＲは、複数の素線７４１が束ねられているとともに、束ねられた素線間の抵抗値が素線７４１そのものの抵抗値よりも大きい素線集合体であるとよい。なお、素線７４１が、複数の導電材の集合体として構成されていてもよい。 As shown in FIG. 88, the conductive wire CR is a rectangular conductive wire having a substantially rectangular cross section, and includes a plurality of (six in the figure) strands 741 and a resin, for example, made of resin surrounding the plurality of strands 741. It has an outer coating 742 (outer insulating layer) and an intermediate layer 743 filled around each element wire 741 in the outer coating 742. The wire 741 has a configuration in which a conductor portion 741a made of a copper material is covered with a conductor coating 741b (wire insulation layer) made of an insulating material. In this case, the conductor CR has a plurality of insulating coatings in the inner and outer multilayers, the outer coating 742 is an outer insulating coating, the intermediate layer 743 is an intermediate insulating coating, and the conductor coating 741b of the strand 741 is provided. Is an inner insulating coating. When viewed as the stator winding 721, at least the phases are insulated by the outer layer coating 742. The conductor CR is preferably a wire aggregate in which a plurality of wires 741 are bundled and the resistance value between the bundled wires is larger than the resistance value of the wire 741 itself. Note that the strand 741 may be configured as an aggregate of a plurality of conductive materials.
　外層被膜７４２は、導体被膜７４１ｂに比べて被膜厚さ寸法が大きくなっている。この場合、相間絶縁層である外層被膜７４２の厚さ寸法が、素線７４１の導体被膜７４１ｂよりも大きいことにより、高電圧に対する耐性強化を図ることができる。つまり、導線材ＣＲにおいて複数の絶縁被膜のうち外側の絶縁被膜の絶縁能力が、内側の絶縁被膜の絶縁能力よりも高められている。この場合、例えば導線の一般的な被膜厚さ（５～４０μｍ）よりも大きい耐圧が必要な電圧帯においても好適に用いることができる。 The outer layer coating 742 has a larger thickness dimension than the conductor coating 741b. In this case, since the thickness of the outer layer coating 742, which is the interphase insulating layer, is larger than the conductor coating 741b of the strand 741, the resistance to high voltage can be enhanced. That is, in the conductor CR, the insulating ability of the outer insulating coating among the plurality of insulating coatings is higher than the insulating ability of the inner insulating coating. In this case, for example, it can be suitably used even in a voltage band that requires a withstand voltage larger than the general thickness of the conductive wire (5 to 40 μm).
　導線材ＣＲは、外周部に絶縁被膜としての外層被膜７４２を有し、各相の部分巻線７３１の中間導線群７３２において周方向に隣り合う導線材ＣＲどうしが外層被膜７４２により互いに絶縁されている。本構成では、部分巻線７３１の中間導線群７３２において周方向に導線材ＣＲが接触又は接近した状態で並んでいても、その中間導線群７３２において導線材ＣＲの外層被膜７４２により絶縁性が確保される。したがって、ティースレス構造を用いた固定子コア７２２において、固定子巻線７２１の絶縁を適正に実現できるものとなっている。 The conductor CR has an outer coating 742 as an insulating coating on the outer peripheral portion. In the intermediate conductor group 732 of the partial winding 731 of each phase, the conductors CR adjacent to each other in the circumferential direction are insulated from each other by the outer coating 742. I have. In the present configuration, even if the conductors CR are arranged in a circumferential direction in the middle conductor group 732 of the partial winding 731 in a state of contacting or approaching, insulation is secured by the outer layer coating 742 of the conductor CR in the middle conductor group 732. Is done. Therefore, in the stator core 722 using the teethless structure, the insulation of the stator winding 721 can be appropriately realized.
　ここで、各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗにおける接続の構造を、図８４（ａ），（ｂ）と図８９とを用いて説明する。 Here, the connection structure in the partial windings 731U, 731V, 731W of each phase will be described with reference to FIGS. 84 (a), (b) and FIG.
　各相の部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗは、それぞれに巻線端部７３５，７３６を有しており、そのうち一方の巻線端部７３５が中性点接続用の導線端部、他方の巻線端部７３６が電力入出力用の導線端部となっている。図８４（ａ），（ｂ）に示すように、各相の巻線端部７３５には中性点バスバー７３７が接続されている。中性点バスバー７３７は、各相１つずつの部分巻線７３１に対して、つまり３つの部分巻線７３１に対して１つの割合で設けられており、本例では、固定子巻線７２１に、計６個の中性点バスバー７３７が設けられている。中性点バスバー７３７は、固定子巻線７２１の渡り部７３３に軸方向に重なる位置に設けられている。 Each of the partial windings 731U, 731V, and 731W of each phase has winding ends 735 and 736. One of the winding ends 735 is a conductor end for neutral point connection, and the other winding end 735 is the other winding end. The wire end 736 is a wire end for power input / output. As shown in FIGS. 84 (a) and (b), a neutral point bus bar 737 is connected to the winding end 735 of each phase. The neutral point bus bar 737 is provided for each partial winding 731 of each phase, that is, one for each of the three partial windings 731. In this example, the neutral bus bar 737 is provided for the stator winding 721. , A total of six neutral point bus bars 737 are provided. Neutral point bus bar 737 is provided at a position axially overlapping transition portion 733 of stator winding 721.
　また、図８９に示すように、各相の巻線端部７３６には、相ごとに、各相の部分巻線７３１に対する電力の入出力を行わせる電力バスバー７５１，７５２，７５３が接続されている。各相の電力バスバー７５１～７５３は、いずれも円形リング状をなしており、各々に接続端子７５４，７５５，７５６を有している。そして、接続端子７５４～７５６を不図示のハーネスを介してインバータに接続することにより、固定子巻線７２１に対する電力の入出力が可能となっている。各相の電力バスバー７５１～７５３は、いずれも同一の大きさの環状部を有しており、固定子巻線７２１の渡り部７３３に軸方向に重なり、かつ中性点バスバー７３７よりも径方向内側となる位置に設けられている（図８０参照）。 As shown in FIG. 89, power bus bars 751, 752, and 753 for inputting and outputting power to and from the partial winding 731 of each phase are connected to the winding end portion 736 of each phase. I have. Each of the power bus bars 751 to 753 of each phase has a circular ring shape, and has connection terminals 754, 755, 756. By connecting the connection terminals 754 to 756 to an inverter via a harness (not shown), power can be input to and output from the stator winding 721. Each of the power bus bars 751 to 753 of each phase has an annular portion of the same size, overlaps with the transition portion 733 of the stator winding 721 in the axial direction, and has a radial direction more than the neutral point bus bar 737. It is provided at a position on the inside (see FIG. 80).
　中性点バスバー７３７により異相の部分巻線７３１どうしが接続され、電力バスバー７５１～７５３により同相の部分巻線７３１どうしが接続されている。これら中性点バスバー７３７及び電力バスバー７５１～７５３が接続部材に相当する。 異 Partial windings 731 of different phases are connected to each other by neutral point bus bar 737, and partial windings 731 of same phase are connected to each other by power bus bars 751 to 753. The neutral bus bar 737 and the power bus bars 751 to 753 correspond to connection members.
　本例では、上記のとおり各相１つずつの部分巻線７３１を用いて１単位の巻線アセンブリ（１磁極対分の巻線アセンブリ）が形成されるようになっており、各磁極対分の巻線アセンブリに対して個々に中性点バスバー７３７が接続されている。これにより、１磁極対ごとに、中性点バスバー７３７による各相の部分巻線７３１の結線を容易に実施することが可能となり、中性点バスバー７３７の溶接作業等を容易化することが可能となっている。 In this example, as described above, one unit of a winding assembly (a winding assembly for one magnetic pole pair) is formed using the partial windings 731 for each phase, as described above. Neutral point bus bars 737 are individually connected to the winding assemblies. This makes it possible to easily connect the partial windings 731 of each phase by the neutral point bus bar 737 for each magnetic pole pair, thereby facilitating welding work of the neutral point bus bar 737 and the like. It has become.
　図９０は、３相の部分巻線７３１Ｕ，７３１Ｖ，７３１ＷのうちＵ相の部分巻線７３１Ｕについて互いの接続状態を模式的に示す図である。図９０には、周方向に配置される複数の部分巻線７３１Ｕを平面展開して示しており、各部分巻線７３１Ｕの一方の巻線端部７３６には、それぞれ電力バスバー７５１が接続されている。なお、図示は略すが、周方向において部分巻線７３１Ｕの各中間導線群７３２の間には、他２相の部分巻線７３１Ｖ，７３１Ｗの中間導線群７３２がそれぞれ配置されている。 FIG. 90 is a diagram schematically showing the connection state of the U-phase partial winding 731U among the three-phase partial windings 731U, 731V, 731W. In FIG. 90, a plurality of partial windings 731U arranged in the circumferential direction are shown in plan development, and a power bus bar 751 is connected to one winding end 736 of each partial winding 731U. I have. Although not shown, intermediate conductor groups 732 of the other two-phase partial windings 731V and 731W are arranged between the intermediate conductor groups 732 of the partial winding 731U in the circumferential direction.
　各相の部分巻線７３１は、１磁極ごとに、直列接続された各３本のコイルサイド導線部７３４からなる中間導線群７３２を有しており、各部分巻線７３１Ｕの通電時には、各中間導線群７３２に同相の電流が同位相で流れる。つまり、各部分巻線７３１において、磁極ごとに３本のコイルサイド導線部７３４に分かれて電流が流れる。また、部分巻線７３１Ｕを構成する導線材ＣＲが複数本（本例では６本）の素線７４１からなる束線であることを考えると、磁極ごとに１８本の各素線７４１に分かれて電流が流れる。この場合、各部分巻線７３１において、同相の電流が３本のコイルサイド導線部７３４に分かれて流れること（換言すれば、１８本の素線７４１に分かれて流れること）で、各部分巻線７３１での渦電流の発生を抑制できる。 The partial winding 731 of each phase has an intermediate conductor group 732 composed of three coil side conductors 734 connected in series for each magnetic pole. In-phase currents flow in the conducting wire group 732 in the same phase. That is, in each of the partial windings 731, a current flows separately to the three coil side conductor portions 734 for each magnetic pole. Further, considering that the conductor CR constituting the partial winding 731U is a bundle of a plurality of (six in this example) strands 741, each of the magnetic poles is divided into 18 strands 741. Electric current flows. In this case, in each of the partial windings 731, an in-phase current is split and flows through the three coil-side conductor portions 734 (in other words, split and flows through the 18 element wires 741), so that each of the partial windings 731. The generation of the eddy current at 731 can be suppressed.
　また、各部分巻線７３１は、導線材ＣＲを多重に周回させて構成されているため、同相のコイルサイド導線部７３４は直列に接続されたものとなり、循環電流の発生も抑制される。したがって、例えば、導線材ＣＲとして複数の素線を撚り合わせた撚り線を用いなくても、循環電流の抑制を図ることができる。以上により、回転電機７００において渦電流や循環電流による損失の低減を図ることができるものとなっている。 Further, since each of the partial windings 731 is configured by wrapping the conducting wire CR in multiple layers, the in-phase coil side conducting wire portions 734 are connected in series, and the occurrence of circulating current is suppressed. Therefore, for example, circulating current can be suppressed without using a stranded wire in which a plurality of strands are twisted as the conductive wire CR. As described above, in the rotating electric machine 700, the loss due to the eddy current and the circulating current can be reduced.
　本例の回転電機７００では、回転子７１０において、永久磁石として固有保磁力が４００［ｋＡ／ｍ］以上であり、かつ残留磁束密度Ｂｒが１．０［Ｔ］以上である焼結磁石が用いられていることから、磁石磁束が高められている。また、固定子コア７２２がティースレス構造となっていることから、磁石ユニット７１２により生じた磁石磁束は固定子巻線７２１に対して直接的に鎖交し、渦電流発生の懸念が大きくなっている。この点、上述したとおり各部分巻線７３１を、周方向に隣り合う２つの磁極を跨ぐ状態で、導線材ＣＲを複数回、重ね巻することで形成したため、鎖交磁束が固定子巻線７２１（具体的には部分巻線７３１）に直接作用しても、固定子巻線７２１での渦電流の発生を抑制できる。 In the rotating electric machine 700 of the present example, a sintered magnet having a specific coercive force of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] or more is used as a permanent magnet in the rotor 710. As a result, the magnetic flux of the magnet is increased. Further, since the stator core 722 has a teethless structure, the magnet magnetic flux generated by the magnet unit 712 is directly linked to the stator winding 721, and the concern of eddy current generation increases. I have. In this regard, as described above, since each of the partial windings 731 is formed by overlappingly winding the conductive wire CR a plurality of times while straddling two magnetic poles adjacent to each other in the circumferential direction, the linkage flux is reduced by the stator winding 721. (Specifically, even if it acts directly on the partial winding 731), the generation of the eddy current in the stator winding 721 can be suppressed.
　また、導線材ＣＲとして複数の素線７４１を束ねた束線を用いる構成としたため、部分巻線７３１において、磁極ごとに流れる電流を一層細かく分断させて流すことが可能となる。これにより、渦電流を抑制する上で一層好適な構成を実現できる。 In addition, since a configuration in which a bundle of a plurality of strands 741 is used as the conductive wire CR is used, in the partial winding 731, the current flowing for each magnetic pole can be further divided and flown. As a result, a more preferable configuration for suppressing the eddy current can be realized.
　各部分巻線７３１では、一対の中間導線群７３２の間に、他相の部分巻線７３１における一対の中間導線群７３２のうち一方の中間導線群７３２を配置することで、各相の中間導線群７３２を周方向に好適に並べることができる。また、軸方向両側の渡り部７３３が径方向に延びる向きで折り曲げられた状態になっていることで、周方向に隣り合う部分巻線７３１どうしの干渉を好適に回避することができる。 In each of the partial windings 731, one intermediate conductor group 732 of the pair of intermediate conductor groups 732 in the other-phase partial winding 731 is arranged between the pair of intermediate conductor groups 732, so that the intermediate conductor of each phase is arranged. The groups 732 can be suitably arranged in the circumferential direction. Further, since the transition portions 733 on both sides in the axial direction are bent in a direction extending in the radial direction, interference between the partial windings 731 adjacent in the circumferential direction can be preferably avoided.
　各部分巻線７３１における巻線端部７３５，７３６に中性点バスバー７３７及び電力バスバー７５１～７５３を接続する構成としたため、例えば回転電機７００の巻線構造に応じて中性点バスバー７３７や電力バスバー７５１～７５３を適宜変更することで、固定子巻線７２１の結線状態を容易に変更することができる。つまり、固定子コア７２２に対する各部分巻線７３１の組み付け状態を不変にしつつ、中性点バスバー７３７や電力バスバー７５１～７５３の接続相手を変更するだけで、回転電機７００の種類に応じた異なる形態の固定子巻線７２１を容易に実現できる。 Since the neutral bus bar 737 and the power bus bars 751 to 753 are connected to the winding ends 735 and 736 of each partial winding 731, the neutral bus bar 737 and the power By appropriately changing the bus bars 751 to 753, the connection state of the stator winding 721 can be easily changed. In other words, a different configuration according to the type of the rotating electric machine 700 can be achieved by simply changing the connection partner of the neutral bus bar 737 and the power bus bars 751 to 753 while keeping the assembled state of the respective partial windings 731 to the stator core 722 unchanged. Of the stator winding 721 can be easily realized.
　また、中性点バスバー７３７及び電力バスバー７５１～７５３を、固定子７２０の軸方向両側のうち一方側においてコイルエンドＣＥに沿って周方向に延びるように設ける構成としたため、周方向長さが異なる等により種類の異なるバスバーを用いる場合にも、バスバーの変更等に容易に対処できる。 In addition, since the neutral point bus bar 737 and the power bus bars 751 to 753 are provided so as to extend in the circumferential direction along the coil end CE on one of the axial sides of the stator 720, the circumferential lengths are different. In the case where different types of busbars are used, it is possible to easily deal with changes in the busbars.
　また、本例の回転電機７００では、例えば図８４（ａ），（ｂ）に示すように、固定子巻線７２１においてコイルサイド導線部７３４よりも軸方向外側に、径方向外側すなわち回転子７１０の側に突出する突出部７７１が設けられている。以下に、突出部７７１に関する構成を説明する。 Further, in the rotating electric machine 700 of the present example, as shown in FIGS. 84 (a) and (b), for example, the stator winding 721 is disposed radially outward, that is, the rotor 710 outside the coil side conductor 734 in the axial direction. Is provided. Hereinafter, the configuration related to the protrusion 771 will be described.
　図９１は、回転電機７００の縦断面の一部を拡大して示す断面図である。図９１に示すように、固定子巻線７２１のコイルサイド導線部７３４と、回転子７１０の磁石ユニット７１２とは径方向に互いに離間した状態で対向配置されており、その間にエアギャップＧが形成されている。そして、固定子巻線７２１において、エアギャップＧよりも軸方向外側となる位置に、突出部７７１が設けられている。 FIG. 91 is a cross-sectional view showing a part of a vertical cross-section of rotating electric machine 700 in an enlarged manner. As shown in FIG. 91, the coil side conductive wire portion 734 of the stator winding 721 and the magnet unit 712 of the rotor 710 are opposed to each other in a radially separated state, and an air gap G is formed therebetween. Have been. In the stator winding 721, a protrusion 771 is provided at a position axially outside the air gap G.
　この場合、突出部７７１は、軸方向から見て、エアギャップＧへの異物の侵入を抑制する障壁として機能する。したがって、円筒状をなす固定子コア７２２の外周側に固定子巻線７２１が組み付けられた固定子７２０、すなわちティースレス構造の固定子７２０において、固定子巻線７２１が回転子７１０に対して近い位置に配置される構成であっても、エアギャップＧへの異物の侵入を抑制し、ひいては異物の侵入に起因する回転電機７００の動作への悪影響を抑制できるものとなっている。なお、エアギャップＧの径方向の幅寸法をＤ１、突出部７７１と磁石ユニット７１２との間の最短距離をＤ２とすると、Ｄ１＞Ｄ２であるとよい。 In this case, the protruding portion 771 functions as a barrier that suppresses entry of foreign matter into the air gap G when viewed from the axial direction. Therefore, in the stator 720 in which the stator winding 721 is mounted on the outer peripheral side of the cylindrical stator core 722, that is, in the stator 720 having the teethless structure, the stator winding 721 is closer to the rotor 710. Even if it is arranged at a position, it is possible to suppress the intrusion of foreign matter into the air gap G, and furthermore, to suppress the adverse effect on the operation of the rotary electric machine 700 due to the intrusion of foreign matter. It is preferable that D1> D2, where D1 is the radial width of the air gap G and D2 is the shortest distance between the protrusion 771 and the magnet unit 712.
　突出部７７１は、径方向外側に円弧状に膨出した状態で設けられている。より詳しくは、固定子巻線７２１が、コイルエンドＣＥにおいて固定子コア７２２の軸方向端面に対向するように径方向に折り曲げられており、その折り曲げ部において、固定子コア７２２とは逆側（すなわち折り曲げ方向とは逆側）に膨出させるようにして突出部７７１が設けられている。 The protruding portion 771 is provided so as to protrude in an arc shape outward in the radial direction. More specifically, the stator winding 721 is bent in the radial direction so as to face the axial end face of the stator core 722 at the coil end CE, and at the bent portion, on the side opposite to the stator core 722 ( That is, the protruding portion 771 is provided so as to bulge in the direction opposite to the bending direction.
　要するに、コイルエンドＣＥにおいて固定子巻線７２１を径方向に折り曲げた構成では、その折り曲げによる固定子巻線７２１の負荷（曲げ応力）を抑えるべく、曲げ半径を所定以上とすることが望ましいと考えられる。例えば、導線材ＣＲの曲げ半径（導線材ＣＲの中心部の半径）を、例えば５ｍｍ以上とするとよい。この点、上記のとおり固定子巻線７２１の径方向の折り曲げ部に、その折り曲げ方向とは逆側に膨出させるようにして突出部７７１を設けたことにより、固定子巻線７２１において、負荷軽減を図る上で十分な曲げ半径を確保しやすくなっている。これにより、固定子巻線７２１への負荷軽減を図りつつ、エアギャップＧに対する異物の混入を抑制する上で好適な構成を実現できるものとなっている。 In short, in the configuration in which the stator winding 721 is bent in the radial direction at the coil end CE, it is preferable that the bending radius be more than a predetermined value in order to suppress the load (bending stress) of the stator winding 721 due to the bending. Can be For example, the bending radius of the conducting wire CR (the radius at the center of the conducting wire CR) may be, for example, 5 mm or more. In this regard, as described above, the radially bent portion of the stator winding 721 is provided with the protruding portion 771 so as to bulge in a direction opposite to the bending direction. It is easy to secure a sufficient bending radius in order to achieve reduction. This makes it possible to reduce the load on the stator windings 721 and to achieve a configuration suitable for suppressing the entry of foreign matter into the air gap G.
　また、突出部７７１の径方向の突出寸法Ｄ３が、エアギャップＧの径方向の幅寸法Ｄ１よりも大きいことが望ましい。これにより、エアギャップＧに対する異物の混入が一層抑制され、より一層好適な構成を実現できる。ただし、Ｄ３＞Ｄ１であることは必須でなく、Ｄ３＝Ｄ１、又はＤ３＜Ｄ１であってもよい。 Further, it is desirable that the radial projection D3 of the projection 771 is larger than the radial width D1 of the air gap G. Thereby, the entry of foreign matter into the air gap G is further suppressed, and a more preferable configuration can be realized. However, it is not essential that D3> D1. D3 = D1 or D3 <D1.
　なお、突出部７７１の径方向の突出寸法Ｄ３がエアギャップＧの径方向の幅寸法Ｄ１よりも大きい構成、換言すれば、突出部７７１における外形寸法が回転子７１０（磁石ユニット７１２）の内径寸法よりも大きい構成では、回転子７１０に対する固定子７２０の組み付け時に、突出部７７１が組み付けの支障となることが懸念される。この点、図７８に示したように、回転子７１０の回転子キャリア７１１を、筒状部７１３と端板部７１４とに分割可能な構成とし、回転子７１０の磁石ユニット７１２の内周側に固定子７２０を組み付けた後に、回転子キャリア７１１の筒状部７１３に対して端板部７１４を固定するようにするとよい。 Note that a configuration in which the radial projection dimension D3 of the projection 771 is larger than the radial width D1 of the air gap G, in other words, the outer dimension of the projection 771 is the inner diameter of the rotor 710 (magnet unit 712) With a larger configuration, there is a concern that the protrusion 771 may hinder assembly when the stator 720 is assembled to the rotor 710. In this regard, as shown in FIG. 78, the rotor carrier 711 of the rotor 710 is configured to be divided into a cylindrical portion 713 and an end plate portion 714, and the rotor carrier 711 is provided on the inner peripheral side of the magnet unit 712 of the rotor 710. After assembling the stator 720, the end plate portion 714 may be fixed to the cylindrical portion 713 of the rotor carrier 711.
　固定子巻線７２１においては、各相の相巻線ごとにコイルエンドＣＥでの軸方向の導線高さ位置が異なっている。そのため、突出部７７１の軸方向位置が相ごとに異なっている。例えば図７９において、Ｕ相、Ｖ相、Ｗ相の各部分巻線７３１Ｕ，７３１Ｖ，７３１Ｗで比べると、突出部７７１の軸方向位置が相ごとに互いに異なり、軸方向に見て段違いの位置となっている。 In the stator winding 721, the position of the conductor wire height in the axial direction at the coil end CE differs for each phase winding of each phase. Therefore, the axial position of the protrusion 771 differs for each phase. For example, in FIG. 79, when compared with the U-phase, V-phase, and W-phase partial windings 731U, 731V, and 731W, the axial position of the projecting portion 771 is different for each phase, and the stepped position when viewed in the axial direction is different. Has become.
　こうした構成によれば、エアギャップＧへの異物の侵入を抑制しつつ、仮にエアギャップＧに異物が侵入した場合には、その異物を外部に放出することが可能になっている。この場合、各相の相巻線における突出部７７１の軸方向位置が互いに異なっていることで、回転子７１０の回転に伴いエアギャップＧ内で軸方向への旋回流が生じる。そのため、エアギャップＧからの異物の放出が生じ易い構成となっている。また、エアギャップＧ内で軸方向への旋回流が生じることにより、固定子巻線７２１や回転子７１０の冷却効果を高めることができるようになっている。 According to such a configuration, if a foreign object enters the air gap G, it is possible to release the foreign object to the outside while suppressing the entry of the foreign object into the air gap G. In this case, since the axial positions of the projecting portions 771 in the phase windings of the respective phases are different from each other, a swirling flow is generated in the air gap G in the air gap G as the rotor 710 rotates. Therefore, the structure is such that foreign matter is easily released from the air gap G. Further, the generation of the swirling flow in the axial direction in the air gap G can enhance the cooling effect of the stator winding 721 and the rotor 710.
　また、仮に各相の相巻線における突出部７７１の軸方向位置が同一になっていると、軸方向に直交する方向に突出部７７１が一列に並ぶことになり、エアギャップＧから排出される空気が突出部７７１の立ち上がり部に一様に当たり続け、それに起因する導線材ＣＲの絶縁被膜の劣化が生じうることが懸念される。この点、上記のとおり各相の相巻線における突出部７７１の軸方向位置が異なっていることにより、エアギャップＧから排出される空気が好適に排出され、導線材ＣＲの絶縁劣化の懸念が解消される。 If the projections 771 in the phase windings of the respective phases have the same axial position, the projections 771 are arranged in a line in a direction orthogonal to the axial direction, and are discharged from the air gap G. There is a concern that the air may evenly hit the rising portion of the protruding portion 771, which may cause deterioration of the insulating film of the conductive wire CR. In this regard, as described above, since the axial positions of the projecting portions 771 in the phase windings of the respective phases are different, the air discharged from the air gap G is appropriately discharged, and there is a concern that the insulation of the conductor CR may be deteriorated. Will be resolved.
　固定子巻線７２１において、周方向に並ぶコイルサイド導線部７３４が、突出部７７１を含む範囲でモールド材によりモールドされていてもよい。具体的には、図９１に示すように、固定子巻線７２１は、固定子コア７２２に組み付けられた状態で、モールド材としての合成樹脂によりモールドされており、固定子コア７２２の外周面とコイルサイド導線部７３４及び突出部７７１との間には樹脂層７７３が形成されている。また、直線部分であるコイルサイド導線部７３４と突出部７７１とを比べると、これら各部位では、導線材ＣＲから固定子コア７２２までの距離（径方向距離）が互いに異なることから、突出部７７１の内側（固定子コア７２２側）は合成樹脂が溜まった溜まり部７７４となっている。この場合、溜まり部７７４がヒートシンクになることで、コイルサイド導線部７３４の側とコイルエンドＣＥの側との間での熱の伝わりが抑制されるものとなっている。 In the stator winding 721, the coil side conducting wire portions 734 arranged in the circumferential direction may be molded with a molding material in a range including the projecting portion 771. Specifically, as shown in FIG. 91, the stator winding 721 is molded with a synthetic resin as a molding material in a state where the stator winding 721 is assembled to the stator core 722. A resin layer 773 is formed between the coil side conductive wire portion 734 and the projecting portion 771. Also, comparing the coil side conductive wire portion 734, which is a straight line portion, with the projecting portion 771, the distance (radial distance) from the conductive wire CR to the stator core 722 is different in each of these portions. Inside (stator core 722 side) is a pool portion 774 in which synthetic resin is stored. In this case, since the pool portion 774 serves as a heat sink, the transfer of heat between the side of the coil side conductive wire portion 734 and the side of the coil end CE is suppressed.
　また、固定子巻線７２１において、周方向に並ぶコイルサイド導線部７３４は、合成樹脂（モールド材）によりモールドされるのに対し、コイルエンドＣＥに相当する部分は、合成樹脂によるモールドがなされていない構成であるとよい。この場合、コイルエンドＣＥの巻線部分を露出させておくことで、空気冷却を促すことができる。 In the stator winding 721, the coil side conductors 734 arranged in the circumferential direction are molded with a synthetic resin (molding material), whereas the portion corresponding to the coil end CE is molded with a synthetic resin. It is good to have no configuration. In this case, by exposing the winding portion of the coil end CE, air cooling can be promoted.
　次に、固定子保持部材である固定子ホルダ７６０について、図９２を用いて説明する。 Next, the stator holder 760 as the stator holding member will be described with reference to FIG.
　図９２に示すように、固定子ホルダ７６０は、アウタハウジング７６１と、その径方向内側に設けられたインナハウジング７６２とを有している。これら各ハウジング７６１，７６２は例えば鉄系材料よりなり、互いに同軸になるように結合されている。なお、インナハウジング７６２は、軸受７０２，７０３を保持する軸受保持部材であるため、鉄系材料により形成されていることが望ましいが、アウタハウジング７６１は、導電体としてのアルミニウム等により形成されていてもよい。 固定 As shown in FIG. 92, the stator holder 760 has an outer housing 761 and an inner housing 762 provided radially inward thereof. These housings 761 and 762 are made of, for example, an iron-based material, and are coupled so as to be coaxial with each other. Note that the inner housing 762 is a bearing holding member that holds the bearings 702 and 703, and therefore is preferably formed of an iron-based material. However, the outer housing 761 is formed of aluminum or the like as a conductor. Is also good.
　アウタハウジング７６１は、固定子コア７２２の径方向内側に組み付けられる円筒部７６３と、その円筒部７６３の軸方向一端に設けられるフランジ７６４とを有している。フランジ７６４が、例えば車体側のフレーム等に固定されることで、回転電機７００が車体に取り付けられるようになっている。円筒部７６３には、冷却水等の冷媒を環状に流通させる冷媒通路７６５が設けられている。なお、図示は略すが、円筒部７６３の外周面には、固定子コア７２２の内周面に形成された突起部７２５に係合可能な凹部が設けられている。 The outer housing 761 has a cylindrical portion 763 assembled inside the stator core 722 in the radial direction, and a flange 764 provided at one axial end of the cylindrical portion 763. The rotating electric machine 700 is attached to the vehicle body by fixing the flange 764 to, for example, a frame or the like on the vehicle body side. The cylindrical portion 763 is provided with a refrigerant passage 765 through which a refrigerant such as cooling water flows in a ring shape. Although not shown, a concave portion is provided on the outer peripheral surface of the cylindrical portion 763 so as to be able to engage with the protrusion 725 formed on the inner peripheral surface of the stator core 722.
　また、インナハウジング７６２は、円筒部７６６と端板部７６７とを有しており、端板部７６７にてアウタハウジング７６１の内周側に固定されている。円筒部７６６は、円筒部７６３と同心でかつ円筒部７６３よりも小径となっており、端板部７６７により各円筒部７６３，７６６が互いに繋げられた（すなわち連結された）構成となっている。より詳細には、アウタハウジング７６１の円筒部７６３とインナハウジング７６２の円筒部７６６とは径方向内外に対向しており、円筒部７６６において軸方向一端側（図の下端側）が第１端部７６６ａ、軸方向他端側（図の上端側）が第２端部７６６ｂとなっている。そして、円筒部７６６の第２端部７６６ｂの側に端板部７６７が繋がっている構成となっている。なお、説明の便宜上、円筒部７６３を外側円筒部７６３、円筒部７６６を内側円筒部７６６とも称する。 The inner housing 762 has a cylindrical portion 766 and an end plate portion 767, and is fixed to the inner peripheral side of the outer housing 761 by the end plate portion 767. The cylindrical portion 766 is concentric with the cylindrical portion 763 and has a smaller diameter than the cylindrical portion 763, and has a configuration in which the cylindrical portions 766 and 766 are connected to each other (that is, connected) by an end plate portion 767. . More specifically, the cylindrical portion 763 of the outer housing 761 and the cylindrical portion 766 of the inner housing 762 face inward and outward in the radial direction, and one end of the cylindrical portion 766 in the axial direction (the lower end in the drawing) is the first end. 766a, the other end in the axial direction (upper end in the figure) is a second end 766b. The end plate portion 767 is connected to the second end portion 766b of the cylindrical portion 766. For convenience of explanation, the cylindrical portion 763 is also referred to as an outer cylindrical portion 763, and the cylindrical portion 766 is also referred to as an inner cylindrical portion 766.
　図７７において回転子７１０と固定子ホルダ７６０との関係で言えば、軸方向において、内側円筒部７６６の第１端部７６６ａと第２端部７６６ｂとのうち第１端部７６６ａが回転子キャリア７１１の端板部７１４側の端部、第２端部７６６ｂが反端板部側の端部（端板部７１４の逆側の端部）となっており、固定子ホルダ７６０において反端板部側の第２端部７６６ｂに端板部７６７が設けられている。 Referring to the relationship between the rotor 710 and the stator holder 760 in FIG. 77, in the axial direction, the first end 766a of the first end 766a and the second end 766b of the inner cylindrical portion 766 is the rotor carrier. An end of the end plate 711 on the end plate portion 714 side and a second end 766b are ends on the opposite end plate portion side (ends on the opposite side of the end plate portion 714). An end plate 767 is provided on the second end 766b on the side of the unit.
　内側円筒部７６６の径方向内側には、回転軸７０１が挿通されるとともに、回転軸７０１を回転自在に支持する一対の軸受７０２，７０３が収容されている。軸受７０２，７０３は、例えば外輪と内輪とそれらの間に配置された複数の玉とを有するラジアル玉軸受であり、軸方向に並べて配置されている。 回 転 A rotating shaft 701 is inserted radially inside the inner cylindrical portion 766, and a pair of bearings 702 and 703 that rotatably support the rotating shaft 701 are accommodated therein. The bearings 702 and 703 are, for example, radial ball bearings having an outer ring, an inner ring, and a plurality of balls disposed therebetween, and are arranged side by side in the axial direction.
　なお、固定子ホルダ７６０において、外側円筒部７６３が「第１円筒部」に相当し、内側円筒部７６６が「第２円筒部」に相当する。また、端板部７６７が「繋ぎ部」に相当する。 In the stator holder 760, the outer cylindrical portion 763 corresponds to a “first cylindrical portion”, and the inner cylindrical portion 766 corresponds to a “second cylindrical portion”. Further, the end plate portion 767 corresponds to a “joining portion”.
　外側円筒部７６３及び内側円筒部７６６は、径方向の内外に対向しており、その間に形成された環状空間内に複数の電気モジュール７６８が固定されている。各電気モジュール７６８は、電力変換器（インバータ）を構成する半導体スイッチング素子や平滑用コンデンサといった電気部品を個々にモジュール化したものであり、外側円筒部７６３の内周面に沿って周方向に並べて配置されている。電気モジュール７６８は、冷媒通路７６５を流れる冷媒により冷却される。 The outer cylindrical portion 763 and the inner cylindrical portion 766 face inward and outward in the radial direction, and a plurality of electric modules 768 are fixed in an annular space formed therebetween. Each electric module 768 is obtained by individually modularizing electric components such as a semiconductor switching element and a smoothing capacitor constituting a power converter (inverter), and is arranged in a circumferential direction along the inner peripheral surface of the outer cylindrical portion 763. Are located. The electric module 768 is cooled by the refrigerant flowing through the refrigerant passage 765.
　回転電機７００では、電力変換器としてのインバータにより、固定子巻線７２１における各相の相巻線の通電が相ごとに切り替えられる。なお、インバータの構成については、例えば図５９のインバータ６００の構成を参照されたい。インバータでは、相ごとに設けられた半導体スイッチング素子が所定のスイッチング周波数でスイッチングされることにより、電気角で１２０度ずつずれた位相で各相の相巻線が通電される。 In the rotating electric machine 700, the energization of the phase winding of each phase in the stator winding 721 is switched for each phase by the inverter as the power converter. For the configuration of the inverter, refer to the configuration of the inverter 600 in FIG. 59, for example. In the inverter, a semiconductor switching element provided for each phase is switched at a predetermined switching frequency, so that phase windings of each phase are energized at phases shifted by 120 electrical degrees.
　ここで、各相の相巻線の通電が相ごとに切り替えられる際には、相間のスイッチングタイミングの差に起因して、回転軸７０１を支持する一対の軸受７０２，７０３間に電流が流れ、それに伴い軸受７０２，７０３において電食が生じることが懸念される。また、本実施形態の回転電機７００では、固定子７２０において、導線間部材としてのティースが設けられていないか又は磁気的に脆弱に設けられている構成となっており、導線間部材としての各ティースに磁気経路が形成される構成に比べて、起電力による意図しない電流の発生やそれに伴う軸受７０２，７０３の電食の問題が懸念されることが考えられる。 Here, when the energization of the phase winding of each phase is switched for each phase, a current flows between a pair of bearings 702 and 703 supporting the rotating shaft 701 due to a difference in switching timing between the phases, Accordingly, there is a concern that electrolytic corrosion may occur in the bearings 702 and 703. Also, in the rotating electric machine 700 of the present embodiment, the teeth are not provided or the magnetic members are weakly provided as the members between the conductors in the stator 720. Compared to the configuration in which the magnetic path is formed in the teeth, it is conceivable that the occurrence of unintended current due to the electromotive force and the problem of electrolytic corrosion of the bearings 702 and 703 due to the electromotive force may be concerned.
　この点、本実施形態の回転電機７００では、固定子ホルダ７６０において、固定子７２０の径方向内側（すなわち固定子コア７２２の径方向内側）に組み付けられる外側円筒部７６３に一体的に、かつその外側円筒部７６３よりも径方向内側となる位置に内側円筒部７６６を設け、その内側円筒部７６６の内周側（内側円筒部７６６と回転軸７０１との間）に一対の軸受７０２，７０３を軸方向に並べて設ける構成とした。これにより、一対の軸受７０２，７０３間における電位差を無くし、ひいては軸受７０２，７０３での電食の発生を抑制することができるようになっている。 In this regard, in the rotating electric machine 700 of the present embodiment, in the stator holder 760, the outer cylindrical portion 763 that is assembled radially inside the stator 720 (that is, radially inside the stator core 722) is integrated with the outer cylindrical portion 763. An inner cylindrical portion 766 is provided at a position radially inner than the outer cylindrical portion 763, and a pair of bearings 702 and 703 are provided on the inner peripheral side of the inner cylindrical portion 766 (between the inner cylindrical portion 766 and the rotation shaft 701). It was configured to be provided side by side in the axial direction. As a result, the potential difference between the pair of bearings 702 and 703 can be eliminated, and the occurrence of electrolytic corrosion in the bearings 702 and 703 can be suppressed.
　また、本実施形態では、固定子ホルダ７６０において内側円筒部７６６の軸方向両側である第１端部７６６ａ（回転子キャリア７１１の端板部７１４側の端部）と第２端部７６６ｂ（反端板部側の端部）とのうち第２端部７６６ｂの側で、端板部７６７を介して外側円筒部７６３に内側円筒部７６６を連結する構成とした。この構成では、固定子ホルダ７６０において各円筒部７６３，７６６の間に形成される環状空間において、軸方向の一方側を回転子キャリア７１１の端板部７１４により閉じ、他方側を固定子ホルダ７６０の端板部７６７により閉じることができ、固定子７２０の内周側に、回転軸７０１を囲み、かつ軸方向両側に閉じた空間を形成できる。これにより、回転子７１０及び固定子７２０を含む磁気回路部と一対の軸受７０２，７０３とを径方向内外となるようにそれぞれ配置して、回転電機７００をコンパクト化することを実現できる。また、回転電機７００に対して電力変換器（インバータ）やその他の電気装置を一体的に設ける上で好適な構成を実現できる。 Further, in the present embodiment, the first end 766a (the end on the end plate 714 side of the rotor carrier 711) and the second end 766b (the opposite end) on both sides in the axial direction of the inner cylindrical portion 766 in the stator holder 760. The inner cylindrical portion 766 is connected to the outer cylindrical portion 763 via the end plate portion 767 on the side of the second end portion 766b with respect to the end portion on the side of the end plate portion. In this configuration, in the annular space formed between the cylindrical portions 763 and 766 in the stator holder 760, one side in the axial direction is closed by the end plate portion 714 of the rotor carrier 711, and the other side is stator holder 760. Can be closed by the end plate portion 767, and a closed space can be formed on the inner peripheral side of the stator 720, surrounding the rotating shaft 701 and being closed on both sides in the axial direction. Accordingly, the magnetic circuit unit including the rotor 710 and the stator 720 and the pair of bearings 702 and 703 are arranged so as to be radially inward and outward, respectively, so that the rotating electric machine 700 can be downsized. In addition, a preferable configuration can be realized when a power converter (inverter) and other electric devices are provided integrally with the rotating electric machine 700.
　（変形例１５の別例）
　・回転電機７００の一部を変更し、図９３に示す構成としてもよい。なお、以下に示す構成では、変形例１５として説明した回転電機７００と同じ構成については同じ符号を付すとともに説明を適宜割愛する。 (Another example of Modification 15)
-A part of rotating electric machine 700 may be changed to have a configuration shown in FIG. In the configuration described below, the same components as those of the rotary electric machine 700 described as Modification Example 15 are denoted by the same reference numerals, and description thereof will be omitted as appropriate.
　図９３に示す回転電機７００は、アウタロータ式の回転電機であり、回転子７１０を径方向外側、固定子７２０を径方向内側とし、これら回転子７１０及び固定子７２０を径方向に対向配置した構成となっている。 A rotary electric machine 700 shown in FIG. 93 is an outer rotor type rotary electric machine, in which a rotor 710 is radially outside, a stator 720 is radially inside, and the rotor 710 and the stator 720 are arranged to face each other in the radial direction. It has become.
　固定子ホルダ７６０は、固定子コア７２２の径方向内側に組み付けられる外側円筒部７６３と、その外側円筒部７６３よりも小径の内側円筒部７６６と、それら各円筒部７６３，７６６を繋ぐ端板部７６７とを有している。そして、内側円筒部７６６の軸方向両側である第１端部７６６ａ（回転子キャリア７１１の端板部７１４側の端部）とその逆側の第２端部７６６ｂ（反端板部側の端部）とのうち第１端部７６６ａの側で、端板部７６７を介して外側円筒部７６３に内側円筒部７６６が連結されている。つまり、図９３の構成では、回転子キャリア７１１の端板部７１４と、固定子ホルダ７６０の端板部７６７とが軸方向に見て同じ側にそれぞれ設けられている。 The stator holder 760 includes an outer cylindrical portion 763 assembled radially inside the stator core 722, an inner cylindrical portion 766 smaller in diameter than the outer cylindrical portion 763, and an end plate portion connecting the cylindrical portions 763 and 766. 767. The first end 766a (the end on the end plate 714 side of the rotor carrier 711), which is on both sides in the axial direction of the inner cylindrical portion 766, and the second end 766b on the opposite side (the end on the opposite end plate side). The inner cylindrical portion 766 is connected to the outer cylindrical portion 763 via an end plate portion 767 on the side of the first end portion 766a. That is, in the configuration of FIG. 93, the end plate portion 714 of the rotor carrier 711 and the end plate portion 767 of the stator holder 760 are provided on the same side as viewed in the axial direction.
　上記構成では、固定子ホルダ７６０の各円筒部７６３，７６６の間に形成される環状空間において、その軸方向の一方側に、回転子キャリア７１１の端板部７１４と固定子ホルダ７６０の端板部７６７とが設けられることで、当該環状空間の軸方向他方側が開放される構成となっている。環状空間には、軸方向において各端板部７１４，７６７の逆側から、例えば変速装置７８０が組み付けられる。これにより、回転電機７００に対して一体的に変速装置７８０等を設ける場合において、固定子ホルダ７６０の各円筒部７６３，７６６の間の環状空間に対して軸方向一方からの変速装置７８０等の組み付けが可能になっている。 In the above configuration, in the annular space formed between the cylindrical portions 763 and 766 of the stator holder 760, the end plate portion 714 of the rotor carrier 711 and the end plate of the stator holder 760 are provided on one side in the axial direction. By providing the portion 767, the other side in the axial direction of the annular space is opened. For example, a transmission 780 is attached to the annular space from the opposite side of the end plates 714 and 767 in the axial direction. Thus, when the transmission 780 and the like are provided integrally with the rotating electric machine 700, the transmission 780 and the like from one side in the axial direction with respect to the annular space between the cylindrical portions 763 and 766 of the stator holder 760. Assembly is possible.
　・回転電機７００の一部を変更し、図９４に示す構成としてもよい。図９４に示す回転電機７００は、インナロータ式の回転電機であり、回転子７１０を径方向内側、固定子７２０を径方向外側とし、これら回転子７１０及び固定子７２０を径方向に対向配置した構成となっている。 · A part of the rotating electric machine 700 may be changed to have a configuration shown in FIG. A rotating electric machine 700 shown in FIG. 94 is an inner-rotor-type rotating electric machine, in which a rotor 710 is radially inward, a stator 720 is radially outward, and the rotor 710 and the stator 720 are arranged to face each other in the radial direction. It has become.
　固定子ホルダ７６０は、固定子コア７２２の径方向外側に組み付けられる外側円筒部７６３と、その外側円筒部７６３よりも小径の内側円筒部７６６と、それら各円筒部７６３，７６６を繋ぐ端板部７６７とを有している。内側円筒部７６６の外周側には複数の電気モジュール７６８が固定されている。そして、内側円筒部７６６の軸方向両側である第１端部７６６ａ（回転子キャリア７１１の端板部７１４側の端部）とその逆側の第２端部７６６ｂ（反端板部側の端部）とのうち第２端部７６６ｂの側で、端板部７６７を介して外側円筒部７６３に内側円筒部７６６が連結されている。つまり、図９４の構成では、回転子キャリア７１１の端板部７１４と、固定子ホルダ７６０の端板部７６７とが軸方向に見て互いに逆側に設けられている。 The stator holder 760 includes an outer cylindrical portion 763 assembled radially outside the stator core 722, an inner cylindrical portion 766 smaller in diameter than the outer cylindrical portion 763, and an end plate portion connecting the cylindrical portions 763 and 766. 767. A plurality of electric modules 768 are fixed to the outer peripheral side of the inner cylindrical portion 766. The first end 766a (the end on the end plate 714 side of the rotor carrier 711), which is on both sides in the axial direction of the inner cylindrical portion 766, and the second end 766b on the opposite side (the end on the opposite end plate side). The inner cylindrical portion 766 is connected to the outer cylindrical portion 763 via an end plate portion 767 on the side of the second end portion 766b. That is, in the configuration of FIG. 94, the end plate portion 714 of the rotor carrier 711 and the end plate portion 767 of the stator holder 760 are provided on opposite sides when viewed in the axial direction.
　上記構成では、固定子ホルダ７６０の内側円筒部７６６と回転子キャリア７１１の筒状部７１３との間に形成される環状空間において、軸方向の一方側を回転子キャリア７１１の端板部７１４により閉じ、他方側を固定子ホルダ７６０の端板部７６７により閉じることができ、回転子７１０の内周側に、回転軸７０１を囲み、かつ軸方向両側に閉じた空間を形成できる。これにより、例えば回転電機７００に対して電力変換器（インバータ）等の電気装置を一体的に設ける上で好適な構成を実現できる。 In the above configuration, in the annular space formed between the inner cylindrical portion 766 of the stator holder 760 and the cylindrical portion 713 of the rotor carrier 711, one axial side is formed by the end plate portion 714 of the rotor carrier 711. The rotor 710 can be closed and the other side can be closed by the end plate portion 767 of the stator holder 760, and a space surrounding the rotating shaft 701 and closed on both sides in the axial direction can be formed on the inner peripheral side of the rotor 710. Thereby, for example, a preferable configuration can be realized when an electric device such as a power converter (inverter) is provided integrally with the rotating electric machine 700.
　・回転電機７００における固定子巻線７２１は２相の相巻線（Ｕ相巻線及びＶ相巻線）を有する構成であってもよい。この場合、例えば部分巻線７３１では、一対の中間導線群７３２の間に、他１相の部分巻線７３１における中間導線群７３２が１つ配置される構成となっていればよい。 The stator winding 721 in the rotating electric machine 700 may have a configuration having two-phase windings (U-phase winding and V-phase winding). In this case, for example, the partial winding 731 may have a configuration in which one intermediate conductor group 732 in the other one-phase partial winding 731 is arranged between the pair of intermediate conductor groups 732.
　・回転電機７００に用いられる固定子コア７２２は、バックヨークから延びる突起部（例えばティース）を有するものであってもよい。この場合にも、固定子コア７２２に対する部分巻線７３１の組み付けがバックヨークに対して行われるものであればよい。 The stator core 722 used in the rotating electric machine 700 may have a protrusion (for example, a tooth) extending from the back yoke. Also in this case, it is sufficient that the partial winding 731 is assembled to the stator core 722 to the back yoke.
　・回転電機としては、星形結線のものに限らず、Δ結線のものであってもよい。 The rotating electric machine is not limited to the star-connection type, but may be a Δ-connection type.
　この明細書における開示は、例示された実施形態に制限されない。開示は、例示された実施形態と、それらに基づく当業者による変形態様を包含する。例えば、開示は、実施形態において示された部品および／または要素の組み合わせに限定されない。開示は、多様な組み合わせによって実施可能である。開示は、実施形態に追加可能な追加的な部分をもつことができる。開示は、実施形態の部品および／または要素が省略されたものを包含する。開示は、ひとつの実施形態と他の実施形態との間における部品および／または要素の置き換え、または組み合わせを包含する。開示される技術的範囲は、実施形態の記載に限定されない。開示されるいくつかの技術的範囲は、請求の範囲の記載によって示され、さらに請求の範囲の記載と均等の意味及び範囲内での全ての変更を含むものと解されるべきである。 開 示 The disclosure in this specification is not limited to the illustrated embodiment. The disclosure includes the illustrated embodiments and variations based thereon based on 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 may have additional parts that can be added to the embodiments. The disclosure includes embodiments in which parts and / or elements are omitted. The disclosure encompasses the replacement or combination of parts and / or elements between one embodiment and another. The disclosed technical scope is not limited to the description of the embodiments. Some of the disclosed technical ranges are indicated by the description of the claims, and should be construed to include all modifications within the scope and meaning equivalent to the description of the claims.
　本開示は、実施例に準拠して記述されたが、本開示は当該実施例や構造に限定されるものではないと理解される。本開示は、様々な変形例や均等範囲内の変形をも包含する。加えて、様々な組み合わせや形態、さらには、それらに一要素のみ、それ以上、あるいはそれ以下、を含む他の組み合わせや形態をも、本開示の範疇や思想範囲に入るものである。 Although the present disclosure has been described based on the embodiments, it is understood that the present disclosure is not limited to the embodiments and the structure. The present disclosure also encompasses various modifications and variations within an equivalent range. In addition, various combinations and forms, and other combinations and forms including only one element, more or less, are also included in the scope and concept of the present disclosure.

Claims (5)

  1. 　周方向に極性が交互となる複数の磁極を含む磁石部（７１２）を有する回転子（７１０）と、
    　多相の固定子巻線（７２１）を有する筒状の固定子（７２０）と、
    　前記固定子の径方向内側又は径方向外側に組み付けられる第１円筒部（７６３）を有する固定子保持部材（７６０）と、
    　前記回転子の回転軸（７０１）を回転可能に支持する一対の軸受（７０２，７０３）と、を備える回転電機（７００）であって、
    　前記固定子保持部材は、前記第１円筒部と同心でかつ該第１円筒部よりも小径の第２円筒部（７６６）と、前記第１円筒部と前記第２円筒部とを繋ぐ繋ぎ部（７６７）とを有し、
    　前記第２円筒部内には前記回転軸が挿通されており、前記第２円筒部と前記回転軸との間に、前記一対の軸受が軸方向に並べて設けられている回転電機。     A rotor (710) having a magnet portion (712) including a plurality of magnetic poles having alternating polarities in a circumferential direction;
    A cylindrical stator (720) having a polyphase stator winding (721);
    A stator holding member (760) having a first cylindrical portion (763) assembled radially inward or radially outward of the stator;
    A rotating bearing (700) comprising: a pair of bearings (702, 703) rotatably supporting a rotating shaft (701) of the rotor;
    The stator holding member includes a second cylindrical portion (766) concentric with the first cylindrical portion and having a smaller diameter than the first cylindrical portion, and a connecting portion connecting the first cylindrical portion and the second cylindrical portion. (767)
    A rotating electric machine, wherein the rotating shaft is inserted into the second cylindrical portion, and the pair of bearings are provided in the axial direction between the second cylindrical portion and the rotating shaft.
  2. 　前記固定子巻線は、前記磁石部に対向する位置で周方向に所定間隔で配置される導線部（７３４）を有し、
    　前記固定子において、
    　周方向における前記各導線部の間に導線間部材を設け、かつその導線間部材として、１磁極における前記導線間部材の周方向の幅寸法をＷｔ、前記導線間部材の飽和磁束密度をＢｓ、１磁極における前記磁石部の周方向の幅寸法をＷｍ、前記磁石部の残留磁束密度をＢｒとした場合に、Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒの関係となる磁性材料、若しくは非磁性材料を用いる構成か、
    　又は周方向における前記各導線部の間に導線間部材を設けていない構成となっている請求項１に記載の回転電機。     The stator winding has a conductor portion (734) arranged at a predetermined interval in a circumferential direction at a position facing the magnet portion,
    In the stator,
    An inter-conductor member is provided between the respective conductor portions in the circumferential direction, and as the inter-conductor member, the circumferential width of the inter-conductor member at one magnetic pole is Wt, and the saturation magnetic flux density of the inter-conductor member is Bs. A configuration using a magnetic material or a non-magnetic material that satisfies the relationship of Wt × Bs ≦ Wm × Br, where Wm is the circumferential width of the magnet portion in one magnetic pole and Br is the residual magnetic flux density of the magnet portion. Or
    2. The rotating electric machine according to claim 1, wherein an inter-conductor member is not provided between the respective conductor portions in the circumferential direction. 3.
  3. 　前記回転子を径方向外側、前記固定子を径方向内側とし、これら回転子及び固定子を径方向に対向配置したアウタロータ式の回転電機であって、
    　前記回転子は、前記磁石部を保持する磁石保持部材（７１１）を有し、
    　前記磁石保持部材は、前記磁石部が固定された筒状部（７１３）と、前記回転軸から前記筒状部まで径方向に延びる端板部（７１４）とを有しており、
    　前記固定子保持部材において前記第２円筒部は、前記第１円筒部に対して径方向に対向するように設けられており、軸方向において前記第２円筒部の前記端板部側の第１端部（７６６ａ）とその逆側の第２端部（７６６ｂ）とのうち前記第２端部の側に前記繋ぎ部が繋がっている請求項１又は２に記載の回転電機。     An outer rotor type rotating electric machine in which the rotor is radially outward, the stator is radially inward, and the rotor and the stator are radially opposed to each other.
    The rotor has a magnet holding member (711) for holding the magnet unit,
    The magnet holding member has a tubular portion (713) to which the magnet portion is fixed, and an end plate (714) extending radially from the rotation axis to the tubular portion,
    In the stator holding member, the second cylindrical portion is provided so as to be radially opposed to the first cylindrical portion, and the first cylindrical portion on the end plate side of the second cylindrical portion in the axial direction. 3. The rotating electric machine according to claim 1, wherein the connecting portion is connected to the end portion (766 a) and the opposite second end portion (766 b) on the side of the second end portion. 4.
  4. 　前記回転子を径方向外側、前記固定子を径方向内側とし、これら回転子及び固定子を径方向に対向配置したアウタロータ式の回転電機であって、
    　前記回転子は、前記磁石部を保持する磁石保持部材（７１１）を有し、
    　前記磁石保持部材は、前記磁石部が固定された筒状部（７１３）と、前記回転軸から前記筒状部まで径方向に延びる端板部（７１４）とを有しており、
    　前記固定子保持部材において前記第２円筒部は、前記第１円筒部に対して径方向に対向するように設けられており、軸方向において前記第２円筒部の前記端板部側の第１端部（７６６ａ）とその逆側の第２端部（７６６ａ）とのうち前記第１端部の側に前記繋ぎ部が繋がっている請求項１又は２に記載の回転電機。     An outer rotor type rotating electric machine in which the rotor is radially outward, the stator is radially inward, and the rotor and the stator are radially opposed to each other.
    The rotor has a magnet holding member (711) for holding the magnet unit,
    The magnet holding member has a tubular portion (713) to which the magnet portion is fixed, and an end plate (714) extending radially from the rotation axis to the tubular portion,
    In the stator holding member, the second cylindrical portion is provided so as to be radially opposed to the first cylindrical portion, and the first cylindrical portion on the end plate side of the second cylindrical portion in the axial direction. 3. The rotating electric machine according to claim 1, wherein the connecting portion is connected to the first end side of the end portion (766 a) and the second end portion (766 a) on the opposite side.
  5. 　前記回転子を径方向内側、前記固定子を径方向外側とし、これら回転子及び固定子を径方向に対向配置したインナロータ式の回転電機であって、
    　前記回転子は、前記磁石部を保持する磁石保持部材（７１１）を有し、
    　前記磁石保持部材は、前記磁石部が固定された筒状部（７１３）と、前記回転軸から前記筒状部まで径方向に延びる端板部（７１４）とを有しており、
    　前記固定子保持部材において前記第２円筒部は、前記筒状部の径方向内側に、当該筒状部に対して径方向に対向するように設けられており、軸方向において前記第２円筒部の前記端板部側の第１端部とその逆側の第２端部とのうち前記第２端部の側に前記繋ぎ部が繋がっている請求項１又は２に記載の回転電機。     An inner-rotor type rotating electric machine in which the rotor is radially inward, the stator is radially outward, and these rotors and stators are radially opposed to each other.
    The rotor has a magnet holding member (711) for holding the magnet unit,
    The magnet holding member has a tubular portion (713) to which the magnet portion is fixed, and an end plate (714) extending radially from the rotation axis to the tubular portion,
    In the stator holding member, the second cylindrical portion is provided radially inward of the cylindrical portion so as to radially oppose the cylindrical portion, and the second cylindrical portion in the axial direction. 3. The rotating electric machine according to claim 1, wherein the connecting portion is connected to the second end of the first end on the side of the end plate and the second end on the opposite side. 4.
PCT/JP2019/028697 2018-07-25 2019-07-22 Rotating electrical machine WO2020022282A1 (en)

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